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GBH Enterprises, LTD.: GBHE-PEG-MAS-611
GBH Enterprises, LTD.: GBHE-PEG-MAS-611
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Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
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0 INTRODUCTION/PURPOSE 3
1 SCOPE 4
2 FIELD OF APPLICATION 4
3 DEFINITIONS 4
4 DESIGN PHILOSOPHY 4
5 PERFORMANCE GUARANTEES 5
6 TRAY DESCRIPTION 6
7 DESIGN CALCULATIONS 9
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Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
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10 TRAY VIBRATION 23
11 REFERENCES 27
APPENDICES
A TRAY DEFINITIONS 44
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5 LIQUID FEEDS 18
8 CHIMMNEY TRAY 20
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GBHE does not manufacture distillation trays - they are purchased from
specialist tray manufacturers. The detailed design of the trays IS generally
undertaken by the manufacturers. Competitive bids will generally be sought from
various manufacturers.
(b) Ensure that what is offered by the bidding manufacturers will meet these
requirements.
On existing plant there is often the need to assess the performance of trays for
several reasons:
(1) To assess the reasons for any shortfall in the performance of the trays,
compared with design or earlier operation.
(2) To assess up-rating capability of the existing trays from high rate plant
trials.
(3) To explore modifications to the trays for operation at higher or lower rates.
The design of proprietary trays depends on the design methods supplied by their
manufacturers. These design methods are sometimes unreliable and expert
advice should be sought when considering proprietary trays.
4 SCCPE
This Guide deals with the design and rating of trays for distillation columns. It
covers neither guidance on the selection of trays and packings nor some aspects
of their performance characteristics: advice on both of these is given In GBHE-
PEG-MAS-610 (Reference 6).
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2 Field of Application
3 Definitions
4 Design Philosophy
5 Performance Guarantees
6 Tray Description
7 Design Calculations
10 Tray Vibration
2 FIELD OF APPLICATION
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With the exception of proper nouns. terms with initial capital letters which appear
In this Guide and are not defined above, are defined In the Glossary of
Engineering Terms (Reference 7).
4 DESIGN PHILOSOPHY
GBHE does not manufacture distillation trays; they are purchased from specialist
tray manufacturers. Generally speaking, the tray manufacturers have more
experience In tray design than GBH Enterprises Process Engineers. It is
therefore preferable for the manufacturer to take responsibility for the tray design.
If modifications are required the aim should be to agree changes with the
manufacturer which do not diminish his design contingencies, while removing the
risk of poor performance. This is generally achievable since we will usually be
seeking extra contingency in the design.
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The recommended practice for tray design is dependent on the purpose for
which the design is required:
(a) A rough column sizing is usually all that is needed for initial flowsheeting
studies.
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The question arises of whether to seek guarantees from tray manufacturers. This
needs to be decided by each Project Team, because there are 'pros and 'cons. If
a guarantee is obtained, the manufacturer is bound to do all he can to resolve
any shortcoming in his tray design, up to the limit of his liability (which will be
stated In the guarantee). In practice, It may not be clear whether a particular
problem has been caused by the tray design, the tray installation, or the
subsequent operation. Since the manufacturer is bound by a guarantee, he will
be concerned not to say or do anything which could be construed as an
admission of liability. Experience shows that, even where there is no
guarantee, most manufacturers are very willing to help resolve the problem,
Since they stand to learn from a detailed knowledge of what went wrong, no
matter whose fault It is.
Guarantees do not cover consequential losses. If a failure occurs and the plant is
shut down, the consequential loss will far exceed any sum in the manufacturer's
guarantee - In cash terms a guarantee is of little value. Furthermore, the
guarantee will generally contain clauses defining requirements of access for
testing, dismantling and examination In the event of failure. The guarantee may
become void if we do not meet these requirements.
6 TRAY DESCRIPTION
While there are exceptions, the vast majority of column and tray designs are
essentially similar and their features are described below. In describing trays,
customary terminology (largely based on FRI definitions) is introduced. A
comprehensive listing of definitions is given In Appendix A. The definitions are
those used by Fractionation Research Inc and are understood by the majority of
tray manufacturers. Also, other terminology in common use is Included.
