Diseño de Equipos de Destilación

+
UNIVERSIDAD AUTÓNOMA DE NUEVO LEÓN

FACULTAD DE CIENCIAS QUÍMICAS
PROCESOS DE SEPARACIÓN Y LABORATORIO
Diseño de equipos de
destilación
Dra. Nancy Elizabeth Dávila Guzmán
+ Instructional Objectives 2
After completing this chapter, you should be able to:
 Explain the need in distillation for a condenser to produce

reflux and a reboiler to produce boilup.
 Determine the five construction lines of the McCabe–Thiele

method using material balances and vapor–liquid
equilibrium relations.
 Distinguish among five possible phase conditions of the

feed.
 Apply the McCabe–Thiele method for determining

minimum reflux ratio, minimum equilibrium stages, number
of stages for a specified reflux ratio greater than minimum,
and optimal feed-stage location, given the required split
between the two feed components.

+ 3
 Use a Murphree vapor-stage efficiency to determine the

number of actual stages (plates) from the number of
equilibrium stages.
 Extend the McCabe–Thiele method to multiple feeds,

sidestreams, and open steam (in place of a reboiler).
 Estimate overall stage efficiency for binary distillation from

correlations and laboratory column data.
 Determine the diameter of a trayed tower and the size of the

reflux drum.
 Determine packed height and diameter of a packed column.

+ Introduction 4
Distillation is defined as:
a 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.

+ Introduction 5
Optimal reflux/minimum
reflux between 1.1 to 1.5.
Minimum theoretical
10.7 minimum stages/theoretical
theoretical stages. stages = 2 (common
practice).
Stage efficiency,
80%
Figure 1. Distillation of a
binary mixture of benzene
and toluene.

+ Introduction 6
Table 1. Representative commercial binary distillation operations.

Some initial considerations 7
1. The column operating pressure in the reflux

drum should correspond to a distillate
temperature somewhat higher than the
supply temperature of the cooling water to
the overhead condenser.
2. If this pressure approaches the critical

pressure of the more volatile component,
then a lower pressure must be used and a
refrigerant is required as coolant.

+ Some initial considerations 8

Some initial considerations 9
3. If the estimated pressure is less than

atmospheric, the operating pressure at the
top is often set just above atmospheric to
avoid vacuum operation, unless the
temperature at the bottom of the column is
limited by decomposition, polymerization,
excessive corrosion, or other chemical
reactions. In that case, vacuum operation is
necessary.


For given (1) feed, (2) desired degree of separation, and

(3) operating pressure, a minimum reflux ratio exists that
corresponds to an infinite number of theoretical stages;
and a minimum number of theoretical stages exists that
corresponds to an infinite reflux ratio. The design trade-
off is between the number of stages and the reflux ratio.

+ Extermal column balances 12
• Mass and energy balances around the entire column.
Circled variables are

typically specified in
design problems

Figure 2. Binary distillation column.
The overall mass balance is:
F=B+D
The more volatile component mass

balance is:
QR will be positive and

Fz=BxB+DxD QC negative.
The steady-stage energy balance

around the entire column is :
FhF+QR+QC=BhB+DhD

The enthalpies can be

calculated from enthalpy-
composition diagrams or from
the heat capacities and latent
heats of vaporization:
Still two unknown variables:

hF=hF(z,TF, p);
hD=hD(xD,Treflux, p);
hB=hB(xB,saturated liquid, p) Qc, QR

The total condenser changes the phase of the entering

vapor stream but does not affect the composition. The
splitter after the condenser changes only flow rates.
y1=xD=x0
The condenser mass balance is:
V1=L0+D
The external reflux ratio is:
R=L0/D How many unknown variables?


The condenser energy balance is:
V1H1+QC=DhD+L0h0
Since stream V1 is a vapor leaving

Since the reflux and distillate
an equilibrium stage in the
streams are at the same
distillation column, it is a
composition, temperature, and
saturated vapor. Thus:
pressure:
h0=hD
H1=H1(y1,saturated vapor, p)
V1H1+QC=hD(D+L0)=V1hD
With Qc known we can

QC=V1(hD-H1) solve the column energy
balance for QR.
+ Example 1. 17
A steady-state, countercurrent, staged distillation column

is to be used to separate ethanol from water. The feed is
a 30 wt % ethanol, 70 wt % water mixture at 40°C. Flow
rate of feed is 10,000 kg/h. The column operates at a
pressure of 1 kg/cm2. The reflux is returned as a
saturated liquid. A reflux ratio of L/D = 3.0 is being used.
We desire a bottoms composition of xB = 0.05 (weight
fraction ethanol) and a distillate composition of xD = 0.80
(weight fraction ethanol). The system has a total
condenser and a partial reboiler. Find D, B, Qc, and QR.

