PRG PR Ves 0011 r00 e Columns

$
DESIGN CRITERIA
RIA
A
GUIDE TO PROCESS
ROCESS SIZING
ROCE
ZZ FRACTIONATING
ATING COLUMNS
NATING
PRG.PR.VES.0011
RG.PR.VES.001
BO
R 0
Rev.
December 1996
Decem
Dece
Ex PRG.PR.VES.3 - Rev. 0 - January 1989
Form code: MDT.GG.QUA.0508 Sht. 01/Rev. 1.94 File code: CRIDESBI.DOT Data file: PRG_PR_VES_0011_R0_E.doc
CONFIDENTIAL document. Sole property of Snamprogetti. Not to be shown to Third parties or used for purposes other than those for which it has been
sent.
$ PRG.PR.VES.0011
Rev. 0 Date Dec. 1996
Sheet 2 (35)
CONTENTS
1. GENERAL 3
1.1 Scope and field of application 3
A
1.2 References 3
2. FRACTIONATING COLUMN DESIGN 4

2.1 Definition of heat and material balance 4
2.2 Contact devices 6
2.3 Overall column configuration 20
3.
3.1
3.2
ZZ
Vessel data sheet
Graphic information
ATA
TA SHEETS
GUIDE TO FILLING OUT DATA 29
29
31
3.3 Tray or packing data sheet 32
BO
sent.
$ PRG.PR.VES.0011
Sheet 3 (35)
1. GENERAL
1.1 Scope and field of application
The purpose of the present document is to define the criteria to follow

ow for the process
sizing of fractionating columns, including internals and nozzles.
s.
The field of application is that of oil and chemical plants.
A
1.2 References
1.2.1 International Regulations and Standards References

rences
ences
ASME, Sect. VIII, Div. 1 Boiler and Pressure

ressure
essure Vessel Code
1.2.2 Company Standardization References

ces
es
ZZ
OPR.GE.XE.0001
OPR.MO.XE.5011
PRG.GG.GEN.0001
Design engine
engineering for oil and chemical plants
Process engineering for primary oil and chemical
Definition and s
selection of design
chem
n temper
tempera
systems
temperature and pressure
0001
PRG.GG.NRM.0001 Guide to metric
etric (SI) unit of measurem
measurement
S.0001
0001
PRG.PR.VES.0001 ssi
Guide to selecting and process sizing vessels
.GEN.0001
PRG.PR.GEN.0001 Material selection and corros
corrosion prevention in process units
G.PR.GEN.0003
PR.GEN.0003
PRG.PR.GEN.0003 Guide to selecting standa
stand
standards for process equipment internals
STD.CR.GEN.7041
D.CR.GEN.7041 Feed a
and re flux
lux distr
reflux distri
distributors
STD.CR.GEN.7029
D.CR.GEN.7029 Tangential entra
entran
entrance with anti-erosion plate
BO
STD.SM.GEN.0001
D.SM.GEN.0001 Overall dime
dimensions and types of installation for instruments
on
n pressu
pres
pressurized and atmospheric vessels
sent.
$ PRG.PR.VES.0011
Sheet 4 (35)
2. FRACTIONATING COLUMN DESIGN
The process design of a fractionating column comprises the following phases:

phases
x Definition of heat and material balance, via simulation.
x Choice of contact devices (trays or packings).
x Calculation of diameter and other dimensions.
A
2.1 Definition of heat and material balance
The heat and material balance calculation represents

presents
pr esents the first phase in the design of a
fractionating column. It defines the operating
ng conditions for the column, the number
numbe of
theoretical stages and the liquid and vapor
orr loads
loads for each stage. This phase requires tthe
definition of:
x constraints
ZZ x parameters
Constraints are determined
load and products, while
d from basic pro
the functioning of the column

Constraints are defined
olumn wwithin
with
project data according
e the parameters are
ing to the characteristics
in the established constraints.

fined before starting the calculation,
ccalculation, while
char
chara
ar defined by the design engineer
engin
e the parameters
pa
of
to optimize
are refined
during the study of the base case, i.e. thee case that conditions the size of the column.
2.1.1 Constraints
s
The constraints
onstraints that affect the calculation
calculation of the heat a
ca an
and material balance are:
a)) Feed flow and composition
The flow and composition of the feed areare normally
n determined by the performance
of the upstream units. Before st
starting tthe
h calculation, the process design engineer
BO
must check that these are unambiguously

unambiguo
unam defined and that all operating situations
or
of the column are covered in order to guarantee operability under all foreseen and
foreseeable
oreseeable circumstances.
b) Product specifications and flow rate
ecifications for the products are fixed by contract or by the requirements of
The specifications
the downstream units.
un
The flow rate can be determined from the total balance of the plant or complex, or
om a cost
from co study of the column.
c) Column
umn operating
oper pressure
he specifications
The spe
specifi for the column head product, together with the normally available
means of o cooling (air or water), define the pressure to be established in the column.
If the pressure creates critical conditions for the bottom product (temperature close
to critical conditions or that of decomposition), it may be necessary to provide head
cooling with a coolant fluid or operate in a vacuum or in the presence of steam to
reduce the partial pressure.
In general, it is assumed that the operating temperature must be at least 30°C
below the critical temperature.
For example, in the design of an absorption column, the pressure value is dictated
by a cost balance. A higher pressure increases the cost of compression but
reduces the cost of absorption. In general, decisions are made on the basis of
sent.
$ PRG.PR.VES.0011
Sheet 5 (35)
previous projects fixing, for example, the pressure at a level that can
n reached with
wit
one or two compression stages.
2.1.2 Parameters
The parameters that affect the calculation of the heat and material
terial balance
nce a
are:
a) Feed conditions
A
If it is wished to balance the diameter of a column mn
n above and below the feed, it is
necessary to control the feed’s enthalpy content.nt.
t.
Too low a temperature overloads the reboiler, boiler, while too high a temperature
eboiler, tempera
oversizes the condenser. Sometimes, it may be advantageous to preheat the feed
up to the limit that can be achieved by heat exchange with the column bottom bo
product.
The optimal preheating temperature ure can be defined as that which minimizes the
ture tth
sum of the heat quantities to supply
pply to tthe
upply condenser.
he reboiler and to take from the condens
condense
b)
ZZ Pressure
Normally, the pressure iss a constraint,
design parameter. For
decrease the number
pressure can be
a cooling cycle.
le.
constraint but at times, it can also be considered
or example, in ssuperfractionation,
ber of trays and the reflux by working
e achieved
chieved by maintaining
maintainin a low
low temperature
cons
consid
n, it can be opportune to
uperfractionation,
as a
lower pressure. Low

ng at a lowe
ture in the
th reflux drum using
c) Feed tray
y position
The optimal
timal position for the feed tray is that
ptimal t th reflux requirement is least.
for which the
Bad
d positioning thus results in excessive reflux.
d) Side ex
extractions
Extraction must be provided from the tray in which the liquid has the most similar
composition to that of the desired product
product. According to whether it is wished have
good fractionation of the light or heavy ends, extraction can be carried out in the
BO
column’s stripping or rectification

rectification sections
secti respectively.
e) Fractionation trays in terms o of rreflux
The trays increases as the reflux decreases.
he number of fractionation tra
tray
Generally,
nerally, it is economically advantageous to use a large number of trays, keeping
reflux as low as possible, minimum reflux permitting.
f) liquid in absorption systems
Cold rrecycling of liqu
The num
number and po positioning of cold liquid recycles are parameters to examine in the
design
sign o absorption system. Increasing the number of recycles reduces the
of an ab
number
ber o trays and the flow of absorption oil.
of tray
2.1.3 Calculation methodology

m
The ca
calculation of the heat and material balance is normally carried out using
com
comp
computerized calculation systems.
T
Th
The final calculation uses tray-tray simulation, but the analysis to define the base case
and optimal parameters can be made with short-cut methods. Short-cut methods should
also be used to develop the results of each attempt at rigorous calculation and to
prepare the start data for the subsequent attempt.
sent.
$ PRG.PR.VES.0011
Sheet 6 (35)
In addition to using short-cut methods to shorten the calculation times, the following
followin
stratagems can also be adopted in the exploratory phase to size up the base case:
x Group components and then divide them in the final rigorous
us
s calculat
calculation. It is
necessary however to have the foresight not to group components
mponents
nents close to kkey
components.
x Opportunely choose the thermodynamic methods to use e in the preliminary
iminary and final
phase. The choice of thermodynamic methods (method ethod
thod of calculating equilibrium
A
constants, the definition of any tuning parameters rs
s and interaction constants, and
evaluation of the achieved separation sensitivity with respe respec
respectt to these factors)
actors) is one
o
ns that perform “difficult” separation
of the critical criteria in sizing distillation columns separations.
x Initially set just a few trays and a high reflux.
x.
x Preferably set operating variables such
ch as temperatures, pressure and flow rate
r
instead of product specifications.
The following programs for rigorouss calculations
calcula ons are currently
calculati tly used within the company:
compa
compan
ZZ
2.2
2.2.1
–
–
PROCSIM, developed in-house
PRO/II, licensed from SSI
Contact devices
SI
ouse
Description of the fundamental components

