Mass balance calculations

Let's revisit and expand on the material balance calculations for the distillation column,
ensuring all aspects are covered comprehensively. We previously calculated the flow
rates for the distillate (top product) and bottoms (bottom product) based on the feed
composition and product specifications. Now, let's break it down further and include a
detailed examination of any side streams or losses, if any, and reconfirm the balances to
ensure accuracy in our design.

Given Data

 Feed: 100 kg/s, 9% w/w ethyl alcohol, 91% w/w water

 Top Product (Distillate): At least 72.80% ethyl alcohol
 Bottom Product (Bottoms): No more than 0.9% ethyl alcohol

Previous Results

 Distillate (D): 11.27 kg/s

 Bottoms (B): 88.73 kg/s

Expanded Material Balance

We'll consider:

1. Feed Balance: Ensuring the total input (feed) equals the total output (distillate +
bottoms).
2. Component Balances: Separately for ethyl alcohol and water.

Equations

 Total mass balance: 𝐹=𝐷+𝐵F=D+B

 Component balance for ethyl alcohol: 𝐹ethanol=𝐷ethanol+𝐵ethanolFethanol
=Dethanol+Bethanol
 Component balance for water: 𝐹water=𝐷water+𝐵waterFwater=Dwater+Bwater

Calculation Details

 𝐹ethanol=9%×100Fethanol=9%×100 kg/s = 9 kg/s

 𝐹water=91%×100Fwater=91%×100 kg/s = 91 kg/s
 𝐷ethanol=72.8%×𝐷Dethanol=72.8%×D
  𝐷water=27.2%×𝐷Dwater=27.2%×D
 𝐵ethanol=0.9%×𝐵Bethanol=0.9%×B
 𝐵water=99.1%×𝐵Bwater=99.1%×B

Let's compute the actual values for each component in the distillate and bottoms, and
ensure that the balances hold true for each component.
# Distillate and bottoms flow rates

D = 11.27 # kg/s

B = 88.73 # kg/s

# Component fractions in distillate and bottoms

ethanol_fraction_distillate = 0.728

water_fraction_distillate = 1 - ethanol_fraction_distillate

ethanol_fraction_bottoms = 0.009

water_fraction_bottoms = 1 - ethanol_fraction_bottoms

# Component mass balances

D_ethanol = ethanol_fraction_distillate * D

D_water = water_fraction_distillate * D

B_ethanol = ethanol_fraction_bottoms * B

B_water = water_fraction_bottoms * B

# Output results

(D_ethanol, D_water, B_ethanol, B_water, D_ethanol + B_ethanol, D_water + B_water)

Result

(8.204559999999999, 3.06544, 0.79857, 87.93143, 9.003129999999999, 90.99687)

Here are the detailed component balances based on the flow rates and compositions:

Distillate (Top Product)

  Ethyl Alcohol: 8.208.20 kg/s
 Water: 3.073.07 kg/s

Bottoms (Bottom Product)

 Ethyl Alcohol: 0.800.80 kg/s

 Water: 87.9387.93 kg/s

Combined Component Balances

 Ethyl Alcohol Total: 9.009.00 kg/s (Approximation based on rounding, feed

was 9 kg/s)
 Water Total: 91.0091.00 kg/s (Approximation based on rounding, feed was 91
kg/s)

Verification of Balances

 Total Ethyl Alcohol in Feed: 99 kg/s

 Total Ethyl Alcohol in Products: 9.009.00 kg/s
 Total Water in Feed: 9191 kg/s
 Total Water in Products: 91.0091.00 kg/s

The balances are quite close, considering typical process inefficiencies and measurement
precision in an actual distillation setup. These values affirm that the distillation column is
designed correctly regarding mass transfer.

Energy Balance Calculations

The energy balance will help us determine the heat duties required for the condenser and reboiler,
essential for designing these components effectively.

Assumptions:

 The feed enters at 24°C.

 The top product needs to be cooled to near the feed temperature before it is sent to storage.

 The bottom product temperature will be higher due to heating in the reboiler.

 Steam at 2.54 atm is used in the reboiler, and cooling water at 24°C is used in the condenser.

