CN3132 Separation Processes

Column Sizing

Dr Suraj Vasudevan
Email: chesura@nus.edu.sg

Department of Chemical &

Biomolecular Engineering

VasudevanS/CN3132/Column Sizing 1
 Overview
Covered in online lecture
 Flash drum sizing

 Multi-stage column sizing  Packed column sizing

 Stage capacity and efficiency  Diameter calculation based
 Column hydraulics on flooding curve or
acceptable pressure drop
 Diameter calculation
 Tray efficiency Reference:
 Tray layout Wankat 2nd edition (Sections 10.6 to 10.9)
 Height calculation Wankat 3rd edition (Sections 10.7 to 10.10)
Wankat 4th edition (Sections 10.7 to 10.10)

Reference:
Wankat 2nd edition (Section 2.8 and Sections 10.1 to 10.5)
Wankat 3rd edition (Section 2.9 and Sections 10.1 to 10.6)
Wankat 4th edition (Section 2.9 and Sections 10.1 to 10.6)

VasudevanS/CN3132/Column Sizing 2
FLASH DRUM SIZING

VasudevanS/CN3132/Column Sizing 3
 Flash Drum Sizing: Empirical Procedure
 Once vapor and liquid compositions and flow rates
have been determined, flash drum can be sized
 Presented procedure is for vertical flash drums
1. Step 1: Calculate permissible vapor velocity,
𝒖𝒖𝒑𝒑𝒑𝒑𝒑𝒑𝒑𝒑 :
𝜌𝜌𝐿𝐿 −𝜌𝜌𝑉𝑉
𝑢𝑢𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 = 𝐾𝐾𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
𝜌𝜌𝑉𝑉
 𝑢𝑢𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 is the maximum permissible vapor
velocity in ft/s at the maximum cross-sectional
area
 𝜌𝜌𝐿𝐿 and 𝜌𝜌𝑉𝑉 are the liquid and vapor densities
 𝐾𝐾𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 is in ft/s, an empirical constant that
depends on the type of drum
VasudevanS/CN3132/Column Sizing
 𝐾𝐾𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 has been correlated graphically by Watkins
(1967) for 85% of flood with no demister
 Approximately 5% liquid will be entrained with the
vapor
 Use of the same design with a demister will reduce
entrainment to less than 1%
 The demister traps small liquid droplets on fine
wires and prevents them from exiting. The droplets
then coalesce into larger droplets, which fall off the
wire and through the rising vapor into the liquid
pool at the bottom of the flash chamber.
4
 Blackwell (1984) fit Watkins’ correlation to the
following equation:
2 2. Step 2: Using the known vapor rate 𝑉𝑉, convert
𝐾𝐾𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 𝑐𝑐𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜. exp[𝐴𝐴 + 𝐵𝐵𝐵𝐵𝐵𝐵𝐹𝐹𝑙𝑙𝑙𝑙 + 𝐶𝐶 ln 𝐹𝐹𝑙𝑙𝑙𝑙 +
𝐷𝐷 ln 𝐹𝐹𝑙𝑙𝑙𝑙 3 + 𝐸𝐸 ln 𝐹𝐹𝑙𝑙𝑙𝑙 4 ] 𝑢𝑢𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 into a horizontal area:

𝑓𝑓𝑓𝑓 3600𝑠𝑠 𝑙𝑙𝑙𝑙

𝑊𝑊𝐿𝐿 𝜌𝜌𝑉𝑉 𝑢𝑢𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 𝑠𝑠 𝐴𝐴𝑐𝑐 𝑓𝑓𝑓𝑓 2 𝜌𝜌𝑉𝑉 3
 𝐹𝐹𝑙𝑙𝑙𝑙 = and 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐. = 1.0 𝑓𝑓𝑓𝑓/𝑠𝑠 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 ℎ 𝑓𝑓𝑓𝑓
𝑊𝑊𝑉𝑉 𝜌𝜌𝐿𝐿 𝑉𝑉 = 𝑙𝑙𝑙𝑙
ℎ 𝑀𝑀𝑀𝑀𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙
 𝑊𝑊𝐿𝐿 and 𝑊𝑊𝑉𝑉 are the liquid and vapor flow rates in
 Solving for cross-sectional area:
weight units per hour (e.g., lb/h)
𝑉𝑉(𝑀𝑀𝑀𝑀𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣𝑣 )
 The constants are: 𝐴𝐴𝑐𝑐 =
𝑢𝑢𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝 (3600)𝜌𝜌𝑉𝑉
𝐴𝐴 =– 1.877478097
 For a vertical drum, diameter:
𝐵𝐵 =– 0.8145804597
4𝐴𝐴𝑐𝑐
𝐶𝐶 =– 0.1870744085 𝑑𝑑 =
𝜋𝜋
𝐷𝐷 =– 0.0145228667
• Usually the diameter is increased to the next
𝐸𝐸 =– 0.0010148518 largest 6-in. increment
 The resulting value for 𝐾𝐾𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 typically ranges
from 0.1 to 0.35

