MASS TRANSFER OPERATION II

CH 4152








DESIGN OF A BERL SADDLES PACKED
DISTILLATION COLUMN









NAME : N.G.A.K.K.N. NISSANKA
INDEX NO : 090354 T
DATE OF SUB : 2013-08-01
1

Contents
INTRODUCTION .................................................................................................................................... 2
Selection of suitable packing material and size ....................................................................................... 3
Material selection ................................................................................................................................. 3
Size selection ........................................................................................................................................ 3
Pressure drop across packing ................................................................................................................... 4
HETP value .............................................................................................................................................. 4
Number of ideal stages required ............................................................................................................... 5
Construction of Q line .......................................................................................................................... 6
Construct top operating line (TOL) for minimum reflux ratio ............................................................. 6
Construct top operating line (TOL) for actual reflux ratio ................................................................... 7
The column height .................................................................................................................................... 9
Feed tray location ..................................................................................................................................... 9
Diameter of the column ............................................................................................................................ 9
Flow rates and compositions calculation ............................................................................................ 10
Diameter for rectifying section ........................................................................................................... 11
Diameter for stripping section ............................................................................................................ 15
Heat load of condenser ........................................................................................................................... 19
Heat load of re-boiler ............................................................................................................................. 20
Summary ................................................................................................................................................ 21
References .............................................................................................................................................. 22








2

INTRODUCTION
Generally packed columns are used for distillation, gas absorption and liquid-liquid extraction.
The gas-liquid contact in a packed column is continuous, not stage-wise, as in a plate column. The
liquid flows down in the column over a packing surface and the vapor (or the gas) moves counter-
currently, up the column. The performance of a packed column is very dependent on the maintenance
of good liquid and gas distribution through the packed bed, and this is an important consideration in
packed column design.
I can arrange given data for distillation column as bellow
System : chloroform-benzene
Operating pressure : 1 bar
Feed rate : 48 kmol/hr
Feed condition : 50% sat. liquid and 50% sat. vapour
Feed composition : 45 mol% chloroform
Distillate composition : 85 mol% chloroform
Bottom product composition : 20 mol% chloroform
Column type : packed column
Packing type : berl saddles
As well as we design distillation column with a total condenser and a partial re boiler
I need to find bellow data and calculations for this design
Suitable packing material and packing size
Number of ideal stage required
Column height and diameter
Feed tray location condenser and re boiler heat loads




3

Selection of suitable packing material and size
Material selection
There two packing method for packed distillation which random and structured packing. According to
the given data we need to use berl saddles type packing material. Berl saddles type is used in random
packing method. So we have to use random packing method for our distillation process. In berl saddles
type has different type raw material such as ceramic, metal, plastic and carbon. Lot of plastic type
reacts with chloroform without polythene and polypropylene. As well as some pressure and
temperature condition we can ignore plastic type. When we consider the ceramic and plastic both are
good for our distillation column. As well as weight of column increase due to ceramic weight higher
than metal. So metal is good for packing material. But consider the availability in market most berl
saddles type are ceramic. Therefore we use ceramic berl saddle for our packing material.
Material : ceramic berl saddle
Size selection
According to market data we can categorize sizes and there data as bellow table

When flow rate increase we need to increase packing size. As well as when size increase efficiency
decrease. Our flow rate is got low value. So we can use smaller size packing such as (19 - 25) mm. But
low sizes get high weight. So I select packing size as a 25 mm.
Size : 25 mm


Packing factor
F
p
110
98
52
40

4

Pressure drop across packing











We need to assume pressure drop across packing using above table. 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

According to our packing size we can get HETP value from below table as 0.46 m.



5

Number of ideal stages required
Chloroform-benzene vapour-liquid equilibrium data at 1 bar for 24 data points
temperature(K)
mole fraction of
chloroform in
liquid phase (X)
mole fraction of
chloroform in
vapour phase (Y)
353.26 0.0000 0.0000
352.67 0.0269 0.0437
352.36 0.0417 0.0692
349.80 0.1855 0.2581
350.87 0.1332 0.1849
348.85 0.2372 0.3316
347.87 0.2948 0.3980
347.04 0.3506 0.4749
346.51 0.3921 0.5245
345.58 0.4427 0.5714
344.57 0.4897 0.6257
343.78 0.5347 0.6742
342.77 0.5781 0.7164
341.95 0.6209 0.7553
341.07 0.6654 0.7936
340.02 0.7181 0.8257
338.87 0.7579 0.8595
338.13 0.7954 0.8851
337.49 0.8278 0.9057
336.86 0.8603 0.9262
336.31 0.8892 0.9427
335.53 0.9308 0.9648
335.07 0.9571 0.9792
334.28 1.0000 1.0000

Using above data we can draw Chloroform-benzene vapour-liquid equilibrium curve like below graph.

