Example Problem 3 :

Determine the total packed bed height for the separation of ethyl benzene-styrene for
which the operating conditions and the physical properties are given in Table A. Use the gauze
packing. The physical parameters may be taken from table 3. Assume the values of HV and HL
are constants in the enriching and stripping section.
Solution :
(i)

The calculation procedure for liquid and vapor phase heights of transfer units is
presented in table B.
HL = 0.041 m
HV = 0.152 m

(ii)

A model calculations to obtain an incremental packed height in the enriching section

is shown in table C and the final results are given in table D.
Packed bed height in enriching section

3.8319 m

Packed bed height in stripping section

5.3447 m
===============

Total height of packed bed

9.1766 m

Table A. DESIGH DATA FOR THE EXAMPLE PROBLEM : SEPARATION OF

ETHYL BENZENE-

STYRENE

1. Operating conditions :
Top pressure

6.664 kpa

Allowable bottom pressure

11.33 Kpa

Top temperature

331.15 K

Allowable bottom temperature

Feed rate, F

351.15 K

38 kg/moles/hr (saturated

liquid)
Composition of ethyl benzene in feed xF
Distillation rate, D

:
:

0.54

20.9 kg moles/hr

Composition of ethyl benzene in distillation, xD

0.98

Bottom product rate, B

17.1 kg moles/hr

Composition of ethyl benzene in bottom product, xB:

0.001

Reflux ratio

6.8

Liquid rate in enriching section

142.12 kg moles/hr

Vapor rate in enriching section

163.02 kg.moles/hr

2. Physical properties of ethyl benzene-styrene at average condition of

pressure and temperature.
Relative

Average Mol Wt
Liquid
Vapor

Density
Liquid
Vapor

Viscosity
Liquid
Vapor

Diffusion Coefficient
Liquid
Vapor

Kg/cu m

Kg/cu m

Kg/cu m

Kg/ cu

Kg/cu m

Kg/ cu m

0.43

m
7.55

3.2

33.2

Volatility avg

1.40

105.6

Kg/cu m
105.6

835

Kg/ cum
0.37

Design of Structured Packed Beds for Distillation

A. CALCULATION PROCEDURE FOR LIQUID AND VAPOR PHASE HEIGHT OF
TRANSFER UNITS
1.

(a) calculate the column diameter, Dc, m.

1.

(a) Dc = 0.02 [163.02 (105.16

(341.15/8.997)0.5]0.5

(using Billets equatin)

Dc = 0.02 [VM M (T/P)0.5]0.5

= 2.029 m ~ 2m

(Average values of M, t and P are used)

(b) At = 0.784 (2)0.5 = 3.14 m2

(b) calculate total cross-sectional area of

the column
2.

At = 0.785 Dc2
Compute liquid and mass velocities :

2.

L,V, KG/s.m2

(a) L = (142.12 * 105.16)/(3600*3.14)

= 1.322

(a) Liquid mass velocity,

(b) V= (163.02*105.16)/(3600*3.14)

L = (LM*Mav)/(3600*At)

= 1.517

(b) Vapor Mass Velocity

3.

V = (VM*Mav)/(3600*At)
Calculate superficial vapor velocity, UVS,

3.

m/s
4.

= 4.009

UVS = VM*Mav/3600*V*At
Calculate effective vapor liquid velocities,
UV, eff, UL,eff, m/s
(a) Effective vapor velocity, UV,eff
UV,eff = UVS/( sin)
(b) Effective liquid velocity, UL,eff

5.

UVS = (163.20*105.16)/(3600*0.37*3.14)

4.

(a) UV,eff = 4.009/(0.9*sin 60) = 5.26

(b) P = {(4*8.9 + 2*12.7)/
+ (4*8.9)/( 12.7*6.4)}/2
= 0.594/mm = 594/m
= 1.322 / 594 = 2.226 x 10-3

= L/P

UL,eff = {(3*2.226*10-3)/(2*835)}

P=((4S+2B)/Bh + 4S /Bh)/2

+{(8352 *9.81)/(3*0.43*10-3*2.226*10-3)}0.333

UL,eff = (3/2 L) (L2g/3 L )0.333

Calculate Reynolds no, schmidt no, and
Sherwood number for vapor phase

= 0.052899 = 0.053
(a) NRe = (0.072 * 0.37) (0.053 + 5.26)

(a) Reynolds No. NRe

/(7.55*10-6)

NRe = (deq (V /) (UV, eff + UL,eff)

= 1874.7

(b) Schmidt number, NSc

Nsc = (V / V DV)
(c) Sherwood number, NSh

(b) NSc =(7.55*10-6)/(0.37*33.2*10-6) =

0.6146
(c) NSh= 0.0338 (1874.7)0.8(0.6146)0.333

(Correlation of Bravo et al)

6.

NSh = 0.0338 (NRe)0.8 (NSc)0.333

Predict vapor phase mass transfer

6.
KV = (11.94*33.2*10-6)/(7.2*10-3) = 0.055

coefficient from Sherwood no, KV, m/s

7.

KV = (NSc)V DV /deq
Predict liquid phase mass transfer

7.

= 7.788* 10-5

coefficient using Higbie penetration theory

8.

KL = 2 [DL UL,eff / S]0.5

Calculate the value of height of transfer

KL = 2[(3.2*10-9*0.053)/(3.14*8.9*10-3)]0.5

8.