+ Enthalpy-composition diagram for ethanol-water at a pressure
of 1 kg/cm2.
18

+ Example 2. 19
A distillation column with two feeds is separating ethanol from

water. The first feed is 60 wt % ethanol, has a total flow rate of
1000 kg/h, and is a mix of liquid and vapor at 81°C. The second
feed is 10 wt % ethanol, has a total flow rate of 500 kg/h, and is
liquid at 20°C. We desire a bottoms product that is 0.01 wt %
ethanol and a distillate product that is 85 wt % ethanol. The
column operates at 1 kg/cm2 and is adiabatic. The column has a
partial reboiler, which acts as an equilibrium contact, and a total
condenser. The distillate and reflux are saturated liquids. Find B
and D in kg/h, and find Qc and QR in kcal/h.
a. External reflux ratio, Lo/D = 3.0

b. Boilup ratio, V/B = 2.5.

+ Example 3. 20
A distillation column receives a feed that is 40 mol% n-pentane

and 60 mol% n-hexane. Feed flow rate is 2500 lbmol/h, and feed
temperature is 30°C. The column is at 1 atm. A distillate that is 99.9
mol% n-pentane is desired. A total condenser is used. Reflux is a
saturated liquid. The external reflux ratio is L0/D = 3. Bottoms from
the partial reboiler is 99.8 mol% n-hexane. Find D, B, QR, Qc.

+ 21
Internal Stage-by-Stage Balances

 In the enriching section of the column it is convenient to use
a balance envelope that goes around the desired stage and
around the condenser.
The mass and energy balances are:
V j+1
= Lj+D
V yj+1 j+1
= L jx j + D x D
Qc+V H j+1 j+1

= L jh j + D h D
The equilibrium relationships are:

h = h (x )
j j j
H j+1
= H j+1 (y ) j+1 Note: j can be
from 1 to f-1,
x = x (y )
j j j where f is the
feed stage.
+ 22

 In the stripping section of the column it is convenient to use a
balance envelope that goes around the desired stage and
around the partial condenser.
V =L k k-1
-B
V y =L x
k k k-1 k-1
-B x B
V H =L h
k k k-1 k-1
-B h +Q
B R
The equilibrium relationships are:

h k-1
= h k-1 ( x k-1)
H = H (y )k k k
x k-1
= x k-1 (y ) k-1

+ 23

 The phase and temperature of the feed affect the vapor and
liquid flow rates in the column.
F +V + L = L +V
F h +V H
F f +1
+L h f -1
=L h +V H
f f

+ 24
Lewis Method
 In many cases the molar vapor and liquid flow rates in each
section were constant. This will occur if:
1. The column is adiabatic.

2. The specific heat changes are small compared to latent heat
changes. ¹
L L
3. The heat of vaporization per mole is constant (constant molal
overflow).
4. An alternative to conditions 2 ¹
V V
and 3 is: the saturated liquid and
vapor lines on an enthalpy-compositions diagram (in molar
units) are parallel.
For some systems, such as hydrocarbons, the latent heat of

vaporization per kilogram is approximately constant. Then the mass
flow rates are constant, and constant mass overflow should be used.

+ 25
Lewis Method
 Assuming constant molal overflow, the mass balance for the
enriching section is:
V y j+1 j+1
= L jx j + (V j+1
-Lj )x D
Solving for yj+1, we have:

æ ö
y j+1 = L j x j + çç1- L j ÷÷ x D
V j+1 è V j+1 ø
Since L and V are constant, this equation becomes:
æ ö
y =L x +
j ç
ç1- L ÷÷ x D Operation equation in
the enriching section.
V j+1
è V ø

+ 26
Lewis Method
 Assuming constant molal overflow.
For the stripping section:

æ ö Operation equation in
y =L x k-1 - çç L -1÷÷ x B the stripping section.
k
V èV ø
At the feed stage:
F h + (V -V ) H = ( L - L ) h
F
Hf+1 ≈ Hf and hf-1 ≈ hf

