Swinburne University of Technology

Sarawak Campus
School of Engineering, Computing and Science

Module Code: HEC4722

Module Name: Process Mass Transfer

Distillation Column Design

Prepared by:
Joan Caroline Yong Jun Dhing (4323483)
Joyce Song Wee Wee (4321693)
Joevinder Augustty anak Joggery (4328817)
Gong Duckwon (100068451)
Reema Shakeel (4317874)

Semester: Semester 2, 2016

Due Date: 12/12/2016

Date Received: 12/12/2016
Lecturer: Assoc. Prof. Farouq Twaiq
Group: A

“We declare that this report is solely our own work.

All contributions made by others have been duly
acknowledged.”
Table of Contents
1 Executive Summary ................................................................................................................ 1
2 Introduction ............................................................................................................................. 1
3 Objectives ............................................................................................................................... 1
4 Results and Calculation Methods for Distillation Column Design ......................................... 2
4.1 Tray Column Design ........................................................................................................ 2
4.1.1 Vapor Liquid Equilibrium Data ................................................................................ 2
4.1.2 Number of Trays ....................................................................................................... 4
4.1.3 Feed Stage Allocated ................................................................................................ 6
4.1.4 Column Diameter ...................................................................................................... 6
4.1.5 Column Height ........................................................................................................ 11
4.2 Condenser and Reboiler ................................................................................................. 12
4.2.1 4.2.1 Condenser & Reboiler Duties (from experimental data) ............................... 12
4.2.2 Condenser Duty ...................................................................................................... 14
4.2.3 Reboiler Duty .......................................................................................................... 14
4.2.4 Condenser and Reboiler Design.............................................................................. 15
4.2.5 Materials of Construction ....................................................................................... 16
4.3 Operating Cost Analysis................................................................................................. 18
4.4 Capital Cost Analysis ..................................................................................................... 19
4.5 Total Cost Analysis ........................................................................................................ 20
5 Discussion ............................................................................................................................. 20
6 Schematic of Distillation Column Design ............................................................................ 22
7 Conclusion ............................................................................................................................ 23
8 Recommendations ................................................................................................................. 23
9 References ............................................................................................................................. 24
10 Appendix ............................................................................................................................... 25
List of Figures
Figure 1: Distillation Column Design Specifications of Ethanol-Water Mixture ........................ 22
Figure 2: 𝑲𝒍 against 𝑭𝑳𝑽 .............................................................................................................. 28

List of Tables
Table 1: Constants of Ethanol and Water for Antoine Equation .................................................... 2
Table 2: Margules Constant ............................................................................................................ 2
Table 3: Saturated Temperature of Ethanol and Water .................................................................. 3
Table 4: Data for plotting VLE Graph ............................................................................................ 4
Table 5: Number of Trays at Each Reflux Ratio ............................................................................ 6
Table 6: Feed Stage Allocated at each Reflux Ratio ...................................................................... 6
Table 7: Graphical Temperature at the Bottom and Top of Column .............................................. 7
Table 8: Mole Fraction at the top and bottom obtained from T-xy Graph ..................................... 7
Table 9: Data to Calculate Average Density in Liquid Phase ........................................................ 8
Table 10: Density of Ethanol and Water at particular Temperature ............................................... 8
Table 11: Data of Calculation of Column Height ......................................................................... 11
Table 12: Properties of carbon steel and stainless steel ................................................................ 17

List of Graphs
Graph 1: T-xy Diagram ................................................................................................................... 7
Graph 2: Costings at Different Reflux Ratio ................................................................................ 20
Graph 3: VLE Graph of Mixture .................................................................................................. 25
Graph 4: VLE Graph with Operating Line and Number of Trays (Total Reflux) ........................ 25
Graph 5: VLE Graph with Operating Line and Number of Trays (R = 1.6) ................................ 26
Graph 6: VLE Graph with Operating Line and Number of Trays (R = 2.6) ................................ 26
Graph 7: VLE Graph with Operating Line and Number of Trays (R = 3.2) ................................ 27
Graph 8: Refractive index against Mole Fraction of EtOH .......................................................... 27
HEC4722 Process Mass Transfer Group A: Distillation Column Design

1 Executive Summary
Demand for ethanol is increasing over the year as it is an alternative biofuel which is more
sustainable than traditional fuel such as fossil fuel. It is used widely in the automotive industry
and many countries are promoting its usage compared to fossil fuel as a cleaner source of energy.
The report written here consists of the design of distillation column to produce one metric tonne
of 80% mole ethanol in water. In the report, the distillation column in the lab was operated at
different reflux ration to obtain and determine the optimum reflux ratio. The design parameters
such as the flowrates in the column, height of the tower, column diameter, reboiler and
condenser duty as well as the capital cost and operation cost were analysed to get a clearer view
of the optimum reflux ratio. At the end of this study, the optimum reflux ratio is found to be 1.6
and a final design schematics of the distillation column is drafted.

2 Introduction
With the demand for ethanol has risen for the past few year as a cleaner and better biofuel
source, more and more countries are competing to produce the chemical compound. More
countries are now promoting the production of ethanol as it is a sustainable source for fuel usage
compared to traditional fuel. One of the most common ways of producing ethanol is by starch
fermentation process. The source of ethanol is starch which is carbohydrate and some example of
starch sources are potato, rice, maize and barley. Most common starch used is potato. As said
before, ethanol is highly used for the automotive industry with most countries promoting the
usage of biofuel (ethanol) rather than traditional fuel such as fossil fuel. It is a cleaner fuel as it
has less emission of toxic compounds such as carbon monoxide. It proves as a more sustainable
fuel compared to fossil fuels.

In this report, a distillation column (tray column) is design to purify ethanol at different reflux
ratios. The optimum reflux ratio is then determined experimentally and by calculation. The
design of the distillation column includes tray column design, condenser and reboiler duties and
design, the energy costs, the capital costs and the respective operating cost for every different
reflux ratio.

3 Objectives
The experiment was done to design a distillation column that will purify and distilled ethanol to
produce a metric tonne per hour of 80% mole ethanol in water. Various other objectives for this
project are listed as below:

1. To design distillation column (tray columns).

2. To determine the column performance.
3. To find optimum reflux ratio.
4. To determine the heat and cooling duties in top cooler (condenser) and bottom heater
(reboiler) and their respective energy costs.
5. To estimate the capital and operating cost for the operation of a distillation column.
6. To estimate optimum cost for a distillation plant.

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HEC4722 Process Mass Transfer Group A: Distillation Column Design

4 Results and Calculation Methods for Distillation Column Design

All calculations are performed in MS Excel and sample calculations are shown below.

