Lecture 4 Distillation Column-5192-16142479047124

Lecture 4
How to sizing and costing tower unit?
ผศ.ดร. อภินันท สุทธิธารธวัช

Email: apinan.s@chula.ac.th
ภาควิชาวิศวกรรมเคมี คณะวิศวกรรมศาสตร
จุฬาลงกรณมหาวิทยาลัย 1
Lecture 4-1
How to estimate the price of Distillation?

Cost of Distillation
1. Cost of tower as pressure vessel

2. Cost of internal (Packing or Tray)
3
Bare Module Approach
C BM  FBM C 0
p
• CBM = Bare module equipment cost: direct and indirect

costs
• FBM = Bare module cost factor: multiplication factor to
account plus the specific materials of construction and
operating pressure
• Cp0= Purchased cost for base conditions: equipment made
of the most common material, usually carbon steel, and
operating at near-ambient pressures (P=1bar, C=CS)
4
Bare Module Approach
log10 C  K1  K 2 log10 A  K 3 log10 A
0 2
p
Tower trays
Tray Type K1 K2 K3 Amin(m2) Amax(m2)
Sieve 2.9949 0.4465 0.3961 0.07 12.3
(D=0.30 m) (D=3.95 m)
Valve 3.3322 0.4838 0.3434 0.7 10.5
(D=0.94 m) (D=3.65 m)
Tower packings
Materials of Construction K1 K2 K3 Vmin(m3) Vmax(m3)
Ceramic 3.0664 0.9744 0.0055 0.03 628
304 SS 3.2999 0.9744 0.0055 0.03 628
Plastic Saddle 2.4493 0.9744 0.0055 0.03 628
Bare Module Cost Factor (FBM)
Tower trays
MOC Sieve Valve
CS 1.0 1.0
SS 1.8 1.83
Fluorocarbon - -
Ni-alloy 5.6 5.58
Tower packings
Materials of Construction FBM
Ceramic 4.14
304 SS 7.09
Plastic Saddle 1.00
6
Bare Module of Tray towers
C BM  FBM C NFq 0
p
• N is the number of trays

• Fq = A quantity factor for trays N Fq
1 3.00
2 2.96
( 0.4771 0.08516 log N  0.3473(log N ) 2 )
Fq  10 N  20 3 2.75
4 2.53
Fq  1 N  20 5 2.33
8 1.87
10 1.64
15 1.25
20 1.007
Lecture 4-2
How to do a conceptual design of distillation

tower ?
Conceptual design of distillation column
1. Order the components by their normal boiling point.
2. Sequencing the distillation train.
3. Specify the specification/target of each distillation column
(only two degree of freedoms) i.e. recovery of heavy key
and light key components. Do mass balance from the last
column to the first column of train to meet the
specification.
4. From the specification, do the mass balance to get the
product distribution (LNKs and HNKs might be estimated).
5. Determine the operating pressure by specifying the
temperature of condenser. The column pressure drop might
be used to determine the top and bottom column pressure.9
6. Use FUG/DSTWU column to estimate Rmin, optimal R and N.
R=L/D Practical value of reflux 0.08<R<20
Optimal value of reflux R~ 1.05-1.20 Rmin

If Rmin > 20, Re-specify purity and recovery of column
10
7. Use optimal R and N for rigorous calculation (RADFRAC
model) to reach the specification of column. In this step, the
sensitivity tools in ASPEN can be used instead of trail &
error for fine tuning of R&N (NQ curve).
8. Determine Nequi, NR, NS, Roptimal, NFeed, F, D, B, Composition and
state of distillated and bottom products
9. Determine (molar, mass, volume) flow rate of each stream
in each equilibrium stage as well as their hydrodynamic
properties (viscosity, density, surface tension)
10. Use the tray column as the first choice for determine the
diameter of column
Tray column
1. Specify the type of tray Column (Sieve tray, Valve tray,
Bubble cap) by using the ratio of maximum superficial
velocity of vapor / Minimum superficial velocity of vapor in
column (turndown ratio)
2. Determine the diameter of column to avoid flooding
condition: uvapor < ut i.e. udesign= (70-80 %) uflooding
• Determine the diameter of column for 1. above feed stage and 2.
below feed stage
3. Calculate the liquid loading flux (m3/m2.h) to select the
suitable type of column (tray or pack).
Tray column
4. Determine the height of tower
• Estimate the overall efficiency for 2 sections as above feed
and below feed stage.
N tray ,above feed  Eo  N eqi ,above feed N tray ,below feed  Eo  N eqi ,below feed
• Calculate the actual tray using overall efficiency.

