Design Of Distillation Column 1

DESIGN OF DISTILLATION
COLUMN
PURPOSE OF THE UNIT

Separating the Diesel-cut* from waste engine oil.
*The term "diesel cut" refers to a medium distillate with a boiling point
range of the products of which it is composed, ar!ing from "## to $%#& C.
Significance of Unit In Over-all Proce!-
'f we allow the diesel to go in final product then it will increase
flammabilit! and has effect on iscosit! grades of (ube
't is important not to sub)ect the waste oil aboe $*# because high
molecular weight component in the waste oil will under-go thermal-
crac+ing and form petroleum co+e. So b! creating acuum of 1* Torr
the operation become stable and separation become eas!.
,ractionation is more effectie at low pressure than at high pressure
because of larger differences in the apor pressures of the components
at a low pressure
-tmospheric distillation aboe "*# is not economical because of
steam-cost. So b! creating acuum we are saing energ!.
.rocess Design
Design Of Distillation Column "
CHOICE "ET#EEN PLATE AND PAC$ED COLUMN
/apour li0uid mass transfer operation ma! be carried either in plate column or
pac+ed column. These two t!pes of operations are 0uite different. - selection
scheme considering the factors under three headings.
i1 ,actors that depend on the s!stem i.e. scale, foaming, fouling
factors, corrosie s!stems, heat eolution, pressure drop, li0uid
holdup.
ii1 ,actors that depend on the fluid flow moment.
iii1 ,actors that depends upon the ph!sical characteristics of the
column and its internals i.e. maintenance, weight, side stream, si2e
and cost.

.rocess Design
Design Of Distillation Column $
The relatie merits of plate oer pac+ed column are as follows3
i1 .late column are designed to handle wide range of li0uid flow
rates without flooding.
ii1 'f a s!stem contains solid contents, it will be handled in plate
column, because solid will accumulate in the oids, coating the
pac+ing materials and ma+ing it ineffectie.
iii1 Dispersion difficulties are handled in plate column when flow rate
of li0uid are low as compared to gases.
i1 ,or large column heights, weight of the pac+ed column is more
than plate column.
1 'f periodic cleaning is re0uired, man holes will be proided for
cleaning. 'n pac+ed columns pac+ing must be remoed before
cleaning.
i1 ,or non-foaming s!stems the plate column is preferred.
ii1 Design information for plate column are more readil! aailable
and more reliable than that for pac+ed column.
iii1 'nter stage cooling can be proide to remoe heat of reaction or
solution in plate column.
i41 5hen temperature change is inoled, pac+ing ma! be damaged.
,or this particular process, 67asoline, 5ater, Diesel, (ube, 8ea! 9esidue:,
' hae selected plate column because3
i1 Diameter is ; #.%<m
ii1 -.Temperature is high =1>?
o
C1.
iii1 8eight of the Column is er! large as it comprises *> stages.
i1 S!stem comprises of hea! residue up to *@
.rocess Design
Design Of Distillation Column >
CHOICE OF PLATE T%PE
There are three main tra! t!pes, the bubble cap, siee tra!, ale tra!s. '
hae selected siee tra! because3
i1 The! are lighter in weight and less e4pensie. 't is easier and
cheaper to install.
ii1 .ressure drop is low as compared to bubble cap tra!s.
iii1 The! can easil! handle wide ariation in flow rates.
i1 Aaintenance cost is reduced due to the ease of cleaning.
1 Their fundamentals are well established and entailing low ris+.

Material "alance
.rocess Design
Siee
Tra!
Bubble Cap Tra! /ale Tra!
Design Of Distillation Column *
Co&'onent Fee(
)$g*+r,
"otto&
)$g*+r,
To'
)$g*+r,
7asoline -./0. 1 -./0.
5ater 2/34 1 2/34
Diesel -53/4. 21/64 --5/.1.
(ube 5676 563./2-. -1/6.5
S- Compounds 72/76 72/76 1
8ea!- 9esidue 20./.42 --6/-27 1
TOT-( F839502/76 "8 322./76 D8-.3/11
F 8 " : D
Selection Of $e; On t+e <ai of Relative =olatilit;
7asoline C (ighter than light +e! =(.(.D1
5ater C (ighter than hea! +e! =(.(.D1
Diesel C (ight EDe!=9ecoer! at top C ?*@1
(ube C 8ea! De!=9ecoer! at bottom C??.*@1
S-Compounds C 8eaier than hea! De!
8ea! 9esidue C 8eaier than hea! De!
ENERG% "ALANCE
HEAT IN 8 HEAT OUT
2,!-Nat>re of Fee(/
,eed is entering in column as a saturated li0uid at
TC1$#
#
C F .C"#".%*D.a
B! Bubble point G it is erified that feed is at saturated
.rocess Design
=mCpHT1Top I=0H.1TopI =mCpHT1BI=0H.1BI=Condenser1D>t;
*J?.1" D-watt
=mCpHT1,eed I = 0H.1,eedI=9eboiler1D>t;
%#".<1D-watt
Distributed Component
Design Of Distillation Column %
li0uid
-,!-Eti&ation of
To'
Te&'erat>re/
B! Dew point
calculation9
?DiKLdCMLdG
TC1#< and P=3.0KPa

