Stage Efficiency or Plate Efficiency

Lecture 8
  Stage Efficiency or Plate Efficiency
2  Types of plate efficiency
 There are three kinds of plate efficiency
a. Overall efficiency
𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒊𝒅𝒆𝒂𝒍 𝒑𝒍𝒂𝒕𝒆𝒔
 𝑬𝒐𝒗 = 𝒏𝒖𝒎𝒃𝒆𝒓 𝒐𝒇 𝒂𝒄𝒕𝒖𝒂𝒍 𝒑𝒍𝒂𝒕𝒆𝒔
 𝐈𝐟 𝐭𝐡𝐞 𝐧𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 𝐢𝐝𝐞𝐚𝐥 𝐩𝐥𝐚𝐭𝐞𝐬 = 𝟔 𝐚𝐧𝐝 𝑬𝒐𝒗 = 𝟔𝟎%
𝟔
 𝐧𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 𝐚𝐜𝐭𝐮𝐚𝐥 𝐩𝐥𝐚𝐭𝐞𝐬 = 𝟎.𝟔
≈ 𝟏𝟎
 Empirical Correlations of Tray Efficiency
A. A simple empirical relationship for the overall efficiency,
𝑬𝒐𝒗 , of columns handling petroleum hydrocarbons is given
by Drickamer and Bradford
 He relate efficiency of the column to the average viscosity of the feed by:
 𝑬𝒐𝒗 = 𝟏𝟑. 𝟑 − 𝟔𝟔. 𝟖 𝐥𝐨𝐠 𝝁
 Where 𝑬𝒐𝒗 is in % and 𝝁 is in 𝒄𝑷.
 The average deviations of the empirical equation was ranged from 5.0% and 13.0%.
 A plot of the Drickamer and Bradford correlation, compared to performance data for
distillation, is given in Figure .
 B. O’CONNELL found that a rather better relation may obtained by plotting the
3 overall efficiency as a function of the product of the viscosity and the relative
volatility of the key components.
 The O’Connell correlation fits the empirical equation
 𝑬𝒐𝒗 = 𝟓𝟎. 𝟑(𝜶𝝁)−𝟎.𝟐𝟔
 Where 𝑬𝒐𝒗 is in % ,𝝁 𝐢𝐧 𝐜𝐏 and 𝜶 is at average column conditions
 The data in Figure are mostly for columns with liquid flow paths from 2 to 3 ft.
 Flow path length is the distance
between the outlet down
comer & inlet down comer.
 The minimum limit for flow
path length is 400 mm in
order to provide good contacting
between vapor and liquid.
  Lockhart and Leggett recommend adding the increments in Table to the
4 value of 𝑬𝒐𝒗 from Figure when the liquid flow path is greater than 3 ft.
5
  E.g; Estimation of Stage Efficiency from Empirical Correlations.
6  For the benzene–toluene distillation, use the Drickamer–Bradford and
O’Connell correlations to estimate 𝑬𝒐𝒗 and the number of actual plates
required. Obtain the column height, assuming 24-inch tray spacing with 4 ft.
above the top tray for removal of entrained liquid and 10 ft. below the bottom
tray for bottoms surge capacity and the column diameter is 5 ft. The
separation requires 20 equilibrium stages plus a partial re-boiler that acts as
an equilibrium stage.
 Solution
 The liquid viscosity is determined at
the feed-stage condition of 𝟐𝟐𝟎𝟎 𝐅,
assuming a liquid composition of
50 mole% benzene; 𝝁 𝐨𝐟 𝐛𝐞𝐧𝐳𝐞𝐧𝐞 = 𝟎. 𝟏 𝐜𝐏
𝝁 𝐨𝐟 𝐭𝐨𝐥𝐮𝐞𝐧𝐞 = 𝟎. 𝟏𝟐 𝐜𝐏
and average 𝝁 = 𝟎. 𝟏𝟏 𝐜𝐏
𝜶𝒕𝒐𝒑 +𝜶𝒃𝒐𝒕𝒕𝒐𝒎 𝟐.𝟓𝟐+𝟐.𝟐𝟔
 𝜶𝑨𝑩 = = = 𝟐. 𝟑𝟗
𝟐 𝟐
 A. From the Drickamer – Bradford correlation
7  𝑬𝒐𝒗 = 𝟏𝟑. 𝟑 − 𝟔𝟔. 𝟖 𝐥𝐨𝐠 𝝁
 𝑬𝒐𝒗 = 𝟏𝟑. 𝟑 − 𝟔𝟔. 𝟖 log 𝟎. 𝟏𝟏 = 𝟕𝟕. 𝟑𝟑
𝟐𝟎
 𝐍𝐮𝐦𝐛𝐞𝐫 𝐨𝐟 𝐚𝐜𝐭𝐮𝐚𝐥 𝐩𝐥𝐚𝐭𝐞𝐬 = = 𝟐𝟔
𝟎.𝟕𝟕
𝟐𝟒
 𝐓𝐫𝐚𝐲 𝐬𝐩𝐚𝐜𝐢𝐧𝐠 = = 𝟐 𝒇𝒕
𝟏𝟐
 𝐂𝐨𝐥𝐮𝐦𝐧 𝐡𝐞𝐢𝐠𝐡𝐭 = 𝟒 + 𝟐 𝟐𝟔 − 𝟏 + 𝟏𝟎 = 𝟔𝟒 𝒇𝒕
B. From the O’Connell correlation,
 𝑬𝒐𝒗 = 𝟓𝟎. 𝟑(𝜶𝝁)−𝟎.𝟐𝟔
 𝟓𝟎. 𝟑(𝟐. 𝟑𝟗 ∗ 𝟎. 𝟏𝟏)−.𝟎𝟐𝟔 = 𝟔𝟖%
 For a 5 ft. diameter column, the length of the liquid flow path is about 𝟑 𝐟𝐭. for a
single pass tray and even less for two pass tray
 From Table , the efficiency correction is zero
𝟐𝟎
 So, Number of actual plates = 𝟎𝟔𝟖 = 𝟐𝟗. 𝟒, or round up to 30 trays
 Column height = 𝟒 + 𝟐 𝟑𝟎 − 𝟏 + 𝟏𝟎 = 𝟕𝟐 𝒇𝒕
  Example
8  A continuous fractionating column, operating at atmospheric pressure, is to be
designed to separate a mixture containing 15.67 % CS2 and 84.33 % CCl4 into
an overhead product containing 91% CS2 and a waste of 97.3% CCl4, all by
mass.
 A plate overall efficiency of 70 % and a reflux of 3.16 𝐤𝐦𝐨𝐥/𝐤𝐦𝐨𝐥 of product
may be assumed.
 Determine the number of plates required. The feed enters at 𝟐𝟗𝟎 𝐊 with a
𝐤𝐉
specific heat capacity of 1.7 and has a boiling point of 𝟑𝟑𝟔 𝐊.
𝐤𝐠.𝐊

