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Inlet
Stream FEED
Components kg/hr. kmol/hr. wt.%
Ethanol 295.29 6.42 11
Water 958.74 53.25 89
TOTAL 1254.03 59.67 100
Outlet
Stream DISTILLATE BOTTOMS
Component kg/hr. kmol/hr. wt% kg/hr. kmol/hr. wt%
Ethanol 292.38 6.36 84 2.76 0.06 0.1
Water 21.81 1.20 16 936.90 52.05 99.9
TOTAL 314.19 7.56 100 939.66 52.11 100
For the ethanol-water system, the Antoine constants are shown in the table below.
1 𝑥 𝛼𝐴𝐵 (1−𝑥𝐷 )
𝑅𝑚𝑖𝑛 = [𝛼 ]( 𝑥𝐷 − )
𝐴𝐵 −1 𝐹 1−𝑥𝐹
Where,
Rmin : minimum reflux ratio
αAB : relative volatility
xD : mole fraction of ethanol in distillate
xF : mole fraction of ethanol in feed
1 0.84 6.3(1−0.84)
𝑅𝑚𝑖𝑛 = [6.3−1](0.11 − )
1−0.11
= 1.23
R = 1.2Rmin
= 1.2×1.23
= 1.48
Where,
αAB : relative volatility
xAB : mole fraction of ethanol in distillate
xBD : mole fraction of water in distillate
xBW : mole fraction of water in bottoms
xAW : mole fraction of ethanol in bottoms
0.84 0.99
𝑙𝑜𝑔[( )( )]
0.16 0.01
(𝑛 + 1)𝑚 = 𝑙𝑜𝑔6.3
= 3.40
The Gilliland correlation can now be used to calculate the number of theoretical stages.
From the graph it can be determined that the curve is intersected at 0.51
(𝑛+1)−(𝑛𝑚 =1)
From the y-axis: 𝑛+2
(𝑛+1)−(3.40)
So, = 0.51
𝑛+2
Therefore,
n = 6.98 ≈ 7 stages
6.1.4 Internal traffic
DISTILATE
D
L
FEED
F
G’
W
BOTTOMS
L’
𝑛𝑅𝑇
𝑉= 𝑃
𝑀 𝑛𝑅𝑇
=
𝜌 𝑃
𝜌𝑣𝑤 = 0.61𝑘𝑔/𝑚3
𝜌𝑣𝑇 = 1.45𝑘𝑔/𝑚3
Vapour density in bottom section
Following the same procedure, vapour density in bottoms:
𝜌𝑣𝐵 = 0.71𝑘𝑔/𝑚3
Where,
FLV : Liquid-vapour flow factor
L : Liquid mass flow rate
V : Vapour mass flow rate
ρV : Vapour density
ρL : Liquid density
FLV will be calculated for both the enriching and the stripping section.
Enriching section (FLVTOP)
465 1.45 0.5
𝐹𝐿𝑉𝑇𝑂𝑃 = (779.19) × (822.76)
𝐹𝐿𝑉𝑇𝑂𝑃 =0.025
From the calculated FLV the corresponding CSB=K1TOP, value can be obtained
𝐹𝐿𝑉𝐵𝑂𝑇𝑇𝑂𝑀 = 0.059
Also assuming a tray spacing of 225mm,
𝐾1𝐵𝑂𝑇𝑇𝑂𝑀 = 0.053
Where,
UF : Flooding vapour velocity
K1 : Constant
ρL : Liquid density
ρV : Vapour density
Where,
Umax: Maximum volumetric flow rate
V : Molar vapour flowrate
ρ : Vapour density
Mr : Relative molecular mass
𝑈𝑚𝑎𝑥,𝑡𝑜𝑝 = 0.15 𝑚3 /𝑠
𝑈𝑚𝑎𝑥,𝑏𝑜𝑡𝑡𝑜𝑚 = 0.13 𝑚3 /𝑠
Where,
d : diameter
A : area
So,
4×0.14 0.5
𝑑𝑡𝑜𝑝 = ( )
𝜋
So,
4×0.08 0.5
𝑑𝑏𝑜𝑡𝑡𝑜𝑚 = ( )
𝜋
𝑑𝑏𝑜𝑡𝑡𝑜𝑚 = 0.32 𝑚
Therefore the largest figure is taken as the column diameter, which is 0.42m.
