Module – 3: Process Design of Distillation Column

Distillation
Vaporization followed by Condensation
Separation of components of solution which are relatively
volatile
Most widely used separation technique in chemical
industries
Simple/Batch distillation was invented first; Multistage
counter current distillation was invented later
No method for design of DC is 100% reliable; every
method has limitations
Pilot plant scale to Commercial Scale design --- right way
to implement
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Selection Criteria:
 When all components of mixture are relatively volatile
 If relative volatility of 2 adjacent components in mixture is
very low, or close to 1 or equal to 1
 When relative volatility is equal to or very close to 1, use
Extractive or Azeotropic Distillation (e.g. mixture of 95.6%
ethanol and water)
 If economical, liquid-liquid extraction, crystallization,
membrane separation, pervaporation can be alternative to
distillation
 If separation of only one component is required rather than
a separation of all components in mixture, then absorption,
stripping or liquid liquid extraction, are more economical
than distillation

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Equipment Selection for Distillation:
 Distillation ---carried either in Tray tower or Packed tower
 When to choose Tray tower and when Packed tower?
Packed Tower Tray Tower
For High Vacuum Distillation; Provides Provides high pressure drop compared to
Low pressure drop Packed tower
Provide lower residence time for liquid More residence time compared to packed
tower
Good for thermally sensitive material

Variety of packing options available Require special metal alloy trays to

(plastic packings, glass fiber reinforced handle corrosive liquids, which may
plastic packings) in case of handling increase cost
corrosive liquids
Preferred for small diameter columns Preferred for large diameter columns;
(less than 0.6 m); because liquid because fabrication of trays –difficult in
distribution –difficult in case of large case of small diameter column
diameter packed column
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 Tray Tower
Good for..handling higher ratio of liquid to Good for…handling low liquid rates and
vapor flow lower ratio of liquid to vapor flow
Preferred when side products are to be
drawn from distillation column
Foaming liquids can be handled more Good for dirty services, as plates are
easily easier to clean

Distillation Column Design:

Design Steps are…..
1. Select 2 key components (if feed mixture has more than 2
components)
2. Fix the operating pressure of column and find
corresponding VLE data
3. Specify degree of separation; for binary system, decide
top and bottom product composition; for multicomponent
system, decide distribution of key components in distillate
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 4. Decide Rmin
5. Determine Ropt, Number of theoretical stages
6. Select tray or packed tower (w.r.t. previous criteria) & select
tray or packing type
7. Evaluate tower diameter & pressure drop across tower &
top & bottom disengagement space
8. Decide tray efficiency & find actual number of trays (in
case of tray tower); OR find HETP and decide height of
packing (in case of packed column); in case of packed
column, also decide design of liquid distributor, packing
support, etc.
9. Select MOC for all parts, design suitable insulation system
10. Design Condenser & Reboiler
11. Finalize control strategy for DC, line sizing & nozzle
locations
12. Mechanical design of DC --- design of skirt support
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 Out of above 12 steps, calculations & equations for first 5
steps are different for binary and multicomponent system

 Discussion on Different steps in DC design:

1. Selection of Key Components
 In case of actually binary mixture (or assumed binary
mixture, where except 2 major components, other
components are in negligible amount), no need to select
key component
 In case of multicomponent mixture, to separate each
component in pure--- N-1 DCs will be required in case of
N component mixture
 In case of multicomponent mixture…can fix distribution
of 2 components of feed only in distillate and residue &
not the distribution of all components; 2 components are --
- ‘light key component (more volatile)’ and ‘heavy key
component (less volatile)’
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  Light key component---
• component of feed mixture which is to be kept apart from bottom
product
• Most volatile component in residue mixture
• Lighter than light key components are present in negligible amount
or absent at all in residue
 Heavy key component—
• Component of feed mixture which is to be kept apart from
distillate product (top product)
• Least volatile component in distillate mixture
• Heavier than heavy key component are present in negligible
amount or absent at all in distillate
 Light and heavy key components are selected as per their
volatility
 Components lying in between ---- split keys
 Components distributed in top and bottom product --- non
key components