6

Construction of Q line

q = 0.5
Q line equation
(

X : mole fraction of chloroform in liquid phase
Y : mole fraction of chloroform in vapour phase
X
f
: feed composition of chloroform
(

Y = -1 X + 0.90
Construct top operating line (TOL) for minimum reflux ratio
According to given data value of distillate composition is 0.85. So we can construct line go
through where (0.85, 0.85) and (Q line and equilibrium curve cutting point).


7

Calculate minimum reflux ratio (R
m
) Using TOL

R
m
= 2.5417
Calculate R
actual
using R
m
value
R
actual
=R
m
1.2= 2.54171.2 = 3.05 (1.2 is constant vale we can use it between 1.2-1.5)
Construct top operating line (TOL) for actual reflux ratio

X
d
: distillate composition

Y
n+1
= 0.7531 X
n
+ 0.21
Construct Bottom operating line (BOL) using given data
According to given data value of bottom product composition is 0.20. So we can construct line
go through where (0.20, 0.20) and (Q line and TOL curve cutting point).
Q line and TOL curve cutting point = (0.394, 0.501)
Equation for Bottom operating line

L' : Downward liquid flow rate in stripping section
W : Bottom product (kmol/hr)
X
w
: Bottom product composition of chloroform
Total stages = 14 but it has partial re boiler
Number of ideal stages = 13
8































9

The column height


Feed tray location
According to stages counting figure feed location should be between six and seven stages from the top
and six and seven stages from the bottom.
Therefore feed location should be middle of the column

Diameter of the column















F : Feed (kmol/hr)
D : Distillate (kmol/hr)
W : Bottom product (kmol/hr)
X
F :
Feed composition of chloroform

X
D :
Distillate product composition of chloroform

X
W :
bottom product composition of chloroform

X
D

X
F

X
W

G
'
L
'
10

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
Flow rates and compositions calculation
F : 48kmol/hr
X
F
: 0.45
X
D
: 0.85
X
W
: 0.20

Mass balance for the system
F = D + W
48 = D + W
Mass balance for the chloroform
F X
F
= D X
D
+ W X
W
21.6 = 0.85 D + 0.2 W
D =18.46 kmol/hr
W = 29.53 kmol/hr

G = L + D = 56.3 + 18.46 = 74.76 kmol/hr
(

) (

)
L' = 83.22 kmol/hr
G' = L' - W = 83.22 - 29.53 = 53.69 kmol/hr
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.
Molecular weight of chloroform = 1395.4 g/mol
Molecular weight of benzene = 827.49 g/mol

11

Diameter for rectifying section
I consider one stage above the feed tray and top stage for get average values in rectifying section.


12

According to above graph data we can get below data
DATA Value temperature
F 48 kmol/hr
D 18.46 kmol/hr
G 56.30 kmol/hr
L 74.76 kmol/hr
At one stage above the feed tray
Chloroform Composition in liquid 0.42 346 K
Chloroform Composition in vapour 0.52 346.5 K
At top stage
Chloroform Composition in liquid 0.85 337 K
Chloroform Composition in vapour 0.85 339 K

Average temperature for liquid phase

Average Chloroform Composition in liquid = 0.62
Average Chloroform Composition in vapour = 0.76
Density of the liquid at 342 K
Density of chloroform at temp = 1395.4 Kg/m
3

Density of benzene at temp = 827.49 Kg/m
3

Mass fraction of chloroform in liquid (w/w) =

Mass fraction of benzene in liquid (w/w) =1-0.7138 = 0.2862
Volume of the chloroform for 1000 kg =

Volume of benzene for 1000 kg =

Molar mass of mixture (M) =
Density of the mixture (

) =

Liquid Flow rate

(LM) = 74.76103.7 = 7752.61 Kg/hr

13

Density of the vapor at 342 K
Saturated vapor pressure of chloroform

= 129.27 KPa
Saturated vapor pressure of benzene

= 70.7 KPa
Average Molar fraction of chloroform

= 0.76
Average molar fraction of benzene

= 0.24
Average molecular weight of vapor mixture =
Vapor flow rate

(GM) = 56.30109.48= 6163.72 Kg/hr

Raoults Law for vapour phase

Applying Gas Law for find density

Where
P = absolute pressure (Pa)
V = volume m
3

n = mols of gas
T = absolute temperature K
R = universal gas constant 8.314 J/(mol*K)
m = mass
M= molecular weight
= density
Assumption: all gasses behavior is ideal

Viscosity of the mixture at 342 K
Viscosity of chloroform =

Viscosity of benzene =

Find K
4
value finding F
LV
value and using graph

14
















According to selected pressure drop value of 62.5 K
4
can be found = 1.8
At flooding line K
4
is equal to the = 4
So percentage of flooding =

= 63.25 % satisfactory
Packing factor (F
p
) = 98

15

Diameter for stripping section
I consider one stage bellow the feed tray and bottom stage for get average values in rectifying section.


