Separation Processes (CHEG 485)

Dr. Mohammad Abu Zahra

(Associate Professor, Chemical Engineering)

Lecture 4: Multistage distillation

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 Topic 2:

Distillation
(paragraphs 7.1-7.3)

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Continuous flash distillation

12 x
y
12  1 x  1
q 1
y x z
1 q 1 q

KB KA
q  z  (1  z )
1 KB 1 KA

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From flash drums to column

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Tray column for multistage distillation

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 Multistage Distillation
• Reflux: part of the top vapor is condensed and
returned to the first stage.
• The reflux ratio (R) is defined as the ratio of the
reflux rate to the rate of product removal
(reflux/distillate (L’/D).
• Boilup: part of the bottom liquid is evaporated
and returned to the bottom stage.
• The boilup ratio is the fractional amount of
liquid that is boiled back into the column to the
amount of liquid leaving (Bottoms).
• Reflux and boilup help in controlling the
internal vapor and liquid flow rates at specific
heating (bottom reboiler) and /or cooling (top
condenser).
• The section of column above the feed is called
the rectifying section and the section below the
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feed is referred to as the stripping section.
Multistage column distillation

Rectifying section:
Section above the feed

Stripping section:
Section below the feed

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 Feasible distillation conditions

Multi-stage distillation is feasible if:

• Relative volatility: α > 1.2
• Reboiler: T < 300 oC (high pressure steam)
• Condenser: T > 40 oC (cooling water)
• Column pressure: 2 mbar < Ptot < 50 bar
• Number of stages: N < 100

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 McCabe-Thiele Method – Assumptions
• Suitable for binary mixtures in continuous columns
• Can be used as a preliminary study for multi component
• Combination of VLE data and operating lines
• Constant molar overflow: Liquid and vapor flow rates tend to
remain approximately constant as long as heat losses from the
column are negligible and the pressure is uniform throughout
the column.
• With the assumption of no heat loss from column and constant
molar flow conditions, energy balances are not necessary in
either the rectifying or stripping sections.
• Based on these assumptions the McCabe-Thiele method
provides a graphical solution to the material balances and
equilibrium relationships inside the column.
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Multistage column distillation

Separation of feed (F) into

distillate (D) and bottom (B)
streams

For binary mixtures the

subscripts F, D and B are used
to indicate the mole fractions of
the most volatile compound
(xF, xD and xB)

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 Overall (external) mass balances

• Total mass balance:

F  DB
• Mass balance for the most volatile compound:

xF F  xD D  xB B
• If F and xF are given:
xF  xB xD  xF
D F and B F
xD  xB xD  xB

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 Equilibrium line

• Relative volatility:
 1 P1sat K1 y/x
12   
 2 P2sat
K 2 1  y  / 1  x 

• Equilibrium line:

12 x
y
12  1 x  1
The equilibrium line establishes the relation between the
composition of the liquid and the vapor on a tray at equilibrium

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Equilibrium line: from x to y

and so on…

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 Internal flows within sections
V’ V’
Equal molar overflow:
D D
V’ L’ L’ L’
constant molar vapor and
liquid flow in each section
V’ L’ (ΔHAvap ≈ ΔHBvap)
V’ L’
V’ L’ • In the rectifying section
V’ and L’ are constant in
V’ L’
mol/s (not in composition)
V’ L’
• At the feed tray: V’ and L’
V’’ L’’ are converted to V’’ and L’’

V’’ L’’ • In the stripping section

V’’ L’’ V” and L” are constant in
V’’ L’’ mol/s (not in composition)
V’’ L’’ V’’ V’’

L’’ B L’’ B 14
Operating line stripping section

Mole balance:

Operating line for the

stripping section:

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 Operating line stripping section

• Straight line with slope L”/V”

(slope > 1)
• Line goes through the point (xB)
(which lies on y=x)
• Makes the connection between ym+1 and xm

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 Operating line stripping section

Equilibrium line

Diagonal (y=x)

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From x to y to x to y…

xB

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From (xB, xB) to (xB, yB) to (yB, xN)
to (xN, yN), etc…

Constructing a staircase
between the equilibrium
line and the operating line

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Operating line rectifying section

Mole balance:

Operating line for the

rectifying section:

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 Operating line rectifying section

• Straight line with slope L’/V’

(slope < 1)
• Line goes through the point (xD)
(which lies on y=x)
• Makes the connection between yn+1 and xn

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 Reflux ratio (R)

Slope operating line

(internal flow ratio)

Reflux ratio
(external flow ratio)
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 Reflux

• Reflux is required to wash out the remaining traces of the

high-boiling compound in the top vapor

• With: and

the operating line of the rectifying section becomes:

• The reflux ratio (R) can freely be chosen by the designer.

Once R is fixed, the slopes of both operating lines (L’/V’ in
the rectifying section and L”/V” in the stripping section) are
also fixed. 23
Operating line rectifying section

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 Total number of equilibrium stages

Constructing staircase between equilibrium line and operating lines:

Equilibrium line

Operating line
rectifying section

Operating line
stripping section

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 Stages versus trays

5 equilibrium stages = 4 theoretical trays

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 Trays versus reflux ratio

6 trays, R = 1.2 6 trays, R = 3.0

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Minimum number of trays (Nmin)

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Minimum reflux ratio (Rmin)

Rmin is determined by
the intersection of
the feed line with the
equilibrium line

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 Optimal reflux ratio (Ropt)

• A trade off between operating cost and capital cost is

needed.
• Increase R Less stages, less capital cost BUT
More boiling and condensing
• Decrease R More stages, More capital cost BUT
also Less boiling and condensing
• Capital and operating costs combine to give a total
cost.
• Rule of thumb R = 1.1 to 1.5 times Rmin

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Optimal reflux ratio (Ropt)

Rule of thumb:

Ropt = 1.2 × Rmin

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