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Agenda KLM Technology Group

Practical Solutions

1. Introduction

2. History of Distillation

3. Types of Stages

4. Tray Fundamentals

5. Tray Efficiencies
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Introduction KLM Technology Group
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Distillation

Distillation is the separation of key components by


the difference in their relative volatility, or boiling
points. It can also be called fractional distillation
or fractionation.

For close boiling mixtures many stages are


required to reach the desired purity.

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Introduction KLM Technology Group
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Distillation is favored over other


separation techniques such as
crystallization or membranes when;
1. The relative volatility is greater than 1.2,
2. Products are thermally stable,
3. Large rates are desired,
4. No corrosion, precipitation or explosion issues
are present.

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Introduction Practical Solutions

1.0

0.8 a=5

a=3
0.6
Y

a=2
0.4

a=1
0.2

0.0
0.0 0.2 0.4 0.6 0.8 1.0
X
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Introduction KLM Technology Group
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Distillation is the most common separation


technique and is energy intensive.

Distillation can consume more than 50% of


a plant’s operating energy cost.

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Introduction KLM Technology Group
Practical Solutions

A way to improve an existing plant’s operating


cost is to improve their efficiency and operations
by process optimization and control.

This cannot be achieved without first an


understanding of distillation principles and
design.

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site that publishes technical articles on distillation, process optimization, operations training, personal
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Introduction KLM Technology Group
Practical Solutions

This introduction of Distillation is provided by

www.Kolmetz.Com
www.klmtechgroup.com

which is a chemical engineering web site that publishes


technical articles on distillation, process optimization,
operations training, personal improvement, process unit
safety and environmental concerns.

This introduction of Distillation is provided by www.Kolmetz.Com which is a chemical engineering web


site that publishes technical articles on distillation, process optimization, operations training, personal
improvement, process unit safety and environmental concerns.
Introduction KLM Technology Group
Practical Solutions

This introduction of Distillation is provided by

www.kolmetz.com
www.klmtechgroup.com

KLM Technology Group provides specialized training courses


in the areas of Petroleum Refining, Petrochemicals, Distillation,
Operational Excellence, Safety, Chemical Engineering for Non
Chemical Engineers, Petroleum Refining for Non Technical
Professionals, Petrochemicals for Non Technical Professionals,
Olefin and Aromatics Processes, and Project Management.

Our courses can be held 'in house' or in regional seminars.

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site that publishes technical articles on distillation, process optimization, operations training, personal
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KLM Technology Group
Distillation History Practical Solutions

Early Distillation was basically batch stills


to produce ethanol.

The Crude ethanol was placed in a still and


heated, the vapor condensed for
consumption.

Later crude oil was placed in batch stills to


produce lamp oil.

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Distillation History
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Distillation History
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Distillation History Practical Solutions

The next progression was to continually feed


the still and recover the light product.

Notice the separation that can be


accomplished in one stage.

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Distillation History KLM Technology Group
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Distillation History
Distillation History KLM Technology Group
Practical Solutions

The next progression was to place the


stills in a column and interchange the
vapor and liquid to improve recovery.

To obtain good separation you need


many stills in series.

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Distillation History
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Distillation History
Distillation History KLM Technology Group

Early trays were dual flow trays, which then


progressed to bubble cap trays and then
down comers were added.
Distillation History KLM Technology Group
Practical Solutions

Early small towers has one or two


large bubble caps per tray.

Early flow measurement was made by


counting the strokes of a positive
displacement pump.

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Distillation History KLM Technology Group
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Early still men set their reflux rates in strokes per


minute.

All instrumentation was local.

You ran the units by sound and feel.

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Distillation History Practical Solutions

A Kerosene Hydrotreater built in 1952


had one bubble cap per tray on the
Stripper Tower, which was one meter in
diameter.

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Distillation History KLM Technology Group

1 Bubble cap per Tray

1m
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Distillation History

The liquid and vapor traveled through the


center of the column and mixed on the
outer ring of each bubble cap.
Distillation History KLM Technology Group

Later when tray efficiency became more


important, flow on the tray began to be studied
and several types of trays with changed flow
patterns were developed.
Types Of Distillation Columns KLM Technology Group
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1. Batch Distillation
2. Continuous Distillation
A. Multiple Feeds and Products
B. Extractive Distillation
C. Reactive Distillation

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Types Of Distillation Columns KLM Technology Group
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There are many types of distillation columns; each


designed to perform specific types of separations and
each with different characteristics.

