MFP Train Refining-Petrochemicals-Chemicals-Engineering INTERNAL DEVICES FOR LIQUID-VAPOR CONTACT IN DISTILLATION COLUMNS MASS TRANSFER IN LIQUID VAPOR EQUILIBRIA...., eee eae 1 TRAYS AND PACKINGS: COMPARISON 2 CHOICE FOR TRAYS AND PACKINGS a 3 EFFICIENCY OF TRAYS AND PACKINGS .......rsnnntnnnn ne 4 STANDARD TRAYS TECHNOLOGY: withtout downcomers.... ccm 6 8 9 STANDARD TRAYS: with downcomer...... scree CONTACTING DEVICES ON THE ACTIVE AREA... TRAYS INSTALLATION .. SLIDED TRAYS. 10 TRAYS OPERATION. eet 1" FLOODING AND MISOPERATION: gas 9s foadng 846 cto 12 FLOODING AND MISOPERATION: liquid flooding... sennnenseesesene 1B MISOPERATION: WEEPING AND BLOWING. 14 MULTI PASS TRAY... atte inane HIGH PERFORMANCE TRAYS......0csssnnnnenese ntact 16 TROUBLESHOOTING TRAYS. ee pi eeiteetiaany TECHNOLOGY OF A PACKED BED eas 18 DIFFERENT TYPES OF TRAYS - Comparison of results... 19 PACKED BEDS: RANDOM PACKINGS.......0000usenne on 5 PACKED BEDS: STRUCTURED PACKINGS....n.cssssnsnnnnnnne ec 24 MAIN TYPES OF PACKING ELEMENTS ......... a eit: PACKED BEDS: COMPARISON RANDOM & STRUCTURED «0.0 23 LIQUID DISTRIBUTION ... hcpeenleaeaata earner 24 PACKED BEDS OPERATION... reac TTA eget 2D. GAMMAGRAPHIC TESTS... ea 26 DT PLA- 01871_/ 6102/2011 ©2011 - IFP TrainingOMASS TRANSFER IN LIQUID VAPOR EQUILIBRIA Trough a liquid-vapor contact, mass is being transferred between the two phases: light compounds leave the liquid to the vapor and simuttaneously heavy ones migrate from the vapor to the liquid phase. Heat transfer accompanies this. The transfers occur across the interface between the two phases, inthe limited volume where the liquid isin direct contact with the vapor. S, Vapor fim PLE a equiorium Light ‘compounds Heavy ‘compounds. The structure of this interface consists of many layers represented on the following figure: = two very thin films (probably two or tree molecules thickness), one liquid and one vapor, where equilibrium is reached ~— according == to.-~—sthermodynamic-~—=—equations: +X i" = /= (and ¥ are molar fractions inthe quid and in he gas respectively) = a laminar liquid layer between the liquid fm and the bulk of the liquid phase. In this layer, the molecules migrate according to Fick ciffusion laws = laminar gaseous layer between the gas film and the bulk of the gaseous phase. In this gas layer, the molecules migrate according to the same laws along the concentration gradient Interface Light compounds Gaslayer. concerzaton scale o _Liquid layer Gaseous fim 7 Liquid fim Diflusion is the limiting phenomena, particularly in the liquid phase: there the gradient is smaller because the thickness of the layer is larger. This is due to the high viscosity of the liquid, compared to the one in the gaseous phase. The higher the liquid viscosity, the thicker the liquid layer and the slower the mass transfer The contact devices provide the largest possible interface area with the maximum turbulent liquid ners AA © 2014 -IFP Training—— ee TRAYS AND PACKINGS: COMPARISON | ‘There are two main types of internal systems for liguid-vapor contact: rays or packed beds. On the trays, the liquid is the continuous phase where the gas is dispersed. In the packed beds, the liquid is dispersed in the continuous gas phase. ‘The comparison between the two devices is as follows: Trays Packed beds Pressure drop High | Low I pee eee Capacity (for a given diameter) Lower | Higher Capacity Factor | Higher than 0.25 Lower than 0.1 Efficiency Good Higher, {specifically for low liquid rates) Materials Metals (or graphite) Almost any Kind, leading toa ‘good resistance to corrosion Good for raditonal rays High* Flexibility Lower for high performance trays | Cost | Rather low"* [eee Eee Eee eee eee cee | Liquid holdup is larger and dynamic | Flooding phenomena are more Operation response to disturbances is slower | difficult to detect in advance | Vacuum pressure Most often used Foaming tendency Main uses Fouling duties Small diameter columns Side streams Revamping * Except for very low liquid flow rates “Except for small diameter columns This table presents only the rough characteristics of both systems, but each special case should be investigated carefully. ‘The *Capacity factor" Fp is one parameter that helps for the choice between trays and packings. It's a kind of volumetric ratio between liquid and gas flow rates, The definition is as follows: Fp = UG (palpi)? With the following symbols: LL = liquid mass flow rate and p, = density of the liquid G = vapor mass flow rate and pg = density ofthe gas In the field between 0.1 and 0.25, the choice can be helped on the basis of the following criteria as exposed on the chart on