Selection of column type: Plate or Packed:

• Packed towers (columns) are also used as the contacting devices for gas absorption, liquid-liquid
extraction and distillation
• The gaseous mixture is allowed to contact continuously with the liquid countercurrently in a packed
column. The liquid flows downward over the packing surface, and the gaseous mixture flows upward
through the space in the packing.
• The performance of the column strongly depends on the arrangement of the packings to provide good
liquid and gas contact throughout the packed bed
• The solute gas is absorbed by the fresh solvent (liquid) entering at the top of the tower where the lean gas
leaves system. The liquid enriched with absorbed solute gas, leaves the column bottom through the exit
port
• In a plate tower, the liquid and gas are contacted in stage-wise manner on the trays; while gas-liquid
contact is continuous in a packed column. There are always some uncertainly to maintain good liquid
distribution in a packed tower. For this reason, it is difficult to accurately estimate the packed tower
efficiency.
• Plate towers exhibit larger pressure drops and liquid holdup at a higher gas flow rate. While, packed
towers are not appropriate for very low liquid flow rates
• Packed column is the preferred choice than a plate column to handle toxic and flammable liquids due to
lower liquid holdup to keep the unit as small as possible for the sake of safety
• Plate columns are normally suitable for fouling liquids or laden with solids. They are easier to clean and
could handle substantial temperature variation during operation
• Packed towers are more suitable for foaming and corrosive services.
• It is easier to make the provision for the installation of internal cooling coils or withdrawal of side streams
from a plate column
Plate Contactors
• The separation of liquid mixtures by distillation depends on differences in volatility between the components.
The greater the relative volatilities, the easier the separation
• Vapour flows up the column and liquid counter-currently down the column. The vapour and liquid are brought
into contact on plates, or packing
• Part of the condensate from the condenser is returned to the top of the column to provide liquid flow above the
feed point (reflux), and part of the liquid from the base of the column is vaporised in the reboiler and returned
to provide the vapour flow.
• In the section below the feed, the more volatile components are stripped from the liquid and this is known as
the stripping section. Above the feed, the concentration of the more volatile components is increased and this
is called the enrichment, or more commonly, the rectifying section.
• Figure -1.a. shows a column producing two product streams, referred to as tops and bottoms, from a single
feed. Columns are occasionally used with more than one feed* and with side streams withdrawn at points up
the column, Figure -1.b. This does not alter the basic operation, but complicates the analysis of the process,
to some extent.
• If the process requirement is to strip a volatile component from a relatively nonvolatile solvent, the
rectifying section may be omitted, and the column would then be called a stripping column.
• In some operations, where the top product is required as a vapour, only sufficient liquid is condensed to
provide the reflux flow to the column, and the condenser is referred to as a partial condenser
• When the liquid is totally condensed, the liquid returned to the column will have the same composition
as the top product. In a partial condenser the reflux will be in equilibrium with the vapour leaving the
condenser.
• Virtually pure top and bottom products can be obtained in a single column from a binary feed, but where
the feed contains more than two components, only a single "pure" product can be produced, either from
the top or bottom of the column. Several columns will be needed to separate a multicomponent feed
into its constituent parts.
• The liquid enters at the top of the column and flows across the tray and then through a downcomer
(cross-flow mode) to the next tray below
• The gas/vapor from the lower tray flows in the upward direction through the opening/holes in the tray to
form a gas-liquid dispersion.
• In this way, the mass transfer between the phases (gas/vapor-liquid) takes place across the tray and
through the column in a stage-wise manner.
Plate contractors
• Plate contractors/ towers are vertical cylindrical columns in which a vertical stack of trays
or plates are installed across the column height.
• The liquid enters at the top of the column and flows across the tray and then through a
downcomer (cross-flow mode) to the next tray below.
• The gas/vapor from the lower tray flows in the upward direction through the
opening/holes in the tray to form a gas-liquid dispersion.
• In this way, the mass transfer between the phases (gas/vapor-liquid) takes place across
the tray and through the column in a stage-wise manner.
Definition of tray areas
The definition of tray areas and its nomenclature illustrated in Figures are followed
throughout the design procedure.
Total tower cross-section area (𝑨𝑻):
The empty tower inside cross-sectional area without trays or downspouts.
Net area (𝑨𝑵) (also called free area):
The total tower crosssectional area (𝐴𝑇) minus the area at the top of the downcomer (𝐴𝐷
T). The net area symbolizes the smallest area available for vapor flow in the inter-tray

