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Minimum reflux for binary or pseudobinary mixtures is given by the following when
separation is esentially complete (x
D
1) and D / F is the ratio of overhead product
and feed rates:
Bubble point of the bottom
Table 3. Bubble point of the bottom
Component P (kPa) m Y X
Cellulose 2,47 0,02 0,00 0,00
Formic Acid 2,43 0,02 0,00 0,00
Furfural 2,47 0,02 0,00 0,01
Glucose 0,00 0,00 0,00 0,00
Hemicellulose 2,47 0,02 0,00 0,00
HMF 0,19 0,00 0,00 0,00
Levulinic Acid 0,19 0,00 0,00 0,04
Lignin 2,47 0,02 0,00 0,01
Sodium Hydroxid 0,00 0,00 0,00 0,00
Water 110,11 1,09 1,00 0,92
Xylose 2,47 0,02 0,00 0,02
1,00 1,00
Bottom bubble point is 102,78
o
C.
where,
, so that
101,55
o
C.
3. Relative Volatilities
Relative Volatility of each component is defined base to T
av
= 101,55
o
C.and
HK
as the
base .
Table 4. Relative volatilities of the distillate
Component P m
Formic Acid (LK) 1,00 1,00 1,80
Furfural (HK) 0,02 0,02 0,76
Where,
4. log[
= log [
From Figure 4.1, we can define N
M
.
Figure 2. Fenske equation for minimum plates expressed in graph form (Source: Gulf, 2002)
From this figure, we can get log N
M
= 1,28 ; so that, N
M
= 19,05 trays 19 trays
5. Defining Nopt/N
M
from Figure 4.2, for finding Nopt.
Figure 3. Relation between optimum-to-minimum ratio and Fenske separation factor (Source: Gulf, 2002)
From this figure, we can get Nopt/NM = 1,84, so that Nopt = 1,84 x 19,05 = 35,052 35.By
assuming the tray efficiency is about 85%, we can calculate Nactual as (Nopt/Tray Efficiency), so
that we get Nactual = 41 trays.
6. log[
= log [
After getting this value, we can define Ropt/R
M
from figure 4.3.
Figure 4. Optimum-minimum reflux ratio relationship to the columns feed, distillate, and bottoms
composition (Source: Gulf, 2002)
Based on this figure, if we have log[
] = 2,20 and
, the value R
opt
/R
M
= 1,35.
7. Defining the value of by using Figure 4.4
The calculated value of
and
= = 0,87, then
= 1,58
Figure 5. Underwoods vs key ratios in feed (Source: Gulf, 2002)
By using Figure 4.5-4.7, the value of(i.xi
D
)/(i-) will be obtained as:
Figure 6. Underwoods vs parameter for in range 1,01 to 1,11 (Source: Gulf, 2002)
Figure 7. Underwoods vs parameter for in range 1,05 to 3,00 (Source: Gulf, 2002)
Figure 8. Underwoods vs parameter for heavy key and heavier components(Source: Gulf, 2002)
RM + 1 = (i.xi
D
)/(i-) = -6,21
RM = -6,21 1 = -7,21
9. R
opt
= (-7,21) x (1.35) = -9,73.
10. Tray Spacing = 0.5 m (Heuristic: Stage spacing range 20 24 inch).
11. Height of Tower
20,71 m
(Heuristic: Maximum column height allowed is 175 ft or 53,025 m, so the result is meeting the
requirements.)
12. Column Diameter
Where
= Plate spacing
2,04 m.
13. Plate Design
Column Diameter (D
c
) = 2,04 m
Column Area (A
c
) = D
c
2
/4 = 3,27m
2
Downcomer Area (A
d
) = 0.12 x A
c
= 0,12 x 3,27m
2
= 0,39 m
2
Net Area (A
n
) = (A
c
A
d
) = 2,88 m
2
Active Area (A
a
) = (A
c
2A
d
) = [2,66 (2 x 0,32)] m
2
= 2,49 m
2
Hole Area (A
h
) = 0.1A
a
(10% estimated from active area) = 0,1 2,49= 0,25 m
2
Weir Length is define from Figure 11.31 of Coulson and Richardson Book.
