CHAPTER # 5

DESIGN OF
EQUIPMENTS
 DESIGN OF EQUIPMENTS:

EXTRACTOR DESIGN:

LIQUID LIQUID EXTRACTION:

The separation of the components of a liquid mixture by treatment with a solvent
in which one or more of the desired components is preferentially soluble is known
as liquid–liquid extraction—an operation which is used, for example, in the
processing of coal tar liquids and in the production of fuels in the nuclear
industry, and which has been applied extensively to the separation of
hydrocarbons in the petroleum industry. In this operation, it is essential that the
liquid-mixture feed and solvent are at least partially if not completely immiscible
and, in essence, three stages are involved:

(a) Bringing the feed mixture and the solvent into intimate contact,
(b) Separation of the resulting two phases, and
(c) Removal and recovery of the solvent from each phase.

Extraction is in many ways complementary to distillation and is preferable in the

following cases:

(a) Where distillation would require excessive amounts of heat, such as, for
example, when the relative volatility is near unity.
(b) When the formation of azeotropes limits the degree of separation obtainable
in distillation.
(c) When heating must be avoided.
(d) When the components to be separated are quite different in nature.
 APPLICATIONS OF EXTRACTION PROCESS:
Important applications of liquid–liquid extraction include the separation of
aromatics from kerosene-based fuel oils to improve their burning qualities and
the separation of aromatics from paraffin and naphthenic compounds to improve
the temperature-viscosity characteristics of lubricating oils. It may also be used to
obtain, for example, relatively pure compounds such as benzene, toluene, and
xylene from catalytically produced reformates in the oil industry, in the
production of anhydrous acetic acid, in the extraction of phenol from coal tar
liquors, and in the metallurgical and biotechnology industries.

EXTRACTION PROCESSES:
The three steps necessary in all liquid–liquid extraction operations may be carried
out either as a batch or as a continuous process.

In the single-stage batch process illustrated in Figure, the solvent and solution
are mixed together and then allowed to separate into the two phases—the
extract E containing the required solute in the added solvent and the raffinate R,
the weaker solution with some associated solvent. With this simple arrangement
mixing and separation occur in the same vessel.
DESIRABLE SOLVENT PROPERTIES:
The following properties of a potential solvent should be
considered before use in a liquid-liquid extraction process.

1- Selectivity:
The relative separation or selectivity of a solvent is the ratio of
two components in the extraction solvent phase divided by the ratio of the
same components in the feed solvent phase. The separation power of a
liquid-liquid system is governed by the deviation from unity, analogous to
relative volatility in distillation.

2- Recoverability:
The extraction solvent must usually be recovered from extract
stream and also from the raffinate stream in an extraction process. Since
distillation is often used, the relative volatility of the extraction solvent to
non solvent components should be significantly greater or less than unity. A
low latent heat of vaporization is desirable for a volatile solvent.

3- Partition Ratio:
Partition ratio actually determines the quantity of solvent
needed. It is the ratio of weight fraction of solute in extract to weight
fraction of solute in raffinate. The partition ratio for a solute should
preferably be large so that a low ratio of extraction solvent to feed can be
used.

4- Solvent Solubility:
A low solubility of extraction solvent in the raffinate generally
leads to a high relative volatility in a raffinate stripper or a low solvent loss
if the raffinate is not desolventized. A low solubility of feed solvent in the
 extract leads to a high relative separation and generally to low solute
recovery costs.

5- Density:
The difference in density between the two liquid phases in
equilibrium affects the counter current flow rates that can be achieved in
extraction equipment as well as coalescence rates.

6- Interfacial Tension:
A high interfacial tension promotes rapid coalescence and
generally requires high mechanical agitation to produce small droplets. A
low interfacial tension allows drop backup with low agitation intensity but
also leads to slow coalescence rates. Interfacial tension usually decreases as
solubility and solute concentration increases and falls to zero at the plait
point.

TYPES OF EXTRACTORS:
There are two major types of extractors which are
used for extraction purposes.
1- Packed column
2- Plate column

COMPARISON BETWEEN PACKED AND PLATE

COLUMN:

1- The packed column provides continuous contact between liquid and liquid
phases while the plate column brings the two phases into contact stage
wise basis.
 2- Scale: For column diameter of less than approximately 3 ft. it is more usual
to employ packed towers because of high fabrication cost of small trays.
But if column is very large then the liquid distribution is problem and large
volume of packing and its weight is problem.
3- Pressure Drop: Pressure drop in packed column is less than the plate
column. In plate column there is additional friction generated as the two
phases on each tray. If there are large numbers of plates in the tower, this
pressure drop may be quit high and the use of packed column effect
considerable saving.
4- Size and Cost: For diameters of less than 3 ft, packed towers requires low
fabrication and material costs than plate tower with regard to height, a
packed column is usually shorter than the equivalent plate column.

From the above consideration packed column is selected as the extractor,

because in our case the diameter of the column is about 3 ft. Moreover it will
provide more contact time between the two phases. Also it is easy to operate.

PRINCIPAL REQUIREMENT OF PACKING:

The principal requirements of a packing are that it should:
Provide a large surface area: a high interfacial area between the liquid and liquid.
Have an open structure: low resistance to gas flow.
Promote uniform liquid distribution on the packing surface.