𝐴𝑐 = 0.14 𝑚2
Net area: 𝐴𝑛 = 𝐴𝑐 − 𝐴𝑑
𝐴𝑛 = 0.14 − 0.017
𝐴𝑛 = 0.123 𝑚2
The hole area (Ah) is taken as 10% of the active area (Aa).
𝐴ℎ = 0.1 × 0.106
𝐴ℎ = 0.0106 𝑚2
The weir length (lw) is calculated using the figure below which shows the relationship between
downcomer area and weir length.
Figure 4: Pitch (Sinnot R K, 2005b)
𝐴𝑑
From the y-axis: × 100
𝐴𝑐
0.017
× 100 = 12%
0.14
𝐿𝑤
The corresponding value can be obtained from the figure above. The value is determined to
𝐷𝑐
be 0.76
Weir length: 𝐿𝑤 = 0.76 × 0.42
𝐿𝑤 = 0.32 𝑚
Where,
Uh : minimum vapour velocity
dh : hole diameter
K2 : Constant
Weeping check
In order to determine K2 the depth of liquid over the weir (how) must be calculated first. The
Francis weir formula is utilised.
𝑙 2⁄3
ℎ𝑜𝑤 = 750 [𝜌 𝑤𝐿 ]
𝑙 𝑤
Where,
how : weir crest
Lw : weir length
lw : liquid flow rate
ρl : liquid density
0.48 2⁄3
ℎ𝑜𝑤,𝑚𝑎𝑥 = 750 [976.79×0.32]
0.34 2⁄3
ℎ𝑜𝑤,𝑚𝑖𝑛 = 750 [976.79×0.32]
Then,
30−0.90(25.4−5)]
[𝑈ℎ ]𝑚𝑖𝑛 = [1.45]0.5
= 10.53 𝑚/𝑠
The minimum operating rate is well above the weeping point.
Plate pressure drop
Total pressure drop is the sum of the dry plate pressure drop (hd), the head of the clear liquid
the plate (hw + how) and residual losses.
Where,
Uh : maximum vapour velocity through the holes
Co : orifice coefficient
To determine Co:
𝑃𝑙𝑎𝑡𝑒 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 5
= =1
𝐻𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 5
ℎ𝑑 = 21.48 𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑
12.5 × 103
ℎ𝑟 = = 12.80 𝑚𝑚 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑
976.79
Total drop, ht
ℎ𝑡 = ℎ𝑑 + (ℎ𝑤 + ℎ𝑜𝑤 ) + ℎ𝑟
ℎ𝑡 = 21.48 + (40 + 7.93) + 12.80
ℎ𝑡 = 82.21 𝑚𝑚 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑
The head loss in the downcomer may be estimated using the equation below.
𝐿 2
ℎ𝑑𝑐 = 166 [𝜌 𝑤𝑑 ]
𝐴 𝐿 𝑚
Where,
Lwd : liquid flow rate in downcomer
Am : the smallest value between downcomer area (Ad) and clearance area under
downcomer (Asp).
𝐴𝑠𝑝 = ℎ𝑠𝑝 𝐿𝑤
Assuming a value of 35mm for hsp, this implies that
𝐴𝑠𝑝 = 0.035 × 0.32 = 0.011 𝑚2
It can be seen that 𝐴𝑠𝑝 < 𝐴𝑑 therefore 𝐴𝑚 = 𝐴𝑠𝑝 = 0.011
So,
0.48 2
ℎ𝑑𝑐 = 166 [976.79×0.011]
ℎ𝑑𝑐 = 0.33 𝑚𝑚
The downcomer backup come now be calculated.
Downcomer backup height should be less than 0.5 times the plate spacing and weir height.
1
ℎ𝑏 < [0.225 + 0.04] = 0.133 𝑚
2
6.1.18 Entrainment
The correlation developed by Fair is used to estimate entrainment. Assumed percentage
flooding is 80% and FLV = 0.059. The corresponding fractional entrainment (ψ) is obtained
from the figure below.
The corresponding fractional entrainment (ψ) is found to be 0.041 which is well below 0.1 for
safe operation.
Figure 7: Entrainment (Sinnot R K, 2005e)
Perforated area
𝐿𝑤 0.32
From x-axis = = = 0.76
𝐷𝑐 0.42
Assuming an equilateral triangular pattern, the total hole area as fraction of the perforated area
is expressed in the following equation.
