SIZING OF PLATE AND

PACKED COLUMN
 Column Sizing for Absorption , Distillation, and Extraction:

The objective is to achieve an intimate contact between the phases and to

Ensure a rate of mass transfer.

A high degree of turbulent mixing to generate a large interfacial area of contact leading to
increase mass transfer coefficient.

Interfacial area is generated by passage of the gas in to the liquid through perforations or
openings. TRAY TOWERS/COLUMNS

Alternatively, interfacial area is created by spreading the liquid on the packing surface.
PACKED TOWERS/COLUMNS
Selection Criterion between tray tower and packed tower:

1. Pressure Drop: Packed tower generally provides low pressure drops, therefore for
high vacuum distillation, a packed tower is selected.

2. Tower Diameter: For very small tower diameter packed tower is preferred. With large
tower diameter, tray tower is preferred. With very small diameter (less than 150 mm),
fabrication of trays is difficult while with large diameter, liquid distribution is difficult in
the packed tower.

3. L/V Ratio: For handling higher ratio of liquid to vapor flow rate (L/V), packed tower are
preferred. But for low L/V ratio tray tower is selected. [Packed tower requires minimum
wetting rate to work efficiently. At low gas flow Rate plate columns are prone to weeping
and dumping]

4. Residence Time of liquid: Liquid hold up in tray tower is 8 to 12 % of tower volume against
1 to 6 % in case of packed tower. So the packed tower offers a smaller liquid residence
time and is more suitable for processing heat sensitive liquids.

5. Corrosive System: For corrosive system, packed tower with plastic packings like
polypropylene packings, glass fibres reinforced plastic packings, etc. is more economical
than tray tower made from special metal alloys.
6. Foaming liquids: It is difficult to process a foaming liquid in a tray tower
since bubbling aggravates the problem of foaming and flooding. The
problem is less severe in a packed tower.

7. Suspended solids: The packings are more prone to deposition and choking
if the liquid has suspended solids in it. A tray tower can handle a dirty liquid Or a slurry
with relative ease . Also, it can be cleaned easily.

8. Side products: If the side products are to be drawn from the distillation
column, like the distillation column of refinery, tray tower is preferred.
Tray Tower :

Tray :

A tray has two major functions:

1. It allows the gas to flow through the holes or passages; the gas vigorously bubbles through the
liquid to from a gas-liquid dispersion. The tray holds the dispersion on it.

2. The trays separate the column in to a number of compartments each of which constitutes a
stage. Mass transfer between phases occurs on a tray. The performance of a column depends upon
the performance of the trays.

Types of Trays :

1. Bubble cap plate

2. Valve plate

3. Sieve plate
Bubble Cap Tray Valve Tray

Sieve Tray
Selection of Tray Type:
Definition of tray areas :
Total tower cross-section area (AT): The empty tower inside cross-sectional area without
trays or downspouts/downcomer.

Net area (AN) (also called free area): The total tower cross-sectional area (AT) minus the
area at the top of the down comer (ADT). The net area symbolizes the smallest area
available for vapor flow in the inter-tray spacing.

Bubbling area or active area (AA): The total tower cross-sectional area minus sum of the
downcomer top area (ADT) and downcomer seal area (ADB) and any other non perforated
areas on the tray. The bubbling area represents the area available for vapor flow just above
the tray floor.

Hole area (Ah): The total area of the perforations on the tray. The hole area is the smallest
area available for vapor/gas passage.
Typical cross-flow plate (sieve)
Dumping
Tower Diameter and Pressure Drop (For sieve tray):

The required diameter of the column for the given flow rates of the gas and the liquid phases is
determined from flooding considerations.

As the gas velocity in a column is gradually increased, a limiting velocity is attained above which
entrainment is high enough to cause accumulation of liquid on the trays leading to flooding.

This velocity corresponds to the theoretical maximum capacity of the column.

Methods of Calculating Flooding Velocity:

Fairs Method:
This method is based on Souders-Brown equation,
O .5
L G
0.2

vF C f
20 G
Where, V = vapor density, kg/m3
L= liquid density, kg/m3
= liquid surface tension, mN/m (dyn/cm)
 O .5
L G
0.2

vF C f
0.02 G

when, = liquid surface tension, N/m

In above equation Cf is Souders-Brown flooding constant.
But in reality its not constant, as it depends upon tray spacing and liquid load.

Cf can be obtained from a chart given as a function of a flow parameter, FLV for different
values of the plate spacing.