• Tray spacing is usually around 60 cm.
• Estimate the height of tower include the tray spacing,
manhole, feed stage, bottom sump and reflux tray
5. Round up the height and diameter of column
Standard increments of pressure vessel
Diameter
Specify vessel I.D. by standard shell diameter
• 450-1000 mm: 50 mm increments
• > 5000 mm: 200 mm or 300 mm increments
Height
• Standard size of Length increment in 6 in series.
• Round off L or H in 0.25 m increments (for
example, 5.0, 5.25, 5.5, 5.75 etc.).
Pack column
1. Specify the type of pack column (Random pack or structure
pack)
2. If random packing, specify the dimension of packing as
well as the type of random pack. The packing factor value is
required for further calculation.
3. Determine the diameter of column to avoid flooding
condition: uvapor < ut i.e. udesign= (50-70 %) uflooding
• Determine the diameter of column for 1. above feed stage and 2.
below feed stage
• Determine the liquid load flux (in the range of pack or not)
Pack column
4. Determine the height of packing
• Estimate the height of packing.
H packing  HETP  N eqi
• Pack column do not have the efficiency, the HETP is related
to the efficiency (higher efficiency, lower HETP)
• Estimate the height of tower include the tray spacing,
manhole, feed stage, bottom sump and reflux tray
5. Round up the height and diameter of column
Lecture 4-3
Pack or Tray Tower ?

Tray or Pack
Cross Flow Counter current Flow

Using pressure for selection
Pressure range Pressure Trays Random Structured
Packings Packings
Low to moderate 1-500 mbar
pressure
Dp/NTS 6 mbar 3 mbar 1 mbar
Atm to medium 1-6 bar
pressure
High pressure
Distillation 6-30 bar
Absorption up to 150 bar

Using liquid-load for selection
Pressure range Liquid load Trays Random Structured
(m3/m2.h) Packings Packings
Low liquid load 0.10-5
Medium liquid 5-50

load
High liquid load > 50
Other criteria
When tray column
1. Usually used in columns of large diameters and towers
that have more than 20 to 30 equilibrium stages,
2. Need high liquid residence time
3. Dirty service (tray columns are easier to clean)
4. Stable and robust operation of the separation process
5. More flexible to variations in operating conditions
Other criteria When packed column
1. Packings are generally more expensive than plates, less
expensive than tray columns for small column diameter (D<0.6
m)
2. More choices in materials of construction especially in corrosive
service (e.g. plastic, ceramic, metal alloys, carbon),
3. Less liquid entrainment, low liquid holdup, especially suitable for
thermally sensitive material
4. Cleaning of a packing section is much too complicated and
expensive
5. Foaming liquids can be handled more readily (less agitation of
liquid by the vapour)
6. Due to novel developments of packing elements the industrial
use of packed columns is steadily increasing
Lecture 4-4
What is the criterial for type of tray column

selection?
Hydrodynamic in tray column
Operation windows for tray column
Excessive= Flooding entrainment

Vapor rate
(Spray regime: vapor is continuous)

Coning (vapor bypass)
Jet flooding
(Froth regime: liquid is continuous)
Area of satisfactory
operation Downcomer flooding
Weeping
Liquid rate
Criteria used: Turndown ratio
Vapor rate
Coning (vapor bypass) V2 Jet flooding
V1
Weeping
Liquid rate
Criteria used: Turndown ratio
V1, y1 Lc, x0
Condenser
L0, x0 D
1 Drum
L1, x1 V2, y2 x0=xD
2 Distillated Product
L2, x2 V3, y3
3
L3, x3 V4, y4
4
L4, x4 V5, y5
5
L5, x5 V6, y6
Feed 6
F= 100 L6, x6 V7, y7
zF=0.30 7
L7, x7 V8, y8
8
L8, x8 V9, y9
9 V10, y10
Bottom Product
Reboiler
L9, x9 x10=xB B
Sieve tray
• Tray has holes punched in it
• Liquid is retained by vapor
upflow
• Cheapest design
• Lowest pressure drop
• Turndown performance is poor
due to weeping
plate • 2 to 1 turndown (50%)
Vapor flow • Good efficiency vs. cost
• Good for high pressure, high
liquid load
Valve tray • Have moving and non-moving
(fixed) valve tray
• Moving valves close when
vapor flow is low
• Fixed valves is less prone to
corrosion or fouling than
moving valves, but poorer
turndown performance
• Cost about 1.1 times sieve
plate plate trays for fixed and 1.2 for
Vapor flow Vapor flow moving
• Better turndown performance
(5:1 range)
Fixed valve Moving valve

