SPECIFICIATION SHEET

Equipment Name Beer Still

Equipment Tag DS – 01

Operation Batch

Type Distillation Column

OPERATING CONDITIONS

Operating Temperature (oC) 85

Operating Pressure (atm) 1

PROCESS DATA SHEET

Reflux Ratio 5.1

Number of Stages 36

Feed Plate Location 28th stage from the bottom

Tray Spacing (mm) 600

Downcomer head loss (mm) 61.23

MECHANICAL DATA SHEET

Column Diameter (m) 2.1

Column Height (m) 21.6

Weir Length (mm) 1.62

Weir Height (mm) 40

Hole Diameter (mm) 5

Hole Pitch (mm) 1.37

Downcomer area (m2) 0.3884

ISOMETRIC VIEW
TOP VIEW
SIDE VIEW
Design Calculations
One of the major considerations in performing column design is the relative volatility.
Thus, sufficient data must be gathered in order to provide accurate estimate of the
relative volatility of the system. The following Antoine equation constants and
corresponding boiling points are gathered as summarized in Table 1.

Boiling
Compound Name A B C
Point
A Ethanol 16.8958 3795.17 230.918 78.2
B Water 16.3872 3885.7 230.17 100
Table 1. Antoine coefficients and boiling points for Ethanol and Water
compounds
Using Antoine equation based on the data provided in Table 1, the following data can
be obtained as summarized in Table 2.

SYSTEM Ethanol Water

Vapor Pressure
Temperature (oC) (kPa) Mole Fraction
Comp A Comp B Xa Ya
78.2 101.3302 44.09861 1.000 1.000
82.56 120.1986 52.56786 0.721 0.855
85 131.9801 57.87573 0.586 0.764
89.36 155.4289 68.47896 0.378 0.579
93.72 182.2415 80.65862 0.203 0.366
100 227.5087 101.3332 0.000 0.000
Table 2. VLE Calculation Results for Ethanol and Water
Calculating the relative volatility of Ethanol and Water at 85 degree Celsius,

𝑃𝑠𝑎𝑡𝐴 131.9801
𝛼= = = 2.28
𝑃𝑠𝑎𝑡𝐵 57.87573

Using Fenske Equation, the minimum number of plates can be calculated as depicted
by the equation

𝑦 𝑥
𝑙𝑜𝑔 ( 𝐴 × 𝐵 )
𝑦𝐵 𝑥𝐴
𝑁𝑚𝑖𝑛 =
𝑙𝑜𝑔(𝛼)
From the material balance, the following data were gathered:
 Component Feed Mole Distillate Mole Bottoms Mole
Composition (%) Composition (%) Composition (%)
Ethanol 3.53 28.18 0.0196
Water 95.87 71.63 99.32
Table 3. Material Balance Data on Compositions

28.18 0.0196
𝑙𝑛 (71.63 × 99.32 )
𝑁𝑚𝑖𝑛 =
𝑙𝑛(2.28)

𝑁𝑚𝑖𝑛 = 8.29 𝑠𝑡𝑎𝑔𝑒𝑠

Minimum Reflux Ratio

𝛼𝑖 𝑥𝑓𝑖
1+𝑞 = ∑
𝛼𝑖 − 𝛳
𝑖

Since the feed is liquid, q = 1

(1)(0.0353) (2.28)(0.9587)
1+1 = +
1−𝛳 2.28 − 𝛳
𝛳 = 0.9122

𝛼𝑖 𝑥𝐷𝑖
𝑅𝑚𝑖𝑛 + 1 = ∑
𝛼𝑖 − 𝛳
𝑖

(1)(0.2818) (2.28)(0.7163)
𝑅𝑚𝑖𝑛 + 1 = +
1 − 0.9122 2.28 − 0.9122
𝑅𝑚𝑖𝑛 = 3.4028
Actual Reflux Ratio

