Distillation Tower Design

• As computer technology advances, the

fundamental aspects of plant design are
becoming a lost art. … N.P. Lieberman,
Refinery Manager, GHR Energy Inc., La
• The following steps are taken to design and
optimize a distillation tower:
(a) Select a Process Sequence
• Consider a five component feed as shown below.
Arrange in order of descending vapor pressure.

• C2 3
• C3 20
• C4 37
• C5 35
• C6 5
• Total 100 lb moles/hr
 Process Sequence Cont’d
• Make a split between C3 and C4
• Show this as C2, C3 / C4, C5, C6
• This called a depropanizer.
• C3 is identified as the light key.
• C4 is identified as the heavy key.
Establish Key Component Specs
• C3, light key composition in bottoms shall
be 1.0 mole %. (2.0% sales spec)
• C4, heavy key composition in the overheads
shall be 1.5 mole %. (3.0% sales spec).
Set Up Mass Balance for Tower

Fe e d Fe e d Ohds Btms
C2 3 3
C3 lk 20 20 - Y Y
C4 hk 37 X 37 - X
C5 35 35
C6 5 5
100 23 + X - Y 77 + Y - X
 Mass Balance Equations

Light Ke y In Btms = 1.00%

He a vy Ke y In Ohds = 1.50%

Y 0.01 Eqn 1
77 + Y - X

X 0.015 Eqn 2
23 + X - Y
 Mass Balance Solution

Fe e d mf in Fe e d Ohds mf in Ohds Btms mf In Btms

C2 3 0.0300 3.00 0.1330
C3 lk 20 0.2000 19.23 0.8520 0.77 0.0100
C4 hk 37 0.3700 0.34 0.0150 36.66 0.4734
C5 35 0.3500 35.00 0.4520
C6 5 0.0500 5.00 0.0646
100 1.0000 22.56 1.0000 77.44 1.0000
 Obtain Antoine Constants
• Need Antoine constants for Vapor Pressure
• Vap Press, VP = 10^(A + B / (t°C + C)) psia

Compone nt A B C
C2 5.0120015 -823.03103 328.18
C3 lk 4.3742477 -587.76681 248.90
C4hk 3.8201853 -367.50819 153.30
C5 4.0537542 -539.73661 169.60
C6 4.0165587 -545.39181 141.15
 Feed Conditions
• Temperature of feed = 225 deg F = 107.22
deg C.
• Pressure of feed = 264.7 psia
 Determine Bubble Point of Feed
As s ume T, de g F = 212.5714318 T, De g C = 100.317462
At P re s s = 264.7 ps ia

Compone nt Mole s /h, M VP , ps ia K = VP /P M*K

C2 3 1233.86 4.66133 13.98400
C3 lk 20 491.08 1.85523 37.10452
C4 hk 37 235.03 0.88790 32.85248
C5 35 113.27 0.42792 14.97726
C6 5 57.27 0.21635 1.08173
100.00 99.999999
 Determine Dew Point of Feed
As s s ume T = 269.7699145 T, De g C = 132.094397
At P re s s = 264.7 ps ia

Compone nt Mole s /hr, M VP , ps ia K = VP /P M/K

C2 3 1674.442 6.3258 0.4742
C3 lk 20 678.469 2.5632 7.8029
C4 hk 37 340.773 1.2874 28.7403
C5 35 183.966 0.6950 50.3600
C6 5 104.851 0.3961 12.6227
100.00 100.000001
 Assess Feed Condition
• Feed Bubble Point = 100.32 deg C
• Feed Temp = 107.22 deg C
• Feed Dew Point = 132.09 deg C
• Feed temp between Bubble Pt. and Dew Pt.
• Feed must be in a two-phase V / L state.
• Special care will have to be taken for feed
distributor design on feed tray.
 Determine V / L for Feed
As s ume V/L = 0.17114

1 2 3 4 5 6
Compone nt Mole s /hr, M K = VP /264.7 K(V/L) 1+K(V/L) L= 1 / 4 V= 1 -5
C2 3 5.0000 0.856 1.856 1.617 1.383
C3 lk 20 2.0000 0.342 1.342 14.900 5.100
C4 hk 37 0.9700 0.166 1.166 31.732 5.268
C5 35 0.4800 0.082 1.082 32.343 2.657
C6 5 0.2500 0.043 1.043 4.795 0.205
100.00 85.387 14.613

Flas h Frac tio n Vapo r in Fe e d = 1-q = V / M = 0.14613121 V/L ca lc'd = 0.17114

V/L As s 'd = 0.17114
Diff = 0.00000
 Solve For Ø, The Underwood
Parameter
• Example In article by J.M. Ledanois,
Hydrocarbon Processing, April, 1981, P-
231
• Trial and error solution with as many
solutions as there are components.
• Solution is a Newton convergence method.
• Not all cases converge.
 Solve For Ø, The Underwood
Parameter, Cont’d
Ne xt Ø 1.5976753 from Ne qton Conve rge nce

