SPECIFICATION SHEET: DISTILLATION COLUMN

SHEET 1 OF 1
REVISION DATE BY APPROVED

DISTILLATION COLUMN SKETCH

Item No. T-201
Process Service EtOH Low Pressure
Purification Column
OPERATING CONDITIONS
Temperature (‫ﹾ‬C) 65
Pressure (kPa) 120
DESIGN CONDITIONS
Temperature (‫ﹾ‬C) 121.11
Pressure (kPa) 132
MAIN SPECIFICATIONS
Number of Trays 30
Feed Stage 25
Inside Diameter (m) 9.1961
Outside Diameter (m) 9.2202
Column Height (m) 18
Tray Type Sieve
Tray Spacing (m) 0.6
Hole Area (m2) 5.0479
Hole Diameter (mm) 5 CONSTRUCTION SPECIFICATIONS
Weir Height (mm) 50 Construction Material Carbon Steel A285
Weir Length (mm) 7081 Geometry Cylindrical
Plate Thickness (mm) 5 Orientation Vertical
Plate Pressure Drop (Pa) 1747.7095 Type of Closure Torispherical Head
% Flooding 85 Vessel Support Skirt Support
Downcomer Area (m2) 7.9703 Closure Thickness 12.0803
(mm)
Residence Time (s) 31.596 Minimum Wall 12.0367
Thickness (mm)
A. INITIAL CONDITIONS

Operating and Design Conditions. Towler & Sinnott (2013) indicates that for vessels

under internal pressure, the design pressure is taken as the pressure at which the relief device is

set. This will normally be 5% to 10% above the normal working pressure, to avoid spurious

operation during minor process upsets. Thus, the basis of design temperature is in accordance with

the guidelines presented by Hall (2018) that is shown below:

Table 1. Design Temperature and Pressure Guidelines (Hall,2018)

Operating T Design T Operating P Design P

0-200 °F 250 °F 0 -25 psig 50 psig

Over 200 °F Operating + 50 °F 25-250 psig Operating + 25 psig

Reactors Operating + °F 250-1000 psig Operating + 10%

Over 1000 psig Operating + 5%

Table 2. Operating and Design Temperature and Pressure Conditions of T-201

Operating Temperature °C 65

°F 149

Design Temperature °C 121.11

°F 250

Operating Pressure kPa 120

bar 1.2

psi 17.4045

Design Pressure kPa 132

 bar 1.32

psi 19.145

Aspen HYSIS Simulation v.9.0. The ethanol low pressure purification column was
simulated using the software of Aspen HYSIS v.9.0. The results of the simulation were shown
below:

Table 3. Initial Conditions of T-201

Feed Rate, kg/h 35131.5828
Distillate Rate, kg/h 28786.8002
Bottom Rate, kg/h 6344.7822
Optimal Feed Stage 25
Number of Stages 30
Reflux Ratio 6.402

Table 4. Transport Properties of T-201

Distillate Bottom
Stream Name 16 17
Liquid Density, kg/m3 799.5479 989.1895
Vapor Density, kg/m3 0.1728 0.0914
Surface Tension, N/m 0.02670346 0.06835763
B. PLATE DESIGN

Liquid and Vapor Flowrates. The equation, 𝐿 = 𝑅𝐷, will be used for the liquid flow above

feed since the feed is a saturated liquid, Whereas, the equation, 𝐿′ = 𝑅𝐷+ F, will be used for the

liquid flow below feed wherein R is the actual reflux ratio, D is the mass flowrate of distillate and

F is the mass flow rate of the feed. Thus, the liquid rate is comprised of liquid flow rate above

feed, Ltop and below feed, Lbot.

Sieve Plate Performance Diagram

Distillate Product Vapor Rate, V

V = D (1+R)

𝑘𝑔
V = 28786.8002 (1 + 6.402)
ℎ𝑟

𝑘𝑔
V = 213079.8951
ℎ𝑟

Liquid Flow Above Feed, L TOP

LTOP = RD
 𝑘𝑔
LTOP = (6.402) (28786.8002 )
ℎ𝑟

𝑘𝑔
LTOP = 184293.0949
ℎ𝑟

Liquid Flow Below Feed, LBOT

LBOT = RD + F

𝑘𝑔 𝑘𝑔
LBOT = (6.402) (28786.8002 ) + 35131.5828 ℎ𝑟
ℎ𝑟

𝑘𝑔
LBOT = 219424.6777
ℎ𝑟

Plate Spacing. Plate spacing is set to 0.6 m. Based on Towler and Sinnott (2013), the plate

spacing of the column from 0.15 m (6 in) to 1 m (36 in) are normally used. The spacing chosen

will depend on the column diameter and operating conditions. Thus, close spacing is used with

small diameter columns. Plate spacings of 0.3 m to 0.6 m will normally be used for columns above

1 m diameter and 0.5 m (18 in) can be taken as an initial estimate.

