Distillation is a unit operation that involves removing a vaporizable component

from a multicomponent system and condensing the resulting vapors. The distribution
of the various components of a liquid solution between a vapor phase and a liquid
phase determines the separation of these components. In both phases, all components
are present.
Fractional distillation towers or columns are designed to efficiently achieve the
required separation. Fractionation columns are typically designed in two steps: a
process design and a mechanical design. The process design calculates the number of
theoretical stages and stream flows required, including the reflux ratio, heat reflux, and
other heat duties.
The Reflux ratio is one of the most important variables in large-scale fractional
distillation. This is calculated by dividing the weight of liquid retained as reflux by the
weight removed as overhead product. The Reflux ratio is the ratio of the amount of
reflux that returns down the distillation column to the amount of reflux collected in the
receiver (distillate).
The reflux ratio is 5:1 if 5 parts of the reflux are returned to the distillation
column and 1 part is collected as distillate. If all of the reflux is collected as distillate, the
reflux ratio is 0:1. A reflux ratio is not assigned if no distillate is collected. Instead, we
refer to this as "total reflux" or "equilibration."
At total reflux, i.e., a reflux ratio of infinity, the desired separation is achieved
with the smallest packed height. In this experiment, the packed height is fixed, and the
reflux ratio must be less than total reflux. Increased reflux ratio improves separation
and, as a result, increases the proportion of ethanol in the overhead product.
The greater the reflux ratio, the greater the possibility of vapor/liquid contact in
the distillation column. As a result, higher reflux ratios usually imply higher distillate
purity. It also implies that the distillate collection rate will be slower.
A higher reflux ratio (R) results in fewer theoretical trays (N) required for a given
separation (i.e. constant xD and xB) from a given feed condition (x F and q), and vice
versa. In other words, there are numerous combinations of the reflux ratio R and the
number of theoretical trays, N.
The reflux ratio and the number of theoretical stages have an inverse
relationship. Of course, for a new design, the reflux ratio and number of theoretical
stages can both be adjusted to achieve the best possible balance. Because the number of
trays in an existing column is fixed, increasing the reflux ratio is the only way to achieve
higher distillate concentration (mole fraction xD).