(A
d
/A
c
) x 100% = 12 %
Lw/Dc = 0,76
Lw = 1,55 m.
Figure 9. Relation between downcomer and weir length (Source: Coulson and Richardson, 2002)
Hole Diameter = 0,005 m
Plate Thickness = 0,005 m
Number of Holes = 2,04/(1.965 x 10
-5
) = 103816,79 holes.
14. Plate Pressure Drop
Dry Plate Pressure Drop
Maximum vapor velocity through holes:
U
h(max)
= V
m
/A
h
= 8,20m/s
(A
h
/A
a
)*100 = (0,25/2,49)*100
= 10,04
From Figure 11.34, 6th Ed. Coulson and Richardsons if the (A
h
/A
a
)*100 = 10,04, when plate
thickness to plate diameter is 1, then C
o
= 0.83
h
d
= 51 (U
h
/C
o
)
2
(d
v
/d
l
)
= 51 (8,20/0.83)
2
(1,00/1134,31)
= 4,39 mm liquid
Residual Drop
h
r
= 12.5*1000/d
l
= 12.5*1000/1134,31
=11,02 mm liquid
h
w
+ h
ow
= 50 + 4,39
= 54,39 mm liquid
Total Plate Pressure Drop
h
t
= h
d
+ h
r
+ (h
w
+ h
ow
)
= 4,39 + 11,02 + 54,39
= 69,80 mm liquid
Pt = 9,81*10
-3
*h
t
*d
l
= 776,71 Pa
=0,77 kPa = 0,12 psi
P
top
= 14,5 psi
P
bottom
= 14,5+ (19*0,12) = 16,78 psi
15. Shell Calculations
Minimum Shell Thickness
in
Therefore, 3/16 in thickness can be used
Selection of Head and Head Thickness Calculation
Torispherical Head
Diameter
OD + (OD/24) + 2 sf + 2/3 icr
= 40,16 + 1,67 + (2*3) + (2/3*4)
= 50,50 in
Weight of Head
= 328,70 lb
Calculation of Axial Stress in Shell
16. Specifications and Operation Condition
Table 5. Specifications and operation condition of distillation column I
1. Type Distillation Column
2. Material Carbon Steel
3. Temperature 102,78
o
C
4. P
top
14,5 psi
5. P
bottom
16,78 psi
5. Light Key Formic Acid
6. Heavy Key Furfural
7. Space between Tray 0,5 m
8. Column Height 20,71 m
9. Column Diameter 2,04 m
10. Column Thickness 0,18 in
11. Plate Thickness 0,005 m
12. Plate Pressure Drop 0,12 psi
13. Hole Valve Tray Size 0,005 m
14. Number Hole Valve Tray 103816,79
15. Hole Area 0,25 m
2
16. Weir Length 1,55 m
17. Column Area 3,27 m
2
18. Net Area 2,88 m
2
19. Active Area 2,49 m
2
20. Price $ 65000
B.2. Distillation Column II (C-102)
1. Stream Composition
Basis = 1 hour, feed = 13749,505 kg/hour
Table 6.Feed, distillate, and bottoms composition
Component Feed (%) Distillate (%) Bottoms (%)
Cellulose 0,02 0,00 0,02
Formic Acid 0,00 0,00 0,00
Furfural 1,15 99,97 0,00
Glucose 0,04 0,00 0,04
Hemicellulose 0,10 0,00 0,10
HMF 0,29 0,00 0,29
Levulinic Acid 3,65 0,03 3,70
Lignin 1,19 0,00 1,20
Sodium Hydroxid 0,00 0,00 0,00
Water 91,69 0,00 92,75
Xylose 1,88 0,00 1,90
100 100 100
2. Temperatures
Dew point of the distillate
Table 7. Dew point of the distillate
Component P m Y X
Furfural (LK) 150,02 1,00 0,99 1,00
Levulinic Acid (HK) 73,00 4,93 0,01 0,00
1,00 1,00
Distillate dew point is 103,45
o
C
Where:
Bubble point of the bottom
Table 8. Bubble point of the bottom
Component P (kPa) m Y X
Cellulose 2,48 0,02 0,00 0,00
Formic Acid 2,43 0,02 0,00 0,00
Furfural 0,06 0,00 0,00 0,00
Glucose 0,00 0,00 0,00 0,00
Hemicellulose 2,48 0,02 0,00 0,00
HMF 0,19 0,00 0,00 0,00
Levulinic Acid 0,19 0,00 0,00 0,04
Lignin 2,48 0,02 0,00 0,01
Sodium Hydroxid 0,00 0,00 0,00 0,00
Water 110,41 1,09 1,01 0,93
Xylose 2,48 0,02 0,00 0,02
1,01 1,00
Bottom bubble point is 170
o
C.