the following page. OUTLAA ©2011 -IFP Training4 (WV) oni ds sojouresed ‘mou areinaje9 : Toye d ‘6 3 a aqeonu pve lunp aie 5 re) bunped ipsucoey ‘ysu BuiB6njd pue uorsouco aye6nuyy ov cael [=] x [=] 8 ‘nes e018 for) ‘anssiue 2 ‘vosouco s} on ‘unssaud 5) vowutenue 5, = & = o oN Lx] 2 t g ‘onssijeat e ‘anssj ue 5 BurBnd st rT oN ma Buuoy 5} suneuie 2 ‘yoa ye0u9 wi _ 8 t 3 >> 2 Buyped s20> 44> 0 ] shen = 1poj0seig I veoweag | + ~— oro> dy dy seo Normal operating fled Liquid flowrate eco 18k ‘Vapor flowrate = Atoo low vapor velocity favors the weeping of the liquid through the holes ofthe active area. = Aiigh vapor flow rate provokes flooding phenomena due to an increased pressure drop across the tray. Ahh liquid flow rate promotes flooding phenomena as well, because of enlarged liquid level on the tray. low liquid flow rate may favor blowing phenomena and by-pass of the gas along the downcomers, CAPACITY is in relation with carry over phenomena that reduce the effcienoy of the contacting systems. It is the abilty to keep a sound efficiency in case of high liquid or vapor flow rates. FLEXIBILITY isin relationship with changes of flow rates. Is the ability to Keep a sound efficiency in case of low or high flow rates, either liquid or gaseous, overt AA © 2011 - FP Training2 FLOODING AND MISOPERATION: gas flooding {An excess of gas flow rate may be due to an overloaded reboller or to many other parameters. This leads to the following phenomena’ ~ increased pressure drop across the trays and increased overall pressure drop all along the column ~ increased liquid level in the downcomer up tothe liquid level on the tray above = reduced volume for separation of quid and gas bubbles in the downcomer = carry over of liquid droplets to the upper tray. If the gas load increases further, it will rise the liquid level in the downcomer and accordingly on the tray until the whole volume corresponding to the tray spacing is full of froth. The separation cannot be achieved correctly any more and the phenomena wil invade progressively the complete column: the flooding situation wil invalidate the efficiency ofthe column, Vapor flooding ori as ©2011 - IFP Trainingoer a 13 FLOODING AND MISOPERATION: LIQUID FLOODING An excess of liquid flow rate may be due to a very high reflux flow rate, or a liquid feed, in the stripping section. Consequently = the liquid level over the weir increases, thus the liquid leve! on the active area on the tray ~ the increase of liquid velocity in the donwcomer caries down more bubbles and thus decreases the density ~ these phenomena provoke an increase of liquid level in the downcomer leading to similar flooding situation uco22t0H| Liquid flooding ©2011 - IFP Training14 | MISOPERATION: WEEPING AND BLOWING * Weeping ‘At low vapor flow rate, the liquid has the possibilty to flow through the holes of the active area leading to a bypassing of two trays. This will decrease the efficiency of the iquid-vapor contact. x sea egtaas lb agstt hoes. iad ce eS ‘wea 2081 + Blowing Low liquid fow rate and simultaneously high vapor flow rate form gas chimneys inthe froth on the active area: lke channeling it reduces the interface area and decreases the efficiency of the contact ‘Mears rer © 2011 -IFP Training15 MULTI PASS TRAY | (One pass trays are characterized by one liquid flow from one side to the other side of the tray. Their limit is due to the liquid height above the weir at the outlet of the tray. It increases much when the liquid flow rate is high. Ths leads to increased pressure drop across the tray and unstable vapor flow rate In order to decrease this liquid height, the weir length may be increased with twisted weirs. ea rtp ‘An other means to decrease the liquid height over the weir is to split the liquid flow rate into two or four equivalent passes. Active area 4 passes tray (One pass tray ‘Advantages of mull-pass trays: - handling of high liquid flow rates = lower pressure drop Disadvantages of multi-pass trays + higher diameter ofthe column ~ easier channeling phenomena Trays like “Calming section trays’ (Shell patented) or "MD trays" (UOP patented) have been designed to increase the weir length and process high liquid flow rates. oer AA © 2011 -IFP TrainingIMPLEMENTATION. AIM EFFICIENCY MEANS: DYNAMIC SEAL ‘SHRINKING CHANNELS: 16 Spee ce eee eee eee HIGH PERFORMANCE TRAYS services where there is no fouling increase of capacity and efficiency between 20 and 20% increase ~ extension ofthe active area under the upstream downcomer - decrease of channeling phenomena ~ implementation of specific fixed or mobile valves In classical trays, the seal consists of a weir height