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Distillation Column

Distillation Column. Distillation :. “Process in which a liquid or vapour mixture of two or more substances is separated into its component fractions of desired purity, by the application and removal of heat”. CHOICE BETWEEN PLATE AND PACKED COLUMN.

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Distillation Column

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  1. Distillation Column

  2. Distillation: “Process in which a liquid or vapour mixture of two or more substances is separated into its component fractions of desired purity, by the application and removal of heat”

  3. CHOICE BETWEEN PLATE AND PACKED COLUMN The choice between use of tray column or a packed column for a given mass transfer operation should, theoretically, be based on a detail cost analysis for the two types of contactors. However, the decision can be made on the basis of a qualitative analysis of relative advantages and disadvantages, eliminating the need for a detailed cost comparison. Which are as follows

  4. Liquid dispersion difficulties • Capable of handling wide rangesliquid rates • Cleaning. • Non-foaming systems • Periodic cleaning • weightof the column • Design information • Inter stage cooling • Temperature change • Diameters

  5. As my system is non foaming and diameter calculated is larger than 0.67 m so I am going to use Tray column. Also as average temperature calculated for my distillation column is higher that is approximately equal to 98oc. So I prefer Tray column.

  6. PLATE CONTACTORS: Cross flow plate are the most commonly used plate contactor in distillation. In which liquid flows downward and vapours flow upward. The liquid move from plate to plate via down comer. A certain level of liquid is maintained on the plates by weir.

  7. Three basic types of cross flow trays used are • Sieve Plate (Perforated Plate) • Bubble Cap Plates • Valve plates (floating cap plates)

  8. Selection of Trays:

  9. I prefer Sieve Plate because: • Pressure drop is low as compared to bubble cap trays • Their fundamentals are well established, entailing low risk. • The trays are low in cost relative to many other types of trays. • They can easily handlewide variations in flowrates. • They are lighter in weight. It is easier and cheaper to install. • Maintenance cost is reduced due to the ease of cleaning.

  10. Sieve Tray

  11. Label Diagram (sieve tray) Man Way Downcomer And Weir Calming Zone Plate Support Ring Major Beam

  12. FACTORS AFFECTING DISTILLATION COLUMN OPERATION Adverse vapour flow conditions can cause: • Blowing • Coning • Dumping • Raining • Weeping • Flooding

  13. Condenser Pump Reboiler FLOW SHEET REFLUX DRUM REFLUX DRUM (1) Methyl Iodide = 0.212 (2) Acetic Acid = 0.0005 (3)Methyl Acetate = 0.62 (4) Water = 0.167 (1) Methyl Iodide = 0.21 (2) Acetic Acid = 0.0005 (3)Methyl Acetate = 0.62 (4) Water = 0.17 FEED FEED (1) Methyl Iodide = 0.07 (2) Acetic Acid = 0.65 (3)MethylAcetate=0.22 (4) Water = 0.065 (1) Methyl Iodide = 0.074 (2) Acetic Acid = 0.65 (3)Methyl Acetate = 0.215 (4) Water = 0.065 (1)Acetic Acid = 0.99 (2)Water = 0.01

  14. From Material Balance: • Heavy Key Component = Acetic Acid • Light Key Component = Water

  15. DESIGNING STEPS OF DISTILLATION COLUMN • Calculation of Minimum number of stages.Nmin • Calculation of Minimum Reflux Ratio Rm. • Calculation of Actual Reflux Ratio. • Calculation of theoretical number of stages. • Calculation of actual number of stages. • Calculation of diameter of the column. • Calculation of weeping point, entrainment. • Calculation of pressure drop. • Calculation of the height of the column.

