Design Of Distillation Column 50

CHAPTER
8
Design of
Distillation
Column

8.1 PURPOSE OF THE UNIT

Separating the Diesel-cut* from waste engine oil.

*The term "diesel cut" refers to a medium distillate with a boiling point
range of the products of which it is composed, varying from 200 to 360° C.

8.2 Significance of Unit In Over-all Process:-

 If we allow the diesel to go in final product then it will increase flammability and
has effect on viscosity grades of Lube
 It is important not to subject the waste oil above 350 ℃ because high molecular
weight component in the waste oil will under-go thermal-cracking and form
petroleum coke. So by creating vacuum of 15 Torr the operation become stable and
separation become easy.
 Fractionation is more effective at low pressure than at high pressure because of larger
differences in the vapor pressures of the components at a low pressure
 Atmospheric distillation above 250 ℃ is not economical because of steam-cost. So
by creating vacuum we are saving energy.

8.3 Choice Between Plate And Packed Column1

Vapour liquid mass transfer operation may be carried either in plate column or packed column.
These two types of operations are quite different. A selection scheme considering the factors under
three headings.

i) Factors that depend on the system i.e. scale, foaming, fouling factors, corrosive
systems, heat evolution, pressure drop, liquid holdup.
ii) Factors that depend on the fluid flow moment.
Design Of Distillation Column 51

iii) Factors that depends upon the physical characteristics of the column and its
internals i.e. maintenance, weight, side stream, size and cost.
Fig 8.1

The relative merits of plate over packed column are as follows:

i) Plate column are designed to handle wide range of liquid flow rates without
flooding.
ii) If a system contains solid contents, it will be handled in plate column, because
solid will accumulate in the voids, coating the packing materials and making it
ineffective.
iii) Dispersion difficulties are handled in plate column when flow rate of liquid are
low as compared to gases.
iv) For large column heights, weight of the packed column is more than plate column.
v) If periodic cleaning is required, man holes will be provided for cleaning. In
packed columns packing must be removed before cleaning.
vi) For non-foaming systems the plate column is preferred.
vii) Design information for plate column are more readily available and more reliable
than that for packed column.
viii) Inter stage cooling can be provide to remove heat of reaction or solution in plate
column.
ix) When temperature change is involved, packing may be damaged.

For this particular process, “Gasoline, Water, Diesel, Lube, Heavy Residue”, I have selected
plate column because:
i) Diameter is > 0.67m
ii) Av.Temperature is high (149o C).
Design Of Distillation Column 52

iii) Height of the Column is very large as it comprises 54 stages.

iv) System comprises of heavy residue up to 5%

8.4 Choice Of Plate Type2

There are three main tray types, the bubble cap, sieve tray, valve trays. I have selected sieve
tray because:
i) They are lighter in weight and less expensive. It is easier and cheaper to install.

ii) Pressure drop is low as compared to bubble cap trays.

iii) They can easily handle wide variation in flow rates.

iv) Maintenance cost is reduced due to the ease of cleaning.

v) Their fundamentals are well established and entailing low risk.

3 Fig 8.2

Sieve Bubble Cap Tray Valve Tray

Tray

8.5 Material Balance

Table 8.1
Component Feed Bottom Top
(Kg/hr) (Kg/hr) (Kg/hr)
Gasoline 27.97 0 27.97

Water 1.45 0 1.45

Diesel 234.57 10.85 223.707

Design Of Distillation Column 53

Lube 3868 3847.127 20.873

S- Compounds 61.68 61.68 0

Heavy- Residue 197.751 228.216 0

TOTAL F=4,391.68 B= 4117.68 D=274.00

F = B + D

Selection Of Key On the basis of Relative Volatility

Gasoline = Lighter than light key (L.L.K)

Water = Lighter than heavy key (L.L.K)
Diesel = Light –Key(Recovery at top = 95%)
Lube = Heavy Key(Recovery at bottom =99.5%) Distributed Component