+ 27
Lewis Method
Combining mass and energy balances:
-L - hF q is the “quality”, the

qº L » H fraction of feed that is
F H -h liquid.
liquid flow rate below feed stage - liquid flow rate above feed stage
qº
feed rate
vapor enthalpy on feed plate - feed enthalpy

q»
vapor enthalpy on feed plate - liquid enthalpy on feed plate

+ 28
Lewis Method
From the mass balance:
L = L +q F
V = V - (1-q ) F

+ 29
Lewis Method
 Example: A steady-state countercurrent, staged distillation column
is to be used to separate ethanol from water. The feed is a 30 wt %
ethanol, 70 wt % water mixture that is a saturated liquid at 1 atm
pressure. Flow rate of feed is 10,000 kg/h. The column operates at a
pressure of 1 atm. The reflux is returned as a saturated liquid. A
reflux ratio of L/D = 3.0 is being used. We desire a bottoms
composition of xB = 0.05 (weight fraction ethanol) and a distillate
composition of xD = 0.80 (weight fraction ethanol). The system has a
total condenser and a partial reboiler. The column is well insulated.
Use the Lewis method to find the number of equilibrium contacts
required if the feed is input on the second stage from the top.

+ 30

+ Introduction to the McCabe-Thiele method. 31
Equilibrium for top stage Stage 1 calculation on

on McCabe-Thiele
McCabe-Thiele diagram.
diagram.

Stepping off stages in Stepping off stages in

rectifying section. stripping section.


When stepping off stages from the top down, the

fractional number of stages can be calculated as:
dis tan ce from operating line to xB

Franction =
dis tan ce from operating line to equilibrium curve
The fraction is somewhat useful when the stage efficiency is < 1.

Feed line is obtained from the intersection of the

enriching and stripping operation equations:
æL-Lö FzF
y = -ç ÷ x +
è V -V ø V -V
An overall mass balance around the feed stage is:

F +V + L = V + L
Substituting in the feed line, dividing numerator and
denominator of each term b the feed rate F, and
using q, we get:
q 1
y= x+ zF
q -1 1- q
Type Feed T hF q Slope=q/(q-1)
Subcooled TF<TBP hF<h q>1 >1

liquid
Saturated TF=TBP h 1 ∞
liquid
Two-phase TBP<TF<TDP h<hF<H 0<q<1 (-)
mixture
Saturated TF=TDP H 0 0
vapor
Superheated TF>TDP hF>H q<0 0<slope<1
vapor



Optimum feed plate calculation
Lbelow× feed - Labove× feed

q=
feed flow rate
Vabove× feed -Vbelow× feed

f=
feed flow rate

Feed line calculations.

Calculate the feed line slope for the following cases:
a. A two-phase feed where 80% of the feed is vaporized

under column conditions.
b. A superheated vapor feed where 1 mole of liquid will
vaporize on the feed stage for each 9 moles of feed
input.
c. A liquid feed subcooled by 35ºF. Average liquid heat
capacity is 30 Btu/lmolºF and λ= 15,000 Btu/lbmol.
d. A mixture of ethanol and water that is 40 mol% ethanol.
Feed is at 40ºC. Pressure is 1.0 kg/cm2.
+ Complete McCabe-Thiele Method. 41
A distillation column with a total condenser and a partial

reboiler is separating an ethanol-water mixture. The feed
is 20 mol% ethanol, feed rate is 1000 kmol/h, and feed
temperature is 80°F. A distillate composition of 80 mol%
ethanol and a bottoms composition of 2 mol% ethanol are
desired. The external reflux ratio is 5/3. The reflux is
returned as a saturated liquid and CMO can be assumed.
Find the optimum feed plate location and the total number
of equilibrium stages required. Pressure is 1 atm.

+ Limiting Operations Conditions. 42
Total Reflux: Minimum equilibrium stages

+ Limiting Operations Conditions. 43
Minimum Reflux Ratio

+ Distillation Problems 44
Tarea para el 28 de agosto

A column at 101 kPa is to separate 30 kg/h of a bubble-
point solution of benzene and toluene containing 0.6 mass-
fraction toluene into an overhead product of 0.97 mass-
fraction benzene and a bottoms product of 0.98 mass-
fraction toluene at a reflux ratio of 3.5. The feed is sent to
the optimal tray, and the reflux is at saturation temperature.
Determine the: (a) top and bottom products and (b) number
of stages using the following vapor–liquid equilibrium data.

A distillation unit consists of a partial reboiler, a column with

seven equilibrium plates, and a total condenser. The feed is
a 50 mol% mixture of benzene in toluene. It is desired to
produce a distillate containing 96 mol% benzene, when
operating at 101 kPa.
(a) With saturated-liquid feed fed to the fifth plate from the
top, calculate: (1) the minimum equilibrium stages, (2)
minimum reflux ratio (L/D)min; (3) the bottoms composition,
using a reflux ratio (L/D) of twice the minimum; and (4)
moles of product per 100 moles of feed.
(b) Repeat part (a) for a saturated vapor fed to the fifth plate
from the top.

