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Mass Transfer Lab.

College of Engineering & Petroleum
CHEMICAL ENGINEERING DEPARTMENT

Second Semester 2020/2021

Mass Transfer Operations

Laboratory
(CHE443)
Packed and Bubble Cap Column
Continuous Distillation

Done By:
ID No:
Experiment Date: Submission
Date:
Lab. Supervisor: Prof. Tareq Al-Bahri Lab.
Instructor:
 Lab Report Grading

Topic Grade Out of

1 Title page 1
2 Abstract 5
3 Table of content 1
4 List of Figures 1
5 List of Tables 1
6 Nomenclature 1
7 Introduction 3
8 Theoretical Background 3
9 Experiment Objectives 2
10 Experimental Procedure 2
11 Results including Tables and Graphs 25
12 Discussion 25
13 Conclusions and Recommendations 8
14 References 5
15 Sample calculations 15
17 Neatness 2
Total 100
Abstract:
Distillation is one of the most used types of separation processes that is used in chemical
and petroleum industries, where two or more volatile components are separated. There are
many different types of distillation columns, but in this experiment only the Bubble Cap and
Packed Bed were studied. A mixture of Ethanol and water was used in this experiment to
examine and operate bubble cap and packed bed distillation columns under total and partial
reflux ratio. A comparison was made between the separation efficiencies of both types.
Number of theoretical stages was obtained graphically in this experiment using the McCabe
Thiele Method.
Contents
Abstract:.....................................................................................................................................3
Nomenclature:............................................................................................................................5
Introduction:...............................................................................................................................6
Theoretical Background:............................................................................................................8
Objective:...................................................................................................................................9
Procedure:................................................................................................................................10
Results:.....................................................................................................................................12
Discussion:...............................................................................................................................13
Conclusion and recommendation:............................................................................................14
References:...............................................................................................................................15
Sample calculations:.................................................................................................................16

List of Figures
Figure 1: Schematic diagram of Distillation Column............................................................................6
Figure 2: Flow diagram of combined bubble-cap and packed distillation column.................................7
Figure 3: X –Y Diagram Total Reflux Bubble Cape Colum................................................................10
Figure 4: X –Y Diagram Partial Reflux Bubble Cape Column............................................................11
Figure 5: X –Y Diagram Total Reflux Packed Column.......................................................................12
Figure 6: X –Y Diagram Partial Reflux Packed Column.....................................................................13
Figure 7: Vol% Ethanol in water vs refractive index...........................................................................17
Figure 8: T-xy Diagram for ethanol water system...............................................................................17

List of Tables
Table 1: Efficiency calculation for bubble column at total reflux........................................................11
Table 2: Q re-boiler calculation for bubble column at total reflux.......................................................11
Table 3: Qcondesor calculation for bubble column at total reflux.......................................................11
Table 4: Qloss calculation for bubble column at total reflux...............................................................11
Table 5: Efficiency calculation for bubble column at Partial reflux.....................................................12
Table 6: Q re-boiler calculation for bubble column at Partial reflux....................................................12
Table 7: Qcondesor calculation for bubble column at Partial reflux....................................................12
Table 8: Qloss calculation for bubble column at Partial reflux............................................................12
Table 9: Efficiency calculation for packed column at total reflux.......................................................13
Table 10: Q re-boiler calculation for packed column at total reflux....................................................13
Table 11: Qcondesor calculation for packed column at total reflux.....................................................13
Table 12: Qloss calculation for packed column at total reflux.............................................................13
Table 13: Efficiency calculation for packed column at Partial reflux..................................................14
Table 14: Q re-boiler calculation for packed column at Partial reflux.................................................14
Table 15: Qcondesor calculation for packed column at Partial reflux..................................................14
Table 16: Qloss calculation for packed column at Partial reflux..........................................................14
Table 17: Data Sheet Bubble Tray Column.........................................................................................17
Table 18 : Data Sheet Packed Column.................................................................................................17
Table 19: volume % vs Refractive Index Table...................................................................................18
Table 20: Equilibrium data for ethanol water mixture.........................................................................18
Nomenclature:
NTS Number of theoretical stages
NA Actual number of stages
Eo Overall efficiency of the column
HETS Height equivalent to a theoretical stage

Z Height of the packing in the column (m)

Na Actual number of stages.