4.1 Tray Column Design

Tray column are vertical cylindrical column. They are positioned across the height of a
distillation column. The liquid enters from the top of the column and will flow across the trays. It
will then flow down through a downcomer to the next tray below. As vapour from lower trays
will flow upward through holes in the tray column, a vapour-liquid dispersion is formed. The
mass transfer from these vapour-liquid phases occurs in a stage-wise manner. To separate the
products, tray columns use the differential of temperature and pressure.

4.1.1 Vapor Liquid Equilibrium Data

Equations applied are:
i. Antoine Equation:
𝐵
𝑙𝑛𝑃 𝑠𝑎𝑡 (𝑘𝑃𝑎) = 𝐴 −
𝑇(℃) + 𝐶

ii. Modified Raoult’s Law:

𝑥1 𝛾1 𝑃1𝑠𝑎𝑡
𝑦1 =
𝑃
iii. Margules’ Equation:
𝑙𝑛𝛾1 = 𝑥22 [𝐴12 + 2(𝐴21 − 𝐴12 )𝑥1 ]
𝑙𝑛𝛾2 = 𝑥12 [𝐴21 + 2(𝐴12 − 𝐴21 )𝑥2 ]

Table 1: Constants of Ethanol and Water for Antoine Equation

Constants for Antoine Equation A B C

Ethanol (1) 16.8958 3795.17 230.918
Water (2) 16.3872 3885.7 230.17

Table 2: Margules Constant

𝑨𝟏𝟐 𝑨𝟐𝟏
Margules’ Constant
1.6022 0.7947

2
HEC4722 Process Mass Transfer Group A: Distillation Column Design
Table 3: Saturated Temperature of Ethanol and Water

Saturated Temperature of Ethanol,𝑇1𝑠𝑎𝑡 (°C) 78.2

Saturated Temperature of water, 𝑇2𝑠𝑎𝑡 (°C) 100
At P = 1 atm (kPa) 101.325

Sample Calculation: at T=86.6°C

To calculate Margules constant:

𝑙𝑛𝛾1 = 𝑥22 [𝐴12 + 2(𝐴21 − 𝐴12 )𝑥1 ]
𝛾1 = 𝐸𝑋𝑃[0.12 [1.6022 + 2(0.7947 − 1.6022)0.1]]
= 3.2
𝑙𝑛𝛾2 = 𝑥12 [𝐴21 + 2(𝐴12 − 𝐴21 )𝑥2 ]
𝛾2 = 𝐸𝑋𝑃[0.92 [0.7947 + 2(1.6022 − 0.7947)0.9]]
= 1.0

To calculate Saturated Pressure of Ethanol and Water: at T=86.6°C

𝑙𝑛𝑃1𝑠𝑎𝑡 (𝑘𝑃𝑎) 𝐵
=𝐴−
𝑇(℃) + 𝐶
3795.17
= 𝐸𝑋𝑃(16.8958 − )
86.6 + 230.918
𝑃1𝑠𝑎𝑡
= 140.17 𝑘𝑃𝑎
3885.7
= 𝐸𝑋𝑃(16.3872 − )
86.6 + 230.17
𝑃2𝑠𝑎𝑡 = 61.57 𝑘𝑃𝑎
To calculate 𝑦1 at T=86.6°C
𝑦1 𝑥1 𝛾1𝑃1𝑠𝑎𝑡
=
𝑃
(0.1)(3.2)(140.17)
=
101.3
= 0.44

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HEC4722 Process Mass Transfer Group A: Distillation Column Design
Table 4: Data for plotting VLE Graph

T (°C) 𝒙𝟏 𝒙𝟐 𝜸𝟏 𝜸𝟐 𝑷𝒔𝒂𝒕
𝟏 𝑷𝒔𝒂𝒕
𝟐 P 𝒚𝟏
100.0 0.0 1.0 5.0 1.0 227.51 101.33 101.30 0.00
86.6 0.1 0.9 3.2 1.0 140.17 61.57 101.30 0.44
82.9 0.2 0.8 2.3 1.1 121.98 53.37 101.30 0.55
81.5 0.3 0.7 1.7 1.2 115.36 50.39 101.30 0.59
80.7 0.4 0.6 1.4 1.3 111.82 48.80 101.30 0.62
80.0 0.5 0.5 1.2 1.5 108.76 47.43 101.30 0.65
79.4 0.6 0.4 1.1 1.7 106.33 46.34 101.30 0.70
78.9 0.7 0.3 1.0 1.9 104.35 45.45 101.30 0.75
78.6 0.8 0.2 1.0 2.0 102.96 44.83 101.30 0.82
78.4 0.9 0.1 1.0 2.2 102.16 44.47 101.30 0.91
78.2 1.0 0.0 1.0 2.2 101.33 44.10 101.30 1.00

Graph 3 is plotted from the calculated data in Table 4 as shown in Appendix.

4.1.2 Number of Trays

The graphical method used is McCabe-Thiele.
First, set total reflux for VLE graph to find mole ratio of residue, 𝑥𝐵 and minimum reflux ratio,
𝑅𝑚𝑖𝑛 . The mass flow rate of distillate, D = 1000 kg/hr and 𝑥𝐷 = 0.8 𝑘𝑔𝑚𝑜𝑙 are given in lab
manual. Mole ratio of distillate is assumed to remain constant for every reflux ratio.

From Graph 3, we obtained 𝑅𝑚𝑖𝑛 = 1.1 which calculated from the tangent of the line between x D
and xB as illustrated in Graph 4 (Appendix).
𝑅𝑚𝑖𝑛 0.8 − 0.39
=
𝑅𝑚𝑖𝑛 − 1 0.8 − 0

𝑹𝒎𝒊𝒏 = 𝟏. 𝟏

Therefore, to reach to distillate composition we defined, we need to work with reflux ratio higher
than 1.1.

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HEC4722 Process Mass Transfer Group A: Distillation Column Design
To obtain Feed flow rate, F and Bottom flow rate, B by using mass balance and material balance.

Mass Balance: 𝑭 = 𝑩 + 𝑫

Material Balance: 𝑭𝒙𝑭 = 𝑩𝒙𝑩 + 𝑫𝒙𝑫

(𝐵 + 1000)(0.15) = 0.1𝐵 + 1000(0.8)

∴ 𝐵 = 13000 𝑘𝑔⁄ℎ
𝐹 = 13000 + 1000 = 14000 𝑘𝑔⁄ℎ

Therefore,
𝐹 = 14000 𝑘𝑔⁄ℎ 𝑥𝐹 = 0.15 𝑘𝑔𝑚𝑜𝑙
𝐵 = 𝐿𝑤 = 13000 𝑘𝑔⁄ℎ = 3.61 𝑘𝑔⁄𝑠 𝑥𝐵 = 0.1 𝑘𝑔𝑚𝑜𝑙
𝐷 = 𝑉𝑤 = 1000 𝑘𝑔⁄ℎ = 0.28 𝑘𝑔⁄𝑠 𝑥𝐷 = 0.8 𝑘𝑔𝑚𝑜𝑙

To obtain the number of trays for each reflux ratio, we assumed it is saturated liquid, so the q
line = 1 on the VLE graph (as illustrated in Graph 2), which is vertical line while slope is
infinite.

