TABLE OF CONTENTS

I. TRAYS ........................................................................................................................................... 1
A. DIFFERENT TYPES OF TRAYS .................................................................................................... 1
1. Bubble cap tray........................................................................................................................... 1
2. Sieve tray .................................................................................................................................... 2
3. Dual flow tray ............................................................................................................................. 3
4. Valve tray .................................................................................................................................... 4
B. TRAY OPERATING LIMITS ........................................................................................................... 5
1. Entrainment limit ....................................................................................................................... 5
2. Jet Flood ..................................................................................................................................... 5
3. Weeping ...................................................................................................................................... 6
4. Blowing Flood ............................................................................................................................ 6
5. Downcomer Flood ...................................................................................................................... 6
6. Downcomer Back-up Flood ....................................................................................................... 6
7. Tray Pressure Drop .................................................................................................................... 6
II. PACKINGS ............................................................................................................................... 6
A. DIFFERENT TYPES OF PACKINGS............................................................................................. 7
1. Structured packings ................................................................................................................... 7
2. Random packings ....................................................................................................................... 8
3. Grid packings ............................................................................................................................. 9
B. COLUMN OPERATING LIMITS .................................................................................................... 9
1. Pressure drop.............................................................................................................................. 9
2. Liquid holdup ........................................................................................................................... 10
3. Liquid rate ................................................................................................................................ 10
4. Vapor rate ................................................................................................................................. 10
C. APPLICATIONS ........................................................................................................................... 10
 TRAYS AND PACKINGS USED IN DISTILLATION AND GAS ABSORPTION

Distillation and absorption are two most widely used mass transfer processes in chemical
industries. Design of plate column for absorption and distillation involves many common steps
of calculation such as determination of number of theoretical plates, column diameter, plate
hydraulic design, etc.In absorption process, a soluble component is absorbed in a liquid (called
solvent) from a gaseous mixture. The gas and liquid streams leaving the tray are in equilibrium
under the ideal condition. The separation in distillation is based on the relative volatility of the
components. Additional vapor phase is generated by the vaporization of more volatile
components (called stripping) and by condensation of relatively less volatile
components(called absorption) adds to the liquid phase.

I. TRAYS
Tray Columns utilize a pressure and temperature differential to separate the products. For
most tray columns, the weir holds a liquid level of each tray. Liquid enters from the downcomer
of the tray above. The vapor must overcome this liquid head to move up the column. On the
tray the vapor and liquid are contacted becomes bubble or froth where the mass transfer takes
place and then above the tray they are separated where froth flows over the outlet weir and
vapor with the light volatile compound is disengaged.
Tray column performs well in high liquid and vapor loading. Tray have higher pressure
drop than packed, and It also have high resistance to corrosion.

A. DIFFERENT TYPES OF TRAYS

1. Bubble cap tray
The oldest widely used equilibrium-stage plate is the bubble cap tray. A bubble cap tray is
perforated flat plate which has a riser (chimney) over the holes covered with a cap. They are
usually equipped with slots to allow the passage of vapor to be mixed with the liquid flowing
across the tray forming bubble where the mass transfer takes place. Each tray is provided with
one or more downcomers which the liquid flowing across the tray is conducted to the tray
below. A liquid head is maintained on the tray by a dam placed on outlet side of the tray near
the downcomer, it is called the outlet weir. Bubble cap tray is able to operate at low vapor and
liquid rates (less than 2 gpm per foot of average flow width) because liquid and foam is trapped
on the tray to a depth at least equal to the weir height.

1
 Bubble cap trays work well in high turndown applications because the orifices in the bubble
caps are in the form of risers whose top opening is elevated significantly above the tray deck.
The size of the cap tends to create hydraulic gradient across the deck and a high vapor side
pressure drop. The cost of the bubble cap tray is far the highest.