 The latent heats of 𝐂𝐒𝟐 𝐚𝐧𝐝 𝐨𝐟 𝐂𝐂𝐥𝟒 are 𝟐𝟓𝟗𝟎𝟎 𝐤𝐉 𝐤𝐦𝐨𝐥

𝑪𝑺𝟐
Vapor 0 8.23 15.55 26.60 33.2 49.50 63.4 74.70 82.9 87.8 93.2
(Mole %)
𝑪𝑺𝟐
liquid
0 2.36 6.15 11.06 14.35 25.85 33.0 53.18 66.3 75.75 86.04
(Mole %)
  Solution
9
 Top product:
(𝟗𝟏 𝟕𝟔)
 𝒙𝑫 = = 𝟎. 𝟗𝟓𝟑
(𝟗𝟏 𝟕𝟔)+(𝟗 𝟏𝟓𝟒)

 Feed:
(𝟏𝟓.𝟔𝟕 𝟕𝟔)
 𝒙𝑭 = = 𝟎. 𝟐𝟕𝟒
(𝟏𝟓.𝟔𝟕 𝟕𝟔)+(𝟖𝟒.𝟑𝟑 𝟏𝟓𝟒)

 Bottom product:
(𝟐.𝟕 𝟕𝟔)
 𝒙𝑩 = = 𝟎. 𝟎𝟓𝟑
(𝟐.𝟕 𝟕𝟔)+(𝟗𝟕.𝟑 𝟏𝟓𝟒)