Sample Calculation: R = 1.6

First, calculate the y-intercept of rectifying line:
𝑥𝐷 0.8
= = 0.31
𝑅 + 1 1.6 + 1
Therefore, rectifying line: y = 0.61x + 0.31
Next, draw in the operating line, from 𝑥𝐷 = 0.8 𝑘𝑔𝑚𝑜𝑙 on the diagonal to y-intercept of
rectifying line. Then, draw in the bottom operating line, from 𝑥𝐵 = 0.1 𝑘𝑔𝑚𝑜𝑙 on the diagonal to
the point of intersection of the top operating line and the q line. After that, starting at 𝑥𝐷 or 𝑥𝐵 ,
step off the number of stages.
***Same method repeated to calculated number of stages for R = 2.6 and R = 3.2. The number
of stages for each reflux ratio are tabulated and shown below. The graph of each reflux ratio will
be shown in Appendix.

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HEC4722 Process Mass Transfer Group A: Distillation Column Design
Table 5: Number of Trays at Each Reflux Ratio

Reflux Ratio Number of Trays

Total Reflux 6
1.6 14
2.6 9
3.2 8

4.1.3 Feed Stage Allocated

The feed stage location can be read off from the graph drawn for theoretical number of trays. It is
the number of triangle drawn from 𝑥𝐵 , to the feed line, which is shown on graph in appendix.
Table 6: Feed Stage Allocated at each Reflux Ratio

Reflux Ratio Feed Stage Allocated

1.6 14
2.6 9
3.2 8

4.1.4 Column Diameter

The flooding velocity can be estimated from the correlation given by Fair (1961)

𝜌𝐿 − 𝜌𝑣
𝑢𝑓 = 𝐾𝑙 √
𝜌𝑣

where, 𝑢𝑓 = flooding vapor velocity, m/s, based on the net column cross-sectional area, 𝐴𝑛 .
𝐾𝑙 = a constant obtained from Figure 2 shown in Appendix.
The liquid-vapor flow factor, 𝐹𝐿𝑉 in Figure 2 is given by:

𝑳𝒘 𝝆𝒗
𝑭𝑳𝑽 = √
𝑽𝒘 𝝆𝑳

where 𝐿𝑤 = Liquid mass flow rate, kg/s.

𝑉𝑤 = Vapor mass flow rate, kg/s.

6
HEC4722 Process Mass Transfer Group A: Distillation Column Design
First, T-xy graph is plotted to obtain the temperature on top and bottom. Then, calculate the
average density of liquid phase for top and bottom by calculating mass at the bottom and top, as
well as mass fraction at the top and bottom.
Table 7: Graphical Temperature at the Bottom and Top of Column

Graphical Temperature values from T-xy plot

Temperature (Celsius) Temperature (K)
At the bottom 86.5 359.65
At the top 77 350.15

Graph 1: T-xy Diagram

4.1.4.1 Calculation of Average Density of Liquid Phase

Table 8: Mole Fraction at the top and bottom obtained from T-xy Graph

Component Ethanol water

Mole fraction at the bottom 0.44 0.56
Mole fraction at the top 0.8 0.2

i. Mass at the bottom = 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑚𝑜𝑙𝑒 × 𝑀𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡

𝑀𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑔
= 0.2 𝑘𝑔𝑚𝑜𝑙 × 46.49
𝑘𝑔𝑚𝑜𝑙
= 4.61 𝑘𝑔
𝑔
𝑀𝑤𝑎𝑡𝑒𝑟 = 0.8 𝑘𝑔𝑚𝑜𝑙 × 18.015
𝑘𝑔𝑚𝑜𝑙
7
HEC4722 Process Mass Transfer Group A: Distillation Column Design
Liquid Density at the bottom = (𝑀𝑎𝑠𝑠 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 𝑎𝑡 𝑡ℎ𝑒 𝑏𝑜𝑡𝑡𝑜𝑚
× 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑎𝑡 359.65𝐾 )
+ (𝑀𝑎𝑠𝑠 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟 𝑎𝑡 𝑡ℎ𝑒 𝑏𝑜𝑡𝑡𝑜𝑚
× 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑊𝑎𝑡𝑒𝑟 𝑎𝑡 359.65𝐾)
= (0.67 × 718.2) + (0.33 × 957.34)
= 797.67 𝑘𝑔⁄𝑚3
= 14.41 𝑘𝑔
*** Same approach to calculate mass at the top.

ii. Mass fraction at the = 𝑀𝑎𝑠𝑠 𝑜𝑓 𝑏𝑜𝑡𝑡𝑜𝑚 × 𝑇𝑜𝑡𝑎𝑙 𝑚𝑎𝑠𝑠

bottom = 20.27 ÷ (20.27 + 10.09)
𝑀𝑒𝑡ℎ𝑎𝑛𝑜𝑙 = 0.67
= 10.09 ÷ (20.27 + 10.09)
𝑀𝑤𝑎𝑡𝑒𝑟 = 0.33
*** Same approach to calculate mass fraction at the top.
Table 9: Data to Calculate Average Density in Liquid Phase

Ethanol Water
Mole fraction at the bottom 0.44 0.56
Mole fraction at the top 0.8 0.2
Mass at the bottom 20.27036 10.0884
Mass at the top 36.8552 3.603
Mass fraction at the bottom 0.667693937 0.332306063
Mass fraction at the top 0.910945124 0.089054876
Next, calculate the density of Ethanol and Water at T = 359.65K and 350.15K using Online
Calculator. The results are shown in table below:
Table 10: Density of Ethanol and Water at particular Temperature

Components Temperature Density

359.65 718.20
Ethanol
350.15 729.02
359.65 957.344
Water
350.15 964.166

*** Same approach to calculate density at the top.

8
HEC4722 Process Mass Transfer Group A: Distillation Column Design
Therefore, density at the top is 749.96 𝑘𝑔⁄𝑚3
797.67 + 749.96
𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑫𝒆𝒏𝒔𝒊𝒕𝒚 𝒊𝒏 𝑳𝒊𝒒𝒖𝒊𝒅 𝑷𝒉𝒂𝒔𝒆, 𝝆𝑳 = = 𝟕𝟕𝟑. 𝟖𝟏 𝒌𝒈⁄𝒎𝟑
2
4.1.4.2 Calculation of Average Density of Vapor Phase
Assumed the overall process is carried out ideally. Therefore, density of vapor phase is
calculated by using ideal gas law.
𝑃𝑉 = 𝑛𝑅𝑇 ; 𝑅 = 8.314 𝑘𝑃𝑎. 𝑚3 ⁄𝑘𝑔𝑚𝑜𝑙. 𝐾
𝑃𝑉
𝑛=
𝑅𝑇
𝑚 𝑃𝑉
=
𝑀𝑤 𝑅𝑇
𝑚 𝑃𝑀𝑤
=
𝑉 𝑅𝑇

