The Industrial Distillation Plant

The distillation plant consists of three distillation columns in series. They separate
a highly non ideal multicomponent mixture, which contains at least twelve
important components. The total number of components, however, is unknown, as
it is often the case in the chemical industries. A schematic flowsheet, showing
how feeds and products connect the columns, is shown in Figure 1. The bottom
product of the first column is split into two parts and then fed into the second
column. The distillate flow of the second column is recycled to the first column.
The main product is taken from the second column as a side stream. While the first
two columns are tray columns, the third one is a packed column. Its feed consists
of the bottom product of the second column, and its distillate flows back to the
second column, forming the second recycle of the system. Inspection of the
mixture which is separated reveals, however, that the third column may not be
necessary, if a good controller exists which ensures that the specifications for the
main product are met. Thus we will concentrate on the first two columns, leaving
the third column unmodelled. The recycle from column 3 to column 2, however, is
included in the model as an external feed, to enable a comparison of
measurements and simulations. The current operation of the plant makes an
improvement of the control system desirable: When the feed flow to the first
column is changed, the specifications for the main product are no longer met. It
typically takes two days to get the plant back on track. Currently, the bottom level
of each column is controlled by the corresponding bottom product stream; the
pressure drop of the column is controlled by the heat input to the column. The
temperature of a tray is used as an indicator for the composition profile; if its
setpoint is not reached, the product flows are adjusted manually. Both columns are
operated under vaccum.
Figure 1. Schematic Flowsheet for how feeds and products are connected for the process of distillation
Distillation

Distillation is a commonly used method for purifying liquids and separating

mixtures of liquids into their individual components. Familiar examples include the
distillation of crude fermentation broths into alcoholic spirits such as gin and
vodka, and the fractionation of crude oil into useful products such as gasoline and
heating oil. In the organic lab, distillation is used for purifying solvents and liquid
reaction products.

Types of distillation

There are two main types of distillation

1. Batch distillation
2. Continuous distillation

Batch Distillation

The mixture is added to the unit at the start of the distillation, distillate fractions
are taken out sequentially in time (one after another) during the distillation, and the
remaining bottoms fraction is removed at the end. Because each of the distillate
fractions are taken out at different times, only one distillate exit point is needed for
a batch distillation and the distillate can just be switched to a different receiver, a
fraction-collecting container. Batch distillation is often used when smaller
quantities are distilled.

Continuous Distillation

Continuous distillation, a form of distillation, is an ongoing separation in which a

mixture is continuously (without interruption) fed into the process and separated
fractions are removed continuously as output streams. In a continuous distillation,
each of the fraction streams is taken simultaneously throughout operation;
therefore, a separate exit point is needed for each fraction. Continuous distillation
is used for larger quantities.

Types of Distillation Towers

There are two main types of distillation towers

1. The ‘Packed’ Type

2. The ‘Tray’ Type

The ‘Packed’ Type

As its name implies, the packed tower is a vertical, steel column which contains
'Beds' of packing material which are used to bring the rising vapours into intimate
contact with falling liquid within the tower. The heat added to the mixture before
entering the tower partially vaporises the mixture and the vapours rise up the tower
and begin to cool.

The liquid falls towards the bottom of the tower. At the tower bottom, in general,
more heat is added to the liquid by a 'Reboiler' which may be steam heated or a
fuel fired furnace type.

The addition of heat here causes more vapours to rise up the column. As the two
phases of the mixture - falling liquid and rising vapour - come together, light
components are stripped out of the liquid and enter the gas phase while heavy
components in the vapour are condensed into the liquid phase.

In this way, as the vapour rises and gradually cools, it becomes lighter and, as the
liquid falls, it becomes hotter and heavier.

With this type of distillation column there is generally only a top and bottom
product. The quality of the products depends upon the height of the tower, the
number of contacting devices, the tower temperature and pressure and their
control, and the velocity of the rising vapours.

The type of packing materials used, also plays a part in the separation process. The
packing can be of such types as Ceramic Raschig Rings, Stainless Steel Pall Rings
or Ceramic Saddles.

The ‘Tray’ Type

This is also a tall, cylindrical column. Inside, a series of trays are placed, one above
the other. The trays are used to bring the rising vapour and falling liquid into
intimate contact. Tray towers do the same job as packed towers but they are very
much more efficient in the separation process than packed towers and, they are
also more costly. There are various types of tray in use and the type selected
depends upon the degree of product purity required, the type of fluids, fluid
velocity and other process parameters of the system.

The types of tray used in distillation columns are as follows:

THE SIEVE TRAY is simply a metal plate containing drilled holes through which
the rising vapour can pass into the liquid flowing across the tray.

THE VALVE TRAY is similar to the sieve type but, each hole is fitted with a
flapper valve which opens as vapour passes through the hole. This type is used
where vapour velocity is not constant and the valves prevent liquid from dumping
through the holes at times of low gas velocity.

THE BUBBLE-CAP TRAY is the most efficient separation device but, is also the
most costly. It consists of a number of 'Chimneys' or 'Risers' (small, short pipes set
into the tray), through which the vapour can pass. Fitted over the riser is a 'Cap'
which causes the rising vapour to turn through 180 °. This forces the gas to
'Bubble' through the liquid flowing across the tray. The liquid level on the tray is
maintained below the top of the riser to prevent dumping of liquid down the tower.

Each of the above trays also has a 'WEIR' that maintains the liquid level on the
tray. As the liquid flows over the weir, it enters a 'DOWNCOMER' - (a short pipe),
that carries the liquid down to the tray below. The downcomer outlet is below the
surface of the liquid on the tray below, acting as a seal to prevent gas from
bypassing the tray above.
DIAGRAM FOR ‘PACKED TYPE’ DISTILLATION COLUMN
DIAGRAM FOR ‘TRAY TYPE’ DISTILLATION COLUMN