Distillation Design

Design of T-101

 Sieve plates are the least expensive and least prone to contamination. It is used in
most chemical industries as they are the least expensive plates to manufacture. So,
distillation columns design, sieve plate was used in both columns (T-101 and T-102).
 Considering the chemical compatibility of EG, water, EO, DEG and TEG with
carbon-steel material for tower and tray design has been selected carbon-steel
material. Also, the most used materials in the chemical industry are carbon-steel and
stainless steel. So, carbon steel material is used in both distillation columns. (T-101
and T-102)

Feed stream of T-101 is stream 12 Outlet Stream of T-101 are Stream 13 and Stream 14
Top stream is stream 13 and bottom stream is Stream 14

According to the previous calculations about mass and compositions balance:

Table.. Amounts of components in feed, top and bottom streams (kg/h)

Component Feed Stream (12) Top Stream (13) Bottom Stream (14)
Water 1387384.5 kg/h 1387371.37 kg/h 13.3 kg/h

EO 6.3792 kg/h  6.3792 kg/h 0 kg/h

EG 532980 kg/h 47.4080 kg/h 532933.0 kg/h

DEG 172248.6 kg/h 0 kg/h 172248.6 kg/h

TEG 18751.9 kg/h 0 kg/h 18751.97 kg/h

Total 2111371.379 kg/h 1387425.16 kg/h 723946.87

Table .. Amounts of components in top and bottom streams (kmol/h)

Component Feed Stream (12) Top Stream (13) Bottom Stream (14)
Water 77011.54 kmol/h 77010.8 kmol/h 0.738 kmol/h

EO 0.1433 kmol/h  0.1433 kmol/h 0 kmol/h

EG 8586.76 kmol/h 0.763 kmol/h 8585.99 kmol/h

DEG 1623.15 kmol/h 0 kmol/h 1623.15 kmol/h

TEG 124.87 kmol/h 0 kmol/h 124.87 kmol/h

Total 87346.4633 kmol/h 77011.7063 kmol/h 10334.748 kmol/h

Dew Point / Bubble Point Calculations:

To find dew point and bubble point Ki values are calculated from Antoine equation where P
in pressure in mmHg and temperature is taken in °C, using A, B and C constants shown in
Table x.

B
log ( P )= A−
T +C

Antoine Equation Constants[Yaws, C., Narasimhan, P. and Gabbula, C., 2005. Yaws'
Handbook of Antoine coefficients for vapor pressure. Norwich, N.Y.: Knovel.]

Table x. Antoine Equation Constants

Components A B C

Water 8.1401 1810.94 244.485

EO 7.19462 1100.6722 243.301
EG 9.6554 3147.1 264.246
DEG 7.65732 2065.8762 186.657
TEG 9.33075 3742.2446 295.198

Temperature of feed = 110 °C

Pressure of feed = 75.006 mmHg

Pi
K=
Pt

Where; Pi=Vapor pressure of component i∧Pt =Total Pressure.

All Ki values calculated from Antoine equation is given Table…

 Dew point calculation:

Trial 1: Assume 50℃

Component yi Ki Yi/ki
Water 0.99 1.30 0.7615
EO 0.000001 36.88 2.7x10−8
EG 0.000009 0.0058 1.5x10−3
DEG 0 0.0013 0
 TEG 0 0.00042 0
yi
∑ Ki =0.763
Trial 2: Assume 40℃

Component yi Ki Yi/ki
Water 0.99 0.79 1.25
EO 0.000001 27.18 2.7x10−8
EG 0.000009 2.73x10−3 1.5x10−3
DEG 0 0.00046 0
TEG 0 0.00019 0
yi
∑ Ki =1.236
Trial 3: Assume 44.5 ℃

Component yi Ki Yi/ki
Water 0.99 0.9964 0.9935
EO 0.000001 31.26 3.19x10−8
EG 0.000009 3.86 x 10−3 2.32x10−3
DEG 0 0.0007 0
TEG 0 0.00027 0
yi
∑ ki =0.9958~
¿1

So, we can take 44.5℃ for dew point.