  16. Calculation of Minimum no. of Plates: The minimum no. of stages Nmin is obtained from Fenske equation which is, Nmin = LN[(xLK/xHK)D(xHK /xLK)B] LN (αLK/HK) average Average geometric relative volatility = 1.53 So, Nmin = 24

  17. Calculation of Minimum Reflux Ratio Rm: Using Underwood equations As feed is entering as saturated vapors so, q = 0 By trial,  = 1.68 Using equation of minimum reflux ratio, Putting all values we get, Rm = 4.154

  18. Actual Reflux Ratio: The rule of thumb is: R = (1.2 ------- 1.5) R min R = 1.5 R min R = 6.23

  19. Theoretical no. of Plates: Gilliland related the number of equilibrium stages and the minimum reflux ratio and the no. of equilibrium stages with a plot that was transformed by Eduljee into the relation; From which the theoretical no. of stages to be, N= 39

  20. Calculation of actual number of stages: Overall Tray Efficiency: α avg =average relative volatility of light key component =1.75 μ avg = molar average liquid viscosity of feed evaluated at average temperature of column

  21. Average temperature of column =(118+71)/2 = 95 oC Feed viscosity at average temperature = avg = 0.39 mNs/m2 So, Eo = 56.60% So, No. of actual trays = 39/0.566 = 68

  22. Location of feed Plate: The Kirk bride method is used to determine the ratio of trays above and below the feed point. From which, Number of Plates above the feed tray = ND = 47 Number of Plates below the feed tray = NB = 21

  23. Determination of the Column Diameter: Flow Parameter: FLV = Liquid Vapor Factor = 0.056

  24. Capacity Parameter: Assumed tray spacing = 18 inch (0.5 m) From Fig (15-5) Plant Design and Economics for Chemical Engineering, sieve tray flooding capacity, Csb = 0.0760 m/Sec Surface tension of Mixture = σ= 18.35 dynes/Cm Vnf=1.67 m/sec Assume 90% of flooding then Vn=0.9Vnf So, actual vapor velocity, Vn=1.51 m/sec

  25. Net column area used in separation is An = mv/Vn Volumetric flow rate of vapors = mv mv= (mass vapor flow rate /(3600) vapor density) mv = 2.1184m3/sec Now, net area An= mv/Vn = 1.41m2 Assume that downcommer occupies 15% of cross sectional Area (Ac) of column thus: Ac = An + Ad Where, Ad= downcommer area

  26. Ac = An + 0.15(Ac) Ac = An / 0.85 Ac=1.65 m2 So Diameter of Column Is Ac =(π/4)D2 D = (4Ac/π) D = 1.45 meter = 5ft (based upon bottom conditions)

  27. Liquid flow arrangement: In order to find liquid flow arrangement first find maximum liquid volumetric flow rate So liquid flow rate = (Liquid mass rate)/ (3600) (Liquid density) Max Liquid Rate Is At the bottom of column so using "Lm" values So Maximum liquid flow rate = 0.005 m3/sec So from fig11.28 Coulson & Richardson 6th volume 3rd editioncross flow single pass plate is selected

  28. Provisional Plate Design: Column Diameter Dc= 1.4513 m Column Cross-sectional Area(Ac)= 1.65 m2 Down comer area Ad = 0.15Ac = 0.25 m2 Net Area (An) = Ac - Ad =1.41 m2 Active area Aa=Ac-2Ad = 1.16 m2 Hole area Ah take 10% Aa = 0.1 × 1.16 =0.0462 m2 Weir length Ad / Ac = 0.248 / 1.654 = 0.15

  29. From figure 11.31Coulson & Richardson 6th volume 3rd edition Lw / dc = 0.80 Lw = 1.452*0.80 = 0.733 m Weir length should be 60 to 85% of column diameter which is satisfactory Take weir height, hw= 50 mm Hole diameter, dh = 5 mm Plate thickness = 5 mm

  30. Check Weeping: where Umin is the minimum design vapor velocity. The vapor velocity at weeping point is the minimum velocity for the stable operation. In order to have K2 value from fig11.30 Coulson & Richardson 6th volume 3rd edition we have to 1st find how(depth of the crest of liquid over the weir) where howis calculated by following formula:

  31. how=750[(Lm/lw*ρ)2/3] Maximum liquid rate “Lm”= 4.7 kg/sec Minimum Liquid Rate At 70% turn down ratio = 3.3Kg/sec At Maximum rate ( how)= 20 mm Liquid At Minimum rate(how) = 16 mm Liquid hw + how = 50 + 16 = 66 mm Liquid from fig 11.30, Coulson and Richardson Vol.6 K2 = 30.50 So, U (min) = 9 m/sec

  32. Now maximum volumetric flow rate (vapors) Base = 2.12 m3/sec Top = 1.14 m3/sec At 70% turn down ratio Actual minimum vapor velocity =minimum vapor rate / Ah = 12.81 m/sec So minimum vapor rate will be well above the weep point.