where,
, so that
136,73
o
C.
3. Relative Volatilities
Relative Volatility of each component is defined base to T
av
= 136,73
o
Cand
HK
as the
base .
Table 9. Relative volatilities of the distillate
Component P m
Furfural (LK) 1,00 1,00 1,80
Levulinic Acid (HK) 0,56 0,02 3,62
Where,
4. log[
= log [
From Figure 4.1, we can define N
M
.
Figure 10. Fenske equation for minimum plates expressed in graph form (Source: Gulf, 2002)
From this figure, we can get log N
M
= 1,19 ; so that, N
M
= 15,38 trays 15 trays
5. Defining Nopt/N
M
from Figure 4.2, for finding Nopt.
Figure 11. Relation between optimum-to-minimum ratio and Fenske separation factor (Source: Gulf, 2002)
From this figure, we can get Nopt/N
M
= 1,81, so that Nopt = 1,81 x 15,38 = 27,84 28.By assuming
the tray efficiency is about 85%, we can calculate Nactual as (Nopt/Tray Efficiency), so that we get
Nactual = 33 trays.
6. log[
= log [(
) (
) (
)
After getting this value, we can define Ropt/R
M
from figure 4.3.
Figure 12. Optimum-minimum reflux ratio relationship to the columns feed, distillate, and bottoms
composition (Source: Gulf, 2002)
Based on this figure, if we have log[
] = 5,81 and
, the value R
opt
/R
M
= 1,47.
7. Defining the value of by using Figure 12
The calculated value of
and
16,66 m
(Heuristic: Maximum column height allowed is 175 ft or 53,025 m, so the result is meeting the
requirements.)
12. Column Diameter
Where
= Plate spacing
2,12 m.
13. Plate Design
Column Diameter (D
c
) = 2,12 m
Column Area (A
c
) = D
c
2
/4 = 3,53m
2
Downcomer Area (A
d
) = 0.12 x A
c
= 0,12 x 3,53m
2
= 0,42 m
2
Net Area (A
n
) = (A
c
A
d
) = 3,11 m
2
Active Area (A
a
) = (A
c
2A
d
) = [2,66 (2 x 0,32)] m
2
= 2,69 m
2
Hole Area (A
h
) = 0.1A
a
(10% estimated from active area) = 0,1 2,49= 0,27 m
2
Weir Length is define from Figure 11.31 of Coulson and Richardson Book.
(A
d
/A
c
) x 100% = 12 %
Lw/Dc = 0,76
Lw = 1,61 m.
Figure 17. Relation between downcomer and weir length (Source: Coulson and Richardson, 2002)
Hole Diameter = 0,005 m
Plate Thickness = 0,005 m
Number of Holes = 2,12/(1.965 x 10
-5
) = 107888,00 holes.