Column Liquid-Vapor Factor. The column liquid-vapor factor can be calculated using

the equation given below from Towler and Sinnott (2013).

𝐿 𝜌
FLV = 𝑉𝑤 √𝜌𝑣
𝑤 𝐿

where Lw – liquid mass flowrate

Vw – vapor mass flowrate

𝜌v – vapor density

𝜌L – liquid density
Colum Liquid-Vapor Top Factor, FLV-TOP

𝑘𝑔 𝑘𝑔
184293.0949 0.1728
ℎ𝑟 𝑚3
FLV-TOP = 𝑘𝑔 √ 𝑘𝑔
213079.8951 ℎ𝑟 799.5479 3
𝑚

FLV-TOP = 0.01271

Colum Liquid-Vapor Bottom Factor, FLV-BOT

𝑘𝑔 𝑘𝑔
219424.6777 0.0914
ℎ𝑟 𝑚3
FLV-BOT = 𝑘𝑔 √ 𝑘𝑔
213079.8951 ℎ𝑟 989.1895 3
𝑚

FLV-BOT = 0.009899

Relationship Between K and FLV

Using the following data:

Plate Spacing = 0.6 m

FLV-TOP = 0.01271

FLV-BOT = 0.009899 ≈ 0.01

The resulting values of KTOP and KBOT based on the graph are 0.12 and 0.098, respectively.

Surface Tension. According to Towler and Sinnott (2013), the surface tension, 𝜎 must be

considered for K adjustment using the formula shown below:

𝜎
K1, corrected = K (0.02)0.2

KTOP Adjustment

𝑁
0.02670346 𝑚
K1, TOP = (0.12) ( )0.2
0.02

K1, TOP = 0.1271

KBOT Adjustment

𝑁
0.06835763 𝑚
K1, BOT = (0.098) ( )0.2
0.02

K1, BOT = 0.1253

Flooding Velocity, 𝝊𝒇 . The flooding condition fixes the upper limit of vapor velocity

based on Towler and Sinnott (2013). The flooding velocity can be estimated from the correlation

given by Fair.
 𝜌𝐿 − 𝜌𝑣
𝜐𝑓 = K1, corrected √ 𝜌𝑣

Flooding Velocity Above Feed, 𝝊𝒇,𝑻𝑶𝑷

𝑘𝑔 𝑘𝑔
799.5479 − 0.1728 3
𝑚3 𝑚
𝜐𝑓,𝑇𝑂𝑃 = (0.1271) √ 𝑘𝑔
0.1728 3
𝑚

𝑚
𝜐𝑓,𝑇𝑂𝑃 = 8.6447
𝑠

Flooding Velocity Below Feed, 𝝊𝒇,𝑩𝑶𝑻

𝑘𝑔 𝑘𝑔
989.1895 − 0.0914 3
𝑚3 𝑚
𝜐𝑓,𝐵𝑂𝑇 = (0.1253) √ 𝑘𝑔
0.0914 3
𝑚

𝑚
𝜐𝑓,𝐵𝑂𝑇 = 13.0346
𝑠

Flooding Rate at Maximum Flow, 𝝊𝑵 . It is said that flooding is considered as one of the

factors that affect the distillation column wherein the increased pressure from excessive vapor also

backs up the liquid in the down comer that caused an increase in liquid holdup on the plate.

Flooding is brought about by the excessive vapor flow that caused the liquid to be entrained in the

vapor up the column. The maximum capacity of the column may be severely reduced depending

on the degree of flooding. It is detected by sharp increases in column differential pressure and

significant decrease in separation efficiency. For the design, a value of 80% to 85% of the flooding

velocity should be used. In this case, 85% of flooding velocity for the design is being considered

(Towler & Sinnott, 2013).