As s ume d Ø = 1.5976753 S olution 2

1-q= 0.1461312 e nte r no. ma nua lly va lue from ce ll P 55 - Fra ction Va por In Fe e d

Te mp = 225 °F 107.22 °C Is t Es tima te

P re s s , P T = 264.7 ps ia Eqn 13-43 Of Ø
Mole s /Hr re l vola tility Alpha *xFi Avg Alpha
Fe e d Fi xF1 Ki = VP i / P T Alpha i Alpha *xFi Aplha - Ø Adj Compts
C2 3 0.0300 5.0000 5.1546 0.155 0.043 3.6082
C3 lk 20 0.2000 2.0000 2.0619 0.412 0.888 1.5309
C4 hk 37 0.3700 0.9700 1.0000 0.370 -0.619 0.7474
C5 35 0.3500 0.4800 0.4948 0.173 -0.157 0.3763
C6 5 0.0500 0.2500 0.2577 0.013 -0.010

100 1.0000 ∑= 0.1461312 = 1-q

 Solve For Ø, The Underwood
Parameter, Cont’d
1-q= 0.1461312

Is t Es tima te Fina l Es t
Eqn 13-43 Of Ø Of Ø
Alpha *xFi Avg Alpha Avg Alpha
Fe e d Alpha *xFi Aplha - Ø Adj Compts S olution No. Ø S olutions
C2 0.155 0.043 3.6082 1 4.80084859
C3 lk 0.412 0.888 1.5309 2 1.59767531
C4 hk 0.370 -0.619 0.7474 3 0.64185818
C5 0.173 -0.157 0.3763 4 0.26706697
C6 0.013 -0.010

∑= 0.1461312 = 1-q
 Calc Minimum Reflux Ratio by
Underwood
• See Perry VI, Chem Eng HB, Page 13-36
• Solution For Minimum Reflux Ratio By
Solving For ∑ [Alpha*xDi / (Alpha - Ø)] =
L/D min. + 1
• Ø, The Underwood Parameter, was
determined above.
 Calc Minimum Reflux Ratio by
Underwood, Cont’d

Unde rwood pa ra me te r = 1.5977

Te mp = 225 °F 107.22 °C
P re s s ure = 264.7 ps ia
Eqn 13-42
Alpha i Alpha *xDi
Ohds Mole s /hr xD1 Ki = VP i / PT Ki/K hk Alpha *xDi Aplha - Ø
C2 3.00 0.1327 5.0000 5.1546 0.684 0.192
C3 lk 19.30 0.8540 2.0000 2.0619 1.761 3.793
C4hk 0.30 0.0133 0.9700 1.0000 0.013 -0.022
22.6 1.0000 L/Dmin. + 1= 3.9635

L/D min. = 2.9635

 Determine Minimum No. Trays
by Fenske - Underwood
• Assume top and bottom pressure equal feed
pressure of 264.7 psia for now.
• Assume overhead distillate is removed as a
vapor from the condenser.
 Determine Minimum No. Trays by
Fenske – Underwood, Cont’d
De w Po int o f Ove rhe ad Vapo r S tre am and Alpha o f Ke ys

Te mp = 118.3 °F 47.94 °C
Pre s s ure = 264.7 ps ia

Ohds , D Mole s /hr, M xD1 Ki = VP i / P T M/K

C2 3.00 0.1327 2.5180 1.19
C3 lk 19.30 0.8540 0.9364 20.61
C4hk 0.30 0.0133 0.3726 0.81
1.0000
22.6 22.61

Alpha Top = KC3 / KC4 = 2.51 For Dis tilla te a t 118 °F

 Determine Minimum No. Trays by
Fenske – Underwood, Cont’d
Bubble Po int Of Bo tto ms S tre am and Alpha o f the Ke ys

Te mp = 274.0 °F 134.44 °C
P re s s = 264.7 ps ia

Mole s /hr, M xF1 Ki = VP i / P T M(K)

C3 lk 0.7 0.009044 2.6196 1.834
C4hk 36.7 0.474160 1.3189 48.405
C5 35 0.452196 0.7175 25.112
C6 5 0.064599 0.4119 2.060
MT = 1.000000
77.4 77.411

Alpha Btm = KC3 / KC4 = 1.99 For Btms a t 274°F

Determine Minimum No. Trays by
Fenske – Underwood, Cont’d
• Determine geometric Average Alpha
between top and bottom of the tower.
• Geometric Avg = (Alpha Top*Alpha
Btm)^0.5
• Avg Alpha = ((2.51)(1.99))^0.5 = 2.23
Determine Minimum No. Trays by
Fenske – Underwood, Cont’d

• Min. Trays = LN((C3 lkD / C4 hkD)*

(C4 hkB / C3 lkB)) / LN(Alpha Avg)

