Composition of feed, top and bottom and relative volatilities are:

The key components selected are n-C4 and i-C5 as light and heavy key respctively.
Components

Xf

H2
CH4
C2H6
C3H8
i-C4
n-C4
i-C5
n-C5
5N5
2,2 DMC4
2,3 DMC4
2MC5
3MC5
NP6
5N6
6N6
NP7
6N7
6N8
K-Value (HK)
Avg Temp T

0.0953
0.0235
0.0209
0.0375
0.031
0.0179
0.2959
0.0992
0.0221
0.058
0.0167
0.0607
0.0372
0.0214
0.0396
0.0362
0.078
0.0024
0.0063
0.6927922272
238 F

Xd
0.5399
0.1334
0.1148
0.114
0.0514
0.0239
0.0214
0.0011
0.1
0
0
0
0
0
0
0
0
0
0

Xb
0
0
0.0008
0.0212
0.0267
0.0166
0.3547
0.1202
0.0269
0.0704
0.0203
0.0737
0.0452
0.026
0.0481
0.044
0.0947
0.0029
0.0076

K-Values
42.301999852
14.6248911009
5.2478040536
2.5630552627
1.4622811889
1.241435261
0.6927922272
0.6089335497
0.4770987237
0.4364368189
0.3714730397
0.360529413
0.3362551971
0.2982579424
0.2875283057
0.2449354634
0.1553248322
0.150274396
9.55E-02

114.4 C

Calculation of minimum number of stages Nm:

From Fenske Equation

Nm
Nm

5.4386996977
6

Calculation of minimum reflux ratio:

From Colburn and Underwood we have an expression for minimum reflux ratio
(i * Xif)/(i - )
0.0980292719
0.0255582102
0.0269478038
0.0693813501
0.1593154165
0.3489122836
-0.4227142857
-0.1061969101
-0.0150487561
-0.0341467626
-0.0076941607
-0.0267788426
-0.014864906
-0.0072573063
-0.0127902545
-0.0095053132
-0.0118496447
-0.0003510153
-0.0005556325

-value can be found by

feed is at boiling point so q=1

therefore at =1.7

Rm+1
Rm

1.689562929
0.689562929

Sum
-Value 1.7

0.0583905457

Reflux ratio is 1.2 times the minimum reflux ratio

Reflux Ratio
Reflux Ratio

1.2 Rm
0.8274755148

Calculation of Number of theoretical plates:

we first need to find the ratios of (Rm/Rm+1) and (R/R+1)
Rm/Rm+1

0.4081309534

R/R+1

0.452797046

From Erbar-Maddox correlation

Nm/N
Nm
N

Vis A

0.37
6
16.216216216

Number of theoretical plates

Nth

17

Plate Efficiency calculation (Eo):

O'Connell's correlation.

For Viscosity we have

Molar avg Viscosity a

a*a

13.82
114.14
156.6
222.67
302.51
265.84

5.39
57.6
95.57
133.41
170.2
160.2

367.32
313.66

191.58
182.48

406.69
438.44
444.19
384.13
372.11
362.79
440.52
653.62
436.73
528.41
506.43

231.67
226.67
228.86
208.27
207.55
207.09
243.24
290.84
232.53
271.58
280.76

0.122189135 mNs/m2

Relative volatility a

1.7919301232

0.2189543918

from O'Connell's graph for efficiency of the column (E o)

Eo

67.5 %

Actual Number of Trays:

Nth
Eo
Actual Plates

17
0.675
Nth/Eo

Vis B

N
N

25.185185185
26

Feed-point location:
Using Krikbride empirical equation

here

B
D

2022 lbmol/hr
456.5 lbmol/hr

log (Nr/Ns)
Nr/Ns

0.3386683122
2.1810635114

Plates in stripping section (Below the feed)

N=Nr+Ns
Nr+Ns
Ns
Ns

26
8.173367148
9

Plates in rectifying section (Above the feed)

Nr
Nr
Feed-point

N-Ns
17
18

Column Diameter Calculation:

Flooding velocity can be estimated from the correlation given by Fair

here Uf is the flooding velocity based on net area An

At this stage we need to find the liquid-vapor flow factor F LV for top and bottom for constant K1

Assume tray spacing of

0.5 m

Rectifying Section:
Following are the necessary physical properties for Diameter calculation taken from HYSYS
v

24.76 Kg/m3

510 Kg/m3
6.37 dyne/cm

Lw
Vw
FLV

or

0.00637

14610 kg/hr
18840 kg/hr
0.1708675332

from graph
K1

0.06
for values other than 0.02N/m surface tension a correction is applied for K 1

K1

0.04773

Now the flooding velocity

Uf
0.2112886239 m/s
Design for 85% flooding at maximum flow rate
Maximum allowable vapor velocity based on the net column cross sctional area
Uv
Uf * 0.85
Uv

0.1795953303 m/s

Maximum volumetric flow rate

760.6 m3/hr
0.211278 m3/s

Net Area required

An

Take downcomer area as 12% of the total cross sectional area

1.2

Total column cross sectional area

Ac

1.34

Diameter of the column

D=((At 4)/)
Dia
1.3045627066 m
or

4.3

Stripping Section:
Following are the necessary physical properties for Diameter calculation taken from HYSYS
v

40.64 Kg/m3

466 Kg/m3
4.135 dyne/cm

Lw
Vw
FLV

or

0.004135

107300 kg/hr
33440 kg/hr
0.9475831828

from graph
K1

0.03
for values other than 0.02N/m surface tension a correction is applied for K 1

K1

0.02

Now the flooding velocity

Uf
0.0708128106 m/s
Design for 85% flooding at maximum flow rate
Maximum allowable vapor velocity based on the net column cross sctional area
Uv
Uf * 0.85
Uv

0.060190889 m/s

Maximum volumetric flow rate

822.7 m3/hr
0.228528 m3/s

Net Area required

An

3.8

Take downcomer area as 12% of the total cross sectional area

Total column cross sectional area
Diameter of the column
Dia

Ac

4.31

D=((At 4)/)

2.3436334528 m

or

7.7

Both diameters differ more than 20%, therefore we will have two different diameters for the column.

Plate Areas:
Ac

Total column cross seectional area

for top

Ac

1.34 m2

for bottom

Ac

4.31 m2

Ad

Cross sectional area of downcomer

for top

Ad

0.1604195722 m

for bottom

Ad

0.5177341502 m2

An

Net area available

for top

An

1.18 m2

for bottom

An

3.80 m2

Aa

Active or bubbling area

for top

Aa

1.0159906241 m2

for bottom

Aa

3.278982951 m2

Ah

Hole area

normally 10% of Aa

for top

Ah

0.1015990624 m2

for bottom

Ah

0.3278982951 m2

12% of Ac

Ac-Ad (for single pass)

Ac-2Ad

Weir Dimensions:
Recommended values for columns operating above atmospheric pressure for Weir Height
hw
hw

40-50mm
50 mm

Weir length of 0.77 times Dc is recommended or we can use graph for weir length
Ad/Ac

0.12 or

12

From graph the ratio

lw/Dc
for top
for bottom

lw
lw

0.77
1.0045132841 m
1.8045977587 m

or

Number of tray passes:

For one pass design, the liquid flow rate does not exceed 7to 13 gpm/in of outletweir .
for top section
liq flow
weir length lw
Ratio

126.1 gpm
39.547788447 in
3.1885474498 gpm/in of weir

for bottom section

liq flow
weir length lw
Ratio

1014 gpm
71.047194218 in
14.272203303 gpm/in of weir

Both top and bottom liquid flow rate are nearly in the given recommended range.
So we have selected singe pass cross flow with sgmental downcomer.