𝒌𝒈
 𝑴𝒘𝑭 = 𝟎. 𝟐𝟕𝟒 ∗ 𝟕𝟔 + 𝟎. 𝟕𝟐𝟔 ∗ 𝟏𝟓𝟒 = 𝟏𝟑𝟐. 𝟔
𝒌𝒎𝒐𝒍
𝒌𝑱 𝒌𝒎𝒐𝒍 𝒌𝑱
 ∆𝑯𝑭 = 𝟎. 𝟐𝟕𝟒 ∆𝑯𝑪𝑺𝟐 + 𝟎. 𝟕𝟐𝟔( ∆𝑯𝑪𝑪𝒍𝟒 = 𝟐𝟓𝟗𝟎𝟎 𝒌𝒎𝒐𝒍 ∗ = 𝟏𝟗𝟔. 𝟐𝟏𝟐𝟏 𝒌𝒈
𝟏𝟑𝟐𝒌𝒈

 𝐓𝐡𝐞 𝐟𝐞𝐞𝐝 𝐢𝐬 𝐬𝐮𝐛𝐜𝐨𝐨𝐥𝐞𝐝

𝑪𝒑𝒍 (𝑻𝑩.𝒑 −𝑻𝑭 ) 𝟏.𝟕 𝒌𝑱 𝒌𝒈
 𝒒=𝟏+ =𝟏+ ∗ 𝟑𝟑𝟔 − 𝟐𝟗𝟎 𝑲 ∗ = 𝟏. 𝟒
∆𝑯𝑭 𝒌𝒈.𝑲 𝟏𝟗𝟔.𝟐𝟏𝟐𝟏 𝒌𝑱
  For the q-line
10 𝒒 𝒙𝑭
 𝒚𝒒 = 𝒙𝒒 −
𝒒−𝟏 𝒒−𝟏

 𝒚𝒒 =𝟑.𝟓 𝒙𝒒 +𝟎.𝟔𝟖𝟓
 𝜽 = 𝐭𝐚𝐧−𝟏 𝟑. 𝟓 = 𝟖𝟐. 𝟐𝟖 𝟎
 For the top operating line
𝑹𝑫 𝒙𝑫
 𝒚𝒏+𝟏 = 𝒙𝒏 +
𝑹𝑫 +𝟏 𝑹𝑫 +𝟏

= 𝟎. 𝟕𝟓𝟗𝒙𝒏 + 𝟎. 𝟐𝟐𝟗
 Number of ideal plates
= 9 + re-boiler plate
𝟗
 Actual number of plates = = 𝟏𝟐. 𝟖5 ≅ 𝟏𝟑
𝟎.𝟕
 b. Murphree efficiency
11 I. Murphree plate efficiency
1. In terms of vapor composition
𝒚𝒏,𝒂𝒄𝒕𝒖𝒂𝒍 −𝒚𝒏−𝟏 𝐚𝐜𝐭𝐮𝐚𝐥 𝐞𝐧𝐫𝐢𝐜𝐡𝐦𝐞𝐧𝐭
 𝑬𝑴𝒗 = =
𝒚𝒏,𝒊𝒅𝒆𝒂𝒍 −𝒚𝒏−𝟏 𝐭𝐡𝐞𝐨𝐫𝐢𝐭𝐢𝐜𝐚𝐥 𝐞𝐧𝐫𝐢𝐜𝐡𝐦𝐞𝐧𝐭