spacing.
Bubbling area or active area (𝑨𝑨):
The total tower cross-sectional area minus sum of the downcomer top area(𝐴𝐷𝑇) and
downcomer seal area (𝐴𝐷𝐵)and any other nonperforated areas on the tray. The bubbling
area represents the area available for vapor flow just above the tray floor.
Hole area (𝑨𝒉):
The total area of the perforations on the tray. The hole area is the smallest area available
for vapor/gas passage.
Plate types
Gas and liquid flow across the tray can either be by cross-flow or counter-flow manner
(Figure 7.4). The cross-flow plates are most widely practiced and the three main types
of cross flow plates are: bubble cap, valve and sieve trays with downcomer.
Bubble cap plates
• An enhanced gas-liquid contact can be achieved having
bubble caps on the tray at very low liquid flow rates.
• A bubble cap consists of a riser (also called chimney) fixed
to the tray through a hole and a cap is mounted over the
riser.
• The gas flows up through the riser, directed downward by
the cap through the annular space between riser
and cap. Finally, the gas is dispersed into the liquid.
• A number of slots in the lower part of the cap help in gas
bubble dispersion. Un-slotted types of cap designs are also
common in application.
• Bubble caps are especially suitable for higher turndown
ratio. Turndown ratio is the ratio of maximum operating
vapor rate to the minimum allowable vapor rate, below
which weeping starts.
Valve plates
• Valve trays (or floating cap plate) are the modified design of sieve trays where
relatively large plate perforations are covered by movable caps/valves.
• Valves cover may be round or rectangular. The very common hole diameter is 40 mm
but upto 150 mm are also used.
• The valve lifts up as the vapor flow rate increases and the valve sits over the
perforation at lower flow rate, thus stops the liquid from weeping. Valve trays provide
good vapor-liquid contact at low flow rates (high turndown ratio).
Sieve plate
• The sieve tray (also known as perforated plate) is a flat perforated metal sheet.
• The hole diameter from 1.5 to 25 mm are very commonly used.
• The sieve tray layout is a typical square or equilateral triangular pitch holes.
• The gas/vapor flows upward through the perforation and disperses into the flowing liquid over the plate.
• There is no liquid seal in case of trays without downcomer and the liquid weeps (called weeping) through the
holes at low flow rates, reducing the efficiency of plate.
• For this reason, sieve tray has the lowest turndown ratio. Sieve tray construction is simple and
relatively cheap.
Selection of tray type
• The capacity, efficiency, pressure drop and entrainment of the sieve and valve trays are almost same
• Bubble cap trays have lower capacity and efficiency and but higher pressure drop and entrainment
compared to valve and sieve trays
• The turndown ratio comes in the order of: bubble cap>valve>sieve. However, valve trays have the best
turndown ratio in case of refinery applications
• Sieve trays are the least expensive and suitable for almost all applications
• Valve trays can be considered where the higher turndown ratio is needed
• Bubble cap trays should be used at very low liquid flow rate, which is not achievable
using sieve trays.
Introduction to Multicomponent Distillation
• In industry, most of the distillation processes involve with more than two components. The multi-
component separations are carried out by using the same type of distillation columns, reboilers,
condensers, heat exchangers and so on
• However, some fundamental differences are there which is to be thoroughly understood by the designer.
These differences are from the phase rule to specify the thermodynamic conditions of a stream of
equilibrium.
• In multi-component systems, the same degree of freedom is not achieved because of the presence of
other components. Neither the distillate nor the bottom composition is completely specified.
• The components that have their distillate and bottoms fractional recoveries specified are called key
components. The most volatile of the keys is called the light key (LK) and the least volatile is called the
heavy key (HK). The other components are called non-keys (NK)
• Light no-key (LNK) is referred when non-key is more volatile than the light key, whereas heavy non-key
(HNK) is less volatile than the heavy key.
• Proper selection of key components is important if a multicomponent separation is adequately specified.
Several short-cut methods are used for carrying out calculations in multicomponent systems
• These involve generally an estimation of the minimum number of trays, the estimation of the minimum
reflux rate and the number of stages at finite reflux for simple fractionators. Although rigorous
computational methods are available to solve multi-component separation problems, approximate methods
are used in practice. A widely used approximate method is commonly referred to as the
Fenske-Underwood-Gilliland method.
Estimation of Minimum number of trays: Fenske Equation
• Fenske (1932) was the first to derive an Equation to calculate the minimum number of trays for multi-
component distillation at total reflux. The derivation was based on the assumptions that the stages are
equilibrium stages. Consider a multi-component distillation column operating at total reflux as given by