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2. Selection of Operating Pressure and Determining VLE
Data:
 (a) Operating pressure in DC ----fixed by ‘T’ of cheapest
cooling medium (generally Cooling water), which can
condense distillate vapor
 For this ---- bubble point of distillate (in case of total
condenser) > cooling water ‘T’; bubble point of reflux (equal
to dew point of distillate vapor) (in case of partial condenser)
> cooling water ‘T’
 If operating ‘P’ (calculated based on cooling water ‘T’) is very
high, chilled water / brine to be used as cooling medium (for
overhead condenser)
 Operating ‘P’ in DC is always < critical ‘P’ of top product or
‘T’ of cooling medium can’t be greater than critical ‘T’ of top
product
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 In some cases --- distillation – carried out under vacuum --- to
avoid thermal degradation of heat sensitive product or to
enable use of cheaper heating medium (saturated steam) in
Reboiler or to change VLE data

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 Vacuum Distillation --- used in case of distillation
of heat sensitive material, to facilitate the use of
cheaper heating medium in reboiler.
Advantages:
Prevents decomposition of heat sensitive material
Allows use of more economical heating medium such as
saturated steam rather than using hot oil (costlier)
Requires fewer stages or lower reflux ratio, or both in cases
where relative volatility increases with decrease in operating
pressure
In some cases, vacuum helps in breaking the azeotrope and
makes the separation easy (e.g. if distillation of ethanol water
mixture is carried out below 70 torr absolute pressure, azeotrope
is not formed

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 Reduces undesirable side reactions (if occuring); e.g. distillation of
ethyl benzene styrene mixture under vacuum reduces
polymerization
 Provides safety in case of distillation of hazardous/toxic material.
E.g. separation of pure HNO3 from azeotrope of HNO3 and H2O,
extractive distillation (solvent- conc. H2SO4) under slight vacuum is
carried out
 Increases product recovery while dealing with maximum ‘T’
constraints

Disadvantages:
 Requires large diameter column & large diameter vapor line
 Because of reduction in condensation ‘T’ –costlier cooling medium
required for condensation
 Presence of air as non condensable, reduces efficiency of main
condenser
 Increases chances of contamination of product by air or other
components of atmosphere
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Determining VLE data :
 Has to be determined @ operating ‘P’ of column
 Can be determined by –
 Experiment OR
 From literature (if available for given system) OR
 From Phase equilibrium equation (using Raoult’s law for
ideal VLE)
For ideal system, find VLE data from –

For non ideal system, VLE is determined from equation ---

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Fugacity coefficient – represents deviation of vapor phase from
ideal gas mixture; if operating pressure is close to atmospheric
pressure, vapor phase can be assumed as ideal gas & fugacity
coefficient is unity.
Fugacity coefficient --- can be calculated using Redlich-Kwong
or Peng-Robinson equation
Activity coefficient --- represents deviation of behavior of
component in given solution from behavior of same component
in ideal solution; it is function of ‘T’ and liquid composition but
independent of ‘P’.
Activity coefficient --- can be determined using van Laar
equation or UNIFAC , UNIQUAC method

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3. Determining Degree of Separation
 Binary distillation --- specify xD & xW; find D & W from ---

Feed can be saturated liquid, saturate vapour or mixture of

liquid & vapor, hence symbol, zF is used. If feed is only liquid,
we can use xF

Multicomponent system --- specify distribution of 2 key

components in distillate & residue, considering equilibrium
limitations; distribution of non-key componets can be
determined using Hegstebeck & Geddes equation ---

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Problem 1:
Feed mixture to a distillation column contains 30% n-hexane, 32% n-propane,
20% n-butane and 18% n-pentane (by mole). Total flow rate of the feed is 100
kmol/h. If butane and pentane are selected as light key and heavy key
components, respectively then (a) fix the operating pressure of distillation
column and (b) find the product compositions. (BPs of n-hexane, n-propane, n-
butane and n-pentane are 68oC, - 42oC, - 1oC and 36.1oC respectively); As a first
trial, assume 99% recovery of light key component in distillate and 99%
recovery of heavy key component in residue.
(Assume: Cooling water T = 32oC and hence, Bubble point T of Distillate =
60oC)