Bubble-cap tray
• Ensure that liquid level is
maintained on each tray
• Turndown performance is
better, but most prone to
fouling and corrosion damage
• Best for low liquid rate
• 3 times the sieve tray cost (if
cap
your tower is bubble-cap,
plate estimate cost (CBM) by 3 time
riser of sieve tray)
Vapor flow • Pressure drop is highest
• Widely used before 1970s, but
seldom now
Summarize for type of tray selection
1. Sieve plates are the cheapest and least prone to fouling and
are satisfactory for most applications.
2. Fixed valve plates are almost as cheap as sieve plates and
have improved turndown behavior. The improved performance
usually justifies the increased cost and this type is most
commonly selected for nonfouling applications.
3. Moving valve plates should be considered if the specified
turndown ratio cannot be met with sieve plates or fixed valve
plates.
4. Bubble-caps should only be used where very low vapor (gas)
rates have to be handled and a positive liquid seal is
essential at all flow rates.
Summarize for type of tray selection
Criteria Sieve Valve Bubble cap
Capacity High High to very high Moderate
Pressure drop Low to moderate Moderate High
Efficiency High (0.70-0.90) High (0.70-0.90) Moderate (0.6-0.8)
Tundown 2:1 3-5:1 Very high (can
handle very low
liquid rate)
Maintenance Low Low to moderate Relative high
Fouling tendency Low Low to moderate High (Tends to
accumulate solid
particles)
Main application Most columns where Most columns Very low flow
turndown not services where conditions where
important turndown leakage needs to be
important minimized
Cost Low 1.1-1.2 time of 2-3 times of sieve
sieve
What column internals would you specify for
the following applications?
• Gasoline debutanizer Sieve trays
• Ethanol-water (azeotropic distillation) Sieve trays
• Acid gas scrubbing using alkanolamine Packings or
(corrosive, high liquid loading) Sieve trays
• Styrene monomer re-run column Packings or
(polymerizes easily) Sieve trays
• Fermentation broth stripper (high fouling) Sieve trays

• VOC recovery fractionation (high Bubble caps
turndown)
Example
21
20
Example
If tray tower is first selected, what is the
type of tray tower?
Valve tray tower

Lecture 4-5
How to estimate the diameter of tray

column ?
Operation windows for tray column

Vapor rate
(Spray regime: vapor is continuous)

Coning (vapor bypass)
Jet flooding
(Froth regime: liquid is continuous)
Weeping
Liquid rate
Estimate the diameter of column
• To determine the minimum diameter
of column, maximum vapor flow rate
was used.
• The vapor flow rate is used to
calculate the column diameter
because it distribute to all of area of
column.
• The maximum vapor flow rate is the
entrainment flooding (spray regime:
vapor is continuous) .
Entrainment flooding velocity
ucon
ut  ucon
ut
1 dv
 pV p g   f V p g  C D (  f v ) A   pV p
2
2 dt
For Sphere
4(  p   f ) gD
ut 
3 f C D
for dp=150-200 m
Tray column
Capacity parameters
S
Column diameter
Use single-pass for the first estimate

