Distillation Column Tray Selection & Sizing

Tray Parameters
a) No. of passes (Np):

The numbers of flowpaths of liquid on tray are 1, 2, 3 or 4 as per liquid capacity requirement of
column. From a capacity viewpoint, a liquid rate greater than 6 gpm / inch of weir (weir
loading), is the rate at which a higher number of flow paths should be considered. The maximum
allowable weir loading is 13 gpm/in of weir length. If the weir loading exceeds this the tray
needs redesign with higher number of passes.

b) Tray Spacing (S):

Tray spacing is the distance between two trays. Generally tray spacing ranges from 8 to 36
inches (200 mm to 900 mm). Prime factor in setting tray spacing is the economic trade-off
between column height and column diameter. Most columns have 600 mm tray spacing.
Cryogenic columns have tray spacing of 200-300 mm.

c) Outlet Weirs (hw):

An outlet weir maintains a desired liquid level on the tray. As the liquid leaves the contacting
area of the tray, it flows over the tray weir to enter into the downcomer.

d) Downcomer Clearance (hcl):

This is the vertical distance between the tray floor and the bottom edge of the downcomer apron.
The Normalpractice is to use a downcomer clearance of 1/2 inch less than the overflow weir
height to provide a static liquid seal

e) Inlet Weirs & Recessed Seal Pans:

Inlet weirs and recessed seal pans are primarily used for achieving a downcomer seal in cases
where a potential positive sealing problem exists and clearance under downcomer is limited

f) Downcomers:

Passage of liquid from the top tray to the bottom of tray occurs via downcomers. Downcomers
are conduits having circular, segmental, or rectangular cross sections that convey liquid from
upper tray to a lower tray in a distillation column.

g) Downcomer width (Chord height, WDC):

It is maximum horizontal distance between tower wall and weir.

h) Flow path length (FPL):

Flow path length is the distance between the inlet downcomer & outlet downcomer. The
minimum limit for flow path length is 400 mm in order to provide good contacting between
vapour and liquid. This is also necessary for the mechanical reason of providing tray manway.

i) Tray deck thickness (t):

Trays normally used in commercial service need a minimum material thickness to provide
structural strength (personnel walk on them during installation) and corrosion allowance. A
thickness of 10 to 12 gauge (2.5 to 3.5 mm) is customary for carbon steel, while 12 to 14 gauge
(1.9 to 2.5 mm) is used for stainless steel trays (in general no C.A. for SS)

j) Hole pitch (P):

Centre to centre distance between holes is called pitch. Normal practice is to use a hole pitch to
hole diameter ratio between 2.2 to 3.8.

k) System (Derating) factors:

Derating factors are often closely related to the foaming tendency of the system. Higher the
foaming tendency, the lower is the Derating factor. System factors are used in three of the rating
correlations (jet flood, down comer backup flood, down comer choke) to account for system
effects on hydraulic capacity limits. It includes both foaming effects and high vapour density.

l) Bubbling (Active) Area (AB):

Bubbling area is the column area, which is actually available for vapour bubbling through liquid.
It can be defined as column area minus downcomer areas, downcomer seal & large calming
zones.

m) % Hole Area:

This is the ratio of hole area to bubbling area. The default practice is to target a hole area of 8 to
10 % of bubbling area for pressure services. The acceptable range for percentage hole area is 5 %
to 15 %. However for some critical services, we can go % hole area up to 17-17.5% provided
that weeping is under control. Hole areas below 5 % are not used.

n) Anti jump baffles:

Anti jump baffles plates suspended vertically above centre or off centre downcomers, which
stops liquid jumping from one deck onto the opposite deck, flow path

Tray Hydraulic Parameters

Following are the some important output parameters of tray hydraulics.

a) Flood:

Jet Flood:

In spray regime operation flooding is brought about by excessive vapour flow, causing excessive
liquid to be entrained in the vapour up the column. In froth and emulsion flows regimes
operation excessive froth entrainment in the vapour up the column causes jet flooding.

Down-comer Back-up Flood:

Occurs when the pressure available for a given height of liquid and froth in the downcomer
cannot overcome the total pressure drop across the tray This pressure imbalance causes the froth
in the downcomer to start backing-up until it reaches the tray above, causing an increased
accumulation of liquid on it. It requires high liquid and vapour loads.

