CH 7 SULCOL For Tray and Packing

Sulzer Design Tool for Packing and Tray Sulzer Chemtech
Lee Siang Hua | 29.08.2013 | Sulzer Chemtech Technical Training | Thailand

Content Sulzer Chemtech
Overview
Tray design with SULCOL
Packing design with SULCOL
lsh-sulcol | 29.08.2013 | slide 2
Overview
Overview Sulzer Chemtech
Hydraulic design program
SULCOL.exe
contains
Sulzer structured packing
Sulzer random packing
Sulzer tray
to be downloaded at
http://www.sulzer.com/en/Resources/Online-Tools
SULCOL is an easy-to-use sizing program for distillation, stripping and
absorption columns with Sulzer mass transfer products.
The sizing procedure leads to estimated values for the product specific design
figures like capacity, pressure drop, holdup etc., based on the specified liquid
and gas flow rates and physical properties at a given column diameter.
The calculation procedure is based on data taken from laboratory
measurements in columns of up to 1.6 m in diameter as well as from the
actual operating results of many industrial installations.
Structured and random packing hydraulic design and rating
Default packing efficiency based on standard organic test mixtures
Efficiency calculation may be suppressed
Graphical capacity diagram with operating points
Tray hydraulic design and rating
Fixed and movable valves
One pass and multipass tray design
Conventional downcomer design
Description of Sulzer tray portfolio including SHELL tray technology
Import input data from
PRO II (Simulation Science Ltd)
ASPENPLUS (Aspen Tech Ltd)
Excel-File (Sulcol Format)
Export data to following formats
RTF
XML
Excel (SulcolFormat)
Current version: 3.0
Section/Frame
A Section contains
process and
important equipment
related design
information
Unlimited number of
sections can be
added
The section type is
either packing or
tray, is
interchangeable by
clicking
Conventions
White: data input
Yellow: data calculated
File/Preferences
General
User Profile
Turn-up/
Turn-down
Gas Density Calculation
SULCOL helps you calculating the gas density of your mixtures. First of all, you will have to
right click one of the 'gas density' input boxes. Then, select Tools/Calculate gas density.
Fill in 'Molecular weight', 'Pressure' and 'Temperature'.
Press 'Calculate' and the gas density will be displayed. Press 'Accept' to copy the result to
the sizing screen or hit 'Cancel'.
Introduction
Tray Design with SULCOL Sulzer Chemtech
Tray Design Strategies
The SULCOL program is an excellent rating program for existing trays. It can also be used
to design new trays, but the design task can be more difficult. Sulzer Chemtech suggests
the following procedure for design:
1. Enter the Process Loads
2. Enter approximate tower diameter, tray spacing, and number of passes.
3. Choose valve type, and then iterate on % open area to achieve a dry tray pressure
drop of 1.1-1.5 inches of water.
4. Start with vertical downcomers, set DC widths to satisfy Inlet Velocity.
5. There is an Optimize Downcomer Size button that gives the user the ability to look at
downcomer size(s) for a target velocity.
6. Downcomer Velocity and back-up values should not exceed 80% simultaneously.
7. Optimize the weir heights and DC clearance to minimize the DC Back-up limitations
and equalize tray pressure drops on all the zones of multi-pass designs.
8. Review overall design, optimize, save, and print.
Tray Design with SULCOL – Loadings Window Sulzer Chemtech
a. White: data input; Yellow: data calculated
b. Fluid Data: Name it as Fluid 1 or any indication of column section
c. Tray design: Name the tray geometry section, such as #Tray 1-20
Tray Design with SULCOL – Geometry Detail Sulzer Chemtech
Tray Geometry
- ID (Inner diameter),
- TS (tray spacing),
- DC (downcomer) width