We wish to separate ethanol from water in a distillation column

with a total condenser and a partial reboiler. We have 200
kmol/h of feed 1, which is 30 mol% ethanol and is saturated
vapor. We also have 300 kmol/h of feed 2, which is 40 mol%
ethanol. Feed 2 is a subcooled liquid. One mole of vapor must
condense inside the column to heat up 4 moles of feed 2 to its
boiling point. We desire a bottoms product that is 2 mol%
ethanol and a distillate product that is 72 mol% ethanol.
External reflux ratio is L0/D = 1.0. The reflux is a saturated
liquid. Column pressure is 101.3 kPa, and the column is well
insulated. The feeds are to be input at their optimum feed
locations. Find the optimum feed locations (reported as stages
above the reboiler) and the total number of equilibrium stages
required.
47
xD=0.72
One mole of
F2=300 kmol/h L/D = 1 vapor must
z=0.40 condense inside
subcooled liquid the column to
heat up 4 moles of
F1=200 kmol/h feed 2 to its
z=0.30 boiling point.
saturated vapor
xB=0.02

48
Ethanol-water ELV, 101.3 kPa

49
Feed 1: Saturated vapor, q1=0
Feed 2: Subcooled liquid
q2 = (Lbelow – Labove)/F2 q2=5/4
L V
F2
C
Lbelow =L’=L+F2+C L’ V’
C=(1/4) F2

50
Top Operating Line (TOL):

æ ö
y= R x + çç 1 ÷÷ x D
R+1 è R+1 ø
y = 0.5 x + 0.36
Bottom Operating Line (BOL):

51
xD=0.72
F2=300 kmol/h L/D = 1

z=0.40
subcooled liquid
F1=200 kmol/h
z=0.30
saturated vapor
xB=0.02

MÉTODO DE PONCHON
+ SAVARIT
Desarrollo de método de Ponchon - Savarit
Zona de enriquecimiento (condensador total)
QC Balance global de materia
Vn+1 = Ln + D (1)
V1,
y1 Balance del componente más liviano
Lo, x0
D, yD yn+1 Vn+1 = xn Ln + yD D (2)
1
L1 , x 1 Balance de entalpía global
V2, y2
2
L2 , x 2 Vn+1 HVn+1 = Ln HL n + D HD + QC (3)
Vn, yn n (Considerando pérdidas despreciables)
Ln , x n
Sea Q’ = (D HD + QC) / D (4)
Vn+1, yn+1
A partir de las ecuaciones (3) y (4):
Vn+1 HVn+1 - Ln HL n = D Q’ (5)
(D Q’ cte)
Sustituyendo el valor de D de la ecuación (1) en (2) y (5), y

despejando Ln / Vn+1 (relación de reflujo interno) se tiene:
Ln / Vn+1 = (yD - yn+1) / (yD - xn) = (Q’ - HVn+1) / (Q’ - HLn) (6)
La ecuación (6) representa una línea recta en el diagrama entalpía-
composición, Hxy. La línea recta pasará por los puntos (xn, HLn), (yn+1,
Hvn+1) y (yD, Q’). El punto (yD, Q’) se denomina punto de diferencia
y se simboliza con DD (o P’). En el diagrama x,y la ec. (6) permite
graficar la curva de operación para la zona de enriquecimiento

Representación gráfica de la zona de enriquecimiento
DD Q’
Hv vs.y Evaluando la ec. (6) y la ec.(1) en n = 0:
L0 / V1 = (yD - y1) / (yD - x0)

H 3 = (Q’ - Hv1) / (Q’ – HLo) (7)
2 1
V1 =Lo + D (8)
HL vs. x
Sustituyendo (8) en (7):
x, y
Lo / D = (Q’ - Hv1) / (Hv1 - HLo) (9)
entonces,
Pendient
y e Ln / Vn+1
R = (Q’ - HV1) / (HV1 - HLo) (10)
x yD = x0
Zona de agotamiento (rehervidor parcial)
LN-3 , xN-3 Balance global de materia

VN-2, yN-2 N-2
LN-2, xN-2 LN-3 = VN-2 + B (11)
VN-1, yN-1 Balance del componente más

N-1
liviano
LN-1, xN-1
VN, yN N xN-3 LN-3 = yN-2 VN-2 + xB B (12)
Balance de entalpía global

