TCN3132 Separation Processes

Lecture 2: Binary and

Multicomponent Flash Distillation

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

Department of Chemical &

Biomolecular Engineering

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 1

 Overview Words of Advise
• Binary flash distillation • Separation Processes is a conceptual and
 The equations procedure heavy module
 Design and performance analysis • The basic concept of equilibrium and mass transfer
 Operating line equation and graphical solution is the same for every separation process
 Recovery • You would need to understand the important
concepts right from the beginning as it forms the
basis and foundation for subsequent topics
• Multicomponent flash distillation • Please keep pace with the lectures and tutorials
 The problem every week
 Analytical solution procedure • Best is to attend the class every week and
participate in the interactive class discussion and
problem solving (Remember participation marks!)
Reference: • Practice, practice and practice!
Wankat 3rd edition • Always feel free to ask or consult me when in
Chapter 2 doubt or if anything is not clear

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 2

 Flash Distillation: Basic Equations

• Mass balance:
 𝐹𝐹 = 𝐿𝐿 + 𝑉𝑉 (overall)
 𝐹𝐹𝐹𝐹 = 𝐿𝐿𝐿𝐿 + 𝑉𝑉𝑉𝑉 (more volatile component)
• Energy balance:
 𝐹𝐹ℎ𝐹𝐹 + 𝑄𝑄 = 𝐿𝐿ℎ𝐿𝐿 + 𝑉𝑉𝐻𝐻𝑉𝑉
• Equilibrium:
 𝑦𝑦𝐴𝐴 = 𝐾𝐾𝐴𝐴 𝑥𝑥𝐴𝐴
• Assumptions:  𝑦𝑦𝐵𝐵 = 𝐾𝐾𝐵𝐵 𝑥𝑥𝐵𝐵
 Flash drum is adiabatic • We have two degrees of freedom out of 𝑥𝑥𝐴𝐴 , 𝑦𝑦𝐴𝐴 ,
 Because of intimate contact between the 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 , 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 :
liquid and vapor phases in the drum, the  One degree of freedom is usually 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
system inside the drum is very close to an
equilibrium stage
VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 3
Flash Distillation: Design and Performance Analysis

• Possible choices for last degree of freedom:

 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
x
y
 Fraction feed vaporized 𝑉𝑉⁄
𝐹𝐹

• If one of the equilibrium conditions is specified, that is, 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 , x or y:

 Solve mass balance and equilibrium equations or use T-x-y and x-y diagrams
• If 𝑉𝑉⁄𝐹𝐹 is specified:
 Derive an equation in 𝑉𝑉⁄𝐹𝐹 from the mass balance equation => Design equation
for flash

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 4

• Problem type 1: If 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 (i.e., operating condition) is
given
 A performance analysis problem
• Problem type 3: If 𝑉𝑉⁄𝐹𝐹 is given
 Use T-x-y plot to find x and y at 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
 A design problem as operating condition
 Solve mass balance equations for V and L
is unknown
 Solve energy balance equation for Q
 Designate 𝑽𝑽⁄𝑭𝑭 = 𝒇𝒇 => Fraction of feed
• Problem type 2: If x (or y) is given
vaporized
 A design problem as operating condition is
 Derive operating line equation from
unknown
component mass balance
 Use T-x-y plot to find 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 at given x (or y)
 Solve mass balance equations for V and L
 Solve energy balance equation for Q