S-Compounds = Heavier than heavy Key

Heavy Residue = Heavier than heavy Key

8.6 Energy Balance

HEAT IN = HEAT OUT

(mCp∆T)Feed+ = (mCp∆T)B +(mCp∆T)Top + (Condenser)Duty

(q∆P)Feed +(Reboiler )Duty (q∆P)Top + (q∆P)B

602.71K-watt = 589.12 K-watt

 Design Of Distillation Column 54

8.7 Design Of Column

Nature of Feed. 4
Feed is entering in column as a saturated liquid at T=1300C & P=202.65KPa
By Bubble point ; it is verified that feed is at saturated liquid
Component Xf Ki α Ki*Xf Estimation of Top
Temperature. 4-a
Gasoline 0.00196 19.45 32.40 0.00369 By Dew point
Water 0.0111 4.30 7.20 0.04 calculation,
∑Ki/Xd=∑Xd;
Diesel 0.2820 2.5 4.20 0.7050
T=107℃ and P=3.0KPa
Lube 0.606 0.60 1 0.360
∑Ki*Xf
=1.09
Hence by dew point calculation; T=1070C & P=3.0KPa

Component Xd Ki α Ki/Xd
Gasoline 0.0064 43.89 58.50 .00004
Water 0.03 23.36 31.20 .00158
Diesel 0.95 .98 1.30 0.964
Lube 0.01 0.75 1 0.050
∑Ki/Xd 1.01
 Design Of Distillation Column 55

Estimation Of Bottom Temperature.4-b

By Bubble-point Calculation ∑Ki.Xb=∑Xb ;T=190℃ & P=25KPa
Comp Xb Ki α Ki*Xb
Diesel 0.0042 3.0 2.50 0.010
Lube 0..890 1.2 1 1.060
∑Ki*Xb=
1.07

Table 8.2
TOP CONDITION BOTTOM CONDTION

LN = 16.89Kgmol/hr.
LW′=2501.62Kg/hr.
VN′=LN+D=18.26Kgmol/hr.
T=1070C
P=3KPa
(d)vapor=14.53Kg/m3
(d)liquid=754 Kg/m3
LM=LN+F=29.67Kgmol/hr.
LW=6893.30Kg/hr.
VM=LM-B=18.8Kgmol/hr.
T=1900C
P=25KPa
(d)vapor=14.53Kg/m3
(d)liquid=850 Kg/m3

8.8 Standard Design Steps Of Distillation Column5

 Calculation of Minimum Reflux Ratio Rm.
 Calculation of Actual reflux ratio.
 Calculation of Theoretical number of stages.
 Calculation of Actual number of stages.
 Calculation of Diameter of the column.
 Calculation of Weeping point.
 Calculation of Pressure drop.
 Calculation of Entrainment.
 Calculation of the Height of the column
 Design Of Distillation Column 56

FLOW SHEET-6

T =1070C
P=3KPa

(1) Gasoline = 0.0064

(2) Diesel= 0.95
(3 Lube = 0.0105
(4) Water = 0.037
TOP PRODUCT
Total-
Moles=1.775Kgmol/hr

T=1900C
P=25KPa

Feed

P=202.65KPa
T=1300C
(1) Gasoline = 0.0019
(2) Water = 0.0411
(3) Diesel = 0.282
(4) Lube = 0.606 1)Diesel=0.0042; (2)LUBE=0.89; (3)H.Residue=.04; (4)S-
(6) H. Residue =.028 Compounds=.07 ; Total Moles=11kgmol/hr BOTTOM PRODUCT
(7) S-Compounds
=.044
Total Fig 8.3
Moles=12.78Kgmol/hr
. 8.8-1 Minimum Reflux Ratio
Rmin ; By using underwood method:
Design Of Distillation Column 57