ents of a fractionation tray
A fractionation
tion
on tray, indifferently of ty
type,
pe, is character
characteriz
characterized by the fundamental
nts described below
components below.
a) Tower a area
This is the sum of the bubbling
bubbling area and the do
dow
downcomer areas.
b) Fre
Free area
This is the minimum column are
area availab
available for vapor flow or the tower area less the
BO
downcomer area.
dow
c) Bubblin
Bubbling area
This
his is the area included between
betw the walls of the column, the outlet weir and the
inlet weir, excluding the area that is delimited by a line around the edge (100 mm) of
the holee area.
d) Downc
Downcomer
This is th
the pipe tha
that allows the liquid to descend from one tray to the one below.
e) Downcomer
wnco u
upper area
This
s is th
the m
maximum area at the top (or inlet) of the downcomer.
f) Downco
Downc
Downcomer lower area
This iis the minimum area at the bottom of the downcomer.
g) D
Downcomer seal area
This is the area at the bottom of the downcomer that, in addition to sealing the
downcomer, also serves for distributing the liquid on the tray.
h) Hole area
This is the area through which vapor arriving from the tray below passes.
sent.
$ PRG.PR.VES.0011
Sheet 7 (35)
2.2.2 Meaning of more frequently used terms
a) Blowing
Blowing is the fine dispersion of a liquid that is entrained to the
e upper tray due to
t the
high velocity of vapor through the holes.
The high velocity of the vapor through the holes is due to high vapor apor load or a low
percentage open area, or both. Blowing causes unstable ble contact because
ecause it lifts the
comes the continuous phase.
liquid phase out of the tray and the vapor phase becomes
A
The blowing point, which is the vapor load for or which there is maximum liquid
entrainment, is determined as part of the tray calculation.
b) Dumping
Dumping is an excessive loss of liquid uid through the openings in the tray. It is
characterized by a drop in the tray’s efficiency. The minimum vapor flow rate for
y’s efficiency.
acceptable tray performance is equal
qual greater
ual or g
gr eater than that
hat at which dumping occurs
occurs.
The dumping point, or rather thehee vapo
vapor flow rate at which through
hich the liquid passes thro
c)
ZZ the holes in the tray, is determined
Jet flood percentage
This is a vapor limiting
ng
rmined
mined as part of the tray calcula
caused
g condition. It is caus
from a tray to the one above due to the excessive
free area of the column.
lumn.
Jet flooding occurs at the maximum vvapor flow rate
calculation.
ed by "jet” entrainment
ntrainment of drops
excessive velocity vva
d
city of the vapor
of liquid
through the
e for the tray and at a given

distance between
etween the trays (spacing).
g).
d) Liquid d flooding (or Downcomer Backu
Backup)
Thiss is an unstable condition in which the
th height
eight of the
tth liquid in the downcomer and
on
n the tray increases until the
th column
columnn becomes full
ful of liquid.
fu
e)) Wee
Weeping
The weep point is the vapor flow rate at w which the liquid starts to drip through the
holes in the tray in a continuous manner
manner.
BO
It is not necessarily the lowest operating

operat
o limit for good tray efficiency. For systems
with a high liquid/vapor ratio, a small
sma quantity that passes through the holes to the
tray
ray below does not significantly reduce the tray’s efficiency.
f) Flexibility
This is the ratio between the maximum and minimum vapor loads for which tray
performance is considered
conside
cons satisfactory.
For exa
example, a tray functions satisfactorily when its efficiency remains above 90%
of its maximum
ma value.
va
g) Efficiency
cienc
Thiss is the
th measure of effective contact between the liquid and vapor on a tray. For
a theor
theoretical tray, it has a value of 1. For values applicable to the various examples
theore
of columns,
co please refer to Table 2.2.2.a, which lists some estimated overall
efficiency
eff
effi values.
It should be borne in mind that efficiency can vary significantly with the physical
properties, the tray geometry parameters and the slope of the equilibrium line.
sent.
$ PRG.PR.VES.0011
Sheet 8 (35)
Table 2.2.2.a – Estimated overall efficiency
Overall effic
efficiency
Unit Column type
Above
bove feed Below fe
feed
Reforming Stripper feed 85 75
Deisopentanizer 90 80
A
Depentanizer 95 75
Stabilizer (deisobutanizer) 110 85
Absorber - deethanizer 65 75
Debutanizer 95 80
Hydrotreaters Kerosene stripper 80 35
Diesel fuel stripperer 80 2
20
ZZ Polymers Propylene/propane
CO2/propylene
Hexane
Hexane
xane
ylene
opane
pane sp
ane drying column

Hexane
exane recovery colum
Isobutylene
splitter
ene splitter
e undercutter
column
butylene purification column
100
100
65
35
10
-
100*
95
80
45
70
35
100*
Cat Light Ends
s Naphtha light cat splitter
plitte 85 70
St
Stabilizer 90 60
Debutan
Debutanizer 100 90
Absorber-deethanizer 60-100 60
Sponge-oil absorber - 50
Distillate stripper - 55
Dist.
st. Atm. Naphtha splitter 90 70
BO
Light
ht Ends Depropanizer 90 70
Debutanizer 90 70-90
Deisopentaniz
Deisopentanizer
Deisopentanize 90 65
Steam
S Demethanizer
Demethaniz 110* 110*
Crackers Ethylene/Ethane splitter
Ethylene
Ethylen 105* 105*
Deethanizer
Deeth 110* 110*
Depropanizer
De 95 80
Debutanizer 100 80
Absorber-deethanizer 60 75
Absorber-depropanizer 65 75
Naphtha rerun column 70 60
Stripper steam cracked naphtha - 60
Distillate splitter 55 70
Debenzenizer 70 50
Detoluenizer 60 60
Primary absorber - 35
Sponge oil stripper - 45
sent.
$ PRG.PR.VES.0011
Sheet 9 (35)
Table 2.2.2.a – Estimated overall efficiency (continued)
Overall effic
efficiency
Unit Column type
Above
bove feed Above fe
feed
Aromatics Deisohexanizer 90 80
Benzene column 70 70
A
Toluene column 65-90 70
Xylene splitter 85-90* 85-90*
8
C8/C9 splitter 90 80
Gas Treating H2S/MEA absorber - 15-25
H2S/MEA absorber - 1
10-15
CO2 absorber - 15-25
15
15-
ZZ Solvents
Miscellaneous
Light Ends
iC3OH dehydration
iC3OH recovery
Hexane
Ethane
ane
e column
ne column
ration
ation co
overy colum
Propylene/Propane
ropylene/Propane
26.7 bar
column
column
40
50
85
80
100-110
75
60
90
85
(from FRI) 27.6 bar 95-105

34.5 bar 85-100
i-Butane
i-Butane/n-Butane
1
11.4 bar 100-115
20. bar
20.7 90-105
27.6 bar 85-100
Cyclohexane/n-
Cyclohexane/n-Heptane
BO
0.3 bar 70-75

1.7 ba
bar 80-90
3.
3.5 bar 85-95
i-Octane/Toluene
i-Octane/To
0.2 bar 60-75
1.4 bar 80-90
2.4 bar 85-95
Other columns
olumn Ethanol/Water 60
Isopropyl alcohol/Water 60-90
Sour Water Stripper 40
h)
h) Derating factor (System Factor)
This is a factor (less than 1) that takes into account the tendency of the liquid on the
tray to froth; it is used in the definition of downcomer area and the active area. The
values to be used are listed in Table 2.2.2.b.
sent.
$ PRG.PR.VES.0011
Sheet 10 (35)
In fractionating columns that operate with vapor densities of more than

han 30 kg/m
kg/m³,
the “system factor” can be calculated with the following formula:
SF 2,94 d 0v,32
where dv, is the vapor density under design conditions and is expressed
essed in kg/m³.
A
ces
es
Table 2.2.2.b – Derating factor for some services
Service System Factor