Molecular weight, 𝑀𝑤 = (𝑚𝑜𝑙𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙 × 𝑀𝑤 𝑜𝑓 𝑒𝑡ℎ𝑎𝑛𝑜𝑙)

𝑀𝑤,𝑏𝑜𝑡𝑡𝑜𝑚 + (𝑚𝑜𝑙𝑒 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟
× 𝑀𝑤 𝑜𝑓 𝑤𝑎𝑡𝑒𝑟)
𝑀𝑤,𝑡𝑜𝑝 = (0.44 × 46.069) + (0.56 × 18.015)
= 30.36 𝑘𝑔⁄𝑘𝑔𝑚𝑜𝑙
= (0.8 × 46.069) + (0.2 × 18.015)
Vapor Density at the bottom, 𝜌𝑣 = 40.46 𝑘𝑔⁄𝑘𝑔𝑚𝑜𝑙

𝜌𝑣,𝑏𝑜𝑡𝑡𝑜𝑚 𝑃𝑀𝑤
=
𝑅𝑇
(101.3)(30.36)
𝜌𝑣,𝑡𝑜𝑝 =
(8.314)(359.65)
= 1.03 𝑘𝑔⁄𝑚3
(101.3)(40.46)
=
(8.314)(350.15)
= 1.41 𝑘𝑔⁄𝑚3

1.03 + 1.41
𝑨𝒗𝒆𝒓𝒂𝒈𝒆 𝑫𝒆𝒏𝒔𝒊𝒕𝒚 𝒊𝒏 𝑽𝒂𝒑𝒐𝒓 𝑷𝒉𝒂𝒔𝒆, 𝝆𝒗 = = 𝟏. 𝟐𝟐 𝒌𝒈⁄𝒎𝟑
2

9
HEC4722 Process Mass Transfer Group A: Distillation Column Design
Then, calculate flooding velocity, 𝑢𝑓 .
To obtain 𝐾𝑙 , calculate liquid-vapor flow factor, 𝐹𝐿𝑉 first, which is

From Figure 2 (Appendix), 𝐾𝑙 = 0.019

𝐹𝐿𝑉 𝐿𝑤 𝜌𝑣
= √
𝑉𝑤 𝜌𝐿

3.61 1.22
= √
0.28 773.81

= 0.52

From Figure 2 (Appendix), 𝐾𝑙 = 0.019

𝑢𝑓 𝜌𝐿 − 𝜌𝑣
= 𝐾𝑙 √
𝜌𝑣

773.81 − 1.22
= 0.019√
1.22

= 0.48 𝑚⁄𝑠

Design for 80% flooding at maximum flow rate,

Therefore, 𝑢𝑛 = 80% 𝑜𝑓𝑢𝑓

𝑢𝑛 = 0.8 × 0.48
= 0.38 𝑚⁄𝑠
Maximum Volumetric Vapor Flow Rate, 𝑄𝑚𝑎𝑥 𝑉𝑤
=
𝐴𝑣𝑒𝑟𝑎𝑔𝑒 𝐷𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑉𝑎𝑝𝑜𝑟, 𝜌𝑣
0.28
=
1.22
= 0.23 𝑚3 ⁄𝑠
To calculate the column diameter, an estimate of the net area, 𝐴𝑛 is required.
Assumed the downcomer area, 𝐴𝑐 as 12 percent of the total.
𝐴𝑛 𝑄𝑚𝑎𝑥
=
𝑢𝑛
= 0.60𝑚2

10
HEC4722 Process Mass Transfer Group A: Distillation Column Design
𝐴𝑐 𝐴𝑛
=
𝜋 2 % 𝐶𝑜𝑙𝑢𝑚𝑛 𝐴𝑟𝑒𝑎
𝐷
4 = 0.68𝑚2
𝑫 = 𝟎. 𝟗𝟑𝒎
Hence, the column diameter D = 0.93m

4.1.5 Column Height

Initially, assumed tray spacing is 0.6m and column efficiency is 0.7
Equations applied are:
i. Efficiency, 𝜺 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒕𝒉𝒆𝒐𝒓𝒆𝒕𝒊𝒄𝒂𝒍 𝒔𝒕𝒂𝒈𝒆𝒔
=
𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒂𝒄𝒕𝒖𝒂𝒍 𝒔𝒕𝒂𝒈𝒆𝒔
ii. Actual height of column = 𝑻𝒓𝒂𝒚 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 × 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒂𝒄𝒕𝒖𝒂𝒍 𝒕𝒓𝒂𝒚𝒔
iii. Theoretical height of
= 𝑻𝒓𝒂𝒚 𝒔𝒑𝒂𝒄𝒊𝒏𝒈 × 𝑵𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒕𝒉𝒆𝒐𝒓𝒆𝒕𝒊𝒄𝒂𝒍 𝒕𝒓𝒂𝒚𝒔
column
Sample Calculation: R=1.6
Number of actual stages 𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒𝑜𝑟𝑒𝑡𝑖𝑐𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠
=
𝜀
= 15
14
𝐶𝑜𝑙𝑢𝑚𝑛 𝑃𝑒𝑟𝑓𝑜𝑟𝑚𝑎𝑛𝑐𝑒 = × 100% = 93.33%
15
Actual height of column = 0.6 × 15
= 9𝑚
Theoretical height of column = 0.6 × 14
= 8.4𝑚

Table 11: Data of Calculation of Column Height

Reflux ratio 1.6 2.6 3.2

Number of theoretical trays 14 9 8
Efficiency 0.93 0.60 0.53
Number of actual trays 15 15 15
Theoretical height of column (m) 8.4 5.4 4.8
Actual height of column (m) 9 9 9

11
HEC4722 Process Mass Transfer Group A: Distillation Column Design
4.2 Condenser and Reboiler

4.2.1 4.2.1 Condenser & Reboiler Duties (from experimental data)

A graph of refractive index against mole fraction of ethanol in water is plotted and equation of
the graph is determined to be:

𝑦 = 0.1227 𝑥 + 13324 (1)

This equation is used to determine mole fraction of ethanol in water samples collected from
experiment at different reflux ratios.