Towers can be classified into two main classifications


based on how they are operated. These two classes are
Batch Distillation and Continuous Distillation.

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Batch Distillation, the feed to the column is


introduced batch-wise. The column is charged with
a 'batch' and then the distillation process is carried
out.

When the desired task is achieved, a next batch of


feed is introduced.

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Types Of Distillation Columns KLM Technology Group
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In contrast, Continuous Distillation processes a


continuous feed stream. No interruptions occur
unless there is a problem with the column or
surrounding process units.

They are capable of handling high throughputs


and are the more common of the two types.

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Types Of Distillation Columns KLM Technology Group
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Additional variations may be utilized in a


Continuous Distillation Column.

The column may have multiple feed points and


products.

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Types Of Distillation Columns KLM Technology Group
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The column may have a solvent added to the system to help


increase the separation; this type of column is named an
extractive distillation column.

The column may have a catalyst bed and reaction occurring


in the column; this type of column is named a reactive
distillation column.

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Types of Stages KLM Technology Group
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1. Flash Drum
2. Reboiler / Condenser
3. Trays
A. Dual Flow Tray /Ripple Tray
B. Bubble Cap Tray
C. Sieve Deck Tray
D. Valve Tray
E. Down comer Advances
4. Packing
A. Random
B. Structured
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Types of Stages KLM Technology Group
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1. Flash Drum

The simplest type of distillation device is the


flash drum. It is a single stage and can
approach 100% of equilibrium limits it there is
sufficient residence time.

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Types of Stages KLM Technology Group
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1. Flash Drum

An over head receiver is an example of a flash drum.


The separation of a single flash drum is limited.

A 50:50 mixture of ethylene and propylene can only be


separated to about 80:20 in a single flash drum.

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Types of Stages KLM Technology Group
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Vapor

Liquid

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Types of Stages KLM Technology Group
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2. Reboiler / Condenser

A reboiler is a flash drum with heat exchange. It can approach


100% of equilibrium limits it there is sufficient residence time. The
three normal types of reboilers are horizontal thermosyphon,
vertical thermosyphon, and kettle drums.

The best design is for the liquid from the bottom tray to pass
through the reboiler at least once before being drawn off as tower
bottoms.

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Types of Stages KLM Technology Group
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2. Reboiler / Condenser

A Condensers is a flash drum with heat exchange

There are three major types of condensers;


total,
partial,
and hot vapor by-pass.

Each has its best application.

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Types of Stages KLM Technology Group
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A. Partial Condenser

The partial condenser is best used when there is a large


difference in the overhead vapor compositions. For
example when there is a small amount of methane and
hydrogen mixed in a propylene stream, like in the
propylene towers. The partial condenser condenses the
propylene and leaves the methane and hydrogen as a
vapor to be vented from the overhead receiver.

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Types of Stages KLM Technology Group
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A. Partial Condenser

This type of condenser works well for most applications.


The system needs to be reviewed to address the potential
build of on non-condensable gases in the heat exchanger
that can reduce the cooling potential of the exchanger.

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Types of Stages KLM Technology Group
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Vent

A. Partial Condenser

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Types of Stages KLM Technology Group
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B. Total Condenser

The total condenser is best used when there is a small


difference in the overhead vapor compositions. The
overhead vapors can be condensed at approximately the
same temperature.

This system also needs to be reviewed to address the


potential build of non-condensable gases in the heat
exchanger that can reduce the cooling potential of the
exchanger.

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Types of Stages KLM Technology Group
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Vent

B. Total Condenser

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Types of Stages KLM Technology Group
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C. Hot Vapor By Pass Condenser

The hot vapor by pass condenser is best utilized when


there is the potential for large changes of overhead
vapor composition. The vapor by pass can be used to
maintain the pressure in the tower system when the light
components are lower than design. The hot vapor by
pass condenser also has a lower installed cost due to the
heat exchanger being installed on the ground level.

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Types of Stages KLM Technology Group
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C. Hot Vapor By Pass Condenser

The negatives of the Hot Vapor By Pass Condenser is that the by


pass can be opened too much, increasing the temperature of the
reflux. This reduces the tray efficiency in the top of the tower, and
raises the tower pressure, which makes hydrocarbons harder to
separate.

