Week 2

Distillation Sequencing

ChE 453
Chemical Engineering Design (2020-21)
IIT Kanpur
 Distillation Sequencing ChE453 (2020-21), IIT Kanpur

Now will start our discussion on sequencing of distillation columns. Here, we consider that only simple
distillation is possible where only 2 product outlets are present, the distillate and the bottoms.

If we consider a simple binary AB mixture, then only one distillation scheme is possible, where A is taken as
distillate and B is taken as the bottoms. If we have of mixture of more than 2 components such as an ABC
mixture, then more than one sequences are possible.
a. Direct Sequence: A/B split is targeted. From the first column A is taken as distillate and BC mixture as the
bottoms Which is sent to the second column. There B is taken as the distillate and C as bottoms.
b. In-direct Sequence: hey BC split is targeted. on the first column AB mixture is taken as distillate and C as
bottoms. the AB mixture is then sent to the second column, where A is taken out as distillate and B as
bottoms.

So the natural question is out of these 2 possible sequences which sequence should be preferred and why ?
There are few guidelines which exist but their scope is rather limited and they do not work in different
situations, therefore it is not straight forward to decide what sequence should be preferred. However, over the
years, scientists have developed few heuristics which help us with the decision making.

Few Guidelines
a. Remove the hazardous or the toxic component as early as possible.
b. Remove the components which are temperature sensitive as early as possible.
 Heuristics ChE453 (2020-21), IIT Kanpur

Heuristics:
i. Do the easy separation first and difficult later.

Let us take an example of an ABC mixture. Here, the relative volatility of A-B is high but the relative volatility of
BC is low. The heuristic suggest that we should do the AB split first and favour the direct sequence over the
indirect sequence. let's see why?

let's assume that the mixture is equimolar with all the components feed rate as 100 kmol per hour. In the direct
sequence in column 1 (C1), distillate will be A ~ 100 kmol hr-1 and since the split (A/B) is easy a moderate reflux
~ 100 kmol hr-1 will work. In column 2, distillate will be B ~ 100 kmol hr-1 and since the split (B/C) is difficult so
higher reflux ~ 10* distillate (i.e. 1000 100 kmol hr-1) will be needed. So the design requirement for column 2 is
constraint both in terms of the capital cost (column dia) as well as the operating cost (reboiler duty). If we now
consider the indirect sequence, in column 1 distillate will be AB~ 200 kmol hr-1 and since the split is difficult a
reflux ~ 2000 kmol hr-1 will be needed. In column 2 hey distillate will be A ~ 100 kmol hr-1 so a reflux of 100
kmol hr-1 will be adequate. So clearly in the indirect sequence the design requirement for C1is much more
stringent compared to the design requirement of C2 in the direct sequence. Therefore the direct sequence is
more economically favourable compare to the indirect sequence.
 Heuristics ChE453 (2020-21), IIT Kanpur

Heuristics:
ii. Prefer the direct split over indirect split
Again let's consider the example of an ABC mixture. In the direct split in column 1 A is taken out as distillate
and in Column 2 B is taken out as distillate. So essentially both A and B are being vaporized only once.
However if we consider the indirect split, then in column 1 AB mixture is being distillated which is then sent to
the second column for separation. Hence A is being vaporized twice so we spend more energy compared to
the direct split.

iii. Remove in the component in excess first

let's assume that the ABC mixture with A~10 kmol/hr, B ~10 kmol/hr and C~200 kmol/hr. If we do the direct
split then both C1 has to be designed to handle feed of 220 kmol/hr and C2 will have to be designed to
handle 210 kmol/hr. Whereas, if we do the indirect split C1 will have to be designed to handle 220 kmol/hr
feed but C2 for 20 kmol/hr. So since one of the components was in excess the design requirements became
less stringent if that component is removed early.

iv. Favor the split with near equal molar flow rates from the two sections in all columns
To understand this heuristic first we need to understand an important concept of remixing in columns.
Suppose we do a direct split for an ABC mixture. C being the heaviest component will mainly go to the
stripping section and will not leak beyond few trays (say n) above the feed tray in the rectifying section. C will
not leak to any tray above n. B being the intermediate boiling point component will leak to few trays (above n)
in the rectifying section, beyond which there will be no leakage of B. It will be only A above that. In the
rectifying section, A will only leak upto a few trays beyond which there be no A. It is at that point B will be
maximum in concentration as beyond that C will start to increase.
 Heuristics ChE453 (2020-21), IIT Kanpur

It is at that tray that B will be maximum in concentration. As we go down C will start to increase so B will decrease
again (see figure). So essentially, we purified the intermediate component and then remixed that with the
heaviest component again, which leads to energy inefficiency. Similar inefficiency will be there in the indirect split.
This inefficiency will always be there whenever we have an intermediate boiling point component

Same problem will be with the indirect split. One way to remove this inefficiency is to target the AC split instead
of AB (direct) or BC (indirect) split. Because of this intended split some amount of B is allowed to go with the
distillate which means we get AB mixture from the distillate and BC mixture from the bottoms. These mixtures
can be further separated in separate columns. In the overall scheme in the first column the concentration profile
of B remains nearly flat with minimal remixing. This overall scheme is also known as pre fractionator sequence.
 Heuristics ChE453 (2020-21), IIT Kanpur

Prefractionator Scheme

The capital cost is higher due to one extra column, which however can be coupled with other (which will be
discussed in state task network lectures). But this scheme is known to save 20-30% operating cost because of
reduced issue of re-mixing of intermediate component.
 Heuristics ChE453 (2020-21), IIT Kanpur

Next, we need to understand the effect of skewness of the fed composition on the operating cost. Lets use
Mcabe Theiele method for that:
Consider two types of AB mixture feed
1) F1 is the feed such xB~xD. It remains mid way to xD and xB.
2) F2 is the feed for the skewed split xB>>xD. It shifts closer to xB.
Overall F1 and F2 molar flow rates are the same just that its position shifts. x is the mole fraction of the volatile
component (A).

o For F1, the slop of the operating line is lesser so

lower reflux ratio
o For F2, operating line is closer to the y=x i.e.
maximum reflux ratio line, so higher R

o Therefore if the feed is less skewed the R is lesser

so the reboiler duty becomes less
 Heuristics ChE453 (2020-21), IIT Kanpur

Now that we understand Remixing of intermediate component and the effect of the skewness of feed on
the operating cost, lets see how the heuristic iv helps.
Lets take an example of ternary ABC mixture feed such that A ~50 , B ~150 and C ~ 100 kmol/hr

IF we follow the heuristic and do AC split, instead as

In Direct Split, C1 operates at skewed feed and faces following both the issues of remixing and skewness
the issue of remixing. Similarly in In-direct split C1 and of feed can be minimized and operating cost can be
C2 both operate with skewed split and C1 faces the reduced (infrastructure cost can be reduced through
issue of Remixing. combining C2 and C3, will be discussed later).

50 50
200
150

250 150
C1 100 100
C2
C2 C1

Direct Split In-Direct Split

 Triple outlet column ChE453 (2020-21), IIT Kanpur

Sometimes it is possible to draw an additional outlet from a simple column. Two such possibilities are shown
below.
In the first column side vapor draw of B is taken (below feed) and in the other a liquid side draw of B is taken
(from above feed).
The first one is typically used when B is in majority (>50%) and C is very less compared to A. Since C is very less
the tray below feed at which B is maximum will be nearly pure B, when A/B split is targeted.
The second is used when A is very less so that above the feed at some where B will be maximum when B/C split is
targeted.