At reflux ratio, R = 1.6;

Refractive index: n bottom = 1.3469 n distillate = 1.3571

From equation (1), sub respective n values into (1),

⸫ Mole fraction of ethanol in distillate,

1.3571 − 1.3324
𝑥𝐷 = = 0.2013
0.1227

Mole fraction of ethanol is residue (bottom),

1.3496 − 1.3324
𝑥𝐵 = = 0.1402
0.1227

Mole fraction of ethanol: n feed, 𝑥𝐹 = 0.15 (known)

Convert mole fraction to mass fraction

𝑘𝑔 𝑘𝑔
Molecular weight: 𝑀𝑊𝐸𝑡𝑂𝐻 = 46.069 𝑀𝑊𝐻2𝑂 = 18.015
𝑘𝑔𝑚𝑜𝑙 𝑘𝑔𝑚𝑜𝑙

⸫ Mass fraction of ethanol in feed,

46.069 × 0.15
𝑥𝐹 = = 0.3109
(46.069 ∗ 0.15) + (18.015)(1 − 0.15)

Mass fraction of ethanol in distillate,

46.069 × 0.2013
𝑥𝐷 = = 0.3919
(46.069 ∗ 0.2013) + (18.015)(1 − 0.2013)

12
HEC4722 Process Mass Transfer Group A: Distillation Column Design
Mass fraction of ethanol in residue,
46.069 × 0.1402
𝑥𝐵 = = 0.2943
(46.069 ∗ 0.1402) + (18.015)(1 − 0.140)

𝐿
Known – Feed volumetric flow rate (ℎ) = 15

𝐿 𝑘𝑔
Convert (ℎ) 𝑡𝑜 ( ℎ )

First, the density of the mixture in feed is determined (20°C)

𝑘𝑔
𝜌𝐸𝑡𝑂𝐻 = 788.886
𝑚3
𝑘𝑔
𝜌𝐻2𝑂 = 1002.09
𝑚3
At R = 1.6,

𝑥𝐹 = 0.3109 𝑥𝐷 = 0.3919 𝑥𝐵 = 0.2942

⸫ 𝜌𝑚𝑖𝑥𝑡𝑢𝑟𝑒,𝐹 = 𝑥𝐹 𝜌𝐸𝑡𝑂𝐻 + (1 − 𝑥𝐹 )𝜌𝐻2𝑂

= 0.3109 (788.886) + (1 − 0.3109)(1002.09)

𝑘𝑔
= 935.8
𝑚3

⸫ Feed flowrate is,

𝑘𝑔 𝐿 𝑘𝑔 1𝑚3 𝑘𝑔
𝐹 = 15 × 935.8 3 × = 14.04
ℎ ℎ 𝑚 1000𝐿 ℎ

Overall mass balance, 𝐹 =𝐵+𝐷

𝐵 =𝐹−𝐷 (2)

Ethanol mass balance, 𝐹𝑥𝐹 = 𝐵𝑥𝐵 + 𝐷𝑥𝐷 (3)

Substitute (2) into (3)

𝐹𝑥𝐹 = (𝐹 − 𝐷)𝑥𝐵 + 𝐷𝑥𝐷

𝐹(𝑥𝐹 − 𝑥𝐵 ) = 𝐷(𝑥𝐷 − 𝑥𝐵 )

13
HEC4722 Process Mass Transfer Group A: Distillation Column Design
𝐹 (𝑥𝐹 − 𝑥𝐵 ) 14.04(0.3109 − 0.2942) 𝑘𝑔
𝐷= = = 2.40
(𝑥𝐷 − 𝑥𝐵 ) (0.3919 − 0.2942) ℎ

𝑘𝑔
∴ 𝐵 = 14.04 − 2.40 = 11.64
ℎ

4.2.2 Condenser Duty

𝑄𝐶 (𝑊 ) = 𝐷(𝑅 + 1) ∆𝐻𝑣𝑎𝑝, 𝑚𝑖𝑥𝑡𝑢𝑟𝑒

𝑘𝑔
𝐷 = 2.40 𝑅 = 1.6
ℎ

∆𝐻𝑣𝑎𝑝, 𝑚𝑖𝑥𝑡𝑢𝑟𝑒(𝑇14 = 76.1°𝐶 ) = 𝑥𝐷 𝐻𝑣𝑎𝑝, 𝐸𝑡𝑂𝐻 + (1 − 𝑥𝐷 ) 𝐻𝑣𝑎𝑝, 𝐻2𝑂

Note: Hvap,EtOH and Hvap,H2O are determined from online property calculation, DDBST.
𝑘𝐽 1𝑘𝑔𝑚𝑜𝑙 𝑘𝐽
∆𝐻𝑣𝑎𝑝, 𝑚𝑖𝑥𝑡𝑢𝑟𝑒 = (0.3919) (38890.8 𝑘𝑔𝑚𝑜𝑙 × 46.069𝑘𝑔) + (1 − 0.3919) (41464 𝑘𝑔𝑚𝑜𝑙 ×
1𝑘𝑔𝑚𝑜𝑙 𝑘𝐽
18.015𝑘𝑔
) = 1730.6 𝑘𝑔

𝑘𝑔 1ℎ 𝑘𝐽 𝑘𝐽
𝑄𝐶 = 2.40 ( )( ) (1.6 + 1) (1730.6 ) = 3.00 = 3.00 𝑘𝑊
ℎ 3600𝑠 𝑘𝑔 𝑠

4.2.3 Reboiler Duty

𝑄𝑅 (𝑊 ) = 𝐻𝐷 𝐷 + 𝐻𝐵 𝐵 − 𝐻𝐹 𝐹 + 𝑄𝑐

Where HD = Heat of vaporization of mixture in top column, HB = heat of vaporization of mixture

in at the column bottom, HF = heat of vaporization of mixture in feed.

Step to determine HD, HB and HF is similar to that of condenser but at 20°C, T12 = 82.3°C, TI4 =
76.1°C. Thus, using the online property calculation, DDBST, we determine the following
properties of mixture:

𝐻𝐷 (𝑇14 = 76.1°𝐶 ) = 𝑥𝐷 𝐻𝑣𝑎𝑝, 𝐸𝑡𝑂𝐻 + (1 − 𝑥𝐷 ) 𝐻𝑣𝑎𝑝, 𝐻2𝑂

𝑘𝐽 1𝑘𝑔𝑚𝑜𝑙 𝑘𝐽 1𝑘𝑔𝑚𝑜𝑙
𝐻𝐷 = (0.3919) (38890.8 )( ) + (1 − 0.3919) (41464 )( )
𝑘𝑔𝑚𝑜𝑙 46.069𝑘𝑔 𝑘𝑔𝑚𝑜𝑙 18.015𝑘𝑔
𝑘𝐽
= 1730.6
𝑘𝑔