Absorbers (above -18°C) 0.8
0.85
Absorbers (below -18°C) 0.80
Glycol/ammine absorbers 0.75
0.75
Vacuum distillation columnsns 0.85
ZZ Ammine regenerators
Furan fractionators
Upper part of De-C1/De-C2
CO2 absorbers
Caustic
rs
s
CO2 regenerators
e-C1/De-C2 abso
nerators
ators
c soda wash
absorbers
0
0.85
.
0.85
0.85
0.80
0.85
0.65
Sour
ur water stripper / Caustic soda regenerator 0.60
Oil reclaimer 0.70
2.2.3 Contact
ontact
tact device characteristics
BO
Tablele 2.2
2.2.3.a qualitatively lists the
he capacity,
ca efficiency, cost and flexibility characteristics
for the
he va
various contact devices.
2.2.3.1 tray
Fractionation trays
The most commonly used fractionation
fra trays are of the valve, sieve, bubble-cap and
cartridge ttypes.
a) Valve tra
trays
ese are
These ar based on the check valve principle. When the flow of vapor increase, the
start to rise and the vapor passes. At 20÷30% vapor load, some floats start to
float starts
move
ove upwards
up
upw and at 50÷70% they are completely raised. This allows a broad
range ofo operating loads, whilst maintaining good tray efficiency. Valve trays require
spec attention when they are used in columns that work under vacuum, because
specia
special
th valves can stick to the tray surface or wear due to the frequent variations in
the
pressure.
Valve trays are not suitable in the presence of fluids that can give rise to encrusting,
corrosion or coke formation. Instead, they are recommended for high flexibility in
non-vacuum services.
sent.
$ PRG.PR.VES.0011
Sheet 11 (35)
Table 2.2.3.a – Summary of characteristics
VALVE TRAYS
Capacity: medium/high Efficiency: high - like Cost/area: medium
dium - Flexibility: good - 5 to 1
- like sieve trays. sieve trays. 10÷20% - greater
reater than can be achieved.
sieve trays.
ys.
s.
A
Not recommended in the case of services subject to fouling.
g..
SIEVE TRAYS
Capacity: medium/high Efficiency: high - same Cost/area:
Cost/a : lowe
Cost/area lower than all Flexibility:
bility:
- usually better than or better than bubble- trays with downcomer
downc medium/good
m/good - 3 to 1
bubble-cap trays. cap trays. achieve
can be achieved.
Type suitable for the majority of applications.
ions.
ons
ZZ BUBBLE-CAP TRAYS
Capacity: medium/low.
Used to obtain high flexibility

STRUCTURED PACKING
ACKING
KING
bility
Efficiency:
ency::
ency
medium/high.
edium/high.
dium/high
ility in services subjec
subject to fouling.
Cost/area: high
igh - the
double of sieve
ve trays.
tra
Flexibility:
Flexib
Flexibi
from 3 to 1.
medium/high
Capacity: very high.

igh. Efficiency: low like
ke Cost/area:
Cost/area
a: Flexibility: low, less
fractionation. Good
od for medium/high.
m/high. than 2:4.
heat
he exchange.
Suitable
e for services with high load for vapor with
with respect to liliq
liquid to minimize entrainment.
RANDOM
ANDOM
NDOM PACKING
Capacity:
Capacity
pacity: medium. Efficiency:
Efficiency
ency:: Cost/area:
C medium/low Flexibility:
medium/high.
m/high. also depending on the medium/high.
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material.
ry good for their low 'P and in the
Very he case
ca o of diameters below 900 mm.
DISC
C & DON
DONUTS
Capacity:: medium/high.
C
Capacity Efficiency:
Efficienc low - like Cost/area: medium. Flexibility: low.
fractionation.
fractio
Used in se
services subject to ssignificant fouling.
Some
me examp
examples
ex of usage:
x when the
t vapor flow varies significantly and unpredictably in a given section of
the column
x w
when a column is used in blocked operation with flow rates and feed
compositions that can vary considerably
x when a column can run with low flow rates (less than 30% of design rates).
b) Sieve trays
These are characterized by low cost, excellent efficiency, good capacity and
adequate flexibility.
sent.
$ PRG.PR.VES.0011
Sheet 12 (35)
Sieve trays can be used in nearly all services and can be designed ed to operat
operate
satisfactorily over a wide range of operating conditions. The maximum um capacity of a
sieve tray is at least equal or greater than that of a well-designed signed valve tray.
esigned
Flexibility can arrive to a maximum of approximately 3 to 1. They ey can also be used
ameterr of 20 a 25 mm.
in services subject to fouling as long as the holes have a diameter
Sieve trays are not suitable for services that require high gh flexibilityy (more than 3 to
1). Bubble-cap and valve trays, even if more expensive, nsive, must be e used for such
services.
A
At very low vapor speeds (as during startup), sieve eve
ve trays can lose liquid to the point
poin
of emptying.
Therefore, when thermosiphon reboilers are arre planned with extraction from a sieve
tray, it is necessary to ensure the feed byy installing, as alternatives:
alte
x an auxiliary line from the column bottom to the reboiler inlet (it must be poss
possible
oiler generates enough vapor to maintain the liqu
to close this line when the reboiler liquid
on the tray)
c)
ZZ x a chimney tray as an extraction
Bubble-cap trays
ed
only be considered
oke
gh
These have quite high
e forma
encrusting or coke
raction
action tray
tray.
h costs, from 50 to 100% more than
formation exist.
an valve trays
trays. They should
d when more than 3:1 flexibility iss desired and
a problems of
d) rays
Cartridge trays
Cartridgee trays have a special tray structure for columns wwith diameters of less than
900 mm.m.
nerally, they are more economic than packing
Generally, packing and
an it is also easier to predict the
efficiency
fficiency of the trays rather than the packing’s
packing’ HETP (Height Equivalent to a
Theoretical Plate).
Theor
Cartridge trays are connected in bundles. EaEach bundle can contain 5y6 trays.
The main problem is the sealin
sealing ring, wh
which is used to avoid leakage between the
BO
column’ shell.
edge of the tray and the column’s
Column flanges must also be p provid
provided every two packs to allow disassembly for
mainte
maintenance.
2.2.3.2 P
Packing
Packing is used in a fractio
fractionating column for the same purposes as trays. From the
economic sstandpoint, trays are more advantageous for treating large volumes of vapors
and liquids.
Packing colum
columns sh
should be taken into consideration for the following services:
x corrosive,
osive, bu
but not encrusting services
x heat
eat exc
exch
exchange zones
x in col
columns that work under vacuum and in non-fouling services where a low pressure
colu
dro
drop is required
x fractionating columns with diameters of less than 1000 mm, as an alternative to
cartridge trays.
Capacity, efficiency, corrosion resistance and cost must be evaluated in order to choose
the best packing. Fig. 2.2.3.2.a shows several types of packing.
sent.
$ PRG.PR.VES.0011
Sheet 13 (35)
A
Raschig Rings Pallll Rings Berl Sa
Saddles
Fig. 2.2.3.2.a – Types of packing

pack
As first choice, steel Pall rings should be considered. They have have the advantage
ha e of hi
high
capacity, are unbreakable and have the hee highest
highe flexibility
flexibility of the various types of packing.
packin
packing
If there is no corrosion, the life of packing
acking with
with Pall rings can
an be considered infinite.
infinite Pall
ZZ rings are also available in otherr materials
Plastic Pall rings can be used

materials. Pall rings in aluminum
pump-around zones of heavy hydrocarbons.
Ceramic Pall rings are to be preferred in corrosive environments,

limit, although this can
n arrive to ten years in well-run columns.
Ceramic rings are resistant
uminum can be used for the
hydrocarbons There is a limit to packing height.
ed up to 120°C and are preferable to polypropylene
sed polypropyle ones.
nments, duration
dura
ant to acids, alkalis and solvents, with the exceptions

e
being their
of caustic
solutions and hydrofluoric
ydrofluoric acid.
bility
ity of installing orderly (structured)
The possibility (structured) types oof packing should also be
considered
ed in the design of a fractionating column.mn. Generally,
Gen this type of packing is
more expensive but finds application when when high s separation performance with low
se
ssure
sure drops is required.
pressure
Examples
mples can be columns for superfractionation
superfractionation or
o columns that work in a vacuum.
BO
2.2.4 Fundamental
dam sizing parameters
2.2.4.1
.2.4.1 Fractionation
tionatio tray
In addition to the type of tray, the sizing of a fractionation tray is also conditioned by the
following parameters:
a) Distan between trays
Distance tra
A distan
distance of 450 to 600 mm between the trays is normally an economic choice. In
special
ecial cases
c (su
(superfractionation columns), smaller spacing may also be justified
but this
his renders
rrender maintenance more difficult. At times, the distance can arrive to 900
mmm in or
order to have a higher vapor velocity.
Table 22.2
2.2.5.1.a indicates the minimum spacings according to the diameter and type
of ser
serv
service.
b) Nu
N
Number of liquid passages
The capacity of a tray with high liquid flow rates (> 70 m3/hxm weir) can be
increased with the use of trays with multiple liquid passages.
However, trays with more than one passage are more expensive and their
utilization only becomes advantageous if there is at least a 5% reduction in
diameter.
In general, trays with more than one passage are not used for column diameters
below 1500 mm and for liquid flow rates below 60 m3/h per meter of diameter.
sent.
$ PRG.PR.VES.0011
Sheet 14 (35)
Table 2.2.5.1.a – Minimum tray spacing in a fractionating column

mn
Column Minimum space (1), mm

m
diameter Clean service Fouling
ouling service
servic
mm 2 steps
ps 1 step
<1500 300 - 450
4
A
1500÷2299 300 450 600
2300÷2999 380 600 700
>3000 550 700 -
Note:
(1) If there are no manholes between the trays.
ZZ c)
When there are manholes,
the manhole increased
Jet flood percentage