• Minimum No. Trays, Sm = 10.11

Determine Trays versus Reflux
Ratio by Gilliland Method
• Use Chang equation to represent Gilliland.
• Huan Yang Chang, HC Proc, Oct 1981, P-146
• A partial condenser and a reboiler represent two
theoretical trays.
• No. trays = S – 2.
• Assume the economic reflux ratio is 1.2 times the
minimum reflux ratio,
• Plot the results.
 Determine Trays versus Reflux
Ratio by Gilliland Method, con’d
L/D Min. = 2.9635 Sm = 10.11
L/D = 3.56
Cha ng Fa ctor = (S - S m) / (S + 1) = 1 - EXP (1.49+0.315*C-1.805/C^0.1)
whe re C = (L/D - L/Dmin) / (L/D + 1)
Cha ng Fa ctor
A B C (S - S m) By Cha ng
L/D L/D - L/Dmin B/(A +1) (S + 1) S N=S -2
3.1 0.14 0.0333 0.65 30.30 28.30
3.2 0.24 0.0563 0.59 26.29 24.29
3.3 0.34 0.0783 0.56 24.07 22.07
3.56 0.59 0.1301 0.49 20.97 18.97
4 1.04 0.2073 0.43 18.39 16.39
4.5 1.54 0.2794 0.38 16.81 14.81
6 3.04 0.4338 0.29 14.53 12.53
Plot of Trays Versus Reflux Ratio
Reflux Versus Number of Trays

40.00

35.00

30.00

25.00
Number of Trays

20.00 Example

15.00

10.00

5.00

0.00
2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50
Reflux Ratio, L/D
 Determine Feed Tray Location
Fe e d Tray Lo c atio n By Kirbride Equatio n
Oil And Ga s J ourna l, Oct. 20, 1980, P -138, by He nry Y. Ma k

Fe e d Tra y Loca tion = EXP [0.206*LN(B/D*fhk/flk*((blk/B)/(dhk/D))^2)]

B = 77.44 fhk = 37 dhk = 0.34

D = 22.56 flk = 20 blk = 0.77

Kirbride Fe e d Tra y Loca tion = 1.25 = # tra ys a bove fd / # tra ys be low fd

No the ore tica l tra ys = 19

Tra ys Above = 10.55 11 10

Tra ys Be low = 8.45 8 fina l s e le ction 9
Ra tio A/B = 1.25 1.38 1.11
 Determine Reflux Flow & Comp’n

Te mp = 118.65 °F 48.14 °C
P re s s ure = 264.7 ps ia
L/D = 2.963 L= 66.868
Comp of Re flux
Mole Fra c De w P t. Liq Re flux S tre a m,
Ohds , D Mole s /hr, M y, D Ki = VP i / P T M/K x=y/K mole /hr, L
C2 3.00 0.1330 2.5246 1.19 0.05266 3.522
C3 lk 19.23 0.8520 0.9392 20.47 0.90724 60.666
C4hk 0.34 0.0150 0.3741 0.90 0.04009 2.681
1.0000
D= 22.5641 22.5641 1.00000 66.868
 Calculate Overhead Vapor Flow
from Top Tray = 19

Minimum Re flux Ra tio = 2.963

D= 22.56 mole s /hr
L = (2.963)(D) = 66.868 mole s /hr.
V= L+ D= 89.432 mole s /hr
 Calc Vapor Composition from
Top Tray 19
Te mp = 118.65 °F 48.14 °C
P re s s ure = 264.7 ps ia
Comp of Re flux Va pour Va por
Mole Fra c De w P t. Liq Re flux S tre a m, S tre a m Comp'n
Ohds , D Mole s /hr, M y, D Ki = VP i / P T M/ K x=y/K mole /hr, L mole s /hr, V mole fra c
C2 3.00 0.1330 2.5246 1.19 0.05266 3.522 6.52 0.0729216
C3 lk 19.23 0.8520 0.9392 20.47 0.90724 60.666 79.89 0.893316
C4hk 0.34 0.0150 0.3741 0.90 0.04009 2.681 3.02 0.0337624
1.0000
22.5641 22.5641 1.00000 66.868 89.432 1.00000
Show Molar Balance Around
Top Tray 19
To p Tray n, As s ume e qual mo lar flo w
Mo lar balanc e = V18 = V19 + L19 - L

V19 = 89.4324 V19 = L + D

Re flux L
Tray 19 66.868

L19
66.868 Liq fr Tray 19

V18 = 89.4324
 Calc Dew Pt of Vapor Fr T19
and Liquid Comp’n Fr T19
Te mp = 126.5378 °F 52.52 °C
P re s s ure = 264.7 ps ia
Comp of
Mole Fra c De w P t. Liq fr Tra y n
Ohds , V Mole s /hr, V y, V Ki = VP i / P T M/ K x=y/K
C2 6.52 0.0729 2.6753 2.44 0.02726
C3 lk 79.89 0.8933 1.0035 79.61 0.89022
C4hk 3.02 0.0338 0.4091 7.38 0.08252
1.0000
89.4324 89.4325 1.00000
Mole s /hr, V 89.4324
Diff = 0.0001
 Vapor Comp’n From Tray 18

