Table of Contents

Chapter 6...........................................................................................................................................3

Binary Distillation Column Design..................................................................................................3

6.1 Distillation Column Design........................................................................................................4

6.1.1 Feed Conditions:..................................................................................................................4

6.1.2 Distillate Conditions:...........................................................................................................4

6.1.3 Bottom Conditions:..............................................................................................................4

6.1.4 Operating Conditions:..........................................................................................................4

6.1.5 Determine the Reflux Ratio (R):..........................................................................................5

6.1.6 q-Line Calculation(4):............................................................................................................7

6.1.7 McCabe-Thiele Graphical Solution(5):.................................................................................7

6.1.8 Determine Theoretical Stages:.............................................................................................9

6.1.9 Correct for Murphree Efficiency:......................................................................................10

6.2 Hydraulic and Process Design for Methanol-Water Distillation Column (3)..............................11

6.2.1 Feed Conditions:................................................................................................................11

6.2.2 Product Composition:........................................................................................................11

6.2.3 Material Balance:...............................................................................................................11

6.2.3 Column Design Parameters:..............................................................................................11

6.2.4 Temperature Conditions:....................................................................................................12

6.2.5 Vapor and Liquid Flow rates:.............................................................................................12

6.2.6 Density Values:..................................................................................................................12

6.2.7 Column Diameter:..............................................................................................................12

6.2.8 Weeping Calculation:.........................................................................................................14

6.2.9 Plate Pressure Drop............................................................................................................16

6.2.10 Down Comer Liquid Backup:..........................................................................................17

 6.2.11 Entrainment:.....................................................................................................................18

List of Tables:
Table 6.1: Antoine Constants..............................................................................................5
Table 6.2: Equilibrium data.................................................................................................9
Table 6.3: Column diameter calculations..........................................................................12
Table 6.4: Pressure Drop Calculation...............................................................................16
Table 6.5: Down Comer liquid back-up calculations........................................................17
Table 6.6: Entrainment calculations..................................................................................18
Table 6.7: Down Comer liquid back-up calculations........................................................19

List of Figures:
Figure 1: McCabe Theile Graph for no of stages................................................................9
 Chapter 6

Binary Distillation Column Design

 6.1 Distillation Column Design

6.1.1 Feed Conditions:

Total feed flow rate (F)¿ 204.6537 kmol /hr

Methanol composition in feed (XF)¿ 0.2798

Enthalpy of feed ¿ 949977.4362 kJ /hr

6.1.2 Distillate Conditions:

Distillate flow rate (D)¿ 45.9641 kmol /hr

Methanol composition in distillate (XD)¿ 0.9323

Enthalpy of distillate ¿ 157216.4317 kJ /hr

6.1.3 Bottom Conditions:

Bottom flow rate (B) ¿ 158.7077 kmol /hr

Methanol composition in bottoms (XB) = 0.0909

Enthalpy of bottom ¿ 892709.4319 kJ /hr

6.1.4 Operating Conditions:

Column pressure ¿ 1 ¯¿

Condenser duty¿−4927064.386 kJ /hr

Re-boiler duty ¿ 5027012.814 kJ /hr

Relative volatility (α)¿ 3.04

6.1.5 Determine the Reflux Ratio (R):

Using Fenske’s equation(6):

ln[( X D (1− X B ))/(X B (1− X D ))]

N min =
ln(α )
Where Relative volatility is calculated as:

 By using Antoine Equation(1);

B
ln ( P )= A−
sat
C +T

Table 6.1: Antoine Constants

Components A B C

Methanol 8.08097 1582.271 239.726

Water 8.14019 1810.94 1810.94

 α at Top Temperature (67°C) :

For methanol;

sat (8.0897− 239.726−67

1582.871
)
P =e

sat
P =30.1 48

For water;

sat (8.14019− 1810.94−67

1810.94
)
P =e

sat
P =10.247

sat
P M
α= sat
P W

α T =2.94

 α at Top Temperature (99°C) :

For methanol;

sat (8.0897− 239.726−99

1582.871
)
P =e

sat
P =40 .5223

For water;

sat (8.14019− 1810.94−99

1810.94
)
P =e

sat
P =12.9 009

sat
P M
α= sat
P W

α B =3.141

 Average Volatility:

α T +α B
α avg=
2

α avg=3.04

Now by usingα =3.04 ;

( 0.9323 × 0.9091 )
N min =ln ⁡[ ]
ln ⁡(3.04 )

ln ⁡( 137.8) 4.93
N min = = =4.433
ln ⁡(3.04 ) 1.112

Minimum Reflux Ratio:

 Underwood Equation for binary system;

 ( α × X D )− X B
Rmin = −1
X D− X B

Rmin =2.26

Practical Design Reflux Ratio:

R=1.5× Rmin =1.5 ×2.260=3.39

6.1.6 q-Line Calculation(4):

H V −¿ H
q= F
¿
H V −¿ H ¿
l

(5403705.383−949977.4362)
q=
(5403705.383−319424.565)

q=0.875

Since 0 < q < 1, the feed is a partially vaporized mixture.

q Zf
q−line equation : y =( ) x−( )
(q−1) ( q−1)

y=(−0.287) x+ 0.36

6.1.7 McCabe-Thiele Graphical Solution(5):

Rectifying section operating line(1):

y=(R/(R+1)) x+(xD/(R +1))

y=(3.39/ 4.39) x+(0.9323 /4.39)

y=0.7722 X+ 0.2123

Stripping section operating line:

 B
y= X−( X B ( +1))
D

0.0909
y= X−
(4.45)
6.1.8 Determine Theoretical Stages:
Using stepwise McCabe-Thiele construction:

α×x
y=
1+(α −1)× x

Where α =3.04 ;

Table 6.2: Equilibrium data

x 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

y 0.25 0.42 0.56 0.66 0.75 0.81 0.875 0.923 0.964 1

8 2

Figure 1: McCabe Theile Graph for no of stages

Total Theoretical Stages (Nt)¿ 8.3 ≈ 9

Including Reboiler(Nt )≈10 stages

6.1.9 Correct for Murphree Efficiency:

Given Murphree efficiency = 70% to 85%, we take 80% for calculation.

Nt
Nactual¿
EM

10
Nactual ¿ =12.5 ≈ 13 stages
0.80
 6.2 Hydraulic and Process Design for Methanol-Water Distillation
Column (3)

6.2.1 Feed Conditions:

Feed Rate (F)=4489.97 kg /h Molar Weight =21.9284 Kg/kmol

Molar Flow−Rate=204.654 Kmol /hrTurn−down Ratio=0.75
Feed Methanol Composition=0.2798 mole fraction
Feed Water Composition=0.7202 mole fraction

6.2.2 Product Composition:

Distillate Methanol Purity=0.9323 mole fraction
Distillate Water Composition=0.0677 mole fraction
Bottom Product Composition=0.0909 mole fraction

6.2.3 Material Balance:

The total mass balance equation is given as:

F=D+ B

Bottom Flow Rate(B)=158.6292 kmol /hr Distillate Flow Rate(D)=47.0009 kmol /hr

6.2.3 Column Design Parameters:

Number of Ideal Trays=11Reflux Ratio=0.5Tray Efficiency=0.75

Tray Spacing=0.5 metersHole Area(Active Area)=0.08 m²
Downcomer Area=16 % of column area

6.2.4 Temperature Conditions:

Base Temperature=99 ° CTopTemperature=67 ° C

6.2.5 Vapor and Liquid Flow rates:

Vapor Flowrate=70.5014 kmol/hr Liquid Flow Above Feed=23.5005 kmol /hr

Liquid Flow Below Feed=228.1545 kmol /hr
6.2.6 Density Values:

Density of Vapor (Bottom)=0.74 kg /m ³Density of Liquid (Bottom)=960.63 kg /m ³

Density of Vapor (Top)=1.48 kg /m ³Density of Liquid (Top)=782.123 kg /m³

6.2.7 Column Diameter:

Formulas used:

U f =K √ ρL ​− ρV
ρV

F LV =
lw
Vw √ ρV
ρL

V
A=
Uf

Table 6.3: Column diameter calculations

Coulmn Diameter

Parameter Value Units

Flv top 0.01450014

Flv Bottom 0.08981914

From Fiqure, We get

Base K1 0.056

Top K1 0.081

Corrected K1

Corrected K1 ( Base ) 0.06933725

Corrected K1 ( Top ) 0.08050806

 Base Uf 2.49724699 m/sec

Top Uf 1.84899077 m/sec

85% flooding velocity 85%

Base Uf 2.12265994 m/sec

Top Uf 1.57164215 m/sec

12% of DownComer Area Assumed 12%

Cross-sectional Area Top 0.31141675 m2

Cross-sectional Area 0.28630978 m2

Bottom

Column Diameter

Top D 0.62984858 m

Bottom D 0.60392535 m

Coulmn Diameter 0.6604 m

or 26 in

6.2.8 Weeping Calculation:

Weeping in Distillation Column:

 Weeping in a distillation column occurs when the liquid starts to leak through the
perforations of the tray instead of flowing across the tray to the down comer. This
happens when the vapor flow rate is too low to support the liquid on the tray.