This is a parameter
sed
tage
age
oles, the minimum
holes,
ed by 150 mm
m
mm.
spacing
er that is used to calculate

meter
in order to have liquid entrainment
g is given by the diameter
spacing
calculate the diameter

calc
ent bby tthe
diam of
er of a fractionating
he vapor within a
fr column
acceptable limits. It is
expressed d as a percentage.
esents
sents the flooding value for the active area of a cca
It represents calculated tray.
articular:
In particular:
oad GPM
Vload G FPL 13000
% Jet Flood
AA CAF
BO
where:
whe
Vload = vapor flow on tray
GPM = liquid flow on tray
FPLL = Flow Path Length (s (see Fig. 2.2.4.1.a - Dwg A)
AA = active area (see Fig. 2.2.4.1.a - Dwg B)
CAF = capacity facto
factor, or rather:
UV
CA
CAF vs
UL UV
where:
where
vs = vapor velocity
UL = density of liquid
UV = density of vapor
sent.
$ PRG.PR.VES.0011
Sheet 15 (35)
active active
ctive
area area
A
Dis. A Dis. B
ZZ Fig. 2.2.4.1.a – Defin

Definition of FPL
Definition L and active area
Generally, a value not exceeding

eeding 77% is a assumed columns that
ssumed for design loads in colu
colum
work in a vacuum and a value not exceeding 82% in columns that work in all other
services.
a
With these values, liquid entrainment that does not exceed 10% is achieved.
For columns withh diameters below 900 mm, a flooding value
alue equal
equ
equa to 80-90% of the
normal one is assumed.
d) Downcomer mer flood percentage (choke
hoke flood)
owncomer
wncomer flood percentage indicates
The downcomer indica the
e percentage
the percen
percent of flooding in the tray’s
wncomer.
downcomer.
n particular, this value depends on the velocity
In veloc
veloci of the liquid that enters the
downcomer. If this velocity is too high, a floo
flooding situation is created above the
tray’s inlet weir, thus compromising
compromi correct
orrect h
hy
hydraulic operation.
Values that do not exceed 75% are consid
considered acceptable.
BO
e) percentag
Downcomer aerated percentage
percen
pe
This parameter indicates the percentage of liquid inside the downcomer.
Itt differs from the downcomer fflo
flood percentage because it does not depend on the
ocity of the liquid entering the downcomer, but only on the liquid head in the
velocity
comer.
downcomer.
hydrau malfunctioning on the tray, the resultant values from the
In order to avoid hydraulic
calcula
calculation sheet must not exceed 75%.
f) Downco
Downcomer back
backup
dow
downcome backup must not exceed 40% of the spacing when the vapor
The downcomer
3 3
sity is greater
density gr than 45 kg/m , 60% for vapor densities below 15 kg/m and 50%
for
or intermediate
interm
interme vapor densities.
g) Pres
Press
Pressure drop on each tray
The
Th pressure drop through a tray is given by the sum of the pressure drop of the dry
tray
t and the liquid head on the tray.
The pressure drop of the dry tray generally varies in the range from 25 to 75 mm of
hot liquid.
The total pressure drop entails variable filling of liquid in the downcomer tray
(downcomer backup).
sent.
$ PRG.PR.VES.0011
Sheet 16 (35)
2.2.4.2 Packing
In addition to the type of packing, the sizing of packing is also condition

conditioned by the
following parameters:
a) Flooding percentage
As a rule, packing columns operate at 25 to 85% flooding. ding. A high
h percentage can
result in having excessive liquid entrainment, while, ile,
e, on the other hand, a low
A
percentage can result in low efficiency due to insufficient
fficient contact between liquid and
ufficient
vapor.
b) Packing height
The most commonly used method forr determining
determining the height of packing is to
heoretic
eoretical
calculate the equivalent height for a theoretical al tray (HETP). This method is valid for
multi-component or binary systems s of distillation, absorptio
absorption or stripping.
In any case, the maximum height ht (see Table 2.2.5.2.a) depends mainly on the type ty
ZZ of packing and the material off which it is made.
x the need to redistribute

bute
acking
cking heigh
The factors that limit the packing height are:
ute the liquid
x the shattering off ceramic packing
x the collapse
e of aluminum
luminum packing at high temperatures
For liquid redistribution, the height of the
the packing section isi limited to approximately
six meters.
ers. meters
s. It is possible to arrive to 6 me metal Pall rings as long as the
ters with met
meta
liquid
d is well distributed at the beginning and thethe velocity
veloc of the liquid is greater than
25 m3/h per m2 of cross-section.
cross-se
For aluminum rings, temperature is the limitation.
limitat
limitatio The maximum height is 3÷3.5
meters
mete at 200°C.
pa
Table 2.2.5.2.a – Maximum packing h
height
BO
Type of packing Maximum packing height

Raschig rin
rings from 2.5 to 3 diameters or 6 m, the lesser of the two
Berl saddles from 5 to 8 diameters or 6 m, the lesser of the two
Intalox saddles
Intal from 5 to 8 diameters or 6 m, the lesser of the two
Pall ring
rings from 5 to 10 diameters or 6 m, the lesser of the two
(*) or
o the maximum distance from nearby redistributor, if present.
c) Pressu
Pressur
Pressure drop
The ccalculation of the pressure drop for a packing is not needed to calculate the
dimensions of a packing column, but is important for working out the process
di
dim
calculations.
The dependence of the pressure drop on other parameters is shown in Fig.
2.2.5.2.a.
sent.
$ PRG.PR.VES.0011
Sheet 17 (35)
A
ZZ
Fig. 2.2.5.2.a – Correlation of pre
pressure
pr drops in a packing column
BO
2.2.5
.5 Calculation
culatio methodology
The guarantee
uarantee of adequate dime dimensions for the fractionation trays and packing is
dimen
provided by the internals supplier
supplier.
The design engineer must however
ho define the diameter and height of the column and all
of those parameters
pa necessary
neces for sizing the internals. The criteria for the development
calculations are provided below.
of these calcu
2.2.5.1 Fractionating tray columns

c
iamete ccalculation for fractionating tray columns shall be carried out according to
The diameter
the succes
success
successive steps listed below:
a) After calculating the heat and material balance of the column, the various types of
Aft
Afte
possible trays are analyzed and the most suitable one chosen as illustrated in
section 2.2.3.
b) The diameter for the entire column or sections thereof (if they have different
diameters) is determined through the use of sizing programs.
The diameter obtained from Fig. 2.2.6.1.a can be used for an initial calculation
attempt.
sent.
$ PRG.PR.VES.0011
Sheet 18 (35)
For four-pass trays:

(1) Divide V flow by 2
(2) Divide GPM by 2
(3) Obtain diameter of two-pass tray line
A
(4) Multiply diameter by 2.0
ZZ
BO
Fig. 2.2.6.1.a – Determining the tray diameter
sent.
$ PRG.PR.VES.0011
Sheet 19 (35)
With the available calculation programs, following the respective manuals and an
instructions, the influence of the following parameters on tray geometry
etry is analyzed:
x distance between trays
x number of liquid passages
x flooding percentage
x pressure drop
A
Limitations of the tray, such as blowing, jet flooding,
ding, filling of downcomer, maximum
oding, maximu
tray capacity, weeping etc. are also checked. d.
In this way, it is possible to define the tray
y configuration ththat optimized the
he diam
diameter
and height of the column.
c) The types of internals and the final
al configuration
onfiguration are determined in agreement w
with
the supplier of the internals.
2.2.5.2
ZZ
Packing columns
When packing is chosen foror the entire column

are similar to those described
calculation programs
colum or for
for sectionss of it, the calculation
escribed above for fractionating
s are
re those for packing.
calc
calcu criteria
fractionating trayy columns, except that the
BO
sent.
$ PRG.PR.VES.0011
Sheet 20 (35)
2.3 Overall column configuration
The complete process definition of a tray or packing column entails the e choice and sizing
he
(in addition to that of the contact devices) of the process and d service noz
nozzles,
instrumentation connections, etc.
It must also be borne in mind that a column with a diameter less than 900 mm, whether
cartridge trays or packing is used, must have flanged sections
ions to facilitate
te assembly and
maintenance of internals.
A
The length of each section is related to the height off the packing or number of cartridge
trays, as well as the presence of internals such ass distributors, liquid or vapor inlets and
a
outlets, support or hold-down trays, etc.
The length of each section must never be lesss than 2 000÷2 50050 mm.
2.3.1 Tray column