Va por, V19 Re flux, L L19 Comp L19 Flow Va p, V18 Va p, V18

mole s /hr mole s /hr mole fr mole s /hr mole s /hr mole fra c
C2 6.52 3.52 0.0273 1.82 4.82 0.0539
C3 lk 79.89 60.67 0.8902 59.53 78.75 0.8806
C4hk 3.02 2.68 0.0825 5.52 5.86 0.0655

89.43 66.87 1.0000 66.87 89.43 1.0000

 Calc Dew Point of Vapor V18
Te mp = 133.0915 °F 56.16 °C
P re s s ure = 264.7 ps ia

V18 Mole Fra c De w P t.

Vap V18 Mole s /hr, M y, V18 Ki = VP i / P T M/K
C2 4.82 0.0539 2.8044 1.72
C3 lk 78.75 0.8806 1.0587 74.39
C4hk 5.86 0.0655 0.4394 13.33
1.0000
89.4326 89.4326
Mole s /hr V18 89.4326
Diff 0.0001
 Design Data For Top of Tower
Va p, V18 L19 Flow Liq De ns ity
MW lb/hr lb/hr lb/cf
C2 30.07 145 55 22.2
C3 lk 44.10 3,473 2,625 31.6
C4 hk 58.12 340 321 35.1
3,958 3,001 31.80

MW = 44.26 44.87

De w Po int o f Vapo r fro m Tray 18 = Vapo ur to To p Tray 19

Te mp = 133.0915 De g F
P re s s ure = 264.7 ps ia

Vapo r De ns ity = (MW)(Ps ia) / (10.73) / (De g Rankine ) = 1.841 lb/cf

 Input Shortcut Tower Dia. (FWG)
Input Data
Va por To Tra y, V, lb/hr = 3,958 CFS Va por = 0.60 CFS Va por = V / DV / 3600
Va por De ns ity, Dv, lb/cf = 1.841
Liquid From Tra y, L, lb/hr = 3,001 US GPM = 11.76 US GP M = L / DL / 60 * 7.481
Liquid De ns ity, DL, lb/cf = 31.80
S ys te m Fa ctor, S F = 1.00 FWG 4900 / 5, Ta ble 1b No n Fo aming Sys te m
Tra y S pa cing, TS , Inche s = 18 As s ume 18 inche s or 24 inche s a s a Firs t Try. 24 inch TS is pre fe rre d.
S pra y Ht. / Tra y S pa cing, = 50.00% As s ume 70% a s a de fa ult va lue .
As s ume Minimum Va lve s / AA = 8 No. Va lve s / s f AA A Highe r va lue , e g 13, ma y le a d to a n uns uita ble , s ma lle r to
Downcome r Flood, % DCF = 50.00% As s ume 60% a s a de fa ult va lue .

Pre liminary Sizing

Downcome r Are a (One S ide ), s f = 0.14 DCA = (L*7.481 / DL /60)/(7.5*TS^0.5*(DL-Dv)^0.5*S F) / %DC Flood
Active Are a , AA, s f = 1.39 AA = V/3600/Dv/(((((TS *S H/TS )-4.5213)/4.3662)*DL/Dv)^0.5)*78.5/(No Va lve s /
Towe r Are a s f = 1.66 AT = AA + 2*DCA
Towe r Dia , ft. = 1.45 D = (AT*3/)^0.5

S e le ct Towe r Dia m = 2.00 ft. (ne xt 6" incre me nt)

 Shortcut Method by Dr Prakash
Kv = 0.04070 by Kv = -0.17*(TS)^2+0.27*(TS )-0.047 whe re TS is in me te rs
cm/s = 0.01691 cm/s by cfs /3.2808^3
ve l = 0.16419 m/s by Vma x =Kv(DL-DV/DV)^0.5, the S oude r Eqn
A= 0.103 sm cm/s / m/s
D me tric = 0.362 m D = (s m/.785)^0.5
D Englis h = 1.188 ft D = m*3.2808
 Check Tower Mole Balance
89.43 22.56

66.87 re flux
Tra y 19

89.43 66.8684

14.61
Fe e d Tra y Mola l Ba la nce
100.00 Fla s hing fe e d 74.82 Fe e d Tra y Fe e d In = 241.69
Fe e d Out = 241.69
85.39