 𝜐𝑁 = 0.85𝜐𝑓

85% Flooding Velocity Above Feed at Maximum Flow, 𝝊𝑵,𝑻𝑶𝑷

𝑚
𝜐𝑁,𝑇𝑂𝑃 = 0.85 (8.6447 )
𝑠

𝑚
𝜐𝑁,𝑇𝑂𝑃 = 7.3480
𝑠

85% Flooding Velocity Below Feed at Maximum Flow, 𝝊𝑵,𝑩𝑶𝑻

𝑚
𝜐𝑁,𝐵𝑂𝑇 = 0.85 (13.0346 )
𝑠

𝑚
𝜐𝑁,𝐵𝑂𝑇 = 11.0794
𝑠

Maximum Volumetric Flowrate, 𝝊𝑽 . It is the maximum allowable vapor velocity, based

on the gross total column cross-sectional area.

𝑉𝑤
𝜐𝑉 =
𝜌𝑣

Maximum Volumetric Flowrate Above Feed, 𝝊𝑽,𝑻𝑶𝑷

𝑘𝑔
213079.8951 ℎ𝑟
𝜐𝑉,𝑇𝑂𝑃 = 𝑘𝑔
0.1728
𝑚3

𝑚3 𝑚3
𝜐𝑉,𝑇𝑂𝑃 = 1233101.245 ≈ 342.5281
ℎ𝑟 𝑠
Maximum Volumetric Flowrate Below Feed, 𝝊𝑽,𝑩𝑶𝑻

𝑘𝑔
213079.8951 ℎ𝑟
𝜐𝑉,𝐵𝑂𝑇 = 𝑘𝑔
0.0914
𝑚3

𝑚3 𝑚3
𝜐𝑉,𝐵𝑂𝑇 = 2331289.881 ≈ 647.5805
ℎ𝑟 𝑠

Net Area Required, AN. Net area which is also called as free area represents the smallest

area available for vapor flow in the inter-tray spacing. It is defined as the fraction of maximum

volumetric flowrate over the flooding velocity at maximum flow.

𝜐
𝐴𝑁 = 𝜐𝑉
𝑁

Net Area Above Feed, 𝑨𝑵,𝑻𝑶𝑷

𝑚3
342.5281 𝑠
𝐴𝑁,𝑇𝑂𝑃 = 𝑚
7.3480 𝑠

𝐴𝑁,𝑇𝑂𝑃 = 46.6151 m2

Net Area Below Feed, 𝑨𝑵,𝑩𝑶𝑻

𝑚3
647.5805 𝑠
𝐴𝑁,𝐵𝑂𝑇 = 𝑚
11.0794 𝑠

𝐴𝑁,𝐵𝑂𝑇 = 58.4491 m2

Column Cross-Sectional Area, AC. Based on Towler and Sinnott (2013), the column

cross sectional area can be calculated using the equation shown below.
 𝑁 𝐴
𝐴𝐶 = 0.88

Cross-Sectional Area Above Feed, 𝑨𝑪,𝑻𝑶𝑷

46.6151 𝑚2
𝐴𝐶,𝑇𝑂𝑃 =
0.88

𝐴𝐶,𝑇𝑂𝑃 = 52.9717 m2

Cross-Sectional Area, 𝑨𝑪,𝑩𝑶𝑻

58.4491 𝑚2
𝐴𝐶,𝐵𝑂𝑇 =
0.88

𝐴𝐶,𝐵𝑂𝑇 = 66.4194 m2

Column Diameter, DC. To calculate the column diameter, use the equation given below:

𝜋
Ac = 4 Dc2

4 𝐴𝑐
Dc = √ 𝜋

Column Diameter Above Feed, 𝑫𝑪,𝑻𝑶𝑷

4 (52.9717 𝑚2 )
𝐷𝐶,𝑇𝑂𝑃 = √
𝜋

𝐷𝐶,𝑇𝑂𝑃 = 8.2125 m

Column Diameter Below Feed, 𝑫𝑪,𝑩𝑶𝑻

4 (66.4194 𝑚2 )
𝐷𝐶,𝐵𝑂𝑇 = √
𝜋
 𝐷𝐶,𝐵𝑂𝑇 = 9.1961 m

Column Height, HC. The column height is calculated by multiplying the number of stages

to the plate spacing. The total height should not be above 175 ft or 53m based on the heuristics.