Figure 1: Bubble cap tray

 The bubble cap tray can be used where very low vapor rates have to be handled or
adequate residence time is necessary for separation

2. Sieve tray
Sieve tray is perforated plate with holes punched into the plate and usually has holes 3/16
in to 1 in diameter. The standard size is 0.5 inch with the perforation punched downward. Vapor
comes out from the holes to give a multi orifice effect. The vapor velocity keeps the liquid
from flowing do through the holes (weeping). The number and size of the perforations control
the vapor flow through the tray deck to contact the liquid.
The punching direction affects the dry pressure drop, a smaller hole diameter result in lower
pressure drop for the same open area. This due to the ratio of the hole diameter to the tray
thickness. The number and hole size are based on vapor flow up the tower. The liquid flow is
transported down the tower by down-comers, a dam and overflow device on the side of the
plate.
A sieve tray has higher entrainment than valve tray at the same vapor velocity. This is due
to the spray of liquid directed upwards to the next tray. For efficient operation, the hole velocity
must be sufficient to balance the head of liquid on the tray deck and thus prevent liquid from
passing through the perforations to the tray. Sieve tray can be used in almost all services.

2
 Sieve deck tray has a minimum capacity approximately 70%.Their capacity and efficiency
are atleast as high as that of other standard trays used commercially. Sieve trays may be used
in moderately fouling services, provided that large holes (3/4 in to 1 in) are used. Sieve trays
are simple and easy to fabricate and therefore relatively inexpensive.

Figure 2: Sieve tray

• The sieve tray can be used in the distillation of highly viscous or self-polymerized
mixtures such as the separation of vinyl acetate from a polyvinyl acetate.

3. Dual flow tray

Dual flow tray is a sieve tray without downcomer. Vapors move up to the tray move through
the hole, while the liquid travels down in the same hole that can result in mal-distribution and
low efficiency.
Dual flow trays are designed with enough open area on the tray deck to eliminate stagnation
and promote back missing that makes it suited to handle highly fouling services, slurries and
corrosive services. Dual flow trays are well suited also for the fractionation of polymerizable
compounds and give more bubbling area, therefore have a greater capacity than other tray
types.
Dual flow tray is also the least expensive to make and easiest to install and maintain. Dual
flow tray performs best in the operating region of 60-85% of flood and increases the efficiency
with vapor rate. The challenge of dual flow instability is developed it propagates down the
column.
The top of a column will move in a typical storm as much as 6 inches. This movement will
cause the hydraulic load to migrate in the column. If the hydraulic flow instability is developed
it propagated the column.

3
 Improper feed, reflux or vapor distribution can also create mal-distribution problems. Dual
flow tray have poor turndown ration resulting from the rapid fall off in efficiency as the vapor
loading decreases. Therefore, the operating vapor and liquid rate ranges must be kept small.
Two types of dual flow trays are available, the standard deck and ripped deck. The standard
deck has a flat plate while the ripped deck has sinusoidal waves.

Figure 3: Dual flow tray

 The dual flow tray can be applied when fouling or polymerization has to be expected.

4. Valve tray
Valve tray uses valve (movable disc) which almost closes off completely at low vapor rate,
thus minimize tray open area. When lifted, as vapor rate increases, the open area increases for
vapor flow between the valve disc and tray disc.
Valves can be round or rectangular, with or without caging structured. Most types of valves,
the opening may be varied by the flow, so that the trays can operate over a wide range of flow
rates with high separation efficiency and large flexibility.
Because of their flexibility and price 9slightly more expensive that sieve tray), valve trays
are tending to replace bubble-cap trays.
Valve tray has maximum capacity approximately 60%. The dry pressure drop of valve tray
is lower than bubble cap, because the valve does not need a chimney for the vapor and it
depends on weight valve.
The valve tray can used in condition where vapor rate change unpredictability over a given
section of tower. A tower utilized in blocked operation at varying rate and feed compositions,
a fluctuation in feed rate, and servicing of auxiliary equipment operating the entire unit.

4
 Figure 4: Valve tray
The valve tray can be used for the following:
 Suitability in large variety of mass transfer applications
 Can be used in contaminated media
 Suitable for contact with corrosive substances

B. TRAY OPERATING LIMITS

The tray operating envelope the relationship between liquid and vapour rates and the
normal tray operating limits. The absolute locations of the envelope boundaries are a function
of the tray layout and so each tray design will result in a unique set of operating limits. Ideal
tray designs have the full range of expected column operation located within the envelope.