Area of downcomer
 0.1 FLV  0.1
Ad
 0.1  ( FLV  0.1) / 9 0.1  FLV  1.0
A
 0.2 FLV  1
Example
21
26
13
20
Stage Liquid (kg/hr) Vapor (kg/hr) Density liquid Density vapor FLV surface FST CF CF C
(gm/cc) (gm/cc) tension (ft/s) (m/s) (m/s)
(dyne/cm)
2 4483 24157 0.895 0.001 0.007 54.033 1.220 0.390 0.119 0.145
3 4479 24152 0.894 0.001 0.007 53.949 1.220 0.390 0.119 0.145
4 4474 24148 0.894 0.001 0.007 53.871 1.219 0.390 0.119 0.145
5 4470 24144 0.894 0.001 0.007 53.793 1.219 0.390 0.119 0.145
6 4466 24139 0.893 0.001 0.007 53.716 1.218 0.390 0.119 0.145
7 4462 24135 0.893 0.001 0.007 53.640 1.218 0.390 0.119 0.145
8 4458 24131 0.892 0.001 0.007 53.564 1.218 0.390 0.119 0.145
9 4454 24128 0.892 0.001 0.007 53.488 1.217 0.390 0.119 0.145
… … … … … … … … … … …
13 (Feed) 30948 28506 0.908 0.001 0.041 52.885 1.215 0.370 0.113 0.137
… … … … … … … … … … …
18 31013 28571 0.906 0.001 0.042 52.517 1.213 0.370 0.113 0.137
19 31028 28585 0.905 0.001 0.043 52.448 1.213 0.370 0.113 0.137
20 31043 28600 0.905 0.001 0.043 52.380 1.212 0.370 0.113 0.137
21 31064 28622 0.905 0.001 0.043 52.310 1.212 0.370 0.113 0.137
22 31182 28740 0.905 0.001 0.043 52.195 1.211 0.370 0.113 0.137
23 32854 30412 0.914 0.002 0.044 51.316 1.207 0.370 0.113 0.136
24 54312 51869 0.972 0.003 0.058 39.459 1.146 0.360 0.110 0.126
25 80127 77684 0.877 0.005 0.075 25.692 1.051 0.340 0.104 0.109
26 85991 83549 0.866 0.005 0.076 25.178 1.047 0.340 0.104 0.109
0.50 L= Liquid molar flow rate ML= Average molecular weight of liquid
 LM L  V  V= Vapor molar flow rate MV= Average molecular weight of vapor
FLV    
 VM V   L  LML= Liquid mass flow rate
VMV= Vapor mass flow rate
Example of calculation at stage 2
0.50
 LM L  V 
FLV    
 VM V   L 
0.50
 4483  0.001 
FLV   
 24157  0.895 
FLV  0.0062
First estimate using Plate spacing= 60 cm
CF= 0.39 ft/s=0.119 m/s

Example of calculation at stage 2
0.20
 54.3 
FST     1.22
 20 
6.71
0.80  4.33 
( A  0.10 A)
C  1.22  1 1 0.119
A  2.15 m 2
C  0.145 m / s D  1.65 m
Check liquid loading
0.895  0.001
ut  0.145 m/s
0.001 m3
QL  5.01
hr
ut  4.33m / s
5.01 m 3 m3
LL   2.33 2
2.15 m  hr
2
m h
FLV= 0.0062
Low liquid load: Pack should be used

Determine diameter of tray tower
• Calculate the diameter of each tray

• or At least 1 stage in each section – rectifying and
stripping section) or (above and below feed)
• Use the same diameter in each section (larger one) when
each section diameter is not much different (i.e (Dstrip-
Drec)/Drec < 0.20)
• For different diameter for each section calculate the cost of
column separately.
Stage Liquid Vapor Density Density C ut uv Qv QL A D D LL
(kg/hr) (kg/hr) liquid vapor (m/s) (m/s) =0.80ut (m3/h) (m3/h) (m2) (m) (m) (m3/m2.
(gm/cc) (gm/cc) (m/s) h)
2 4483 24157 0.895 0.001 0.145 4.34 3.47 24157 5.01 2.15 1.65 2.33
3 4479 24152 0.894 0.001 0.145 4.34 3.47 24152 5.01 2.15 1.65 2.33
4 4474 24148 0.894 0.001 0.145 4.33 3.47 24148 5.00 2.15 1.65 2.33
5 4470 24144 0.894 0.001 0.145 4.33 3.47 24144 5.00 2.15 1.65 2.33
1.66
6 4466 24139 0.893 0.001 0.145 4.33 3.46 24139 5.00 2.15 1.66 2.32
7 4462 24135 0.893 0.001 0.145 4.33 3.46 24135 5.00 2.15 1.65 2.32
8 4458 24131 0.892 0.001 0.145 4.33 3.46 24131 5.00 2.15 1.66 2.32
9 4454 24128 0.892 0.001 0.145 4.32 3.46 24128 4.99 2.15 1.66 2.32
… … … … … … … … … … … … …
13 (Feed) 30948 28506 0.908 0.001 0.137 4.13 3.31 28506 34.08 2.66 1.84 12.81
… … … … … … … … … … … … …
18 31013 28571 0.906 0.001 0.137 4.12 3.30 28571 34.23 2.67 1.84 12.81
19 31028 28585 0.905 0.001 0.137 4.12 3.30 28585 34.29 2.68 1.85 12.81
20 31043 28600 0.905 0.001 0.137 4.12 3.29 28600 34.30 2.68 1.85 12.80
21 31064 28622 0.905 0.001 0.137 4.12 3.29 28622 34.32 2.68 1.85 12.80
22 31182 28740 0.905 0.001 0.137 4.11 3.29 28740 34.46 2.69 1.85 12.79
2.40
23 32854 30412 0.914 0.002 0.136 2.91 2.33 15206 35.95 2.01 1.60 17.85
24 54312 51869 0.972 0.003 0.126 17289.66
2.27 1.81 7 55.88 2.94 1.94 18.98
25 80127 77684 0.877 0.005 0.109 1.44 1.15 15536.8 91.36 4.15 2.30 22.00
26 85991 83549 0.866 0.005 0.109 1.43 1.14 16709.8 99.30 4.51 2.40 22.01
Lecture 4-6
How to estimate the height of tray