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The Simplest design is a one pass tray (Figures 1 & 3) in which the downcomer
is of segmental shape. One pass trays are used mostly in small and medium
sized columns (up to 3 m diameter). As diameter Increases, the liquid load on a
one pass tray tends to limit its capacity and higher capacity can be achieved with
a two pass tray. Large one pass trays also tend to suffer loss of efficiency
through recirculation eddies at the sides of the trays as shown in Figure 2. Three
and four pass trays (Figure 3) are not recommended because it is difficult to
ensure the proper distribution of liquid and vapor to each pass; failure to do so
results In the passes operating at different L V ratios With a consequent risk of
poor efficiency.
A column sectional sketch is shown In Figure 4, which shows the various types of
downcomer used: straight (as In Figures 1 & 3), sloped and stepped.
Also shown are the recessed seal pan and the Inlet weir. Either of these can be
used, when the liquid load is low, to ensure a positive seal at the bottom of the
downcomer, this is to avoid the possibility of vapor flowing up the downcomer
and causing premature flooding of the downcomer. Most trays have an outlet
weir to ensure that there is an adequate liquid holdup to achieve good efficiency.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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Three categories of design can be identified which fall roughly in line with the
stages of estimate in a Project for a new plant:
For the assessment of existing trays or for plant modifications (except where a
new column is required) all calculations will be in the detailed design category.
The following Clauses are concerned primarily with Sieve and valve trays, which
are the commonest types of tray. Bubble cap and dualflow trays are also briefly
considered; for these and other types. Seek expert advice.
The equation given In the FRI Design Handbook (Reference 1), Section 5.1, P4,
converted to metric units, is:
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Commercially available tray design programs are suitable for preliminary tray
design.
These programs typically use correlations which may or may not be up-to-date,
and the results should not be used for detailed design. Nevertheless, it is
convenient to use and provides a good preliminary design, with little effort.
When the preliminary design stage has been reached It is strongly recommended
to gather the design data on GBHE Data Sheet pro-forma’s, allowing this to be
done In a structured and systematic manner which should avoid the confusion
which can so easily arise if the data are transferred manually from, other
commercially available programs.
Depending on the data supplied, the program will design or check the
performance of valve, sieve and bubble cap trays with t, 2, 3 or 4 flow paths. The
design/performance alternatives are available In three aspects of the design:
Specify the diameter, or the program will calculate the diameter from the
specified maximum fraction of flood.
Specify downcomer width(s), or the program will balance jet flood and
downcomer loading.
(c ) Tray flexibility:
Specify the number of units (valve or bubble cap) or fractional hole area
(Sieve), or the program will design to achieve the specified turndown ratio
and maximum pressure drop.
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(a) Column sizing, to determine diameter and height, prior to enquiry on tray
manufacturers.
(c) Exploring tray design options for uprating an existing column or changing
its duty.
The first of these starts with an approximate sizing as described In 5.2. Then, as
in the other cases, the starting point for detailed calculations is an established
design; Data Sheets and tray drawings should be available for existing trays, and
manufacturers' quotations should contain enough detail for assessment. If
quotations do not contain enough data we should request the missing
Information. The tray manufacturing business is a highly competitive one and we
can usually choose to go to another supplier, so we usually get what we ask for,
provided our request is reasonable.
Plant data may show that a given system with a given tray design floods at, say,
105% of the predicted flood point. Care is needed In using this Information In the
design of new trays or the assessment of existing trays for a new duty:
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(2) The same system may not perform so well on a different tray
design or column diameter. It may flood at a lower predicted %
flood If the correlation does not properly account for the effects of
mechanical features In the tray design.
(3) A different system may not perform so well on the same tray
design. It may flood at a lower predicted % flood if the correlation
does not properly account for the effects of system physical
properties.
For sieve trays, commercial programs are available. They are typically capable
only of rating tray designs; design has to be done iteratively with repeated rating
runs.
For valve trays, commercial programs are available. Although it was said in 7.1
they are suitable for preliminary design only, they can be used for detailed design
in two circumstances:
(i) For uprating studies, when data are available on the existing trays at
conditions close to flood, since this allows Judgment to be taken on the
accuracy of the program's correlations for the system and tray design
being studied.
The sieve and bubble cap tray options in most commercially available programs
should not be used for detailed design work.
The FRI Tray Design Handbook also contains design methods for dualflow trays
(sieve trays with no downcomers), bubble cap trays and baffle trays. Computer
programs are available for the first two of these, but they are rating programs and
design has to be done by repeated rating. Bubble cap tray programs are difficult
to use and require a large number of data items to describe the tray design.
Dualflow tray programs are simpler.