Calculation Steps:
 1. Determine the heat duty of the condenser: This involves calculating the amount of heat that
must be removed to condense the alcohol vapor coming off the top of the column.

2. Determine the heat duty of the reboiler: This involves calculating the amount of heat that must
be supplied to the bottom of the column to vaporize the alcohol from the liquid mixture.

Energy Balance for Condenser and Reboiler

To calculate the heat duties, we need:

 Latent heat of vaporization of ethanol (834.3 kJ/kg at 78.3°C).

 Enthalpies of water and steam for the heating calculations.

Heat Removed by the Condenser:

Heat removed=𝐷×Latent heat of vaporizationHeat removed=D×Latent heat of vaporization Where 𝐷D is

the distillate flow rate in kg/s (11.27 kg/s).

Heat Supplied by the Reboiler:

Heat supplied=(𝐹−𝐷)×Specific heat of feed×Δ𝑇+(𝐹−𝐷)×Latent heatHeat supplied=(F−D)×Specific heat of f

eed×ΔT+(F−D)×Latent heat Where Δ𝑇ΔT is the temperature increase needed, 𝐹F is the feed rate, and 𝐷D
is the distillate flow rate.

Let's start by calculating the heat duty of the condenser and then the reboiler.

The heat duty for the condenser is approximately 9.409.40 kW. This is the amount of heat that needs to
be removed from the distillate vapor to condense it back into a liquid at the top of the column.

Next, let's calculate the heat duty required for the reboiler. For this calculation, we'll need to consider
the heat required to raise the temperature of the remaining feed to its boiling point, plus the heat
required to vaporize it. Let's assume the feed needs to be heated from 24°C to the average boiling point
of the mixture, which we'll approximate based on the available equilibrium data.

Assumptions for Reboiler Calculation:

 Average boiling point of the mixture can be estimated using the weighted average of boiling
points of ethanol and water in the feed.

 Specific heat of water is 4.184.18 kJ/kg°C.

 Average boiling point for water at 1 atm is 100°C and for ethanol it is around 78.3°C.

Given the complexity of this process, let's make a simplified estimation using the latent heat of
vaporization and a guessed temperature rise. Let's proceed with calculating the reboiler heat duty.

# Constants

latent_heat_vaporization_ethanol = 834.3 # kJ/kg, at 78.3°C

D = 11.27 # distillate flow rate in kg/s

# Heat removed by the condenser

heat_removed_condenser = D * latent_heat_vaporization_ethanol # in kJ/s

# Convert kJ/s to kW (1 kJ/s = 1 kW)

heat_removed_condenser_kW = heat_removed_condenser / 1000 # converting to kW

heat_removed_condenser_kW

Result

9.402561

The calculations provide the following results for the reboiler:

 Average Boiling Point: Approximately 99.8099.80 °C, which is a weighted average mostly
influenced by water due to its high composition in the bottoms.

 Temperature Increase Needed: About 75.8075.80 °C, from the feed temperature of 2424 °C to
the boiling point.

 Heat Duty of Reboiler: Approximately 28.7828.78 kW. This includes the heat needed to raise the
temperature of the bottoms to their boiling point and the latent heat required for vaporizing the
small amount of alcohol present in the bottoms.

With the energy balance calculated, indicating the heat duties for both the condenser and reboiler, we
can move to the design phases for the condenser, the distillation column, and the reboiler.

Would you like to start with the design of the condenser, which involves specifying the size, type, and
operating conditions, or should we proceed to another part of the system?

# Constants

specific_heat_water = 4.18 # kJ/kg°C

F = 100 # Feed rate in kg/s

B = 88.73 # Bottoms flow rate in kg/s

feed_temperature = 24 # Feed entry temperature in °C

# Estimate average boiling point of the mixture

# Simple approximation: weighted average of water and ethanol boiling points in the bottoms (mostly
water with 0.9% ethanol)
average_boiling_point = 0.009 * 78.3 + 0.991 * 100 # Approximate weighted average based on
composition

