MASS TRANSFER EQUIPMENT—GENERAL ASPECTS 479

. What are the considerations involved in recommending
tray spacing for different operating pressures?
& Spacing involves optimization of column height and
diameter.
& With larger tray spacing, the column height in-
& Cross-flow trays are much more common in com-
mercial practice than counterflow trays because of
their higher separation efficiency, wider operating
range and lower costs.
& Parallel-flow trays, if properly designed, can provide

creases, while the required diameter decreases. higher efficiency that can be higher by 10% or more.
& As the column diameter increases, the ratio of weir
& Height/diameter ratios more than 25–30 are gener-

ally not recommended. length to throughput decreases. Moreover, as the

& The purpose of tray spacing is to remove entrainment
column diameter increases, the liquid load increases
of liquid droplets from rising vapors (For high-pres- faster than the vapor load and the columns and trays
sure columns it is easy to remove entrainment com- begin having difficulty handling the flow of liquid,
pared to vacuum columns.), provide for accessibility which restricts column capacity.
& For larger diameter columns, multipass trays, that
(Providing for man holes, nozzles, etc.), avoiding/
reducing flooding, foam carryover, and so on. split the load, are often used for better liquid distri-
& Tray spacings are in the range of 450–900 mm.
bution. This allows half the liquid to go one way and
& Recommended tray spacings for the following ap-
half to move the other, which reduces the liquid load.
& If the load is still too large, the trays can be split again
plications (Table 16.1).
into a four-pass tray, but it can become problematic
. “Tray spacing at a distillation column feed point should
because in one or two passes, there is good level of
be more than normal spacing if vapor–liquid mixture is
symmetry, but in four or more passes, symmetry is
admitted as feed.” Comment.
difficult to obtain.
& Amount of entrainment and velocities and turbulence
& The lack of symmetry causes maldistribution, which
involved will be more than normal, requiring larger
occurs when the liquid to vapor ratio on one pass
spacing for disengagement of vapor bubbles from
significantly differs from that of another and causes
liquid portion and de-entrainment of droplets from
the separation process to suffer and efficiency to be
rising vapors.
reduced, sometimes by a large magnitude.
& Feed nozzle is located half way between the two trays
& Dual flow trays are ripple trays, with round slots and
by increasing spacing to one spacing þ diameter of
turbogrid trays with rectangular slots, are not very
the feed nozzle.
common. These have no downcomers.
. Illustrate parallel flow and single pass trays in a distil- . What are the causes for vapor cross-flow channeling on
lation column.
a distillation tray?
& Tray designs can be divided into cross-flow and
& Vapor cross-flow channeling is mainly attributed to
parallel-flow types.
the liquid hydraulic gradients that often occur on
& Figures 16.6 illustrate flow arrangements on trays.

TABLE 16.1 Recommended Tray Spacings

Recommended
Service Spacing (mm) Comments
Based on column pressure
Atmospheric column 600 (24) –
High-pressure column 450 (18) –
Vacuum column 760 (30) –
Based on column diameter
D > 3000 mm >600 (>24) Larger spacing required due to support beams restricting maintenance
access
D ¼ 1200–3000 mm 600 (24) Spacing sufficient for maintenance access
D ¼ 750–1200 mm 450 (18) Easy access to column wall through manways
Fouling and corrosive service >600 (>24) Requirement of frequent maintenance
Highly foaming systems or operation 450 (18) Preferably 600 mm to avoid premature flooding
involving spray regime
Column operation in spray regime 450 (18) Preferably 600 mm to avoid excessive entrainment
Column operating in froth regime <450 (<18) Lower spacing restricts allowable vapor velocity, promoting operation
in froth regime
480 MASS TRANSFER EQUIPMENT

&After selecting the number of passes, the column

diameter is adjusted in order to provide a minimum
path length of 400 mm.
➢ For column diameters less than 1200 mm, single

pass trays should be selected.

➢ For a column diameter of 1200–2100 mm, a max-

imum of two tray passes should be selected.

➢ For a column diameter of 2100–3000 mm, a max-

imum of three tray passes should be selected.

Three pass trays are rarely used because they are
asymmetric and difficult to balance.
➢ For a column diameter above 3000 mm, a maxi-

mum of four tray passes should be selected.

. What is the function of a downcomer?
& The primary function of a downcomer is to convey
liquid from a tray to the one immediately below.
➢ It should provide sufficient residence time for

disengagement of the entrapped vapors in the

liquid being conveyed to the tray below.
. What are the recommended minimum residence times
for liquid in a downcomer?
& Table 16.2 gives recommended minimum residence
times for liquid in a downcomer.
. “Highly foaming liquids require larger residence times
in a downcomer.” True/False?
FIGURE 16.6 Types of flows on distillation trays.
& True. Any significant amount of vapor traveling out

from the downcomer reduces tray capacity and

efficiency.
trays having high liquid rates, long flow path lengths . What are the shapes of cross sections used for
that are mainly the result of large tray diameters, downcomers?
short outlet weirs, elevated tray decks like with & Circular, segmental, or rectangular shapes are used in