This system, because of the physical location of the exchanger, has


even higher potential to build non-condensable gases in the heat
exchanger that can reduce the cooling potential of the exchanger.

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Types of Stages KLM Technology Group
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C. Hot Vapor By Pass Condenser

Vent

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Types of Stages KLM Technology Group
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3. Trays
A. Baffle Trays
B. Dual Flow Tray /Ripple Tray
C. Bubble Cap Tray
D. Sieve Deck Tray
E. Valve Tray
F. Tray advances

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Types of Stages KLM Technology Group
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3. Tray design

Trayed Columns utilize a pressure and temperature


differential to separate the products. For most trayed
columns, the weir holds a liquid level of each tray.

The vapor must over come this liquid head to move up


the column. On the tray the vapor and liquid are
contacted and then above the tray they are separated.

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Types of Stages KLM Technology Group
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3. Tray design

Any deviation that develops that restricts the vapor and


liquid from contacting and then separating will
deteriorate the column’s ability to meet design
specifications.

Trays utilize the staged contact principle to separate


products.

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Types of Stages KLM Technology Group
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3. Tray design
One of the first trays developed was the dual flow tray.
The liquid and vapor traveled up and down the column
in the same tray opening.
Tray design then moved to sieve decks, to bubble caps,
valve trays, and to directional flow valve trays. For
trays to function they need to mix the vapor and the
liquid, then separate the vapor and the liquid. Each
function must be as complete as possible.

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Staged Equipment: the mechanism KLM Technology Group

• Vapor and liquid mixes to form a froth.


• Mass transfer occurs within the froth.
• The froth overflows across a weir.
• The vapor disengages and move to the tray
above.
• The bulk liquid flows down the downcomer to
the next tray.
• The steps are repeated in the next tray.
Types of Stages KLM Technology Group
Practical Solutions

A. Baffle Trays

Baffle trays are trays of low fouling potential, with low


efficiency. They have open areas approaching 50%
where a high efficiency tray will have an open area of less
than 15%.

Three major types of baffle trays are


1. Shed Decks
2. Side to Side Trays
3. Disk and Donut

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Types of Stages KLM Technology Group
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1. Shed Decks

Shed decks are essentially angle iron beams of


various sizes from two to ten inches that are
placed in rows across the column.

They typically are at on 24 inch tray spacing.


They may be set in overlapping rows or rotated
90 degrees from tray to tray.

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Types of Stages KLM Technology Group
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2. Disk and donut trays

Disk and donut trays are slightly sloped trays that allow
the liquid to splash from inner circle ring to outer circle
ring. Fouling potential of this tray is low along with the
efficiency.

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Types of Stages KLM Technology Group
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3. Side to side trays

Side-to-side trays are trays that allow the liquid to splash


from side to side. The decks can be sloped. Fouling potential
of this tray is low, as with efficiency

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Types of Stages KLM Technology Group
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B. Dual Flow Tray /Ripple Tray

Because dual flow trays do not have weirs the vapor rate
is what maintains the level on the trays.

It is very important in the operation of dual flow trays to


keep the reflux and reboiler rates very stable to maintain
a constant level on the tray deck.

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Types of Stages KLM Technology Group
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B. Dual Flow Tray /Ripple Tray

These openings can vary in size from very small (1/8”) to


large (1”) diameter openings. Smaller holes have been
found experimentally to obtain higher tray capacity for
exactly the same open area.

However, smaller holes have the potential to plug up in


fouling service. Typical perforation sizes are 1/4” to 1/2”
for most applications.

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Types of Stages KLM Technology Group
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B. Dual Flow Tray /Ripple Tray

The challenge of dual flow trays is mal-distribution, the


vapor traveling up one side of the column and the liquid
down the opposite side.

In a windstorm the top of a column can move as much as


6 inches (150 MM), and build a hydraulic instability
within the column, which a dual flow tray cannot correct
within itself.

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Types of Stages KLM Technology Group
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C. Bubble Cap Tray


A bubble cap tray has a riser or chimney fitted over each
hole, and a cap that covers the riser. The cap is mounted so
that there is a space between the riser and the cap to allow
the passage of vapor.
This vapor rises through the chimney and is directed
downward by the cap, finally discharging through the slots
in the cap, and bubbling through the liquid on the tray.

