DESIGN CALCULATIONS

RMIN = 0.75 ; R= 1.13

1) Average molecular weight of feed
= (0.46 x 32.04) + (0.54 x 18)
kg
= 24.46
kmol

2) Molar Feed Flow Rate, F

kg kmol
= 25000 *
hr 24.46 kg
kmol
=1022.077
hr

3) Methanol Balance
kmol
D * 0.99 = 1022.077 * 0.46
hr
kmol
D = 474.9
hr

4) Vapor Flow Rate Above Feed Plate, V

V = D (1+R)
= 474.9 (1 + 1.13)
kmol
= 1011.54
hr

5) Top Section Liquid Flow Rate, L

L=V–D
= 1011.54 – 474.9
kmol
= 536.64
hr

6) Bottom Product Molar Flow Rate, B

B=F–D
= 1022.077 – 474.9
kmol
= 347.177
hr

7) Mass Balance Below Feed Plate

L’ = V’ + B
 L' (0.46−0.03)
=
V ' (0.76−0.03)
= 0.59
L’ = V’ (0.59)
Optimum Vapor Flow Rate, V’
0.59V’ = V’ + 547.77
kmol
V’ = 927.42
hr

Optimum Liquid Flow Rate, L’

L’ = V’ + B
= 927.42 + 547.77
kmol
= 1475.19
hr

60 % Column Efficiency ; Reboiler is assumed to be 1 stage

Number of Theoretical Stages
= 12 Stages

Number of Real Stages

12−1
=
0.6
= 18 stages
TOP SECTION
Column Top Pressure = 101325 Pa (1 atm)
Column Top Temperature = 65˚C

Average Molecular Weight of Vapor

(0.995 x 32) + (0.005 x 18)
kg
= 31.9
mol

Average Molecular Weight of Liquid

(0.995 x 32) + (0.005 x 18)
kg
= 31.9
mol

Average Molecular Weight of Liquid

(0.99 x 32) + (0.01 x 18)
kg
= 31.8
mol

Density of Vapor
PM
ծv=
RT
101325 X 32.9
=
8314 X 338.15
kg
= 1.15
m3
Density of Liquid (Mixture)
kg
= 750
m3

BOTTOM SECTION
Column Bottom Pressure = 123825 Pa
Column Bottom Temperature = 100˚C

Average Molecular Weight of Vapor

kg
= 31.6
mol

Average Molecular Weight of Liquid

(0.995 x 32) + (0.005 x 18)
kg
= 31.9
mol

Average Molecular Weight of Liquid

(0.99 x 32) + (0.01 x 18)
kg
= 18.42
mol

Density of Vapor
PM
ծv=
RT
101325 X 31.6
=
8314 X 373.15
 kg
= 1.03
m3

Density of Liquid
kg
= 955
m3

PLATE DESIGN
Plate Spacing = 600 mm (initial assumption)
Column Diameter = More than 1.5 m
Flooding = 80% of Maximum Gas Flow Rate
Total Downcomer (Top & Bottom Seal Area) = 10% of Net Area

TOP SECTION

Liquid-Vapour Flow Factor FLV

L ρV 0.5
FLV = ¿ )
V ρL
536.64 x 31.8 1.15 0.5
= ( )
1011.54 x 31.9 750
= 0.021

Csf = 0.12 m/s

Gas Velocity Through The Net Area

σ 0.2 ρL−ρV
Unf = Csf ( ) ( )0.5
20 1011.54 x 31.9
 13.5 0.2 750−1.15 0.5
= 0.12 x ( ) ( )
20 1.15
= 3.02 m/s

LINEAR DESIGN GAS VELOCITY (Un)

Un = 0.8 x 3.02
= 2.42 m/s

Maximum Volumetric Vapor Flow Rate (QMAX)

1011.54 x 31.9
Q MAX =
1.15
= 7.79 m3/s
Net Area Required
QMAX
=
Un
7.79
=
2.42
= 3.322 m2

