Inda kola weri Design a distillation column with a total condenser and partial re boiler for the following

separation . DATA system ethanol-water Feed rate -150 K mole /hr Feed composition 28mole % ethanol 98% of ethanol recovery is required?????????????????? Operating pressure: 1 bar Feed composition: 50% sat liquid and 50% sat vapor Distillate composition: 82% mole ethanol Column type: packed column Packing type: raschig rings Select a suitable packing material ,packing size ,pressure drop across packing or percentage of flooding and a reflux ratio .obtain an appropriate HETPvalue for HTU from the literature and determine the number of ideal stages required ,the column height and the diameter of the column ,feed tray location and the condenser and reboiler heat loads .

Detail calculation Graphical constructions data used for the calculation , Assumptions made Reference

1. Selection of packing material and packing size

Material
Heart of the distillation column is begin with the selection of packing material ..In this distillation column design Raschig types rings are used as packing material .they are usually made up by ceramic or metal or carbon. Ceramic packing are resistant to corrosion and comparatively cheap but which are heavy and may require a stronger packing support and foundations.so ceramic packaging is rejected from the design.Metal, carbon steel packings are usually the first choice for noncorrosive services. Here in this problem waterethanol mixture is separated using packing distillation column which mixture is comparatively low corrosive .so in this case carbon steel packing is selected which offer higher efficiency , a wider range geometries , higher turndown are unbreakable , and have a higher compression resistance .

Figure 1-1: Raschig ring

SIZE
The size of packing used influences the height and diameter of a column, the pressuredrop and cost of packing. When packing size is increased, the cost per unitvolume of packing and the pressure drop per unit height of packing are reduced, but in other side which will reduce the mass transfer efficiency. Reduced mass transfer efficiency results in a tallercolumn .So for this design 38 mm Size metal Raschig type ring is selected as a packing material and column diameter is expected to maintain around 0.3 to 0.9 m. Here the column Column diameter <0.3 m (1 ft) 0.3 to 0.9 m (1 to 3 ft) >0.9 m Use packing size <25 mm (1 in.) 25 to 38 mm (1 to 1.5 in.) 50 to 75 mm (2 to 3 in.)

Table 1: Raschig Ring data table

Packing method = random type packing

Pressure Drop
Pressure drop can be assumed from the [1][3] . it can be assumed as a 0.75 inch water /ft packing . that means which is equal to the 62.5 mm water /m packing .

HETP value
HETP value for a packing size of 38 mm for full scale plant can be assumed as a 0.66 m .

Figure 0-1 : Volume 6 page no 640

Calculation

D,XD

F,XF

W,Xw

Figure 0-2: distillation Column sketch diagram

F - Feed (Kmol/hr) D Distillate (kmol/hr) W Bottom product (kmol/hr) X - mole fraction of heptane G Upward gas flow rate in rectifying section G Upward gas flow rate in stripping section L Downward liquid flow rate in rectifying section L Downward liquid flow rate in stripping section

F=Feed rate X=mole composition of ethanol D= Top product rate B=Bottom product rate F=150 kmol/hr XF=0.28 XD = 0.82

Figure 0-3 : Distillation Column Diagram

Ethanol entering rate as feed

= 0.28 X 150 Kmol/hr =42 Kmol/hr

If 98% of ethanol is recovered from the top product Ethanol mole leaving rate from the distillate Mole composition in the feed= D*XD =41.16 o D=41.16/0.82 = 50.195 Kmol /hr Mass balance for the system F=D+B 150=50.195+ B B=99.805 Kmol/hr Mass balance for the ethanol F.XF =D.XD+ B.XB XB=(42-41.16)/99.805 =0.0084 = 42 X 0.98 = 41.16 Kmol/hr

Water-ethanol equilibrium data can be founded as follow .

Table 2: Ethanol-water liquid equilibrium at 1 Bar

Source: :physical property table, mcgraw-hill [1] By using the ethanol water liquid equilibrium data VLE diagram is drawn .