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Types of Stages KLM Technology Group
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improvement, process unit safety and environmental concerns.
Types of Stages KLM Technology Group
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D. Sieve Deck Tray

A sieve tray is essentially a plate with holes punched


into the plate. The number and size of the holes is
based on the vapor flow up the tower.

The liquid flow is transported down the tower by down


comers, a dam and overflow device on the side of the
plate, which maintains a set liquid level on the tray.

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Types of Stages KLM Technology Group
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D. Sieve Deck Tray

To maintain the liquid level on the tray a minimum


amount of vapor traffic up the tower must be
maintained, or the liquid level on the tray will weep
down to the next tray through the holes punched on
the plate.
Typically sieve deck trays have a minimum capacity,
or downturn, of approximately 70%.

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Types of Stages KLM Technology Group
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E. Valve Tray

One of the next developments was to add a


variable valve opening to the tray deck.

This valve would open in relation to the


vapor flow. The advantage to this design
was the ability to maintain the liquid level on
the tray deck.

Typically valve deck trays have a minimum


capacity, or downturn, of approximately
60%.
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Types of Stages KLM Technology Group
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Tray Advancements

The latest in tray advancements


involve the flow across the tray
and the down comer design.

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Design of Trays to Improve KLM Technology Group
Efficiencies and Capacities

Items that lead to improvements in efficiency


include;

1. Path flow length

2. Deck opening size

3. Elimination of stagnant zones

4. Down comer outlet devices / froth promoters

5. Weir Heights

6. Hydraulic Rates
Design of Trays to Improve KLM Technology Group
Efficiencies and Capacities

Path Flow Length – For a conventional tray


recommendation would be maintain above 500 mm.
For a multiple downcomer recommendation would be
to maintain above 300 mm

Swept back weirs that are utilized for more capacity,


has the added advantage that they increases the path
flow length.

This is one of the few cases where one can see both
capacity and efficiency increases at the same times.
Normally there is a trade off between capacity and
efficiency.
Design of Trays to Improve KLM Technology Group
Efficiencies and Capacities

Opening Size – There is an optimum bubble


size, therefore an optimum opening size.

Too small or too large can effect the size of the


bubble, leading to loss of efficiency.

Here is the normal trade off between capacity


and efficiency.
Design of Trays to Improve KLM Technology Group
Efficiencies and Capacities

Elimination of stagnant zones – parallel flow


across a cordial surface can lead to stagnant
areas.

Liquid directional valves can help eliminated


the stagnant zones.
Design of Trays to Improve
KLM Technology Group
Efficiencies and Capacities

Concept

The devices force the liquid on the tray to go in


directions it does not naturally wish to flow.

By strategically designing and placing the


devices on the tray deck, plug flow of liquid is
achieved and stagnation eliminated.
Design of Trays to Improve KLM Technology Group
Efficiencies and Capacities

Down comer outlet devices / froth


promoters – the clear liquid exiting the
down comer becomes a froth on the tray.

Items that assist this froth generation


improve efficiency. A small inlet weir will
help efficiency, but should not be utilized in
fouling service.
Design of Trays to Improve KLM Technology Group
Efficiencies and Capacities

Weir Heights - The


weir height has an 120

effect on the tray 100

efficiency.
80

Point Efficiency (%)


Recommendations 60

are not to exceed


100 mm or 1/6 of 40

tray spacing, and 20

50 to 75 is
0

suggested for all 0 20 40 60

Liquid Height (mm)


80 100 120

services except
vacuum services.
Types of Stages KLM Technology Group
Design of Trays to Improve KLM Technology Group
Efficiencies and Capacities

Hydraulic Rates - The hydraulic rate has an effect on


the tray efficiency.

At low rate trays will weep, at high rates froth touches


the next tray.

When the V:L ratios are not equal molar, efficiency


will decrease.
Types of Stages KLM Technology Group
Practical Solutions

4. Packing

Random and Structured Packed Columns generate a


mass transfer area by providing a large surface area
over which the liquid can transfer heat and mass to
the vapor.

Packing utilizes a continuous contacting principle to


separate products. A major advantage to packed
columns is the reduction in pressure across the
column.