Estimation of Minimum Reflux: Underwood’s Equation

• In case of multi-component distillation, Rm can be determined by Underwood’s equation. In this method
Rm is determined by solving the following two equations.
Estimation of Numbers of Stages at Finite Reflux: Gilliland Correlation
• Gilliland (1940) developed an empirical correlation to relate the number of stagesN as a finite reflux ratio
L/D to the minimum number of stages and to the minimum reflux ratio.

Applications
• Estimate the minimum number trays of multi-component distillation using Fennskey equation
• Determine the minimum reflux ratio and actual number of trays for multicomponent using Underwood’s
method.
• Calculate number of trays required for multi-component distillation using Gilliland’s method.
A feed 100 kmoles/h of saturated liquid containing 10 mole % LNK, 55 mole % LK, and 35 mole % HK and is
to be separated in a distillation column. The reflux ratio is 1.2 the minimum. It is desired to have a 99.5%
recovery of the light key in the distillate. The mole fraction of the light key in the distillate should be 0.75.
equilibrium data: αLNK = 4.0, αLK = 1.0, αHK = 0.75. Find (i) Minimum number of stages required by Fenske
method (ii) Minimum reflux ratio by Underwood method (iii) Number of ideal stages at R = 1.2 Rmin by Gilliland
method (iv) Also find the number of ideal stages at rectifying section and the stripping section at the
operating reflux ratio and location of feed stage.
A distillation column is to separate 4750 mols/h of feed composed of 37% nbutane, 32% Iso- Pentane, 21% n
Pentane and 10% n-Hexane. The column operates at an average pressure of 2 atm and will produce a
distillate product containing 95 % n-Butane and 5% iso-pentane. The bottom product is allowed to contain no
more than 570 mol/hr of n- butane. Calculate minimum number of theoretical trays required for the separation.
Take average relative volatility of light volatile component with respective heavy component is 2.567. (Use
Fenskey’s equation). Light key component: n-Butane; Heavy key component: Iso-pentane.
Effect of vapor flow conditions on tray design
Flooding consideration
• Excessive liquid buildup inside the column leads to the column flooding condition.
• The nature of flooding depends on the column operating pressure and the liquid to vapor flow ratio. It may
be downcomer backup, spray entrainment or froth entrainment type floodings.
• Higher tray pressure drop due to excessive vapor flow rates holds up the liquid in the downcomer,
increases the liquid level on the plate and leads to downcomer flooding situation.
• The column flooding conditions sets the upper limit of vapor velocity for steady operation. Gas velocity
through the net area at flooding condition can be estimated using Fair’s correlation.

• ρv = vapor density, kg/m3, ρl = liquid density, kg/m3, = liquid surface tension, N/m,
Co= capacity parameter (m/s) can be calculated in terms of plate spacing and flow parameter FLV.