𝑅 = 1.5𝑅𝑚𝑖𝑛 = 1.5(3.4028) = 5.1042

Number of ideal plates

𝑁 − 𝑁𝑚𝑖𝑛 𝑅 − 𝑅𝑚𝑖𝑛
= 0.75 [1 − ( )]
𝑁+1 𝑅+1
𝑁 − 8.29 5.1042 − 3.4028
= 0.75 [1 − ( )]
𝑁+1 5.1042 + 1
𝑵 = 𝟏𝟗. 𝟐𝟒
Tray Efficiency
𝐸 = 51 − 32.5log(µ ∝)
At 85 degrees, the average liquid viscosity is 0.3334 nMs/m2.

𝐸 = 51 − 32.5 log(0.3334(2.28))
𝐸 = 54.87%
Since plate and overall column efficiencies are normally between 30 to 80%, then the
calculated efficiency is acceptable.

Actual number of stages

𝑁 19.24
𝑁𝑎𝑐𝑡𝑢𝑎𝑙 = = = 35.06 𝑠𝑡𝑎𝑔𝑒𝑠 ≈ 𝟑𝟔 𝒔𝒕𝒂𝒈𝒆𝒔
𝐸 0.5487
Determination of feed location:
Using Kirkbridge equation:

2
𝑁𝐵 𝐵 𝑋𝐹𝐴 𝑥𝐵
log = 0.206 log [ × 𝐵 × ( ) ]
𝑁𝐷 𝐷 𝑋𝐹 𝑦𝐴

From material balance, bottoms feed rate = 26748.5333 kmol/hr and distillate federate =
3675.53 kmol/hr.
Since ND = N – NB
2
𝑁𝐵 𝐵 𝑋𝐹𝐴 𝑥𝐵
log = 0.206 log [ × 𝐵 × ( ) ]
𝑁 − 𝑁𝐵 𝐷 𝑋𝐹 𝑦𝐴

𝑁𝐵 26748.5333 0.0353 0.9932 2

log = 0.206 log [ × ×( ) ]
36 − 𝑁𝐵 3675.53 0.9587 0.0196

𝑁𝐵 = 28.52 ≈ 28𝑡ℎ 𝑠𝑡𝑎𝑔𝑒

Therefore, the feed is entering 28th stages from the bottom.
Determination of Physical Properties
Using the process simulation software SIMSCI Pro/II v9.4, the following properties are
estimated given the feed conditions:
Property Top Section Bottom Section
Average density (kg/m3) 1.033 968.628
Average molecular weight 30.047 18.015
(kg/kmol)
Surface Tension (N/m) 0.020 0.0618
Table 4. Simulation Results for Physical Property Estimation using SIMSCI PRO/II
Tray Spacing
Based on literature (Perry’s Chemical Engineering Handbook, 8th Ed.), typical tray
spacing of 600 mm is used in the normal design practice for columns and towers. Thus,
use
𝑇𝑆 = 600 𝑚𝑚
Tower Height
The tower height can be estimated by
𝑇𝐻 = 𝑇𝑆 × 𝐴𝑐𝑡𝑢𝑎𝑙 𝑛𝑜. 𝑜𝑓 𝑆𝑡𝑎𝑔𝑒𝑠
𝑇𝐻 = 0.6 𝑚 × 36
𝑻𝑯 = 𝟐𝟏. 𝟔 𝒎
Case 1: Calculations for the top section
Material balance around top section
i. Vapor flow above feed plate
𝑉 = 𝐷(1 + 𝑅)
𝑉 = 3675.53(1 + 2.28)
𝑉 = 12055.7384 𝑘𝑚𝑜𝑙/𝑑𝑎𝑦
ii. Liquid Flowrate below feed plate
Assuming constant molar overflow, top section liquid flow rate is
𝐿 =𝑉−𝐷
𝐿 = 12055.7384 − 3675.53
𝐿 = 8380.2084 𝑘𝑚𝑜𝑙/𝑑𝑎𝑦
Flow Parameter
Flow parameter FLG can be calculated as follows based on mass flow rate (NPTEL
Chemical Engineering Design)
0.5
𝐿 𝜌𝑣
𝐹𝐿𝐺 = ( )
𝑉 𝜌𝐿