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Problem 1:
Feed mixture to a distillation column contains 30% n-hexane, 32% n-propane,
20% n-butane and 18% n-pentane (by mole). Total flow rate of the feed is 100
kmol/h. If butane and pentane are selected as light key and heavy key
components, respectively then (a) fix the operating pressure of distillation
column and (b) find the product compositions. (BPs of n-hexane, n-propane, n-
butane and n-pentane are 68oC, - 42oC, - 1oC and 36.1oC respectively); As a first
trial, assume 99% recovery of light key component in distillate and 99%
recovery of heavy key component in residue.
(Assume: Cooling water T = 32oC and hence, Bubble point T of Distillate =
60oC)

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• 4. Determining Minimum Reflux Ratio (Rm)
 At Rm --- Minimum trays required for desired
separation
 At Rm --- minimum cooling load at condenser &
minimum heating load at reboiler for desired
separation
 As RR decreases, ease of separation decreases and
once Rm is reached, separation becomes impossible

 For Binary System---

• With ideal VLE curve….

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• (i) if feed is at bubble point (saturated liquid) (q = 1)….

T @ top of DC = Dew point T of overhead vapor

T @ bottom of DC = Bubble point T of residue
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• (ii) if feed is at dew point (saturated vapour) (q = 0)….

(iii) If feed at any condition (any value of q)…..

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 Rm can also be determined by Mc Cabe Thiele Method
for ideal system ----

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 This is for Non ideal system

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 For multicomponent Distillation…..Rm is determined
by Underwood’s method…by solving 2 equations….

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 Value of this constant lies between and

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Problem 2:
Determine the minimum reflux ratio for the binary distillation at
standard atmospheric pressure based on the following data. Feed
= 100 kmol/h Feed mixture: benzene -toluene Mole fraction of
benzene in feed = 0.4 Condition of feed = Saturated liquid Mole
fraction of benzene in distillate required = 0.99 Mole fraction of
benzene in Residue required = 0.02 Average relative volatility =
2.25
Problem 3:
In the previous example, if the feed is at room temperature (30o
C), what is the value of Rm required?

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• 4. Determination of Optimum Reflux Ratio (Ropt):
 Ropt ---- most economical ----@ Ropt , total cost of
distillation is minimum (annual fixed charges + annual
operating cost – minimum)
 Ropt --- depends on type of feed mixture, specified
separation, operating conditions
 @ Rm ---- N ∞ , Fixed cost Operating cost
 As R N , column ‘d’ & size of Reboiler, condenser
 As R increases further, N becomes constant, but other 3
things keep increasing….so fixed cost again increases ---
 Operating cost as R --- at Ropt ----- Total cost passes
through minimum
 Many times Ropt = 1.2 to 1.5 Rm; for difficult distillation, Ropt >
1.5 Rm

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Determining Theoretical number of stages:
 Mc-Cabe Thiele method
 Use of Open steam
 Ponchon Savarit method

Methods available for Multicomponent Distillation

2 Categories…….
 Short cut Methods: FUG method, FUE method, Smith
Brinkley method, etc
 Rigorous Methods: Lewis Matheson method, Thiele
Geddes method, Relaxation method, Linear algebra
method, etc…

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FUG method: (Fenskey Underwood Gilliland’s
Method)
 Most widely used short cut technique
 Fenskey equation --- to calculate min number of theoretical
stages ---

If value at top and bottom are much different then

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 FUG method: (Fenskey Underwood Gilliland’s
Method)
Most widely used short cut technique
Fenskey equation --- to calculate min number of
theoretical stages ---

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• If value at top and bottom are much different then, use
another equation in Fenskey’s equation, which gives less Nm
than actual required Nm

Where, is relative volatility of light key with respect to

heavy key component at bubble point of feed

Gilliland’s Correlation for Rm and Nm:

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Problem 4:
• A fatty acid mixture contains 11% palmitic acid, 4% stearic acid,
28.5% oleic acid and rest linoleic acid (by mass). It is to be
distilled to separate in pure components in distillation columns
operating at 2 torr absolute at top. Feed is a saturated liquid.
Determine the number of theoretical stages required for the
desired separation.

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Problem 4:
• A fatty acid mixture contains 11% palmitic acid, 4% stearic acid,
28.5% oleic acid and rest linoleic acid (by mass). It is to be
distilled to separate in pure components in distillation columns
operating at 2 torr absolute at top. Feed is a saturated liquid.
Determine the number of theoretical stages required for the
desired separation.