8ence b! dew point calculationG TC1#<
F .C$.#D.a
5,!-Eti&ation Of "otto& Te&'erat>re/
B! Bubble-point Calculation MDi.LbCMLb GTC1?# F .C"*D.a
.rocess Design
Co&'onent @f $i A $iB@f
Gaoline 1/11207 20/34 5-/31 1/11570
#ater 1/1222 3/51 ./-1 1/13
Dieel 1/-6-1 -/4 3/-1 1/.141
L><e 1/717 1/71 2 1/571
?$iB@f 82/10
Co&'onent @( $i A $i*@(
Gaoline 1/1173 35/60 46/41 /11113
#ater 1/15 -5/57 52/-1 /11246
Dieel 1/04 /06 2/51 1/073
L><e 1/12 1/.4 2 1/141
?$i*@(
2/12
Co&' @< $i A $iB@<
Dieel 1/113- 5/1 -/41 1/121
L><e 1//601 2/- 2 2/171
?$iB@<8 2/1.
Design Of Distillation Column <
STANDARD DESIGN STEPS OF DISTILLATION COLUMN
Calc>lation of Mini&>& Refl>C Ratio R
&
/
Calc>lation of Act>al refl>C ratio/
Calc>lation of T+eoretical n>&<er of tage/
Calc>lation of Act>al n>&<er of tage/
Calc>lation of Dia&eter of t+e col>&n/
Calc>lation of #ee'ing 'oint/
Calc>lation of Pre>re (ro'/
Calc>lation of Entrain&ent/
Calc>lation of t+e Heig+t of t+e col>&n
.rocess Design
TOP CONDITION "OTTOM CONDTION
(
N
C 1%.J?DgmolKhr.
(
A
C(
N
I,C"?.%<DgmolKhr.
(
5
OC"*#1.%"DgKhr. (
5
C%J?$.$#DgKhr.
/
N
OC(
N
IDC1J."%DgmolKhr. /
A
C(
A
-BC1J.JDgmolKhr.
TC1#<
#
C TC1?#
#
C
.C$D.a .C"*D.a
=d1
apor
C1>.*$DgKm$ =d1
apor
C1>.*$DgKm
$
=d1
li0uid
C<*> DgKm
$
=d1
li0uid
CJ*# DgKm
$
Design Of Distillation Column J
.rocess Design
)2, Gaoline 8 1/1120
)-, #ater 8 1/1322
)5, Dieel 8 1/-6-
)3, L><e 8 1/717
)7, H/ Rei(>e 8/1-6
)., S-Co&'o>n(
8/133
Total
Mole82-/.6$g&ol*+r/
Fee(
2,Dieel81/113-D )-,LU"E81/60D )5,H/Rei(>e8/13D )3,S-
Co&'o>n(8/1. G Total Mole822Eg&ol*+r "OTTOM PRODUCT
)2, Gaoline 8 1/1173
)-, Dieel8 1/04
)5 L><e 8 1/1214
)3, #ater 8 1/15.
TOP PRODUCT
Total-
Mole82/..4$g&ol*+r
FLO# SHEET
.C"#".%*D.a
TC1$#
#
C
T C1#<
#
C
.C$D.a
TC1?#
#
C
.C"*D.a
Design Of Distillation Column ?
Mini&>& Refl>C Ratio
9
min
G B!