 Buble point calculation:

Trial 1: Assume 150 ℃

Component xi Ki Xi*ki
Water 0.00007 47.24 3.3x10−3
EO 0 331.8 0
EG 0.830 1.52 1.26
DEG 0.157 0.43 0.07
TEG 0.012 0.12 1.34x10−3
 ∑ ki∗xi=1.33
Trial 2: Assume 140 ℃

Component xi Ki Xi*ki
Water 0.00007 35.88 2.5 x10−3
EO 0 280.5 0
EG 0.830 1.23 1.021
DEG 0.157 0.282 0.045
TEG 0.012 0.072 8.61x10−4

∑ ki∗xi=1.09
Trial 3: Assume 143 ℃

Component xi Ki Xi*ki
Water 0.00007 39.03 2.73x10−3
EO 0 259.29 0
EG 0.830 1.12 0.936
DEG 0.157 0.327 0.0514
TEG 0.012 0.082 9.8x10−4
∑ ki∗xi=0.9911~
¿1

So, we can take 143℃ for buble point.

Tray Numbers Calculation

 Fenske Equation for caluculation of Nmin

 Underwood Equation for calculation of Rmin
 Erbar-Maddox correlation for find the ideal stage numbers.

x Lk
N min =log [ ] log ¿ ¿
x Hk d

Fenske Equation[Towler, G., & Sinnott, R. (2018). 2nd edition. Chemical Engineering Design
Principles, Practice and Economics of Plant and Process Design. Elsevier. p. 833 ]

αLK : The average relative volatility of the light key with respect to the heavy key
 (xLK)D : Molar ratio of light key in distillate ; 100,159/103,56 = 0,96

(xLK)B : Molar ratio of light key in bottom ; 1,01/ 386,2735 = 2,61*10-3

(xHK)D : Molar ratio of heavy key in distillate ; 0,013/103,56 = 1,2*10-4

(xHK)B : Molar ratio of heavy key in bottom ; 25,14 / 386,2735 = 0,065

α lk =The average relative volatility of the light key withrespect ¿ the heavy key

Light key avarege= (0,012+3,27*10-14)/2=0,006 0,96261

0,06512

Heavy key average= (0,0388+0,99)/2=0.5144

0,006
α lk = =0,011 -0,51 14,78 3,9 1,39 1,16
0,5144

0,012
N min =log [ ] log ¿ ¿
0,0388 d

So, Nmin=6.61

Equilibrium Flash Calculations

Ai=(L/V)/ki assume Ai=(L/V)/ki assume

Component zi Ki(@110 ° C ) (L/V)=30 (L/V) = 33

Water 0.88 14.33 2.09 2.30

Ethylene oxide 0.0000016 158.3 0.19 0.208
Ethylene glycol 0.098 0.232 129.3 142.24
DEG 0.0185 0.065 461.53 507.69
TEG 0.00143 0.0166 1807.2 1807.22
Total 1 2400 2480

F=87346.46 kmol/h

V=2480 kmol/h

L=(87346.46-2480)=84866.46 kmol/h
 ~
So, Reflux ratio (R) = 33.22 ¿ 33

Minimum Reflux Ratio

Underwood Equation[Towler, G., & Sinnott, R. (2013). 2nd edition. Chemical Engineering Design
Principles, Practice and Economics of Plant and Process Design. Elsevier. p. 835 ]

q=1 (the feed saturated liquid)

Calculated θ is given Table…

Component xf αi αixf θ =4 assume θ =4.5 assume

Water (LK) 0.88 34.54 30.4 0.995 1.01

Ethylene oxide 0.0000016 251.63 0.0004 0.000001 0.000001
Ethylene glycol (HK) 0.098 1 0.098 -0.032 -0.028
DEG 0.0185 0.283 0.0053 -0.0015 -0.00125
TEG 0.00143 0.071 0.0001 -0.000025 -0.00002
Total 1 0.96 0.99

For= θ =4.5

Calculation of Rmin value is given table…

Component xid αi αixid αixid /(αi−θ)