HC = No. of Stages x plate spacing

HC = 30 stages x 0.6 m

HC = 18 m

Liquid Flow Arrangement. The choice of plate type (reverse, single pass or multiple pass)

will depend on the maximum liquid flow rate and column diameter of the bottom.

𝐿𝑤
Maximum Volumetric Liquid Flowrate =
𝜌𝐿

𝐿𝐵𝑂𝑇
Maximum Volumetric Liquid Flowrate Below Feed,
𝜌𝐿,𝐵𝑂𝑇

𝑘𝑔
𝐿𝐵𝑂𝑇 219424.6777 𝑚3 𝑚3
ℎ𝑟
= 𝑘𝑔 = 221.8227 ≈ 0.0616
𝜌𝐿,𝐵𝑂𝑇 989.1895 3 ℎ𝑟 𝑠
𝑚

Using the Following Data:

𝑚3
Maximum Liquid Flowrate Below Feed = 0.0616 , 𝐷𝐶,𝐵𝑂𝑇 = 9.1961 m
𝑠

An initial selection can be made using the figure shown below. The relationship between the

maximum liquid flow rate and column diameter of the bottom is outside the range based from the

graph. Thus, it can be concluded that a double pass plate can be used.
 Selection for Liquid Flow Arrangement

Downcomer Area, AD. A downcomer is known as the drainpipe of the tray wherein it

conducts the liquid from one tray to the tray below. To calculate the downcomer area, take the

12% of the total cross-sectional area that is based on the bottom (Towler and Sinnott, 2013).

𝐴𝐷 = 0.12 𝐴𝐶

𝐴𝐷 = 0.12 (66.4194 m2)

𝐴𝐷 = 7.9703 m2

Active Area, AA. It is also known as the bubbling area wherein it represents the area

available for vapor flow just above the tray floor. To calculate the active area, take the difference

of the cross-sectional area and the twice of downcomer area that is based on the bottom (Towler

and Sinnott, 2013).

𝐴𝐴 = 𝐴𝐶 - 2 𝐴𝐷
 𝐴𝐴 = 66.4194 m2 - 2 (7.9703 m2)

𝐴𝐴 = 50.4788 m2

Hole Area, AH. It is the smallest area available for vapor passage on a tray. To calculate
the hole area, take the 10% of the active area that is based on the bottom (Towler and Sinnott,
2013).

𝐴𝐻 = 0.10 𝐴𝐴

𝐴𝐻 = 0.10 (50.4788 m2)

𝐴𝐻 = 5.0479 m2

C. WEIR DIMENSIONS

Weir Height, HW. According to Towler and Sinnott (2013), the height of the weir

determines the volume of liquid on the plate and is an important factor in determining the plate

efficiency. A high weir will increase the plate efficiency but at the expense of a higher plate

pressure drop. For columns operating above atmospheric pressure, the weir heights will normally

be between 40 mm to 90 mm (1.5 to 3.5 in.); 40 to 50 mm is recommended. For vacuum operation

lower weir heights are used to reduce the pressure drop; 6 to 12 mm (1 4 to 1 2 in.) is recommended.

Hole Diameter, DH. According to Towler and Sinnott (2013), the hole sizes used vary

from 2.5 to 19 mm; 5 mm is the preferred size for nonfouling applications. Larger holes are

recommended for fouling systems. The holes are drilled or punched. Punching is cheaper, but the

minimum size of hole that can be punched will depend on the plate thickness. For carbon steel,

hole sizes approximately equal to the plate thickness can be punched, but for stainless steel the

minimum hole size that can be punched is about twice the plate thickness.
 Plate Thickness, LT. According to Towler and Sinnott (2013), the typical plate thicknesses

used are: 5 mm (3/16 in.) for carbon steel, and 3 mm (12 gauge) for stainless steel.

Picket Fence Weir

Assumptions:

HW = 50 mm

DH = 5 mm

LT = 5 mm

Weir Length, lw. A graph that shows the relationship between weir length and downcomer

area from Towler and Sinnott (2013) is can be used to determine the weir length.

Using the following data:

𝐴𝐷 7.9703 𝑚2
= x 100 = 11.99% ≈ 12%
𝐴𝑐 66.4194 𝑚2

The weir length over the column diameter is approximately equal to 0.77.

lW = 0.77 DC

lW = 0.77 (9.1961 m)

lW = 7.0810 m
 Relationship Between Downcomer Area and Weir Length

D. WEEPING RATE

Weep Point. It is the lower limit of the operating range occurs when liquid leakage through

the plate holes becomes excessive (Towler and Sinnott, 2013).