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 Problem 4 continued…..

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Rigorous Methods: (Detailed methods)
1. Lewis – Matheson Method (used to calculate number of
theoretical stages)
 Assumes constant molar overflow
 For each stage, molar latent heat of vaporization of liquid
phase is equal to latent heat of condensation of vapor
phase
 Molar flow rates of liquid and vapor in enriching section
(L & V) and in stripping section
 Information to be provided----
 F, its conditions & compositions; D or W; R; ‘P’ in
column; Product composition or distribution of key/non-
key components

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 Step wise methodology:
1. Assume – total condenser ; L = RD; V = (R+1)D;
Find dew point T of overhead vapor by using equations--

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• Further xNi can also be calculated from yNi as below:

Composition of vapor leaving the (N-1)th tray---from MB around

top section

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• Dew point of vapor leaving (N-1)th tray is the determined
from ---

Similarly, calculations can be carried out for other trays up to

feed tray

2. Feed Tray Identification

To identify feed tray, there are different conditions to be satisfied

----
(i) If feed is liquid then,

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• Where,
feed tray ---- liquid leaving feed tray
feed --- actual feed liquid
tray above feed tray ---- liquid leaving tray above feed tray

(ii) If feed is mixture of liquid and vapor, then also above

condition is valid, however, only liquid phase molar ratio is to
be considered

(iii) If feed is vapor then, condition is—

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 3. For stripping section –
molar flow rate of Liquid and Vapor in stripping section is ---

To calculate bubble point T of residue---

Composition of vapor leaving Reboiler can be calculated in

similar fashion ----

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 MB around Reboiler gives ---

Calculate bubble point T of liquid leaving 1st tray

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 From MB ---

X2i is composition of liquid leaving 2nd tray

Like, carry the calculations from bottom to feed tray

The calculations are assumed to be correct when xLK/xHk ratio

obtained from rectifying section calculations and stripping
section are close.

If not, then need to start 2nd trial with change in xDi, xWi, D and
W

Change in moles of component i in distillate for 2nd trial

calculations,
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 Corresponding changes required in bottom product for
component i ----

Calculations are repeated until feed tray composition during top

to bottom and bottom to top calculations are same
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Problem 5:
A saturated liquid, consisting of phenol and cresols with some
xylenols, is fractioned to give a top product of 95.3 mole%
phenol. Metacresol is heavy key and phenol is light key
component. Total condenser is used. The composition ofthe top
product and ofthe phenols in the bottoms are given. (a) Complete
the material balance over the still for a feed rate of 100 kmol/h.
(b) Calculate the minimum reflux ratio by Underwood's method.
(c) For R = 3Rm, calculate the composition of vapour entering to
the top most tray by Lewis-Matheson method

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 Rigorous Methods: (Detailed methods)
2. Thiele Geddes Method (known as rating method;
distribution of components between distillate and
bottoms is predicted for specified number of stages)
 Input data required to apply this method:
• N above and below feed
• Column P & T
• RR
• D
• F , feed condition, feed composition
• L & V flow rates leaving each stage

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Algorithm for this method:

1. MB for any component around Condenser

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 2. Component MB for Tray:

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3. MB for any Component around Reboiler:

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 Rigorous Methods: (Detailed methods)
2. Thiele Geddes Method (known as rating method;
distribution of components between distillate and
bottoms is predicted for specified number of stages)
 Input data required to apply this method:
• N above and below feed
• Column P & T
• RR
• D
• F , feed condition, feed composition
• L & V flow rates leaving each stage

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Algorithm for this method:

1. MB for any component around Condenser

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 2. Component MB for Tray:

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3. MB for any Component around Reboiler:

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Problem 6:

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 Selection of Tray:
Different types of Trays:
Sieve Trays
Bubble cap trays
Valve trays
Linde trays

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 Factors to be considered During Tray Selection:
1. Cost:
Bubble cap tray --- costliest
If MS is MOC, General Cost ratio scenario is: 3:1.5:1
(Bubble cap:Valve:Sieve)
With different MOCs, above ratio varies slightly