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The aim is to explain the significance of the data and how it is affected by
changes in the tray design. This is to help the user not only to Judge whether a
given design is a good one, but also to change the design to improve its
performance. For tray types other than sieve and valve trays, expert help should
be sought.
The art of tray design is in balancing the design so that the risks of poor
performance from various causes are nicely balanced, resulting in a design
which will work well but is not overly conservative in a way that makes it too
expensive. Since the GBHE Process Engineer will generally be evaluating
existing or proposed designs, the major concerns are:
(a) Will it work for the operating conditions required (I.e. over the specified
operating range).
(b) Are the risks to performance (flooding, entrainment, weeping, etc) well
balanced in the sense that none of them stands out as being much closer
to its limit than the others.
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This Clause concentrates on the main performance parameters and how a tray
design can be modified to improve them. Generally, the same considerations
apply to both valve and sieve trays. Extra comments are given in Appendix E.
(a) System limit - In concept the system limit represents the ultimate capacity
of a column. No matter what tray design you choose, you cannot do better
than the system limit correlation suggests. Where the Jet flood
approaches the system limit (which often happens with high pressure
systems), there is little hope of increasing column capacity by changes in
tray design, or even by changing to packing.
(1) Increasing column diameter (a major change which could have far
reaching consequences).
(4) Increasing hole area and or reducing hole size, but these will
reduce the weeping
Note that two values of Jet flood are given by, one at constant
vapor liquid ratio and the other at constant liquid rate. The first of these is
usually the one relevant to distillation duties and always gives a lower
safety factor. Some manufacturers quote the constant liquid rate value,
which is more optimistic.
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Some programs also list a froth height, but this should be disregarded
because the correlation used for froth density is not reliable. For non-
foaming low pressure (less than 10 bar) systems, the clear liquid
backup should not exceed 55% of the tray spacing plus the outlet weir
height. For foaming or high pressure systems (greater than 10 bar, a
backup less than 25% should be satisfactory, but will often be too
conservative – seek expert advice. The % downcomer backup may be
reduced by increasing tray spacing, reducing pressure drop, or Increasing
the downcomer escape area.
(f) Downcomer seal - It is important that the clear liquid height on the tray
should not be lower than the bottom edge of the downcomer. If it is, there
is a risk that vapor will enter the downcomer and cause flooding by
aerating the froth In the downcomer, similar to a foaming or high pressure
system.
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(1) Provide an inlet weir higher than the bottom edge of the
downcomer; Inlet weir is are not often used except In low liquid rate
designs (less than 1.2 m 3 hr m2 of tower area).
(2) Provide a recessed seal pan, which generally allows the bottom
edge of the downcomer to be at the tray floor level.
(3) Ensure that the outlet weir height is at least 15 mm above the
bottom edge of the downcomer.
In considering the downcomer seal, use the liquid height on the tray, HL,
rather than the inlet liquid height on the tray panel below. HIN, which is
believed to be an overestimate.
(g) Pressure drop - there are several reasons why It may be desirable to limit
the pressure drop of a tray design, such as:
For the first two, packing may be a better choice than trays.
There are two main components to tray pressure drop: the pressure drop
through the holes In the tray floor and the liquid head on the tray. Although the
Correlation for the pressure drop through the holes Includes an allowance for
the presence of liquid on the tray. It is usually referred to as the dry tray
pressure drop.
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All of these will reduce the turndown available, by increasing the vapor load
at which weeping starts.
The liquid head on the tray can be reduced by reducing the outlet weir height.
The normal height is 50 mm; this can be reduced to 25 mm with little or no
loss in efficiency, but below 25 mm the efficiency can be expected to suffer.
Reduced outlet weir height should increase the turndown but only marginally.
With low outlet weir heights it is necessary to pay attention to the downcomer
seal (see (f) above).
The most common arrangement is to introduce the liquid at the inlet side of the
tray (see Figure 5). The design should not produce a non-uniform flow pattern on
the tray. Feeds should not be introduced Into a down comer because of the risk
of causing premature flooding due to boiling In the down comer through heat
transfer either from a hotter feed, or to a cooler more volatile feed.
Intermediate vapor feeds are often introduced through a perforated feed pipe
similar to that for liquid feeds. Care is needed to avoid disturbance of the liquid
on the tray below. Typically the feed branch is centrally mounted with horizontally
oriented slots for the vapor distribution. This helps mixing with the vapor coming
up the column. Drain holes should be provided.