Water (LK) 0.99 34.19 34.19 1.134
Ethylene oxide 0.0000 251.63 0.00252 0.000001
1
Ethylene glycol (HK) 0.0000 1 0.00009 -0.00002
9
DEG 0 0.283 0 0
TEG 0 0.071 0 0
 Total 1 1.14

Rm+1=1.14

Rm=0.14

Rm 0.02
= =0.0196
Rm +1 1,02

R=33

R 5
= =0.95
R +1 56

Figure …Erbar and Maddow correlation(Towler, G., & Sinnott, R. (2013). 2nd edition. Chemical
Engineering Design Principles, Practice and Economics of Plant and Process Design. Elsevier. p. 834 )

 The values of 0.13 and 0.95 were used in the Erbar and Maddow correlation plot to
find the number of stages

From the Erbar-Maddox Correlation: Nm/N= 0.92

N=7.21 ~¿7 stage

Plate Efficiency

μa =the molar average liquid viscosity, mNs/m2

Table … Viscosity value at average temperature

Component Average viscosity Xi Xi*Viscosity

Water 0.02067 0.00007 0.0000014469
EO 0.0517 0 0
EG 0.0712 0.830 0.059
DEG 0.122 0.157 0.01915
TEG 0.172 0.012 0.002064

μa =0.0000014469+0.059+0.01915+0.002064 = 0.059

Average relative volatility αa = 24.64

24.64∗0.059=1.453

Figure… Dist Collumn Efficiencies (bubble-caps) [Towler, G., & Sinnott, R. (2013). 2nd edition.
Chemical Engineering Design Principles, Practice and Economics of Plant and Process Design. Elsevier.
p.846]

Efficiency=η=32%

Nideal 7
Nreal= = =21,875≈
η 0.32

Calculation of Column Height and Diameter

Column Height

For columns above 1 m diameter, plate spacings of 0.3 m to 0.6 m will normally be used, and
0.5 m (18 in) can be taken as an initial estimate .[Towler, G., & Sinnott, R. (2013). 2nd edition.
Chemical Engineering Design Principles, Practice and Economics of Plant and Process Design. Elsevier.
p. 853].

So, plate spacing=0.6 m assumes

Nreal= 15.15=15

Bottom and top space are taken 1.5 m

Column height= (N-1)*(Plate spacing)+bottom space+top space[üsttekiyle aynı]

Column height= (15-1)x0.6+1.5+1.5=11.4m

Column Diameter

Souders and Brown equation can be used to estimate superficial vapor velocity, and then
column area and diameter.[üsttekiyle aynı]

[ ]
1
ρL−ρv
uv=( −0.171l 2 t+0.27 <−0.047 ) 2
ρv

Uv = Max. allowable vapor velocity

It = Plate Spacing
We assumed plate spacing = 0.6 m

Table.. Calculation of ρL

Component Xi Xi* ρi
Water 0.00007 0.0698
EG 0.830 864.86
DEG 0.157 175.84
TEG 0.012 13.5
kg
∑ Xi∗ρi=ρL=1054.26 m3

Table.. Calculation of ρV

Component Yi Yi* ρi
Water 0.99 987.03
EO 0.000001 0.000882
EG 0.000009 0.009378
kg
∑ Yi∗ρi= ρV =805,38 m3

uv=( −0.171 ( 0.6 )2+ 0.27 ( 0.6 )−0.047 )

[ 833,19−805,38
805,38 ]
=8,53 x 10−2 m/s

And Dc can be calculated by equation below:

( )
1
4 Vm
Dc= 2
πρvuv

V w = Max. vapor rate =385 kg/s

Dc=5 m

Our distillation column diameter is relatively high due to high inlet volumes since it is logical
to choose diameter between 65 centimeters to 6 meters (kaynak:
https://en.wikipedia.org/wiki/Fractionating_column)

Feed Point Location

An estimate of feed point location can be made by Kirkbride equation [Towler, G., & Sinnott, R.
(2013). 2nd edition. Chemical Engineering Design Principles, Practice and Economics of Plant and
Process Design. Elsevier. p. 836]

[ ] [( )( )( ) ]
2
Nr B Xfhk Xblk
log =0.206 log
Ns D Xdlk Xdhk

Nr = number of stages above the feed, including any partial condenser

Ns = number of stages below the feed , including the reboiler

xf,HK= concentration of the heavy key in the feed

xf,,LK = concentration of the light key in the feed

xd,HK= concentration of the heavy key in the top product

xf,,LK = concentration of the light key in the bottom product

[ ] [( )( )( )]
2
Nr 2850,772 0 , 79 0. 012
log =0.206 log
Ns 740,32 0 , 012 0,038

Nr
=0.856 253,458
Ns

Total Stages=15=0.856 Ns+ NsNs=8.082≈ 8

So, feed entered at 8th plate from below.