8380.2084 1.033 0.5

𝐹𝐿𝐺 = ( )
12055.7384 968.628
𝑭𝑳𝑮 = 𝟎. 𝟎𝟐𝟐𝟕
Capacity Parameter
The capacity parameter can be calculated using the Lygeros and Magoulas Equation
(Equation 14-90, Perry’s Chemical Engineering Handbook, 8th Ed, p. 14-37)

𝐶𝑏𝑠𝑓 = 0.0105 + 8.127(10−4 )( 𝑇𝑆 0.755 )exp[−1.463𝐹𝐿𝐺

0.842
]

𝐶𝑏𝑠𝑓 = 0.0105 + 8.127(10−4 )( (600)0.755 )exp[−1.463(0.0227)0.842 ]

𝑪𝒃𝒔𝒇 = 𝟎. 𝟏𝟎𝟔𝟑 𝒎/𝒔

Gas Velocity
Using the Fair Correlation equation (Equation 14-91, Perry’s Chemical Engineering
Handbook, 8th. Ed), the gas velocity can be estimated as follows
0.5
𝜎 0.2 𝜌𝐿 − 𝜌𝑣
𝑈𝑛𝑓 = 𝐶𝑏𝑠𝑓 ( ) ( )
20 𝜌𝑣

20 0.2 968.628 − 1.033 0.5

𝑈𝑛𝑓 = 0.1063 ( ) ( )
20 1.033
𝑈𝑛𝑓 = 3.253 𝑚/𝑠

Linear Gas Velocity

The linear gas velocity is calculated as follows (NPTEL Chemical Engineering Design)
𝑚
𝑈𝑛 = 0.8𝑈𝑛𝑓 = 0.8(3.253 )
𝑠
𝑈𝑛 = 02 = 2.603 𝑚/𝑠
Maximum volumetric vapor flow rate
The maximum volumetric vapor flow rate in the tower can be determined using the
equation below (NPTEL Chemical Engineering Design)
𝑉×𝑀
𝑄𝑚𝑎𝑥 =
𝜌𝑣
12055.7384 × 30.047
𝑄𝑚𝑎𝑥 =
1.033
12055.7384 × 30.047
𝑄𝑚𝑎𝑥 =
1.033
𝑚3
𝑄𝑚𝑎𝑥 = 350666.7683 = 4.0586 𝑚3/𝑠
𝑑𝑎𝑦
Net area required
Sufficient contact between the vapor and liquid phase determines the net effective area
for heat and mass transfer between vapor and fluid. The net contact area is calculated
based on the maximum volumetric vapor flowrate, as shown below

𝑄𝑚𝑎𝑥
𝐴𝑛𝑒𝑡 =
𝑈𝑛
4.0586
𝐴𝑛𝑒𝑡 =
2.603
𝐴𝑛𝑒𝑡 = 1.559 𝑚2

Total tower cross-section area

Given that the total downcomer top and bottom seal are is 10% of the net area, the total
tower cross-section area can be calculated as:

𝐴𝑛𝑒𝑡
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 =
0.90
1.559
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 =
0.90
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 = 1.732 𝑚2
Column diameter
The tower diameter can be determined by solving the diameter corresponding to the
area of the column

𝐷 2
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 = 𝜋( )
2
𝐷 2
1.732 = 𝜋 ( )
2
𝑫 = 𝟏. 𝟒𝟖𝟓 𝒎