ZZ
The sizing criteria are now described
bed
ed for th
the following:
x liquid and vapor inlets and outlets, with related accessories
x extraction pot for reboilers
lers
ers
x column bottom
The arrangementsnts are shown in detail in design

design criteria document
de docume PRG.PR.GEN.0003,
to which reference
ence should be made for the
he figures referred to in the following.
2.3.1.1 Liquid orr vapor inlet or outlet with related accessories
a) Top v vapor outlet

Normally implemented via a vertical nozzle
nozzle at
a the center of the upper domed end. If
the column is flanged at the top or a dem
demister is installed and it is wished to improve
demis
BO
liquid-vapor
liqu separation, the top vapors can be made to leave laterally (as shown in
PRG.PR.GEN.003 / Fig. 2.2.8.a and Fig. 2.2.8.b).
b) Reflux ininlet on top tray
Forr single-pass trays, this consists of a normal nozzle installed behind the
protection
ction of a false downcomer
downc with a baffle positioned over the top to prevent the
liquid from splashing ab above the downcomer. The nozzle usually has the same size
abo
as the line. For two-pass
tw trays, a perforated pipe distributor (for internal
downcom
downcomers) or a T-distributor (for external downcomers) is normally installed (see
PRG.PR.GEN.00
G.PR.
PRG.PR.GEN.003 / Figs 2.2.4.a, 2.2.4.b and 2.2.4.c).
c) Liquid
uid o
or liq
liquid-vapor inlet located between two trays of the column
For a liq
liquid or liquid-vapor mixture where pressure drops are not critical, a
perfor
perfora
perforated pipe distributor is used (see PRG.PR.GEN.003 / Figs 2.2.1.a, 2.2.1.b
and 2.2.3.a).
W
When the pressure drop must be small, a tangential inlet with an impingement plate
is used for the liquid-vapor mixture (STD.CR.GEN.7029).
d) Vapor inlet between two trays
A normal nozzle, positioned at a minimum distance from the tray, or a T-distributor
is used (as shown in PRG.PR.GEN.003 / Fig. 2.2.2.a).
sent.
$ PRG.PR.VES.0011
Sheet 21 (35)
e) Liquid side extractions

All or part of the liquid can be extracted as a side product, or recirculation
culation or reflux.
The choice between a partial or total outlet normally depends s on the effects on
control of the column or on the stability of the internal reflux. Ass a general rule,
rule the
partial outlet flow must not be greater than 60% of the sum of the internal reflux flow
and the flow of the product on the extraction tray, excluding
ing any recirculation
circulation flow.
Extraction can be made by a downcomer or a chimneyy tray.
A
x Partial side extraction of liquid
An extraction pan is located beneath the downcomer
wncomer
wnc omer of the extraction tray with a
nozzle on the bottom or side of the pan. The he pan’s dimensions are related to t the
diameter of the nozzle. The pan must st extend for the entire chord length
length. The
nozzle must be as close as possible sible
ible to the bottom of the pan to facil facilitate
drainage. The distance between the he bottom
bott ou
of the pan and the top of the outlet
weir on the underlying tray must ust
st not b
be le ss than 300 mm in order not to restr
less restric
restrict
access to the downcomer. If nece necessary, tray spacing ng should be increased ((see
ZZ PRG.PR.GEN.003 / Fig. 2.2.9.a).
x Total side extraction of liquid
The extraction nozzle
downcomer at the
An outlet weir
flowing to
ozzle must be sufficiently
he tray’s maximum p
eir from the downcome
sufficiently high
pressure drop.
downcomer mu
o the underlying tray during
d
must
h to guarantee
st be provided
guarante sealing of
ded to prevent
normal operati
operatio
p liquid from
operation. Sometimes it is
sary to operate temporarily
necessary y in p
parti al extraction
partial ction m
mo
mode, allowing some liquid
verflow.
rflow. To allow such operation,
to overflow. operatio the spacing
pacing between
b the trays must be
ufficiently large enough to allow overflow at the
sufficiently th maximum flow rate without
completely filling the downcomer (see
(see PRG.PR.GEN.003
PRG.PR.G
PRG.PR. / Fig. 2.2.10.a).
x Partial or total extraction from a chimney tray
tra
A chimney tray is used when the liquid ho h
hold-up must be high or when tray leaks
cannot be tolerated for process motives.
motiv The chimney trays must have a total
BO
perforated area of the tray above and must be

section that is at least equal tto the p
evenly distributed.
ev
The distance between the chimney
chim
c tray and the tray below must be equal to the
distance between the und unde
underlying trays. The distance between the high liquid
level
evel in the chimney tra tray and the tray above must be equal to the distance
between
ween the trays in theth section above (see PRG.PR.GEN.003 / Fig. 2.2.11.a e
Fig. 2.2.11.b).
f) Reboile extraction
Reboiler extractio
umn extraction
Column extracti for feeding the reboiler can be achieved in a different ways
ording to the type of reboiler (recirculation or “once-through”) and the type of
according
ay (one pass
tray p or two pass, and in the latter case, with an internal or external
downco
downcom
downcomer).
(See design criteria document PRG.PR.GEN.003, section 2.2.13).
g) B
Bottom liquid outlet
This is normally implements via a vertical nozzle at the center of the lower domed
end. If the liquid goes to feed a pump, a vortex breaker should be provided. To
separate any solids in suspension or drops of heavier liquids, the outlet nozzle
should extend inside the vessel for 100÷150 mm.
In the case of columns in which coke formation can occur, a coke filter must be
provided (see PRG.PR.GEN.003 / Fig. 2.2.15.a).
sent.
$ PRG.PR.VES.0011
Sheet 22 (35)
2.3.1.2 Column bottom

he
The height of the low level (LLL), the level range (HLL-LLL) and the e distance b
between
ulated.
ed. The methods of
the high level (HLL) and the seal pot of the bottom tray are calculated.
calculation are as follows:
a) ent line
Calculation of low level (LLL) height from bottom tangent
A
The value of H1 is assumed to be the greater of:
x Distance of liquid outlet nozzle from the low
w liquid level (LLL) calculated as:
0.4
0.887 Q L 60
H1 0. 2
(1)
1 U V UL
where:
ZZ QL =
UV
UL
=
=
x Distance between
ween
he value
given by the
Bottom product
Liquid
uid
uct
Vapor density
ensity
rate (in m3/minute).
ct flow ra ).
(kg/m3).
nsity under operating conditions (k
id density under operating conditions (kg/m3).

een the bottom tangent line and the low liquid level
e of 0.2 meters (corresponds
(co to the
he minim
le
l (LLL), which is
minimum distance between
tom tangent line and the axis of the levell instru
the bottom instrum
instrument’s lower nozzle) plus
the distance
nce between the axis of the same e nozzl
nozzle and the low liquid level
alculated
lculated in accordance with STD.SM.GEN.001.
calculated
b) ran
Calculation of liquid level range
The height in meters between the high liquid le
level (HLL) and low liquid level (LLL),
H2, is calculated with the following formula:
Q L TR
BO
H2 1.272 (2)
Di 2
where:
QL = prod
Bottom product flow rate (in m3/minute).
TR = Bottom product residence time (minutes).
Refer to Table 2.3.1.3.a for the residence time to be assumed.
Di = Internal
In diameter of column bottom (meters).
The immedia
immediately
imm superior standard level range is chosen.
Table 2.3.1.3.a - Residence times
Service Residence time

Column bottom to storage 2 minutes for stored product
Column bottom to other plant 10 minutes for product
Column bottom to another column 5 minutes for product
Column bottom to reboiler heater 5 minutes for fraction of vaporized liquid
sent.
$ PRG.PR.VES.0011
Sheet 23 (35)
plus as above for the product.