𝐻𝐵 (𝑇12 = 82.3°𝐶 ) = 𝑥𝐵 𝐻𝑣𝑎𝑝, 𝐸𝑡𝑂𝐻 + (1 − 𝑥𝐵 ) 𝐻𝑣𝑎𝑝, 𝐻2𝑂

14
HEC4722 Process Mass Transfer Group A: Distillation Column Design
𝑘𝐽 1𝑘𝑔𝑚𝑜𝑙
𝐻𝐵 = (0.2942) (39402.3 )( )
𝑘𝑔𝑚𝑜𝑙 46.069𝑘𝑔
𝑘𝐽 1𝑘𝑔𝑚𝑜𝑙 𝑘𝐽
+ (1 − 0.2942) (41752.5 )( ) = 1887.4
𝑘𝑔𝑚𝑜𝑙 18.015𝑘𝑔 𝑘𝑔

𝐻𝐹 (𝑇 = 20°𝐶 ) = 𝑥𝐹 𝐻𝑣𝑎𝑝, 𝐸𝑡𝑂𝐻 + (1 − 𝑥𝐹 ) 𝐻𝑣𝑎𝑝, 𝐻2𝑂

𝑘𝐽 1𝑘𝑔𝑚𝑜𝑙 𝑘𝐽 1𝑘𝑔𝑚𝑜𝑙
𝐻𝐹 = (0.3109) (42521.1 )( ) + (1 − 0.3109) (44139 )( )
𝑘𝑔𝑚𝑜𝑙 46.069𝑘𝑔 𝑘𝑔𝑚𝑜𝑙 18.015𝑘𝑔
𝑘𝐽
= 1975.2
𝑘𝑔

𝑘𝐽
[(1730.6)(2.40) + (1887.4)(11.6) − (1975.2)(14.04)] [ ]
∴ 𝑄𝑅 = ℎ + 3.00 𝑘𝑊
3600𝑠

𝑘𝐽
= 2.53
𝑠

= 2.53 𝑘𝑊

4.2.4 Condenser and Reboiler Design

Generally,

𝑄 = 𝑈𝐴∆𝑇𝑚

∆𝑇𝑚 = 𝐹𝑡 ∆𝑇𝑙𝑚

In this study, we assume correction factor for temperature, 𝐹𝑡 = 1

T1 = coolant inlet temperature

T2 = coolant outlet temperature

∆𝑇𝑚 = ∆𝑇𝑙𝑚

𝑇2 − 𝑇1
∆𝑇𝑙𝑚 =
𝑇 −𝑇
𝑙𝑛 𝑇𝑠𝑎𝑡,𝑚𝑖𝑥𝑡𝑢𝑟𝑒 − 𝑇1
𝑠𝑎𝑡,𝑚𝑖𝑥𝑡𝑢𝑟𝑒 2

For condenser,

𝑇𝑠𝑎𝑡,𝑚𝑖𝑥𝑡𝑢𝑟𝑒 = 𝑥𝐷 𝑇𝑠𝑎𝑡,𝐸𝑡𝑂𝐻 + (1 − 𝑥𝐷 )𝑇𝑠𝑎𝑡,𝐻2𝑂

15
HEC4722 Process Mass Transfer Group A: Distillation Column Design
= 0.8(78.3) + (1 − 0.8)(100)
= 82.64°𝐶

29.6 − 28.5
∆𝑇𝑙𝑚 = = 53.59°𝐶
82.64 − 28.5
𝑙𝑛 82.64 − 29.6

𝑊
Assume,𝑈 = 800 ,
𝑚2 °𝐶

𝑄𝐶 = 𝑈𝐴𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 ∆𝑇𝑚

𝑊
1250 𝑘𝑊 × 1000
∴ 𝐴𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 = 𝑘𝑊 = 29.16 𝑚2
𝑊
800 2 × 53.59°𝐶
𝑚 °𝐶

For reboiler,

𝑇𝑠𝑎𝑡,𝑚𝑖𝑥𝑡𝑢𝑟𝑒 = 𝑥𝐵 𝑇𝑠𝑎𝑡,𝐸𝑡𝑂𝐻 + (1 − 𝑥𝐵 )𝑇𝑠𝑎𝑡,𝐻2𝑂

= 0.1(78.3) + (1 − 0.1)(100)
= 97.83°𝐶

82.3 − 84.3
∆𝑇𝑙𝑚 = = 14.51°𝐶
97.83 − 84.3
𝑙𝑛 97.83 − 82.3

𝑊
Assume, = 1000 ,
𝑚2 °𝐶

𝑄𝑅 = 𝑈𝐴𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟 ∆𝑇𝑚

𝑊
1054 𝑘𝑊 × 1000
∴ 𝐴𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟 = 𝑘𝑊 = 72.64 𝑚2
𝑊
1000 2 × 14.51°𝐶
𝑚 °𝐶

4.2.5 Materials of Construction

Materials used in distillation column plays an important role in determining the capital cost of a
plant. Different materials have its own correction factor to be used in calculating capital cost. In
a literature using Guthrie’s correlations to calculate capital cost (Chen & Lin 2001), materials
were not specified but correction factors were set for distillation equipment. Thus, we have
assumed that the most suitable material used in our design is carbon steel due to its economically
16
HEC4722 Process Mass Transfer Group A: Distillation Column Design
superior properties. An acidic reaction would need a distillation column that is made up of
material that is resistant towards corrosion caused by acidic reaction. In the case of ethanol
production, the material most suitable used would be carbon steel or stainless steel. Between the
two material stated, carbon steel is a better material to be used as a construction material. The
properties of each material are shown below in a table.

Table 12: Properties of carbon steel and stainless steel

Thermal
Type of Metal Corrosion Price (per
Component Durability Conductivity
material finish Resistant ton)*
At 20 ̊ C

Alloy of Hard, US $469 – 500

Carbon Dull and
iron and wear- 54 (W/m K) X MYR 2,075.79
Steel matte
carbon resistant – 2,213.00

US $600 -
Alloy of 1,500
Stainless Non- 12 – 45
iron and Lustrous √
Steel brittle, soft (W/m K) MYR 2,655.60
chromium
– 6,639.00

*Price quoted from Alibaba.com and conversion rate using Google from USD to MYR as of 9th Dec 2016

From data above, it can be seen that carbon steel would make a better material for construction
of distillation column. In terms of durability, carbon steel is hard and wear resistant. Compared
to stainless steel which is non-brittle and soft, carbon steel would ensure that the distillation
column would have a longer industrial lifespan thus cutting industrial cost as it would not be
replace for quite some time. In terms of heat conducting, carbon steel is a better material
compared to stainless steel. It has a higher thermal conductivity compared to stainless steel. Thus
no heat energy is loss to surrounding during the process of ethanol production. Although carbon
steel is not corrosion resistant, the process of distilling ethanol-water mixture is not acidic in
nature. For this reason, carbon steel can be used as the construction material even though
stainless steel is corrosion resistant. In terms of cost, provided by Alibaba.com, carbon steel is
cheaper compared to stainless steel. At the highest price of both materials, it can be seen that the
two materials has a difference of about RM4000.00. The right selection of construction material
is important as it determines the cost of the ethanol production indirectly. In this case, carbon
steel is the best material to be used as construction material.