column ?
Height of tower
• Feed tray spacing = 1000-1200 mm
• Reflux return tray spacing = 1200-1500 mm
• Tropical tray spacing is 600 mm
• Man hole (600 mm diameter) every 15-20 actual
trays and (at that tray spacing = 900 mm)
• Column sump vapor space height = (0.5 to
0.8)*D
• Height of Liquid bottom sump : use residence
time 5-10 min using the liquid flow rate of stage
before the reboiler to calculate the liquid
volume.
Actual number of stage
Eov=Overall Efficiency
Why the overall efficiency is not 100 %?

1. Insufficient time of contact between the liquid and vapor
phases
2. Insufficient degree of mixing of the both phases (the
presence of stagnant zones on large-diameter distillation
trays)
3. The effects of entrainment and weeping.
Overall efficiency
• Tray efficiency is the most important parameter in scale-up
and design of real columns.
• Design efficiency must be < Actual observed efficiency for
design safety margin (e.g. design 70% vs. actual 83%)
• For other columns, tray efficiency may vary by section due to
change in vapor-liquid load and composition
• Below feed vs. above feed
• Below, between, above side cuts
Tray Type Tunnel Tray Bubble Cup Tray Sieve Tray Valve Tray
EOV 0.5 – 0.7 0.6 – 0.8 0.7 – 0.8 0.7 – 0.9
Overall efficiency
O’Connell’s correlation (1946) for hydrocarbons, bubble cap trays
Molar average liquid Relative volatility

viscosity mMs/m2 of light key
• High relative volatility = low tray efficiency

• High viscosity = low tray efficiency
Design tray efficiency from experiences
Services Tray efficiency
HP Deethanizers 50-60
De-isobutenizer 80-100
BTX 75-80
Xylene Fractionators 80-100
Naphta Fractionators 65-75
Deporpanizer 75-80
Columns with low P 40-60
Gas strippers 7-10
Distillation dryers 15
Absorbers 20-30
Design tray efficiency from experiences
Process Type of tower Above feed Below feed
Powerformers Feed stripper 85 75
Deisopentanizer 90 80
Depentanizer 95 75
Stabilizer (Deisobutanizer) 110 85
Absorber-Deethanizer 65 75
Debutanizer 95 80
Splitter and Rerun tower 80 70
Hydrotreaters Kerosene stripper 80 35
Gas oil stripper 100 20
Polymers Propylene/Propane splitter 100 95
CO2/Propylene splitter 100 80
Hexane undercutter 65 45
Hexane drying tower - 70
hexane recovery tower 35 35
Isobutylene purification tower 100 100
Example
21
20
Overall efficiency at stage 2
Using O’Connell’s correlation
Overall efficiency for above and below feed

Height of column
1. Bottom sump : tres=10 min
=8.40 m
=>1.20 m
2. Tray spacing
Height of column
3. Feed stage/man hole
4. Vapor space
Total Height
= 31.5 m
Lecture 4-7
How to estimate the diameter of pack

column ?
Type of packing : Random Pack
First Generation (Raschig Ring, Berl Saddle) Third Generation (Net/Grid Structures, IMPT Ring)
1895 to the 1950s late 1970s to the 1990s
simple shapes with closed surfaces, robust framework structure, large free cross section,
and stable design, cost-effective production low pressure drop, high efficiency
Second Generation (Pall Ring, Intalox Saddle) Fourth Generation (Raschig Super-Ring)
late 1950s to the early 1970s late 1990s until present
surfaces with cutted windows and bent tongues, lower pressure drop and better mass transfer
improved area distribution lowering pressure efficiency
drop and enhancing capacity
Type of packing : Structure Pack
Structured packing of
corrugated metal sheets
Fitting structured packing elements Flexipac to a large-
diameter tower
Folded or stamped perforated sheets

assembled into a block, with high voidage
Structured packings Mellapak
made of metal and plastic
When random packings
• Low column diameter because of ease of fabricate
and cheaper.
When structure packings