𝑀𝑐 Cooling water mass flowrate (kg/s).

𝑀𝑆 Steam mass flowrate (kg/s).

𝑛𝐴 𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑚𝑜𝑙𝑒𝑠(𝑚𝑜𝑙).
𝑛𝐵 𝑊𝑎𝑡𝑒𝑟 𝑚𝑜𝑙𝑒𝑠(𝑚𝑜𝑙).
𝜌 Density (kg/L).
T Temperature (Kelvin).
Mwt Molecular weight (g/mol).
E0 Efficiency.
Q= Heat (kJ/s or kW).
Cp Heat capacity (kJ/kg).
λs Latent heat of vaporization of steam (kJ/kg).

xf Mole fraction of feed.

xd Mole fraction of distillate.
Ps Pressure of steam (bar).
R.I Refractive Index

Introduction:
Distillation is a major commercial process used in the chemical and petroleum industries. It
is a physical separation process used to separate the liquid into different products based on
the difference in volatility (difference in boiling point). There are many types of distillation
columns, some of them are: Bubble-cap, packed bed, ballast trays and perorated (Sieve)
plates. This experiment examines two types of distillation columns Bubble-cap and Packed.
A bubble cap tray has some holes that a riser is fitted in each hole. And the riser is covered
by a cap. The vapor inside will be flowing up through the tower and contacts the liquid by
passing through bubble caps. Then the vapor is turned downward to bubble into the liquid
surrounding. Bubble cap trays cannot weep, this is because of their design. And they cost
more than valve trays and sieve trays. Bubble cap was mounted in a rectifying column that
concentrates the alcohol. Packed columns are commonly found in absorption, distillation,
stripping, heat exchangers and other operations, like removal of dust, mist and odors and for
other purposes. The distillation column contains one feed stream and two product streams.
The feed which is liquid introduced continuously at the midpoint (feed tray) into the column.
The product stream exiting the top is the overhead product (distillate). And the other product
stream leaving is called the bottom. The column has two sections. The top section is referred
to as the rectifying section (enriching). The bottom section is known as the stripping section.

Figure 1: Schematic diagram of Distillation Column

Distillation column operates as follows, the liquid entered through the midpoint flows over
the plates, and vapor bubbles up through the liquid via holes in the plates. As liquid travels
down the column, the vapor comes in contact with it several times due to the multiple plates a
critical process in distillation columns. The liquid and vapor phases are brought into contact
because as one molecule of higher boiling material converts from vapor to liquid phase by
energy release, another molecule of the low boiling material utilizes the free energy to
convert from liquid to vapor phase. The top product stream passes through a total or partial
condenser. This effectively condenses all or portion of the vapor distillate to liquid. The
bottom product stream uses a re-boiler, this allows for the input of energy into the column.

Figure 2: Flow diagram of combined bubble-cap and packed distillation column

Theoretical Background:
Using the McCabe-Thiele diagram, the number of theoretical stages (NTS) can be extracted
using the graphical data. They can also be numerically determined by solving the mass
balance for each stage composition with consideration of two sections including stripping and
enriching sections. After extraction of values of number of theoretical stages, the overall
efficiency can be calculated using:

NTS
Eo = ∗100 (1)
NA

The height equivalent to a theoretical stage (HETS) and height of transfer unit can be used for
analyzing the columns in packed column distillation. If packing height (Z) is known, then
value of height equivalent to theoretical stage can be found using:

Z
HETS= (2)
NTS

The other approach uses differential mass balance, and it is given as:

Gdy=K OG α ( y ¿− y ) dz (3)
2 2
v v
G dy dy
Z= ∫ =G ,∫ ¿ (4)
K OG α v
1
¿
y −y v
y −y
1