Downcomer Choke Flood:

The mechanism by which this type of flooding occurs is one related to frictional pressure losses
in the downcomer becoming excessive. In addition, the vapour carried into the downcomer must
separate from the liquid and then flow counter-current to the liquid entering the downcomer.
When the combination of vapour exiting and the liquid entering becomes excessive, the
downcomer entrance is choked causing the liquid to backup on the tray. It requires relatively
high liquid rates, surpassing a velocity limitation on the downcomer.

b) Weeping/Dumping

The pressure exerted by the vapour is insufficient to hold up the liquid on the tray. Therefore,
liquid starts to leak through perforations.

c) Pressure Drop:

Pressure drop is an important consideration while designing a tray. It becomes more critical for
the vacuum systems than the high-pressure systems. The tray pressure drop is viewed as the sum
of the pressure drop through the valves or sieves and pressure drop through the aerated liquid on
the tray deck.

d) Turndown ratio:

Turndown ratio defines the range of vapour load between which the column can operate without
substantially affecting its’ primary separation objective (i.e. fractionation efficiency) or over
which acceptable tray performance is achieved. The tray efficiency stays at or above the design
value throughout the turndown range.

Tray Sizing
 The sizing procedure is an iterative calculation. A preliminary design is set, and then refined by
checking against the performance correlations until an adequate design is achieved. The sizing
calculations are performed at the point where column loading is expected to be highest and
lowest for each section, i.e.,

i) The top tray

ii) Above every feed, product drawoff, or point of heat addition or removal.

iii) Below every feed, product drawoff, or point of heat addition or removal.

iv) The bottom tray.

v) At any point in the column where the calculated vapour or liquid loading peaks

The sizing is done at all above load points and also detailed sizing is checked at all above load
points. All design parameters given in the design procedure below are calculated at all above
load points at turndown and turn-up loads so that the feasibility of design for varied loads is
tested.

a) Preliminary determination of tower area:

The methods used for determining tower diameter are:

• “C” Factor Method

• Nomograph Method

• FRI Tray design handbook

However in this technical guideline we are describing method using C-Factor Method.

C-Factor Method:

The following calculations are done at all the loading points mentioned above and diameters are
found separately. If the difference in calculated diameter at different sections exceeds 20 percent,
different diameters for the sections are likely to be economical. The section having different
diameter should be at least 20ft in length else same diameter can be maintained.

i. Tray Area

Assume appropriate values for following parameters (based on system requirements) for
preliminary diameter calculation.

dH = Hole diameter, inches (¼ to ½ inch) S = Tray spacing, inches (18 – 24″)

hct = Clear Liquid height at the transition from the froth to spray regime, in of liquid.

Assumption: The starting values for these can be dH=1/4″, S=24″, h ct=2″

Calculate C-Factor (CSB) using following Kister and Haas Correlation:

ii. Flood Velocity Calculation

This is the velocity of upward vapour at which liquid droplets are suspended. Calculate Flood
Velocity (uN) using following equation:

iii. Net Area Calculation

The net area represents smallest area available for vapour flow in the inter-tray spacing.
Calculate Net Area (AN) from the flood velocity using following equation: Assume the column
is to be designed for 80% of flood.

iv. Downcomer Area Calculation Calculate downcomer area (AD) from clear liquid velocity in
downcomer using following formula:

Where,
QL = Liquid Flow Rate, ft3/s

VCL = Clear Liquid Velocity in Downcomer

Value of VCL obtained from table below. No derating factor is required for this calculation, as
VCL values have taken care of foaming

Table: Recommended VCL values for different foaming tendencies

Foaming VCL in downcomer, ft/s

Tendency Example 18-in 24-in 30-in
Spacing Spacing Spacing
Low pressure (<100-psia) light
Low hydrocarbon, 0.4-0.5 0.5-0.6 0.5-0.6
stabilizers, air-water simulators
Oil systems, crude oil distillation,
Medium absorbers, 0.3-0.4 0.4-0.5 0.4-0.5
med. pressure (100-300 psia)
hydrocarbon
Amine, glycerine, glycols, high-
High pressure 0.2-0.25 0.2- 0.2-0.3
(>300-psi) light hydrocarbons 0.25

v. Tower Diameter Calculation

TotalTowerArea (AT) = AD + AN

b) Preliminary tray layout:

A Preliminary layout is needed as layout influences the column size.

Downcomer Layout:

Check the % of Downcomer area with respect to tower area:

The Fractional area should around 10% but avoid less than 8% in normal circumstances. Note
that AD should in no circumstance be less that 5% of AT

Net Area (AN):

The total tower cross-section area AT less the area at the top of the downcomer (sometime refer
to as free area, the term free area.)

The net area represents the smallest area available for vapour flow in the inter-tray spacing.

AN = AT – AD

Bubbling (Active) area (AB):

The total cross-section area AT less the area at the inlet & outlet downcomer is called as
bubbling area.