16

According to above graph data we can get below data
DATA Value temperature
F 48 kmol/hr
W 29.53 kmol/hr
G' 53.69 kmol/hr
L' 83.22 kmol/hr
At one stage bellow the feed tray
Chloroform Composition in liquid 0.39 347 K
Chloroform Composition in vapour 0.50 347.5 K
At bottom stage
Chloroform Composition in liquid 0.20 350.5 K
Chloroform Composition in vapour 0.20 349.5 K

Average temperature for liquid phase

Average Chloroform Composition in liquid = 0.27
Average Chloroform Composition in vapour = 0.37
Density of the liquid at 348.6 K
Density of chloroform at temp = 1382.04 Kg/m
3

Density of benzene at temp = 820.22 Kg/m
3

Mass fraction of chloroform in liquid (w/w) =

Mass fraction of benzene in liquid (w/w) =1-0.3611 = 0.6389
Volume of the chloroform for 1000 kg =

Volume of benzene for 1000 kg =

Molar mass of mixture (M) =
Density of the mixture (

) =

Liquid Flow rate

(L'M) = 83.2289.25 = 7427.38 Kg/hr

17

Density of the vapor at 348.6 K
Saturated vapor pressure of chloroform

= 157.76 KPa
Saturated vapor pressure of benzene

= 87.62 KPa
Average Molar fraction of chloroform

= 0.37
Average molar fraction of benzene

= 0.63
Average molecular weight of vapor mixture =
Vapor flow rate

(G'M) = 53.6993.38= 5013.57 Kg/hr

Raoults Law for vapour phase

Applying Gas Law for find density

Viscosity of the mixture at 348.6 K
Viscosity of chloroform =

Viscosity of benzene =

Find K
4
value finding F
LV
value and using graph

18
















According to selected pressure drop value of 62.5 K
4
can be found = 1.4
At flooding line K
4
is equal to the = 3.2
So percentage of flooding =

= 66.14 % satisfactory
Packing factor (F
p
) = 98

19

Heat load of condenser

data chloroform benzene
X
D
0.85 0.15
Boiling point T
b
335 k 353.1 K
Critical temperature T
C
537 K 562 K
Operating temperature T 339 K 339 K
Latent heat @ boiling point L
v,b
29486.86 J/mol 30462.9 J/mol
Gas flow rate G 56.30 kmol/hr

Latent heat at temperature T

For chloroform

(


)

For benzene

(


)

Latent heat of mixture L =

Condenser heat load Q
C

20

Heat load of re-boiler

Data chloroform benzene
X
D
0.85 0.15
Boiling point T
b
335 k 353.1 K
Critical temperature T
C
537 K 562 K
Operating temperature T 350.5 K 350.5 K
Latent heat @ boiling point L
v,b
29486.86 J/mol 30462.9 J/mol
Gas flow rate G' 53.69 kmol/hr

Latent heat at temperature T

For chloroform

(


)

For benzene

(


)

Latent heat of mixture L =

Condenser heat load Q
C

21

Summary

According to all calculations of this report we can summaries all important data in below table
data Value or details
System Chloroform-Benzene
Column type Packed bed
Packing type Berl saddle
Packing material Ceramic
Packing size 25 mm
Pressure drop across packing 62.5 mm water /m
HETP value 0.46 m
Reflux ratio 3.05
Number of ideal stages 13
F feed 48 kmol/hr
D distillate 18.46 kmol/hr
W bottom product 29.53 kmol/hr
G gas flow in rectifying system 56.30 kmol/hr
L liquid flow in rectifying system 74.76 kmol/hr
G' gas flow in stripping system 83.22 kmol/hr
L' liquid flow in stripping system 53.69 kmol/hr
Column height 6 m
Feed tray location Middle point (3 m from bottom)
Diameter of rectifying system 0.62 m
Diameter of stripping system 0.656 m
Heat load of condenser 462.26 kW
Heat load of re-boiler 450.49 kW







22

References


http://ddbonline.ddbst.de/DIPPR105DensityCalculation/DIPPR105CalculationCGI.exe
http://ddbonline.ddbst.de/VogelCalculation/VogelCalculationCGI.exe
http://ddbonline.ddbst.de/AntoineCalculation/AntoineCalculationCGI.exe
http://www.engineeringtoolbox.com/fluids-evaporation-latent-heat-d_147.html
http://www.cheric.org/kdb/kdb/hcvle/showvle.php?vleid=3565 from (http://vle-calc.com/index.html)
Colson & Richadson chemical engineering volume 6