𝑘𝑔 𝑘𝑔
Maximum Liquid Rate = 219424.6777 ≈ 60.9513
ℎ𝑟 𝑠

At 70% Turndown,

𝑘𝑔 𝑘𝑔
Minimum Liquid Rate = 0.7 x 60.9513 = 42.6660
𝑠 𝑠
 Weir Liquid Crest, HOW. The height of the liquid crest over the weir can be estimated

using the Francis weir formula (Towler and Sinnott, 2013).

𝐿𝑊 2⁄
HOW = 750( ) 3
𝜌𝐿 𝐿𝑊

Maximum Weir Crest, HOW, MAX

𝐿𝑊 2⁄
HOW, MAX = 750 ( ) 3
𝜌𝐿 𝐿𝑊

𝑘𝑔
60.9513 2⁄
𝑠
HOW, MAX = 750 ( 𝑘𝑔 𝑘𝑔 ) 3
(989.1895 3 )(60.9513 𝑠 )
𝑚

HOW, MAX = 7.5545 mm

Minimum Weir Crest, HOW, MIN

𝐿𝑊 2⁄
HOW, MIN = 750 ( ) 3
𝜌𝐿 𝐿𝑊

𝑘𝑔
42.6660 2⁄
𝑠
HOW, MIN = 750 ( 𝑘𝑔 𝑘𝑔 ) 3
(989.1895 3)(42.6660 𝑠 )
𝑚

HOW, MIN = 7.5545 mm

Using the following data:

At minimum weir crest, HW + HOW

HW + HOW = 50 mm + 7.5545 mm = 57.5545 mm, K2 = 30.2.

 Weep Point Correlation

Minimum Vapor Velocity, 𝝊𝑯

𝐾2 −0.90 (25.4− 𝐷𝐻 )
𝜐𝐻 = 𝜌𝑉 1/2

30.2−0.90 (25.4− 5 𝑚𝑚)

𝜐𝐻 = 𝑘𝑔 1/2
(0.0914 )
𝑚3

𝑚
𝜐𝐻 = 39.1632 𝑠

Actual Minimum Vapor Velocity,𝝊𝑯,𝑨𝑪𝑻𝑼𝑨𝑳

𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑟𝑎𝑡𝑒

𝜐𝐻,𝐴𝐶𝑇𝑈𝐴𝐿 = 𝐴𝐻

𝑚3
647.5805 x 0.70
𝑠
𝜐𝐻,𝐴𝐶𝑇𝑈𝐴𝐿 = 5.0479 𝑚2
 𝑚
𝜐𝐻,𝐴𝐶𝑇𝑈𝐴𝐿 = 89.8010 𝑠

𝑚 𝑚
Since 𝜐𝐻,𝐴𝐶𝑇𝑈𝐴𝐿 = 89.8010 > 𝜐𝐻 = 39.1632 𝑠 , ∴ the design is acceptable.
𝑠

E. PLATE PRESSURE DROP

Pressure Drop. Based on Towler and Sinnott (2013), the pressure drop over the plates is

an important design consideration. There are two main sources of pressure loss: that due to vapor

flow through the holes (an orifice loss), and that due to the static head of liquid on the plate.

Maximum Vapor Velocity

𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑟 𝑟𝑎𝑡𝑒

Maximum Vapor Velocity =
𝐴𝐻

𝑚3
647.5805 𝑠
Maximum Vapor Velocity = 2
5.0479 𝑚

𝑚
Maximum Vapor Velocity = 128.2871
𝑠

Using the following data:

𝑝𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 5 𝑚𝑚
=
ℎ𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 5 𝑚𝑚

𝑝𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
=1
ℎ𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟

𝐴𝐻 5.0479 𝑚2
% Perforated Area = 𝐴 x 100 = 50.4788 𝑚2 x 100
𝑃 = 𝐴𝐴

% Perforated Area = 10%

The orifice coefficient, CO is equals to 0.84.

 Discharge Coefficient, Sieve Trays

Dry Plate Drop. The pressure drop through the dry plate can be estimated using

expressions derived for flow through orifices that is shown below.

