Distillation

NA Zubir, Dr
Outline
5. Continuous distillation (fractionation)
5.1 Description of process

5.2. Reflux ratio

fgchfhfjfgjf -total reflux, Rmin, Optimum R

5.3. Calculation of theoretical stages

- McCabe-Thiele Method
- Lewis-Sorel Method

5.4. Overall plate efficiency

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 Course
Outcomes
Upon completion of this course, students
should be able to:

i. Apply separation process principles of

unit operation in solving
chemical/environmental engineering
problems (C3).
ii. Explain the solutions of complex
chemical/environmental engineering
problems using separation process
principles (C6).
iii. Explain the solutions of complex
chemical/environment engineering
problem using the principles of
separation process design (C6).

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 Course Learning
Outcomes
Students should be able to:

i. Explain the concept of fractionation

distillation, VLE, reflux ratio, theoretical
stages & overall plate efficiency.
ii. Calculate the equilibrium compositions
and mass flowrates of the outlet
streams, no of stages, reflux ratio of
distillation column for given problems.
iii. Explain the solutions of complex
chemical/environmental engineering
problems using separation process
principles (i.e. distillation).

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Description of fractionation distillation
Example of illustration inside the column

The fractionator consists of

many trays which have holes to
permit the vapor, V which rises
up from the lower tray to bubble
through and mixes with the
liquid, L on the upper tray and
equilibrated, and V and L stream
leave in equilibrium.

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Description of fractionation distillation
Example of illustration inside the column

During the mixing, the vapor will pick up more of component 1

from the liquid while the liquid will be richer with component 2.
As the vapor rises further up, it becomes richer and richer in
component 1 but poorer with component 2.

Conversely, as the liquid falls downwards, it becomes poorer

with 1 but richer in 2.

Thus acquires bottom product and an overhead product of

higher purity in comparison to those obtained by single – stage
simple batch or flash distillation.

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Description of fractionation distillation
Industrial example (3.46 MW) Rmin=1.708
Optimal ratio of R/Rmin = 1.1 to 1.5
R=2.215
(124 kPa)

1/2 = 2.52
(360K)
(133 kPa)
(379 kPa, 419K) Distillation of a binary mixture of benzene and toluene.
0.1 psi/tray
(0.69 kPa/ tray)
Overall tray efficiency = 80%
1/2 = 2.26

(141 kPa)
(2.94 MW)

(395 K)
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Distillation of a binary mixture of benzene and toluene (Seader, 2011). 7
Reflux Ratio (R) Ratio of flow rate of liquid has returned (L) to the distillation
column from reflux drum to the flow rate of the amount of
distillate (D) is removed
R = L/D
1) Total reflux (R =); Min no of stages

Rwwe Frenske eq.

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Reflux Ratio (R)
2) Minimum reflux ratio (Rmin); infinite no of stages

𝑅𝑚𝑖𝑛 𝑥𝐷 − 𝑦 ′
=
𝑅𝑚𝑖𝑛 + 1 𝑥𝐷 − 𝑥 ′

𝑑Rwwe

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Reflux Ratio
3) Optimum reflux ratio (Rop); optimal no of stages

Total R < Rop < Rmin

1.1Rmin - 1.5Rmin

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Calculation of theoretical stages
(McCabe-Thiele Method)
 A mathematical-graphical method to determine the no. of theoretical stages required
in fractionation column for a given separation of binary mixture.

 Assumptions:
Constant-molar overflow

ccccc

Vn+1= Vn =Vn-1= V = constant value

Ln+1= Ln =Ln-1= L = constant value

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Calculation of theoretical stages
(McCabe-Thiele Method)

rectifying/

ccccc

𝐹 =𝐷+𝑊
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𝐹𝑥𝐹 = 𝐷𝑥𝐷 + 𝑊𝑥𝑤 12
Calculation of theoretical stages
(McCabe-Thiele Method)
At boundary:
A. rectifying/ enriching section Overall mass b/ce
𝑉𝑛+1 = 𝐿𝑛 + 𝐷
Component 1 b/ce:
𝑉𝑛+1 𝑦𝑛+1,1 = 𝐿𝑛 𝑥𝑛,1 + 𝐷𝑥𝐷,1
Enriching operating line:
ccccc
𝐿𝑛 𝐷
𝑦𝑛+1,1 = 𝑥𝑛,1 + 𝑥
𝑉𝑛+1 𝑉𝑛+1 𝐷,1
@
𝑅 𝑥𝐷,1
𝑦𝑛+1,1 = 𝑥 +
𝑅 + 1 𝑛,1 𝑅 + 1

Where: R=L/D =reflux ratio =constant

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Calculation of theoretical stages
(McCabe-Thiele Method)
At boundary:
B. Stripping section Overall mass b/ce
𝑉𝑚+1 = 𝐿𝑚 − 𝑊
Component 1 b/ce:
𝑉𝑚+1 𝑦𝑚+1,1 = 𝐿𝑚 𝑥𝑚,1 − 𝑊𝑥𝑤,1
Stripping operating line:
ccccc
𝐿𝑚 𝑊
𝑦𝑚+1,1 = 𝑥 − 𝑥
𝑉𝑚+1 𝑚,1 𝑉𝑚+1 𝑤,1

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Calculation of theoretical stages
(McCabe-Thiele Method)
 The condition of feed stream (F) entering
C. Effect of feed conditions the column determines the relation
between the vapor Vm (stripping section)
and Vn (enriching section) as well as
between Lm and Ln.