17
HEC4722 Process Mass Transfer Group A: Distillation Column Design

4.3 Operating Cost Analysis

Assumptions: Distillation column is operating 24 hours a day and 365 days a year.

Problem Statement: To produce one metric ton per hour (1000 kg/h) of 0.8 mole% EtOH.

Industry Pricing and Tariff by Sarawak Energy = RM0.26 / unit (1 unit = 1 kWh).

At R = 1.6,

𝑄𝐶 = 3.00 𝑘𝑊

𝑘𝑔
𝐷 = 2.40
ℎ

𝑘𝑔 3.00
∴ 𝑄𝐶 𝑡𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 1000 𝐸𝑡𝑂𝐻 = × 1000 = 1250 𝑘𝑊
ℎ 2.40

𝑄𝑅 = 2.53 𝑘𝑊

𝑘𝑔
𝐷 = 2.40
ℎ

𝑘𝑔 2.53
∴ 𝑄𝑅 𝑡𝑜 𝑝𝑟𝑜𝑑𝑢𝑐𝑒 1000 𝐸𝑡𝑂𝐻 = × 1000 = 1054 𝑘𝑊
ℎ 2.40

Thus,

Daily energy consumption for condenser= 1250 × 24 ℎ𝑜𝑢𝑟𝑠 = 30000 𝑘𝑊 ℎ

Daily energy consumption for reboiler= 1054 × 24 ℎ𝑜𝑢𝑟𝑠 = 25300 𝑘𝑊 ℎ

Cost of electricity per day (RM),

𝑅𝑀 0.26
𝐶𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 = 30000 𝑘𝑊ℎ × = 𝑅𝑀 7,800/𝑑𝑎𝑦
𝑘𝑊ℎ

𝑅𝑀 0.26
𝑅𝑒𝑏𝑜𝑖𝑙𝑒𝑟 = 25300 𝑘𝑊ℎ × = 𝑅𝑀 6,578/𝑑𝑎𝑦
𝑘𝑊ℎ

Thus, annualized cost for electricity,

𝐶𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟 = 𝑅𝑀 7800 × 365 𝑑𝑎𝑦𝑠 = 𝑅𝑀 2,847,000

𝑅𝑒𝑏𝑜𝑖𝑙𝑒𝑟 = 𝑅𝑀 6,578 × 365 𝑑𝑎𝑦𝑠 = 𝑅𝑀 2,400,970

TOTAL operating cost (annualized) = RM 2,847,000 + RM 2,400,970 = RM 5,247,970.

18
HEC4722 Process Mass Transfer Group A: Distillation Column Design
4.4 Capital Cost Analysis
For heat exchangers, the following equation is used for capital cost calculation:

𝑀&𝑆
𝐶 ($) = ( ) (101.3)𝐴0.65(2.29 + 𝐹𝐶 )
280

Where A is heat transfer area in ft2 and FC is correction factor. In this case, FC = 1.0 for
condenser and FC = 1.45 for reboiler. M&S index is set at 792.

Purchase cost for condenser, CC

792 10.7639 𝑓𝑡 2
= 280 (101.3) ((29.16𝑚2 ) ( ))0.65(2.29 + 1.0) = $ 39,561
1𝑚2

In MYR,

4.42
$ 39,561 × 𝑅𝑀 = 𝑅𝑀 174,859
$1

Purchase cost for reboiler, CR

792 10.7639 𝑓𝑡2

= 280 (101.3) ((72.64 𝑚2 ) ( ))0.65(2.29 + 1.45) = $ 81,394
1𝑚2

In MYR,

4.42
$ 81,394 × 𝑅𝑀 = 𝑅𝑀 359,760
$1

For distillation column, the equation used for capital cost calculation is as follows:

𝑀&𝑆
𝐶 ($) = ( ) (101.9)𝐷1.066𝐻 0.802(2.18 + 𝐹𝐶 )
280

Where D is column diameter in ft, H is column in ft and correction factor, Fc is estimated at 1.15
while M & S = 792.

Purchase cost for distillation column, CD

792 𝑓𝑡 1.066 𝑓𝑡 0.802

=( ) (101.9) [(0.9283 𝑚) (3.28 )] [(8.40) (3.28 )] (2.18 + 1.15)
280 𝑚 𝑚

= $ 44,943

19
HEC4722 Process Mass Transfer Group A: Distillation Column Design
In MYR,

4.42
$ 44,943 × 𝑅𝑀 = 𝑅𝑀 198,650
$1

Thus, total capital cost = RM (174,859 + 359,760 + 198,650) = RM 733,269

4.5 Total Cost Analysis

Therefore, at R = 1.6,

Total Cost of Ethanol-Water Distillation Plant

= Total Annual Operating Cost + Capital Cost

=RM 5,247,970 + RM 733,269 = RM 5,981,239

5 Discussion

Costings at Different Reflux Ratio

12,000,000.00

10,000,000.00

8,000,000.00
Cost (RM)

6,000,000.00

4,000,000.00

Optimum Reflux
2,000,000.00
Ratio, R = 1.6

0.00
1.5 1.7 1.9 2.1 2.3 2.5 2.7 2.9 3.1 3.3
Reflux Ratio, R

Annual Operating Cost (RM) Capital Cost (RM) Total Cost (RM)

Graph 2: Costings at Different Reflux Ratio

20
HEC4722 Process Mass Transfer Group A: Distillation Column Design
Three different reflux ratios are used to find the optimum reflux ratio in this experiment by
totalling up capital cost and annual operating cost calculated. The chosen reflux ratios are 1.6,
2.6 and 3.2. Each different reflux ratio will yield a different dimension and costs in which the
relation as seen in Graph 2, the higher the reflux ratio, the higher the cost of a plant.