Where Z is the height of the packing and G􀀞 is a mass transfer parameter. The integral
maybe evaluated graphically or numerically. Graphically, by calculating the area under the
plot y vs. (y∗ −y) −1, where y is the mole fraction at this stage and y∗ is the “equilibrium”
mole fraction at this stage.
Energy balance will be applied using the following equations:
𝑄𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟= 𝑀 [λ𝑧+𝐶𝑝 (𝑇𝑠−𝑇𝐹)] (5)
TF= TI.4
𝑇𝑠 @ (𝑃𝑠 = 𝑃𝐼.4+1.0132)
𝑀𝑠= Steam flow rate, which was obtained from the volumetric flowrate of steam
𝑄 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟= 𝑀𝑐𝐶𝑝 (𝑇𝑜𝑢𝑡− 𝑇𝑖) (6)
𝑇𝑜𝑢𝑡 = TI.6 (out from the condenser)
𝑇𝑖𝑛 = TI.5 (into the condenser)
𝐶𝑝 @𝑇𝑎𝑣𝑔= [𝑇𝑜𝑢𝑡−𝑇𝑖𝑛 2]
𝑀𝑐 = Cooling water flow rate, which was obtained from the volumetric flowrate of the
cooling water
Objective:
 Examine bubble cap and packed bed distillation columns under total and finite reflux.
 Determine and compare separation efficiencies of bubble cap and pack bed columns.
Procedure: Start-up (Atmospheric operation)
1. The concentration of feed in the re-boiler vessel was ensured that it is correct and the
liquid level was ensured that it is at the vessel equator. (25L of a solution).
a. Valve check list was completed.
b. A bubble cap column was set-up (by closing V13 and V12).
2. Column was set to total reflux condition.
a. Cooling water circuit was start-up.
b. FCV.2 was opened slowly, to prevent a pressure surge to cooling system.
c. Water pressure was not allow to exceed 2.7 bar maximum as indicated by PI.2.
3. Heating circuit was started up.
a. PCV.4 was slowly open to avoid sudden steam surge condensate to re-boiler.
b. V.11 was not closed until steady flow of steam issued from condensate drain.
c. The steam-trap drain hoes was ensured that it was at safely position.
4. The re-boiler temperature was set to approximately 90 C.
a. The return line of product distillate to the re-boiler vessel was kept open.
Sampling and readings:
1. Equilibrium was allowed to be established and the values of temperatures, flowrates.
2. A sample was collected from the distillate by opening the sample valve; then the
refractive index of the sample taken was determined.
3. The reflux control valve, RCV.1 was adjusted to obtain the desired reflux ratio, which
is the ratio of rotameter scale readings.
4. The value of temperature indicators, flow meters and reflux indicators were recorded.
5. A sample from distillate was collected, then its R.I was determined.
a. V2 was closed, and timing was started.
b. Timing was stopped when the distillate approach the top graduation.
c. V2 was opened
Set-up for the packed column:
1. Cooling water ensured that passing through a packed-column overhead condenser.
a. The reflux flow valve was set to the packed column.
b. V13 was opened and V12 was closed.
2. The steps in the sampling and reading section were repeated
Results:
Bubble Cape Column Total Reflux Calculations
Table 1: Efficiency calculation for bubble column at total reflux

Bubble Cape Column at Total Reflux

Xd NTS Eo
0.4186 2.402 30.025%

Table 2: Q re-boiler calculation for bubble column at total reflux

Bubble Cape Column at Total Reflux

Tf Ms Ps Ts ᴥ Tavg Cp
(K) (bar) (K) (KJ) (K) (KJ/Kg.K)
(kg /s )
367 8.844*10^-4 1.6632 385.628 2217.47 376.314 4.22

Table 3: Qcondesor calculation for bubble column at total reflux

Tout Mc Ts Tavg Cp Qc
(K) (K) (K) (KJ/Kg.K) (KJ/s)
(kg /s )
285.4 0.141 280 282.7 4.19296 3.192