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Most reboilers return a two phase mixture to the column. The flow regime will
generally be mist flow. If this is simply fed through the Inlet branch, impingement
of the liquid on the column wall opposite will probably cause erosion and may
lead to failure. The most common design of internal distributor is shown in Figure
6. This directs the vapor/liquid mixture downwards, the liquid falling to the column
base and the vapor turning round, losing much of its velocity and flowing up to
the bottom tray.
Figure 8 shows a chimney tray for partial liquid removal. The overflow weir is
omitted for total removal. The following points should be noted:
(a) For large columns, several chimneys should be used. Chimneys may be
round or rectangular.
(d) The annular area between the top of the chimney and the hat should be
equal to or greater than 1.25 limes the chimney area.
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(f) The overflow weir height is set by the residence time required. This is
typically 3 - 5 min. based on the liquid drawoff rate and subject to sufficient
provision for vapor disengagement.
Vapor drawoff from an Intermediate position in the column may be done by one
of the options shown In Figure 9. Vapor removed by any of these must be
assumed to contain some liquid from the spray In the Inter-tray space. Provision
may be needed for removing this liquid and returning it to the column.
Figure 10 shows the most common column internal arrangements for reboiler
Circuits. These provide for the recirculation of liquid through the reboiler which
will normally operate with much less than 100% vaporization. Design B is
preferred for thermosyphon reboilers since it provides a constant liquid head.
Vortex breakers should generally be used on downward flowing nozzles.
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3. Nozzle C is likely to contain less liquid than Nozzle A at the same height.
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2. See Figure 6 for arrangement below bottom tray for return nozzle.
3. In design A. the effective surge volume in the base of the column may be
constrained by the high and low liquid level limits requited by the
thermosyphon reboiler for efficient operation.
10 TRAY VIBRATION
Tray vibration occurs at relatively low rates of operation and has been observed
mostly in valve trays but also in sieve trays and one instance in a proprietary type
of dualflow tray. When It occurs, tray vibration causes damage to the tray
structure. Experience has shown failures from fatigue cracking of trays, tray
support beams, tie beams and tray-to-column supports. Extensive cracking has
occurred within hours of operation at the damaging vapor rates and at least one
case of total internal collapse is known as well as a case of shell cracking due to
vibration transmission through the tray supports.
Most, but not all, of the columns have been large (range: 1.5 to 9 m 10) and the
most severe vibrations have generally occurred at rates close to the weep point.
The processes have ranged from high vacuum to high pressure though the
majority; have been aqueous systems in the vacuum range.
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The analysis of the tray vibration process rests on the consideration of three
phenomena:
(a) Unstable flow conditions of the vapor passing through the trays.
(c) The coincidence of this frequency with the natural frequency of some part
of the tray structure.
The pressure drop across a tray can be considered as the sum of two terms:
(a) The pressure drop across the holes in the tray floor (dry tray pressure
drop)
(b) The static liquid head at the tray floor (clear liquid height).
Figure 11 shows how these two components would vary with vapor rate in an
idealized situation. The dry tray pressure drop Increases with vapor rate, while
the clear liquid height falls due to increased aeration of the liquid. The total
pressure drop passes through a minimum and there is therefore a range of vapor
rates where the pressure drop is essentially Independent of vapor rate and the
flow is thereby unstable.
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where:
For valve trays: C = 2.7 for valves with a venturi orifice in the tray floor. For the
usual valve type with a plain orifice C is a function of tray thickness:
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For damaging tray vibration to occur me bubbling frequency must coincide with
the natural frequency of one or more elements of the tray structure. The
oscillations observed in columns suffering from tray vibration have been in the
range 15 to 50 Hz.
As noted In Reference 2, several models have been tried for predicting the
bubbling frequency, but none fitted the data particularly well and an empirical
correlation is used to predict the oscillation frequency:
f = 31 p0.3 (10.3)
where:
For estimates of the natural frequencies of the tray structure, methods are to be
found in standard mechanical engineering texts (e.g. Reference 4) but specialist
advice should be sought.
As was noted In the Introduction to Clause 10, only about 1% of trays suffer from
tray vibration and it is not normally considered for new tray designs unless there
is a history of tray vibration in the service being considered.
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K is the reciprocal of the fractional hole area. The actual hole velocity is thus
proportional to K. In the Equation shown In 10.1 the critical hole velocity is
proportional to 1 K. Thus the criterion R 1 IS proportional to K2. The fractional
hole area is thus a powerful means of moving a tray design out of the Vibration
damage region. It is important to consider not only the design point at which the
trays are expected to operate, but also the full range of operation from startup to
shutdown and including any steaming out which operates with refluxed water.