AB = AT – ADT – ADB

Below figure shows the Typical Tray Layout.

Weir Length and Downcomer Width: SinglePass Tray:

The calculation of Weir Length and Downcomer Width involves geometrical relationship
between downcomer area, downcomer width, and downcomer length.

Following Figure shows downcomer geometry:

Calculate downcomer width and weir length using following method

? = sin-1(h/R)
w = 2*R COS (?) or w = 2*(R2 – h2)0.5
?/2 = ?/2 – ?
Sector area = ASECT = ? R2 * ? / (2 * ?)
Area of triangle (ABC) = ATRI. = w*h/2
Where,
Lw = Weir Length = w* (1-fractional weir blockage)
wdc = Downcomer Width = R -h
AD = Adc = Downcomer Area
Fractional weir blockage is the fraction of total weir length that is available for liquid flow by
using picket and fence type of weir. Blocked (Picket fence) weirs are used for handling low
liquid loading.

Down-comer area

AD = ASECT– ATRI
Two Pass Tray:

Two pass trays have alternating arrangements of one center-downcomer and two side-
downcomers.

The side downcomer area can be calculated as that for single pass tray. It should be noted that
side down-comers are on both sides.

Center downcomer calculations can be done as follows in similar manner as side down-comer:
? = sin-1 (h/R)
w = 2*R COS (?1) or w = 2*(R2 – h2)0.5
? = 2*(?/2- ?)
Sector area = ASECT = ? R2 * ? / (2 * ?)
Area of center downcomer = Area of circle -2*area of sector + 2*Area of Triangle Area of
downcomer = ?*R2 – 2* ASECT + h1*w1
In case of more than two pass trays we have to define one more parameter, i.e. off-center
downcomer location from centerline. This needs to be done on a case-by-case basis.

Liquid Flow Path Length (FPL):

For Single Pass Tray:

FPL= (tray diameter) minus (side DC width of the tray) minus (bottom width of DC of tray
above)
Where,
Downcomer width (Centre downcomer, Bottom of
w1dc =Downcomer)
Downcomer width (Side downcomer, Top of
w2dc =Downcomer)
Downcomer width (Centre downcomer, Top of
w3dc =Downcomer)
Downcomer width (Side downcomer, Bottom of
w4dc =Downcomer)

C) Detailed Design

Flooding Check:

The flooding check is performed using following Correlations:

1. Kister and Haas correlation.

2. Downcomer choke-Koch correlation
3. Fair’s correlation
4. Smith et al. correlation

1. Jet Flood: Kister and Haas correlation

This correlation possess following advantage:

– It gives a close approximation to the effects of physical properties, operating variable, and
tray geometry on the flood point.
– It describes spray regime entrainment.
– It was derived from a much wider database of commercial and pilot-scale column data.
– It can predict sieve and valve tray entrainment flooding within ± 15 and ± 20 percent
respectively.

This correlation possess following restriction:

Sr.no. Factors Applicability
1 Flooding Mechanism Entrainment (Jet) flood only
2 Tray Type Sieve or Valve trays only
3 Pressure 1.5-500 psia
4 Gas Velocity 1.5-13 ft/s
5 Liquid Load 0.5-12 gpm/in of outlet weir
6 Gas Density 0.03-10 lb/ft3
7 Liquid Density 20-75 lb/ft3
8 Surface Tension 5-80 dyne/cm
9 Liquid Viscosity 0.05-2.0 cP
10 Tray Spacing 14-36 in
11 Hole Diameter 1/8-1 in
12 Fractional Hole Area 0.06-0.20
13 Weir Height 0-3 in

Steps to calculate % Flooding using Kister and Haas correlation:

i. Calculate Weir Load (QL):

Liquid Load describes the flux of liquid across the tray.

ii. Clear Liquid height at the transition from the froth to spray ((hct)
2. Jet Flood: Fair’s correlation

The Fair correlation has been standard of the industry for entrainment flood prediction. Fair’s
correlation tends to be conservative, especially at high pressure and liquid rate.

This correlation possess following restriction:

Sr.No Factors Applicability

 1Flooding Mechanism Entrainment (Jet) flood only
2Tray Type Sieve Tray, Valve and Bubble-cap Tray
3Hole size Hole£ ½ in (sieve tray)
4Weir height < 15% Tray Spacing

Steps to calculate % Flood using Fair’s correlation:

3. Down-comer choke-Koch correlation:

This is the more conservative correlation for checking Down-comer Design. Steps to calculate %
Load Utilization using Kister and Haas correlation:

4. Hydraulic checks
Hydraulic check involves checking following parameters:
– Flow Regime
– Entrainment
– Downcomer residence time
– Pressure Drop
– Downcomer backup

ii.Determination of Flow Regime

Froth Regime

This is the most commonly encountered flow regime in operating columns. The froth formed
under this regime is described as one where the size and shape of bubbles is non-uniform and
with rather large size distribution, as well as travelling at varying velocities. The liquid surface is
either wavy or it presents oscillations. This is a liquid continuous flow regime.