VasudevanS/CN3132/Column Sizing 5
3. Step 3: Set the length/diameter ratio by rule of
thumb and determine the height:
ℎ𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 ℎ𝑉𝑉 +ℎ𝑓𝑓 +ℎ𝐿𝐿
=
𝐷𝐷 𝐷𝐷
(should be 3 to 5 for vertical flash drums)
 Flash drums are often used as liquid surge tanks in
addition to separating vapor and liquid
See Example 2.4
 Height of the drum above centerline of the feed from textbook
nozzle:
ℎ𝑉𝑉 = 36𝑖𝑖𝑖𝑖. +0.5𝑑𝑑 (Minimum ℎ𝑉𝑉 = 48𝑖𝑖𝑖𝑖.)
 Height of the centerline of the feed above the
𝑑𝑑 is diameter of feed nozzle
maximum level of the liquid pool:
ℎ𝑓𝑓 = 12𝑖𝑖𝑖𝑖. +0.5𝑑𝑑 (Minimum ℎ𝑓𝑓 = 18𝑖𝑖𝑖𝑖.) With values of ℎ𝑉𝑉 , ℎ𝑓𝑓 and ℎ𝐿𝐿 :
 Depth of the liquid pool can be determined from If
ℎ𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡
< 3, increase 𝑉𝑉𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
𝐷𝐷
the required surge volume, 𝑉𝑉𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠 : If
ℎ𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡
> 5, use horizontal flash drum
𝐷𝐷
𝑉𝑉𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
ℎ𝐿𝐿 = 𝜋𝜋𝐷𝐷2⁄
4
VasudevanS/CN3132/Column Sizing 6
TRAY COLUMN SIZING

VasudevanS/CN3132/Column Sizing 7
 Multistage Processes: Stage Capacity and Efficiency
 Degree of separation depends on  Tray types:
 Number of trays  Sieve trays, valve trays and bubble cap trays
 Tray spacing • Sieve trays are easy to manufacture and
 Tray efficiency inexpensive; efficiency is good at design
 Capacity means operating column diameter conditions but not at significantly lower
rates (poor turndown, that is, performance
 Efficiency is the measure of deviation from when operating below designed flow rate)
equilibrium assumption due to
• Valve trays have better turndown
 Inadequate mixing properties than sieve trays
 Finite contact time
 Loss from entrainment of liquid in vapor
stream
 At the preliminary process design stage, sizing
is done using approximate methods
 Selection of tray and sizing are finalized
after discussion with equipment vendor
Sieve trays Fixed valve trays

VasudevanS/CN3132/Column Sizing *Pictures courtesy of Sulzer 8

 Multistage Processes: Flow Pattern and Hydraulics

 Designer must also choose flow pattern on

trays
 Cross-flow pattern is commonly used
 Vapor flows vertically upward and contacts
liquid in cross flow in each tray
 Cross flow gives wider range of operation
and better reliability
 Vapor flows up only through the perforated
regions of the trays and liquid flows down only
through the downcomer
 Residence time of liquid on each tray depends Cross-flow trays
on cross flow distance and weir height
 Downcomers and weirs control liquid
distribution and flow
Tray hydraulics

*Pictures courtesy of Sulzer

VasudevanS/CN3132/Column Sizing 9
 Distillation Column Hydraulics
 Complex fluid flow system  If vapour rate too high:
 Highest pressure at column  Column will flood – liquid cannot
bottoms; negative pressure flow down the column due to the
gradient as we move up the large pressure drop through the
trays
column
 If liquid rate too high:
 Pressure drop through each tray
 Column will flood – height over the
depends on vapour flowrate and weir becomes too high and
height of liquid on the tray (weir increase in pressure drop fills the
height plus height over the weir) downcomer
 Liquid flows down against a  If vapour rate too low:
positive pressure gradient –  Liquid will weep (or dump down)
through the holes - not enough
achieved by using the density
vapour through the holes on the
difference between the two trays to support the liquid
phases to build up enough liquid  If liquid rate too low:
in the downcomer to overcome  Liquid may be poorly distributed
the static pressure difference and dry spots may occur