higher than the clearance between the upstream downcomer and the piane of the tray. A dynamic seal means the clearance is higher. The design of such trays is more tricky inorder to avoid any bypassing of the gas trough the downcomer. Neo 1288 Too small Normal Too large Improvement of liquid circulation thanks to gas orientation by means of fixed valves that are non symmetrical nea 88 Side zones OTA Liquid distribution © 2011 - FP Training7 TROUBLESHOOTING TRAYS PEE Er ee eee eee eee Nature of the problem Diagnostic Solution Camy out a test run and compare with design conditions Modified operating conditions Simulate the column with existing operation conditions | Increase of pressure drop Investigate potential flooding Check fouling or polymerizing tendency ‘Check design conditions Revamp the column t Decrease through put Inject antifouling additives Decrease of efficiency Check design conditions Check liquid of vapor flooding Check possible overload or incidents damaging the equipment ‘Check the injection or draw-off devices Check the bottom equipment including reboiler Check the mechanical state of trays | Decrease flow rates ‘Shut down the column for inspection ‘Shut down the column for inspection Gamma-ray or shut down Foaming phenomena Check foaming tendency Gamma-ray-test the operating column Corrosion phenomena Gamma-ray-test the operating column Inject anti-foaming additives Replace trays with packings [Replace with corrosion resistant | equipment O17 AA © 2011 - IFP Training18 pewecana wawow ‘sjonpoud yj 2 waisks ‘ensouoo Auip ‘sued Guedes ‘uowoo ysow a4), {vo papjone eq 0) 0 Ayes * ‘SSILUY INOUE Lo so so 4 1800 3AUW138 ‘wnpeus unpou dowd 3uNSSaed 0h OF 001-0} ‘ALITIBIXTTS TWHNIXWA 4 4 AONSIOI3 SAUWTSS t + ALIOWAVO SALLWISS a Cs sweiBerg SESBSEE ESS Tn | BRT RS AED ena oo AVAL Teed arsoaunt santa SAVUL BASIS xmainn Sdvo_ sfen jo dK ‘SUBNOONMOG LNOHLIM SAVEL ‘SU3WOONMOG HLIM SAVEL e — syinsau jo uosueduiog — SAVUL 4O S3dAL LNSUIESIO © 2011 - IFP Training or AA19 TECHNOLOGY OF A PACKED BED A bed of packed elements consists of a given volume of materials, wetted with the down flowing liquid ‘contacting the rising vapor flow. The packed elements are piled up on a support grid. They are blocked at the upper part with a fxing grid or protection ord that insures a flat surface and a constant height al over the cross section of the column, The liquid is distributed carefully atthe top ofthe bed. Its also collected below the tray. distrioutor ccm ee Liquid inlet Protection gid Zone filed with packing elements & 2 z Liquid collector Dcpanee VAPOR The packed elements may be either carefully arranged, called “structured packings” or random piled as “randon packings” The loading of brittle elements in random packings may be achieved either with the help of "socks" or when water is filing the column, in order to avoid breakage that would generate fine particles, oerLAA ©2011 - FP Training20 | PACKED BEDS: RANDOM PACKINGS. The elements have a ring shape or a saddle shape, as shown here below. L Fleximax DMEDTR Their size may range from 1/2 to 4 inches. The large elements have a lower pressure drop, but also a smaller speotc area. The largest ones are installed in large diameter columns. ‘The materials may be all kinds of metals, or plastics, ceramic, graphite and others. The correct choice leads to an appropriate resistance to corrosive agents ‘The main process characteristics of random packings are: = the specific area “a," corresponding to the solid surface per unit of volume of the bed (unit = m2im3), The efficiency increases with the specific area, because the interface area becomes larger. = the void fraction “e" in the bed which is the ratio of the void volume between the elements over the volume of the bed (a dimension less parameter). A high void fraction is linked with low pressure drop + the “packing factor" denoted “Fp” equal to ap / €°. The smaller the packing factor, the higher the capacity OWT AA ©2011 - IFP TrainingRaschig ring a MAIN TYPES OF PACKING ELEMENTS. Lessing ring Intalox saddle Berl saddle eo 002 0 ‘The chart below shows, as an example, the characteristics of intalox saddles used in packed bed according to their size from 1/2" 10 2" Intalox, ‘Number of elements ‘Specific weight in kg Specific area Percent free saddles perm? perm? (2m) 98 space 12 730 000 750 620 B oa" 230.000 700 330 7 re 84.000 670 260 715 qe 25.000 500 195 a1 z 9300 | 610 120 79 ‘The chart below compares the characteristics of rings made ofthe 3 most common materials Pall ring 2" Number of elements ‘Specific weight in kg Specific area Percent free 92" | perm of packed bed perm? (m2im3) 928 