Figure 0-4:VLE of water ethanol

Assumptions The lines are made straight by the assumption of constant molar overflow Liquid rate is constant and the vapor rate constant. from tray to tray in each section of the column between addition (feed) and withdrawal (product) points.

Construction of Q line

q=0.5/1 q=0.5 equation of Q line

Y = - X 2Xf = - X+ 2* 0.28 = -X+0.56 After constructing Q line Minimum reflux ratio is calculated by connecting the point (Xd ,Xd) and point of intersection between the q-line and the equilibrium curve. R of this curve is known as the minimum reflux ratio .

Rmin = 1 Ractual = 1.5 * R min [2] = 1.5

Figure 0-5 : VLE with Minimum Reflux ratio

Using the value R min Top operating line and Bottom operating line of the Distillation curve is derived . TOL ( )

Yn+1= 0.6 .Xn + 0.4* 0.82 = 0.6 Xn + 0.328

By combing the points (Xb,Xb) and intersection point of the q line and TOL BOL is drawn . ( fig3 ) Equation of the BOL BOL is passed through the points (0.145,0415) and (0.0084,0.0084) So equation of the line Y=2.97657x - 0.0166 Equation of bottom line (general formula) ( )

, here B = 99.805 Kmol/hr L=150.29 Kmol/hr

TOL

Q line

BOL

Number of ideal stage = 33-1 =32stages [from the stair case construction of the graph(in annex 1) ]

Location of the feed tray = 30th tray (

?????? Wite the figure

no )
From the calculated value R =1.5 following can be found Molar flow rate (Kmol/hr) F Feed (Kmol/hr) D Distillate (kmol/hr) B Bottom product (kmol/hr) G Upward gas flow rate in rectifying section G Upward gas flow rate in stripping section L Downward liquid flow rate in rectifying section L Downward liquid flow rate in stripping section 150 50.195 99.805 126.3875 50.485 76.1925 150.29

Here

G=L-B

and

G = L+B

G L
F,XF

D,XD

W,Xw

Column height =number of stages * HETP = 32* 0.66 m =21.12 m Height of the stripping section = Height of the Rectifying section =29*0.66 = 19.14 m

Calculation of Column Diameter

In Rectifying section and Stripping section, from stage to stage composition of G and L are varied, so it is not possible to get Constant Mass flow rate of vapor and Constant Mass flow rate of liquid. So in this calculation, It is better to Take an average value of the Mass flow rate across the Rectifying Section and stripping section .

For rectifying section

F Feed (Kmol/hr) D Distillate (kmol/hr) G Upward gas flow rate in rectifying section L Downward liquid flow rate in rectifying section One stage above the feed tray :

Molar flow rate (Kmol/hr) 150 50.195 126.3875

76.1925

Composition of the ethanol in liquid = 0.24 { Temperature at the 82.5 oC } Composition of the ethanol in the vapor = 0.47

At the top stage Composition of the Ethanol in liquid = 0.82 Composition of the ethanol in vapor = 0.82 Temperature at the top = 78.5oC Average temperature of the stripping section = (78.5+82.5)/2 =80.5oC

F Feed (Kmol/hr) D Distillate (kmol/hr) G Upward gas flow rate in rectifying section L Downward liquid flow rate in rectifying section

Molar flow rate (Kmol/hr) 150 50.195 126.3875

76.1925

Average Molar fraction in the liquid = 0.45 Average Molar fraction in the vapor = 0.64

Density of the liquid at 80.5oC . Density of ethanol at temp @ 80.5 Density of water at temp 80.5 Mass fraction of ethanol in liquid Mass of water in liquid (w/w) Volume of the ethanol = 676 /725.238 m3 Volume of water = 324/961.778 m3 Molar mass of mixture =0.932 = 0.3368 = 0.55*18 +0.45*46.05 = 30.625 g/mol = 725.238 Kg/m3 = 961.778 Kg/m3 (w/w) =0.45* 46/(0.55*18+0.45*46)=0.676 =1-0.676 =0.324

