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Extraction column with its main interface at the top: The heavy phase is
continuous; the light phase is dispersed
Extraction column with the main interface at the bottom: The light phase
is continuous, and the heavy is dispersed
Countercurrent contacting
Axial mixing and plug flow In all the cases described above, axial
mixing (mixing in the direction of overall flow) is detrimental to mass-
transfer efficiency. This is because mixing in the direction of flow actually
reduces the concentration gradients available for mass transfer,
consequently reducing the volumetric efficiency of the device.
Various forms of axial mixing or axial dispersion can occur. The most
common is phase maldistribution, where one or both phases in a column
show an uneven velocity profile in portions of the column. This is the type
of maldistribution often associated with trickling liquid in packed columns.
Also, the lack of true plug flow in liquid-extraction columns leads to lower
efficiencies through conventional axial dispersion, which mixes the
continuous phase in the direction of flow.
Preserves the plug-flow nature of the contacting (i.e., limits axial mixing)
Can be installed easily and properly in a column and has the required
mechanical strength
Column internals
The internals used in industrial columns can be roughly classified into two
categories: trays and packings.
Trays promote contact between vapor and liquid through bubbling and
jetting. In this article, we will consider ``conventional trays'' to be those
with traditional downcomers. The bubbling devices of conventional trays
are bubble caps or valves, or the holes of a sieve tray.
The selection of the most effective mass transfer internals for a distillation
application depends on the conditions of the distillation. A recent paper
<25> describes a procedure to select the most appropriate device based on
the value of the flow parameter, Fp.
where L = liquid mass velocity, G = gas mass velocity, rhog = gas density
and rhol = liquid density
The Figure on p. 80 shows that packings are the device of choice at low
flow parameters in terms of maximum available capacity, whereas trays
yield more capacity at high flow parameters.
Temperature-sensitive products
Preferable over trays because they offer lower pressure drop and reduced
entrainment tendencies, packings provide better volumetric efficiency than
trays in vacuum distillation and produce smaller, less-expensive new
towers for the same capacity or offer much better capacity in existing tower
shells. The cost-performance ratio for structured packings is low, and
payout times for retrofits are generally short.
Packing size selection per pressure drop criteria (as opposed to only
considering capacity criteria)
Styrene-ethylbenzene separation
Glycerin separation
In general, the lower the pressure, the more attractive packings will be in
terms of capacity, when fouling is not a consideration. Here, the volumetric
efficiency of packings and trays is equivalent. Packings do offer the
advantage of lower pressure drop, which can be important when
temperature is of concern (e.g., because of product degradation or heat-
medium limitations). Packings are better to address foaming systems, but
offer less corrosion resistance than trays when metal construction is used.
At the same time, however, there are some important exceptions to the
advantages of trays in these applications. In the case of cryogenic
separation of air (into oxygen and nitrogen), the pressure drop across the
distillation column is crucial in terms of its effect on the temperature
profile.
De-butanizers in cat-crackers
Propane-propylene splitters
Ethane-ethylene superfractionators
Absorption
In absorption, one or more components are moved from a gas mixture into
a liquid solvent. Unlike distillation, absorption applications involve gas and
liquid phases that are not undergoing bulk condensation or boiling. Herein
lies the most important difference between distillation and absorption:
Volumetric rates of mass transfer are low in the noncondensing systems.
Good absorption solvents exhibit high solubility and selectivity for the
desired component. In many cases, solubility and selectivity are enhanced
via a chemical reaction in the liquid that allows the solution uptake to be
larger and faster. This is the principle of chemically enhanced absorption.
Physical absorption is also commonly used. In some instances, as in the
case of ammonia absorption into water, the lines between reactive and
physical absorption are blurred.
Stripping
In stripping, a volatile component is removed from a liquid. The lower
portions of distillation columns are generally called ``stripping sections''
for this reason. Unlike absorption, many stripping applications involve
boiling liquids and condensing vapors in contact with each other. In this
fashion, stripping is really a subset of distillation. Exceptions to this are
common inert-gas strippers used to remove volatile organics from water.
(i.e., air strippers). In these, as in absorption, both phases are removed
from saturation.