Table 4: Qloss calculation for bubble column at total reflux

Time(min) Qc(KJ/s) Qr(KJ/s) Qloss(KJ/s)

5 3.192 0.02037 3.21237
10 3.192 0.02037 3.21237
15 3.192 0.02037 3.21237
1.2

0.8

0.6
Y

0.4

0.2

0
0 0.2 0.4 0.6 0.8 1 1.2
X

Figure 3: X –Y Diagram Total Reflux Bubble Cape Colum

Bubble Cape Column Partial Reflux Calculations
Table 5: Efficiency calculation for bubble column at Partial reflux

Bubble Cape Column at Total Reflux

Xd NTS Eo
0.4486 2.213 27.66%

Table 6: Q re-boiler calculation for bubble column at Partial reflux

Bubble Cape Column at Partial Reflux

Tf Ms Ps Ts ᴥ Tavg Cp
(K) (bar) (K) (KJ) (K) (KJ/Kg.K)
(kg /s )
367 8.844*10^-4 1.6632 385.628 2217.47 376.314 4.22

Table 7: Qcondesor calculation for bubble column at Partial reflux

Tout Mc Ts Tavg Cp Qc
(K) (K) (K) (KJ/Kg.K) (KJ/s)
(kg /s )
286.2 0.141 280 283.1 4.1954 3.6807
 1.2

0.8

0.6
Y

0.4

0.2

0
0 0.2 0.4 0.6 0.8 1 1.2
X

Table 8: Qloss calculation for bubble column at Partial reflux

Time(min) Qc(KJ/s) Qr(KJ/s) Qloss(KJ/s)

5 3.6807 0.02037 3.8222
10 3.6807 0.02037 3.8222
15 3.6807 0.02037 3.8222

Packed Column Total Reflux Calculations

Figure 4: X –Y Diagram Partial Reflux Bubble Cape Column

Table 9: Efficiency calculation for packed column at total reflux

Packed Bed Column at Total Reflux

Xd NTS Eo
0.4809 2.712 36.87%

Table 10: Q re-boiler calculation for packed column at total reflux

Bubble Cape Column at Total Reflux

Tf Ms Ps Ts ᴥ Tavg Cp
(K) (bar) (K) (KJ) (K) (KJ/Kg.K)
(kg /s )
367 8.844*10^-4 1.6632 385.628 2217.47 376.314 4.22

Table 11: Qcondesor calculation for packed column at total reflux

Tout Mc Ts Tavg Cp Qc
(K) (K) (K) (KJ/Kg.K) (KJ/s)
(kg /s )
286.8 0.141 280 283.4 4.1953 4.0366

Table 12: Qloss calculation for packed column at total reflux

Time(min) Qc(KJ/s) Qr(KJ/s) Qloss(KJ/s)

 5 4.0366 0.02037 4.1775
10 4.0366 0.02037 4.1775
15 4.0366 0.02037 4.1775

1.2

0.8

0.6
Y

0.4

0.2

0
0 0.2 0.4 0.6 0.8 1 1.2
X

Figure 5: X –Y Diagram Total Reflux Packed Column

Packed Column Partial Reflux Calculations

Table 13: Efficiency calculation for packed column at Partial reflux

Packed Bed Column at Partial Reflux

Xd NTS Eo
0.5153 3.13 31.94%

Table 14: Q re-boiler calculation for packed column at Partial reflux

Bubble Cape Column at Partial Reflux

Tf Ms Ps Ts ᴥ Tavg Cp
(K) (bar) (K) (KJ) (K) (KJ/Kg.K)
(kg /s )
367 8.844*10^-4 1.6632 385.628 2217.47 376.314 4.22

Table 15: Qcondesor calculation for packed column at Partial reflux

Tout Mc Ts Tavg Cp Qc
(K) (K) (K) (KJ/Kg.K) (KJ/s)
(kg /s )
287.2 0.141 280 283.6 4.1951 4.274
Table 16: Qloss calculation for packed column at Partial reflux