2. Capacity:
For given flow rate, if Tower Diameter required is more,
then Capacity of tray is less
For same flow rate, Tower Diameter --- Maximum for
Bubble cap tray & Minimum for Modified Sieve tray
Difference in tower diameter --- not much large (according
to different trays)
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 Capacity:
 Capacity of tray --- relates to tower diameter
 More tower diameter required ---- means capacity of tray is less
 For given flow rate, tower diameter ---max for bubble cap tray -
-- min for sieve tray
 i.e. capacity decreases from sieve tray to valve tray to bubble
cap tray
Operating Range:
 Important factor for tray selection
 Operating range of tray --- range of L & V flow rates over
which tray works satisfactorily
 Bubble cap tray --- provides max op range; Sieve tray ----
provides min op range
 Process plants --- always designed for max and min op capacity
 DC---- also ---operated in range of max to min feed flow rates
 Turn down ratio --- ratio of max to min flow rates

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  Some process plants --- frequebtly operated @ high turn down
ratio --- to meet product demand & avoid frequent shut down –
start-ups – as it decreases efficiency
 Higher turn down ratios --- bubble cap try preferred
 Valve trays --- more flexible & good for higher turn down ratio
compared to sieve tray --- but get stuck up if operatings
conditions changed frequently --- then efficiency is lowered
down
Efficiency:
 If operated at design flow rates --- trays always give consistent
efficiency
 Bubble cap tray ---good efficiency over wider range of turn
down ratios
Pressure Drop:
 Pressure drop over tray & in column --- important for vacuum
distillation (preferably packed columns are used here)
 Sieve trays --- provide lowest pressure drop, followed by valve
trays and highest by bubble cap trys
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Process Design of Tray Tower:
Tower Diameter for Sieve tray tower:
It is decided based upon flooding velocity, vF
Design velocity in DC is between 70 to 90% of vF
vF is calculated by ----

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 Sieve tray perforations --- 13 mm or less in diameter
Few other parameters ---

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 Weir:
Height of weir – decides height of liquid over tray
Weirs – straight or rectangular plates
For DC operating above atmospheric P, weir height is
kept between 40 to 90 mm
Height of liquid crest over weir ---calculated by Francis
formula

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 Weeping
At very low value for vapour velocity, liquid rain down
through perforations --- known as weeping
To avoid weeping, minimum vapor velocity is required
and calculated by Eduljees’ equation ---

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 Total Pressure Drop in Sieve tray:
Total Pressure drop in DC is given by ---

 Major pressure drop in vapor is provided by trays

 Conversion of pressure drop in mm of liquid to Pa or N/m2 ---

given by -----

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 • Tray pressure drop ----

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• Pressure drop through dry plate is given by ----

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 Design of Downcomer:
Downcomer -----
Provides passage for liquid flow
Acts as vapor-liquid separator, when foamy liquid enters into it
To facilitate vapor – liquid disengagement, min residence time
required in downcomer is at least 3 seconds

Types of Downcomer ----

oStraight segmental downcomer:
Simplest & cheapest, most preferred
Downcomer channel is formed by flat plate
Portion of flat plate ---extending down below plate from
outlet weir – known as apron (its straight and vertical)

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 o Inclined segmental downcomer:
 Apron is inclined towards wall
 Preferred when liquid is foamy
 Its sloppy apron provides more resistance to flow and makes
phase separation easy
 Increases tray area
o Circular downcomers or pipes:
 Used for small liquid flow rates
Liquid pass through downcomer while passing from tray to
tray
Due to ΔP across tray, liquid flows from lower to higher P
To overcome pressure difference, liquid elevates its level in
downcomer --- known as liquid back up in downcomer
Pressure drop also occurs as liquid flows through downcomer
Pressure drop in downcomer is given by----

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 Liquid back-up in downcomer in terms of clear liquid is given by
----
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 Due to froth formation, actual height of liquid in downcomer is quiet more
and nearly double of hb

To avoid downcomer flooding,

Residence time in downcomer is given by---

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Height of Packings:
For distillation in packed column, height of packing (Z)
required for desired separation ----

Each packing has different HETP

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 Tray Efficiency:
 Overall efficiency of tray tower is given by ---