14. Plate Pressure Drop
Dry Plate Pressure Drop
Maximum vapor velocity through holes:
U
h(max)
= V
m
/A
h
= 7,59m/s
(A
h
/A
a
)*100 = (0,27/2,69)*100
= 10,04
From Figure 11.34, 6th Ed. Coulson and Richardsons if the (A
h
/A
a
)*100 = 10,04, when plate
thickness to plate diameter is 1, then C
o
= 0.83
h
d
= 51 (U
h
/C
o
)
2
(d
v
/d
l
)
= 51 (7,59/0.83)
2
(1,00/971,05)
= 4,40 mm liquid
Residual Drop
h
r
= 12.5*1000/d
l
= 12.5*1000/971,05
=12,87 mm liquid
h
w
+ h
ow
= 50 + 4,40
= 54,40 mm liquid
Total Plate Pressure Drop
h
t
= h
d
+ h
r
+ (h
w
+ h
ow
)
= 4,40 + 12,87 + 54,40
= 71,67 mm liquid
Pt = 9,81*10
-3
*h
t
*d
l
= 682,73 Pa
=0,68 kPa = 0,10 psi
P
top
= 14,5 psi
P
bottom
= 14,5+ (19*0,10) = 16,50 psi
15. Shell Calculations
Minimum Shell Thickness
in
Therefore, 3/16 in thickness can be used
Selection of Head and Head Thickness Calculation
Torispherical Head
Diameter
OD + (OD/24) + 2 sf + 2/3 icr
= 41,73 + 1,74 + (2*3) + (2/3*4)
= 52,14 in
Weight of Head
= 584,11 lb
Calculation of Axial Stress in Shell
16. Specifications and Operation Condition
Table 10. Specifications and operation condition of distillation column II
1. Type Distillation Column
2. Material Carbon Steel
3. Temperature 170
o
C
4. P
top
14,5 psi
5. P
bottom
16,50 psi
5. Light Key Furfural
6. Heavy Key Levulinic Acid
7. Space between Tray 0,5 m
8. Column Height 16,66 m
9. Column Diameter 2,12 m
10. Column Thickness 0,18 in
11. Plate Thickness 0,005 m
12. Plate Pressure Drop 0,10 psi
13. Hole Valve Tray Size 0,005 m
14. Number Hole Valve Tray 107888,00
15. Hole Area 0,27 m
2
16. Weir Length 1,61 m
17. Column Area 3,53 m
2
18. Net Area 3,11 m
2
19. Active Area 2,69 m
2
20. Price $ 65000
B.3. Distillation Column III (C-103)
1. Stream Composition
Basis = 1 hour, feed = 13749,505 kg/hour
Table 11.Feed, distillate, and bottoms composition
Component Feed (%) Distillate (%) Bottoms (%)
Cellulose 0,02 0,00 0,02
Formic Acid 0,00 0,00 0,00
Furfural 0,00 0,00 0,00
Glucose 0,04 0,00 0,04
Hemicellulose 0,10 0,00 0,10
HMF 0,29 0,00 0,30
Levulinic Acid 3,70 99,75 0,00
Lignin 1,20 0,00 1,25
Sodium Hydroxid 0,00 0,00 0,00
Water 92,75 0,25 96,31
Xylose 1,90 0,00 1,98
100 100 100
2. Temperatures
Dew point of the distillate
Table 12. Dew point of the distillate
Component P m Y X
Levulinic Acid (LK) 1,52 0,00 0,01 0,00
Water (HK) 2308,59 1,00 0,99 1,00
1,00 1,00
Distillate dew point is 104,39
o
C
Where:
Bubble point of the bottom
Table 13. Bubble point of the bottom
Component P (kPa) m Y X
Cellulose 2.42 0,02 0,00 0,00
Formic Acid 2.39 0,02 0,00 0,00
Furfural 0.06 0,00 0,00 0,00
Glucose 0.00 0,00 0,01 0,00
Hemicellulose 2.42 0,02 0,00 0,00
HMF 0.18 0,00 0,00 0,00
Levulinic Acid 0.18 0,00 0,00 0,00
Lignin 2.42 0,02 0,01 0,00
Sodium Hydroxid 0.00 0,00 0,00 0,00
Water 105.15 1,04 0,96 1,00
Xylose 2.42 0,02 0,02 0,00
1,00 1,00
Bottom bubble point is 220,00
o
C.
where,
, so that
162,20
o
C.