L V
FLV
V L
Where,
L = liquid flow rate, kg/s
V = vapor flow rate, kg/s
V = vapor density, kg/m3
L= liquid density, kg/m3
This figure of flooding velocity, gives flooding velocity with 10% error
subject to following Restrictions:

1. Hole size less than 13 mm. Entrainment may be greater with larger
hole sizes.

2. Weir height less than 15 per cent of the plate spacing.

3. Non-foaming systems.

4. Value of Cf obtained is valid only if Ah/AA 0.1

For other ratios apply the following corrections by multiplying obtained

value of Cf by correction factors

Ah/AA Correction Factor

0.08 0.9
0.06 0.8
Lygeros and Magoulas have given and algebraic equation for calculating Cf,

C f 0.03445 5.421103 S 0.755 exp 1.463FLV0.842
Where, S = tray spacing inches
Checking of Liquid Entrainment:

As a rough guide, the % liquid entrainment should be less than 10%.

Or in other words fractional liquid entrainment should be less than 0.1.

kg of liquid entrained Mole of liquid entrained

kg of gross liquid flow Moles of gross liquid flow

Where, = Fraction liquid entrainment

Value of as a function of liquid-vapor factor (FLV) with different % of

flood as is given in the figure shown.

From this figure value of obtained at calculated percent flood.

Actual vapor vel ocity based on net area

% of flood 100
Flooding velocity
vn
100
vf
Checking for weeping:

At a very low value of vapor velocity liquid rain down through the perforations, this
phenomena is known as weeping.

Weeping tendency increases with

i. Larger fractional hole area
ii. Larger liquid rate
iii. Larger weir height
iv. Lower surface tension of the liquid
v. Decreasing plate thickness
vi. Closer hole spacing or pitch.

Minimum vapor velocity required to avoid the weeping is given by,

K 0.9(25.4 d h )
vh min
v
Where, d= hole diameter, mm,

v = vapor density, kg/m3 (maximum value of vapor density)

K = constant, which is function of depth of clear liquid on the plate, which can be obtained
from figure given
Depth of Clear Liquid = Height of weir + Height of liquid crest over the weir
= hw + hwc

The height of the liquid crest over the weir can be estimated using the Francis weir
formula,

Where, lw = weir length, m,

hw c = weir crest, mm liquid,
Lw = min. liquid flow-rate, kg/s. which can be taken as 70 to
80 % of max. liq. Flow rate
Total Pressure Drop Sieve Tray Tower:

Total pressure drop in sieve tray tower pT is given by,

pT = (Pressure drop per Tray x No. of Trays) + Pressure drop in inlet nozzle +
Pressure drop in outlet nozzle

But, major pressure drop in vapor is provided by trays, therefore,

pT = (Pressure drop per Tray x No. of Trays)

pT = N x pt

Where, N = Total Number of sieve trays of tower

pt = Tray pressure drop , Pa
Again,
pt = 9.81 x 10-3 ht L

ht = hd + (hw + hwc) + hr
Dry plate pressure drop (hd):

Dry plate pressure drop occurs due to friction within dry short holes. can be
calculated using following expression derived for flow through orifices,

2
vh v
hd 51
Co L
Where, hd = Dry plate pressure drop, mm LC

vh = Velocity of gas through the holes, m/s

Volumetric flow rate of gas, m3 / s QV
=
Total hole area, m 2 Ah

Co = Orifice coefficient which is a function of ratio of

plate thickness to hole diameter and % perforated area.
Residual gas pressure head (hr):

The residual pressure drop results mainly from the surface tension as the gas
releases from a perforation.

The following simple equation can be used to estimate hr with reasonable

accuracy
12.5 103
hr
L

Where,
hr = Residual pressure drop, mm LC
L = Density of liquid, kg/m3
 lw
Weir Design: To decide weir height and weir length
hw
The height of weir decides the height of liquid over the tray.

Weirs are straight and rectangular plates.

A high weir provides higher plate efficiency but at the expense of pressure drop.

For a distillation column:

Operating pressure Weir Height

At and above atm. Pressure. 40 to 90 mm (while 40 to 50 mm is common)

Vacuum Operation 6 mm to 12 mm

Weir length fixes area of segmental down comer. Weir length is normally kept in
between 0.6 to 0.85 times column diameter.

For the first trial calculations, weir length can be taken as 0.77 Di and equivalent
down comer area is 12 %.
Decrease in weir length increases the net area of tray and decreases the tower
diameter, but it decreases the down comer area, increases the pressure drop in down
comer and also decreases the volume of down comer. It also elevates the liquid level
in down comer. Increase in weir length increases the tower diameter. Hence,
balanced weir length and weir height are required.