Total Tower Cross Section Area

3.22
0.9
= 3.58 m2

Column (Tower) Diameter

4x4
=( π ) 0.5

= 2.14 m
BOTTOM SECTION

Liquid-Vapour Flow Factor Flv

L' ρV 0.5
FLV = ¿ )
V ' ρL
1475.19 x 18.42 1.03 0.5
= ( )
927.42 x 31.6 955
= 0.03

Csbf = 0.11 m/s

Gas Velocity Through The Net Area

σ 0.2 ρL−ρV
Unf = Csbf ( ) ( )0.5
20 1011.54 x 31.9
58.85 0.2 955−1.03 0.5
= 0.11 x ( ) ( )
20 955
= 4.15 m/s

Linear Design Gas Velocity (Un)

Un = 0.8 x 4.15
= 3.32 m/s

Maximum Volumetric Vapor Flow Rate (QMAX)

927.42 x 31.6
Q MAX =
1.03
= 7.9 m3/s

Net Area Required

QMAX
=
Un
7.79
=
3.32
= 2.38 m2
Total Tower Cross Section Area
2.38
0.9
= 2.6 m2

Column (Tower) Diameter

2.6
= ( 0.785 ) 0.5

= 1.82 m

 Larger value of the tower diameter is taken as the first trial value.
DESIGN OF COLUMN SHELL
Shell with recommended diameter, D = 2.4m is the closest, in market option to the actual column
diameter of 2.14 m. Carbon steel in IS 2844 – 1964 : ID 2403 mm with minimum wall thickness
of 8mm is used.

LIQUID FLOW ARRANGEMENT

Liquid Volumetric Flow Rate (Top Section)
536.64 x 31.8
=
3600 x 750

= 0.006 m3/s

Liquid Volumetric Flow Rate (Bottom Section)

1475.29 x 18.42
=
3600 x 955

= 0.008 m3/s
*Single pass cross-flow sieve plate is chosen.

PLATE DESIGN
DT = 2.4 m
AT = 0.785 x Dr2
= 4.52 m2
AD = 0.1 AT
= 0.452 m2

Net Area = AN = AT - AD
= 4.52m – 0.452m
= 4.068 m2
Active Area : AA = AT - 2* AD
= 4.52 – 2 * 0.452m
= 3.616 m2

AH = ± 10 % of AN
= 0.489 m2
Weir Length
LW = 0.73 DT
= 1.752 m

Weir Height
hw = 40 mm is considered

Hole Diameter
1st Trial : dh = 12mm
: Plate thickness = Hole Diameter
= 12 mm
CHECK WEEPING (TOP SECTION)

Max Liquid Flow Rate (MMax)

536.64 x 31.8
=
3600
= 4.98 kg/s

Min Liquid Flow Rate (MMin )

= (70% of MMAX)
= 0.7 x 4.98 kg/s
= 3.49 kg/s

Max Weir Crest, hwc

= 750¿) 2/3
= 750¿) 2/3
= 18.23mm Liquid Height
Min Weir Crest, hwc
= 750¿) 2/3
= 750¿) 2/3
= 14.38 mm Liquid Height

Minimum rate, hwc + hw

= 40 + 14.38
= 54.38 mm
Constant (K1) = 30.1 ( pg 587, figure 11.30)

Minimum Vapor Velocity

(Umin) = ¿)

= ¿)
= 16.82 m/s

Actual Minimum Vapor Velocit, Umin actual

= ¿)
= ¿)
=11.15 m/s
CHECK WEEPING (BOTTOM SECTION)

Max Liquid Flow Rate (MMax)

1475.19 x 18.42
=
3600
= 7.5 kg/s

Min Liquid Flow Rate (MMin )

= (70% of MMAX)
= 0.7 x 7.5 kg/s
= 5.25 kg/s

Max Weir Crest, hwc

= 750¿) 2/3
= 750¿) 2/3
= 20.38 mm Liquid Height

Min Weir Crest, hwc

= 750¿) 2/3
= 750¿) 2/3
= 16.08 mm Liquid Height

Minimum rate, hwc + hw

= 40 + 16.08
= 56.08 mm

Constant (K2) = 30.5 ( pg 587, figure 11.30)