(top & btm),
- DC clearance,
- Outlet weir and Inlet
weir,
- Type of perforation
Tray Design with SULCOL – Optimize D.C. Sulzer Chemtech
Optimize D.C.
- Optimize the DC width with
specified DC inlet velocity
Tray Design with SULCOL – Initial Design Sulzer Chemtech
-
Initial Design Button
Program will suggest a design with Sulzer's guidelines:
Percent of Flood of 78% (+/- 4 percentage points)
Downcomer Top(entrance) Velocity of 0.36 ft/sec (~ 0.1 m/s)
Maximum Weir Loading = 12 gpm/in (~107 m3/mh)
Dry Tray Pressure Drop = 1.5 inches Water (38 mm Water) for Fixed openings
- Dry Tray Pressure Drop = 2.0 inches Water (50 mm Water) for Movable Valves
Tray Design with SULCOL – Calculated Output Sulzer Chemtech
Tray Design with SULCOL – Calculated Output Sulzer Chemtech
Summary of Design Guidelines, US Units (SI Units)
Item Minimum Value Maximum Value
Useful Capacity, % 10 95
Flood, % 10 85
System Limit, % 0 90
Weir Loading, gpm/in.(m3/mh) 0.6 (5.37) 13 (116.24)
Dry Drop, in. H2O (mmH2O) 0.3 (7.62) 3 (87.88)*
Pressure Drop, mmHg (mbar) 2.5 (0) 15 (20)
D.C. Froth Backup, % 5 90
D.C. Head Loss, in. (mm) 0.1 (2.54) 1.5 (38.1)
D.C. Flood, % 0 80
D.C. Velocity, ft/sec (m/s) 0.0 (0) 0.45 (0.137)**
VSF/VSFmin 0.9 None
Min Flow Path, in (mm) 16 (406) None
Spray Factor 2.78 None
* Max Dry drop = 16% of TS (mm hot liquid)
** Max DC velocity can be limited by liquid and vapor densities at high pressure
Useful capacity and Jet Flood
Useful Capacity is the standard measure of capacity that was developed at the former
Nutter Engineering.
At increasing column vapor flow rates, the efficiency of all trays declines rapidly before
the tower reaches 100% Jet Flood.
There is a break point in the performance profile beyond which the tray efficiency
declines rapidly due to the adverse effects of entrainment.
The combination of vapor and liquid rates at this break point defines 100% Useful
Capacity.
For practical purposes, the Useful Capacity should not exceed 95% for MVG, MMVG,
and SVG devices. For LVG, BDH and BDP trays use the Jet Flood measurement below
as the definition of vapor capacity and do not exceed 85% of Flood.
System Limit
This is Stokes Law criterion, which predicts a vapor rate limit beyond which entrained
liquid droplets cannot settle back into the bulk liquid phase.
The System Limit is independent of tray design or spacing.
A System Limit usually occurs only at high tower pressures (>150 psia).
The maximum permissible value is 90%.
System Factor
This empirical derating factor reduces the predicted capacity of the tray (increases %
flooding, downcomer froth backup, and reduces maximum downcomer inlet velocity)
to account for a known foaming system.
Classification Foam Factor
Non-Foaming 1.0
Low 0.9
Moderate 0.75
High 0.6
Weir loading
Volumetric flow rate of liquid coming to one of DCs / Weir length of this DC
High weir loading causes more liquid built on deck, results in reduction in max vapor
handling capacity and high pressure
If larger than 116 m3/h m, 2, 4 Passes or HiFi tray should be considered
q'
how = C0 ( ) C1
how lw
Where how liquid crest over weir
Flow direction
C0 & C1: constant
q': liquid volumetric flow rate over weir
lw: Weir length
Dry drop, Pressure drop
Dry tray pressure drops from 0.5 – 2.50 inches of water are recommended for
conventional valve and V-Grid trays.
MVG trays can be designed for dry pressure drops up to 3.0 inches of water.
These ranges provide adequate turndown without weeping or valve movement, which can
cause excessive wear.
Dry tray pressure drop effects on entrainment,
Dry pressure drop contributes to Pressure Drop which might affect downcomer backup.
Min dry drop: likely weeping
Max dry drop: likely excessive entrainment
To reduce Dry drop, increase open % or use MVG or MMVG