using underwood method3
Psing underwood e0uation
0 1
Q R
R
Q R
R
B
fB B
-
f- -

x x
-s feed is at its bubble point so 0 C 1
B! iteration on Aicro-soft S4cel G /alue of C ".#>
Psing e0uation of Ainimum reflu4 ratio,
1 9
Q R
R
Q R
R
m
B
DB B
-
D- -
+

x x
9
min
C %.<%
,or optimum 9eflu4 9atioG Psing 9ule Of Thumb!
9 C =1." ------- 1.$*1 9
m
9 C 1.$* 9
min
9 C ?.1$
Calc>lating Mini&>& No/ Of Stage 9 Uing FenEeF eG>ation
N
min
I 1 C lnT=4
(D
K4
8D
1
D
K=4
(D
K4
8D
1
B
U
ln =R
(D
K
8D
1
aerage

C lnT=#.?*K#.#11K=#.##>"K#.J?1U
ln=1.J#1
C 1%

T+eoretical No/ of Plate
7illiland related the number of e0uilibrium stages and the minimum reflu4 ratio and the
no. of e0uilibrium stages with a plot that was transformed b! Sdul)ee into the relationG
.rocess Design
1
]
1

,
_

*%% . #
min min
1
1 <* . #
1 R
R R
N
N N
Design Of Distillation Column 1#
N E 1% #.<* 1- ?.1$-%.<%
#.*%%
NI1 ?.1$I1
5e get the theoretical No. of stagesG
N8-.
LOCATION OF FEED PLATE
The Dir+ bride method is used to determine the ratio of tra!s aboe and
below the feed point.
(og=NDKNB1 C #."#%(ogT=11K1.<<J1*=#.%#%K#."J"1*=#.##>"K#.#11
"
U
NDKNB C #.%$G NDINB C *>G NBI#.%$NB C*>
NB C $>
ND C "# G So feed is entering at plate "1 from top.
Col>&n Efficienc;!
-erage temperature of column C =1?#I1#<1K"C1>J.*
,eed iscosit! at aerage column temperature C
ae
C #.*J Cp
9elatie olalitol! of (ight +e! =
ae
1. C 1.J#
.utting alues in following relationG
1
]
1

,
_

avg avg o
E . log * . $" *1

C *1- $".*#T(og=1.J#*#.*J1U C *#.>#@
So, No/ of act>al tra; C "<K.*#># C *>
.rocess Design
( )
( )
( )
1
]
1

,
_

,
_

,
_

"
log "#% . log
D HK
B LK
LK
HK
B
D
x
x
x
x
D
B
N
N
Design Of Distillation Column 11
Deter&ination of t+e Col>&n Dia&eter
Because li0uid and apour flow rates are greater at bottom so based upon bottom flow
rates.
=a'o>r loa( at <otto&
$%## V
/
W
/
m
/

C ="<<*.%"1K=.1>*$*$%##1 C <.< m
$
KSec
LiG>i( loa( at <otto&
$%## V
(
W
(
m
(

C =%J?$.$1K=J*#*$%##1 C ".$# 1#
-$
m
$
KSec
Tray Dynamics:
i, FloH Para&eter!
#.*
(

m
m
(/
V
V
/
(
,

,
_

,
_

C
#.*
J*#
1>.*$
1J.J#
"?.%<

,
_

,
_

C#."1
,(/ C (i0uid /apour ,actor
ii, Ca'acit; Para&eter!
-ssumed tra! spacing C "> inches C #.%1m
,rom ,ig 1*-* =b1 of 6 .lant Design F Scnomics for Chemical
Sngineers:, siee tra! ,looding capacit!,
C
sb
C #.#< mKSec
Surface tension of s!stem C C1< d!nesKCm
Net apor elocit! at floodingG



C >.*$ mKsec
.rocess Design
* . # " . #
"#

,
_

,
_

v
v l
C V
sb nf

Design Of Distillation Column 1"
-ctual /apor /elocit!
/
N
C #.J# /nf C $.%# mKsec
Net--rea C-
n
C /olumetric flow rate of apor
-ctual apor elocit!
C <.<#K$.%# C ".1$m
"
-ssume that downcomer occupies 1*@ of Cross-sectional -reaG then
Cross-Sectional -reaC-
C
C ".1$K#.J*C".*#m
"
Diameter of Column C -
c
C
>
X
D
"
C; DC