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Types of Stages KLM Technology Group
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4. Packing

Typically the column pressure drop for a packed


column is less than that of a trayed column because of
the percent open area.

Typical percent open area of a trayed column is 8 to


15%, whereas a packed column can approach 50%.
Liquid accumulation for a packed column is lower
than that of a trayed column.

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Types of Stages KLM Technology Group
Practical Solutions

4. Packing

Another advantage of packed column is reduced


foaming. Packing generates thin films instead of fine
droplets for mass and heat transfer, reducing
entrainment when foaming agents are present.

Packing has been used successfully in low-pressure


distillation applications, less than 150 psig.

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Types of Stages KLM Technology Group
Practical Solutions

A. Random Packing

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Types of Stages KLM Technology Group
Practical Solutions

B. Grid Packing

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Types of Stages KLM Technology Group
Practical Solutions

C. Structured Packing

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Non-staged Equipment: the mechanism KLM Technology Group

• Bulk liquid is broken into fine droplets when


in contact with packings.

• Provides large surface area for effective heat


and mass transfer.

• Appears as a continuous froth across the


height of the packed bed.
Non-staged Equipment: the mechanism KLM Technology Group

The introduction of vapor and liquid to the packing is


very important. Trays will normally eventually equalize
whatever mal-distribution is developed by the vapor and
liquid feeds.

Packing will enhance whatever mal-distribution is


developed by the introduction of the vapor and liquid
feeds.
Non-staged Equipment: Micro phenomena KLM Technology Group

• A distributor showers down liquid at different


locations on the packed bed.

• The liquid needs to travel some distance before


meeting and remixes into a froth.

• A layer of dead zone exist on top of bed.

• Challenge is greater if 2 or more liquid phases


exist.
Concepts KLM Technology Group
Practical Solutions

1. Up till this point we have discussed


hardware.

2. Now let us discussed why the hardware


might work.

3. In distillation the hardware was


developed and then a study was
conducted to understand why it might
work.
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Concepts KLM Technology Group
Practical Solutions

1. Hydrocarbons separate better at lower pressure.

The nature of hydrocarbons is such that they separate


better at lower pressure. Normally the pressure of a tower
is set as low as possible based on the ability of the over head
condenser to condense the over head vapor.

The preferred cooling medium is water and the tower


pressure is raised until the over head vapor can be
condensed at 90 degrees F / 45 degrees C.

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Concepts KLM Technology Group
Practical Solutions

1. Hydrocarbons separate better at lower pressure.

A balance must be done between the construction cost and


the utility cost. The ability to separate determines the
number of trays, which is a construction cost.

To utilize lower pressure can require refrigeration, which is


a utility cost. Low pressure DeMethanizers with Methane
Refrigeration can be shown to be cost effective. Some C2
Splitters run at lower pressure than other designs utilizing
this lower pressure separation ability.

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Concepts Practical Solutions

2. Heat is a form of energy caused by the motion of


molecules.

Heat is a form of energy. The motion of molecules causes


heat energy. When energy is added to a substance, the
motion of the molecules increases.

When energy is added to a substance and the temperature


of the substance increases, this is called sensible heat.
When energy is added to a substance and the substance
changes phases from a liquid to a gas, that energy is called
latent heat.

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Concepts KLM Technology Group
Practical Solutions

2. Heat is a form of energy caused by the motion of


molecules.

The unit of measurement of energy is called a calorie. It is


the amount of energy to raise one gram of water, 1 degree
C. To raise 1kg of water 1 degree requires 1000 calories.

To change the phase of water from liquid to a gas requires


537 calories, which is about 500 times the sensible heat
value. To change the phase of ethylene from liquid to a gas
requires 114 calories.

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Concepts Practical Solutions

2. Heat is a form of energy caused by the motion of


molecules.

The availability and large latent heat value are the reasons
we use water as a heat carrier. The large latent heat value
can be utilized in reboilers.

Because we do not use the latent heat in pumps and


compressors, the temperature and pressure change are the
energy carriers.

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Concepts Practical Solutions

6. Equilibrium is the state which systems will establish, if


given enough time.

A vessel filled with two hydrocarbons is said to be at


equilibrium if the number of light molecules escaping from
the liquid is equal to the number returning to the liquid.