Tray efficiency depends upon ----

1. Composition & properties of components
2. Rate of throughput
3. Geometry of tray tower (tray spacing, etc.)

2 Methods to determine Tray efficiency:

1. Van Winkle’s Correlation
2. AIChE Method
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 1. Van Winkle’s Correlation:
 Can be used for both Sieve Trays as well Bubble cap Trays

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 2. AIChE Method:
Point efficiency is related to NTU by equation -----

Number of Gas & Liquid Phase Transfer Units, i.e. NG & NL are
calculated as below:

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Tray efficiency is equal to point efficiency if liquid on tray is perfectly mixed;
However in practical, its difficult. Tray efficiency can be determined from point
efficiency by plotting the graph of -----

For different values of Peclet number

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• Peclet number for tray is given by ----

Tray efficiency gets reduced due to entrainment of liquid droplets

in vapor phase; considering this entrainment, actual tray efficiency
can be calculated by ---

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• Problem 7:
Design a sieve tray tower for the distillation of acetic acid-water
system. Maximum feed flow rate is 12 000 kg/h and minimum
feed flow rate is 8400 kg/h (70% of the maximum).
(i) Feed composition: 80% acetic acid and 20% water (by mass)
or 54.55% acetic acid and 45.45% water (by mole)
(ii) Mole fractions of water: In distillate xD = 0.9302, In residue
xw = 1.666 x 10-4
(iii) q= 1.272
(iv) Reflux ratio, R = 4.2
(v) Number of theoretical stages required for desired separation,
N = 25

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 Short Path Distillation:
High vacuum distillation
Operating ‘P’ at surface in short path distillation unit
(SPDU) – as low as 10-6 bar
Provides distillation at min possible ‘T’ --- good for heat
sensitive material
Boiling point of distillation product --- if more than
decomposition ‘T’---- distillation not possible at
atmospheric ‘P’
Reduction in absolute ‘P’ ---- reduce distillation/boiling
‘T’

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  In lower ‘P’ range ---- more reduction in boiling ‘T’ for even
small reduction in operating ‘P’
 E.g. in case of stearic acid --- boiling ‘T’ is reduced by 0.2oC
for ‘P’ reduction from 251 to 250 mbar; But 3.8oC reduction
for ‘P’ reduction from 5 to 4 mbar
 For ant heat sensitive product or food product --- reduction
in boiling ‘T’ --- gives good recovery; Max. recovery at Min.
boiling ‘T’
 Decrease in ‘P’ --- increase vapor volume per unit mass ---
increase vapor velocity
 At high vacuum --- high vapor volume need to be handled --
-- requires big size pipes (ducts)---low pressure drops are
achieved
 In vacuum distillation columns, Min. possible value of
absolute ‘P’ at vaporization surface of boiling liquid in
reboiler ----decided by ΔP of vapor flowing from that liquid
surface to heat transfer surface of external condenser
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  Conventional packed tower DC --- vapor travel long path
from Reboiler to external condenser; also no extra care is
taken to reduce flow of non condesnsables
 To overcome barrier of pressure drop of vapor & long path
(as described above) ---- in SPDU, internal condenser is
used
 Here vapor travels very short distance (order of few
centimeters) from liquid surface to internal condenser----
hence the name, SPDU
 If this distance travelled by vapor molecules is less than
mean free path of molecules between 2 successive collision
----SPDU is called as ‘molecular distillation’.

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 Design & Working of SPDU:

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 Design & Working of SPDU:

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  Consists of ---vertically mounted double walled vacuum
chamber; Central inner condenser; Roller wiper system
 Feed – continuously fed on rotating distributor plate
 @bottom of this plate --- 3 to 12 guiding rods mounted ---
contains roller which are passed over rods
 Plate – rotated by electric motor --- entire rotating system --
- knows as ‘Roller – Wiper System’
 Rotating distributor – throws feed to wall / HT surface –
material flows down by gravity over HT surface
 Rollers – don’t touch HT surface --- creates pressure drop
and turbulence in liquid film
 Friction between liquid film & roller --- generates
automatic rotation in roller about their own axis
 Roller wiper system --- creates uniformly mixed thin liquid
film over HT surface
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  Heating – provided by Thermic fluid/hot water/steam
 Liquid film – partially vaporized
 Vapor – travels through shortest path from liquid surface to
internal condenser
 Cooling – by CW/chilled water / brine
 Distillate & Residue --- both falls down by gravity ---
partition is available to separate them
 Vacuum nozzle --- at side bottom of vessel --- non-
condensables along with some vapor drawn through this –
vapors condensed back in cold trap
 Unit – vertically placed --- low residence (few seconds
only) time for liquid on HT surface
 Low residence time -- reduces possibility of thermal
degradation of product – hence good for heat sensitive
material
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  Degassing stage in front of SPDU --- removes dissolved
non condensable like O2, N2
 Entire system is very tight – prevents gaseous cracked
products, lack of stripping gas --- reduce size of vacuum
system required --- reduce operating cost
 HT surface ranges between 0.01 to 42 m2; Heating ‘T’ up to
450 oC; Production capacity from few g/h to t/h