Time(min) Qc(KJ/s) Qr(KJ/s) Qloss(KJ/s)

5 4.274 0.02037 4.2943
10 4.274 0.02037 4.2943
15 4.274 0.02037 4.2943

1.2

0.8

0.6
Y

0.4

0.2

0
0 0.2 0.4 0.6 0.8 1 1.2
X

Figure 6: X –Y Diagram Partial Reflux Packed Column

Discussion:
In given experiment analysis ethanol mole segment in topmost distillate in total reflux
is lower than partial reflux in pack bed column and bubble tray column which can be
evaluated in above result section. The most important point that should be consider is the
efficiency of packed bed column is higher than bubble cap column in both scenario total
reflux as well as partial reflux case. The heat loss factor in case of packed bed column higher
then bubble cap distillation column. Requirement of heat duty for operation of condenser at
total reflux is lower than for operating at partial reflux load in bubble cap as well as packed
bed column.

Conclusion and Recommendation:

The given experiment is done to compute NTS Steps by means of Macabe Thelie
Method to examination working efficiency of bubble cape distillation train column as well as
packed bed distillation train for ethanol-water combination parting by means of entire reflux
and partial reflux circumstances. Observe that packed train column has great efficiency then
as comparison of bubble cape train column. After that heat duties of condenser and re-boiler
are calculated to integrate calculations for heat loss for packed bed train column and bubble
cap train column which shows heat loss for partial reflux heat load is higher than total reflux
heat load loss.

Mistakes & Comments:

Mistakes

 Weeping: At some point the normal fluid rate of flow is less as compare to liquid in
purification train column
 Loading: this is condition when liquid flow rate is lower than the vapor flowrate in
functional purification train in between down comer and space.
 Flooding: is phenomena when liquid flow rate is too low as compare to vapor flow
rate cause not to flow liquid down side from tray/bed in column.

Comments

 There should be correct keep up flow rates of liquid and vapor in given operating
parameters of operating purification train column to avoid cause of flooding and
weeping problems during time of process operation.
 Process equipment may habitually upkeep and examination to improve performance
of apparatus through performing experimentations
References:
[1] J. M. Coulson, J. F. Rihardson, J. R. Backhurst, and J. H. Harker. Particle Technology
and Separation Processes, volume 2 of Chemical Engineering. Pergamon, Oxford, 4th
edition, 1991.
[2] C. J. Geankoplis. Transport Processes and Unit Operations. McGraw Hill, New York,
3rd edition, 1993.
[3] W. L.McCabe, J. C. Smith, and P. Harriott. Unit Operations of Chemical Engineering.
McGraw-Hill, 5th edition, 1993.
[4] P. C. Wankat. Equilibrium Staged Separations. Elsevier, New York, 1988.
[5] http://www.srsengineering.com/our-products/distillation-columns/how-columns-
work/#:~:text=The%20distillation%20column%20is%20made,via%20holes%20in
%20the%20plat
Appendices:
A.1 Data Sheet:
Table 17: Data Sheet Bubble Tray Column
Bubble Tray Column Total Partial
Reflux Reflux
Time (min) 5 10 15 5 10 15
TI.1 (oC) 78.0 78.0 78.0 78.0 78.0 79.0
o
TI.1A ( C) 79.6 79.6 79.6 79.8 79.8 80.0
o
TI.1B ( C) 80.1 80.1 80.1 80.1 80.1 80.0
TI.2 (oC) 80.2 80.2 80.2 80.8 81.0 81.0
o
TI.2A ( C) 80.2 80.2 80.2 81.0 81.0 81.0
o
TI.2B ( C) 79.9 79.9 79.9 80.5 80.5 80.5
o
TI.2C ( C) 80.0 80.0 80.0 85.0 84.5 84.5
o
TI.2D ( C) 79.5 79.5 79.5 84.4 84.6 84.6
o
TI.2E ( C) 81.2 81.2 81.2 87.2 87.2 87.2
o
TI.2F ( C) 81.0 81.0 81.0 87.0 86.8 87.0
TI.3 (oC) 87.0 87.0 87.0 89.0 89.0 89.0
o
TI.4 ( C) 94.0 94.0 94.0 94.0 94.0 94.0
Water PI.2 (bar) 0.9 0.9 0.9 0.9 0.9 0.9
Water FI.2 (L/min) 8.5 8.5 8.5 8.5 8.5 8.5
o
CW In TI.5 ( C) 7.0 7.0 7.0 7.0 7.0 7.0
o
CW Out TI.6 ( C) 12.4 12.4 12.4 13.2 13.2 13.2
Steam PI.4 (bar) 0.65 0.65 0.65 0.65 0.65 0.65
Reflux Ratio (RA/RB) 2.4
Refractive Index (R.I.) 1.363 1.3632