VasudevanS/CN3132/Column Sizing 10
 Column Diameter Calculation Procedure
 Column diameter is an important factor for column  Flooding velocity based on net area for vapor flow is
cost, and has to be estimated even for preliminary determined from
design
𝜎𝜎 0.2 𝜌𝜌𝐿𝐿 −𝜌𝜌𝑉𝑉
 Procedure presented is for sieve trays; valve trays 𝑢𝑢𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 = 𝐶𝐶𝑠𝑠𝑠𝑠,𝑓𝑓 , 𝑓𝑓𝑓𝑓/𝑠𝑠
20 𝜌𝜌𝑉𝑉
almost identical except one minor difference
Where,
 The calculated column diameter prevents flooding
 𝜎𝜎 is the surface tension in dynes/cm
 Several procedures; Fair’s procedure is presented
 𝐶𝐶𝑠𝑠𝑠𝑠,𝑓𝑓 is the capacity factor
here – widely known and used in process
simulators  𝐶𝐶𝑠𝑠𝑠𝑠,𝑓𝑓 is a function of the flow parameter FP

 First estimate vapor velocity that will cause 𝑊𝑊 𝜌𝜌𝑉𝑉

𝐹𝐹𝐹𝐹 = 𝐹𝐹𝑙𝑙𝑙𝑙 = 𝐿𝐿
flooding due to excessive entrainment 𝑊𝑊 𝑉𝑉 𝜌𝜌𝐿𝐿

 Then use a rule of thumb to determine the Where,

operating velocity  𝑊𝑊𝐿𝐿 and 𝑊𝑊𝑉𝑉 are mass flow rates of liquid and vapor
 Column diameter is then determined from this  𝜌𝜌𝐿𝐿 and 𝜌𝜌𝑉𝑉 are mass densities

VasudevanS/CN3132/Column Sizing 11
  The flooding correlation assumes
𝐴𝐴ℎ𝑜𝑜𝑜𝑜𝑜𝑜
β= ≥ 0.1
𝐴𝐴𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎

 If β < 0.1, the calculated flooding

velocity should be multiplied by a
correction factor
 If β = 0.08, correction factor = 0.9
 If β = 0.06, correction factor = 0.8
 A linear correction that can be
interpolated
 Tray spacing is chosen based on
maintenance requirements
 Sieve trays have a tray spacing of 6
to 36 inches, with 12 to 16 inches a
common range for small diameter
Capacity factor for flooding of sieve trays (Fair and Matthews, 1958) columns (less than 5 ft)
 24 inches (0.6096 m) is typically
used for easy human access
VasudevanS/CN3132/Column Sizing 12
  Repeat calculations for different points in
 The operating vapor velocity is determined as the column and choose the largest
𝑢𝑢𝑜𝑜𝑜𝑜 = (𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓)𝑢𝑢𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓 , 𝑓𝑓𝑓𝑓/𝑠𝑠 diameter d as the column diameter
Where,  Round up to the next highest half-foot
 fraction = 0.65 to 0.9; 0.75 is commonly used increment (e.g., 9.28 ft will be rounded
up to 9.5 ft)
 𝑢𝑢𝑜𝑜𝑜𝑜 can be related to the molar vapor flow rate
 Minimum column diameter for tray
𝑉𝑉 𝑀𝑀𝑀𝑀𝑉𝑉
𝑢𝑢𝑜𝑜𝑜𝑜 =
𝜌𝜌𝑉𝑉 𝐴𝐴𝑛𝑛𝑛𝑛𝑛𝑛
, 𝑓𝑓𝑓𝑓/𝑠𝑠 columns is 2.5 ft; if not, use packed
columns
Where,
𝑃𝑃 𝑀𝑀𝑀𝑀𝑉𝑉
 Turndown ratio is also considered at
 𝜌𝜌𝑉𝑉 = (if ideal gas law holds) design stage for protection against
𝑅𝑅𝑅𝑅