Density of the mixture = (1000)/(0.932+0.3368)*103=788.1Kgm-3 Liquid Flow rate (L*) =76.1925*30.625 = 2333.39 Kg/hr Density of the vapor @ 80.5 oC Saturated vapor pressure of ethanol Peo = 829.434 mmHg =110.5 KPa Saturated vapor pressure of water Pwo = 361.785 mmHg =48.2 KPa Average Molar fraction of ethanol in the vapor = 0.64 Average molar fraction of the Water in the vapor = 0.36 Average molecular weight of the Water and ethanol in the vapor mixture = (0.64* molecular mass of ethanol* 0.36 molecular mass of water ) =0.64* 46.04+ 18.01*0.36 =35.9492 Kg/Kmol Vapor flow rate = G*35.9492 Kg/hr = 4543 Kg/hr

By applying Raoults Law PT= XePeo+XwPwo = 0.64* 110.5 + 48.2* 0.36 = 88.07 KPa Density of the vapor By applying Gas Law Assumption :Compressibility factor of the Water-ethanol vapor is approximately equal to 1 . PV=nRT where P = absolute pressure N/m2 (Pa), V = volume m3, n = mols of gas T = absolute temperature, K, R = universal gas constant, 8,314 J K"1 mol"1 (or kJ K"1 kmol"1). Density =PM/RT = ( 88070*35.94) /(8.314 * 353.5) = 1.074 Kg/m3

Viscosity of the mixture mix= mix = =={(0.45*0.43001/3 +0.55*0.356351/3 }1/3 =0.3888 mPa
3

Lw* = average molar mass * molar flow rate = 2333.39 Kg/hr V*w=average molar mass * molar flow rate = 4543 Kg/hr

788.14 =0.02

For pressure drop 42 , K4 value is equal to 1.9 For pressure Drop 83 , K4 value is equal to the 3.3 For pressure drop 62.5 K4 can be found to be a = 2.6

At flooding K4 is equal to the = 6 So percentage of flooding = =65.82 % satisfactory

F p=

270 m3/m2

V* =[ V*=1.61Kg/m2s

]1/2

Column Area required = (mass flow rate of vapor / V*) =(4543/3600)/1.61) =0.7838m2 = *d2/4 =0.7838 d=0.99 m Diameter of the rectifying section =0.99m ~1 m Packing size to column size ratio = (1/0.038 ) =26.31

Diameter of the Stripping section .

For Stripping section

F Feed (Kmol/hr) B Bottom product (kmol/hr) G Upward gas flow rate in stripping section L Downward liquid flow rate in stripping section At the feed tray :

Molar flow rate (Kmol/hr) 150 99.805 50.485 150.29

Composition of the ethanol in liquid = 0.12 { Temperature at the 358. K =85.5 oC } Composition of the ethanol in the vapor = 0.47

At the bottom stage Composition of the Ethanol in liquid = 0.02 Composition of the ethanol in vapor = 0.15 Temperature at the top = 96.5 oC Average temperature of the stripping section = (96.5+85.5 )/2 =91oC

Average Molar fraction of ethanol in the liquid = 0.05 Average Molar fraction of ethanol in the vapor = 0.32 Average mass fraction of ethanol liquid =0.05*46/(0.05*46+0.95*18) =0.118

Density of the liquid at 91oC . Density of ethanol at temp @ 91 Density of water at temp @91 Volume of the ethanol = 118 /713 m3 =0.165 = 713 Kg/m3 = 954 Kg/m3

Volume of water = 881/954 Kg/m3 = 0.963 Density of the liquid mixture = 1000/(0.165+0.963) =886.52 Kg/m3 Average molecular weight of the liquid = 19.5 Kg/Kmol Average mass flow rate of liquid = 19.5 * 150.29 =2930 Kg/hr Density of the vapor @ 91 oC Saturated vapor pressure of ethanol Peo = 164 Kpa Saturated vapor pressure of water Pwo = 361.785 mmHg =72.74 KPa Average Molar fraction of ethanol in the vapor = 0.32 Average molar fraction of the Water in the vapor = 0.68 Average molecular weight of the Water and ethanol in the vapor mixture = (0.32* molecular mass of ethanol* 0.68 molecular mass of water ) =0.32* 46.04+ 18.01*0.68 =26.9796 Kg/Kmol Vapor flow rate = G*26.9796 Kg/hr = 1362 Kg/hr

By applying Raoults Law PT= XePeo+XwPwo = 0.32* 164+ 72.74 * 0.68 = 101.94 KPa Density of the vapor By applying Gas Law Assumption :Compressibility factor of the Water-ethanol vapor is approximately equal to 1 .