Applications of SPDU:
 Pharmaceutical industries (e.g. separation of Vitamin E)
 Fine chemicals industries (separation of monoglycerides)
 Polymer industries (separation of monomers from polymers)
 Food industries (separation of Oleoresin, natural colour additive)
 Oil industries (deacidification of palm/ricebran oil)
 refineries

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 Economics of SPDU:
 At present cost is substantially reduced --- because of --- improved
vacuum technology, higher throuput quantities, increased
availability
 On increasing throughput from 150 kg/h to 3600 kg/h, cost of SPD
reduces by about 85%
 Less maintenance cost

Energy Conservation in Distillation:

 Though Distillation is highly energy intensive
operation, we can conserve the energy in distillation
operation to large extent by simply following energy
efficient design techniques in DC
 To decrease energy consumption in distillation,
various design options can be practiced
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 Optimum Design of System:
 Design the system for desired purity only (instead of specifying
very high purities) – reduces RR – reduces energy consumption
 Carefully select the process parameters at design stage
 Use right technique at each stage

Heat Integration:
 Results in substantial energy savings
 Reboiler of DC can act as cooler for other unit (Reactor with
exothermic reaction can act as reboiler of DC)
 Overhead condenser of DC can act as heater for other unit
 Overhead vapor of one DC can be partially used as heating medium
for reboiler of other DC

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 Use of High Efficiency Trays / Packings:
 Number of equilibrium stages – can be increased by replacing usual
sieve or bubble cap trays by other effective trays/packings
 Increase in number of stages --- reduces RR --- reduces reboiler
energy
 High efficiency trays / packings --- increase capacity of DC
 Saving in energy this way overweighs increased cost for high
efficiency trays / packings

Advanced Process Control:

 Installation of advanced control system based upon accurate
analytical sensors
 Use of reliable control loop hardware & instrumentation

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 Use of Thermally Coupled Distillation:
 Instead of conventional distillation method for separating
multicomponent mixture, thermally coupled distillation is used ---
require less energy consumption as well less fixed capital
 Difference in conventional technique and thermally coupled
distillation technique -- shown below through diagrams

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 In thermally coupled side column rectifier --- vapor stream is withdrawn from
stripping section of main column --- sent for rectification in side column with provision
of overhead condenser --- liquid stream from bottom of side column is sent back to
main column
In thermally coupled side column stripper --- liquid stream from rectifying section of
main column is withdrawn and sent to side column for stripping with provision of
reboiler at bottom --- vapor stream
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Prasadcolumn
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  Selection between above 2 options depend upon concentration
profile of intermediate component, B
 If concentration of B is maximum at any point in stripping
section of main column, the side column rectifier is used
 By withdrawing a side stream from the point at which the
concentration of B is maximized – distillation of B from earlier
C & A is much easier
 Side columns will reduce energy consumption by around 40%

Use of Heat Pumps in DC:

 Steam ejectors are used in DC
 An ejector used high pressure fluid to entrain low pressure
fluid

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Efficient Operation of DC:
 Avoid operating DC to excessively purify the product ---
will reduce RR --- will reduce reboiler duty ---- this can be
achieved by using adequate instrumentation and control
 Replace damaged column internals periodically and follow
preventive measures

Replace Distillation Partially by other

separation techniques :
 Wherever possible, distillation can be partially replaced by
other separation techniques like membrane separation,
reverse osmosis, crystallization, etc.

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