LW=liquid flow rate, kg/s, VW= vpor flow rate, kg/s

The design gas velocities (Vn) are generally 80-85% of Vf for non-foaming liquids and 75% or less for
foaming liquids subject to acceptable entrainment and plate pressure drop.

Sieve tray weeping

• Weeping occurs at low vapor/gas flow rates. The upward vapor flow through the plate perforations
prevents the liquid from leaking through the tray perforation.
• At low vapor flow rates, liquid start to leak/rain through the perforation (called weeping). When none of
the liquid reaches the downcomer at the extreme weeping condition at very low vapor flow rate, it is
called dumping.
• The weeping tendency increases with the increasing fractional hole area and liquid flow rates.
• The vapor velocity at the weep point (where liquid leakage through holes starts) is the minimum value for
stable operation.
• For a chosen hole area, the minimum operating vapor flow velocity (Umin,op) at minimum flow rate for
stable operation should be above weep point vapor velocity. The minimum vapor velocity (Umin) at the
weep point.
• Where, dℎ= hole diameter, mm, ρv= vapor density, kg/m3 (maximum value of vapor density), K2 =
constant (K2) of weep-point correlation depends on the depth of clear liquid (weir crest + weir height) on
the plate. Weir crest (ℎow ) can be determined using the Francis’ weir correlation

• lW = weir length, m, Lm = liquid flow rate over the crest, kg/s, ρl = liquid density, kg/m3,Actual operating
minimum vapor velocity: Umin,op= minimum vapor flow rate/ hole area[m/s] ,
• To avoid weeping: Umin,op > Umin
Liquid entrainment
Entrainment is the phenomena in which liquid droplets are carried by vapor/gas to the tray above.
Therefore, the less volatile liquid components from bottom tray are mixed with liquid having relatively more
volatile materials on the overhead tray. It counteracts the desired mass transfer operation and the plate
efficiency decreases. Entrainment increases with vapor velocity. As a rough guide, the % of liquid
entrainment should be less than 10%.
Tray hydraulic parameters

Total plate pressure drop

All gas pressure drops (ℎ𝑡) are expressed as heads of the clear liquid and ℎ𝑡is given by:

Dry plate pressure drop (𝒉𝒅):

Dry plate pressure drop occurs due to friction within dry short holes. ℎ𝑑can be calculated using following expression
derived for flow through orifices.
Residual gas pressure head (𝒉𝒓):
The residual pressure drop results mainly from the surface tension as the gas releases from a perforation. The
following simple equation can be used to estimate ℎ𝑟 with reasonable accuracy.

Downcomer backup (𝒉𝒃) and downcomer residence time:

The liquid level and froth in the downcomer should be well below the top of the outlet weir on the tray above to
avoid flooding.
The average density of aerated liquid in the dowmncomer can be assumed as 1/2 of the clear liquid density.
Therefore, half of the sum of the plate spacing and weir height should be greater than thedowncomer backup.