 Where
 𝒚𝒏 = the average actual concentration
of the mixed vapor leaving the tray n
 𝒚𝒏−𝟏 = the average concentration of the
mixed vapor entering the tray 𝒏
 𝒚𝒏,𝒊𝒅𝒆𝒂𝒍 = the concentration of the vapor that
would be in equilibrium with the liquid
of concentration 𝒙𝒏 leaving the tray to the down comer.
12
13
 2. In terms of liquid composition
14 𝐱 𝐧+𝟏,𝐚𝐜𝐭𝐮𝐚𝐥 −𝐱 𝐧, 𝐚𝐜𝐭𝐮𝐚𝐥 𝐞𝐧𝐫𝐢𝐜𝐡𝐦𝐞𝐧𝐭
 𝐄𝐌𝐥 = =
𝐱 𝐧+𝟏,𝐢𝐝𝐞𝐚𝐥 −𝒙𝒏 𝐭𝐡𝐞𝐨𝐫𝐢𝐭𝐢𝐜𝐚𝐥 𝐞𝐧𝐫𝐢𝐜𝐡𝐦𝐞𝐧𝐭
 Where
 𝒙𝒏+𝟏 = 𝐜𝐨𝐦𝐩𝐨𝐬𝐢𝐭𝐢𝐨𝐧 𝐨𝐟 𝐚𝐜𝐭𝐮𝐚𝐥 𝐥𝐢𝐪𝐮𝐢𝐝 𝐞𝐧𝐭𝐞𝐫𝐢𝐧𝐠 𝐩𝐥𝐚𝐭𝐞 𝐧
 𝒙𝒏 = 𝐜𝐨𝐦𝐩𝐨𝐬𝐢𝐭𝐢𝐨𝐧 𝐨𝐟 𝐥𝐢𝐪𝐮𝐢𝐝 𝐥𝐞𝐚𝐯𝐢𝐧𝐠 𝐩𝐥𝐚𝐭𝐞 𝐧 𝐚𝐧𝐝
𝐞𝐧𝐭𝐞𝐫𝐢𝐧𝐠 plate 𝒏 − 𝟏
 𝒙𝒏+𝟏,𝒊𝒅𝒆𝒂𝒍 = composition of liquid that would be in equilibrium
with the 𝐯𝐚𝐩𝐨𝐫 𝐥𝐞𝐚𝐯𝐢𝐧𝐠 𝐩𝐥𝐚𝐭𝐞 𝐧 + 𝟏 𝐰𝐢𝐭𝐡 𝐜𝐨𝐦𝐩𝐨𝐬𝐢𝐭𝐢𝐨𝐧 𝒚𝒏+𝟏
15
16
  Factors influencing plate efficiency
17 1. Physical properties
2. Types and structures of columns
3. Operating conditions
 The reboiler plate is not subject to a discount for plate efficiency , and the true equilibrium curve
is used for the last step in the stripping section
18
 II. Local efficiency
19  At certain point on the plate
𝒚𝒏,𝒂𝒄𝒕𝒖𝒂𝒍 ′ −𝒚𝒏−𝟏 ′
 𝑬𝒍𝒗 =
𝒚𝒏,𝒊𝒅𝒆𝒂𝒍 ′ −𝒚𝒏−𝟏 ′
 Where
 𝒚𝒏,𝒂𝒄𝒕𝒖𝒂𝒍 ′ = 𝐜𝐨𝐧𝐜𝐞𝐧𝐭𝐫𝐚𝐭𝐢𝐨𝐧 𝐨𝐟 𝐚𝐜𝐭𝐮𝐚𝐥 𝐯𝐚𝐩𝐨𝐫 𝐥𝐞𝐚𝐯𝐢𝐧𝐠 𝐬𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐥𝐨𝐜𝐚𝐭𝐢𝐨𝐧 𝐨𝐧 𝐩𝐥𝐚𝐭𝐞 𝐧
 𝐲𝐧− 𝟏, ′ = 𝐜𝐨𝐧𝐜𝐞𝐧𝐭𝐫𝐚𝐭𝐢𝐨𝐧 𝐨𝐟 𝐚𝐜𝐭𝐮𝐚𝐥 𝐯𝐚𝐩𝐨𝐫 𝐞𝐧𝐭𝐞𝐫𝐢𝐧𝐠 𝐩𝐥𝐚𝐭𝐞 𝐧 𝐚𝐭 𝐬𝐚𝐦𝐞 𝐬𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐥𝐨𝐜𝐚𝐭𝐢𝐨𝐧
 𝐲𝐧,𝐢𝐝𝐞𝐚𝐥 ′ = 𝐜𝐨𝐧𝐜𝐞𝐧𝐭𝐫𝐚𝐭𝐢𝐨𝐧 𝐨𝐟 𝐯𝐚𝐩𝐨𝐫 𝐢𝐧 𝐞𝐪𝐮𝐢𝐥𝐢𝐛𝐫𝐢𝐮𝐦 𝐰𝐢𝐭𝐡 𝐥𝐢𝐪𝐮𝐢𝐝 𝐱 𝐧 ′ 𝐚𝐭 𝐬𝐚𝐦𝐞 𝐬𝐩𝐞𝐜𝐢𝐟𝐢𝐜 𝐥𝐨𝐜𝐚𝐭𝐢𝐨𝐧
  Example: The following values represent the equilibrium conditions in terms of mole
fraction of benzene in benzene–toluene mixtures at their boiling-point:
20
Liquid 0.521 0.38 0.26 0.15
Vapor 0.72 0.60 0.45 0.30