𝜋𝜋 𝑑𝑑 2 2 weeping
 The net area for vapor flow is 𝐴𝐴𝑛𝑛𝑛𝑛𝑛𝑛 = 4
η, 𝑓𝑓𝑓𝑓
 Ratio of vapor rate at flooding to
• Here, η is the fraction of column cross-sectional area that is minimum vapor rate
available for vapor flow above the tray; typically 0.85 to 0.95
 Below minimum vapor rate, liquid
• This means 1-η is the fraction of the column area taken up weeps through the tray perforations
by one downcomer instead of flowing across the active
area and down the downcomer
VasudevanS/CN3132/Column Sizing 13
 Tray Efficiency
 Simplest approach is to use a correlation to
determine the efficiency
 O’Connell correlation is widely used – gives an
estimate of the overall efficiency as a function
of the relative volatility α of the key
components times the liquid viscosity μ at the
feed composition
 Both α and μ are determined at the
average temperature and pressure of the
column
 Efficiency drops as viscosity increases since
mass transfer rates are slower
 Efficiency drops as relative volatility
O’Connell correlation for overall efficiency of distillation columns
increases since the mass that must be
transferred to obtain equilibrium increases

VasudevanS/CN3132/Column Sizing 14
 Tray Layout
 Besides choosing type of tray, the
designer also needs to select the flow
pattern on the trays
 Most common flow pattern is cross-flow Selection guide for sieve trays

 Works well for average flow rates

 Multiple-pass trays are used in large-
diameter columns with high liquid flow
rates
 Double-pass trays are common
 Liquid flow is divided into two
sections (or passes) to reduce the
liquid gradient on the tray and to A. Cross-flow trays
reduce downcomer loading B. Double-pass trays
 Four-pass trays are used with even
larger liquid loadings

VasudevanS/CN3132/Column Sizing 15
 Column Height

 Height between top and bottom trays:

ℎ 𝑇𝑇 = 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 × 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠𝑠
 Allowance for entrainment removal at the top:
ℎ𝐸𝐸 = 4 𝑓𝑓𝑓𝑓
 Allowance for surge capacity at the bottom:
ℎ𝑆𝑆 = 10 𝑓𝑓𝑓𝑓
 Total column height, 𝐻𝐻 = ℎ 𝑇𝑇 + ℎ𝐸𝐸 + ℎ𝑆𝑆
 Consider using two columns if 𝐻𝐻 > 212 𝑓𝑓𝑓𝑓

These are rules of thumb based on experience,

will differ slightly in different sources!

VasudevanS/CN3132/Column Sizing 16
 Example 1: Diameter of a Tray Column
 A sieve-plate distillation column is separating a feed that is 50 mole % n-hexane and 50 mole % n-heptane.
Feed is a saturated liquid. Plate spacing is 24 in. Average column pressure is 1 atm. Distillate composition is
𝑥𝑥𝐷𝐷 = 0.999 (mole fraction n-hexane) and 𝑥𝑥𝐵𝐵 = 0.001. Feed rate is 1000 lbmol/h. Internal reflux ratio 𝐿𝐿⁄𝑉𝑉 =
0.8. The column has a total reboiler and a total condenser.
 Find:
The diameter of the column at the top.
 Data:
For n-hexane
Property Value
Liquid density (at 20°C) 0.659 g/ml
Viscosity (at 69°C) 0.22 cP
MW 86.17
Surface tension (at 69°C) 13.2 dynes/cm

VasudevanS/CN3132/Column Sizing 17
 Use ideal gas law to estimate vapor densities:
n MWV P MWV 1 atm 86.17 lb/lbmol
ρV = = = atm ft3
= 0.1917 lb/ft 3
V RT 1.314 K lbmol 342 K

 Ratio of liquid to vapor mass flow rates is same as ratio of liquid to vapor flow rates as it is essentially
pure hexane at the top, and hence liquid and vapor compositions are the same (molecular weight is the
same):
WL L MW liquid L
= . = = 0.8
WV V MW vapor V

lb/s lbmol/s lb/lbmol

= .
lb/s lbmol/s lb/lbmol

 Flow parameter:
WL ρV 0.1917 0.5
Flv = = 0.8 62.4 lb/ft3
= 0.055
WV ρL 0.659 g/cm3
g/cm3

VasudevanS/CN3132/Column Sizing 18
  From graph, ordinate for 24-inch tray spacing:
Csb,f = 0.36

 Hence:
σ 0.2 13.2 0.2
Csb,f = 0.36 = 0.331
20 20

 Hence, flooding velocity:

σ 0.2 ρL −ρV
uflood = Csb,f
20 ρV

0.659 62.4 −0.1917

= 0.331 = 4.836 ft/s
0.1917

VasudevanS/CN3132/Column Sizing 19
  Let us take 75% of flooding velocity:
uop = (0.75)uflood = 0.75 4.836 = 3.627 ft/s

 Hence, net area:

lbmol lb
V MWV 0.6944 s
86.17lbmol
Anet = =
How do we get V = 0.6944? ρV uop 0.1917 3
lb ft
3.627 s
ft
= 86.06 ft 2

 Diameter (with η as 0.90):

4Anet 4(86.06)
d= = = 11.04 ft
πη π(0.90)

High reflux rate => V is high => fairly high diameter

VasudevanS/CN3132/Column Sizing 20
PACKED COLUMN SIZING

VasudevanS/CN3132/Column Sizing 21
Packing Materials

 Packing materials provide for intimate contact between

vapor and liquid with a very large surface area for mass
transfer
 The liquid flows over the surface of the packing and the
vapor flows in the void space inside the packing and
between pieces of packing
 The packing should also provide for easy liquid drainage
and have a low pressure drop for gas flow
 Important characteristics: Cost, surface area, void
volume, fouling resistance, mechanical strength, uniform
flow of streams
 Packing available in a variety of styles:
 Can be classified into random packing materials and
structured packing materials

VasudevanS/CN3132/Column Sizing 22
Packed Column Internals

 In addition to the packed sections where separation occurs,

sections needed for:
 Distribution of the reflux, feed, and boilup
 Disengagement between liquid and vapor
 Liquid distributors very important for proper column
operation
 For every 3 m (10 ft) height of packing, a liquid
distributor should be used to prevent channeling of
liquid to the sides
 Helps to rain the liquid evenly down the packing

VasudevanS/CN3132/Column Sizing 23
 Flooding and Pressure Drop Correlation
0.5
L′ ρG
 x-axis: Abscissa =
G′ ρL
L': Liquid mass flux (lb/ft2s)
G': Gas mass flux (lb/ft2s)
ρG: Gas mass density (lb/ft3)
ρL: Liquid mass density (lb/ft3)

G′2 Fψμ0.2
 y-axis: Ordinate =
ρG ρL gc
F: Packing factor (1/ft)
(Tables 10.3 and 10.4, Wankat 3rd edition)
0.5 ψ: ρwater/ρL
L′ ρG
G′ ρL
'
μ: Liquid viscosity in cP
gc: Acceleration due to gravity (32.2 ft/s2)
Generalized flooding correlation developed by Sherwood
et al. (1938) as modified by Eckert (1970, 1979)

VasudevanS/CN3132/Column Sizing 24
 Notes on the Correlation

 The ordinate has units

 Packing factor, F depends on the type and size of
the packing
 The higher the value of F, the larger the
pressure drop per foot of packing
 As packing size increases, F decreases and
hence pressure drop per foot decreases
 Lower F value generally gives smaller diameter
 Figure given is not the best fit of all data
 Better results can be obtained using pressure
drop curves for a particular packing
'
 ∆𝐩𝐩 correlation for regions below flooding curve:
βL′
G′2
∆p = α 10
ρG
 Constants α and β are also given in Table 10.3
 ∆p is in inches of water per foot of packing
 Flooding curve can be fit by the equation, where Y is
ordinate and X is abscissa:
log10 Y = −1.6678 − 1.085logX − 0.29655 logX 2

VasudevanS/CN3132/Column Sizing 25
 Calculation of Packed Column Diameter

 Diameter is calculated based on either the approach to flooding or acceptable

pressure drop
 Designer picks a point in the column
 This determines gas and liquid densities, liquid viscosity, value of ψ
 Designer also determines the packing factor for packing of interest
L′
 For top of the column, ′ is equal to reflux ratio if liquid and vapor has the
G
same composition as area terms cancel out and MWL = MWV
L′ L MWL
 If not, =
G′ V MWV
 Since liquid and vapor densities and flow rates vary throughout the column:
 Designer must calculate the diameter at several locations and use the
largest value
 Variations in vapor flow rate typically dominate diameter calculations