Using underwood equation

α A xfA α x
 B fB  1  q
αA  θ αB  θ
As feed is at its bubble point so q = 1
By iteration on Micro-soft Excel ; Value of  = 2.04
Using equation of Minimum reflux ratio,
α A xDA α x
 B DB  R m  1
αA  θ αB  θ

R min = 6.76

For optimum Reflux Ratio; Using Rule Of Thumb7:

R = (1.2 ------- 1.35) Rm

R = 1.35 Rmin
R = 9.13

8.8.2 Calculating Minimum No. Of Stages , Using Fenske’s equation

Nmin + 1 = ln[(xLK/xHK)D/(xLK /xHK)B]
ln (αLK/HK) average
= ln[(0.95/0.01)/(0.0042/0.89)]
ln(1.80)
= 16

8.8.3 Theoretical No. of Plates

Gilliland related the number of equilibrium stages and the minimum reflux ratio and the no.
of equilibrium stages with a plot that was transformed by Eduljee into the relation;

N – 16 0.75 1- 9.13-6.76 0.566

N+1 9.13+1

We get the theoretical No. of stages;

N=27

8.8.4 Column Efficiency:

Average temperature of column = (190+107)/2=148.5
Feed viscosity at average column temperature = ave = 0.58 Cp
Relative volalitoly of Light key (ave). = 1.80
Design Of Distillation Column 58

Putting values in following relation;

  
  avg . avg
Eo  51  32.5log 

  
= 51- 32.50[Log(1.80*0.58)] = 50.40%
So, No. of actual trays = 27/.5040 = 54

8.8.5 Location Of Feed Plate

The Kirk bride method is used to determine the ratio of trays above and below the feed point.

Log(ND/NB) = 0.206Log[(11/1.778)*(0.606/0.282)*(0.0042/0.01)2]
ND/NB = 0.63; ND+NB = 54; NB+0.63NB =54
NB = 34
ND = 20 ; So feed is entering at plate 21 from top.

8.8.6 Determination of the Column Diameter8

Because liquid and vapour flow rates are greater at bottom so based upon bottom flow rates.

Vapour load at bottom

= (2775.62)/(.1453*3600) = 7.7 m3/Sec

Liquid load at bottom

= (6893.3)/(850*3600) = 2.30  10-3 m3/Sec

Tray Dynamics:
i) Flow Parameter:

= =0.21

FLV = Liquid Vapour Factor

ii) Capacity Parameter:
Assumed tray spacing = 24 inches = 0.61m
From Fig 15-5 (b) of “ Plant Design & Ecnomics for Chemical Engineers”, sieve tray
Flooding capacity,
Csb = 0.07 m/Sec
Surface tension of system =  =17 dynes/Cm
Net vapor velocity at flooding;
Design Of Distillation Column 59

= 4.53 m/sec
Actual Vapor Velocity
VN = 0.80 Vnf = 3.60 m/sec
Net-Area =An= Volumetric flow rate of vapor
Actual vapor velocity
= 7.70/3.60 = 2.13m2
Assume that downcomer occupies 15% of Cross-sectional Area; then
Cross-Sectional Area=AC = 2.13/0.85=2.50m2

Diameter of Column = Ac = D2 => D=

D =1.80m { based upon bottom condition}

By performing calculation in the same manner as above, the diameter comes at top
(Rectifying Section)
D = 1.60m
The calculated diameter at the top of column is 1.60m.As the diameter is more in bottom so
calculations are carried out on the basis Of bottom . Use same diameter at top while reducing
the perforation area at the top.
iii) Flooding Check

Vn = = 7.7/2.13 = 3.61 m/Sec

Vnf = 4.53m/sec
Now F = (3.61/4.53)*100 = 79.8 ~ 80%

iv) Calculation of Entrainment

As FLV = 0.21 and F = 80%
From Figure 11.29 of coulson 6 , we calculate
 = 0.007
 = Fractional Entrainment factor
since  < 0.1, so now process is satisfactory
Net area = An =2.13 m2
Tower Cross-sectional Area=A c= An /.15 = 2.50 m2
Fig 8.4 Fig 8.4
Active area = Aa = Ac - 2Ad = 1.75 m2