74.82 152.26

Tra y No. 1

Va pour to Tra y No. 1 = 74.82 152.26 Liquid From Tra y No. 1

In e quilibrium with bottoms
Note : Towe r s imula tion us ua lly a s s ume this config
Re boile r for the re boile r. In a ctua l pra ctice it is not quite like this
S e e towe r s ke tch for re a s on

77.44 Compos ition From Btms Bubble P t.

 Calc Bubble Point of Bottoms
Te mp = 273.757833 °F 134.31 °C
P re s s ure = 264.7 ps ia

y = K(x)
Mole Fra c Bub P t. Va p to Tr 1
Btms , B Mole s /hr, M x, B Ki = VP i / P T M *K mole fra c
C3 lk 0.77 0.0100 2.6163 2.03 0.02616
C4 hk 36.66 0.4734 1.3171 48.29 0.62359
C5 35.00 0.4520 0.7162 25.07 0.32371
C6 5.00 0.0646 0.4110 2.06 0.02654
1.0000
77.4359 77.4358 1.00000
77.4359
-0.0001
 Vapor Rate To Tray 1
y = K(x)
Vap to Tr 1 Vap to Tr 1 Mo le c ular Vap to Tr 1
Btms , B mo le frac Mo le s /hr, V1 We ig ht lb/hr
C3 lk 0.02616 1.96 44.10 86
C4 hk 0.62359 46.66 58.12 2,712
C5 0.32371 24.22 72.15 1,747
C6 0.02654 1.99 86.18 171

1.00000 74.82 63.04 4,717

 Final Vapor & Liquid Data to Tr 1

Btms , B Vap to Tr 1 Liq Fr Tray 1 Mo le c ular Liq Fr Tray 1 Liq De ns

Btms , B mo le s /hr Mo le s /hr, V1 Mo le s /hr We ig ht lb/hr lb/c f
C3 lk 0.77 1.96 2.73 44.10 120 31.6
C4 hk 36.66 46.66 83.32 58.12 4,842 35.1
C5 35.00 24.22 59.22 72.15 4,273 37.2
C6 5.00 1.99 6.99 86.18 602 40.7

77.44 74.82 152.26 9,838 36.31

Te mp = 273.76 De g F
Pre s s = 264.70 ps ia

Vapo r De ns ity = (MW)(Ps ia) / (10.73) / (De g Rankine ) = 2.119 lb/c f

Tower Diameter For Bottom Tray 1
Va por To Tra y, V, lb/hr = 4,717 CFS Va por = 0.62
Va por De ns ity, Dv, lb/cf = 2.119
Liquid From Tra y, L, lb/hr = 9,838 US GP M = 33.78
Liquid De ns ity, DL, lb/cf = 36.31
S ys te m Fa ctor, S F = 1.00 FWG 4900 / 5, Ta ble 1b
Tra y S pa cing, TS , Inche s = 18 As s ume 18 inche s or 24 inche s a s a Firs
S pra y Ht. / Tra y S pa cing, = 50.00% As s ume 70% a s a de fa ult va lue .
As s ume Minimum Va lve s / AA = 8 No. Va lve s / s f AA A Highe r va lue , e g 1
Downcome r Flood, % DCF = 50.00% As s ume 60% a s a de fa ult va lue .

Pre liminary S izing

Downcome r Are a (One S ide ), s f = 0.36 DCA = (L*7.481 / DL /60)/(7.5*TS ^0
Active Are a , AA, s f = 1.45 AA = V/3600/Dv/(((((TS *S H/TS )-4.5
Towe r Are a s f = 2.17 AT = AA + 2*DCA
Towe r Dia , ft. = 1.66 D = (AT*3/)^0.5

S e le ct Towe r Dia me te r 2 ft. (ne xt 6" incre me n

 Shortcut Method by Dr Prakash
For Bottom of Tower

Kv = 0.04070 by Kv = -0.17*(TS )^2+0.27*(TS)-0.047 whe re TS is in me te rs

cm/s = 0.01751 cm/s by cfs /3.2808^3
ve l = 0.16348 m/s by Vma x =Kv(DL-DV/DV)^0.5, the S oude r Eqn
A= 0.107 sm cm/s / m/s
D me tric = 0.369 m D = (s m/.785)^0.5
D Englis h = 1.212 ft D = m*3.2808
 Tray Efficiency
O'Co nne ll and Dric kame r / Bradfo rd Tray Effic ie nc ie s
Ba s is , P e rry VI, p 18-14, & Ludwig, Applie d P roce s s De s ign For Che mica l P la nt De s ign

As s ume a ve rga e column conditions a t Fe e d te mp = 225 De g F

Liq Vis c Va p P re s s Va p P re Ra tio

Comp Xi, Fe e d cP (Xi)(cP ) ps ia Alpha lk/hk (Alpha lk/hk)(Xi)
C2 0.03000 0.02 0.0006
C3 lk 0.20000 0.06 0.0120 529.40 2.0619 0.2270
C4 hk 0.37000 0.1 0.0370 256.76
C5 0.35000 0.15 0.0525
C6 0.05000 0.16 0.0080
1.00000 0.1101 = X For Dricka me r