-c >
D 81.J#m Y based upon bottom conditionZ
B! performing calculation in the same manner as aboe, the diameter comes
at top =9ectif!ing Section1
D C 1.%#m
The calculated diameter at the top of column is 1.%#m.-s the diameter is
more in bottom so calculations are carried out on the basis Of bottom . Pse
same diameter at top while reducing the perforation area at the top/
iii, Floo(ing C+ecE
/
n
C
n
/
-
W
C <.<K".1$ C $.%1 mKSec
/nf C >.*$mKsec
Now , C =$.%1K>.*$1*1## C <?.J [ J#@
iv, Calc>lation of Entrain&ent
-s ,
(/
C #."1 and , C J#@
,rom ,igure 11."? of coulson % , we calculate
C #.##<
C ,ractional Sntrainment factor
.rocess Design
Design Of Distillation Column 1$
since \ #.1, so now process is satisfactor!
Net area C -
n
C".1$ m
"
Tower Cross-sectional -reaC-
c
C -
n
K.1* C ".*# m
"
-ctie area C -
a
C -
c
- "-
d
C 1.<* m
"
Down comer area C -
d
C #.1* -
c
C .$<* m
"
8ole area C -
h
C #.1 -
a
C #.1<* m
"
Ta+e weir height G h
w
C"*mm
8ole diameterG d
h
C*mm
.late thic+nessC 4
w
C *mm

=, #eir Lengt+)L
#
,!
-
d
K-
c 8
1/24


(
w
KD
c C
#.J"

(
w C
1.>Jm


=I, Eti&ation Of #ee' 'oint !
D
"
C Constant depending upon the depth of the clear li0uid
. #eir Cret
8
ow
C #.>
( )
$ K "
K nth inchweirle GPM
Lm=7.A1 C$*.%JC%J?$.$DgKhrC1.?1DgKhr
8
ow
C %.J mm F -t <#@ turn-down ratio
.rocess Design
( )
#.*
/
h "
h=min1
V
1 d - ="*.> - #.?# T - D
P
Design Of Distillation Column 1>
8
ow C *."mm C #.<# 1.?1 C 1.$> +gKsec
Now 8w I 8ow C "*I%.J C $1.J# mm
Psing figG 11.$# of Coulson ol %.
D" C "?."
h=min1 P
C ".J> mKsec
Aa4. /olumetric flow rate C <.< m
$
Ksec
Ain. /apour 9ate C #.<<.< C *.$? m
$
Ksec
-ctual Ain. /apour /elocit! C =*.$?1 K .1<*
C $#.J mKsec
-ctual Ain. /apour /elocit!

h=min1 P
So no 5eeping
vii, Tra; Pre>re Dro'
8
t
C8
d
I = 8
w
I 8
ow
1 I 8
r
=a1 8
w
C "* mm
8
ow
C %.Jmm
=b1 Dr; Tra; Dro'
8
d
C *1 =P
h
KC
o
1
"
=
/
K
(
1
.rocess Design
( )
#.*
h=min1
1>.*$
*1 - ="*.> #.?# T - "?."
P
Design Of Distillation Column 1*
8
d
C Dr! tra! drop.
P
h
C 8ole elocit! C WK-
h

P
h
C
h
/
-
W
C
<* #.1
<.<#
C $J.*# mKsec
Tra! thic+ness C *mm T,or Carbon steel tra!U
8ole dia C * mm

-a
-h
C #.1
Psing ,ig. 11.$> of Coulson %.
5e find 6C
o
6
C
o
C Orifice Coefficient C #.J>
8
d
C *1
"
O
h
C
P

,
_

,
_

/
C *1
"
#.J>
".J>

,
_

,
_

J*#
*$ . 1>
C ?.?% mm li0uid
)c, Rei(>al Hea( ) Hr,
8r C
]
1#e$ 1".*

,
_

,
_

J*#
1#e$ 1".*
C 1>.< mm li0uid
8
t
C8
d
I = 8
w
I 8
ow
1 I 8
r
C ?.?% I "* I %.J I 1>.<
C *%.>% mm
Total Pre>re Dro'!
.
t
C =?.J11#e
-$
1 8
t

.rocess Design
Design Of Distillation Column 1%
C ?.J11#e
-$
?*.JJ*#
C ><# .aC#.#<.si Kper tra!
-llowable drop is #.1.si per tra!
viii, "acE >' in DoHn co&er )H
<c,

8
bc
C 8
w
I 8
ow
I 8
t
I 8
dc
8
dc
C 1%%
$ K "

,
_

m
Lw!
L

-m C either -d or -ap = The clearance area under the down comer .1 which
one is smaller.
-
ap
C 8
ap
l
w
8
ap
C h
w
- * C "* E * C "# mm
-
ap
C ="#K 1###1 1.>J
C#.#$ m
"
i.e less than -
d
so it is used 'n finding 8
d

8
dc
C 1%%
"
#" . # J*#
?1 . 1

,
_

C ".# mm
8
bc
C 8
w
I 8
ow
I 8
t
I 8
dc
C "* I %." I*%.>% I "
C J?.%% mm C #.#J?%% m
8
bc

^ = Tra! Spacing I 5eir height 1

.rocess Design
Design Of Distillation Column 1<
#.#J?