𝜐𝐻 𝜌𝑣
HD = 51 ( )2 ( )
𝐶𝑂 𝜌𝐿

𝑚 𝑘𝑔
128.2871 0.0914
𝑠 2 𝑚3
HD = 51 ( ) ( 𝑘𝑔 )
0.84 989.1895 3
𝑚

HD = 109.9118 mm
 Residual Head. The residual head can be calculated using the equation presented by Hunt,

Hanson and Wilke as stated by Towler and Sinnott (2013).

12.5 𝑥 103
HR = ( )
𝜌𝐿

12.5 𝑥 103
HR = ( 𝑘𝑔 )
989.1895
𝑚3

HR = 12.6366 mm

Total Pressure Drop. The total pressure drop can be calculated by getting the sum of dry

plate, residual head and the initial head.

HT = HD + (HW + HOW) + HR

HT = 109.9118 mm + (50 mm + 7.5545 mm) + 12.6366 mm

HT = 180.1029 mm ≈ 1747.7095 Pa

Downcomer Pressure Loss, HAP. It is the height of bottom edge of apron above the plate.

This is usually set as 5 to 10 mm below the outlet weir based on Towler and Sinnott (2013).

HAP = HW – 10 mm

HAP = 50 mm – 10 mm

HAP = 40 mm

Clearance Area under Apron, AAP

AAP = lW x HAP

40
AAP = 7.081 m x 1000 m
 AAP = 0.2832 m2

Headloss in Downcomer, HDC

𝐿𝑤
HDC = 166 ( )2
𝜌𝐿 𝑥 𝐴𝐴𝑃

𝑘𝑔
219424.6777 𝑥 1 ℎ𝑟
ℎ𝑟 3600 𝑠 2
HDC = 166 ( 𝑘𝑔 )
(989.1895 3 )(0.2832 𝑚2 )
𝑚

HDC = 7.8583 mm

Downcomer Backup, HB. The downcomer area and plate spacing must be such that the

level of the liquid and froth in the downcomer is well below the top of the outlet weir on the plate

above. If the level rises above the outlet weir the column will flood.

HB = HT + (HW + HOW) + HDC

Downcomer Backup

HB = 180.1029 mm + (50 mm + 7.5545 mm) + 7.8583 mm

HB = 245.5157 mm
 According to Towler and Sinnott (2013), the downcomer backup must be less than the half

of the summation of plate spacing and weir length.

For checking,

1
HB < 2 (plate spacing + weir length)

1
245.5157 mm < 2 (600 mm + 7081 mm)

245.5157 mm < 3840.5 mm ∴ the design is acceptable.

Residence Time. According to Towler and Sinnott (2013), sufficient residence time must

be allowed in the downcomer for the entrained vapor to disengage from the liquid stream to prevent

heavily “aerated” liquid being carried under the downcomer. A time of at least 3 seconds is

recommended. A time at least 3 seconds is recommended.

𝐴𝐷 𝐻𝐵 𝜌𝐿
TR = 𝐿𝑊

𝑘𝑔
(7.9703 𝑚2 )(0.2455)(989.1895 )
𝑚3
TR = 𝑘𝑔 1 ℎ𝑟
219424.6777 𝑥
ℎ𝑟 3600 𝑠

TR = 31.596 s

Since TR = 31.596 s > 3s, ∴ the design is acceptable.

Percent Flooding. According to Towler and Sinnott (2013), the percent flooding must be

less than 85%.

𝜐𝑉
% Flooding = 𝜐 x 100%
𝑓,𝐵𝑂𝑇
 𝑚3
647.5805 𝑠
58.4491 𝑚2
% Flooding = 𝑚 x 100%
13.0346 𝑠

% Flooding = 84.9999%

Since % Flooding = 84.9999% ≤ 85%, ∴ the design is acceptable.

F. PLATE LAYOUT

Entrainment. According to Towler and Sinnott (2013), the entrainment can be estimated

from the correlation given by Fair that gives the fractional entrainment ψ (kg/kg gross liquid flow)

as a function of the liquid-vapor factor FLV, with the percentage approach to flooding as a

parameter.

Using the following data:

FLV-TOP = 0.01271

FLV-BOT = 0.009899

% Flooding = 84.9999% ≈ 90%

The entrainment correlation, ψ for FLV-TOP and FLV-BOT are 0.3 and 0.32, respectively.
 Entrainment Correlation for Sieve Plates

Perforated Area. The area available for perforation will be reduced by the obstruction

caused by structural members (the support rings and beams), and by the use of calming zones.