Case 1: Calculations for the bottom section

Material balance around top section
i. Liquid flowrate above feed plate
𝐿′ = 𝐿 + 𝑞𝐹
𝐿′ = 25748.5333 + (1)(29424.06)
𝐿′ = 55172.5933 𝑘𝑚𝑜𝑙/𝑑𝑎𝑦
ii. Vapor flowrate below feed plate
Assuming constant molar overflow, bottom section vapor flow rate is
𝑉′ = 𝐿 + 𝐷
𝑉 ′ = 25748.5333 + 3675.53
𝑉′ = 29424.0693 𝑘𝑚𝑜𝑙/𝑑𝑎𝑦
Flow Parameter
Flow parameter FLG can be calculated as follows based on mass flow rate (NPTEL
Chemical Engineering Design)
0.5
𝐿′ 𝜌𝑣
𝐹𝐿𝐺 = ( )
𝑉′ 𝜌𝐿

55172.5933 1.033 0.5

𝐹𝐿𝐺 = ( )
12055.7384 968.628
𝑭𝑳𝑮 = 𝟎. 𝟏𝟒𝟗𝟓
Capacity Parameter
The capacity parameter can be calculated using the Lygeros and Magoulas Equation
(Equation 14-90, Perry’s Chemical Engineering Handbook, 8th Ed, p. 14-37)

𝐶𝑏𝑠𝑓 = 0.0105 + 8.127(10−4 )( 𝑇𝑆 0.755 )exp[−1.463𝐹𝐿𝐺

0.842
]

𝐶𝑏𝑠𝑓 = 0.0105 + 8.127(10−4 )( (600)0.755 )exp[−1.463(𝟎. 𝟏𝟒𝟗𝟓 )0.842 ]

𝑪𝒃𝒔𝒇 = 𝟎. 𝟎𝟖𝟔𝟐 𝒎/𝒔

Gas Velocity
Using the Fair Correlation equation (Equation 14-91, Perry’s Chemical Engineering
Handbook, 8th. Ed), the gas velocity can be estimated as follows
0.5
𝜎 0.2 𝜌𝐿 − 𝜌𝑣
𝑈𝑛𝑓 = 𝐶𝑏𝑠𝑓 ( ) ( )
20 𝜌𝑣

61.8 0.2 968.628 − 1.033 0.5

𝑈𝑛𝑓 = 0.1063 ( ) ( )
20 1.033
𝑈𝑛𝑓 = 4.0768 𝑚/𝑠

Linear Gas Velocity

The linear gas velocity is calculated as follows (NPTEL Chemical Engineering Design)
𝑚
𝑈𝑛 = 0.8𝑈𝑛𝑓 = 0.8(4.0768 )
𝑠
𝑈𝑛 = 2.0384 𝑚/𝑠
Maximum volumetric vapor flow rate
The maximum volumetric vapor flow rate in the tower can be determined using the
equation below (NPTEL Chemical Engineering Design)
𝑉′ × 𝑀
𝑄𝑚𝑎𝑥 =
𝜌𝑣
29424.0693 × 18.015
𝑄𝑚𝑎𝑥 =
1.033
𝑚3
𝑄𝑚𝑎𝑥 = 513140 = 5.939 𝑚3/𝑠
𝑑𝑎𝑦
Net area required
Sufficient contact between the vapor and liquid phase determines the net effective area
for heat and mass transfer between vapor and fluid. The net contact area is calculated
based on the maximum volumetric vapor flowrate, as shown below

𝑄𝑚𝑎𝑥
𝐴𝑛𝑒𝑡 =
𝑈𝑛
5.939
𝐴𝑛𝑒𝑡 =
2.0384
𝐴𝑛𝑒𝑡 = 2.9136 𝑚2
Total tower cross-section area
Given that the total downcomer top and bottom seal are is 10% of the net area, the total
tower cross-section area can be calculated as:

𝐴𝑛𝑒𝑡
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 =
0.90
2.9136
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 =
0.90
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 = 3.237 𝑚2
Column diameter
The tower diameter can be determined by solving the diameter corresponding to the
area of the column