Down comer area = Ad = 0.15 Ac = .375 m2

Hole area = Ah = 0.1 Aa = 0.175 m2
Take weir height ; hw=25mm
Hole diameter; dh=5mm
Plate thickness= xw= 5mm
 Design Of Distillation Column 60

V) Weir Length(LW):
Ad/Ac = 0.15
Lw/Dc =0.82
Lw =1.48m

VI) Estimation Of Weep point :

K2 = Constant depending upon the depth of the clear liquid

. Weir Crest
How = 0.4
(GPM) =35.68=6893.3Kg/hr=1.91Kg/hr
How = 6.8 mm & At 70% turn-down ratio
How = 5.2mm = 0.70 1.91 = 1.34 kg/sec
Now Hw + How = 25+6.8 = 31.80 mm
Using fig; 11.30 of Coulson vol 6.
K2 = 29.2

= 2.84 m/sec
Max. Volumetric flow rate = 7.7 m3/sec
Min. Vapour Rate = 0.7 7.7 = 5.39 m3/sec
Actual Min. Vapour Velocity = (5.39) / .175
= 30.8 m/sec Fig 8.5
Actual Min. Vapour Velocity
So no Weeping

vii) Tray Pressure Drop

Ht =Hd + ( Hw + How ) + Hr
(a) Hw = 25 mm
How= 6.8mm
(b) Dry Tray Drop
Hd = 51 (Uh/Co)2 (rV /rL)
Hd = Dry tray drop.
Uh = Hole velocity = Qv/Ah

Uh = = = 38.50 m/sec

Tray thickness = 5mm [For Carbon steel tray]

Hole dia = 5 mm
= 0.1
Design Of Distillation Column 61

Using Fig. 11.34 of Coulson 6. We

find “Co “
Co = Orifice Coefficient = 0.84

Hd = 51

= 51

= 9.96 mm liquid
(c) Residual Head ( Hr)

Hr = =

= 14.7 mm liquid

Ht =Hd + ( Hw + How ) + Hr
= 9.96 + 25 + 6.8 + 14.7
= 56.46 mm Fig 8.6
Total Pressure Drop:
Pt = (9.81 10e-3) Ht
= 9.81 10e-3 95.8 850
= 470 Pa=0.07Psi /per tray
Allowable drop is 0.1Psi per tray

viii) Back up in Down comer (Hbc)

Hbc = Hw + How + Ht + Hdc

Hdc = 166

Am = either Ad or Aap ( The clearance area under the down comer .) which one is smaller.
Aap = Hap lw
Hap = hw - 5 = 25 – 5 = 20 mm
Aap = (20/ 1000) 1.48
=0.03 m2
i.e less than Ad so it is used In finding Hd

Hdc = 166

= 2.0 mm
Hbc = Hw + How + Ht + Hdc
= 25 + 6.2 +56.46 + 2 Fig 8.7
= 89.66 mm = 0.08966 m
Hbc ½ ( Tray Spacing + Weir height )
0.089 ½ ( 0.61 + 0.025)
0.089 0.31
 Design Of Distillation Column 62

As downcomer liquid back up is less than tray spacing; So tray spacing is acceptable.

ix) Total no. Of Holes Fig 8.8

Total no. of holes =

Ah = Area available for holes = 0.175m2

ah =Area of one hole = D2 = (3.14 .0052)/ 4 = 0.00002 m2

Total no. of holes = = 8750

x) Check-Residence Time
Sufficient residence time should be allowed in the downcomer for the entrained vapors to
disengage from liquid stream to prevent aerated liquid being carried under the downcomer.
tr =Ad hbc ρL/L(max)
= (0.375*0.08966*850)/1.91
= 15sec.
It should be greater than > 3sec. So result is satisfactory.