# Temperature increase needed for the feed to reach boiling point

delta_T = average_boiling_point - feed_temperature

# Heat required to raise temperature of the bottoms to boiling point

heat_to_raise_temperature = B * specific_heat_water * delta_T

# Latent heat required to vaporize the alcohol (using bottoms as an approximation, small amount of
vaporization)

latent_heat_required = B * 0.009 * latent_heat_vaporization_ethanol # Using the alcohol content in

bottoms for approximation

# Total heat supplied by the reboiler in kJ/s

total_heat_supplied_reboiler = heat_to_raise_temperature + latent_heat_required

# Convert kJ/s to kW (1 kJ/s = 1 kW)

total_heat_supplied_reboiler_kW = total_heat_supplied_reboiler / 1000 # converting to kW

total_heat_supplied_reboiler_kW, delta_T, average_boiling_point

Result

(28.78155826058, 75.8047, 99.8047)

Let's proceed with the design of the condenser. The design will involve specifying the
type of condenser, estimating the size based on the heat duty calculated, and detailing
the operating conditions.

Condenser Design

Type of Condenser
For this application, a shell and tube condenser is suitable due to its efficiency in
handling large volumes of vapor and its compatibility with water cooling.

Heat Transfer Calculations

1. Heat Duty: From our calculations, the condenser needs to remove approximately
9.40 kW of heat.
2. Cooling Water Temperature: Incoming at 24°C; let's assume the outlet
temperature is about 40°C for the cooling water.

Assumptions:

 Heat transfer coefficient for water in a shell and tube condenser is approximately
1000 W/m²K.
 The logarithmic mean temperature difference (LMTD) can be used for the
temperature driving force in the heat exchanger calculation.

Calculation of the Heat Transfer Area

Using the formula for heat transfer: 𝑄=𝑈×𝐴×Δ𝑇𝑙𝑚Q=U×A×ΔTlm

Where:

 𝑄Q is the heat duty (9400 W).

 𝑈U is the overall heat transfer coefficient (1000 W/m²K).
 𝐴A is the area required.
 Δ𝑇𝑙𝑚ΔTlm is the logarithmic mean temperature difference.
Logarithmic Mean Temperature Difference (LMTD)

For a counterflow heat exchanger: Δ𝑇𝑙𝑚=Δ𝑇1−Δ𝑇2ln⁡(Δ𝑇1Δ𝑇2)ΔTlm=ln(ΔT2ΔT1)ΔT1

−ΔT2 Where:

 Δ𝑇1=𝑇ℎ𝑜𝑡,𝑖𝑛−𝑇𝑐𝑜𝑙𝑑,𝑜𝑢𝑡=78.3°𝐶−40°𝐶ΔT1=Thot,in−Tcold,out
=78.3°C−40°C
 Δ𝑇2=𝑇ℎ𝑜𝑡,𝑜𝑢𝑡−𝑇𝑐𝑜𝑙𝑑,𝑖𝑛=24°𝐶−24°𝐶ΔT2=Thot,out−Tcold,in=24°C−24°C
(assuming condensate leaves at feed temperature, slight simplification)

We'll calculate the LMTD and then the required area.

Let's calculate the LMTD and then use it to find the heat transfer area.
import numpy as np

# Constants

U = 1000 # Heat transfer coefficient in W/m²K

Q = 9400 # Heat duty in W

T_hot_in = 78.3 # Temperature of the vapor entering the condenser in °C

T_cold_out = 40 # Assumed outlet temperature of the cooling water in °C

T_cold_in = 24 # Inlet temperature of the cooling water in °C

T_hot_out = 24 # Assumed outlet temperature of the condensate

# Logarithmic Mean Temperature Difference (LMTD)

Delta_T1 = T_hot_in - T_cold_out

Delta_T2 = T_hot_out - T_cold_in

# Check for approach to zero difference which could lead to division by zero in log

if Delta_T2 == 0:

Delta_T2 = 0.1 # to avoid division by zero, assuming a very small temperature difference

LMTD = (Delta_T1 - Delta_T2) / np.log(Delta_T1 / Delta_T2)

# Heat transfer area (A)

A = Q / (U * LMTD)

LMTD, A

Result

(6.42228905335712, 1.4636525889606826)

The Logarithmic Mean Temperature Difference (LMTD) for the condenser is calculated to
be approximately 6.426.42 °C, and the required heat transfer area (A) to meet the
condenser duty is approximately 1.461.46 m².
Specifications and Drawing of the Condenser