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 5

 Flash Distillation: Operating Line Equation

• Mass balance:
𝐹𝐹𝐹𝐹 = 𝐿𝐿𝐿𝐿 + 𝑉𝑉𝑉𝑉
𝐿𝐿 𝐹𝐹
⇒ 𝑦𝑦 = − 𝑥𝑥 + 𝑧𝑧 ----------------------------------(1) • Substituting equation (2) into equation (1):
𝑉𝑉 𝑉𝑉
• Divide overall mass balance by V: 𝟏𝟏−𝒇𝒇 𝟏𝟏
𝒚𝒚 = − 𝒙𝒙 + 𝒛𝒛 -----------------------------------(3)
𝒇𝒇 𝒇𝒇
𝐹𝐹 𝐿𝐿 𝑉𝑉
= + • Equation (3) is the flash operating line equation
𝑉𝑉 𝑉𝑉 𝑉𝑉
𝐿𝐿
⇒ = −1
𝐹𝐹  Component mass balance is the operating
𝑉𝑉 𝑉𝑉
line equation in any separation process
𝐿𝐿 1 1−𝑓𝑓
⇒ = −1= (Since 𝑉𝑉⁄𝐹𝐹 = 𝑓𝑓) ------------(2)
𝑉𝑉 𝑓𝑓 𝑓𝑓

𝟎𝟎 < 𝒇𝒇 < 𝟏𝟏

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 6

 Flash Distillation: Operating Line

1−𝑓𝑓
• Line b with slope − represents
𝑓𝑓
equation (3)
 Intersects diagonal (𝒙𝒙 = 𝒚𝒚) at z
 Not all points are solutions to the flash
design problem
 Only the point of intersection with the
Line a c
equilibrium curve is the solution, as it
f 1 0
represents that V and L are in
Slope of
0 ∞ equilibrium
equation (3)

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 Flash Distillation: Performance

• Purity of the desired product:

 Lighter component will be enriched in the vapor product
 Heavier component will be enriched in the liquid product
 Either vapor or liquid can be the desired products
• How do we measure performance?
 Define recovery of a component – the percentage of a component present in the feed
that has been recovered in the product stream
 For example, if 10 moles of A is present in the feed, and 9 moles of this A ends up in
vapor product, recovery of A in vapor product is 9/10 = 0.90 (or 90%)

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 8

• Recovery for a flash unit:
𝑉𝑉𝑦𝑦𝐴𝐴 𝑦𝑦𝐴𝐴
 Recovery of lighter component A in the vapor product = = 𝑓𝑓
𝐹𝐹𝑧𝑧𝐴𝐴 𝑧𝑧𝐴𝐴

𝐿𝐿𝑥𝑥𝐵𝐵 𝑥𝑥𝐵𝐵
 Recovery of heavier component B in the liquid product = = 1 − 𝑓𝑓
𝐹𝐹𝑧𝑧𝐵𝐵 𝑧𝑧𝐵𝐵

 If 90% of A is recovered in vapor product, 10% of A will be in liquid product

• You either find the required operating conditions (𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 and 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 ) for the required
recovery or calculate the recovery at a given 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 and 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

Purity and recovery are two different parameters

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 9

 Test Your Understanding
Example 1: Flash Design and Limits
A flash distillation chamber operating at 1 atm (101.3 kPa) is separating ethanol-water mixture containing
60 mole % ethanol.
(a) Is it possible to get a vapor product containing 80 mole% ethanol from this unit?
𝑉𝑉 𝐿𝐿
(b) If the drum temperature is 80oC, find 𝑥𝑥, 𝑦𝑦, , .
𝐹𝐹 𝐹𝐹
(c) What should be the drum temperature if we want 50% of the feed to evaporate?
𝑉𝑉
𝑦𝑦

Assume basis: 𝐹𝐹 = 100 kmol/h

𝐹𝐹
𝑧𝑧 = 0.6

𝐿𝐿
𝑥𝑥 VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 10
a)

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 11

b)

• From T-x-y plot, 𝒙𝒙 = 𝟎𝟎. 𝟒𝟒7 and 𝒚𝒚 = 𝟎𝟎. 𝟔𝟔𝟔𝟔

• Overall mass balance: 𝑉𝑉 + 𝐿𝐿 = 𝐹𝐹 = 100

• Component mass balance: 𝑦𝑦𝑉𝑉 + 𝑥𝑥𝐿𝐿 = 𝑧𝑧𝐹𝐹

⇒ 0.64𝑉𝑉 + 0.47𝐿𝐿 = (0.6)(100)