The diameter of column for each reflux ratio however remains the same which is 0.9283m. The
height of column however decreases as the reflux ratio increases. Similar trend can be seen in
number of trays, actual and theoretical. Reflux ratio 1.6 has the highest height of 8.4m and reflux
ratio 3.2 has a height of only 4.8m. The area of reboiler and condenser is increasing as the reflux
ratio is increasing. Reflux ratio 1.6 has smallest area of condenser and reboiler with respectively
an area of 29.15m2 and 73.31m2. Reflux ratio 3.2 has the biggest area of condenser and reboiler,
with an area of 46.82m2 and 135.53m2 respectively. Each reflux ratio has its own theoretical tray
from the graph, with reflux ratio 1.6 having the highest number of trays of 14, followed by reflux
ratio 2.6 with 9 trays and reflux ratio 3.2 with 8 trays. It can be seen that a smaller reflux ratio
will yield a higher number of trays and a bigger reflux ratio will yield a smaller number of
theoretical trays. The column performance for each reflux ratio is also different and affects
which reflux ratio will be chosen as the optimum reflux ratio. Reflux ratio 1.6 has the highest
efficiency of 93.33%. Reflux ratio 2.6 and 3.2 have an efficiency of 60% and 53% respectively.
This shows that the efficiency decreases as the reflux ratio increases. A smaller reflux ratio
yields a higher efficiency.

In terms of cost, reflux ratio 1.6 has the least operating cost with an annualised operating cost of
RM 5,268,926.94. This is due to it cooling duty and heating duty that is much smaller than the
other two reflux ratio. The cooling duty and heating duty is 1249.83kW and 1063.54kW
respectively. The annualised operating cost for reflux ratio 3.2 is RM 9,040,833.48. This is due
to its large cooling and heating duty of 2027.20kW and 1942.26kW.

Capital cost for reflux ratio of 1.6 is around RM 735,505.59 and capital cost is increasing as
reflux ratio increases. When reflux ratio is 3.2, the capital cost is RM 903,720.54. Thus, the total
cost for both reflux ratio, are RM 6,004,432.53 and RM 9,944,554.02 respectively. This shows
reflux ratio 3.2 operates at the highest cost compared to the other two ratios.

It can be seen that reflux ratio 1.6 is the optimum reflux ratio as it has the lowest total cost as
compared to the other two ratios.

21
HEC4722 Process Mass Transfer Group A: Distillation Column Design

6 Schematic of Distillation Column Design

D = 0.93 m

xD = 0.8,
D = 1000 kg/h

R = 1.6
Theoretical No. of Trays = 14
ε = 93.33%
Condenser
H = 8.4 m
Cooling Duty, Qc = 1250 kW
Area = 29.15 m2
Reboiler
Heating Duty, Qr = 1064 kW
0.6 m Area = 73.31 m2

xF = 0.15

xB = 0.1
Figure 1: Distillation Column Design Specifications of Ethanol-Water Mixture

22
HEC4722 Process Mass Transfer Group A: Distillation Column Design

7 Conclusion
In conclusion, the objective of this report has been achieved. A tray distillation column has been
designed to purify one metric tonne per hour of 80 mole% ethanol in water. It has been
determined that the optimum reflux ratio to obtain the desired purity is 1.6 with minimal
operating cost of RM 5,268,927 annually. Moreover, with this reflux ratio the total cost can also
be kept to a minimum as compared to the higher reflux ratios. It has also been calculated that the
number of theoretical trays required for the distillation column with a reflux ratio of 1.6 is 14
trays along with 8.4-meter height of the column and a diameter of 0.9283 meters. The column
performance at this reflux ratio was also calculated as 93.33%. It has also been found that the
condenser and reboiler duties increase with higher reflux ratios which have a direct impact on the
cost of the column as their energy consumption increases which increases the electricity cost
therefore, increasing the annual operating cost. Thus, it can be concluded that a tray column with
an optimum reflux ratio of 1.6, cooling duty of 1249.83 kW and heating duty of 205.47 kW is
selected as the final design for the distillation column.

8 Recommendations
It is recommended to design a distillation column with an optimum reflux ratio for which the
total cost would be the least. As the reflux ratio increases, the number of stages decreases which
requires larger equipment to handle the large reflux ratio and the increased reboiled vapour load
(Anon 2016). Typically, the optimum reflux ratio is approximately 1.2-1.5 times Rmin. It is also
recommended to have a known correction factor of a known material to estimate the equipment
cost more accurately.

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HEC4722 Process Mass Transfer Group A: Distillation Column Design

9 References

Anon 2016, "Heat of Vaporization Calculation by PPDS12 Equation", DDBST Online Services,
viewed 25 November, 2016,
<http://ddbonline.ddbst.com/PPDS12HVPCalculation/HVP_PPDS12CalculationCGI.exe>.

Anon 2016, "Industrial Pricing & Tariff", Sarawak Energy, viewed 27 November, 2016,
<http://www.sarawakenergy.com.my/index.php/customers/industrial-pricing-tariff>.

Anon 2016, "Liquid Density Calculation by DIPPR105 Equation", DDBST Online Services,
viewed 25 November, 2016,
<http://ddbonline.ddbst.com/DIPPR105DensityCalculation/DIPPR105CalculationCGI.exe>.

Anon 2016, "Optimum Reflux Ratio", Separationprocesses.com, viewed 10 December, 2016,

<http://www.separationprocesses.com/Distillation/DT_Chp04n3.htm>.

Chen, H & Lin, Y 2001, "Case Studies on Optimum Reflux Ratio of Distillation Towers in
Petroleum Refining Processes", Tamkang Journal of Science and Engineering, vol. 4, no. 2, pp.
105-110.

Hoogstraten, C & Dunn, K 1998, The Design of A Distillation Column, 1st ed, viewed 3
November, 2016, <http://learnche.mcmaster.ca/wiki_4M3/images/c/c7/Distillation-project-
report-vanHoogstraten-Dunn-UCT-1998.pdf>.

Sinnott, R 1999, Coulson & Richardson's Chemical Engineering, 3rd ed, Butterworth-
Heinemann, Oxford.

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HEC4722 Process Mass Transfer Group A: Distillation Column Design

10 Appendix

VLE Graph
1.00
0.90
0.80
0.70
Mole Fraction, y

0.60
0.50
0.40
0.30
0.20
0.10
0.00
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Mole Fraction, x

Graph 3: VLE Graph of Mixture

Graph 4: VLE Graph with Operating Line and Number of Trays (Total Reflux)

25
HEC4722 Process Mass Transfer Group A: Distillation Column Design

Graph 5: VLE Graph with Operating Line and Number of Trays (R = 1.6)

Graph 6: VLE Graph with Operating Line and Number of Trays (R = 2.6)

26
HEC4722 Process Mass Transfer Group A: Distillation Column Design

Graph 7: VLE Graph with Operating Line and Number of Trays (R = 3.2)

Refractive index against Mole Fraction of EtOH

1.355

y = 0.1227x + 1.3324
1.3508
1.35 R² = 1
Refraction index

1.345

1.34

1.335

1.3324

1.33
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
Mole Fraction of Ethanol

Graph 8: Refractive index against Mole Fraction of EtOH

27
HEC4722 Process Mass Transfer Group A: Distillation Column Design

Figure 2: 𝑲𝒍 against 𝑭𝑳𝑽

28