t.
2.3.2 Packing column
The performance of a packing column not only depends on the e type off packing, but also
on how the internals have been sized. An appropriate initial itial distribution
ion of liquid and
vapor facilitates the necessary liquid-vapor contact for achieving maximum efficiency
A
old-down trays, which must have a
from the packing. Packing necessitates support and hold-down
sufficiently open area so as not to limit the capacity of the colu
column.
The internal parts are offered in standard sizes byy various man
manufacturers.
Some guidelines are given below on the structure ure and selection criteria for internals
internals.
a) Liquid distributors
Liquid distributors are fundamental al forr the
the operation of a packing column becau because
column efficiency is only achieved eved
ved when the packing g is uniformly wetted by tthe
ZZ liquid. There are various types
the dimensions of the column,
is destined.
The most common types
The "weir riser" type
mm) and with
ype
ypes
es of liqu
liquid dist
pe is generally used fo
h low-capacity
pe distributor is used in
perforated-pipe
ributors, the
distributors, he use of which is related
pes of distributorr are shown in Fig. 2.3.2.a.

forr small-diameter
ow-capacity packings (Raschig rings or B
n small-diameter
sm
small-diameter columns
eter column
rela
relat to
mn, the type of packing and the use for which the packing
columns (less than 950
olumns with
Berl saddles). The
w Pall ring or Intalox
acking. For columns with diameters
saddle packing. diam ater than
greater tha 950 mm, the “through”
ormally used.
type is normally use
eat exchange services and for columns that
In heat that operate
ope with low liquid flow rates
ess than 5 m3/h per square meter of cross-sec
(less cross-section), liquid sprays are normally
cross-sect
used. With these last devices, it is necessary
necessary to plan an accurate distribution to wet
the packing material uniformly.
Liquid distributors should be loclocat ed between
located betwe
betw 150 and 450 mm above the packing
to leave sufficient space for the lliberation of gas.
BO
Fig. 2.3.2.a – Distributor types
sent.
$ PRG.PR.VES.0011
Sheet 24 (35)
b) Liquid redistributors
Liquid redistributors are used to correct poor distribution of liquid along
long the column;
they collect the liquid from an upper bed and uniformly redistribute te it in a lower bed
ute
(see Fig. 2.3.2.b). Liquid redistributors are used with Raschig rings
ngs or Berl sadsaddles,
d’s velocity
but not with Pall rings or Intalox saddles, unless the liquid’s ocity is less than 5
m3/h per square meter of column cross-section or the bed has a height of more
oning, or rather
than 6 meters. The criterion for redistributor positioning, er the maximum
height of the packing sections, is indicated in Tableable
ble 5, according to the type of
A
packing.
c)
ZZ pport plates
Packing support
Fig. 2.3.2.b
.2.b – Redistributor type
h
Packing support plates must have a high ntage of open space to allow the
percentage
simultaneous
neous passage of vapor and liquid.
aneous liqu TwoTwo basic types
ty of support plate can be
used:
d:
x counterflow
coun
x separate passage for liquid and gas
The two types are shown in Fig. 2.3.2.c.
BO
Fig. 2.3.2.c – Packing support types
In certain cases, especially in large-diameter columns, special support plates may

be required. The criteria to follow in sizing a support plate are the following:
x open area greater than 60%
x sufficient resistance to support the weight of the packing plus the liquid hold-up
x openings smaller than the minimum dimensions of the packing.
sent.
$ PRG.PR.VES.0011
Sheet 25 (35)
d) Hold-down plates
Hold-down plates are used for packing made of fragile or light-weight
ight-weight (e.g.
polypropylene) materials when a pressure drop on the upperr bed in excess of
40y60 mm of water per meter of packing is expected, to avoid d fluidization o
void of the
bed, when not restrained, and the consequent formation of powders
wders that can clog
the packing.
La hold-down plate rests directly on the packed bed and must st have a high
A
percentage of open area.
It may be necessary to install a net beneath it to avoid the entrainment of small
sma
pieces of packing material (see Fig. 2.3.2.d).
ZZ
Fig. 2.3.2.d – Hold-down p
plate type
e) Liquid side extraction

A convenient system for the side extraction of a liquid (Fig. 2.3.2.e) consists in a
circular tray with a sufficient number
nu of chimneys,
c an extraction pipe and one or
BO
more metal tubes. The tubes mustm discharge
disc into a "weir-riser" type tray distributor
and be immersed in the liquid. The chimneys must have sufficient height to rise
above the liquid level by at lea
least 150 mm. Circular baffles with the same diameter
s the chimneys must be insta
as instal
installed above the chimneys at a distance such that the
vapor
or outlet area below the baffle
b is at least equal to the section of the chimney.
A distance
ance of at least 300 mm must be provided between the baffle and the packing
above.
abov
Fig. 2.3.2.e – Chimney tray
sent.
$ PRG.PR.VES.0011
Sheet 26 (35)
2.3.3 Process nozzles
Process nozzles generally have the same diameter as the line. In certain cases, the
aller.
er.
nozzle diameter may be greater than that of the line, but never smaller.
Two criteria to consider when sizing nozzles are:
a) he column must not exceed
The velocity of the gas or vapors in the nozzles of the
30 m/sec.
A
b) raction
action must be less than 1 m/sec
The velocity of the liquid in a partial or total extraction m/sec.
For this velocity, the diameter of the nozzle is given by:
D = 44 Q0.4
where:
Q = Liquid flow rate m3/s
s
ZZ
2.3.4 Service nozzles
Manholes, handholes,
er,
r, NPS.
D = Nozzle diameter,
s, vents, drains and purgi

characteristics are described
ribe below.
purging
ng nozzles are servi
servic
service nozzles. Their
a) Manholes s and handholes

le, manholes are installed on a column with a diam
As a rule, dia
diameter equal or greater than
900 mm according to the following rule:
Service Manhole position

C
Clean Top, bottom
bottom, feed, sidestreams
BO
Slightly fouling
S As for cle
A clean service, plus one manhole every 10 trays
Fou
Fouling As fo
A for clean service, plus one manhole every 5 trays
As a rule, the manhole has a diameter that is based on the diameter of the column
(see following
ollowing table).
Column d
diameter, mm Manhole diameter, NPS
t 2 500 24
< 2 500 but > 1 000 20
d 1000 18
Han
Handholes
Ha are installed on a column with a diameter of less than 900 mm.
H
Handholes normally have a diameter of 8" and are installed in the same positions
planned for manholes.
In packing columns, the installation of a manhole or handhole above each packing
section is recommended for inspection purposes.
If frequent loading and discharging of the packing is foreseen, manholes or
handholes must be provided at the bottom of each packing section to facilitate
sent.
$ PRG.PR.VES.0011
Sheet 27 (35)
substitution. In this case, the nozzle must be inclined 45° downwards

s with respect
respec
to the wall to facilitate discharge.
b) Vents
Columns must be fitted with a vent. The vent allows purging ing with steam prior tto
inspection and maintenance operations.
0001.
For sizing, follow the criteria indicated in PRG.PR.VES.0001.
c) Drains
A
The draining of a column is necessary when a heavyeavy liquid accumulates or when a
hydraulic test of the assembled column is contemplated. In the first case, the
conne
process outlet connection must be at least 150 mm above the drainage connection.
This can also be achieved by internallyy extending the outlet pipe with a 150 mm
length of pipe.
umn must be filled and emptied in a reasonab
For the hydraulic test, as the column reasonable
time, the drainage connection mus must have a diameter eter that is based upon tthe
ZZ d)
a nozzle with a blind on
Purging nozzles
lumn
umn (see PRG.PR.VES.0001
diameter and height of the column PRG.PR.VES.0001).
zle is at the lowest point of the
When the liquid outlet nozzle he column, the installation
n the process line might be appropriate, accor
dgment.
gment.
design engineer’s judgment.
insta
instal
accord
according to the
A connection for purging steam or gas is normally provided in all columns for
of
inspection and maintenance operations.tions

g, follow the criteria indicated
For sizing, ed in PRG.PR.VES.0001.
PRG.PR.VES.000
PRG.PR.VES.00
2.3.5 ntation connections