HL = 1.322 /(7.788* 10-5*492*835) = 0.0413

unit for liquid and vapor phases, HL, HV, m

HL = L /( KL ae L )

HV = 1.517 /(0.055*492*0.27) = 0.1515

HV = V/ (KV ae V )

MODEL CALCULATIONS TO OBTAIN THE PACKED BED HEIGHT IN THE ENRICHING

SECTION
Sr.no
1.

Start the calculation taking the value of x1=xD

X1 = xd =y = 0.98

2.

Then x1 = xD = y (for Total condenser)

Calculate the equilibrium vapor composition, y*

Y*=(1.4*0.98)/(1+(0.4*0.98))

3.

Y* = (x)/(1+(-1)x
Determine the value of m, the slope of

= 0.986
m= 1.4/(1+(0.4*0.98))2

equilibrium line

= 0.723
2

4.

m= /[1+( -1)x]
Calculate overall height of transfer unit, HOV, m

HOV = 0.152 +0.723*(163.02/142.12)*0.041

5.
6.

(HOV)i = HV + m (Vm/LM) HL
Calculate the vapor phase driving phase, (y*-y)i
Subtract the value of x from the x1 to obtain xj (in

= 0.1868
Y* - y = (0.986 0.98) = 0.006
Xj = (0.98 0.08) = 0.9

this step x is taken to be 0.08. in subsequent

calculations it is equal to 0.1
Calculate the equilibrium vapor composition yj *at

Yj*=(1.4*0.9)/(1+(0.4*0.9))

x1

= 0.9265

8.

yj * = xj / (1+ (-1)xj)
Determine the value of m at xj

m= 1.4/(1+(0.4*0.9))2

9.

m= /[1+( -1)xj]2
Calculate the vapor composition yj

= 0.757
Yj = (2.09*0.98) + (142*0.9)/(20.9 +142.12)

10.

Yj = (D xD + Lxj)/(L+D)
Calculate overall height of transfer unit, (HOV)j, m

= 0.91
(HOV)j = 0.152

(HOV)j = HV + m (VL/LM) HL

+0.757*(163.02/142.12)*0.041

Calculate the vapor phase driving phase, (y*-y)j

Calculate the incremental packed height = Z, m

= 0.1885
(Y* - y)j = (0.9265 0.91) = 0.0165
Z = {[0.1868/0.006] +

Z = {[HOV/(y*-y)]I + [HOV/(y*-y)]j }*(yi yj)/2

[0.1885/0.0165]}*(0.98-0.97)/2

7.

11.
12.

TABLE D : FINAL RESULTS OF CALCULATION OF PACKED BED HEIGHT

1. ENRICHING SECTION :
X
Y
0.98
0.98
0.90
0.91
0.85
0.866
0.80
0.823
0.75
0.799
0.70
0.736
0.65
0.692
0.6
0.649
0.54
0.596

Y*
0.986
0.9265
0.888
0.848
0.808
0.766
0.722
0.677
0.622

M
0.723
0.757
0.7797
0.803
0.8284
0.854
0.882
0.91
0.947

HOV
0.1868
0,1885
0,1895
0.19
0.192
0.193
0.195
0.1959
0.1976

Z
1.489
0.44
0.349
0.313
0.28
0.2843
0.2898
0.3868
3.8319 m

2. Stripping section
x
y
0.5
0.551
0.45
0.496
0.4
0.4409
0.35
0.3856
0.3
0.33
0.25
0.275
0.2
0.2199
0.15
0.1647
0.1
0.109
0.05
0.054
0.03
0.032
0.02
0.021
0.01
0.01
0.005
0.00448
0.001362
0.000456

Y*
0.583
0.534
0.483
0.4298
0.375
0.318
0.259
0.178
0.1346
0.0686
0.0415
0.0278
0.0139
0.006986
0.0019

m
0.972
1.0058
1.04
1.077
1.116
1.157
1.2
1.246
1.2944
1.346
1.367
1.3779
1.3889
1.394
1.3985

HOV
0.1888
0.19
0.1915
0.1929
0.1944
0.1959
0.1976
0.1993
0.201
0.203
0.204
0.2043
0.2047
0.2049
0.2051

Z
0.3108
0.4775
0.3245
0.2464
0.2414
0.244
0.2648
0.3047
0.386
0.5986
0.389
0.283
0.454
0.37
0.45
5.3447 m

(iii)

Pressure drop calculations :

P = (0.171 + (92.7 /NReV) [V UVeff2 /deq] [1/ ( 1- cFr0.5)]0.5
NReV

= UVeff deq V /UV

= (5.26) (7.2x 10-3)(0.37) / (7.55x10-6)
= 1855.9

Fr

= UL2 /(deq) (g) V2

= (1.322)2 / (835)2 (7.2x10-3) (9.81)
= 3.548 x 10-5

Fr0.5

= 5.5965 x 10-3
= [0.171 +(92.7/1855.9)] [(0.37)(5.26)2 /7.2 x 10-3] [1/{1-(3.38)(5.5965 x 10-3)}]
= (0.2209)(1421.46)(1.10019)
= 345.46 pa/m

Total pressure drop = Height x Pressure drop per unit length

P Total

= (9.2)(345.46)
= 3178.23 pa

Taking safety factor of 1.25

P Total

= 3178.23 x 1.25 = 3972 Pa

= 3.972 Kpa