 If the liquid compositions on four adjacent plates in a column were 0.18, 0.28, 0.41
and 0.57 under conditions of total reflux, determine the plate efficiencies.
 Solution
 Referring to the data given, at total reflux, the
conditions on actual plates in the column are
shown as points A, B, C, and D.
 Considering point A, if equilibrium were
achieved on that plate, point E would represent
the vapor composition and point F the liquid
composition on the next plate.
 The liquid on the next plate is determined by
B however so that the line AGE may be located
and the efficiency is given by AG/AE = 0.59 or 59 per cent
21
22
  Example:
 A plant must distill a mixture containing 75 mole % methanol and 25 mole % water. The
23 overhead product is to contain 99.99 mole% methanol and the bottom product 0.002 mole %
methanol .The feed is cold, and for each mole of feed 0.15 mole of vapor is condensed at the
feed plate. The reflux ratio at the top of the column is 1.4, and the reflux is at its bubble point.
Calculate (a) the minimum number of plates; (b) the minimum reflux ratio; (c) the number of
plates using a total condenser and a reboiler, assuming an average Murphree plate efficiency
of 72 percent; (d) the number of plates using a reboiler and a partial condenser operating with
the reflux in equilibrium with the vapor going to a final condenser. Equilibrium data are given
in Table
Equilibrium data for methanol-water
X 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
y 0.417 0.579 0.669 0.729 0.780 0.825 0.871 0.915 0.959 1.0
 Solution
 For each mol of feed, 0.15 mol of vapor condensed at the feed plate
𝑳−𝑳
 𝒒= , 𝑹𝑫 = 𝟏. 𝟒 , 𝐭𝐡𝐞 𝐫𝐞𝐟𝐥𝐮𝐱 𝐢𝐬 𝐚𝐭 𝐢𝐭𝐬 𝐛𝐮𝐛𝐛𝐥𝐞 𝐩𝐨𝐢𝐧𝐭
𝑭
 Requirements
 𝐍𝐦𝐢𝐧 ,
 𝐑 𝐃𝐦𝐢𝐧 ,
 𝐍 , 𝐢𝐟 𝐄𝐌𝐯 = 𝟎. 𝟕𝟐
  Solution
24
 Basis=100 mol
 𝑭 = 𝑩 + 𝑫 = 𝟏𝟎𝟎, 𝑫 = 𝟏𝟎𝟎 − 𝑩
 Component balance:
 𝑭 ∗ 𝟎. 𝟕𝟓 = 𝑫 ∗ 𝟎. 𝟗𝟗𝟗𝟒 + 𝑩 ∗ 𝟎. 𝟎𝟎𝟐 ∗ 𝟏𝟎−𝟐
 𝑩 = 𝟐𝟓. 𝟎 𝒎𝒐𝒍 𝑫 = 𝟕𝟓 𝒎𝒐𝒍
𝑳
 𝑹𝑫 = = 𝟏. 𝟒 𝑳 = 𝟏. 𝟒𝑫 = 𝟏𝟎𝟓 𝒎𝒐𝒍
𝑫

 𝑽 = 𝑳 + 𝑫 = 𝟏𝟎𝟓 + 𝟕𝟓 = 𝟏𝟖𝟎 𝒎𝒐𝒍

𝑳−𝑳 𝑳+𝑭+𝒄𝒐𝒏𝒅𝒆𝒏𝒔𝒂𝒕𝒆−𝑳 𝟏𝟎𝟎+𝟎.𝟏𝟓∗𝟏𝟖𝟎
 𝒒= = = = 𝟏. 𝟐𝟕
𝑭 𝟏𝟎𝟎 𝟏𝟎𝟎
𝒒 𝟏.𝟐𝟕
 Slope of q line= = = 𝟒. 𝟕
𝒒−𝟏 𝟏.𝟐𝟕−𝟏
𝒙𝑫 𝟎.𝟗𝟗𝟗𝟒
 𝐈𝐧𝐭𝐞𝐫𝐜𝐞𝐩𝐭 𝐨𝐟 𝐫𝐞𝐜𝐭𝐢𝐟𝐲𝐢𝐧𝐠 𝐥𝐢𝐧𝐞 = = = 𝟎. 𝟒𝟏
𝑹𝑫 +𝟏 𝟏.𝟒+𝟏

 𝜽 = 𝐭𝐚𝐧−𝟏 𝟒. 𝟕 = 𝟖𝟔. 𝟕𝟎𝟎

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