LN , x N
LN-3 HLN-3 + QR = VN-2 HVn-2 + B HB
Vn+1, yn+1 (13)
B, xB (Considerando pérdidas despreciables)

QR Sea Q’’ = (B HB - QR) / B (14)
A partir de las ecuaciones (13) y (14) se obtiene:
LN-3 HLN-3 - VN-2 HVn-2 = B Q’’ (15)
(B Q’’ cte)
Sustituyendo el valor de B de la ecuación (11) en (12) y (15), y

despejando LN-3 / VN-2 (relación de reflujo interno) se tiene:
LN-3 / VN-2 = (yN-2 - xB) / (xN-3 - xB) = (HVN-2 – Q’’) / (HLN-3 – Q’’) (16)
La ecuación (16) representa una línea recta en el diagrama entalpía-
composición, Hxy. La línea recta pasará por los puntos (xN-3, HLN-3),
(yN-2, HvN-2) y (xB, Q’’). El punto (xB, Q’’) se denomina punto de
diferencia y se simboliza con DB (o P’’) La ec. (16) permite graficar la
curva de operación de la zona de agotamiento.

Aplicación del método P-S a la columna de destilación completa
(condensador total y rehervidor parcial)
Balance global de materia
F=D+B (1)
Balance global por componente
zF F = yD D + xB B (2)
Balance global de entalpía
F HF = D Q’ + BQ’’ (3)
Despejando F de (1) y sustituyéndola en (2) y (3):
D / B= (zF - xB) / (yD - zF) = (HF – Q’’) / (Q’ - HF) (4)

Número mínimo de etapas (Nm) y relación de reflujo mínimo (Rm)
DD
Hv vs. y Hv vs. y
DDm
B
HL vs. x F HL vs. x D
DB
xB yD xB zF yD = x0
Número mínimo de etapas a reflujo total Relación de reflujo mínimo

D1 Diagrama de Ponchon y Savarit
F, DD, DB están en línea recta

L0
V1
B F
D
D
H/h
D2
y
xB z xD
y, x
DD
Diagrama de Ponchon y Savarit
Cálculo etapa a etapa
B F V1
D
H/h
DB
xB z xD
y, x
+ 62
Método de Ponchon-Savarit
1000 kg/h of a mixture containing 42 mole
percent heptane and 58 mole percent ethyl
benzene is to be fractionated to a distillate
containing 97 mole percent heptane and a
residue containing 99 mole percent ethyl
benzene using a total condenser and feed at its
saturated liquid condition. The enthalpy-
concentration data for the heptane-ethyl benzene
at 1 atm pressure are as follows:

+ 63
Método de Ponchon-Savarit
Calculate the following:
1. Minimum reflux ratio

2. Minimum number of stages at total reflux
3. Number of stages at reflux ratio of 2.5
4. Condenser duty
5. Reboiler duty

Parameters for the design of
+ multiphase mass transfer units
Dra. Nancy Elizabeth Dávila Guzmán 64

+ 65
Stage and packed column
Trays Random packing Random mesh

+ 66
Type of stage columns
Bubble-cap trays
Sieve tray Valve tray

+ 67
Sieve-tray column

+ 68
Bubble-cap tray

+ 69
Trays, Downcomers, and Weirs

In addition to choosing the type of tray, the designer
must select the flow pattern on the trays and design
the weirs and downcomers.
Which flow pattern is appropriate

for a given problem? As the gas
High liquid rates
and liquid rates increase, the
tower diameter increases.
Cross-flow Double-pass

+ 70
Trays, Downcomers, and Weirs
A. Pilot plants B. Most common C. Difficult Disengagement D. Very low liquid flow

+ Limits of stable operation in a trayed tower 71
Weep point: Liquid begins

falling through the
perforations in the trays.
Dump point: weeping

point of 100%. Entrainment: Liquid passes
to the above tray. High gas
flow rates, froth formation.

+ 72
Entrainment

+ 73
Weeping

+ Tray details in a trayed tower 74
Weir: vertedero
Downcomer: tubo
de descenso

+ 75
Tray efficiencies
N equil
EO =
N actual
The number of equilibrium stages required for the given separation
should not include a partial reboiler or a partial condenser.