Other tray specifications:

Assumed tray spacing
Hole diameter
Plate thickness

0.5 m
5 mm
5 mm

for carbon steel

Tray Hydraulics:
Weep Point:

from HYSYS

Maximum liquid rate

Turn down ratio
Min liq rate

107300 kg/hr
29.80556 kg/s
70 %
20.86389

Weir crest
Maximum
Minimum

how
how

At minimum rate
K2
From graph

80.92484 mm of liq
63.799 mm of liq
hw+how

113.799 mm
31

minimum design vapor velocity

Actual minimum vapor velocity

1.9827603442
Minimum Vapor rate/Ah
0.4878629954

Plate pressure drop:

Plate pressure drop is given by
first we calculate dry plate pressure drop

for orifice coefficient Co we use graph

Plate thickness/Hole diameter
Percent perforated area

1
0.1 or

from graph

Co

0.84

maximum vapor velocity through holes

Uh

0.6969471363

now

hd

3.0618158187

Residual head is given by

hr

26.824034335 mm of liq

The total plate drop is given by

ht

ht=hd+hr+(hw+how)

160.81069162 mm of liq

now
P
735.13964434 N/m2
for total pressure drop across all trays

or

Downcomer liquid backup:

here

Am is either the downcomer area or clearance area under the downcomer Aap, whichever is smaller
Taking height of Apron
hap
Area
Aap
Aap
hdc

hap=hw-10
40 mm
hap*lw
0.0721839103 m

less than downcomer area

130.3316481 mm of liq

downcomer liquid backup

hb

422.0672 mm of liq
0.422067 m

Residence time calculation:

tr

3.4164659109 s

3s

Entrainment Check:
percentage flooding = Un (act velocity based on net area)/Uf (flooding velocity based on net area)
Un
Uf
percentage flooding

0.060190889 m/s
0.0708128106 m/s
0.85
85 %

FLV

0.9475831828

from graph
fractional entrainment

0.001 well below 0.1

Total Number of holes:

Number of holes = Ah/ah
here

ah

area of one hole

dh
ah
ah
Number of holes

5 mm
* dh2/4
1.96375E-005 m2/hole
5173.7269209
5174 holes

Height of Distillation Column:

Number of plates
Tray spacing
Distance between 26 plates

26
0.5
tray space*N
13

Top and bottom clearance usually amount to 15% of that required by trays
Top and Bottom Clearance
Tray thickness
total thickness

1.95
5
0.13

Total height of the column

15.08
49.4750672
50

ive volatilities are:

key respctively.
Relative Volatility
61.0601536665
21.1100681079
7.5748598895
3.6996016439
2.1107066903
1.7919301232
1
0.8789555163
0.6886606186
0.6299678342
0.536196893
0.5204004879
0.4853622543
0.430515717
0.4150281923
0.3535482267
0.2242011762
0.2169112038
0.1377809003

reflux ratio
(i * Xid)/(i - )
0.5553620557
0.1450836272
0.1480195156
0.2109193042
0.2641552389
0.4658661216
-0.0305714286
-0.0011775867
-0.0680939189
0
0
0
0
0
0
0
0
0
0
1.689562929

Viscosity
0.00296246
0.020555101
0.0582756837
0.0804438475
0.1007373902
0.1062978504

Xf * Viscosity
0.0002823224
0.0004830449
0.0012179618
0.0030166443
0.0031228591
0.0019027315

0.1072707083 0.0317414026
0.1231593616 0.0122174087
0.1967505846
0.1574151096
0.1604235033
0.1402137612
0.1469910158
0.1528496492
0.2116548985
0.2749104037
0.177310109
0.261682442
0.3183940376
Sum

0.0043481879
0.0091300764
0.0026790725
0.0085109753
0.0054680658
0.0032709825
0.008381534
0.0099517566
0.0138301885
0.0006280379
0.0020058824
0.122189135

and bottom for constant K1

ation taken from HYSYS

N/m

sctional area

m2

m2

ft

ation taken from HYSYS

N/m

sctional area

m2

m2

ft

fferent diameters for the column.

essure for Weir Height

for weir length

%

39.5477884471 in
71.0471942183 in

pm/in of outletweir .

mended range.

m/s
m/s

10

m/s
mm of liq

0.7351396443 KPa
19.1136307527 KPa

ncomer Aap, whichever is smaller

owncomer area

Setisfactory

ing velocity based on net area)

Setisfactory

m
m

m
mm/plate
m
m
ft
ft