In one vessel because of the transfer of molecules from the


liquid to the vapor, total separation of two similar
hydrocarbons cannot be obtained.

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Concepts KLM Technology Group

Hydro Formula Molecular Boiling Density Flammability


Carbon Weight Point (F) (ft3/lb) Limits
Low/High

Hydrogen H2 2.0159 -426.130 188.25 2.3 / 4.00

Methane CH4 16.043 -258.71 23.65 5.0 / 15.0

Ethylene C2H4 28.054 -154.71 13.53 2.7 / 36.0

Ethane C2H6 30.070 -127.46 12.62 2.9 / 13.0

Propylene C3H6 42.081 - 53.83 9.02 2.0 / 11.7

Propane C3H8 44.097 - 43.73 8.61 2.0 / 9.5

Iso Butane C4H10 58.123 10.78 6.53 1.8 / 8.5


Tower Balances KLM Technology Group
Practical Solutions

A. Mass Balance

B. Energy Balance

C Composition Balance

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Mass Balance KLM Technology Group
Practical Solutions

All vessels will eventually reach a material balance,


mass in equals mass out. For distillation towers
the material balance is;

Mass In = Mass Out + Accumulation

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Mass Balance Practical Solutions

Sources of material into the tower normally are the


feed points.

Sources of material out of the tower include


Overhead Vapor, Overhead Liquid, Side Draws
and Tower Bottoms flows.

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Mass Balance Practical Solutions

Sources of accumulation include Overhead Receiver or


Reflux Drum, Tower Bottoms Reservoir, and level of
hydrocarbons on the trays.

Two of the accumulations are straight forward; the


Overhead Receiver and the Bottoms Reservoir.

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Mass Balance KLM Technology Group
Practical Solutions

The third accumulation, the level on the trays, is much


more difficult to quantify. It is by far the largest
accumulation in the tower.

To build the inventory in the C2 Splitter Tower takes 8


hours, but less than one hour for the over head receiver to
be filled.

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Mass Balance KLM Technology Group
Practical Solutions

The tower delta P is a guide to how much level is


on the trays. The tower delta P is based on the
amount of reflux that is added to the tower.

The reflux is made in the reboiler, therefore the


level on the trays is determined by reboiler. A
stable reboiler heat input will stabilize the tower.

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Mass Balance Practical Solutions

One of the first tower control schemes was the


Material Balance that was developed in 1930s. A
field operator looking at sight glasses controlled
the overhead and bottoms levels.

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Mass Balance Practical Solutions

Today with level controls, the Material Balance


Control Scheme can be utilized if the product
specifications are lax.

The Material Balance Control Scheme does not


address the accumulation of level on the trays,
the tower energy, and composition balance.

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Mass Balance Practical Solutions

For most high purity product this is not


the best control scheme due to the large
number of trays in product fractionators.

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Mass Balance Practical Solutions

PI

TI

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KLM Technology Group
Energy Balance Practical Solutions

All vessels will eventually reach an energy balance,


energy in equals energy out. For distillation towers
the energy balance is;

Energy In = Energy Out + Accumulation

The main source of energy into the tower normally is


the reboiler. The feed can also be a source of energy if
it is preheated.

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Energy Balance Practical Solutions

The main sources of energy out of the tower are the


Overhead Condenser and the Tower Bottoms Flow.
Smaller sources include Overhead Vapor, Overhead
Liquid, Side Draws and Tower Feed if it is cooled.

Sources of accumulation include, Tower Bottoms


Reservoir, and level of hydrocarbons on the trays.
Two of the accumulations are straightforward; the
Overhead Receiver and the Bottoms Reservoir.

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Energy Balance Practical Solutions

The third accumulation, the level on the trays, is much more


difficult to quantify. It is by far the largest energy
accumulation in the tower.

Three things happen on a tray when a reflux move is made.

The first is the level on the tray changes.

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Energy Balance Practical Solutions

The second is the energy or temperature on the tray changes.

The third is that the composition on the tray changes.

If each of these changes takes one minute and there are 30 trays
in the column, it takes one hour and thirty minutes for the
change to be seen at the tower bottoms.

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Energy Balance Practical Solutions

If there are 100 trays in the column like in the C2


Splitter, it takes five hours for the change to be seen in
the tower bottoms.