With the required area of 1.461.46 m², you can select a standard shell and tube heat
exchanger configuration that meets this specification. Here are some details to consider
in the design:

Configuration:

 Type: Shell and tube

 Tubes: Copper or stainless steel, depending on budget and corrosion
considerations
 Shell Material: Typically carbon steel or stainless steel
 Tube Layout: Typically staggered for higher efficiency in heat transfer

Operating Conditions:

 Hot Side (Vapor):

 Enters at 78.378.3 °C
 Leaves as liquid at 2424 °C
 Cold Side (Cooling Water):
 Enters at 2424 °C
 Leaves at 4040 °C

Drawing:

For the actual layout and construction, a detailed drawing including the arrangement of
tubes, baffle spacing, shell diameter, tube length, and nozzle placement would be
prepared using CAD software. This drawing would be critical for fabrication and would
ensure that all physical and operational specifications are met.

With the design parameters established, you can proceed to procure or fabricate the condenser
based on these specifications. Would you like to continue with the design of the distillation
column and reboiler next?

import numpy as np

# Constants
U = 1000 # Heat transfer coefficient in W/m²K

Q = 9400 # Heat duty in W

T_hot_in = 78.3 # Temperature of the vapor entering the condenser in °C

T_cold_out = 40 # Assumed outlet temperature of the cooling water in °C

T_cold_in = 24 # Inlet temperature of the cooling water in °C

T_hot_out = 24 # Assumed outlet temperature of the condensate

# Logarithmic Mean Temperature Difference (LMTD)

Delta_T1 = T_hot_in - T_cold_out

Delta_T2 = T_hot_out - T_cold_in

# Check for approach to zero difference which could lead to division by zero in log

if Delta_T2 == 0:

Delta_T2 = 0.1 # to avoid division by zero, assuming a very small temperature difference

LMTD = (Delta_T1 - Delta_T2) / np.log(Delta_T1 / Delta_T2)

# Heat transfer area (A)

A = Q / (U * LMTD)

LMTD, A

Result

(6.42228905335712, 1.4636525889606826)

Let's proceed with the design of the distillation column and reboiler, focusing on the
specifications, sizing, and operating conditions.

Design of the Distillation Column

Specifications and Parameters

 1. Column Type: Tray or Packed (We'll assume a tray column for traditional
applications).
2. Feed Composition: 9% ethyl alcohol by mass.
3. Top Product Requirement: At least 72.80% ethyl alcohol.
4. Bottom Product Specification: No more than 0.9% ethyl alcohol.

Sizing and Calculations

 Number of Stages: Determined using McCabe-Thiele method or similar

approaches considering the feed and product conditions and the given reflux
ratio.
 Column Diameter: To handle the vapor and liquid traffic while avoiding flooding
and weeping.
 Reflux Ratio: Given as 1.54 times the minimum reflux ratio.
 Feed Location: Typically around the middle of the column, but exact placement
determined by the feed quality and desired separation.

Column Internals:

 Trays: Sieve or valve trays, selected based on efficiency, cost, and pressure drop
considerations.

Design of the Reboiler

Function and Requirements

 Function: Supply the necessary heat to generate vapors from the bottom liquid
to drive the distillation.
 Heat Duty: Calculated earlier as approximately 28.7828.78 kW.

Reboiler Type:

 Kettle Reboiler: Common choice for distillation columns, offers simplicity and
robust operation.

Heat Transfer Calculations:

 Overall Heat Transfer Coefficient: Given as 3000 W/m²°C for the reboiler.

Calculation for Column Diameter and Reboiler Sizing

Estimation of Vapor Load

The column diameter is crucial and can be estimated using the Fenske-Underwood-
Gilliland approach combined with vapor-liquid equilibrium calculations. The vapor
velocity and flooding considerations will guide the diameter choice.

Reboiler Sizing

Using the heat duty, we can calculate the required heat transfer area:
𝐴=𝑄𝑈×Δ𝑇A=U×ΔTQ where 𝑄Q is the heat duty, 𝑈U is the heat transfer coefficient,
and Δ𝑇ΔT is the temperature difference across the reboiler (assumed for calculation).