3. Relative Volatilities
Relative Volatility of each component is defined base to T
av
= 162,20
o
Cand
HK
as the
base .
Table 14. Relative volatilities of the distillate
Component P m
Levulinic Acid (LK) 1,00 1,00 2,86
Water (HK) 0,56 0,02 1,02
Where,
4. log[
= log [
From Figure 4.1, we can define N
M
.
Figure 18. Fenske equation for minimum plates expressed in graph form (Source: Gulf, 2002)
From this figure, we can get log N
M
= 1,31 ; so that, N
M
= 20,42 trays 20 trays
5. Defining Nopt/N
M
from Figure 4.2, for finding Nopt.
Figure 19. Relation between optimum-to-minimum ratio and Fenske separation factor (Source: Gulf, 2002)
From this figure, we can get Nopt/N
M
= 1,68, so that Nopt = 1,68 x 20,42 = 34,31 34.By assuming
the tray efficiency is about 85%, we can calculate Nactual as (Nopt/Tray Efficiency), so that we get
Nactual = 40 trays.
6. log[
= log [(
) (
) (
)
After getting this value, we can define Ropt/R
M
from figure 4.3.
Figure 20. Optimum-minimum reflux ratio relationship to the columns feed, distillate, and bottoms
composition (Source: Gulf, 2002)
Based on this figure, if we have log[
] = 5,88 and
, the value R
opt
/R
M
= 1,25.
7. Defining the value of by using Figure 4.4
The calculated value of
and
20,20 m
(Heuristic: Maximum column height allowed is 175 ft or 53,025 m, so the result is meeting the
requirements.)
12. Column Diameter
Where
= Plate spacing
2,05 m.
13. Plate Design
Column Diameter (D
c
) = 2,05 m
Column Area (A
c
) = D
c
2
/4 = 3,31m
2
Downcomer Area (A
d
) = 0.12 x A
c
= 0,12 x 3,53 m
2
= 0,40 m
2
Net Area (A
n
) = (A
c
A
d
) = 2,91 m
2
Active Area (A
a
) = (A
c
2A
d
) = [2,66 (2 x 0,40)] m
2
= 1,86 m
2
Hole Area (A
h
) = 0.1A
a
(10% estimated from active area) = 0,1 1,86= 0,19 m
2
Weir Length is define from Figure 11.31 of Coulson and Richardson Book.
(A
d
/A
c
) x 100% = 12 %
Lw/Dc = 0,76
Lw = 1,56 m.
Figure 25. Relation between downcomer and weir length (Source: Coulson and Richardson, 2002)
Hole Diameter = 0,005 m
Plate Thickness = 0,005 m
Number of Holes = 2,05/(1.965 x 10
-5
) = 104326,00 holes.