+ 76
Murphy efficiency
yout - yin
EMV =
y *out -y *in
xout - xin
EML =
x *out -x *in

+ 77
Tray efficiency
 To have data for the chemical system in the same type

of column of the same size at the same vapor velocity.
The Fractionation Research Institute (FRI) has reams of
efficiency data.
 To have efficiency data for the same chemical system
but with a different type of tray.
 If data are not available, a detailed calculation of the
efficiency can be made on the basis of fundamental
mass and heat transfer calculations.
 The simplest approach is to use a correlation to
determine the efficiency

+ 78
O’Connell correlation
EO = 0.52782 - 0.27511log10 (am) + 0.044923[log10 (am )]2

+ 79
Oldershaw column
Oldershaw column: 55,250,

columna de 10 platos con
2.8 mm de D.I.
Overall efficiency of 1-inch-diameter Oldershaw column compared

to point efficiency of 4-foot-diameter FRI column. System is
cyclohexane/n-heptane.

+ 80
Overall efficiency estimation

A sieve-plate distillation column is separating a feed
that is 50 mole % n-hexane and 50 mole % nheptane.
Feed is a saturated liquid. Plate spacing is 24 in.
Average column pressure is 1 atm. Distillate
composition is xD = 0.999 (mole fraction n-hexane) and
xB = 0.001. Feed rate is 1000 lbmol/h. Internal reflux
ratio L/V = 0.8. The column has a total reboiler and a
total condenser. Estimate the overall efficiency.
x 0 0.341 0.398 0.50 1.0
y 0 0.545 0.609 0.70 1.0
T(ºC) 101.1 87.22 85 82.22 70.55

+ 81
Column Diameter Calculations
 Fair’s procedure:
 Widely known
 Aspen Plus Simulator
This procedure first Uses a rule of Calculates the

estimates the vapor thumb to column
velocity that will cause determine the diameter.
flooding due to excessive operating
entrainment. velocity.

+ 82
Column diameter calculations
 The flooding velocity based on net area for vapor flow is

determined from:
æs ö r L - rv
0.2
u flood = Csb, f ç ÷ , ft / s
è 20 ø rv
 Where s is the surface tension in dynes/cm and Csb,f is the
capacity factor which is function of the flow parameter.
WL rv QL rL
FP = Flv = =
WV r L QV rV

+ 83

+ 84

6’’ tray spacing
log10 Csb, f = -1.1977 - 0.53143log10 Flv - 0.18760 ( log10 Flv )

2

2
log10 Csb, f = -1.0674 - 0.55780 log10 Flv - 0.17919 ( log10 Flv )

2

+ 85


2
Tray spacing is usually selected

according
to maintenance
log C requirements.
= -0.94506 - 0.70234log F - 0.22618 log F ( )
2
10 sb, f 10 lv 10 lv
With
36’’ tray spacing the typical 24-inch tray
spacing, Csb,f ≈ 0.33 ft/s
2

+ 86

 The operating vapor velocity uop is determined as:
uop = ( fraction)u flood , ft / s
Suggesting fraction value of 0.75.

+ 87

 Also, it can be related to the molar vapor flow rate:
V MW v
uop = , ft / s
rV Anet (3600)
 The net area for vapor flow is
p (Di)2
Anet = h, ft 2
4
Typically n lies between 0.85 and 0.95.
where h Exact
is the fraction of the column cross-sectional
values are determine from the tray layout.
area that is available for vapor flow above the tray.
Then 1-h is the fraction of the column area taken up
by one downcomer.
+ 88

 The diameter of the column:
4V MW v
Di = , ft
phrV ( fraction)u flood (3600)
 If the ideal gas law holds
4VRT
Di = , ft
ph(3600)P( fraction)u flood
The largest diameter should be used and rounded

off to the next highest ½-foot increment.
+ 89
Diameter calculation for tray

column
 Determine the required diameter at the top of the
column for the distillation column in Example
“Overall Efficiency Estimation”.
 Repeat the diameter calculation, except calculate

the diameter at the bottom of the column. For n-
heptane: MV=100.2, bp 98.4ºC, sp gravity=0.684, m
(98.4ºC)=0.205 cP., s(98.4ºC)=12.5 dynes/cm.

+ 90
 You have designed a sieve tray column with 0.3048

m tray spacing to operate at a pressure of 1.0 atm.
The value of the flow parameter is Flv = 0.090 and
the flooding velocity was calculated as 1.83 m/s.
Unfortunately, your boss dislikes your design. She
thinks that 0.3048 m tray spacing is not enough and
that your reflux ratio is too low. You must redesign
for a 0.6096 m tray spacing and increase L/V by
11%. Estimate the new flooding velocity.