Formula for Weeping Condition:

Weeping begins when the liquid head on the tray exceeds the pressure exerted by the
rising vapor. The condition for weeping is:

Pv <h l × ρl × g

Where:

Pv = Vapor pressure exerted on the tray (Pa)

hl = Liquid head above the tray (m)

ρl = Liquid density (kg/m³)

g = Gravitational acceleration (9.81 m/s²)

Calculated Parameters for Weeping in Methanol-Water Column:

Maximum Liquid Flow Rate

ṁ L=1.2225 kg /s

Minimum Liquid Flow Rate

ṁ L=0.9169 kg/s

Weir Liquid Crest (Maximum & Minimum)

Maximum: hw , max=18.59 mm=0.01859 m

Minimum:hw , min=15.35 mm=0.01535 m

 Total Weir Liquid Height

h w =hw max+ how

Given:

h ow=65.35 mm=0.06535 m

h w total=0.01859+ 0.06535=0.08394 m

Minimum Vapor Velocity Required to Prevent Weeping

√
Uv min= (
(2× g ×hw , total ×( ρL−ρV ))
ρV
)

Substituting values:

Uv min= √ ((2 × 9.81× 0.08394 ×(960.63−1.48))/1.48)

Uv min= √ ((1.6463 × 959.15)/1.48)

Uv min= √ (1067.98)

m
Uv min=14.58
s

Actual Minimum Velocity in the Column

Uv actual=22.60 m/ s

Since Uvactual > Uvmin, weeping is avoided in this design

6.2.9 Plate Pressure Drop

The following area terms are used in plate design procedure:

 Ac = Total column cross-sectional area

 Ad = Cross-sectional area of down comer
 An = (Ac - Ad ) net area available for vapor-liquid disengagement
 Aa = active area (Ac - 2Ad)
 Ah = hole area, total area of all active holes
 Ap = perforated area
 Aap = clearance area under down comer apron

Pressure drop across the plate is determined using empirical correlations:

Total Pressure Drop: ΔP=h d+ hr

Where: h d (Liquid Head Loss)=51.78 mm of liquid

h r (Frictional Loss)=13.01 mm of liquidTotal Pressure Drop=133.39 mm of liquid

Table 6.4: Pressure Drop Calculation

Plate Pressure Drop

Parameter Value Units

Uh 30.13387796 m/sec
Ah/ Ap 0.08
C0 0.83
hd 51.78447955 mm of liq
hr 13.01229402 mm of liq

Total Pressure Drop 133.3914208 mm of Liq

6.2.10 Down Comer Liquid Backup:

Backup∈ Downcomer is calculated as :Backup Height= H dc+ Approach Height

H dc=0.3069 mmTotal Backup=0.225 m

Table 6.5: Down Comer liquid back-up calculations

LINK Excel. Sheet .12 C:\\Users\\ACER\\Desktop\\hydraulic design T 102.xlsx Sheet 1 ! R 20 C 20: R 29 C

Down Comer Liq Back-Up

Parameter Value Units
h ap 0.04 m
A ap 0.0296 m2
Hdc 0.3068526 mm

Backup∈ DownCOmer 191.964714 mm

Backup∈ Downcomer 0.225 m

Residence Time 6.60698247 sec

¿ 3 sec

6.2.11 Entrainment:
Entrainment occurs when liquid droplets are carried by vapor. It is defined as:

Fractional Entrainment = 0.0027

Flooding Percentage = 78.15%

U f =K 2 ×
√ σ
ρL ​− ρV
 U h =Co×
√ ∆P
ρV

Table 6.6: Entrainment calculations

LINK Excel. Sheet .12 C:\\Users\\ACER\\Desktop\\hydraulic design T 102.xlsx Sheet 1 ! R 30 C 20: R 35 C

Entrainment

Parameter Value Units

Uh 1.86282155 m/sec
% flooding 74.5950061 %
Fractional Entrainment 0.0027

6.2.12 Number of Holes:

π 2
Areaof one hole= ×(dh)
4

Ah
No of holes=
Area of one hole
 Table 6.7: Down Comer liquid back-up calculations
LINK Excel. Sheet .12 C:\\Users\\ACER\\Desktop\\hydraulic design T 102.xlsx Sheet 1 ! R 11C 24 : R 14 C

Number of holes
Parameter Value Units

Areaof one hole 0.000019625 m2

Number of holes 964.7968476
Reference:

1. Perry’s Chemical Engineers’ Handbook, 9th Edition

2. Smith, J. M., Van Ness, H. C., & Abbott, M. M. (2005). Introduction to Chemical
Engineering Thermodynamics.
3. Chemical Engineering Design Colson and Richardson’s series , Sixth Edition ,
Chapter no # 11
4. Seader, J. D., Henley, E. J., & Roper, D. K. (2011). Separation Process Principles.
5. McCabe, W. L., Smith, J. C., & Harriott, P. (1993). Unit Operations of Chemical
Engineering.
6. Fenske, M. R. (1932). Industrial & Engineering Chemistry, 24(9), 482–485