• Folded or stamped perforated sheets assembled into
a block, with high voidage.
• Best for vacuum pressure operation.
Guideline for size of random packing
• Small sizes are more expensive than the larger sizes.

• Above 50 mm the lower cost per cubic meter does not
normally compensate for the lower mass transfer
efficiency.
• Use of too large a size in a small column can cause poor
liquid distribution. (Dpacking< 1/15 Dcolumn)
Minimum packing size
Liquid load for random packings

(m3/h.m2)
< 60
60-95
95-135
135-170
>170
Estimate the diameter of column
• To determine the minimum diameter Liquid Gas
of column, maximum vapor flow rate
was used.
• The vapor flow rate is used to
calculate the column diameter
because it distribute to all of area of
column.
• The maximum vapor flow rate is the
flooding conditions.
• Low vapor flow rate low mass
transfer rate results low efficiency. Liquid Gas
Where is loading point / flooding point ?
Pflood  0.115FP0.7
Pressure drop
• ΔPflood in inches
H2O/ft of packed
height
• FP in ft−1 when
6<FP<60
Loading point flooding point

Superficial gas velocity
Packing factors for random pack Random packings
Packing factors for random pack Random packings
Packing factors for structured pack Structure packings
How to determine flooding velocity Random packings
Generalized pressure drop correlation (GPDC)
0.50 ρL and ρV in the same units

0.50  V 
FC  uV FP     L0.05 uV in ft/s, FP in ft−1,
  L  V  Kinematic viscosity, vL, in centistokes
How to determine flooding velocity Structure packings
Generalized pressure drop correlation (GPDC)
Column Diameter
uv ,design  (0.50  0.70)uv , flooding
Volumetric flow rate of gas phase

uV ,design 
Crossectional area of column
Qv Qv
uV ,design  
A D / 4
2
Using Qv from each equilibrium the same as pack column

(or at least each section between feed or side drew).
Example of calculation
Do not forget to calculate the liquid load to check the suitable type of column.
Industrial column example (Pall rings)
System Pressure Column Packing size HETP (m)
(kPa) diameter (m) (mm)
Hydrocarbon absorption 6000 0.9 50 0.85
Water absorption of 101 0.6 50 0.75
acetone
Pentane-propane 101 0.46 25 0.46
distillation
Acetone-water distillation 101 0.46 25 0.37
MEK-toluene 101 0.38 25 0.35
• Vendors should be contacted for proprietary types and for

structured packing
Lecture 4-8
How to estimate the height of pack

column ?
Pack column
Height of packing
Packed Height  N equilibrium  HETP
HETP= Height Equivalent to a Theoretical Plate

HETS= Height Equivalent to a Theoretical Stage
• Values of HETP are generally derived from experimental data for

a particular type and size of packing and are often available from
packing vendors.
• Typically cited, in the absence of data, is an HETP of 2 ft for
modern random packings and 1 ft for structured packings.
Example of HETP data from vender
Guideline of HETP for preliminary design
Pall Rings and similar high-efficiency random packings with low
viscosity liquids (second and third generation)
HETP (ft)  1.50  d p (in )

Structured packing with low-viscosity liquids
100
Low-to-moderate pressures HETP (ft)   0.33
a
100
High pressures HETP (ft)   0.33
a
Wire gauze packing
HETP (ft)  4 (in ) 1 (ft )

VLE with viscous liquids in general:
HETP (ft)  5  6 ft
Vacuum service
HETP (ft)  1.50  d p (in )  0.50

Small-diameter columns, dT < 2 ft
HETP (ft)  dT but not less than 1 ft
HETP of random packing