O'Conne ll Y = 0.2270

Dricka me r Y = 0.1101
 Tray Efficiency cont’d
Box A
O'Conne ll Tra y Efficie ncy = 70.39% P e rry VI, Fig 18-23a

P e rry VI, Eqn 18-14 Tra y Eff'y = IF Y > 4, (46.514*(Y)^-0.2052)/100 63.06%

IF Y > 1 Tra y Eff'y = (48*(Y)^-0.228)/100 67.31%
IF Y > 0.45 Tra y Eff'y = (48*(Y)^-0.2797)/100 72.67%
Els e , Tra y Eff'y = (49.83*(Y)^-0.233)/100 Ans --> 70.39%

Dricka me r Tra y Eff'y = 76.43% Dricka me r Tra y Eff'y = -27.3*LN(Dricka me r Y / 1.81) / 100
Ludwig, Applie d P roce s s De s ign For Che mica l P la nt De s ign
And P e trole um P la nt, Vol Ii, Gulf P ublis hing, Circa 1960.

Re comme nd Us e Ave ra ge = 73.41% (O'Conne ll + Dricka me r) / 2

 Actual No. of Trays & Feed Tray
Location
No . The o re tic al Trays = 19

Traty Effic ie nc y = 73.41%

Ac tual Trays = 26

Kirbride Fe e d Tray Ratio = 1.25

Trays abo ve Fe e d = 15
Fe e d Tray Lo c atio n = 11

S e le c te d Fe e d Tray Ratio = 1.3636 vs 1.25 by Kirbride

 Tower Dimensions
26 3 ft. to p trat to to p tan line

14 s pc s at 1.5 ft./s pc
52 ft. Tan to Tan 21 ft.

12
11 3 ft. fe e d tray s pac e

10 s pc s at 1.5ft/s p
15 ft.
1

10 ft. to firs t tray

10 ft. s hirt
 Vessel Specs

Ve s s e l S pe c s

Ope ra ting pre s s ure = 264.7 ps ia Che c k Flang e Rating s

De s ign P re s s ure = 300 ps ia
Ma x Ope ra ting te mp = 273.758 de g F Flg Ra ting, ps ig 300 (150/300/400/600)
De s ign te mp = 650 de g F Flg P re s s , ps ig 541 Flgs O.K.
Ma te ria l = S A-516 Gr 70 De s Te mp, °F = 650 de g F
Corros ion a llowa nce = 0.0625 inche s .
Cost of Towers Database v1.1
Ta g No., T - 100
De s cription De pro panize r
Flow S he e t No. 1000
No. Eqt Ite ms 1
90 Actua l Cos t
90 Es t'd Cos t
Towe r Type Tray To we r
Towe r Dia ., ft 2
T-T Le ngth, ft 52
De s ign P re s s , ps ig 300
Corr Allow, in. 0.0625
Yie ld Eff'y 0.85 10% X-RAY
Towe r Ma te ria l No. (26) 4 S A-516 Gr 70
Tra y Option (4) 1 Va lve
No Tra ys 26
Tra y Mtl No. 1 T-410 S S
P a cking Option
P a cking Ht, ft.
Tra y Cos t-88
Cost Estimate for Tower with Trays
S e le ct Towe r No., T- 301 (1 to 16 in Towe r dB) Time P e riod 2001
dB Ite m No. 9 Fa b Eqt Inde x 454
De s cription De propa nize r CND$/US $ 1.54
Flows he e t No. 0 Duty US >CAN 1
No. Eqt Ite ms 1
90 Actua l Cos t 0 S he ll Cos t = $79,204 S hop Fa b
90 Es t'd Cos t 0 Tra y Cos t = $9,268 S hop Ins ta lle d
Towe r Type Tra y Towe r P la tforms = $8,218 S hop Ins ta lle d
Towe r Dia ., ft 2 Tot Towe r Cos t = $96,690
T-T Le ngth, ft 52
De s ign P re s s , ps ig 300
Ba ck Ca lc'd de s pre s s = 306.06996 ps ig
Corr Allow, in. 0.0625
Yie ld Eff'y 0.85 10% X-RAY
Towe r Ma te ria l No. 4 S A-516 Gr 70
Tra y Option 1 Va lve
No Tra ys 26
Tra y Mtl No. 1 T-410 S S
P a cking Option 0 #N/A
P a cking Ht, ft. 0
Tra y Cos t-88 0
Btm Wa ll Thickne s s = 0.53125 Inche s
Top Wa ll Thickne s s = 0.3125 Inche s
Ve s s e l Wt = 5,800 lbs
S kirt Ht = 12 ft.
S kirt Wt = 2,345 lbs As s uming 3/4" Thk
Tra y Wt = 980 lbs As s uming 10 ga . Wt.
Tota l Towe r Wt = 9,125 lbs
 Shortcut
Method for
Packed
Towers
 Ekert Packing Factors
S ome Eke rt We t Dumpe d P a cking Fa ctors , S F/Cf, for s hortcut me thod Note :