1. Entrainment limit
It is reached when the velocity of vapor through the tray open area is high enough to project
liquid droplets to the tray above.

2. Jet Flood
It is the criteria used to predict the point at which massive liquid carryover will occur due
to the height of spray on the tray deck exceeding the available tray space. It is normal practice
to limit tray design to a maximum of 80% of jet flood to allow a safety margin on tower control,
possible discrepancies of VLE data and also the limitations of the flooding correlation used.

5
 3. Weeping
Occurs when the velocity of the vapour through the tray open area is too low to prevent
liquid from leaking through the open area thus bypassing contact area to the tray below. Most
valve and sieve trays will weep in normal operation. Weeping is considered excessive when it
is sufficient to cause loss of efficiency - usually 10 to 20%.

4. Blowing Flood
Occurs at low liquid rates at which the tray operates in the spray regime resulting in massive
entrainment of liquid to the tray above to the extent that the tray deck is essentially blown dry.

5. Downcomer Flood
Occurs at high liquid loads when the downcomers are too small to allow effective vapor
disengagement (either because the downward velocity or "inlet velocity" of the liquid is too
high or else insufficient residence time) causing vapour entrainment to the tray below. The
resulting increased aeration of the liquid in the downcomer may also cause premature
downcomer back-up flood.

6. Downcomer Back-up Flood

Occurs when the head of liquid in the downcomer backs up onto the tray deck. The head of
clear liquid in the downcomer is a balance of the pressure drop across the tray plus the head
loss through the downcomer clearance. However, an aeration factor must be applied to estimate
the actual height of aerated liquid in the downcomer.

7. Tray Pressure Drop

May also be limiting criteria particularly in low pressure services. The operating tray
pressure drop is the sum of the dry pressure drop caused by the resistance to vapor flow through
the tray open area and the head of clear liquid on the tray deck. The head of clear liquid on the
tray deck is a function of weir height and weir length (as well as liquid and vapor rates and
physical properties) and so pressure drop may be reduced by increasing the number of flow
paths in high liquid rate services.

II. PACKINGS
Packed towers (columns) are also used as the contacting devices for gas absorption, liquid-
liquid extraction and distillation. The gaseous mixture is allowed to contact continuously with

6
the liquid counter-currently in a packed column. The liquid flows downward over the packing
surface, and the gaseous mixture flows upward through the space in the packing. The
performance of the column strongly depends on the arrangement of the packings to provide
good liquid and gas contact throughout the packed bed. The solute gas is absorbed by the fresh
solvent (liquid) entering at the top of the tower where the lean gas leaves system. The liquid
enriched with absorbed solute gas, leaves the column bottom through the exit port

A. DIFFERENT TYPES OF PACKINGS

1. Structured packings
Structure Packed column is crimped layers or corrugated sheets which is stacked in the
column. Each layer is oriented at 70° to 90° to the layer below. Structured packed offers 30%
capacities higher than random packed for equal efficiency up to 50% higher at the same
capacity.
Structured packings are typically constructed as blocks of alternating layers of thin
corrugated sheet, gauze, or mesh, which can be fabricated from a wide range of metal alloys or
nonmetals such as plastics, ceramic and graphite. This structure spreads the vapor and liquids
evenly over the cross-section of the tower.
In general, structured packings create lower pressure drops and achieve better separation
efficiencies with shorter bed heights than random packings, but they are also generally more
expensive than random packings and are more time-consuming to install.

The base material for structured packing is generally a thin (0.1–0.2 mm) metal sheet. Lower
surface area packings have deeper crimping and therefore may require a thicker material for
structural purposes. Since structured packing materials are very thin and have a large amount of
surface area, there is essentially no corrosion allowance. Thus, material of construction is a very
important consideration. Wire gauze packings fabricated from woven metal cloth are used for
very-high-efficiency applications at low liquid loadings such as those at deep vacuum (although
high-surface-area sheet-metal packings with high-quality liquid distributors are also successfully
used in deep vacuum services).