Instrumentation
Connections
nnections
nections must be defined on a column for tthe
he iinstallation of temperature, pressure
and leve
level instrumentation.
connections for the related controls on:
It is now described how to arrange the connec
connecti
BO
a) Tem
Temperature
It is advisable to provide a the
thermometric well close to the vapor at the following
thermo
points:
x feed
x head
d
x bottom
bo
x sidestream
sides extra
extractions
b) Pressure
ssure
ually, only the pressure at the bottom of the column is measured.
Usually,
A press
pressur
pressure test point at the top close to the vapor space should also be provided.
c)) Leve
Level
In general, the level controller/recorder and level glass are installed on a carrier
pipe. The height of the normal level with respect to the bottom tangent line, or
another reference point, must always be indicated on the data sheet.
A calming baffle must be provided inside the column, in front of the level
connection.
The sizes and positions of the connections on the column must be in compliance
with standard STD.SM.GEN.0001.
sent.
$ PRG.PR.VES.0011
Sheet 28 (35)
2.3.6 Demister
For sizing the demister and plant engineering details (Standards

ards
rds and
an required
iteria for vessels
dimensions), please see that specified in the design criteria ves
PRG.PR.VES.0001.
A
ZZ
BO
sent.
$ PRG.PR.VES.0011
Sheet 29 (35)
3. GUIDE TO FILLING OUT DATA SHEETS
The standard form that constitutes the data sheet for the design pressurized or
n of pres
atmospheric vessels, which also includes columns, is illustrated in thiss section.
3.1 Vessel data sheet
The items that regard process design are illustrated below.

ow.
w.
A
3.1.1 Service
Brief description of the use for which the equipment

pment is destined
destined.
3.1.2 Design data

ZZ
a) Standard
It must be indicated which
hich standards
standa the equipment
ment must be designed
de
des in
compliance with. This information is obtained from the basic information
informat
informa of each
project.
b) ature
Design temperature ure an
and MDMT
The criterion indicated
ed in PRG.GG.GEN.0001 should be follow
followe
followed.
c) ng temperature
Operating
This is
s the highest temperature under the planned o operating conditions. When a
op
temperature
mperature below the ambient temperature
temperature
temper re is possible,
po
pos the minimum operating
temperature
emperature must also be indicated. In all casecases, it is taken from the heat and
material balance.
mater
For cases of columns divisible into trunks, that
th specified in design criteria document
tha
PRG.GG.GEN.0001 should be considered
considered.
BO
d) Internal
Inte design pressure
This is the pressure utilized for calculating
calc the thickness of the vessel. It should be
indicated
ndicated as “Top pressure” andan the pressure drop of trays and/or other internals
should
ould be indicated in a note.
The criterion indicated in the
th previous point should be followed.
e) External design pre
press
pressure
This is the
t pressure that the atmosphere exerts on a vessel when there is a vacuum
inside.
side.
f) Operating
ratin pre
pressure
This
is is the
t maximum pressure under operating conditions. It is taken from the
materia balance.
material
In va
vac
vacuum conditions, the minimum pressure and relative temperature must be
giv
given.
g) Extra corrosion allowance
This is the thickness that must be added to the mechanical design thickness to
avoid corrosion phenomena endangering the reliability and safety of the equipment.
It is the result of optimization in the choice of material. See document on
construction materials, PRG.PR.GEN.0001.
sent.
$ PRG.PR.VES.0011
Sheet 30 (35)
The planned duration of the specified extra allowance must be indicated.

cated. For iits
calculation, consult the previously mentioned document.
h) Plating or cladding
overed
It is always preferable to use carbon steel, plated and covered red with a material
materi
resistant to the corrosive medium. The thickness of the he plating
ng or covering is
g:
obtained from the corrosion curve after having defined the following:
x the corrosive medium
A
x the temperature of the metal
x the planned theoretical minimum life
In general, the plating thickness should d not exceed 3 millimeters. If a gr
ld greater
thickness is required, a more corrosion
n resistant material should
s be used.
i) Gunite lining
When the medium contained in than
n the vessel has acidity such that the pH is less th
t
l)
ZZ 6, it can prove advantageouss to use carbon
is normally 25 mm thick.
Fluid
According to the
c
Under this item, it must be indicated whether

steel lined with gunite. The gunit
whether the fluid is lethal or cau

e ASME standard, the definition of lethal
gaseous substances
stances unmixed
s that, mixed or un
unmix
gunite layer
caustic.
al is given to those liquid or
cause death if inhaled
ed with air,, can ca
even in small hese ssubstances
mall quantities. Some of these ubstances hydrocyanic acid, carbonyl
s are hy
hyd
chloride,, cyanogens, bromo-ortho-xylene.
anogens, mustard gas and bromo-ortho-xylen
bromo-ortho-xylene
The density
ensity under operating conditions must
m also
so be indicated
in under the fluid item.
nnealing
m) Annealing
Must be provided for process motives when the
th presence of certain fluids, due to
possible strain inside the material, can
can ge
generate instances of stress corrosion
cra
cracking.
BO
n) The
Thermal insulation
moti
Must be provided for process motives when possible heat losses can negatively
affect the operation conditions o
of the equipment and, in consequence, its regular
ocess functioning.
process fun
o) Bottoms
preprin
prepr
The value 2:1 is preprinted on the data sheet. The preprinted value can be changed
in
if it is intended ado a different value.
to adopt
p) ight above
Height a gr
ground
mus be indicated
This must i when it affects the operation of downstream equipment (e.g.
nimum NPSH
minimum N required for centrifugal pumps).
no required for process motives, the following should be indicated: min.
n
When not
3
3.1.3 Materia
Material
Th
The
T he material required for process needs is defined on the basis of document
PRG.PR.GEN.0001.
The design engineer must indicate the material on the data sheet as follows:
x for carbon steel, a generic indication together with any special requirements (e.g.
killed carbon steel) is sufficient.
sent.
$ PRG.PR.VES.0011
Sheet 31 (35)
x for low-alloy steel, the percentage content of the basic alloy elements (e.g. 5% Cr).
x for AISI 400 series stainless steel, the percentage content of Cr (e.g.
e.g.
g. 1
13% Cr).
x for AISI type austenitic stainless steels (e.g. AISI 316).
x for nonferrous alloys, the name of the alloy (e.g. monel, hastelloy
oy etc.) and, when
necessary, the name of the supplier.
A
3.1.4 Nozzles
For each nozzle to install on the vessel, the following

wing must be indicated:
i
a) ID code
Composed of a number and one orr two upper case letters. The number iis a
here are mu
progressive number of origin. If there ltiple nozzles
multiple zzles for the same service,
service a
s added
lower case letter (a, b, c, etc.) is adde to the code. Thehe upper case letter is related
rela
relat
b)
ZZ x N
x M for manholes and
x CN for instrumentation
Rated diameterr
entation
ssociated
ections
ctions
for process connections
sociated with and is:
to the service the nozzle is associated
nd handholes
ntation connections
Is defined ass indicated in sections 2.3.3,

2.3.3, 2.3.4 and 2.3.5 of the
th present document.
c) Series and coupling
p
This iss the same as the connected line.
d) Service
ervice
A clear and concise description is required
required of
o the use to which the nozzle is
dedicated (e.g. feed inlet).
BO
3.2 aphic information
Graphic
The outline of the vessel must be dra

drawn and upon which the following must be indicated:
x e main dimensions, such as
The a diameter and height. If the column is composed of
ple sections with differ
multiple different diameters, indicate the diameter and height of each
section.
x All heig
heights with respe
respect to the bottom tangent line, related to the position of devices
required
equired for proce
process needs.
x Process
cess and service nozzles, with the height indicated where required for process
needs
eds (a
(app
(applies to minimum limit as well).
x Low, n no
normal and high liquid level positions, with indication of the normal level height
and the level range (between low and high levels).
If a level regulator is not provided for, indicate the maximum liquid height.
x The position and height of any alarms or switches.
x Internals, such as demisters, distributors, baffles, vortex breakers, etc., indicating
the reference standard or, if one does not exist, attaching constructional details that
include dimensions, construction materials, position and heights.
sent.
$ PRG.PR.VES.0011
Sheet 32 (35)
3.3 Tray or packing data sheet
The detail geometry and mechanical design of a column tray are developed
develo by the
internals supplier.
The process design engineer must provide useful information ation and evaluate the
appropriateness of the supplier’s documents for the processs needs. The information to
send to the supplier and the basic sizing criteria for a tray or packing
g are described
below.
A
3.3.1 Trays – Information to send to supplier
The information to send to the supplier regarding

garding the sizing of a tray, and whic
which is
s described below.
transmitted using form DAT.PR.INC.001, is
Mechanical data
x
ZZ x
Code
This is the code of the column
from the column data sheet.
Service
This is the service
data sheet.
eet.
which
umn on wh
whic h the trays are installed. It can be deduced
d
deduced from the column

e to which the tray is assigned. It can be deduce
x Column diameter
iameter
This is the internal defined in the present document.
nternal diameter as defined d The column can
be divided own diameter. Obviously, each
vided into multiple sections, each one with its o
ow
section
ction must have its own mechanical dadata.
x Numb of trays
Number
This is the number of real trays in the column
colum that have the indicated information in
common. This can be deduced from the c column’s heat and material balance.
co
BO
x Spa
Spacing
This is the distance between the
t trays indicated in the previous item. It can be
sheet.
deduced from the column data sh
x Number of passages requi
required
requir
liquid passages in the indicated trays and can be deduced
This is the number of liqu
sheet.
from the column data sh
x Top or bottom
b tray numbering
It must be
b indicated
indica if trays are numbered starting from the top tray or the bottom
tray of th column. It can be deduced from the data sheet. Trays are normally
the co
mbere from the bottom, i.e. tray number 1 is the first tray starting from the
numbered
bottom oof the column.
x Man
Manholes and number
The nominal diameter and the number of manholes on the column must be
T
indicated.
x Manhole above tray number
The position of the manhole on the column must be indicated with respect to the
column trays in the section under consideration. This is deduced from the column
data sheet.
sent.
$ PRG.PR.VES.0011
Sheet 33 (35)
x Passage attached on tray from below, above or both sides