  33. Plate Pressure Drop (P.D): Consist of dry plate P.D (orifice loss), P.D due to static head of liquid and residual P.D (bubbles formation result in energy loss) Dry Plate Drop: Max. Vapor velocity through holes (Uh) = Maximum Volumetric Flow Rate /Hole Area = 18.30 m/sec Perforated area Ap (active area) =1.16 m2 Ah/Ap = 0.100

  34. From fig. 11.34 (Coulson & Richardson 6th volume 3rd edition) for plate thickness/hole diameter = 1.00 We get, Co = 0.84 This equation is derived for orifice meter pressure drop. hd= 48 mm Liquid Residual Head (hr): hr = (12.5*103 / ρL) = 13.3 mm Liquid

  35. So, Total pressure drop =48+(50+20)+13.32 ht = 131.35 mm liquid Total column pressure drop Pa, (N/m2) = (9.81*10-3) htρLN = 82771.6 Pa = 82 kPa

  36. Down comer Liquid Backup: Caused by Pressure Drop over the plate and resistance to flow in the downcomer it self. hb = (hw+ how) + ht + hdc The main resistance to flow in downcomer will be caused by constriction in the downcomer outlet, and head loss in the down comer can be estimated using the equation given as, where Lwd is the liquid flow rate in downcomer, kg/sec and Aap is the clearance area under the downcomer, m2 Aap =hapLw

  37. Where hap the height of bottom edge of apron above the plate. hap = hw – (5 to 10 mm) hap = 40 mm so, Area under apron “Aap” = 0.05 m2 As this is less than area of downcomer Ad so using Aap values in above formula. So, hdc = 1.95 mm

  38. As a result, hb = 203.24 mm = 0.203 m hb < ½ (Tray spacing + weir height) 0.20 < 0.25 So tray spacing is acceptable

  39. Check Residence Time: Sufficient residence time should be allowed in the downcomer for the entrained vapors to disengage from liquid stream to prevent aerated liquid being carried under the downcomer. tr =Ad hbc ρL/L(max) tr = 10 sec It should be > 3 sec. so, result is satisfactory

  40. Check Entrainment: (un) actual velocity = (maximum volumetric flow rate at base Vm / net area An) (un) actual velocity = 1.51 m/sec Velocity at flooding condition Uf= 1.67 m/sec So Percent flooding =un/ uf = 0.90 = 90%

  41. Liquid flow factor FLV = 0.056 From fig. 11.29Coulson & Richardson 6th volume 3rd edition fractional entrainment ψcan be found out. Fractional entrainment (ψ) = 0.0750 Well below the upper limit of (ψ) which is 0.1. Below this the effect of entrainment on efficiency is small.

  42. No of Holes: Area of 1 Hole = (π/4) Dhole2 = 0.00002 m2 Area of N Holes = 0.1158 m2 So, Number OF Holes = 5900

  43. Height of Distillation Column Height of column Hc= (Nact-1) Hs+ ∆H+ plates thickness No. of plates = 68 Tray spacingHs = 0.50 m ∆H= 0.5 meter each for liquid hold up and vapor disengagement ∆H=1 m Total thickness of trays = 0.005*68 = 0.34 m So, Height of column = (68-1)*0.50+ 1+0.34 = 35 meters

  44. 1.45m height=35m Plate Specifications how=Weir crust Hole diameter=5mm hap=40 mm No. of holes=5900 h W=50 mm

  45. Specification Sheet Of Distillation Column: Identification: Item Distillation column No. required 1 Tray type Sieve tray Function: Separation of Acetic Acid from iodo methane and Reaction by products. Operation:Continuous

  46. Material handled:

  47. Design data:

  48. References • Coulson & Richardson 6th volume 3rd edition • Plant Design and Economics for Chemical Engineering • Coulson & Richardson 2th volume 5th edition • Perry’s Chemical engineer’s hand book

  49. The End

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