Role of External and Internal reflux and Effect of subcooled reflux on flooding of a distillation column

A distillation column is an essential item used in the distillation of liquid mixtures to separate the mixture into its
component parts, or fractions, based on the differences in volatilities. They can be the most complex to operate
and control because they involve two-phase, multi-stage, counter-current mass, and heat transfer, with each tray
or segment of packing representing a theoretical equilibrium stage. The greater the number of trays, the longer the
time constants related to composition changes.
Degrees of freedom
For a two-product distillation column (top and bottom product), there are typically five degrees of control freedom
(control valves):

-Reflux flow
-Top product flow
-Reboiler heat input flow
-Product flow
-Pressure control valve, the specific location of which depends upon how the pressure is controlled.

What is reflux?

Reflux refers to the portion of the condensed overhead liquid product from a distillation tower that is returned to
the upper part of the tower. Inside the tower, the downflowing reflux liquid provides cooling and partial
condensation of the up-flowing vapors, thereby increasing the efficacy of the distillation tower. The more reflux
that is provided, the better is the tower's separation of the lower boiling from the higher boiling components of the
feed. A balance of heating with a reboiler at the bottom of a column and cooling by condensed reflux at the top of
the column maintains a temperature gradient (or gradual temperature difference) along the height of the column
to provide good conditions for fractionating the feed mixture.

External and internal reflux:

In simple words, as the external reflux cools the top of the tower, vapors made of heavier fraction condense and
liquid made of heavier faction flows down the tower and it’s referred to as internal reflux.
Refluxing increases the purity of the overhead products because condensation of the heavier fraction keeps them
out of the stream of vapor that leaves the top of the tower. Meanwhile, the top of the tower is still hot enough to
keep the lighter fraction in vapor form. The vapor is drawn off the top of the tower into the condenser.
Partial condenser
Partial condensers are used in distillation columns when the distillate product is removed as a vapor stream. This
approach is commonly employed when there are very light components in the feed to the column that would
require a high column pressure or a low condenser temperature to completely condense these very volatile
components. The use of a partial condenser can avoid the use of costly refrigeration in the condenser.
For a total condenser, however, the operating reflux is often a subcooled liquid at column pressure, particularly if
the distillate bubble-point temperature is significantly higher than the inlet cooling-water temperature.

Total condenser
In a total condenser, all of the vapor leaving the top of the column is condensed. Consequently, the composition of
the vapor leaving the top tray y1 is the same as that of the liquid distillate product and reflux, xD.
External and Internal reflux

Reflux ratio

Images for McCabe Thiele diagram: All lines explained

Yn = [ Ln+1/Vn] Xn+1 + [ D/Vn] XD

Ln+1 is liquid going down from n+1 plate, Vn is vapor going up from n plate, Xn+1 is the mole fraction of liquid from
n+1 plate, D is overhead product, and XD is the mole fraction of product in the outgoing stream
In the above equation,
Ln+1/Vn is called as internal reflux ratio (IR).

D/Vn is called as external reflux ratio (ER).

At steady state,
Ln+1/Vn = 1-D/Vn
Total Reflux is the operating condition where vapor and liquid are passing each other in the column but no product
is removed (i.e., D = 0 and R = L/D = ∞). The slopes of the Operating Lines are then L/V = 1.0, that is by mass
balance, between each plate y = x. At total reflux, the number of theoretical plates required is a minimum. As the
reflux ratio is reduced (by taking off product), the number of plates required increases. The Minimum Reflux Ratio
(R min) is the lowest value of reflux at which separation can be achieved with an infinite number of plates. It is
possible to achieve a separation at any reflux ratio above the minimum reflux ratio. As the reflux ratio increases,
the number of theoretical plates required decreases.
The Optimum Reflux Ratio (R0) is that at which the total cost of the distillation is a minimum, taking into account
the capital cost of the column (which depends on the number of theoretical plates) and running cost, which
depends on the reflux ratio. Note that the capital costs of the reboiler and condenser also depend on the reflux
ratio. Thus, usually for very low energy costs R0/Rmin = 1.3, and for high energy cost R0/Rmin = 1.1

Subcooled reflux
What is sub-cooled reflux?
The term subcooling refers to a liquid existing at a temperature below its normal boiling point. Reflux is subcooled
liquid.
If the liquid reflux is colder than the bubble-point temperature, then it will condense some vapor in the top stage.
This changes the reflux ratio to the internal reflux ratio. Most distillation columns are designed so that the reflux is
a saturated (at the bubble-point) liquid. This is not always the case for operational columns. If the condenser type is
partial, the reflux is a saturated liquid unless heat losses cause its temperature to decrease.
Excessive sub-cooling

In the actual operation of distillation columns, the reflux is usually highly subcooled below its bubble point because
of technical difficulties in column operation and overdesigned total condensers. Another reason is it may be
advantageous to sub-cool the overhead product of a column at the condenser instead of using an additional
product cooler.
The subcooled reflux causes partial condensation of the vapor near the top of the column where the subcooled
reflux is introduced and the condensed vapor joins the external reflux to produce a larger internal reflux flow rate.
Similar effects may also be expected at the feed point for the introduction of the subcooled feed. What people
usually do is to sub-cool the feed to the distillation column. One reason is a feed may be subcooled is to optimize
energy. The feed stream going to the column is a source of heat that could be cross-exchanged with the colder
stream. Heat and mass transfer near the point of introduction of the subcooled liquid will be much affected by the
condensation of the vapers
Operational issues with excessive subcooling of reflux
Since mostly, excessive subcooling of reflux is a local decision this is often not taken into account when sizing
column internals. This may lead to premature flooding, loss of column efficiency, and reduced capacity.
Excessive subcooling of a reflux feed condenses some of the internal vapor traffic. This, in turn, increases the liquid
traffic in the affected area of the column thus producing resistance to the rising vapor and generating pressure in
the column. The increased pressure from vapor blocks the liquid flow in the downcomer, causing an increase in a
liquid holdup on the plate above and eventual flooding.
Often, this is countered by cutting back on the amount of reflux being introduced into the column or by adjusting
the condenser duty. When this is done, reductions in reflux being introduced will have an effect on the
effectiveness of the column.

Sub-cooling also reduces overall column efficiency. The subcooled reflux or feed shifts some of the internal
equipment from a mass-transfer service to a heat-transfer service.
Subcooled liquid feed mechanism
Sub-cooled liquid feed is at a temperature below its column-pressure bubble point. The effect of a subcooled feed
or reflux can be estimated by:

LF change in liquid flow at the feed stage

F total moles of feed (reflux)
H molar enthalpy of liquid feed at conditions to the column
h* molar enthalpy of liquid feed at the column pressure boiling point
Heq molar enthalpy of vapor that would exist in equilibrium with the feed if the liquid feed were at the column
pressure boiling point.

L1

L2

Subcooled reflux and

Sub-cooled reflux to tower
premature flood

Referring to above LHS figure, we see that LF equals L2-L1. When a sub-cooled liquid feed is used, the increase in
liquid molar flow at the feed stage is greater than the liquid molar feed rate alone. Vapor rising to the feed stage is
condensed in order to raise the feed conditions to the bubble point temperature. The condensing vapor increases
the liquid flow leaving the feed stage, flooding the column, figure RHS