Weir length l Down comer area A d

w 100
ID of tower Di Column area A c
0.600 5.25

0.650 6.80

0.700 8.80

0.705 9.00

0.715 9.50

0.727 10.00

0.745 11.00

0.770 12.00

0.780 13.00
 Ad
lw

Section of a sieve tray with down comer

From above fig. fractional down comer area (Ad/Ac) can be

calculated as,

Ad sin

Ac 2
Design of Down comer:
There are two functions of a down comer,

a) It provides the passage for the flow of liquid.

b) Foamy or frothy liquid enters into down comer. Hence, down comer
also acts as a vapor-liquid separator. To facilitate the vapor-liquid
disengagement, certain minimum residence time (at least 3 seconds) is
required in the down comer.

Types of down comer:

Straight segmental Inclined Segmental Circular or Pipes

down comer down comer down comer
Liquid falls from tray to tray by passing through the downcomer. Due to the pressure
drop across the tray, liquid flows from lower pressure to higher pressure. To overcome
the pressure difference liquid elevates its level in the downcomer. This is called liquid
back-up in the downcomer. Also some pressure drop occurs when liquid flows through
the downcomer area. Downcomer pressure drop increases the liquid back-up further.

Head loss or pressure drop in the down comer is estimated by following equation:
2
Lmd
hdc 166

L m
A
Where, hdc = Downcomer pressure drop, mm LC.
Lmd = Liquid flow rate in down comer, kg/s
L = Density of liquid, kg/m3
Am = Ad or Aap whichever is smaller, m2
Ad = Downcomer area, m2
Aap = clearance area under downcomer apron, m2
Aap = hap .lw / 106
hap = Height of the bottom edge of the apron above the plate, mm LC
lw = length of weir, mm
hap = hw 5 to 10 mm
hw = height of weir, mm
Liquid back-up in down comer in terms of clear liquid is given by following equation,

hb = (hw + hwc) +ht +hdc

Certain minim residence time must be allowed in the down comer to facilitate the
disengagement of vapor and liquid phases. Residence time of at least 3 seconds is
recommended.

Residence time in down comer is given by following equation,

Ad hbc L
r
Lmd
Where, Ad = Down comer area, m2
hbc = Liquid back-up in down comer in terms of clear liquid , m
L = Density of liquid, kg/m3
Lmd = Liquid flow rate in downcomer, kg/s
The Packed Tower:
A packed tower is a continuous contact equipment widely used for gas absorption,
distillation and liquid-liquid extraction.

It consists of a cylindrical shell filled with a suitable packing material to provide large
interfacial area contact between the phases.

Classification of Packings:

i. Random or dumped packings

ii. Structured packings

iii. Grid packings

(a) Raschig rings

(b) Pall rings

(c) Berl saddle ceramic

(d) Intalox saddle ceramic

(e) Metal Hypac

(f) Ceramic, super Intalox

Grid
Characteristics of Tower Packings:

i. A large surface area: Interfacial area of contact between the gas and liquid is created
in a packed bed by spreading of the liquid on the surface of the packing. Smaller
packings offer a larger area per unit packed volume, but the pressure drop per unit
bed height becomes more.

ii. Uniform flow of the gas and the liquid: The packed bed must have a uniform voidage
so that a uniform flow of the gas and of the liquid occurs. The shape of the packing
should be such that no stagnant pocket of liquid is created in the bed. A stagnant
liquid pool is not effective for mass transfer.

iii. Void volume: A packed bed should have a high fractional voidage so as to keep the
pressure drop low.

iv. Mechanical strength: The packing material should have sufficient mechanical strength
so that it does not break or deform during filling or during operation under the weight
of the bed.

v. Fouling resistance: Fouling or deposition of solid or sediment within the bed is

detrimental to good tower operation. Bigger packings are less susceptible to fouling.
Also, the packings should not trap fine solid particles that may be present in the liquid.
Minimum Wetting Rate:

It is the liquid throughput below which the film on the packing surface breaks up reducing
the wetted area.

A liquid rate below MWR is too small to wet all the packing surface. The effective interfacial
area of the gas-liquid contact decreases and the efficiency of mass transfer decreases as a
result.