Table 18 : Data Sheet Packed Column

Packed Column Total Partial
Reflux Reflux
Time (min) 5 10 15 5 10 15
o
TI.1 ( C) 78 78 78 78.8 79 79
o
TI.2 ( C) 79.9 80 80 80 80 80
o
TI.3 ( C) 84 84 84 87 87 87
o
TI.4 ( C) 94 94 94 94 94 94
Water PI.2 (bar) 0.9 0.9 0.9 0.9 0.9 0.9
Water FI.2 (L/min) 8.5 8.5 8.5 8.5 8.5 8.5
o
CW In TI.5 ( C) 7 7 7 7 7 7
o
CW Out TI.6 ( C) 13.8 13.8 13.8 14.2 14.2 14.2
Steam PI.4 (bar) 0.65 0.65 0.65 0.65 0.65 0.65
Reflux Ratio (RA/RB) 2.4
Refractive Index (R.I.) 1.3634 1.3636
Feed Refractive Index 1.337
(R.I.)
Tair (oC) 25
 Steam Flow Rate (ml/min) 90
Table 19: volume % vs Refractive Index Table

Figure 7: Vol% Ethanol in water vs refractive index

1 Table 20: Equilibrium data for ethanol water

mixture
0.9
Temperatur
0.8 Mole fraction of ethanol
X Y
0.7
e 0C
composition

0.6 100 0 0
0.598.1 0.0079 0.0851
0.4
95.2 0.0202 0.1659
91.8 0.0417 0.3036
0.387.3 0.0891 0.4273
0.2 84 0.1436 0.4929
0.183.2 0.2069 0.5347
82 0.2813 0.5685
0
7581 80 0.369985 0.6013
90 95 100 105
80.1 0.4773 0.6438
79.1 0.6102 Temperature
0.7028
78.3 0.7788 0.8022
78.2 0.8598 x 0.864
y
78.1 0.9038 0.9015
78.2 0.9504 0.9456
78.3 1 1
A.2 Sample Calculations

Calculations for Feed Composition

Figure 8: T-xy Diagram for ethanol water system
Refractive Index= R.I =1.337

From Table 3

Two point formula

 (1.3323-1.337)/(1.3388-1.337)=(0-x)/(10-x)

x= 7.23 % ethanol in water by volume

7.23% by volume ethanol

92.77 % by volume water

Take 100ml Volume Basis

Volume of Ethanol= 100*0.0723=7.23 ml

Volume of Water= 100-7.23=92.77 ml

Density of ethanol pure= 0.789 g/ml

Mass of ethanol=7.23*0.789=5.7044 g

Density of water= 1 g/ml

Mass of water=92.77*1=92.77 g

M.W. of water= 18 g/mol

M.W. of ethanol= 46 g/mol

Moles of ethanol= 5.7044/46=0.124 mol

Moles of water= 92.77/18= 5.153 mol

Total moles= 5.277 mol

Mol fraction of ethnol= Xethanol= 0.124/5.277=2.35%

Mol fraction of water= Xwater=97.65%

Calculations Bubble Cap Colum (Total Reflux)