^ = #.%1 I #.#"*1
#.#J?

#.$1
-s downcomer li0uid bac+ up is less than tra! spacingG So tra! spacing is
acceptable.
iC, Total no/ Of Hole
Total no. of holes =

,
_

ah
-h
-
h
C -rea aailable for holes C #.1<*m
"
a
h
C-rea of one hole C
>
X
D
"
C =$.1>.##*
"
1K > C #.####" m
"
Total no. of holes C

,
_

* - 1#e ".#
#.1<*
C J<*#
C, C+ecE-Rei(ence Ti&e
Sufficient residence time should be allowed in the downcomer for the
entrained apors to disengage from li0uid stream to preent aerated li0uid
being carried under the downcomer.
t
r
8A
(
+
<c
I
L
*L
)&aC,
8 =#.$<**#.#J?%%*J*#1K1.?1
C 1*sec.

't should be greater than ; $sec. So result is satisfactor!.
.rocess Design
Design Of Distillation Column 1J
Ci, Heig+t of Ditillation Col>&n
8eight of column 8
c
C =N
act
-11 8
s
I H8I plates thic+ness
No. of plates C *>
Tra! spacing C #.%1 m
Distance between *> plates C #.%1

*$ C $".$$ m
Top clearance C 1."# m
Bottom clearance C 1.J# m
Tra! thic+ness C * mmKplate
Total thic+ness of tra!s C #.##*

"< C #."< m
Total height of column C $".$$ I 1."# I 1.J# I #."<
C $*.%# m
"he Length$Diameter ratio of a tower sho%l! be no more than &' an!
(referabl) below *'
(engthKDiameter C $*.%K1.J# C 1?.<#
Cii, Hole Pitc+ )l
'
,

,
_

-a
-h
C #.1
d
h
C *mm

,
_

-a
-h
C #.?
"
lp
dh

,
_

8ole .itch C l
p
C 1* mm
.rocess Design
Design Of Distillation Column 1?
PLATE SPECIFICATIONS!
The .lates are supported on a ring welded around the essel wall, and on the
beams about *#mm wide. -llow *#mm wide calming 2ones.
l
w
KD
c
C #.J# G _
c
C 1#?
#
-ngle subtended at plate edge b!
Pnperforated strip C 1J#
o
E 1#?
o
C <1
o
(ength of unperforated edge strips 3
=1.J# E *#*1#-$1 *<1 C "."m
1J#
-rea of unperforated edge strip C-
u

C *#*1#-$*"."
C #.11m
"
Aean length of Claming `one3
=1.J#-*#*1#-$1*Sin=1#?K"1
C 1.$ m
-rea of calming 2one
-
c2
C "**#*1#-$*1.$#C #.1$m"
Total area aailable for perforations3
-
p
C -
a
E =-
u
I -
c2
1
C 1.<* E =#.11 I #.1$1 C 1.*1 m"
-
h
K-
p
C .1<*K1.*1 C #.11
,rom 7raph 11.$$,
%th Sd., Coulson and 9ichardson
l
p
Kd
h
C ".<* =satisfactor! i.e. bKw ".*a>.#1
.rocess Design
Design Of Distillation Column "#
SPECIFICATION SHEET
I(entification!
'tem Distillation column
S0uipment-Code T-1##
No. re0uired 1
Tra! t!pe Siee tra!
F>nction! 9ecoer! of Diesel cut from Snginebs waste oil
O'eration! Continuous
Design Data
No. of tra!s C *> 8ole areaK-ctie area C #.1#
.ressure C $D.a 5eir length C 1.>J m
8eight of column C $*.%# m 9eflu4 ratio C ?.1$
Diameter of column C 1.J# m 8ole si2e C *mm
Tra! spacing C #.%1 m Down comer area C #.$<* m
"
Tra! thic+ness C * mm 8ole area C #.1<* m
"
,looding C J# @ -ctie area C 1.<* m
"
.rocess Design