Spray Regime

This regimes occurs at relatively high vapour velocities (i.e. large vapour flow rates) and low
liquid loads, characteristics which are typical of vacuum systems. The vapour velocity is so
large, that the liquid phase is completely disrupted and is no longer a continuous phase on top of
the tray; liquid is a dispersed phase present only in the form of drops, and therefore the
continuous phase is the vapour.

Emulsion Regime

This flow regime is typically encountered in high-pressure systems and relatively high liquid
loads. The shearing action of the high velocity liquid “tears off” the vapour bubbles leaving the
orifices on the tray. Most of the gas is emulsified in small bubbles within the liquid, with the
mixture behaving as a uniform two-phase fluid, obeying the Francis weir formula. This is a
liquid continuous flow regime.

The determination of regime on tray given below is only for information and has no use in
sizing.

ii. Froth-Emulsion Transition Check

This correlation is applicable for Sieve trays only.

The value of actual flow parameter is calculated as below:

If the value of actual flow parameter exceeds 0.0208 then the regime of operation is emulsion.
iii. Froth-Spray Transition Check:
Porter and Jenkins correlation for the froth to spray transition.

Where,
Lw – weir length in inches, AB – Active area ft2
p – pitch in inches
hc – clear liquid height, inches

5. Entrainment:
If entrainment is excessive, column diameter or tray spacing are usually increased. As
recommended value, the entrainment from the tray should not exceed about 0.10 lb liquid
entrained per pound of liquid flow.

 Methods to determine Entrainment:

Fair’s entrainment correlation

This method holds good for froth and emulsion regime. However it is less accurate for spray
regime. For a trays operating at a high liquid to vapour ratio, 0.1 lb of liquid entrained per pound
of liquid is an excessive quantity of entrained liquid.

 Kister and Haas Correlation

This method is used for Spray Regime; Es is entrainment lb of liquid / lb of vapour

Distillation Tray Downcomer Calculations

 Downcomer Residence Time:

Sufficient residence time must be provided in the downcomer to allow adequate disengagement
of vapour from the descending liquid, so that the liquid is relatively vapour free by the time it
enters the ray below. Inadequate removal of vapour from the liquid may choke the downcomer.

 Steps to calculation of Residence Time in Downcomer:

o Calculation of Average Downcomer Area: It is average of inlet area (ADT) and outlet area
(ADB) of downcomer.

Average Area = ( ) / 2 DT DB A + A

 Calculation of Downcomer Volume

Downcomer Volume = AverageArea * S /12 , where S: Tray spacing, inches

 Calculation of Residence Time:

Residence Time (tR), in sec. = 448.83 * DC Volume/ GPM;

Compare the calculated residence time with recommended, if it is greater than the downcomer
volume is sufficient for disengagement of vapour for the descending liquid, otherwise change the
configuration.

 Pressure Drop Calculation

Steps to determine Pressure Drop:

i. Calculate Discharge Coefficient

Discharge coefficient (CV) is obtained from plot of Ah/Aa Vs discharge coefficient at various
ratio of t/dH

Where,

tt = tray thickness, in consistent units

dH = hole diameter, in consistent units
Ah = hole area, in consistent units
Aa = Active area, in consistent units
  Calculation of Dry Pressure Drop:

The calculation of dry pressure drop (hd) across the disperser unit is given by a variation of the
orifice equation:

h Hydraulic gradient = 0 for sieve tray (Detail calculation Refer Kister Section 6.3.3)
? = (aeration factor) is calculated from the graph below or equation given below.
hW = Weir height, in
hOW = Crest over the weir, in
QL = Liquid flow per unit weir length(GPM/in)

iv. Total Pressure drop (ht)

 Downcomer Backup:

Downcomer backup flooding occur when the backup of aerated liquid in the downcomer exceeds
the tray spacing

i. The factor causing Downcomer backup (hdc) are:

– Froth Height on the Tray

– Pressure Drop on the Tray
– Frictional Loss
Mathematically expressed as:
hdc = hc + ht + hda
Where,
iii. Calculate % Backup in the Downcomer

% Backup should be less than 80%. If it is high the changes in the design as stated above can
be made.