As R.I = 1.363
 From table 3

x= 70 % ethanol in water by volume

70 % by volume ethanol

30 % by volume water

Density of ethanol pure= 0.789 g/ml

Take 100ml Volume Basis

Volume of Ethanol= 100*0.7=70 ml

Volume of Water= 100-70=30 ml

Density of ethanol pure= 0.789 g/ml

Mass of ethanol=70*0.789=55.23 g

Density of water= 1 g/ml

Mass of water=30*1=30 g

M.W. of water= 18 g/mol

M.W. of ethanol= 46 g/mol

Moles of ethanol= 55.23/46=1.2 mol

Moles of water= 30/18= 1.667 mol

Total moles= 2.8667 mol

Mol fraction of ethnol= Xethanol= 1.2/2.8667=0.4186

Mol fraction of water= Xwater=1-0.4186 =0.5814

Using McCabe–Thiele by using graph 3

 NTS= 2.402

Nactual= 8

E0= (NTS/ Nactual)*100

E0= (2.402/ 8)*100

E0= 30.025%

Calculations Bubble Cap Colum (Partial Reflux)

As R.I =1.3632

From Table 3

Wt% R.I

70 1.3630

80 1.3638

Two point formula

(1.3630-1.3632)/(1.3638-1.3632)=(70-x)/(80-x )

x= 72.5% ethanol in water by volume

72.5% by volume ethanol

27.5% by volume water

Take 100ml Volume Basis

Volume of Ethanol= 100*0.725=72.5 ml

Volume of Water= 100-72.5=27.5ml

Density of ethanol pure= 0.789 g/ml

 Mass of ethanol=72.5*0.789=57.2025 g

Density of water= 1 g/ml

Mass of water=27.5*1=27.5 g

M.W. of water= 18 g/mol, M.W. of ethanol= 46 g/mol

Moles of ethanol= 57.2025/46=1.243 mol

Moles of water= 27.5/18= 1.5277 mol

Total moles= 2.7707 mol

Mol fraction of ethnol= Xethanol= 1.243/2.7707=0.4486

Mol fraction of water= Xwater=1-0.4486 =0.5514

Using McCabe–Thiele graph 4

NTS= 2.213, Nactual= 8

E0= (NTS/ Nactual)*100

E0= (2.213/ 8)*100= 27.66%

Calculations Packed Bed Colum (Total Reflux)

As R.I =1.3634

From Table 3

Two point formula

(1.3634-1.3630)/(1.3638-1.3630)=(x-70)/(80-70)

x= 75 % ethanol in water by volume

75 % by volume ethanol
25 % by volume water

Take 100ml Volume Basis

Volume of Ethanol= 100*0.75=75 ml

Volume of Water= 100-75=25ml

Density of ethanol pure= 0.789 g/ml

Mass of ethanol=75*0.789=59.175 g

Density of water= 1 g/ml

Mass of water=25*1=25 g

M.W. of water= 18 g/mol

M.W. of ethanol= 46 g/mol

Moles of ethanol= 59.175/46=1.286 mol

Moles of water= 25/18= 1.388 mol

Total moles= 2.674 mol

Mol fraction of ethanol= Xethanol= 1.286/2.674=0.4809

Mol fraction of water= Xwater=1-0.4809 =0.5191

Using McCabe–Thiele graph 5

NTS= 2.712

HETS= Z/NTS= 1.5/2.712= 0.553

E0= (HETS/Z)*100

E0= (0.553/1.5)*100
 E0 = 36.87%

Calculations Packed Bed Colum (Partial Reflux)