Heat Duty and Total Heat Transfer Area of Boiler and Condenser for T-101

Heat duty for the condenser:

Qc=ΣHin∗nin−ΣHout∗nin

The amount of the outlet of the condenser (D): 10335.0 kmol/h

kmol kmol
Water=77010.8( )/10335.0 ( )=¿0.99
h h

kmol kmol
EO=0.1433( )/10335.0( )=¿0.000001
h h
 kmol kmol
EG=0.763( )/10335.0( )=¿ 0.000009
h h

kmol kmol
DEG=0( )/10335.0( )=¿ 0
h h

kmol kmol
TEG=0( )/10335.0( )=¿ 0
h h

Reflux=L/ D=3  L/77011.7063=3  L=231035.12 kmol /h

The amount of recycle ¿ distillation∈condenser : L=231035.12 kmol /h.

Water=0.99 X L=228724.8 .

EO=0.000001 X L=0.2310 .

EG=0.000009 X L=2.0794 .

DEG=0.

TEG=0 .

Total amount of the inlet the condenser:

Water=77010.8 + 228724.8=305735.6 kmol/h

EO= 0.1433+0.2310 =0.3743 kmol/h

EG=0.763+2.0794=2.8424 kmol/h

DEG=0

TEG=0

TOTAL= 305738.8 kmol /h

Cp values are taken from Table 6.3.5.2 CP Values of Materials Around Flash Column

Qc=305738.8 x (4.18−2.9) x(110−45)=25437468.16 watt

25437468.16 2
Ac= =652.25 m
600∗( 110−45 )

Q=Qc+ Qr=¿ Qr=Q−Qc=143659000−25437468.16=118221531.8 watt

 118221531.8 2
Ar= =3031.4 m
600∗( 110−45 )

Design of T-102

Feed stream of T-102 is stream 15 Outlet Stream of T-102 are Stream 16 and Stream 17 Top
stream is stream 16 and bottom stream is Stream 17. In our system light key (LK) is EG and
heavy key(HK) is DEG.

Table.. Amounts of components in feed, top and bottom streams (kg/h)

Component Feed Stream (15) Top Stream (16) Bottom Stream (17)
EG (LK) 532250,25 kg/h 532244.043 kg/h 6.207
DEG (HK) 168996,1 kg/h 16.9792 kg/h 168979.12
TEG 18395.825 kg/h 1360,54 kg/h 17035.285
Total 719642.175 kg/h 533621.5622 kg/h 186020.62 kg/h

Table.. Amounts of components in feed, top and bottom streams (kmol/h)

Component Feed Stream (15) Top Stream (16) Bottom Stream (17)
EG(LK) 8575 kmol/h 8574.9 kmol/h 0.1 kmol/h
DEG (HK) 1592.5 kmol/h 0.16 kmol/h 1592.34 kmol/h
TEG 122.5 kmol/h 9.06 kmol/h 113.44 kmol/h
Total 10290 kmol/h 8584.12 kmol/h 1705.88 kmol/h

Same calculation methods:

Tdew 141 ° C Nm/N 0.93

Tbuble 175 ° C N 39
Nmin 36.19 Efficiency %43
R 69 Nreal 90.69
R/R+1 0.98 uv 0.087m/s
Rm+1 1.18 Dc 2m
Rm 0.18 Nr/Ns 0.92
Rm/Rm+1 0.15 Feed on tray 47th stage

Condenser Reboiler
Heat Duty -1925212.42 watt 112665000 watt
Heat Area 50.95 m 2 2888.9 m2