Downcomer residence time (𝑡𝑑𝑟𝑡 ) should be sufficient for the disengagement of liquid and vapor in the downcomer
to minimize entrained vapor. The value of 𝑡𝑑𝑟𝑡 >3 s is suggested. Downcomer residence time is given by
Plate Design
Column sizing approximation
• The column sizing is a trial and error calculation procedure, starting with a tentative tray layout.
• The calculation is then revised until an acceptable design is obtained subject to satisfying the tray pressure
drop, weeping, flooding and liquid entrainment limits.
• The column sizing is carried at the tray where the anticipated column loading is the highest and lowest for
each section.
• However, the vapor flow rates have the highest impact on tower diameter.
• For an example, the sizing calculation is performed on the top tray for the above feed section and on the
bottom tray for below feed section, for a single feed distillation column with one top and one bottom
product.
• The tray spacing determines the column height.
• Lower tray spacing is desirable to minimize construction cost by checking against the column
performance criteria.
• The suggested tray spacing (𝑇𝑡) with column diameter is appended below.
Provisional plate design
Column diameter
• The column diameter is determined from the flooding correlation for a chosen plate
spacing.
• The superficial vapor/gas velocity (𝑈𝑛𝑓 ) at flooding through the net area relates to
liquid and vapor densities according to Fair’s correlation .
• 𝐶𝑠𝑏𝑓 is an empirical constant, depends on tray spacing and can be estimated against the
flow parameter (𝐹𝐿𝐺) based on mass flow rate of liquid (𝐿) and vapor (𝑉).
• Typically, the design velocity (𝑈𝑛) through the net area is about 80 to 85% of 𝑈𝑛𝑓 for
non-foaming liquids and 75% or less for foaming liquid depending on allowable plate
pressure drop and entrainment. It is a common practice to have uniform tower diameter
in all sections of the column even though the vapor/gas and liquid loadings are expected
to be different to minimize the cost of construction. The uniformity in tower diameter
may require selecting different plate spacing in different sections of the tower.
Hole diameter,hole pitchand plate thickness
• The plate hole diameters (𝑑ℎ) from 3 to 12 mm are commonly used. The bigger sizes are susceptible to
weeping.
• The holes may be drilled or punched and the plate is fabricated from stainless steel and other alloys than
carbon steel.
• The centre to centre distance between two adjacent holes is called hole pitch (𝐼𝑃).
• Perforations can be arranged in square or equilateral triangular arrays with respect to the vapor/gas flow
direction.
• The normal range of 𝐼𝑃 is from 2.5 to 5 times of 𝑑ℎ.

• Plate thickness (𝑡𝑡) typically varies from 0.2 to 1.2 times of the hole diameter and should be verified by checking
the allowable plate pressure drop.
Weir height and weir length
• The depth of liquid on the tray is maintained by installing a vertical flat
plate, called weir.
• Higher weir height (ℎ𝑤 ) increases the plate efficiency.
• But it increases plate pressure drop, entrainment rate and weeping tendency.
Weir heights from 40 to 90 mm are common in applications for the columns
operating above the atmospheric pressure.
• For vacuum operation, ℎ𝑤=6 to 12 mm are recommended.
• The weir length (𝐿𝑤) determines the downcomer area.
• A weir length of 60 to 80% of tower diameter is normally used with
segmental downcomers.

• The dependency of 𝐿𝑤 on downcomer area is calculated against the

percentage value of
Calming zones
• Two blank areas called calming zone, are provided between the inlet downcomer or inlet
weir and the perforation area, and also between the outlet weir and perforation area.
• Inlet calming zone helps in reducing excessive weeping in this area because of high
vertical velocity of the entering liquid in the downward direction.
• Outlet calming zone allows disengagement of vapor before the liquid enters the
downcomer area.
• A calming zone between 50 to 100mm is suggested.
Stepwise design tray procedure
Iterative tray design approach ([3] page 566) is listed below. The design is performed separately both above feed plate (top
section) and below feed plate (bottom section) for single feed two product distillation column.
Step #1: Determine the number of theoretical plate and vapor and liquid flow-rates separately both in top and bottom
sections.
Step #2: Obtain the physical properties of the system
Step #3: Select a trial plate spacing
Step #4: Estimate the column diameter based on flooding considerations
Step #5: Decide the liquid flow arrangement (reverse, single-pass, or multiple-pass).
Step #6: Make a provisional tray layout including downcomer area, active area, perforated area, hole area and size, weir
height, weir length
Step #7: Check the weeping rate, if not satisfactory go back to step #6 and reselect tray layout
Step #8: Check the plate pressure drop, if too high return to step #6
Step #9: Check downcomer back-up, if too high go back to step #6 or #3
Step #10: Decide plate layout including calming zones and unperforated areas and check hole pitch, if unsatisfactory return
to step #6
Step #11: Recalculate the percentage of flooding based upon selected tower diameter
Step #12: Check for entrainment, if too high then return to step #4
Step #13: Optimize design: repeat steps #3 to #9 to find smallest diameter and plate spacing acceptable to get the lowest
cost for the specified application
Step #14: Finalize design: draw up the plate specification and sketch the layout
Design problem
Design a continuous distillation column (plate) to recover acetone from a 50-50 mole % acetone-water mixture available at
30°C. The feed stream flow rate is 25,000 kg/h. The top product should contain at least 95 mole% acetone and the bottom
product should contain <1 % acetone by mole. Consider reboiler as equivalent to one stage. This column is operated at
atmospheric pressure (top tray). Column efficiency of 60% and pressure drop per plate of 1.25 kPa may be assumed. You
can take the minimum liquid flow as 70% of the maximum rate both above and below the feed plate. The vapor liquid
equilibrium (VLE) data for the acetone-water system at atmospheric pressure is provided in following Table.
Data given:
Latent heat of water= 41,360 J/mol; latent heat of acetone= 28,410 J/mol
Specific heat of water=75.3 J/mol°C (mean); Specific heat of acetone 128 J/mol°C (mean)
Column Construction and Internals
Design and construction features of column internals