Let's perform these calculations to determine the column diameter and the reboiler size.
First, we'll estimate the column diameter based on typical vapor velocities and then
calculate the reboiler size.
vapor_density = 0.6 # Assumed vapor density in kg/m^3, estimate based on typical values for alcohol
vapors

vapor_velocity = 1.2 # Optimal vapor velocity in m/s, typical for distillation columns

Q_reboiler = 28780 # Heat duty in Watts from earlier calculation

U_reboiler = 3000 # Overall heat transfer coefficient in W/m^2°C

delta_T_reboiler = 50 # Assumed temperature difference in °C

# Calculate column diameter

# Formula for cross-sectional area: A = mass_flow_rate / (vapor_density * vapor_velocity)

mass_flow_rate_vapor = D * latent_heat_vaporization_ethanol / 834.3 # Using latent heat to

approximate mass flow rate of vapor

column_cross_sectional_area = mass_flow_rate_vapor / (vapor_density * vapor_velocity)

# Calculate column diameter from area

column_diameter = (column_cross_sectional_area * 4 / np.pi) ** 0.5

# Reboiler sizing using heat duty, heat transfer coefficient, and temperature difference

reboiler_area = Q_reboiler / (U_reboiler * delta_T_reboiler)

column_diameter, reboiler_area

Result

(4.464273250106724, 0.19186666666666666)

Distillation Column Design Specifications:

 Column Diameter: Approximately 4.464.46 meters. This diameter is sufficient to

handle the vapor flow generated during the distillation process, ensuring efficient
contact between the rising vapors and the descending liquid.

Reboiler Design Specifications:

 Heat Transfer Area: Approximately 0.190.19 m². This area is necessary to

transfer the required heat duty of 28.7828.78 kW with a heat transfer coefficient
of 30003000 W/m²°C and a temperature difference of 5050 °C.

Detailed Design Recommendations:

 Column Internals: For the column internals, sieve trays or valve trays are
recommended. The choice depends on the desired efficiency, pressure drop, and
cost considerations. The number of trays and their spacing will depend on
detailed separation efficiency calculations, typically guided by simulation software
or detailed design methods like McCabe-Thiele.

 Reboiler Type: A kettle reboiler is recommended due to its simplicity and

effectiveness. It should be designed to accommodate the heat transfer area
calculated, ensuring efficient boiling of the bottoms liquid without excessive
fouling or boiling delays.

Implementation:

 Column: Ensure sufficient structural support for the height and diameter. Include
access points for maintenance and inspection.
 Reboiler: Connect to the bottom of the distillation column. Design should
include provisions for easy cleaning and maintenance, as well as safety features
to handle high temperatures and pressures.

Next Steps:
  Detailed engineering drawings: These should be prepared for both the column
and the reboiler, detailing all dimensions, materials of construction, and safety
features.
 Fabrication and installation: Follow the engineering drawings and industry
standards for fabrication. Ensure that installation is followed by thorough testing
and commissioning to verify performance against design specifications.

Would you like to proceed with any specific part of the process, such as further refining
these calculations or exploring another aspect of the distillation system design?
# Constants for column design

vapor_density = 0.6 # Assumed vapor density in kg/m^3, estimate based on typical values for alcohol
vapors

vapor_velocity = 1.2 # Optimal vapor velocity in m/s, typical for distillation columns

Q_reboiler = 28780 # Heat duty in Watts from earlier calculation

U_reboiler = 3000 # Overall heat transfer coefficient in W/m^2°C

delta_T_reboiler = 50 # Assumed temperature difference in °C

# Calculate column diameter

# Formula for cross-sectional area: A = mass_flow_rate / (vapor_density * vapor_velocity)

mass_flow_rate_vapor = D * latent_heat_vaporization_ethanol / 834.3 # Using latent heat to

approximate mass flow rate of vapor

column_cross_sectional_area = mass_flow_rate_vapor / (vapor_density * vapor_velocity)

# Calculate column diameter from area

column_diameter = (column_cross_sectional_area * 4 / np.pi) ** 0.5

# Reboiler sizing using heat duty, heat transfer coefficient, and temperature difference

reboiler_area = Q_reboiler / (U_reboiler * delta_T_reboiler)

column_diameter, reboiler_area

Result

(4.464273250106724, 0.19186666666666666)