If there are 250 trays like in a Polymer Grade C3


Splitter, it takes 12 hours and thirty minutes for the
change to be seen in the tower bottoms.

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Energy Balance Practical Solutions

The Energy Balance Control Scheme was developed in


1960s. Instrumentation was improving and flow
meters were becoming more accurate.

A current orifice plate flow meter can approach 1.0%


accuracy, if they are installed correctly and calibrated.

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Energy Balance Practical Solutions

An average field orifice plate flow meter is normally


considered to have 2.5% accuracy.

The latest flow meters, which uses the vibrations of a


tube as the fluid flows by can approach 0.01%
accuracy.

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Energy Balance Practical Solutions

Because of the improved instrumentation, the heat


input to the tower could be measured and controlled.

This led to the Tower Energy Balance Control


Scheme. The energy to the reboiler was measured and
used as a control point. The energy was removed in
the overhead condenser.

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Energy Balance Practical Solutions

The overhead product was sampled and the product


was changed by the sample results. The sample
results were returned typically four to five hours after
the samples were caught.

This meant that the tower adjustments were always


behind what the tower actual operation was. To
compensate for this lag time the products were always
kept above the specification to ensure on test product.

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Energy Balance Practical Solutions

To be consistently above the sell specification gives


away product, reducing your cash margin. The main
problem with the energy balance control scheme is
that is does not take into account the composition
balance.

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Energy Balance Practical Solutions

PI

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Energy Balance Practical Solutions

A later variation of the energy balance control scheme


was the Delta T Energy Balance.

At constant pressure the temperature can be an


indication of the composition and the product flow can
be controlled by the difference in the two temperature
points.

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Energy Balance Practical Solutions

For example in a Benzene Toluene Splitter the lower


temperature point will began to increase as the toluene
concentration increases.

This will reduce the delta T between the temperature points.


The product flow can then be decreased, which will increase the
reflux to the tower, resulting in the toluene composition being
decreased at the Benzene Product.

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Energy Balance Practical Solutions

The advantage of a delta T over a single point is


that the delta T takes the pressure deviations
out of the control scheme. This control scheme
works, but ignores the composition balance.

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Energy Balance Practical Solutions

PI

TI

DT

TI

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Energy Balance Practical Solutions

A third variation of the Energy Balance Control


Scheme is the Ratio Energy Balance. This is the
design of 1980s ethylene plants. It works, minimizes
reflux, but ignores the composition balance.

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Energy Balance Practical Solutions

PI

TI

DT

TI

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Composition Balance Practical Solutions

All vessels will eventually reach a composition


balance, composition in equals composition out. For
distillation towers the composition balance is;

Composition In = Composition Out + Accumulation

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Composition Balance Practical Solutions

For the Propylene Tower a propylene balance can be


developed. The propylene in the feed must equal the
propylene that leaves the tower plus the
accumulation of propylene in the tower.

Sources of accumulation include, Tower Bottoms


Reservoir, Overhead Receiver and level of
hydrocarbons on the trays.

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Composition Balance Practical Solutions

Two of the accumulations are straightforward; the


Overhead Receiver and the Bottoms Reservoir.

The third accumulation, the level on the trays, is


much more difficult to quantify. It is again the
largest accumulation in the tower.

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Composition Balance Practical Solutions

In the 1970s analyzers were becoming reliable and


control schemes that utilized them became common.
A composition balance could be maintained by
utilizing the mass flows and the analyzer results
leading to better distillation control.

Present Stone and Webster recommendations are the


composition balance control scheme.

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Composition Balance Practical Solutions

The tower feed and composition are analyzed and used as a


feed forward control for the product.

The product rate and composition are analyzed and used as a


feed back control.

The sum of these two is used to balance the tower considering


all three balances.

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Composition Balance Practical Solutions
PI

AI

AI

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Tower Problem Solving KLM Technology Group
Practical Solutions

1. Foaming
2. Entrainment
3. Weeping / Dumping
4. Flooding

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Tower Problem Solving KLM Technology Group
Practical Solutions

Do simple checks first.

1. Ensure that levels are accurate.


2. Calculate column pressure drop and then
measure pressure drop.
3. Survey column temperature profile. Review
survey temperature reading to operation’s
readings.

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Tower Problem Solving Practical Solutions

Verify Tower Operations.