In almost all cases where vibration has occurred, the action taken has been to
reduce the number of holes or valves on the tray and this has been universally
successful. It does however affect the tray hydraulics: increasing pressure drop,
risking entrainment and bringing the tray closer to flooding.
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A.1 INTRODUCTION
The following definitions are those used by FRI these are understood by most of
the Tray Manufacturers (especially those who are FRI Members - see Appendix
F). Some alternative definitions are also included.
Bubbling Area is the superficial area minus the sum of downcomer top,
downcomer seal and inactive areas
Any section of the tray floor more than the nearest perforation, valve Unit
or bubble cap, and any area behind an envelope downcomer.
Free area is the minimum cross-sectional area between trays available for
vapor flow, (It should be noted that Free Area is sometimes used for the
total area of the holes in the tray floor, especially in academic literature).
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Hole area is the total hole area available for vapor flow through an
Installed tray.
A.2.6 Downcomer
Downcomer seal area is the horizontal area below the bottom of the
downcomer used to seal the downcomer and distribute liquid to the tray. It
is defined by the column wall and:
Area under the downcomer (or downcomer escape area) is the minimum
area through which the liquid must flow to leave the downcomer. It may be
horizontal or vertical. It constitutes a restriction orifice and contributes to
the liquid backup in the downcomer.
Downcomer clearance is the vertical distance from the tray floor, or the
floor of a seal pan, to the bottom of the downcomer. This is the definition
used in the FRI Manual Volume 1.
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Average width of flow path is the arithmetic mean of the wall-to-wall distance at
the inlet, centre and outlet positions of the bubbling area for a single pass tray.
For a mufti-pass tray it is the sum of the average widths for each pass,
Length of flow path is the distance from the Inlet edge of the tray to the outlet
edge of the bubbling area.
On the bubbling area of a tray, the action of the two-phase mixture can take one
of three forms, described as flow regimes. Whichever flow regime obtains on a
tray depends mostly on operating pressure and the liquid to vapor flow ratio.
Three flow regimes are described below; a fourth regime (bubbly flow) is possible
but is rarely obtained in practice on commercial trays.
Under vacuum conditions where the vapor density is low and hence vapor
velocities are high, the action is vapor phase continuous (droplets of liquid in the
vapor rather than bubbles of vapor in the liquid). Tray efficiency tends to be less
than in the other regimes. Foam tendencies will not affect the bubbling area since
the high vapor velocities will effectively tear any foam apart.
This is the most common regime and occurs from around atmospheric up to
moderate pressure (say about 10 bar, depending on flow rates). Close to the tray
floor is froth (bubbles of vapor in the liquid). On top of the froth is a region in the
spray regime. Severe foaming tendencies may affect the bubbling area.
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This occurs at high pressure (above about 15 bar). Since vapor density is high,
the vapor volume rate is relatively low and the kinetic energy of the liquid flowing
across the tray breaks the vapor streams leaving the holes in the tray floor into
small bubbles, less than 5 mm. Disengagement of vapor from this froth is slow
and downcomer flooding is the usual limitation on tray capacity.
A.3.6 Entrainment
Liquid picked up by vapor and carried through the floor of the tray above. This
causes back mixing of the liquid and can cause significant loss of efficiency,
especially in vacuum systems
A.3.7 Flooding
The downcomer is totally full of froth; liquid backs up onto the tray. Downcomer
backup is the usual cause of flooding in high pressure systems (above about 10
bar) and in foaming systems.
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This is caused by a froth volume too great to pass through the downcomer
entrance. In normal operation froth leaving the tray enters the downcomer from
the active area. In the downcomer, the vapor in the froth disengages from the
liquid and rises back out of the top of the downcomer. A downcomer choking
flood IS caused by the interaction between this escaping vapor and the froth
leaving the active area.
A.3.11 Foam
A.3.12 Froth
As the vapor rate through a tray is reduced from its maximum value, a rate is
reached where liquid starts to leak through holes in the tray floor; this is known
as the weep point.
As the vapor rate is further reduced the weeping rate increases. Eventually, all
the liquid on the tray leaks through the tray floor and none goes over the outlet
weir. The point at which this happens is known as the dump point.
A.3.15 Efficiency
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