Plate construction
Two types of plate constructions are practiced depending on the diameter of the column:

Sectional construction:
• The trays, downcomer segments and other tray components are usually constructed in sections for column diameter
of 1 m and above.
• The plate sections are designed in such that it can be removed through the column manholes, preferably detachable
from both above tray and tray below.
• The plate sections are installed usually starting from one side on a peripheral supported ring welded to inside shell
wall.
• The support ring is not normally extended into the downcomer area and tray perforations needs to be avoided over
the support ring area.
• Support ring width is usually between 40 to 90 mm.
• Trays are either clamped or bolted to the support ring.
• The support beams prevent tray deflection under load for larger diameter column.
• One or more major beams are required for large diameter column (usually >3 m).
• Trays can be supported by support rings and minor beams for small diameter column (usually <3 m) i.e. omitting
the major beams.
• The beams are commonly placed at about 0.6 m apart and should able to hold on the necessary weight during
column operation as well as installation.
• The maximum plate deflection under the operating conditions should be less than 3 mm for tower diameter more
than 2.5 m.
• The number of plate sections installed under an apron and across accumulator trays is kept as minimum as
possible.
• Clearance should be provided between the bottom of the beams and the tray below for the perpendicular installation
of the beams to the liquid flow direction on the tray below i.e. in case of cross flow.
Cartridge construction:
• The cartridge or stacked type plate construction is used for column diameter smaller than 1 m as in such small
diameter columns man entry to the column for the installation and necessary maintenance work is difficult.
• Cartridge constructions are employed for sieve, valve and bubble cap trays.
• The cartridge assemblies of 10 plates or so, are formed with the help of screwed rods and plate spacer bars.
• The tall column is divided into numbers of flanged sections and the prefabricated cartridge tray assemblies are
installed in each flanged sections with suitable downcomer clearance.
• The plates are not fixed to the shell wall and leakage may occur.
• A vertical metal seal is frequently used around each tray to decrease leakage around the tray edge.
Downcomer details
• The liquid from the top tray is directed to the tray below through a
downcomer or downspout.
• The downcomer liquid flow passage is normally formed by a vertical
plate starting from the weir outlet, called an apron.
• The adequate residence time needs to be ensured in the downcomers
for the disengagement of vapor/gas from liquid.
• The downcomer residence time of more than 3 s is desirable to get
only clear liquid on the tray.
• The different types of segmental downcomers constructions are
shown in the following Figure.
• The bottom downcomer area is normally more than 50% of the top
downcomer area for sloped downcomers.