Indicates how the internal passage must be bolted onto the tray. In
n general, bolting
on both sides is preferred.
x Fixed or removable downcomers
In general, removable downcomers are preferred for easier
er maintenance.
enanc
x Tray type
The type of tray must be indicated, i.e. sieve, valve,, bubble-cap,
bubb etc.
x Tray material
This is a description of the material that mustt be used to make the tray surface.
x Valve material
This is a description of the material that must be used to make the mobile vavapor
distribution elements (valves or bubble-caps);
bble-caps); it can be different from the tray
tr
surface material.
x Position of feeds
The trays over which the
e feed enters must be indicated.
ed. This is deduced from the
column data sheet.
Process data
x Top, bottom or tray y no.
n load
The numberr of the tray, or if it is the
e top tray or bottom of the column, for which
m tray o
information
on is provided must be indicated. deduced from the column’s heat
dicate This is deduce
and material
aterial
terial balance
balance.
x Vapor
apor phase
The mass flow, molecular weight and compressibility
compres
compress factor of the vapor entering
the tray must be indicated.
These are deduced from the column’s heat and material balance/simulation output.
BO
x Liq
Liquid phase
The mass flow, density, visco viscosity and surface tension under the temperature
conditions of the liquid leaving the
t tray must be indicated.
These
hese are deduced from heat a and material balance/simulation output.
x Operating temperature
temperature of the liquid phase and the vapor phase of the tray
The operating tempera
temperat
under consideration must
m be indicated.
are deduced from heat and material balance/simulation output.
These a
x Operating
eratin pres
pressure
The operating pressure of the tray under consideration must be indicated.
e oper
operatin
This deduced from heat and material balance/simulation output.
his is d
de
x Reco
Recommended derating factor
Th tendency of some systems to form foam is taken into account by using a
The
““derating” factor for the work capacity of the tray.
The value to assume in the tray calculation must be indicated.
x Max. flooding factor
The percentage value to assume in the column tray calculation must be indicated.
sent.
$ PRG.PR.VES.0011
Sheet 34 (35)
x Max. pressure drop per tray

The maximum pressure drop that can be tolerated for the tray underder consideration
must be indicated.
The pressure drop to consider in the mechanical calculation of the support grids
grid for
sections with packings should also be indicated.
x Min/Max load
The minimum/maximum flexibility required for the
e tray must be indicated as a
A
percentage.
3.3.2 Packings – Information to send to the supplier
The information to send to the supplier regarding

arrding the sizing of the packing, and which
whic is
transmitted using form DAT.PR.INC.0002, 2, is described below.
Mechanical data
ZZ x
x
Code
This is the code of the column
Service
This is the service
vice
column data sheet.
lumn on which the packing is installed. It can be deduced
olumn
from the column data sheet.
heet.
e to which the packing is assigned. It can be deduced from the
x Column diameter
This is the internal diameter of the colu section with the packing. This is
column in the sect
secti
deduced
uced from the column’s data sheet.
x Number of theoretical trays for packing sectio
section
This is the number of theoretica trays
theoretical tray necessary for the desired performance.
s necess
necessa
This is deduced from the column’s heat and material balance/simulation output.
BO
x Height of packing section (1)

Hei
This is the height of the packing that gives the desired performance.
x Packing type (1)
This
is is the type of packing util
utilized.
utili
x Packing material (1)
This is a descriptio
description of the material from which the packing is made. This is
deduced from the co
deduce column’s data sheet.
x Position
sition of inte
intermediate feeds
The section
sect above
a which feed occurs must be indicated. This is obtained from the
column’s data sheet.
umn’s da
Note:
Note
e:
(1) For packing,
p both structured and ordered types, this information will be defined after
preliminary consultation with the possible suppliers on the basis of the accessories
p
pr
to be installed, required flexibility and cost.
sent.
$ PRG.PR.VES.0011
Sheet 35 (35)
Process data
x Vapor phase
The mass flow, molecular weight and compressibility factor off the vapor entering
and the vapor leaving the packing must be indicated.
These are deduced from the column’s heat and material balance/simulation
simulation output.
x Liquid phase
The mass flow, density, viscosity and surface tension
ion
on of the liquid entering and the
A
liquid leaving the packing must be indicated.
alance/simulation
ance/simula
These are deduced from heat and material balance/simulation output.
x Operating temperature
The operating temperature of the liquidd phase and the vapor phase affecting the
packing must be indicated.
This is deduced from heat and material
aterial
terial balance/simulation output.
x
ZZ x
Heat exchanged
The quantity of heat exchanged
must be indicated.
Max. flooding factor

The percentage
actor
ctor
ge value
anged
nged when the packing zone
packing
lue to assume in the pa
ne is used for heat e
This is deduced from heat and material balance/simulation output.
cking calculation
exchange
ex
must be indicated. The

tion mu
recommendeded values for the various Table 4.
us cases are indicated in T
x Operating
ing
g pressu
pressure
The operating pressure at the entrance
entrance to the packing must be indicated.
This balance/simulation output.
his is deduced from heat and material balance/sim
x Press
Pressure drop
This is the maximum pressure drop that can bbe tolerated in traversing the packing.
balance/simulation output.
This is deduced from heat and material ba
BO
x Min/
Min/Max heat
flexibility rrequired for the packing used for heat exchange
The minimum/maximum flexibili
percentage.
must be indicated as a percent
percentag
sent.

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$

Ex PRG.PR.VES.3 - Rev. 0 - January 1989

Rev. 0 Date Dec. 1996

2. FRACTIONATING COLUMN DESIGN 4

Rev. 0 Date Dec. 1996

1.1 Scope and field of application

The purpose of the present document is to define the criteria to follow

1.2.1 International Regulations and Standards References

ASME, Sect. VIII, Div. 1 Boiler and Pressure

1.2.2 Company Standardization References

Rev. 0 Date Dec. 1996

2. FRACTIONATING COLUMN DESIGN

The process design of a fractionating column comprises the following phases:

The heat and material balance calculation represents

the functioning of the column

in the established constraints.

must check that these are unambiguously

Rev. 0 Date Dec. 1996

lower pressure. Low

column’s stripping or rectification

2.1.3 Calculation methodology

Rev. 0 Date Dec. 1996

Description of the fundamental components

Rev. 0 Date Dec. 1996

2.2.2 Meaning of more frequently used terms

e for the tray and at a given

It is not necessarily the lowest operating

Rev. 0 Date Dec. 1996

Table 2.2.2.a – Estimated overall efficiency

ane drying column

Rev. 0 Date Dec. 1996

Table 2.2.2.a – Estimated overall efficiency (continued)

(from FRI) 27.6 bar 95-105

0.3 bar 70-75

Rev. 0 Date Dec. 1996

In fractionating columns that operate with vapor densities of more than

Service System Factor

Rev. 0 Date Dec. 1996

Table 2.2.3.a – Summary of characteristics

Used to obtain high flexibility

Capacity: very high.

Rev. 0 Date Dec. 1996

h costs, from 50 to 100% more than

Rev. 0 Date Dec. 1996

Fig. 2.2.3.2.a – Types of packing

Plastic Pall rings can be used

Ceramic Pall rings are to be preferred in corrosive environments,

ant to acids, alkalis and solvents, with the exceptions

Rev. 0 Date Dec. 1996

Table 2.2.5.1.a – Minimum tray spacing in a fractionating column

Column Minimum space (1), mm

Jet flood percentage

er that is used to calculate

calculate the diameter

Rev. 0 Date Dec. 1996

ZZ Fig. 2.2.4.1.a – Defin

Generally, a value not exceeding

Rev. 0 Date Dec. 1996

In addition to the type of packing, the sizing of packing is also condition

x the need to redistribute

Type of packing Maximum packing height

Rev. 0 Date Dec. 1996

2.2.5.1 Fractionating tray columns