Schmidt has given the correlation for MWR as follows,

2 1

6 L
3
9 g 2

usL 7.7 10 4 L
m3/m2.h
a
L g p
Bed Pressure Drop and The Phenomena of Loading and Flooding in Packed Tower
Determination of Tower Diameter in Packed Tower

For packed tower, diameter of tower is determined based on flooding velocity. Actual
velocity of gas through packed tower is kept about 60 to 80 % of flooding velocity.

Flooding velocity is determined by using Eckerts chart ( Generalized pressure drop

correlation) and proceeds as follows:

i. From the total liquid and gas flow rates the abscissa (FLV) is evaluated.

L V
FLV
V L
ii. The value of the ordinate K is obtained from the flooding curve and the mass flow
rate of the gas G at flooding is calculated.

iii. The operating gas rate is normally taken as 60 to 80 % of flooding velocity to guard
against inherent errors in the flooding curves and also to keep some flexibility in the
design to take care of any sudden surge in gas flow rate.

The relation between K and FLV is given in Eckerts Chart on next slide
K = is given by... (next slide)
 GF FPL0.2
2
K
G L g
Where,
GF = Mass velocity of gas at flooding, kg/m2.s
K = Function of velocity of gas through tower
G , L = Density of gas and liquid, respectively, kg/m3
FP = Packing Factor, m-1
= Ratio of density of water to density of liquid
L = Viscosity of liquid, cP

Alternatively an algebraic correlation for the Eckerts flooding curve has been given by
Piche as,

log 10 K 0.296log FLV 1.08 log FLV 1.668

2
Height of a Packed Tower:

Height of packing required for a given separation is determined by,

Z H OG NOG (1)

OR

Z H OL NOL (2)

Where,
Z = Height of packed bed

HOG = Height of overall gas phase transfer units, m

NOG = Number of overall gas phase transfer units

HOL = Height of overall liquid phase transfer units, m

NOL = Number of overall liquid phase transfer units

If overall resistance to mass transfer is controlled by gas film then equation (1) is used to
find the packing height Z.

If overall resistance to mass transfer is controlled by liquid film then equation (2) is used to
find the packing height Z.

For dilute concentrations ( less than 10%):

y1
GM dy
K G aP y2 y ye
Z

On above comparing above equation with equation (1)

Gm
H OG
K G aP

y1
dy
N OG
y2
y ye
Where,
Gm = Molar flow rate of gas per unit cross sectional area,
kmol/m2.s
KG = Overall gas phase mass transfer coefficient,
kmol/(atm.m2.s)
a = Interfacial area per unit volume, m2/m3
P = Operating pressure, atm

In the special case, if equilibrium curve and operating line, both can be assumed as
straight lines and the solvent feed essentially solute free, NOG can be calculated by
equation,
1 mGm y1 Gm
N OG ln 1 m
mGm Lm y2 Lm
1
Lm
Where,
m = Slope of equilibrium line
Gm/Lm = Slope of operating line
When the operating and equilibrium lines are straight, and they can usually be
considered to be so for dilute systems, the number of transfer units is given by:

y1 y2
N OG
ylm
where ylm is the log mean driving force, given by:

Where,
Similarly,
x1
LM dx
Z
K L aCT x xe x
2

LM
Thus,
H OL
K L aCT and

x1
dx
N OL
x x
x2 e

Where,
Lm = Molar flow rate of liquid per unit cross sectional area,
kmol/m2.s
KL = Overall liquid phase mass transfer coefficient,
kmol/(atm.m2.s)
a = Interfacial area per unit volume, m2/m3
CT = Total molar concentration, kmol/m3
Analytical Determination of Number of Overall Transfer Units:

If the gas and the liquid stream are dilute and the Henrys law is applicable,

y1 mx2
ln (1 S ) S
y2 mx2
N OG
1 S
Where,
S 1 mG and A absorption factor
A L
Algebraic Determination of the Number of Ideal Stages (Kremser Euqation):

Y mX o 1 1
log N 1 1
Y1 mX o A A
N
log A

Where,
Y and X compositio n of gas and liquid in molar ratio, respective ly.
A Absorption factor
HETP:
The height equivalent to theoretical plate (HETP) is the height of packing that gives the
same separation as an equilibrium stage.

For the distillation in packed tower, height of packed bed Z, required for the desired
separation, is determined by following equation,

Z = Nt x HETP

Where, Nt = Number of theoretical stages required for the desired separtion.

Also see, page no. 453 of the Book Introduction to Process Engineerin
And Design by Bhatt and Thakore.

Relationship between HETP and HOG:

1
ln 1 A
HETP H OG
1 1
A