14. Plate Pressure Drop
Dry Plate Pressure Drop
Maximum vapor velocity through holes:
U
h(max)
= V
m
/A
h
= 10,79m/s
(A
h
/A
a
)*100 = (0,19/1,86)*100
= 10,22
From Figure 11.34, 6th Ed. Coulson and Richardsons if the (A
h
/A
a
)*100 = 10,22, when plate
thickness to plate diameter is 1, then C
o
= 0.82
h
d
= 51 (U
h
/C
o
)
2
(d
v
/d
l
)
= 51 (10,79/0.82)
2
(1,00/1087,48)
= 8,12 mm liquid
Residual Drop
h
r
= 12.5*1000/d
l
= 12.5*1000/1087,48
=11,49 mm liquid
h
w
+ h
ow
= 50 + 8,12
= 58,12 mm liquid
Total Plate Pressure Drop
h
t
= h
d
+ h
r
+ (h
w
+ h
ow
)
= 8,12 + 11,49 + 58,12
= 77,73 mm liquid
Pt = 9,81*10
-3
*h
t
*d
l
= 829,24 Pa
= 0,83 kPa = 0,12 psi
P
top
= 14,5 psi
P
bottom
= 14,5+ (19*0,12) = 16,78 psi
15. Shell Calculations
Minimum Shell Thickness
in
Therefore, 3/16 in thickness can be used
Selection of Head and Head Thickness Calculation
Torispherical Head
Diameter
OD + (OD/24) + 2 sf + 2/3 icr
= 40,35 + 1,68 + (2*3) + (2/3*4)
= 50,70 in
Weight of Head
= 611,75 lb
Calculation of Axial Stress in Shell
16. Specification and Operation Condition
Table 10. Specifications and operation condition of distillation column III
1. Type Distillation Column
2. Material Carbon Steel
3. Temperature 220
o
C
4. P
top
14,5 psi
5. P
bottom
16,78 psi
5. Light Key Levulinic Acid
6. Heavy Key Water
7. Space between Tray 0,5 m
8. Column Height 20,20 m
9. Column Diameter 2,05 m
10. Column Thickness 0,18 in
11. Plate Thickness 0,005 m
12. Plate Pressure Drop 0,12 psi
13. Hole Valve Tray Size 0,005 m
14. Number Hole Valve Tray 104326,00
15. Hole Area 0,19 m
2
16. Weir Length 1,56 m
17. Column Area 3,31 m
2
18. Net Area 2,91 m
2
19. Active Area 1,86 m
2
20. Price $ 65000
Main Variables in Designing Distillation Column
1. Temperature
Temperature is the variable that is prone to change in the distillation column. Reaction
process in the distillation column temperature must be guarded in order to achieve maximum
process. To keep the temperature in the distillation column then used steam. Temperature sensor
is a thermocouple. Controlled variable is the temperature in the distillation column. Control
parameter is steam flow rate. Temperature is controlled at inlet temperature, bottom temperature,
and distillate temperature.
The literature of optimum sequencing of columns is referenced by King (1980, pp. 711-
720) and Henley and Seader (1981, pp. 527-555). For preliminary selection of near optimal
sequences, several rules can be stated as guides, although some conflicts may arise between
recommendations based on the individual rules. Any recommended cases then may need
economic evaluations.
Perform the easiest separation first, that is, the one least demanding of trays and
reflux, and leave the most difficult to the last.
When neither relative volatility nor concentration in the feed varies widely, remove
the components one-by-one as overhead products.
When the adjacent ordered components in the process feed vary widely in relative
volatility, sequence the splits in the order of decreasing relative volatility.
When the concentrations in the feed vary widely but the relative volatilities do not,
sequence the splits to remove components in the order of decreasing concentration in
the feed.
2. Pressure
Pressure is one of the most important variables in the distillation column. Pressure in the
distillation column is meant to be kept as same as or slightly above atmospheric pressure.
Pressure changes can occur due to input a continuous distillation column and the reaction in the
distillation column. Excessive pressure can affect the quality of the product and can also be
dangerous if the distillation column exploded due to excess pressure. This to prevent excess
pressure distillation column equipped with a relief valve to release the pressure on the
environment. Controlled variable is the pressure in distillation column. When the pressure
exceeds the set point, then the relief valve on the reactor will open thereby releasing the pressure
of the distillation column. Pressure is controlled at top pressure and bottom pressure.
3. Flow Rate
Flow rate in is one of the most important variables to be controlled in a distillation
column. Flow rate in into the distillation column can affect the composition in the distillation
column which will also affect the yield. Besides this flow rate can also affect the height of the
liquid in the distillation column. Sensors are used to measure the flow rate is orificemeter. Then
the flow rate in is controlled by the controller based on set point. Control the flow rate by the
flow control valve (FCV).