Minimum Vapor Velocity at Weep Point

(Umin) = ¿)

= ¿)
= 17.73 m/s

Actual Minimum Vapor Velocity, Umin actual

= ¿)
= ¿)
=25.4 m/s
*Minimum operating rate will be well above weep point.
PLATE PRESSURE DROP (TOP SECTION)
QMAX
Umax =
AH
7.79
=
0.489
= 15.93 m/s

Dry Plate Pressure Drop

Umax 2 ρV
Hd = 51( ) ( )
Co ρL
15.93 2 1.15
= 51( ) ( )
0.88 750
= 25.62 mm Liquid

AH
Co = 0.88 at = 15% & (Plate Thickness/ Hole Diameter) =1
AP

Residual Head
12500
hr =
ρL
12500
=
750
= 16.68 mm Liquid

Total Pressure Drop (Plate)

ht = hd + ( hwc + hw) + hr
= 25.62 + (40 +14.38) + 16.68
= 96.68 mm Liquid

Plate Pressure Drop

= 125kPa= 127 mm H2O
The estimated value in the first trial is acceptable. Max pressure drop at the top of the column
is 96.63 mm H2O and 87.72 mm H2O at the bottom.
PLATE PRESSURE DROP (BOTTOM SECTION)
QMAX
Umax =
AH
7.9
=
0.489
= 16.16 m/s

Dry Plate Pressure Drop

Umax 2 ρV
Hd = 51( ) ( )
Co ρL
16.16 2 1.03
= 51( ) ( )
0.88 955
= 18.55 mm Liquid

Residual Head
12500
hr =
ρL
12500
=
955
= 13.09mm Liquid

Total Pressure Drop (Plate)

ht = hd + ( hwc + hw) + hr
 = 18.55 + (40 +16.08) + 13.09
= 87.72 mm Liquid

DOWNCOMER BACKUP LIQUID AND DOWNCOMER RESIDENCE TIME

hap = hw -10
Aap = hap Lw
= 0.03 x 1.752
= 0.0525 m2
Aap ¿ AD = 0.452 m2

Head Loss In Downcomer (Top Section)

Lwd 2
hdc = 166( )
ծ L Am
4.98
= 166( )2
750 x o .0525
= 2.66 mm
LWD = Am is smaller of Aap & Ap

Downcomer Backup
h’b = (hwc + hw) + ht + hdc
= (40 + 14.3) + 96.68 + 2.66
= 153.64 mm
Downcomer Residence Time, t drt
AD hbc ρL
=
LWD
0.452 x 0.15364 x 955
=
4.98
=13.325 > 3s

Head Loss In Downcomer (Bottom Section)

Lwd 2
hdc = 166( )
ծ L Am
7.5
= 166( )2
955 x o .0525
= 3.71 mm
LWD = Am is smaller of Aap & Ap

Downcomer Backup
hb = (40 + 16.08) + 87.72 + 3.71
= 147.51 mm

Downcomer Residence Time, t drt

AD hbc ρL
=
LWD
0.452 x 0.14751 x 955
=
4.98
=12.795 > 3s
1
(Plate space + Weir Height)
2
= ½ (600 +40)
= 320 mm

hd (top) = 25.62 mm
hd (bottom) = 18.55 mm

PROVISIONAL PLATE DESIGN

Perforated Area (Ap)
Ap = AA – ACZ - AES
ACZ = Calming Zones Area
AES = Area Occupied by edge strip

Angle Sustended by the Chord (Edge Plate)

α = 180˚ - 95˚
= 85˚

Unprotected Edge Strip (Edge Plate) Mean Length From Geometry

ʃES = (DT – 0.05) x (απ/180˚)
= (2.4 – 0.05) x ( 85˚π / 180˚)
= 3.49 m

AES = 0.175 m2
*Use 50 mm wide calming zones (Approximately mean length of zones)