PV=nRT where P = absolute pressure N/m2 (Pa), V = volume m3, n = mols of gas T = absolute temperature, K, R = universal gas constant, 8,314 J K"1 mol"1 (or kJ K"1 kmol"1). Density =PM/RT = ( 101.94*26.97) /(8.314 * 364) = 0.908 Kg/m3 Viscosity of the liquid mixture at 91oC water =0.31222 mPa ethanol = 0.34693 mix= mix = =={(0.05 *0.346931/3 +0.95*0.31221/3 }1/3 =0.3138 mPa
3

=0.068

For pressure drop 62.5 K4 can be found to be a = 0.6

At flooding K4 is equal to the = 0.9

So percentage of flooding = *100

=80 % satisfactory

F p=

270 m3/m2

V* =[ V*=0.77 Kg/m2s

]1/2

Column Area required = (mass flow rate of vapor / V*) =(1362/3600)/0.8) =0.4913 m2 = *d2/4 =0.4913m2 D=0.79 m Diameter of the rectifying section ~0.8 m Packing size to column size ratio = (0.8/0.038 ) =20.81

Feed tray location

It can be assumed as feed is fed into column at 2.5th stage . So the height of the column = 2.5*HETP = 1.65 m

Condensor heat load

Flow rate of the vapor stream of the stripping section (G) As we have 82%( mol/mol)ethanol in this stream, 126.38 kmol/hr

Latent heat of this mixture

Temperature of the distillate product =351 K (vapor molar fraction of 0.82 )

Latent heat of ethanol (@ 1 bar , 351 K ) Normal boiling point of ethanol= 351 K Latent heat of ethanol at normal boiling point = 39300kJ/Kmol.

Latent heat of water (@ 1 bar , 351 K ) Latent heat of water at boiling point =40860 KJ/Kmol

Critical temperature =647 K Tb = 373 T=351

Lv=40860
Latent heat of water at 351 K = 42076.925 KJ/Kmol

Lv mixture = 42076KJ/Kmol *.18 + = 39300kJ/Kmol * 82= Therefore condensor heat load (Qc) = G x = 126.3875 Kmol/hr x 39799.68 KJ/Kmol = 5.03 x 106 kJ/hr = 5.03 x 106 /3600kJ/s (kW) = 1397 KW

Reboiler heat load

A partial reboiler will be used in the distillation colum here. Therefore, only a part of the liquid leaving from the bottom of the column will be evaporated again. Actually the part vaporized in the reboiler is equal to the upwards vapor flow in the stripping section. Vaporized Mixture flow rate can be found as the 50.485 Kmol/hr

G=50.485 Kmol/hr L =150.29 Kmol/hr B = 99.805 Kmol/hr => Xb=0.02

As this liquid stream consists of 97% octane (3% heptane), it is reasonable to assume latent heat of octane as the overall latent heat of this liquid stream and the molecular weight of octane as the molecular weight of whole stream. Therefore latent heat of the liquid stream leaving the column (L) = 298 kJ/kg Therefore reboiler heat load (QR) = (Gx molecular weight) x = 395.15 x 114.2 x 298 = 13.45 x 106 kJ/hr = 3735 kJ/s (kW)

Reference [1] http://highered.mcgraw-hill.com/sites/dl/free/0072849606/315014/physical_properties_table.pdf [2]volume 6 [3] [4] [5]

Information

Annex

Top operating Line calculation (0.81-0.7)

12 stages

Total=22 stages

26

Total No of stages 29

Location of the feed tray 30th tray

30

Stripping section = 3 stages