Design of segmental downcomers: (a) vertical apron, (b) inclined apron, (c) inlet weir and, (d) recessed well
Feed inlets and side stream draws
• The feed liquid is commonly introduced vertically downward into
the downcomer of the tray above the feed point through an open
pipe.
• A slotted branch distributor is used for of flashing feed (liquid)to
avoid early flooding.
• The vapor is generally entered the column tangentially through
anopen inlet nozzle placed almost at right angles to the liquid flow
on the above tray.
• The clearance between the feed pipe end and feed plate below is
normally kept more than 0.4 m when the feed liquid is flashed in
active tray area.
• Wider tray spacing is needed where the feed pipe and the side
stream takeoff pipe to provide a liquid seal are installed.

(a) Takeoff nozzles (draw off) and, (b) Feed

Tray drainage
• Some amount of liquid is usually remains trapped on a bubble cap (positive seal tray) and on certain valve trays
when the column is shut down.
• This liquid is normally drains through weep holes located near the outlet weirs.
• Weep hole diameter usually ranges from 3 to 15 mm.
• The recommended weep hole area is 4 inch2per 100ft2 of tray area with 50 bubble caps and 4 inch weir to drain in
about 8 h.
Tray manways
• The maintenance workers travel from one tray to another through tray manways.
• The size of the manways should be such that a person can safely travel through a tray manway segment and also it is
removable through the column manholes.
• Manways are usually rectangular and the recommended size is 40 cm×50 cm.
• Tray manways should be removable from top and as well as from the tray below.
Column design specifications
The column specifications and operating conditions appended below are continued from the process design calculations
of sieve plate tower.
• Shell ID(𝐷𝑖):2403mm
• Number of trays: 14
• Tray spacing (𝑇𝑡): 600 mm
• Hole diameter (𝑑h):12 mm
• Plate thickness (𝑡𝑡): 12 mm
• Weir height (hW): 40 mm
• Material for trays, down comers and weirs: Stainless steel SS304L
• Shell material: Stainless steel (SS304L), double welded bolt joints
• Allowable stress for shell material: 108×106Pa (108 MPa)
• Density of shell material (𝜌𝑠) =7800 kg/m3
• Skirt height:2 m
• Operating pressure = 118825 Pa (bottom tray pressure)
• Design pressure (𝑝) = 1.1×operating pressure = 130708 Pa
• Operating temperature =56.3 to 105 °C
• Design temperature= 1.1×maximum operating temperature = 116°C
• Top disengaging space: 600 mm (same as the tray spacing taken)
• Bottom separator space:1000mm
• Insulation material taken: Asbestos
• Insulation thickness considered: 50 mm
• Density of insulation (𝜌ins ): 270 kg/m3 (asbestos)
Minimum shell thickness (𝒕𝒔):

Use 𝑡𝑠 =8 mm thickness including corrosion allowance of 6 mm. This value is in accordance to IS 2844-1964.

=1.81 mm ≈ 2 mm

The head thickness of 8 mm is selected with corrosion allowance of 6 mm for uniformity

Stresses developed in column
Axial and circumferential stresses
The axial stress (𝒇𝒂𝒔) resulting from the internal pressure in a closed cylindrical shell is given by
Compressive stresses caused by dead loads
• Stress induced by shell (𝑓dead wt . shell ) and insulation (𝑓dead wt . insulation ) at any distance, 𝑋, from the top of a vessel
having a constant shell thickness
Total liquid contents in the column depend on total number of trays, tray liquid holdup, liquid in down comer etc. Stress
resulted from liquid retained tower in vessel is given by following equation

Active area per tray (𝐴𝐴)=3.616 m2

Stress induced by column attachments like trays, overhead condenser, instruments, platform, ladders etc
Axial stresses due to wind loads
• The wind loading depends on wind velocity, air density and shape of the column.
• The maximum anticipated wind pressure of 2500 Pais used in this design.
• It is considered that fours cables are equally placed for guyed column subtending an angle of 45° with vertical wall.
• The wind loading acting on a vertical vessel is given by:

Above the guy ring: The column is designed like an unguyed vessel and the bending moment is given by following
equation
The compressive stress in column induced by guy wire tension, where angle 𝜃(45°) is making by the guy wires with the
vertical wall

Analysis of stresses