bubble cap trays, low dry pressure drops and exces- the downcomer designs.
sive deck resistance. In response to this gradient, . What are the criteria adopted in the selection of liquid
vapor flows preferentially through the tray outlet velocities in a downcomer?
area. & Liquids with minimal foaming tendencies:
& Clear liquid flows across an appreciable portion of
0.12–0.21 m/s.
the tray without any vapor contact and thus do not
participate in the mass transfer process.
& Liquid weeping occurs near the tray inlet. TABLE 16.2 Recommended Minimum Residence Times for
. What are the ways by which high liquid gradients Liquid in a Downcomer
minimized? Minimum
& By the use of increased number of flow passes, high Residence
outlet weirs, use of sieve or low-rise valve decks and Nature of Liquid Time (s)
reduced deck open areas. Bubble cap trays are par- Low foaming liquids (low molecular 3
ticularly prone to excessive gradients since the caps weight hydrocarbons, alcohols)
provide appreciable resistance to liquid flow. Medium foaming liquids (medium mo 4
. What are the criteria in the selection of number of tray lecular hydrocarbons)
passes? High molecular weight hydrocarbons 5
(mineral oil absorbers)
& Number of tray passes should be selected such that
Very high molecular weight 7
the liquid loads do not exceed 70–90 m3/(h m) of weir hydrocarbons (amines and glycols)
length.

& Medium foaming liquids: 0.09–0.18 m/s.
& Highly foaming liquids: 0.06–0.09 m/s.
. What should be the downcomer area in relation to
column cross-sectional area?
& Not less than 5–8% of column cross-sectional area.
Usually it is 5–30% of the column cross-sectional
area, depending on the liquid load.
. What should be the downcomer width in relation to
column cross section?
& Not be less than 10% of the column diameter.
. How is downcomer clearance specified?
& Downcomer clearance should be not less than the
outlet weir height as otherwise, vapor will flow up the
downcomer rather than through the tray deck above.
& The downcomer clearance should be selected such
that the liquid velocity under the downcomer does not
exceed 0.45–0.50 m/s.
. What are the design guidelines with respect to seal
pans?
& The clearance between the seal pan floor and the
bottom downcomer should exceed the clearance
normally used under the tray downcomers. It should
be at least 50 mm.
& The distance that the downcomer extends downward
within the seal pan should be about the same as the
clearance between downcomer bottom and pan
floor.
. What are the design guidelines with respect to weirs?
& Weir heights in the froth regime are restricted to
50–80 mm.
& Weir heights for columns operating in the spray
regime should be 20–25 mm.
& Weir loadings should be within the range of
15–70 m3/(h m) of weir length.
. What is a picket weir? When is it employed?
& Figure 16.7 illustrates schematic of a picket weir.
& Used when liquid flows are small.
. What are the recommended arrangements for the noz-
zles with respect to the bottom section of a distillation
column?
& Inlets for the bottom feed and reboiler return lines
should be at least 300 mm above the high liquid level.
FIGURE 16.7 Picket weir.
MASS TRANSFER EQUIPMENT—GENERAL ASPECTS 481
& The bottom feed and reboiler return should not
impinge on the bottom seal pan, seal pan overflow,
or the bottom downcomer. The tops of both pipes
should be at least 400–450 mm below the bottom
tray.
. “Sieve trays are usually cheaper than valve trays.” True/
False?
& False.
. What are the parameters involved in the evaluation of
tray performance?
& Tray DP depends on slot opening; static and dynamic
slot seals; liquid height over the weir; and liquid
gradient across the tray.
& Downcomer conditions depend on liquid height;
liquid residence time; and liquid throw over the weir
into the downcomer.
& Vapor distribution.
& Entrainment.
& Tray efficiency.
. What are the requisites for the satisfactory performance
of a bubble cap tray?
& Vapor flowing through all the caps.
& Acceptable bubbling action from efficiency point of
view: Neither too low nor excessive.
& To keep entrainment within design limits.
& Prevention of dumping (back flow) of the liquid down
the risers.
& No undesirable vapor jetting (coning) around the
caps. Reduces effective interfacial area.
. Explain liquid throw, coning, blowing, weeping, dump-
ing, raining, and priming in the operation of a distilla-
tion column.
& Liquid Throw: Horizontal distance traveled by the
liquid after flowing over weir.
& Coning: A condition where the rising vapor pushes
liquid back from the top of the hole and passes
upward with poor liquid contact.
& Blowing: A condition where the rising vapor punches
holes through the liquid layer on a tray and usually
carries large drops or slugs to the tray above.
& Weeping:
➢ Defined as vapor rate when weeping becomes first
noticeable.
➢ At low vapor rates (but somewhat higher than the
rates leading to dumping) liquid flows partly
through the holes and partly over the weir.
➢ As vapor rate is decreased below weep point, weep
rate increases with loss of efficiency. A rule of
thumb states that 20% weeping leads to a 10% loss
in efficiency.