DC Flood
Max. velocity into the top of the downcomer. The limiting value is primarily a function of
vapor-liquid density difference.
DC Flood < 80%
In case too high, increase DC width
DC froth backup, DC backup
This is a limitation due to excessive aerated froth stack-up in the downcomer.
The stack-up is the result of the pressure balance across a tray, and the head loss
under the downcomer.
DC backup % < 90%.
Radius tip
Recess Seal Pan
Headloss
Resistance of liquid when it comes out of DC clearance, too high value might result in DC
backup problem
Headloss < 38.1 mm hot liquid
If too high, increase clearance or use radius tip
VSF/VSF min (valve slot factor)
The ratio of pressure corrected hole velocity divided by the minimum value.
Indicating likely weeping and instability of
Always keep > 0.9 to ensure full activity of BDH valve and stability of V-grid tray
In case too low, reduce open %
Min flow path length
> 406 mm for installation and inspection purposes
Spray factor > 2.78
Always keep > 2.78
Lower than 2.78 means unstable, efficiency is erratic
Solution: using high weir height, bigger opening area
Constriction factor:
Indicating stagnation area
In the past, industry limit Side DC > 4%
High performance tray can design Side DC < 4% now with push valve
Summary
Measures to get high capacity
Use fixed valve, for example, MVG and UFM
Increase free area: slop downcomer, or enhanced downcomer design
Approach Sulzer for high performance tray
DC flood
Expand DC top width
Approach Sulzer for details
DC backup
Reduce pressure drop
Increase clearance or use Radius tip
Introduction
Packing Design with SULCOL Sulzer Chemtech
Maximum vapor load (= 100% capacity) is defined by a pressure drop of 12 mbar/m (1.44
inch H2O/ft), which is about 5 to 10 % below the flooding point.
Maximum design vapor load - vapor load corresponding to a pressure drop of 3 mbar/m
(0.36 inch H2O/ft) for all packings except MellapakPlus with 5.5 mbar/m (0.66 inch H2O/ft).
Above this point the efficiency starts to decrease rapidly.
Expected efficiency is the measured efficiency in a 1 m (3.3 ft) diameter test column at
total reflux. Test column packing height: 1.4 - 8.5 m (4.6 - 27.9 ft). Test mixture: chloro-
/ethylbenzene and trans-/cis-decaline.
Design efficiency - expected efficiency at the maximum design vapor load. This efficiency
is used in the program to calculate the packing height for all packings.
Packing Design with SULCOL _ Input Loading Sulzer Chemtech
name the fluid data and packing section
input
packing
data
White: data input
input V-L data
Yellow: data calculated
Packing Design with SULCOL – Import Pro/II File Sulzer Chemtech
Import V-L data from
simulation output file
Import PRO/II File
Run 4
open 1 back to
output file SULCOL
5
select 2
column
3
decide
sections
Import PRO/II File
To ensure a safe transport of the data into the SULCOL program the following
units should be used:
· Metric:
Flow: [KG/HR]
Density: [KG/M3]
Viscosity: [CP]
Surface Tension: [mN/M]
· English:
Flow: [LB/HR]
Density: [LB/FT3]
Viscosity: [CP]
Surface Tension: [DYNE/CM]
Packing Design with SULCOL – Detail Design Sulzer Chemtech
decide NTS 3 turn down range
4
decide
diameter
5
1
select
packing
type
2
select
material
Packing Design with SULCOL Sulzer Chemtech
Capacity Diagram
Visual presentation of
packing capacity
Comparison with another
packing type on the same
graph is available
Introduction
Thank you for your attention. Sulzer Chemtech

CH 7 SULCOL For Tray and Packing

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Sulzer Design Tool for Packing and Tray Sulzer Chemtech

Lee Siang Hua | 29.08.2013 | Sulzer Chemtech Technical Training | Thailand

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