As R.I =1.3636

From Table 3

Two point formula

(1.3636-1.3630)/(1.3638-1.3630)=(x-70)/(80-70)

x= 77.5% ethanol in water by volume

77.5% by volume ethanol

22.5% by volume water

Take 100ml Volume Basis

Volume of Ethanol= 100*0.775=77.5 ml

Volume of Water= 100-77.5=22.5ml

Density of ethanol pure= 0.789 g/ml

Mass of ethanol=77.5*0.789=61.147 g

Density of water= 1 g/ml

Mass of water=22.5*1=22.5 g

M.W. of water= 18 g/mol

M.W. of ethanol= 46 g/mol

Moles of ethanol= 61.147/46=1.329 mol

Moles of water= 22.5/18= 1.25 mol

 Total moles= 2.579 mol

Mol fraction of ethanol= Xethanol= 1.329 /2.579 =0.5153

Mol fraction of water= Xwater=1-0.5336 =0.4847

Using McCabe–Thiele graph 6

NTS = 3.13

HETS= Z/NTS= 1.5/3.13= 0.4792

E0= (HETS/Z)*100

E0= (0.4792/1.5)*100

E0 = 31.94%

Calculations for heat duties and losses

For total reflux (Bubble cap tray column)

Mass flow rate of steam=90 ml/min

Ms=90*0.58966*10^-6=0.00053069 kg/min

Ms=0.000008844 kg/min

Qrebolier= (0.00000884)*(2217.47 + (4.22*(385.628-367)

Qrebolier = 0.02037 KJ/s

Qcondensor= McCp(Tout-Tin)

Tout= 12.4

Tin= 7

Cp at Tavg (Tout+Tin)/2

Mc= 8.5 *0.999= 8.4915 Kg/min

Mc = 0.141 kg/s

Qcondensor=(0.141)( 4.19296)( 285.4- 280)

Qcondensor= 3.192kJ/sec

Qloss= Qcondensor + Qrebolier= 3.21237 kJ/sec

For partial reflux condenser (Bubble cap tray column)

Mass flow rate of steam=90 ml/min

Ms=90*0.58966*10^-6=0.00053069 kg/min

Ms=0.000008844 kg/min

Qrebolier= (0.00000884)*(2217.47 + (4.22*(387.628-367)

Qrebolier = 0.02037 KJ/s

Qcondensor= McCp(Tout-Tin)

Qcondensor= McCp(Tout-Tin)

Tout= 13.2

Tin= 7

Cp at Tavg (Tout+Tin)/2

Mc= 8.5 *0.999= 8.4915 Kg/min

= 0.1415 kg/s

Qcondensor=(0.1415)( 4.1954)(286.2- 280)

Qcondensor= 3.6807 kJ/sec

Qloss= Qcondensor + Qrebolier= 3.8222 kJ/sec

Heat balance for packed column (total reflux)

Mass flow rate of steam=90 ml/min

Ms=90*0.58966*10^-6=0.00053069 kg/min

Ms=0.000008844 kg/min

Qrebolier= (0.00000884)*(2217.47 + (4.22*(387.628-367)

Qrebolier = 0.02037 KJ/s

Qcondensor= McCp(Tout-Tin)

Tout= 13.8

Tin= 7

Cp at Tavg (Tout+Tin)/2

Mc= 8.5 *0.999= 8.4915 Kg/min

= 0.1415 kg/s

Qcondensor=(0.1415)( 4.1953)( 286.8- 280)

Qcondensor= 4.036 kJ/sec

Qloss= Qcondensor + Qrebolier= 4.1775 kJ/sec

Heat balance for packed column (partial reflux)

Mass flow rate of steam=90 ml/min

Ms=90*0.58966*10^-6=0.00053069 kg/min

Ms=0.000008844 kg/min

Qrebolier= (0.00000884)*(2217.47 + (4.22*(387.628-367)

Qrebolier = 0.02037 KJ/s

Qcondensor= McCp(Tout-Tin)
Tout= 14.2

Tin= 7

Cp at Tavg (Tout+Tin)/2

Mc= 8.5 *0.999= 8.4915 Kg/min

= 0.1415 kg/s

Qcondensor=(0.1415)( 4.1951)( 287.2- 280)

Qcondensor= 4.274 kJ/sec

Qloss= Qcondensor + Qrebolier= 4.2943 kJ/sec