⇒ 𝑉𝑉 = 76.5 and 𝐿𝐿 = 23.5

𝑽𝑽 𝑳𝑳
⇒ = 𝟎𝟎. 𝟕𝟕𝟕𝟕𝟕𝟕 and = 𝟎𝟎. 𝟐𝟐𝟐𝟐𝟐𝟐
𝑭𝑭 𝑭𝑭
VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 12
c)

𝑉𝑉
• Given: 𝑓𝑓 = = 0.50
𝐹𝐹

1−𝑓𝑓
• Slope of flash operating line: − = −1
𝑓𝑓

• Draw operating line on x-y diagram

⇒ 𝒙𝒙 = 𝟎𝟎. 𝟓𝟓𝟓𝟓

⇒ From T-x-y diagram, 𝑻𝑻 = 𝟕𝟕𝟕𝟕𝟕

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 13
 Example 2: Flash Unit Performance Analysis

The T-x-y plot for toluene-phenol system at 1 atm pressure is given on the next slide. It has been decided
that a 35:65 mixture of toluene and phenol will be flash distilled at a feed rate of 1000 kmol/h in a flash
drum at 1 atm pressure and 140°C.

a) Find toluene mole fractions in the vapor and liquid streams leaving the flash unit. Show your
drawings in the figure.
b) Calculate the vapor flow rate leaving the flash unit.

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 14

 Tdrum =
F=1000
140°C
kmol/h
Pdrum =
zA = 0.35
1 atm
zB = 0.65

Important concepts:
• V and L leaving the flash drum are in equilibrium
• Hence, x and y lie on the equilibrium curve
• Both V and L are at Tdrum and Pdrum

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 15

• Given: 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 140℃

• From T-x-y diagram, 𝒙𝒙 = 𝟎𝟎. 𝟐𝟐𝟐𝟐 and 𝒚𝒚 = 𝟎𝟎. 𝟕𝟕𝟕𝟕

• Overall mass balance: 𝑉𝑉 + 𝐿𝐿 = 𝐹𝐹 = 1000

• Component mass balance: 𝑦𝑦𝑦𝑦 + 𝑥𝑥𝑥𝑥 = 𝑧𝑧𝑧𝑧

⇒ 0.79𝑉𝑉 + 0.24𝐿𝐿 = (0.35)(1000)

⇒ 𝑽𝑽 = 𝟐𝟐𝟐𝟐𝟐𝟐 and 𝐿𝐿 = 800

𝑉𝑉 𝐿𝐿
⇒ = 0.2 and = 0.8
𝐹𝐹 𝐹𝐹

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Multicomponent Flash Distillation: The Problem

• Remember V and L are in equilibrium, that is, 𝑥𝑥𝑖𝑖

and 𝑦𝑦𝑖𝑖 are in equilibrium
𝑦𝑦𝑖𝑖 Stream Nomenclature
 𝐾𝐾𝑖𝑖 = (Component i)
𝑥𝑥𝑖𝑖

• ∑𝑛𝑛𝑖𝑖=1 𝑥𝑥𝑖𝑖 = 1 Feed, F 𝑧𝑧𝑖𝑖

Vapor, V 𝑦𝑦𝑖𝑖
• ∑𝑛𝑛𝑖𝑖=1 𝑦𝑦𝑖𝑖 = 1
Liquid, L 𝑥𝑥𝑖𝑖

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 17

• Mass balance:
 𝐹𝐹 = 𝐿𝐿 + 𝑉𝑉 (overall)
=> 𝐿𝐿 = 𝐹𝐹 − 𝑉𝑉
 𝐹𝐹𝑧𝑧𝑖𝑖 = 𝐿𝐿𝑥𝑥𝑖𝑖 + 𝑉𝑉𝑦𝑦𝑖𝑖 (component i)
• Substitute 𝐿𝐿 = 𝐹𝐹 − 𝑉𝑉 and 𝑦𝑦𝑖𝑖 = 𝐾𝐾𝑖𝑖 𝑥𝑥𝑖𝑖 into component mass balance:
 𝐹𝐹𝑧𝑧𝑖𝑖 = 𝐹𝐹 − 𝑉𝑉 𝑥𝑥𝑖𝑖 + 𝑉𝑉𝐾𝐾𝑖𝑖 𝑥𝑥𝑖𝑖
𝐹𝐹𝑧𝑧𝑖𝑖
 𝑥𝑥𝑖𝑖 =
𝐹𝐹−𝑉𝑉 +𝑉𝑉𝐾𝐾𝑖𝑖