Dia m. Inche s 0.625 0.75 1.00 1.50 2.00

Ma te ria l
Ce ra mic S upe r Inta lox 60 30
P la s tic S upe r Inta lox 33 21
Ce ra mic Inta lox S a ddle s 145 98 52 440
Me ta l Hy-P a k Rings 42 18
P la s tic P a ll Rings 97 52 40 25
Me ta l P a ll Rings 70 48 28 20
Ce ra mic Be rl S a ddle s 170 110 65 45
Ce ra mic Ra s chig Ring 380 255 155 95 65
P la s tic Te lle re tte s 40 20
P la s tic Ma pa k 32
Us e r Choice - S e e P e rry VI, P -18-23

S e le ct P a cking Fa ctor = 155 s f/cf FP for s hortcut me thod only

 Approximate HETP
• From Tray Tower design, TS = 18 inches.
• For Approximated Packed Tower Design assume
one HETP = one Tray Spacing.
• HETP = 18 inches.
• Determine Tower Dimensions as for a Trayed
Tower.
• Allow 6 ft. for feed tray and top tray for liquid
distributer.
• No packing height should exceed 20 ft.
• If packing height exceeds 20 ft., must redistribute
liquid which adds another 6 ft.
 FRI Packed Tower V1.2
FRI Pac ke d To we r **FRIPT** Ve rs io n 1.0, 14 No v 93

Ca s e S tudy =Bottom of Towe r Exa mple for CBE 497 Dwg No. = Exa mple from P e rry III
By = RAH Ta g No. = CBE - 497

Input Da ta

Liquid Flow = 9,933 lb/hr P a cking Fa ctor = 155 s f/cf

Liquid De ns ity = 36.31 lb/cf P a cking Type No. = 18
Liquid Vis cos ity = 0.08 Ce ntipois e P a cking Type = Ce ra mic Ra s chig Rings / We t P a cke d
Va por Flow = 4,812 lb/hr P a cking S ize = 1 Inche s
Va por De ns ity = 2.117 lb/cf
Va por Vis cos ity = 0.01 Ce ntipois e
No. The ore tica l Tra ys = 19
Towe r I.D. = 2.00 ft.
S = mG/L Fa ctor = 1.01 Minimum Va lue = 1.01
 FRI Packed Tower Results For 2
ft. Diameter Tower

Fro m Ge ne ralize d Ec ke rt Pre s s ure Dro p Co rre latio n S hortcut Me thod

X = (WL/WG)(RHOG/RHOL)^0.5 = 0.4984
Y = (G)^2(FP )/(gc*RHOG*RHOL) = 0.0113
At X a bove , Y Flooding = YF = 0.0444
% Flood At (X,Y) = (Y/YF)^0.5*100 = 50.56%
Ecke rt P re s ure Drop = 0.20 Inche s H2O/ft. DP = 3.87 In. H2O
 FRI Packed Tower Results For
1.5 ft. Diameter Tower

Fro m Ge ne ralize d Ec ke rt Pre s s ure Dro p Co rre latio n S hortcut Me thod

X = (WL/WG)(RHOG/RHOL)^0.5 = 0.4984
Y = (G)^2(FP )/(gc*RHOG*RHOL) = 0.0358
At X a bove , Y Flooding = YF = 0.0444
% Flood At (X,Y) = (Y/YF)^0.5*100 = 89.88%
Ecke rt P re s ure Drop = 1.77 Inche s H2O/ft. DP = 35.14 In. H2O
 FRI Detailed Method for
Designing a Packed Tower
• Select a Packing Factor from 18 selected
packing types.
• FRI have determined the design factors
which are too numerous to list here.
• FRI Packed Tower V1.2 will use this
packing data and the other data in the
shortcut method to design % Flood and
estimate the HETP.
 FRI Detailed Method For PT
Fro m Ne w FRI Pac king Co rre latio ns , Re po rts 92, 94, and 95, 1984 De ta ile d Me thod

FS Fa ctor = (V)(RHOG)^0.5 = 0.29 Top towe r = 6 ft.