7
 Figure 5: Structured packing

2. Random packings
Random packings come in a wide range of geometries: cylindrical rings, saddles, spheres,
and various other shapes. Traditional shapes such as Raschig Rings (cylinders) and Intalox
saddles have mostly been replaced by more modern designs such as Pall Rings, Nutter Rings,
IMTP packings, and proprietary designs. Suppliers continue to develop n o v e l shapes that
deliver improved performance.
Random packings are usually characterized by their nominal size or diameter, although
different packings of equivalent size may provide very different performance in terms of
capacity and separation efficiency (modern packings typically offer significant performance
advantages over the traditional designs). In small towers with any random packing design, a
minimum tower-to-packing diameter ratio of 8:1 to 10:1 is recommended to minimize loss of
separation efficiency due to voids in the packed bed and wall effects.
Random packings are made from material of various thicknesses, so the maximum allowable
bed depth for each packing needs to be considered carefully. This is especially true with plastic
packings, which may experience some degree of crushing at the bottom of the bed that worsens
at elevated temperatures due to plastic softening. Bed heights as tall as 12 m have been
successfully operated, although these tall towers use larger packing. Even if a packing’s
mechanical strength can withstand a high bed depth, in order to maintain effective liquid
distribution, a height of no more than 10–14 theoretical stages is recommended for a single bed
without liquid redistribution.
Random packing has been used for fractionation, absorption and stripping operations in
gas, refinery and chemical plants for many years and the benefits are well established.
Furthermore, ease of replacement and storage make random packing the ideal choice for

8
systems with heavy fouling or corrosion where packing is frequently replaced.

Figure 6: Random packing

3. Grid packings
Grid packed column is systematically arranged packing use an open-lattice structure. This
device is composed of panels that promote mass transfer and enhance entrainment removal.
They have high open area, resulting in high capacity, low pressure drop, and high tolerance to
fouling.

Figure 7: Grid packing

B. COLUMN OPERATING LIMITS

1. Pressure drop
The pressure drop is entirely by frictional losses through a series of opening and therefore
is proportional to the square of the gas flow rate. In random packing, the opening are randomly
sized and located, and pressure drop is due to expansion, contraction, and changes of direction.

9
In structured packing, the openings are regular and uniform size and pressure drop is due to
changes in direction.
If a packed with gas flow is wetted on the surface of the internal liquid films are produced.
The downflowing liquid reduced the relative voids volume, the free are for passing vapor is
reduced and the vapor pressure drop is increases. Increasing wetting density will increase the
liquid below loading zone which independent from vapor velocity.

2. Liquid holdup
The liquid holdup is the fraction of liquid held up in packed column. The volume of liquid
holdupvolume is often needed for calculating packed bed support beam loadings as well as for
determining how much liquid drains to the bottom of a tower when the vapor rate is stopped.

3. Liquid rate
At lower liquid rates, irrigation to the bed is poor result poor efficiency. When liquid is
well distributed in the column result the minimum wetting rate of the packing. Below minimum
wetting the falling liquid film breaks up, some of the packing surface unwets, and the efficiency
drops. When liquid distributor is poor, it will take more liquid to wet the entire packing bed.

4. Vapor rate
When vapor rate increases, column operation moves into the loading region. Efficiency
improves because of the greater liquid holdup, but this improvement is short-lived. As the flood
point is approached, the efficiency passes through the maximum and the drops because of
excessive entrainment. When vapor rate decreases, it will decrease pressure drop per theoretical
stage, but will increase column diameter.

C. APPLICATIONS
In most applications, the purpose of the packed bed is to provide intimate contacting of the
upward flowing vapor and the downward flowing liquid in separation processes such as
distillation and absorption.
Packed beds are most commonly used in air pollution control, but they are also used in
chemical, petrochemical, food, pharmaceutical, paper and aerospace industries.

10
 Figure 8: Beds used to absorb and eliminate ethylene gases from sterilization chamber

Figure 9: Packed bed absorption used to remove acidic fumes from an inlet gas stream

References
http://nptel.ac.in/courses/103103027/pdf/mod7.pdf
http://instruct.uwo.ca/engin-sc/cbe497/Doc/Icarus/ir08.pdf
https://www.slideshare.net/MohamedSalah69/types-and-design-of-the-towers-trays

11