Some strippers must also deal with reactive systems, e.g., in the case of
ammonia and H2S removal from ``sour'' waters in olefin plants. The removal
efficiency of these strippers is affected significantly by the pH of the water.
Most strippers operate at high liquid-to-gas-flow ratios, which put them into
the high-flow-parameter region. The hydraulics are dominated by the liquid
flow, and internal traffic in the column is dictated by the heat balance.
Use a packed tower to prevent bubbling and jetting. Packed towers are
markedly superior when dealing with foaming systems
Use proper feed inlet devices. Many foaming problems start with
flashing or degassing feeds. New technology in inlet devices, such as
Portatest inlet cyclones, deal very effectively with this problem by
suppressing foam formation at the feed location
Extraction
The most important difference is that the two phases have relatively small
density differences; so extraction is performed at much lower relative
phase velocities than in distillation. In addition, the definition of
``continuous'' and ``dispersed'' phases depends only on the position of the
main interface: In distillation, the main interface is always in the column
sump; whereas, in extraction, it can be found above the internals (light
phase dispersed) or below the internals (heavy phase dispersed). This
subject is discussed extensively in the literature <27, 28>.
The box (above) summarizes the features of packings and trays for
extraction applications. Methods for estimating capacity and efficiency are
listed on p. 78.
Packings have seen less development in the last ten years. Of significance
is the appearance of the Sulzer Optiflow packing, a new structured packing
for low liquid rates. It appears to offer the high efficiencies associated with
wire gauze structured packings, but at lower cost. Most developments in
the packing field are taking place in distributor (gas and liquid) technology
that allows the user to fully realize the inherent advantages of structured
packings.
References
4. Bonilla, J. G., ``Don't neglect liquid distributors,'' Chem. Eng. Prog., Mar.
1993, pp. 47-61
10. Fair, J. R. and Bravo, J. L. , Chem. Eng. Prog., Vol. 86, No. 1;1990
14. Bravo, J. L., Rocha, J. A., and Fair, J. R., Hydrocarbon Processing,
March 1996
15. Bravo, J. L., Rocha, J. A., and Fair, J. R., ``Distillation and Absorption
`92,'' Inst. of Chem. Eng., Symposium Series, No. 128, 1992
16. Seibert, A. F. and Fair, J. R., ``Mass-transfer efficiency,'' Ind. & Eng.
Chem., Oct. 1993, p. 2213
17. Seibert, A. F., et al., ``Performance of a large-scale,'' Ind. & Eng. Chem.,
Sept. 1990, p. 1901
18. Chan, H and Fair, J. R. Ind. & Eng. Chem., Proc. Des. Dev. 23, 1983, p.
814
19. Bravo, J. L. and Fair, J. R., Ind. & Eng. Chem., Proc. Des. Dev. 21, 1982,
p. 162
20. Bolles, W. L. and Fair, J. R., ``Improved mass-transfer model,'' CE, July
1982, p. 109
22. Bravo, J. L., Rocha, J. A., and Fair, J. R., Hydrocarbon Processing,
January 1995
23. Rocha, J. A., Bravo, J. L., and Fair, J. R., ``Distillation columns,'' Indus.
Eng. Chem. Res., 1996, pp. 1660-1667
24. Bravo, J. L., and Fair, J. R., ``Mass transfer efficiency modeling of
packed absorbers and strippers,'' presented at the 1990 Spring AIChE
National Meeting, Orlando, Fla., March 1990
25. Bravo, J. L., Chem. Eng. Prog., Vol. 93, No. 7, 1997
26. Zuiderweg, F., Olujic, Z., Kunesh, J. G., ``Distillation and Absorption `97''
Inst. of Chem. Eng., Symposium Series No. 142, 1997
27. Cusack, R. W., ``Solve wastewater problems,'' Chem. Eng. Prog., 1996,
p. 56
28. Humphrey, J. L., Rocha, J. A. and Fair, J.R., ``The essentials of
extraction,'' CE, September 17, 1984, p. 76
29. Seibert, A. F., Moosberg, D. F., Bravo, J. L. and Johnston, K. P., ``Spray,
Sieve-tray,'' Proceedings of the International Symposum on Supercritical
Fluids, Soc. Franaise de Chimie (1988)
Biography