US GP M = 34.11 US GP M Fe e d tra y - 6 ft.
US GP M / S F = 10.86 US GP M/s f Btm pa cking =9 ft.
a / Eps ilon^3 fa ctor = 146.08 s f/cf Top pa cking 12 ft.
P a cking He ight = 19.42 Ft. btm towe r = 12 ft.
P a cking Volume = 61.01 Cu. ft. Ta n - ta n = 42 ft.
S kirt = 10 ft.
Dry P a cking P re s s ure Drop = 0.46 In. H2O / ft. Dry DP = 9.01 In. H2O
We t P a cking P re s s ure Drop 0.67 In. H2O / ft. We t DP = 13.05 In. H2O

Ma ximum Allowa ble Va por Ra te For Ca lcula te d HETP = 9,150 lb/hr

% Loa d or % Ca pa city = 4812 / 9150 = 52.59%

Ma ximum S ta ble Or Flood Va por Ra te At Unknown HETP = 12,279 lb/hr s kirt ht. = 12 ft.
% Flood = 4812 / 12279 = 39.19%
 FRI HETP Values for 2 ft. Diam.
FRI Vapo r And Liquid Trans fe r Unit Value s

Va por Ba ck Mixing Tra ns fe r Unit = HDUG = 3.53 Inche s

Liquid P ha s e Tra ns fe r Unit = HTUL = 4.56 Inche s
Va por P ha s e Tra ns fe r Unit = HTUG = 4.19 Inche s
Ove ra ll Ga s P ha s e Tra ns fe r Unit = HTOG = 12.33 Inche s

At Above De s ign Va por / Liquid Ra te s , HETP = 12.27 Inche s

HETP Me s s a ge = Within 20% to 80% Ca pa city Limits Tota l He ight of pa cking = 19.42 ft.

HETP Calc ulatio ns (Go o d Only Be twe e n 20% to 80% Of Capac ity
And Fo r Le ve l, FRI Tube d Drip Pan Dis tributo r.)
 Packed Tower Cost Estimate
S e le ct Towe r No., T- 302 (1 to 16 in Towe Timer dB)
P e riod 2001
dB Ite m No. 10 Fa b Eqt Inde x 454.00
De s cription De propa nize r CND$/US $ 1.54
Flows he e t No. 0 Duty US >CAN 1.00
No. Eqt Ite ms 1
90 Actua l Cos t $0 S he ll Cos t = $61,120 S hop Fa b
90 Es t'd Cos t $0 P a cking Cos t = $1,406 Fie ld Ins ta lle d
Towe r Type P a cke d Towe r P la tforms = $7,319 S hop Ins ta lle d
Towe r Dia ., ft 2 Tot Towe r Cos t $69,845
T-T Le ngth, ft 42
De s ign P re s s , ps ig 300
Ba ck Ca lcd De s ign P re s s ure , ps ig = 6.07
Corr Allow, in. 0.0625
Yie ld Eff'y 0.85 10% X-RAY
Towe r Ma te ria l No. 4 S A-516 Gr 70
Tra y Option 0 #N/A
No Tra ys 0
Tra y Mtl No. 0 #N/A
P a cking Option 1 Ce ra mic Ra s chig Rings , 1 in
P a cking Ht, ft. 21
Tra y Cos t-88 $0
Btm Wa ll Thickne s s = 0.4375 Inche s
Top Wa ll Thickne s s = 0.3125 Inche s
Ve s s e l Wt = 4,482 lbs
S kirt Ht = 12 ft.
S kirt Wt = 2,345 lbs As s uming 3/4" Thk
P a cking 0 P a cking Ins ta lle d In Fie ld
Tota l Towe r Wt = 6,827 lbs
 Summary
S ho rtc ut S ho rtc ut De taile d
Trays Pkd Twr Pkd Twr
Diame te r 2 2 2
S he ll t-t 52 53 45
No . The o Tr 19 19 19
Effic ie nc y 73.41%
No . trays 26
Tray S pg 18
HETP, inc he s 18 12.27
Pkg ht. 29 21

S he ll Co s t $79,204 $80,441 $61,120

Tr/Pkg Co s t $9,268 $1,942 $1,406
Platfo rms $8,218 $8,345 $7,319
To tal $96,690 $90,728 $69,845
Word of Caution – Trayed Towers
• Towers with trays are huge mixing devices.
Any slight restriction will cause flooding.
• Three controlling factors:
• (1) % Flood by Liquid and Vapor Load
• (2) % Spray Height by number of holes.
• (3) % Downcomer flood.
• Trays must be level and well supported.
Word of Caution – Trayed Towers
• Vendors will often quote towers with many
holes to reduce diameter and obtain the bid.
• Later on detailed design, they find they
must reduce holes for specified diameter.
• This increases spray height beyond
acceptable level and entrainment will be too
high.
• Buyers must be aware of all design details.
Word of Caution – Packed Towers
• Packed towers are low pressure drop
systems. Flows don’t always go where they
should.
• HETPs offered by vendors are optimistic.
• Vendors claim a wide range of operation.
• In actual practice there is a narrow range.
 Word of caution – Packed
Towers cont’d
• Uniform liquid distribution is difficult.
• If packing ht. Exceeds 20 ft.. Liquid must
be redistributed. This adds cost.
• Vapor is easily misdirected to walls.
• Vapor distributors are often required.