VasudevanS/CN3132/Column Sizing
 The Two Alternative Approaches
 Approach 1: Have a given pressure drop per foot  Approach 2: Operate at 65% to 90% of flooding
of packing (Δp) 1. Designer uses the flooding curve to calculate
1. Designer chooses the Δp (inches of water per the G'flood from the ordinate (Y)
foot): 2. The usual range for actual operating G' is 65%
0.1 to 0.4 for vacuum columns; to 90% of G'flood with 70% to 80% being most
0.25 to 0.4 for absorbers and strippers; common
0.4 to 0.8 for atmospheric and 3. From G' →AC
high-pressure columns
4. Note: The flooding correlation is not perfect; to
2. With the value of the abscissa and the parameter have 95% confidence a safety factor of 1.32
known, the ordinate (Y) can be determined should be used to multiply with the calculated Ac
3. From Y → G' →AC for a conservative design
lbmol lb
V MW of vapor
s lbmol 4Ac
Area Ac = Diameter d =
lb π
G′
s. ft 2

VasudevanS/CN3132/Column Sizing
 Example 2: Diameter of a Packed Column
A distillation column is separating n-hexane from n-heptane using 1-inch ceramic Intalox saddles (F = 98 from
Table 10.3). Average column pressure is 1 atm.

Separation in the column is essentially complete, so the distillate is almost pure hexane and the bottom is
almost pure heptane. Feed is a 50-50 mixture and is a saturated liquid. In the top, L/V = 0.8.

If F = 1000 lbmol/h and D = 500 lbmol/h, estimate the column diameter required at the top for (a) allowable
pressure drop in the column of 0.5 inches of water per foot, (b) operation at 75% of flooding.

Physical properties:
n-hexane: MW = 86.17, BP = 69 °C, μ (at 69 °C) = 0.22 cP, density = 0.659 g/ml
n-heptane: MW = 100.2, BP = 98.4 °C, μ (at 98.4 °C) = 0.205 cP, density = 0.684 g/ml
Water density (at 69 °C) = 0.9783 g/ml

VasudevanS/CN3132/Column Sizing 28
 Use ideal gas law to estimate vapor densities:
n MWV P MWV 1 atm 86.17 lb/lbmol
ρG = = = atm ft3
= 0.1917 lb/ft 3
V RT 1.314 K lbmol 342 K

 Ratio of liquid to vapor fluxes is same as ratio of liquid to vapor flow rates as it is essentially pure hexane
at the top, and hence liquid and vapor compositions are the same (area terms cancel out, and molecular
weight is the same):
L′ L MWL
= . = 0.8
V′ V MWV

lb/ft2 s lbmol/s lb/lbmol

= .
lb/ft2 s lbmol/s lb/lbmol

 Abscissa:
0.5 0.5
L′ ρG 0.1917
= 0.8 62.4 lb/ft3
= 0.055
G′ ρL 0.659 g/cm3
g/cm3

VasudevanS/CN3132/Column Sizing 29
 (a) Approach 1
 From graph, ordinate at 0.5 in. pressure drop:
G′2 Fψμ0.2
= 0.055
ρG ρL gc

 Hence:
0.055×0.1917×0.659×62.4×32.2 0.5 lb
G′ = 0.9873 = 0.36
98× ×0.220.2 ft2 s
0.659

 Hence, cross-sectional area:

lbmol lb
V MWV 0.6944 86.17
Ac = = s
lb
lbmol
= 166 ft 2
G′ 0.36 2
s.ft
0.5
L′ ρG
G′ ρL
 Diameter:
4Ac
V is same as Example 1 d= = 14.54 ft
π

VasudevanS/CN3132/Column Sizing 30
 (b) Approach 2
 From graph, ordinate at flooding line:
G′flood 2 Fψμ0.2
= 0.175
ρG ρL gc
 Hence:
′ 0.175×0.1917×0.659×62.4×32.2 0.5 lb
G flood = 0.9873 = 0.64
98× ×0.220.2 ft2 s
0.659
 Given:
lb
G′ = 0.75G′ flood = 0.75 0.64 = 0.48
ft2 s
 Hence, cross-sectional area:
lbmol lb
V MWV 0.6944 86.17
Ac = = s
lb
lbmol
= 124.7 ft 2
0.5 G′ 0.48 2
L′ ρG s.ft

G′ ρL  Diameter:
4Ac
d= = 12.6 ft
π

High reflux rate => V is high => fairly high diameter

VasudevanS/CN3132/Column Sizing 31
Wishing you the best!

VasudevanS/CN3132/Column Sizing 32