𝑧𝑧𝑖𝑖
 𝑥𝑥𝑖𝑖 = 𝑉𝑉 𝑉𝑉 (dividing numerator and denominator by F)
1−𝐹𝐹 +𝐹𝐹𝐾𝐾𝑖𝑖

𝑧𝑧𝑖𝑖 𝑉𝑉
 𝑥𝑥𝑖𝑖 = (remember 𝑓𝑓 = )
1−𝑓𝑓 +𝑓𝑓𝐾𝐾𝑖𝑖 𝐹𝐹
𝒛𝒛𝒊𝒊
 𝒙𝒙𝒊𝒊 = -------------------------------------(P)
𝟏𝟏+𝒇𝒇 𝑲𝑲𝒊𝒊 −𝟏𝟏

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 18

 Multicomponent Flash Distillation: The Design Equations

• Since ∑𝑛𝑛𝑖𝑖=1 𝑥𝑥𝑖𝑖 = 1:

𝒏𝒏 𝒏𝒏 𝒛𝒛𝒊𝒊
 ∑𝒊𝒊=𝟏𝟏 𝒙𝒙𝒊𝒊 = ∑𝒊𝒊=𝟏𝟏 = 𝟏𝟏 ---------------(A)
𝟏𝟏+𝒇𝒇 𝑲𝑲𝒊𝒊 −𝟏𝟏

• Since ∑𝑛𝑛𝑖𝑖=1 𝑦𝑦𝑖𝑖 = ∑𝑛𝑛𝑖𝑖=1 𝐾𝐾𝑖𝑖 𝑥𝑥𝑖𝑖 = 1: • How do we solve equations

𝑲𝑲𝒊𝒊 𝒛𝒛𝒊𝒊
(A), (B) or (C)?
𝒏𝒏 𝒏𝒏
 ∑𝒊𝒊=𝟏𝟏 𝒚𝒚𝒊𝒊 = ∑𝒊𝒊=𝟏𝟏 = 𝟏𝟏 ---------------(B)
𝟏𝟏+𝒇𝒇 𝑲𝑲𝒊𝒊 −𝟏𝟏  They are non-linear in 𝑓𝑓
• ∑𝑛𝑛𝑖𝑖=1 𝑦𝑦𝑖𝑖 − ∑𝑛𝑛𝑖𝑖=1 𝑥𝑥𝑖𝑖 = 0:  Either solve by trial-and-
𝐾𝐾𝑖𝑖 𝑧𝑧𝑖𝑖 𝑧𝑧𝑖𝑖 error by assuming 𝑓𝑓
 ∑𝑛𝑛𝑖𝑖=1 − ∑𝑛𝑛𝑖𝑖=1 =0
1+𝑓𝑓 𝐾𝐾𝑖𝑖 −1 1+𝑓𝑓 𝐾𝐾𝑖𝑖 −1
 Or use Solver in Excel to
𝑲𝑲𝒊𝒊 −𝟏𝟏 𝒛𝒛𝒊𝒊
𝒏𝒏
 ∑𝒊𝒊=𝟏𝟏 = 𝟎𝟎 -----------------------------(C) solve for 𝑓𝑓
𝟏𝟏+𝒇𝒇 𝑲𝑲𝒊𝒊 −𝟏𝟏

• Equations (A), (B) and (C) are the multicomponent flash design equations
 Any one of the three can be used to solve the problem

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 19

Multicomponent Flash Distillation: Solution Procedure
𝐹𝐹 and 𝑧𝑧𝑖𝑖 are always known