+ 91
Sieve Tray Layout and Tray

Hydraulics
The vapor does not go straight
 The punched holes
upinfrom
the tray
theusually
holesrange in diameter from
1/8 to 1.0 inch.
The active hole area is
 Inconsidered
the range fromto½be
to 12-inch, efficiency is constant and at its
to 3-inches
highest level.
from the peripheral
3.8doholesa reasonable average
The use of standard punching patterns will be cheaper than

use of a nonstandard pattern.
+ 92

Hydraulics
 Typically, 4% to 15% of the entire tower area is
hole area.
 This corresponds to a value of β = Ahole/Aactive of
6% to 25%.
 The average value of β is between 7% and 16%,
with 10% a reasonable first guess.
 The value of β is selected so that the vapor velocity
through the holes, vo, lies between the weep point
and the maximum velocity.

+ 93

Hydraulics
The choice of material for the fabrication of trays is
dependent mainly on the corrosion properties of the
process fluids. In general, tray thickness is about
gauge 10 (0.134 in; 3.40 mm) for carbon steel and
gauge 12 (0.109 in; 2.77 mm) for stainless steel. For
economic reasons the holes are punched, which
dictates that the thickness must be less than the hole
diameter.

+ 94

Hydraulics
Small holes with a diameter in the range of 3/16 to
1/4 in (4.76- 6.35 mm) give better hydraulic and
mass transfer performance than the large ones in the
range of 12 to 34 in (12.7- 19.0 mm). However, large-
hole trays are cheaper and show more resistance to
fouling. Choose the hole size according to design
requirements.

+ 95

Hydraulics
 The vapor velocity through the holes, vo, in ft/s.
V MVV V is the lbmol/h of vapor

vo = ρv is the vapor density in lb/ft3
3600 rV Ahole
Ahole is the total hole area on the tray, ft2
æ do2 ö
Ahole = ( No. of holes) ç p ÷ Ahole = b Aactive
è 4ø

+ 96

Hydraulics
V MVV
vo =
3600 rV Ahole
æ do2 ö Ahole = b Aactive
Ahole = ( No. of holes) ç p ÷
è 4ø
Aactive = Atotal (2h -1)
æ Di 2 ö
Atotal = çp ÷
è 4 ø

+ 97

Hydraulics
1 2
Ad = r (q - sinq )
2
Ad = (1- h) Atotal
+ 98

Hydraulics
Typically the ratio of lw/Di falls

in the range of 0.6 to 0.75
h 0.8 0.825 0.85 0.875 0.90 0.925 0.95 0.975
lw/Di 0.871 0.843 0.811 0.773 0.726 0.669 0.593 0.478

+ 99

Hydraulics
Downcomers are designed on the basis of pressure drop
and liquid residence time.
hdc = hDp,dry + hw + hcrest + hgrad + hdu

+ 100

Hydraulics
The head of liquid required to overcome the
pressure drop of gas on a dry tray, hΔp,dry:
æ rwater ö
hDp,dry = 0.003v rv ç ÷ (1- b ) / Co
2 2 2
inches
è rL ø
o
The orifice coefficient, Co, can be determined from value

The minimum
the
ttray is correlation of Hughmark and O’Connell:
the tray thickness for do/ttray is 1.0
æd ö
2
do
Co = 0.85032 - 0.04231 + 0.0017954 çç o ÷÷
ttray è ttray ø

+ 101

Hydraulics
The minimum weir height is 0.5 inch with 2 to 4 inches
more common. 2
æ Lg ö 3
hcrest = 0.092Fweir ç ÷ inches
è lweir ø
Lg is the liquid flow rate in gal/min that is due to both L
and e (entrainment).
YL
e=
1- Y
Usually, entrainment is not a problem until fractional
entrainment is above 0.1.
+ 102

+ 103

Hydraulics
2
æ Lg ö 3
hcrest = 0.092Fweir ç ÷ inches
è lweir ø
Lg is the liquid flow rate in gal/min that is due to both L
and e. Lweir in ft.
Fweir is a modification factor to take into account the

curvature of the column wall in the downcomer.

+ 104

+ 105

Hydraulics
There is a frictional loss due to flow in the downcomer
and under the downcomer onto the tray, hdu
æ L ö2
hdu = 0.56 çç g
A
÷
÷ inches
è 449 du ø
Adu is the flow area under the downcomer apron in ft2.
Adu = ( gap) lw
The downcomer apron typically has a 1-in gap above
the tray.
+ 106
Sieve Tray Layout and Tray Hydraulics
In an operating distillation column the liquid in the

downcomer is aerated. The density of this aerated liquid
will be less than that of clear liquid, hdc,aerated:
hdc
hdc,aerated =
fdc inches
where φdc is the relative froth density. For normal

operation, a value of φdc = 0.5 is satisfactory.
To avoid downcomer flooding, the tray spacing

must be greater than hdc,aerated.