2
𝐴ℎ 𝑑
= 0.9 [ 𝑙 ℎ ]
𝐴𝑝 𝑝
𝐴ℎ 0.0038
= 0.0264 = 0.14
𝐴𝑝
𝑙𝑝
From the graph below 𝑑 can be determined
ℎ
Figure 9: Hole area and pitch (Sinnot R K, 2005g)
𝑙𝑝
= 2.6, this is acceptable as it is greater than 2.0
𝑑ℎ
= 193 ℎ𝑜𝑙𝑒𝑠
Van Winkle correlation is used to calculate plate efficiency. The equation is as follows:
𝐸𝑚𝑣 = 0.07𝐷𝑔0.14 𝑆𝑐 0.25 𝑅𝑒 0.08
Where,
𝜎𝐿
Dg : surface tension = 𝜇𝐿 ×𝑢𝑉
0.067
= 0.00034×1
= 197.06
𝜇𝐿
Sc : liquid Schmidt number = 𝜌𝐿 ×𝐷𝐿𝐾
0.00034
= 976.79×128×10−7
= 0.027
ℎ𝑤 ×𝑢𝑣 ×𝜌𝑣
Re : Reynolds number = × 𝐹𝐴
𝜇𝐿
40×10−3 ×1.45×1
= 0.00034×0.076
= 2244.58
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒
uv : superficial vapour velocity = 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛
0.05
= = 1 𝑚/𝑠
0.05
Therefore,
𝐸𝑚𝑣 = 0.07 × (127.06)0.14 (0.027)0.25 (2244.58)0.08
= 0.78
Actual number of plates required, taking into consideration the calculated efficiency:
6
= 0.78
= 7.7
≈ 8 𝑝𝑙𝑎𝑡𝑒𝑠
6.1.23 Height of column
Design assumptions
Diameter of column is 0.42m
Material of construction is stainless steel
Column is operating at atmospheric pressure
Column is designed 10% above normal operating pressure
Shell will be insulated with 70 mm of mineral wool
Corrosion allowance is 2 mm
Dynamic wind pressure is 1280 N/m2
Where,
e : cylindrical column minimum shell thickness
Pi : design pressure = 0.1114575 N/mm2
Di : column diameter
f : design stress = 150 N/mm2
0.1114575×0.42×103
So, 𝑒 = 2(150)−0.1114575
= 0.156 𝑚𝑚
The skirt support will be made of a cylindrical shell that is welded to the base of the distillation
column. A flange at the bottom of the skirt will transmit the load to the foundations.
Bending stresses
The following equation is used to determine the bending stresses in the skirt support.
4×𝑀𝑠
𝜎𝑏𝑠 = 𝜋×(𝐷𝑠 +𝑡𝑠 )𝑡𝑠 𝐷𝑠
Where,
𝜎𝑏𝑠 : bending stress in the skirt
Ms : maximum bending moment elevated at the bottom
Ds : column diameter including thickness and insulation
ts : shell thickness
= 1945.71 𝑁𝑚
Now,
4×1945.71 ×103
𝜎𝑏𝑠 = 𝜋×(0.56+2.2×10−3 )2.2×10−3 ×0.56
= 3.58 𝑁/𝑚𝑚2
6.2.3 Dead weight stress
𝑊
Dead weight stresses 𝜎𝑤𝑠 = 𝜋(𝐷 +𝑡
𝑠 𝑠 )𝑡𝑠
Where,
W : total weight of the vessel and contents
2.2
𝐷𝑚 = 0.42 + (1000)
= 0.422
Therefore,
(𝑤1) = 240 × 1.15 × 0.422 × (2.33 + 0.8 × 0.422) × 2.2
= 683.54 𝑁
= 0.684 𝑘𝑁
= 0.33 𝑚2
Weight of one plate = 1.2 × 0.33
= 0.40 𝑘𝑁
Since there are 8 plates, total weight of plates:
= 8 × 0.40
(𝑤2 ) = 3.20 𝑘𝑁
Weight of insulation (𝑤3 )
Insulation volume = 𝜋 × 𝐷𝑐 × 𝐻𝑣 × 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠
= 𝜋 × 0.42 × 2.33 × 0.070
= 0.22 𝑚2
The value of weight of insulation has to be doubled to allow for fittings, therefore weight of
insulation is 561.14 N
This implies that total weight of the column:
𝑤1 + 𝑤2 + 𝑤3 = 0.68 + 3.20 + 0.28
= 4.16 𝑘𝑁
Dead weight stresses can now be calculated
4160
𝜎𝑤𝑠 = 𝜋(422+2.2)2.2