ICZ = Weir Length (LW) + Width of unperforated Edge Strip

= 1.752 + 0.05
= 1.802 m

ACZ = 2( 0.05 x 1.752)

= 0.18 m2

Perforated Area Per Tray (AP)

= 3.616 – 0.18-0.175
= 3.26 m2
Total Hole Area, AH
= 0.15 AA
= 0.489 m2

Number of Holes ,nh

AH = 0.785 x dh2 x nh = 0.489 m2
nh = 4326

AH 0.489
= = 0.15( for equilateral pitch)
AP 3.26

AH dh 2
= 0.907 ( )
AP Ip
dh 2
0.15 = 0.907 ( )
Ip
dh =
2.46
Ip
*The hole-pitch to hole- diameter is close to falling within the normal range of 2.5 to 4 which
is acceptable.

Ip = 29.5 mm

ENTRAINMENT CHECK (TOP SECTION)

Actual Vapor Velocity Based on Net Area (An)

Qmax
Uv =
An
7.79
=
4.068
= 1.91 m/s

% Flooding
Uv
x 100 %
Unf
1.91
= x 100%
3.02
= 63.25 %

Fractional Entrainment, ψ = 0.48 ; FlV = 0.021

*Actual flooding velocity

= 76% (figure 11.29 pg 586)

Murphee plate Efficiency

E MV
Ea = ψEmv
1+
1−ψ
= 0.58
Ea = Murphy Vapor Efficiency = Liquid Entrainment
ENTRAINMENT CHECK (BOTTOM SECTION)

Actual Vapor Velocity Based on Net Area (An)

Qmax
Uv =
An
7.09
=
4.068
= 1.94 m/s

% Flooding
Uv
x 100 %
Unf
1.94
= x 100%
4.15
= 47 %

Fractional Entrainment, ψ = 0.01 ; FlV = 0.03

Murphee plate Efficiency
E MV
Ea = ψEmv
1+
1−ψ
Ea = 0.596

DESIGN OF COVERS FOR THE COLUMN

Head Design – Shallow Dished and Torispherical Head
Thickness of Head, th
P x Rc x W
= ; P = internal Design Pressure( kg/cm2) = 1.03323 kg/cm2
2 x ft x J
; Rc = Crown Radius = Diameter of Shell,mm = 2140 mm
RK = Knuckle Radius, 6% of Crown Radius = 0.06 x 2140 mm = 128.4 mm
ft = Permissible tensile Stress = 970 kg/cm2

W = Stress Intensification Factor for Torispherical Head

W = ¼ x ( 3 + (RC/RK)0.5)
 = ¼ x (3 + (2140/128.4)0.5)
= 1.7706 mm
1.03323 x 2140 x 1.7706
th =
2 x 970 x 0.85
= 2.37 mm

Torisperical Head

CR = Do (standard Type Head) / 1.3 x Do (flat ttype Dished Head)

KR = 15 – 50 mm (Depending on Size)
T = Wall thickness = 2.37 mm
Do = Outside Diameter
Di = Inside Diameter
SF = Straight Hange Height = 8.295 mm
DH = Dished Height
THi = Total Height Inside = 900 mm
CR = Crown Radius = 2140 mm
KR = Knuckle Radius = 128.4 mm

*Operated at Atmospheric Pressure (Top Trays)

Dh = THi – t –SF
Dh = 889.34 mm

Shell Minimum Thickness

ts = ( P x Di) / ( 2 x ft x J) + C
P = Design Pressure, kg/cm2 = 1.03323 kg/cm2
Di = Diameter of Shell,mm = 2140 mm
ft =permissible stress, kg/cm2= 970 kg/cm2
C = Corrosion Allowance, mm = 3mm
J = Joint Factor = 85% = 0.85

ts = (1.03323 x 2140) / (2 x 970 x 0.85) – 1.03323) + 3

= 4.34 mm