𝐷 2
𝐴𝑐𝑜𝑙𝑢𝑚𝑛 = 𝜋( )
2
𝐷 2
3.237 = 𝜋 ( )
2
𝑫 = 𝟐. 𝟎𝟑𝟎𝟏 𝒎
Conclusion: Since the calculated tower diameter in bottom section is greater than the
calculated tower diameter in top section, take the case of bottom section for uniform
diameter as

𝐷𝑐𝑜𝑙𝑢𝑚𝑛 = 𝟐. 𝟏 𝒎
Weir Dimensions
a. Weir Length
The weir length can be estimated using the figure below.

𝑙𝑤 = 𝟎. 𝟕𝟕(𝟐. 𝟏) = 𝟏. 𝟔𝟐 𝒎
b. Weir Height
Based on standard tower design, set weir height as 40 mm (Coulson’s and
Richardson’s Chemical Engineering Design Volume 6, p. 572)

ℎ𝑤 = 𝟒𝟎 𝒎𝒎
Perforation
Hole Diameter
According to Coulson and Richardson, 5 mm is the preferred hole size for towers,
especially for non-fouling systems. Since the feed composition has a low fouling
tendency, therefore we consider

𝑑ℎ = 𝟓 𝒎𝒎
Hole Area
The hole area is calculated by using the considered hole diameter. Therefore,
2
𝐷ℎ
𝐴ℎ = 𝜋( )
2

0.005 2
𝐴ℎ = 𝜋 ( )
2
𝐴ℎ = 0.00963 𝑚2
Perforated Area
The perforated area can be calculated as follows

𝐴𝑝 = 𝐴𝑐 (1 − %𝑑𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 𝑎𝑟𝑒𝑎)

𝐴𝑝 = 3.237(1 − 0.10)

𝐴𝑝 = 𝟐. 𝟗𝟏𝟑𝟑
Hole Pitch
The hole pitch is calculated using the ratio of downcomer area to the column area which
is basically the percent downcomer area as shown below. (Coulson & Richardson’s
Chemical Engineering Volume 6, 3rd Ed, p. 572)
2
𝐴𝑑𝑐 𝑑ℎ
= 0.9 [ ]
𝐴𝑐 𝑙𝑝
2
𝟎. 𝟎𝟎𝟓
0.12 = 0.9 [ ]
𝑙𝑝

𝑙𝑝 = 0.0137 𝑚 = 1.37 𝑚𝑚

Downcomer Data
Downcomer Area
The downcomer area for this design is taken as 12% of the column cross-sectional area
(Coulson & Richardson’s Chemical Engineering Volume 6, 3rd Ed, p. 572). Therefore,

𝑑ℎ = 𝟎. 𝟏𝟐(3.237 ) = 𝟎. 𝟑𝟖𝟖𝟒 𝒎𝟐
Downcomer Head Loss
The head loss in the downcomer can be estimated using the equation given by Cicalese
et. al (1947) as shown below
𝟐
𝐿𝑤𝑑
ℎ𝑑𝑐 = 𝟏𝟔𝟔 ( )
𝜌𝐿 𝐴𝑑𝑐
𝟐
499539.72 𝑘𝑔/𝑑𝑎𝑦
3600 𝑠/𝑑𝑎𝑦
ℎ𝑑𝑐 = 𝟏𝟔𝟔 ( )
kg
(968.628 m3) (𝟎. 𝟑𝟖𝟖𝟒 𝒎𝟐)

𝟐
499539.72 𝑘𝑔/𝑑𝑎𝑦
3600 𝑠/𝑑𝑎𝑦
ℎ𝑑𝑐 = 𝟏𝟔𝟔 ( )
kg
(968.628 m3) (𝟎. 𝟑𝟖𝟖𝟒 𝒎𝟐)

ℎ𝑑𝑐 = 𝟔𝟏. 𝟐𝟐𝟔 𝒎𝒎