Effect of liquid viscosity on packing efficiency
Industrial column example (Pall rings)
System Pressure Column Packing size HETP (m)
(kPa) diameter (m) (mm)
Hydrocarbon absorption 6000 0.9 50 0.85
Water absorption of 101 0.6 50 0.75
acetone
Pentane-propane 101 0.46 25 0.46
distillation
MEK-toluene 101 0.38 25 0.35
• Vendors should be contacted for proprietary types and for

structured packing
Tower height
• Feed tray spacing = 1200-2000 mm, reflux return
tray spacing = 1200-1500 mm (including man hole
+distributor)
• Packed bed: max 15-20 NTS or max 8 m per
section, support grid or plate
• Liquid redistributor every 6-8 m.
• Man hole for distributor access (1100-2000 mm
spacing) every 6-8 m.
• Man hole (1100-2000) at feed tray, reflux return
tray and bottom sump.
• Column sump vapor space height = (0.5 to 0.8)*D
Tower height
• Gas and liquid distribution is critical. Gravity-type
liquid distributor preferred for structured packing
with minimum 40 drip points per m2 (60-100
recommended, 200 max)
• Liquid redistributor every 6-8 m. Special design of
gas distributors for high inlet momentum gas
stream (high v2)
Heuristics for DISTILLATION AND GAS ABSORPTION
1. The height of the column should not be higher than
60 m. Height-to-diameter ratio should be less than
30.
2. If the tower is higher than 65 m, then a design with
smaller tray spacing should be considered.
3. We do not usually build distillation columns that are
in excess of 100 m.
4. (Practical) Maximum number of actual stage (like a
C3 splitter) has almost 200 stages (~120 m). The
column was split in 2 columns
Lecture 4-9
Rule of Thumbs for distillation tower

Heuristics for DISTILLATION AND GAS ABSORPTION
1. The height of the column should not be higher than
60 m. Height-to-diameter ratio should be less than
30.
2. If the tower is higher than 65 m, then a design with
smaller tray spacing should be considered (Douglas,
1988).
3. For example, we do not usually build distillation
columns that are in excess of 100 m.
4. (Practical) Maximum number of actual stage (like a
C3 splitter) has almost 200 stages. The column was
split in 2 columns

Lecture 4 Distillation Column-5192-16142479047124

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Lecture 4

How to sizing and costing tower unit?

ผศ.ดร. อภินันท สุทธิธารธวัช

How to estimate the price of Distillation?

ผศ.ดร. อภินันท สุทธิธารธวัช

1. Cost of tower as pressure vessel

• CBM = Bare module equipment cost: direct and indirect

• N is the number of trays

How to do a conceptual design of distillation

R=L/D Practical value of reflux 0.08<R<20

Optimal value of reflux R~ 1.05-1.20 Rmin

• Calculate the actual tray using overall efficiency.

Pack or Tray Tower ?

ผศ.ดร. อภินันท สุทธิธารธวัช

Cross Flow Counter current Flow

Absorption up to 150 bar

Medium liquid 5-50

What is the criterial for type of tray column

Excessive= Flooding entrainment

(Spray regime: vapor is continuous)

Fixed valve Moving valve

• Fermentation broth stripper (high fouling) Sieve trays

Valve tray tower

How to estimate the diameter of tray

Excessive= Flooding entrainment

(Spray regime: vapor is continuous)

Use single-pass for the first estimate

 0.1 FLV  0.1

First estimate using Plate spacing= 60 cm

CF= 0.39 ft/s=0.119 m/s

Low liquid load: Pack should be used

• Calculate the diameter of each tray

How to estimate the height of tray

Why the overall efficiency is not 100 %?

Molar average liquid Relative volatility

• High relative volatility = low tray efficiency

Overall efficiency for above and below feed

How to estimate the diameter of pack

Folded or stamped perforated sheets

When structure packings

• Small sizes are more expensive than the larger sizes.

Liquid load for random packings

Loading point flooding point

0.50 ρL and ρV in the same units

Volumetric flow rate of gas phase

Using Qv from each equilibrium the same as pack column

• Vendors should be contacted for proprietary types and for

How to estimate the height of pack

HETP= Height Equivalent to a Theoretical Plate

• Values of HETP are generally derived from experimental data for

HETP (ft)  1.50  d p (in )

Wire gauze packing

HETP (ft)  4 (in ) 1 (ft )

HETP (ft)  1.50  d p (in )  0.50

HETP (ft)  dT but not less than 1 ft

HETP of random packing

• Vendors should be contacted for proprietary types and for

Rule of Thumbs for distillation tower

ผศ.ดร. อภินันท สุทธิธารธวัช

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