1. Sample Feeds and Products.
2. Calculate mass balance to within
2% accuracy, if not calibrate flow meters.
3. Survey heating and cooling temperatures.
4. Have engineers simulate these results. If no
problems are identified consider scanning the
column.

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Tower Problem Solving KLM Technology Group
Practical Solutions

In distillation towers there are actually two accumulators.


The first is normally obvious, the over head receiver, the
second is the bottom section of the tower.

These accumulators are used to stabilize the operation of the


tower and down stream operations. This internal surge drum
creates an inventory to act as a buffer.

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Tower Problem Solving Practical Solutions

If this internal level is allowed to rise above the reboiler


return, stripping inlet, or feed inlet, flooding can occur.

There is an inherent error built into sight glass and level


instrumentation. The sight glass and level instrumentation
contain non aerated liquid, called clear liquid, which is not a
true indication of the condition of the liquid within the tower.

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Tower Problem Solving Practical Solutions

The liquid within the tower will have two levels, a clear liquid
level below the aerated liquid level. Because the aerated level
will have lower specific gravity than the clear liquid within
the instrumentation, the tower level will be higher than the
instrumentation indicates.

If the level in the tower is higher than the feed or reboiler


return, entrained liquid can be carried to the next stage
causing flooding.

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Tower Incidents KLM Technology Group
Practical Solutions

Attached is a list of tower incidents that was found in the


literature from HZ Kister “ Recent Trends in Distillation
Tower Malfunctions”

1. Fouling, plugging and Coking issues


2. Tower Bottoms and Reboiler Return issues
3. Packing Liquid Distributors issue
4. Intermediate Draws
5. Assembly Mishaps

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Tower Incidents Practical Solutions

1. Fouling, plugging and Coking issues

A. Coking
B. Precipitation - salts
C. Scale, corrosion products
D. Solids in feeds

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Tower Incidents KLM Technology Group
Practical Solutions

1. Fouling, plugging and Coking issues location

A. Packing beds and Distributors


B. Trays, active areas and down comers
C. Draw lines
D. Instrument lines
E. Feed lines

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Tower Incidents KLM Technology Group
Practical Solutions

2. Tower Bottoms and Reboiler Return issues

A. High liquid levels


B. Impingement by vapor inlets
C. Vapor Mal-distribution
D. Water induced pressure surges
E. Leaking reboiler draw
F. Gas entrainment in liquid bottoms

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Tower Incidents KLM Technology Group
Practical Solutions

3. Packing Liquid Distributors issues

A. Distributor Overflow
B. Plugging
C. Fabrication mishaps
D. Feed entry problems
E. Damage
F. Poor hole pattern
G. Poor irrigation quality

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Tower Incidents KLM Technology Group
Practical Solutions

4. Intermediate Draws

A. Leakage at draw
B. Restriction of vapor - choking of draw line
C. Plugging

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Tower Incidents KLM Technology Group
Practical Solutions

5. Assembly Mishaps

A. Packing Liquid Distributors


B. Packing assembly
C. Tray Panels
D. Internal mis-orientation at feeds and draws

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Conclusions KLM Technology Group
Practical Solutions

Distillation is one of the major unit operations in


processing plants. It is energy intensive and has
opportunities to be optimized. Product recovery
and purity can be improved by understanding
the principles of distillation.

These principles need to be understood in


advance of operating and trouble shooting a
distillation column for the operator or problem
solving to be effective.
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Introduction KLM Technology Group
Practical Solutions

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Kolmetz.Com is a chemical engineering web site that


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site that publishes technical articles on distillation, process optimization, operations training, personal
improvement, process unit safety and environmental concerns.
Introduction KLM Technology Group
Practical Solutions

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www.klmtechgroup.com

KLM Technology Group provides specialized training courses


in the areas of Petroleum Refining, Petrochemicals, Distillation,
Operational Excellence, Safety, Chemical Engineering for Non
Chemical Engineers, Petroleum Refining for Non Technical
Professionals, Petrochemicals for Non Technical Professionals,
Olefin and Aromatics Processes, and Project Management.

Our courses can be held 'in house' or in regional seminars.

This introduction of Distillation is provided by www.Kolmetz.Com which is a chemical engineering web


site that publishes technical articles on distillation, process optimization, operations training, personal
improvement, process unit safety and environmental concerns.

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