xi) Hole Pitch (lp)

= 0.1

dh = 5mm

= 0.9

Hole Pitch = lp = 15 mm

7.8-e Height of Distillation Column9

Height of column Hc= (Nact-1) Hs+ ∆H+ plates thickness

No. of plates = 54
Tray spacing = 0.61 m
Distance between 54 plates = 0.61 53 = 32.33 m
Top clearance = 1.20 m
Bottom clearance = 1.80 m
Tray thickness = 5 mm/plate
Total thickness of trays = 0.005 27 = 0.27 m
Total height of column = 32.33 + 1.20 + 1.80 + 0.27
= 35.60 m
The Length/Diameter ratio of a tower should be no more than 30 and preferably below 20
 Design Of Distillation Column 63

Length/Diameter = 35.6/1.80 = 19.70

7.8 PLATE SPECIFICATIONS:
The Plates are supported on a ring welded around the vessel wall, and on the beams about
50mm wide. Allow 50mm wide calming zones.
lw/Dc = 0.80 ; Өc = 1090
Angle subtended at plate edge by
Unperforated strip = 180o – 109o = 71o
 Length of unperforated edge strips :
(1.80 – 50*10-3) p *71 = 2.2m
180
Area of unperforated edge strip =Au
= 50*10-3*2.2
= 0.11m2
 Mean length of Claming Zone:
(1.80-50*10-3)*Sin(109/2) Fig 8.9
= 1.3 m
 Area of calming zone
Acz = 2*50*10-3*1.30= 0.13m2
 Total area available for perforations:
Ap = Aa – (Au + Acz)
= 1.75 – (0.11 + 0.13) = 1.51 m2
Ah/Ap = .175/1.51 = 0.11
From Graph 11.33,
6th Ed., Coulson and Richardson
lp/dh = 2.75 (satisfactory i.e. b/w 2.5—4.0)

Fig 8.10

Specification Sheet

Identification:
Item Distillation column
Equipment-Code T-100
No. required 1
Tray type Sieve tray
Design Of Distillation Column 64

Function: Recovery of Diesel cut from Engine’s waste oil

Operation: Continuous

Design Data

No. of trays 54 Hole area/Active area 0.10

Pressure 3kPa Weir length 1.48 m

No of Holes 8750 Reflux Ratio)min. 6.76

Height of column 35.60 m Reflux ratio 9.13

Column-Diameter 1.80m Hole size 5mm

Tray spacing 0.61m Down comer area 0.3 75 m2

Tray thickness 5mm Hole area 0.175 m2

Flooding 80 % Active area 1.75 m2

Refrences:
1. Peters, Max S., Timmerhaus, Klaus D., and West, Ronald E., "Plant
Design and Economics for Chemical Engineers", Fifth Edition,Chapter-15, McGraw-Hill,
2003
2 . Rober H.Perry “Perry’s Chemical Engg. Hand book: Chapter-13 ;
McGraw-Hill,1999
3. www.separationprocesses.com /chap-2/theory/pot_chp02b.htm
4’4-a’4-b; Coulson and Richardson’s “Chemical Engg.” Vol.02; 5th Ed.
Design Of Distillation Column 65

Chap.11’p-570
5. PDF Manual; Klm Tech. Group; Engg. Design Guidelines Checked by:
Karl Kolmetz; And all calculation procedure and equation are taken
Coulson and Richardson’s “Chemical Engg.” Vol.06; 5th Ed.
6. www.separationprocesses.com, chapter-2
7. Rules of Thumb for Chemical Engr. Carl Branan; 3rdEd. Chap.-03,p-51
8. PDF Manual; Klm Tech. Group; Engg. Design Guidelines Checked by:
Karl Kolmetz
9. Coulson,Richardson,Vol.6,Ed.3rd ,Chemical Engineering Design,Butterworth Heinemann
Publishing,1999