 The condition of feed can be quantify numerically

ccccc
𝑞=
Relationship between flows above and below
the feed entrance
as q that can be represented by the following eq.:
ℎ𝑒𝑎𝑡 𝑛𝑒𝑒𝑑𝑒𝑑 𝑡𝑜 𝑣𝑎𝑝𝑜𝑟𝑖𝑧𝑒 1 𝑚𝑜𝑙 𝑜𝑓 𝑓𝑒𝑒𝑑 𝑎𝑡 𝑒𝑛𝑡𝑒𝑟𝑖𝑛𝑔 𝑐𝑜𝑛𝑑𝑖𝑡𝑖𝑜𝑛𝑠
𝑚𝑜𝑙𝑎𝑟 𝑙𝑎𝑡𝑒𝑛𝑡 ℎ𝑒𝑎𝑡 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟𝑖𝑧𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑓𝑒𝑒𝑑
𝐻𝑉 − 𝐻𝐹
=
𝐻𝑉 − 𝐻𝐿
Where:
𝐻𝑉 = entalphy of feed at dew point
𝐻𝐿 = entalphy of feed at boiling point
𝐻𝐹 = entalphy of feed at its entrance condition

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Calculation of theoretical stages
(McCabe-Thiele Method)
C. Effect of feed conditions
Enriching section: Stripping section:
(A) 𝑉𝑛+1 𝑦𝑛+1,1 = 𝐿𝑛 𝑥𝑛,1 + 𝐷𝑥𝐷,1 𝑉𝑚+1 𝑦𝑚+1,1 = 𝐿𝑚 𝑥𝑚,1 − 𝑊𝑥𝑤,1
𝑉𝑛 = 𝑉𝑚 + (1 − 𝑞)𝐹 𝑉𝑛 𝑦 = 𝐿𝑛 𝑥 + 𝐷𝑥𝐷 𝑉𝑚 𝑦 = 𝐿𝑚 𝑥 − 𝑊𝑥𝑤
Subtract enriching op. line from stripping op. line:
𝑉𝑚 − 𝑉𝑛 𝑦 = (𝐿𝑚 −𝐿𝑛 )𝑥 − (𝑊𝑥𝑤 +𝐷𝑥𝐷 ) (C)
ccccc
Hence, q operating line:
(𝐿𝑚 −𝐿𝑛 ) (𝑊𝑥𝑤 +𝐷𝑥𝐷 )
𝑦= 𝑥−
𝑉𝑚 − 𝑉𝑛 𝑉𝑚 − 𝑉𝑛
(B)
𝑞𝐹 𝐹𝑥𝐹
𝐿𝑚 = 𝐿𝑛 + 𝑞𝐹 = 𝑥−
𝑞−1 𝐹 𝑞−1 𝐹
𝑞 𝑥𝐹
Relationship between flows above and below 𝑦= 𝑥−
𝑞−1 𝑞−1
the feed entrance

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Calculation of theoretical stages
(McCabe-Thiele Method)
C. Effect of feed conditions

q operating line:
𝑞 𝑥𝐹 ccccc
𝑦= 𝑥−
𝑞−1 𝑞−1

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Calculation of theoretical stages
(McCabe-Thiele Method)
D. Location of feed tray & number of theoretical stages

ccccc

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Example 3 (multistages distillation)

ccccc

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Example 3 (solution)

ccccc

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Example 3 (solution)

93.5oC

ccccc

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Example 3 (solution)

ccccc

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Calculation of theoretical stages
(Lewis_Sorel Method)
 A mathematical-graphical method to determine the no. of theoretical stages required
in fractionation column for a given separation of binary mixture.

 Assumptions:
Constant-molar overflow

ccccc

Vn+1= Vn =Vn-1= V = constant value

Ln+1= Ln =Ln-1= L = constant value Example of Lewis-Sorel method to

determine no. of theoretical stages
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Calculation of theoretical stages
(Lewis_Sorel Method)
 It governs by:
 Enriching operating line eq.
𝐿𝑛 𝐷
𝑦𝑛+1,1 = 𝑥 + 𝑥
𝑉𝑛+1 𝑛,1 𝑉𝑛+1 𝐷,1
Note:
Ln value depends on reflux ratio ccccc

 Stripping operating line equation

𝐿𝑚 𝑊
𝑦𝑚+1,1 = 𝑥𝑚,1 − 𝑥
𝑉𝑚+1 𝑉𝑚+1 𝑤,1

Note:
Lm value depends on the feed’s condition

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Calculation of theoretical stages
(Lewis_Sorel Method)

 Equilibrium data are used to find the

composition of the vapor above the
liquid, and the operating lines are
used to calculate the composition of ccccc
liquid on the next plate.

Example of Lewis-Sorel method to

determine no. of theoretical stages

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Example 4 (Lewis_Sorel Method)

ccccc

(e) Determine the theoretical number of trays in (d) using the Lewis-Sorel method.
(f) Discuss the findings of both methods (McCabe-Thiele & Lewis-Sorel methods)

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Overall plate efficiency (Eo)
 Ratio of the no. of theoretical or ideal trays needed in an entire tower to the number of actual trays
used.

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑒𝑎𝑙 𝑡𝑟𝑎𝑦𝑠

𝐸𝑜 =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑡𝑟𝑎𝑦𝑠

 Nominal value of Eo  80% ccccc

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 Q&A

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 Thank You

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