space Metal 6300 350 100 964 Plastic 6300 70 100 1 Ceramic 5800 | 610 96 1 OLA ©2011 -IFP Training2 PACKED BEDS: STRUCTURED PACKINGS * Sheet packings The beds are made of large blocks of corrugated sheets joined together. The void volume between the sheets is achieved by the 90° orientation of two adjacent sheets, ‘The mass transfer may be increased with rough surface, holes or weaved materials, + Grid packings ‘They are adapted to large gas volumic flow rates, and are specifically adapted for high fouling duties. neath la ek ee ‘OUCUR ve" “aha Na EO 106 OBTLAA © 2011 -IFP Training2B PACKED BEDS: COMPARISON RANDOM & STRUCTURED | | Random packing Structured packing | Grids pee ee eee rece eee eee eee eee ere ‘Advantages | Efficiency at high pressure |Higheffciency atlow pressure Very low pressure drop | Use of ceramic or graphite | Lower pressure drop than random | More resistant to fouling | | material packings | | | Good LV contact even with very low liquid flow rates Disadvantages Higher pressure drop than More expensive Low efficiency rds or structured packings OITA ©2011 - FP Training24 LIQUID DISTRIBUTION [ we distribution above any packed bed is essential for the proper efficiency ofthe separation. One of the disadvantages ofthe packed beds is their high tendency to channeling phenomena. Especially in interaction with the inner wall of the shell: when some Fquid reaches this wall, itis ikely that it will never flow back to the bulk ofthe bed In order to avoid these phenomena, the liquid and the gas flow have to be correctly distributed all over the ‘ross section area of the column. The gas is generally correctly distributed, but has tendency to accumulate in part of the cross section area when the pressure drop of the bed is very low. The liquid, on the other hand, has to be distributed carefully. It may be achieved by two main systems: = a pipe grid equipped with holes or sprays where the liquid is pressurized - aditch system where the liquid flows under gravity a ‘The distribution of the liquid is easier in small diameter columns than in larger ones. Ifthe diameter is very large, then the necessary height for the distributor may be many meters. our AA ©2011 - FP Training25 OS PACKED BEDS OPERATION ee as ‘As for the trays, packed beds are also sensitive to liquid and gas flow rates. + Vapor flooding ‘Atnormal operation conditions, the rising vapor flow rate slows down the liquid downward velocity inthe bed. ‘The consequence isa rather high liquid hold up around the elements, This liquid hold up increases with the vapor fiow rate. An other consequence is a slight increase of the pressure drop. When the vapor velocity exceeds the design value, the bed may become full of quid with gas bubbiing through it. The results are as follows: + large decrease of interface area + decrease of efficiency = increase of pressure drop ‘The vapor fooding phenomena corresponds to lower vapor flow rates ifthe liquid flow rate rises, + Liquid flooding When the liquid flow rate rises to high values over the design ones, the bed becomes filed with liquid, ‘whatever the vapor flow rate may be, This leads to the same type of consequences as described previously. + Low liquid flows ‘At very low liquid flow rates, the surface of the elements becomes dry and the interface area is dramatically reduced OHBTLAA ©2011 - IFP Training26 GAMMAGRAPHIC TESTS. ‘A source emits gamma-rays horizontally across the column. A receiver records the signal that has been more ‘or less adsorbed by the liquid or the metal paris in the column. The denser the matter is, the weaker is the received signal Recorded signal eee Receptor Ez Gas Downcomer quid tray i : The huge advantage of such a testis the possiblity to sound the column during operation. There are possibilities to perform many tests at different operating conditions, including before start up if necessary. The ‘comparison of the different graphs gives much information about troubles inside the columns, that may come. either from the mechanical state of the equipment, or from the hydraulic behavior of the internal flows, or from the process itse The interpretation of the diagrams is difficult and needs experience. Nevertheless these tests may detects the following problems: = mechanical troubles: damaged intemal equipment, corrosion, displacements of some metalic pieces, missing trays, liquid level location at the bottom = hydraulic behavior: cary over Iquid or carry dawn of gas bubbles, flooding phenomena, ‘weeping phenomena or dry trays - problems linked to the process like foaming, fouling, abnormal superheated or subcooled feed O1BTLAA © 2011 -IFP Training