Calming zones are unperforated strips of plate at the inlet and outlet sides of the plate. The width

of each zone is usually made the same; the recommended values are: below 1.5 m diameter, 75

mm; above, 100 mm. The width of the support ring for sectional plates will normally be 50 to 75

mm. The support ring should not extend into the downcomer area (Towler and Sinnott, 2013).
 Relation Between Angle Subtended by Chord, Chord Height and Chord Length

Using the following data:

𝑙𝑊 7.0810 𝑚
= = 0.77
𝐷𝐶 9.1961 𝑚

Based from the graph, 𝜃𝐶 = 100o

Angle Subtended by the Edge of the Plate

𝜃 = 180o - 100o = 80o

Mean Length of Unperforated Edge Strips

𝜃
LMU = (DC – HD) (𝜋) (180)

80
LMU = (9.1961 m – 0.005 m) (𝜋) (180) = 12.8332 m

Area of Unperforated Edge Strips

AMU = HD x LMU
 AMU = 0.005 m x 12.8332 m = 0.06417 m2

Mean Length of Calming Zones

LMC = lw+ width of unperforated strips

LMC = 7.0810 m + 0.05 m = 7.131 m

0.7131 m2Area of Calming Zones

AMC = 2 x LMC x width of unperforated strips

AMC = 2 x 7.131 m x 0.05 m = 0.7131 m2

Total Area of Perforation

AP = 𝐴𝐴 - AMU - AMC

AP = 50.4788 m2 -0.06417 m2 - 0.7131 m2 = 49.7015 m2

Hole Pitch. It is the distance between the hole centers wherein it should not be less than

2.0-hole diameters, and the normal range will be 2.5 to 4.0 diameters. Within this range, the pitch

can be selected to give the number of active holes required for the total hole area specified. Square

and equilateral triangular patterns are used in which triangular is the most preferred. To determine

the hole pitch, lP, there are two methods.

Method 1: Mathematical Approach

𝐴𝐻 𝐷
= 0.9 ( 𝑙 𝐻)2
𝐴𝑃 𝑃

5.0479 𝑚2 𝐷𝐻
= 0.9 ( )2
49.7015 𝑚2 𝑙𝑃
 𝑙𝑃
= 2.9768, it is acceptable since it is within the normal range.
𝐷𝐻

𝑙𝑃 = 2.9768 (0.005 m)

lP = 0.01488 m

Method 2: Graphical Approach

Relation Between Hole Area and Pitch

Using the following data:

𝐴𝐻 5.0479 𝑚2
= = 0.10156
𝐴𝑃 49.7015 𝑚2

The hole pitch over the hole diameter is approximately equals to 2.85 wherein it is in the

normal range of 2.5-4.0 diameters.

𝑙𝑃
= 2.85
𝐷𝐻
 𝑙𝑃 = 2.85 (0.005 m)

𝑙𝑃 = 0.01425 m

Hole Area, AHA

𝜋
AHA = DH2
4

𝜋
AHA = (0.005 m)2
4

AHA = 0.000019635 m2

Number of Holes

𝐴𝐻
No. of holes =
𝐴𝐻𝐴

5.0479 𝑚2
No. of holes =
0.000019635 𝑚2

No. of holes = 257086.8347

G. VESSEL SPECIFICATIONS

Corrosion Allowance. Based on Towler and Sinnott (2013), the corrosion allowance is

the additional thickness of metal added to allow for material lost by corrosion and erosion, or

scaling. The ASME BPV Code Sec. VIII D.1 states that the vessel user shall specify corrosion

allowances. The allowance should be based on experience with the material of construction under

similar service conditions to those for the proposed design. For carbon and low-alloy steels, where

severe corrosion is not expected, a minimum allowance of 2.0 mm should be used; where more

severe conditions are anticipated this should be increased to 4.0 mm (Towler and Sinnott, 2013).
 Maximum Allowable Stress. Using the table shown below from ASME BPV Code Sec.

VIII D.1, the maximum allowable stress for the material, Carbon Steel A285, is 12.9 ksi (12900

psi) at 121.11 ℃ (250 ‫ﹾ‬F).

Maximum Allowable Stress

Maximum Allowable Joint Efficiency. Another table is presented below to determine the

equivalent joint efficiency which is needed for the determination of minimum wall thickness.