107

+ 108

Hydraulics
The downcomer is designed to give a liquid residence
time of three to seven seconds.
Ad hdc (3600) r L
tres = s
12 ( L + e) MW L
Foaming Tendency Examples tres (s)

Low Alcohols, low-MW hydrocarbons 3
Medium Medium-MW hydrocarbons 4
High Mineral oil absorbers 5
Very high Amines, glycols 7

+ 109

Hydraulics
Liquid will not drain through the holes as long as the sum
of heads due to surface tension, hσ, and gas flow, hΔp,dry,
are greater than a function depending on the liquid head.
hDp,dry + hs ³ 0.10392 + 0.25119x - 0.021675x 2

where x = hweir + hcrest + hgrad.
The surface tension head hσ can be estimated from:
0.040s where σ is in dynes/cm,

hs = ρL in lb/ft3,
r L do d0 in inches
hσ in inches of liquid
+ 110
Tray layout and hydraulics
Determine the tray layout and pressure drops for a sieve-

plate distillation column which is separating a feed that is
50% mole % n-hexane and 50% mole %n-heptane. Feed is
a saturated liquid. Plate spacing is 24 in. Average column
pressure is 1 atm. Distillate composition is xD=0.9999
(mole fraction n-hexane) and xB=0.001. Feed rate is 1000
lbmol/h. Internal reflux ratio L/V = 0.8. The column has a
total reboiler and a total condenser. Determine if
entrainment or weeping is a problem. Determine if the
downcomers will work properly. Do these calculations
only at the top of the column.

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UNIVERSIDAD AUTÓNOMA DE NUEVO LEÓN

After completing this chapter, you should be able to:

 Explain the need in distillation for a condenser to produce

 Determine the five construction lines of the McCabe–Thiele

 Distinguish among five possible phase conditions of the

 Apply the McCabe–Thiele method for determining

Dra. Nancy Elizabeth Dávila Guzmán

 Use a Murphree vapor-stage efficiency to determine the

 Extend the McCabe–Thiele method to multiple feeds,

 Estimate overall stage efficiency for binary distillation from

 Determine the diameter of a trayed tower and the size of the

 Determine packed height and diameter of a packed column.

Dra. Nancy Elizabeth Dávila Guzmán

Distillation is defined as:

a process in which a liquid or

Dra. Nancy Elizabeth Dávila Guzmán

Dra. Nancy Elizabeth Dávila Guzmán

Table 1. Representative commercial binary distillation operations.

Dra. Nancy Elizabeth Dávila Guzmán

1. The column operating pressure in the reflux

2. If this pressure approaches the critical

Dra. Nancy Elizabeth Dávila Guzmán

Table 1. Representative commercial binary distillation operations.

Dra. Nancy Elizabeth Dávila Guzmán

3. If the estimated pressure is less than

Dra. Nancy Elizabeth Dávila Guzmán

Table 1. Representative commercial binary distillation operations.

Dra. Nancy Elizabeth Dávila Guzmán

For given (1) feed, (2) desired degree of separation, and

Dra. Nancy Elizabeth Dávila Guzmán

• Mass and energy balances around the entire column.

Circled variables are

Dra. Nancy Elizabeth Dávila Guzmán

• Mass and energy balances around the entire column.

The overall mass balance is:

The more volatile component mass

QR will be positive and

The steady-stage energy balance

Dra. Nancy Elizabeth Dávila Guzmán

• Mass and energy balances around the entire column.

The enthalpies can be

Still two unknown variables:

Dra. Nancy Elizabeth Dávila Guzmán

• Mass and energy balances around the entire column.

The total condenser changes the phase of the entering

The condenser mass balance is:

R=L0/D How many unknown variables?

Dra. Nancy Elizabeth Dávila Guzmán

• Mass and energy balances around the entire column.

Since stream V1 is a vapor leaving

With Qc known we can

A steady-state, countercurrent, staged distillation column

Dra. Nancy Elizabeth Dávila Guzmán

Dra. Nancy Elizabeth Dávila Guzmán

A distillation column with two feeds is separating ethanol from

a. External reflux ratio, Lo/D = 3.0

Dra. Nancy Elizabeth Dávila Guzmán

A distillation column receives a feed that is 40 mol% n-pentane

Dra. Nancy Elizabeth Dávila Guzmán

Internal Stage-by-Stage Balances

The mass and energy balances are:

Qc+V H j+1 j+1