Problem type 1:
• If 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 and 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 is given:
 Get 𝐾𝐾𝑖𝑖 values at given 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 and 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
 Solve equation (A), (B) or (C) for 𝑓𝑓
 With 𝑓𝑓 calculated:
• Use equation (P) to get all 𝑥𝑥𝑖𝑖
• Use 𝑦𝑦𝑖𝑖 = 𝐾𝐾𝑖𝑖 𝑥𝑥𝑖𝑖 to get all 𝑦𝑦𝑖𝑖
𝑉𝑉
• Calculate 𝑉𝑉 from 𝑓𝑓 =
𝐹𝐹
• Calculate 𝐿𝐿 from 𝐿𝐿 = 𝐹𝐹 − 𝑉𝑉
• This is a performance analysis problem at known 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 and 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 20

Problem type 2:
• If 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 and 𝑓𝑓 is given:
 Need to guess 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 so that we can estimate 𝐾𝐾𝑖𝑖 = 𝑓𝑓(𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 , 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 )
 Check whether equation (A), (B) or (C) is satisfied at assumed 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 ; if not,
iterate for 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
 With 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 calculated, using 𝐾𝐾𝑖𝑖 and 𝑓𝑓:
• Use equation (P) to get all 𝑥𝑥𝑖𝑖
• Use 𝑦𝑦𝑖𝑖 = 𝐾𝐾𝑖𝑖 𝑥𝑥𝑖𝑖 to get all 𝑦𝑦𝑖𝑖
𝑉𝑉
• Calculate 𝑉𝑉 from 𝑓𝑓 =
𝐹𝐹
• Calculate 𝐿𝐿 from 𝐿𝐿 = 𝐹𝐹 − 𝑉𝑉
• This is a design problem as we are finding 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 which is an operating condition

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 21

 Example 3: Multicomponent Flash Performance Analysis
A flash chamber operating at 50oC and 200 kPa is separating 1000 kmol/hr of a feed that is 30 mole%
propane, 10 mole% n-butane, 15 mole% n-pentane and 45 mole% n-hexane.
Find the product compositions and flow rates.
• We will use Excel solver to solve for 𝑓𝑓.
𝑉𝑉, 𝑦𝑦𝑖𝑖
• In written exam, you will be expected to show one iteration by manual trial-and-error.

𝑘𝑘𝑘𝑘𝑘𝑘𝑘𝑘 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
𝐹𝐹 = 1000
ℎ𝑟𝑟 = 50𝑜𝑜 C
𝑧𝑧1 = 0.3 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑
𝑧𝑧2 = 0.1 = 200 kPa
𝑧𝑧3 = 0.15
𝑧𝑧4 = 0.45

𝐿𝐿, 𝑥𝑥𝑖𝑖
VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 22
Solution procedure:
• Given: 𝑧𝑧𝑖𝑖 , 𝑇𝑇𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 , 𝑃𝑃𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 => 𝐾𝐾𝑖𝑖 can be determined from DePriester Chart
𝑧𝑧𝑖𝑖
• Design equation: ∑𝟒𝟒𝑖𝑖=1 = 1 => 𝑓𝑓 is the only unknown, solve
1+𝑓𝑓 𝐾𝐾𝑖𝑖 −1
by trial-and-error or use Solver in excel
𝑧𝑧𝑖𝑖
• Calculate 𝑥𝑥𝑖𝑖 from 𝑥𝑥𝑖𝑖 =
1+𝑓𝑓 𝐾𝐾𝑖𝑖 −1

• Calculate 𝑦𝑦𝑖𝑖 from 𝑦𝑦𝑖𝑖 = 𝐾𝐾𝑖𝑖 𝑥𝑥𝑖𝑖

• Calculate 𝑉𝑉 from 𝑉𝑉 = 𝑓𝑓𝑓𝑓
• Calculate 𝐿𝐿 from 𝐿𝐿 = 𝐹𝐹 − 𝑉𝑉

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 23

 Excel Screenshot

VasudevanS/TCN3132/Binary and Multicomponent Flash Distillation 24