Based on the figure shown below, the joint efficiency is generally 0.85 (Towler and Sinnott, 2013).

Maximum Allowable Joint Efficiency

 Minimum Wall Thickness. The minimum wall thickness is required to ensure that any

vessel is sufficiently rigid to withstand its own weight, and any incidental loads. Using the equation

shown below which is stated by the ASME BPV Code Sec. VIII D.1 from Towler and Sinnott

(2013), the minimum wall thickness can be calculated.

As general guide, the wall thickness of any vessel includes a corrosion allowance. In this

case, the corrosion allowance is 4 mm. It is also stated that the minimum wall thickness should not

be less than that calculated by the following formulas:

PD
tmin(1) = 2𝑆𝐸−1.2𝑃

PD
tmin(2) = 4𝑆𝐸+0.8𝑃

where: P – Internal Design Pressure

D – Inside Diameter

S – Maximum Allowable Stress

E – Joint Efficiency

(19.145 psi) (9196.1 mm)

tmin(1) =
2 (12900 psi)(0.85) −1.2 (19.145 psi)

tmin(1) = 8.0367 mm

(19.145 psi) (9196.1 mm)

tmin(2) =
4 (12900 psi)(0.85)+0.8 (19.145 𝑝𝑠𝑖 )

tmin(2) = 4.0127 mm
 Since tmin(1) is greater than tmin(2), the thickness of the reactor that will be used for is

tmin(1) = 8.0367 mm. This is based from Towler and Sinnott (2013) which stated that the highest

computed tmin must be the preferred thickness of the vessel.

Considering the corrosion allowance,

tactual = tmin(1) + Corrosion Allowance

tactual = 8.0367 mm + 4.0 mm

tactual = 12.0367 mm

Outside Diameter

Dout = Din + 2tactual

Dout = 9196.1 mm+ 2 (12.0367 mm)

Dout = 9220.1734 mm ≈ 9.22 m

Design of Head and Closure. The principal types used for the design are flat plates,

hemispherical, ellipsoidal and tori spherical heads. The highest thickness will be the preferred type

of heading that will be used (Towler and Sinnott, 2013).

Head Types

Hemispherical Heads:

PD
t=
4𝑆𝐸−0.4𝑃

(19.145 psi) (9196.1 mm)

t=
4(12900 psi)(0.85) −0.4 (19.145 psi)

t = 4.0148 mm

Ellipsoidal Heads:

PD
t=
2𝑆𝐸−0.2𝑃

(19.145 psi) (9196.1 mm)

t=
2 12900 psi)(0.85) −0.2(19.145 psi)
(

t = 8.0296 mm
 Tori Spherical Heads:

0.885PD
t=
𝑆𝐸−0.1𝑃

0.885 (19.145 psi) (9196.1 mm)

t=
(12900 psi)(0.85) −0.1(19.145 psi)

t = 14.2125 mm

Comparing the thickness calculated for the three head types, Tori Spherical Head has a

greater thickness than the other two types such as hemispherical and ellipsoidal head. Therefore,

this is the preferred head type for the vessel. It is stated by Towler and Sinnott (2013) that the

standard Tori Spherical Head are the most commonly used for vessels with a standard operating

pressure of 15 bar.

Head and Closure Thickness. To calculate the thickness of the head, the formula that will

be used is:

0.885P𝑅𝑐
t=
𝑆𝐸−0.1𝑃

where, P – Internal Design Pressure

𝑅𝑐 – Crown Radius = Inside Diameter

S – Maximum Allowable Stress

E – Joint Efficiency (E= 1, no joint)

 0.885 (19.145 psi) (9196.1 mm)
t=
(12900 psi)(1) −0.1(19.145 psi)

t = 12.0803 mm

Vessel Supports. The design to support a vessel will depend on the size, shape and weight

of the vessel and also, the design temperature and pressure. Thus, the vessel location, arrangement

and the internal and external fittings and attachments. Skirt supports are recommended for vertical

vessels as they do not impose concentrated loads on the vessel shell; they are particularly suitable

for use with tall columns subject to wind loading as the support is equally strong in all directions.

(Towler and Sinnott, 2013). As shown in the figure below, the skirt may be: (a) welded to the

bottom head of the vessel, (b) welded flush with the shell or (c) welded to the outside of the vessel

shell. It is said that the arrangement (b) is usually preferred.

Skirt Support Welds