TYPES OF PACKING:
Many diverse types and shapes of packing have been developed to satisfy these
requirements. They can be divided into two broad classes:
1. Packings with a regular geometry: such as stacked rings, grids and proprietary
structured packings.
2. Random packing’s: rings, saddles and proprietary shapes, which are dumped
into the column and take up a random arrangement.
Grids have an open structure and are used for high gas rates, where low pressure
drop is essential; for example, in cooling towers. Random packings and structured
packing elements are more commonly used in the process industries.

RANDOM PACKING:
Raschig rings are one of the oldest specially manufactured types of
random packing, and are still in general use. Pall rings are essentially Raschig rings
in which openings have been made by folding strips of the surface into the ring.
This increases the free area and improves the liquid distribution characteristics.
Berl saddles were developed to give improved liquid distribution compared to
Raschig rings, Intalox saddles can be considered to be an improved type of Berl
saddle; their shape makes them easier to manufacture than Berl saddles.
Ring and saddle packings are available in a variety of materials: ceramics, metals,
plastics and carbon. Metal and plastics (polypropylene) rings are more efficient
than ceramic rings, as it is possible to make the walls thinner.
Raschig rings are cheaper per unit volume than Pall rings or saddles but are less
efficient, and the total cost of the column will usually be higher if Raschig rings are
specified.

Structured packing:
The term structured packing refers to packing elements made up from wire mesh
or perforated metal sheets. The material is folded and arranged with a regular
geometry, to give a high surface area with a high void fraction.
The cost of structured packings per cubic meter will be significantly higher than
that of random packings, but this is offset by their higher efficiency.

Packing size:
In general, the largest size of packing that is suitable for the size of column should
be used, up to 50 mm. Small sizes are appreciably more expensive than the larger
sizes. Above 50 mm the lower cost per cubic meter does not normally
compensate for the lower mass transfer efficiency. Use of too large a size in a
small column can cause poor liquid distribution.
Recommended size ranges are:
Column diameter
<0.3 m (1 ft)
0.3 to 0.9 m (1 to 3 ft)
>0.9 m
Use packing size
<25 mm (1 in.)
25 to 38 mm (1 to 1.5 in.)
50 to 75 mm (2 to 3 in.)

Packing support:
The function of the support plate is to carry the weight of the wet packing, whilst
allowing free passage of the gas and liquid. These requirements conflict; a poorly
designed support will give a high pressure drop and can cause local flooding.
Simple grid and perforated plate supports are used, but in these designs the liquid
and gas have to vie for the same openings. Wide-spaced grids are used to
increase the flow area; with layers of larger size packing stacked on the grid to
support the small size random packing.
 DESIGN OF EXTRACTION COLUMN:
OBJECTIVE:
To recover Aromatics from the mixture of Aromatics and Non-
Aromatics.

Raffinate

A= 112 kg

P= 3700 kg

S= 1600kg

Feed
Solvent
A= 5500 kg
S= 20,000 kg
P= 4500 kg
A= 226 kg

Extract

A= 5614 kg

P= 800 kg

S= 18400 kg
PROCESS STREAM CONDITIONS:
Qd = 587.53 ft³/hr = 16.65 m³/hr

Qc = 485.94 ft³/hr = 13.774 m³/hr

ρc = 45.37 lb/ ft³ = 726 kg/ m³

ρd = 75.06 lb/ ft³ = 1201 kg/ m³

µd = 6.19 lb/ft.hr = 2.56 cp

µc = 0.884 lb/ft.hr = 0.3656 cp

σ = 18.3 dyne/cm

DESIGN STEPS:
 No. of Stages

 Extractor Diameter

 Extractor Height

 Drop Velocity

 Distributor Hole Size

 Distributor Area
NO. OF STAGES:
Operating Line:
Yn+1 = (F/S)* Xn + (S*Ye-F*XF)/S

XF = 1.22

XR = 0.0302

X’R = 0.024

YS = 0.011

YE = 0.3105

Slope of Operating Line = F/S = 4500/20,000 = 0.225

Operating Solvent to Feed Ratio = 2

Operating Feed to Solvent Ratio = 0.5

mF/mS = K* XF – YS/(XF- XR)

K = 0.66 = m

e = 0.66/0.225 = 2.93

1/e = 0.341

1-1/e = 0.659

ln e = 1.075

Ys/k = 0.01/0.666 = 0.015

N = ln [(XF-YS/K)*(1-1/e)/(XR-YS)+1/e]/lne

N=4
PACKED COLUMN DESIGN:
Packing Size:
The minimum size should be such that the mean void height is not less than the
mean droplet diameter.

dc = 2.42*(σ*gc/∆ρ*g)½

= 0.586m

Packing Size = 1 in = 0.0254m

For 1 in. Pall Rings:

ap = 64ft²/ft³

ap/ε = 64/0.94 = 68.1

(μc/∆ρ)*(σ/ρc)½*(ap/ε)½ = 5.75

From Graph the corresponding value for 5.75 is 1000.

VC*[1+(VD/VC)½]² (ρC/ap*μC) = 1000

VC(flooding velocity) = 115.6ft per hr

Operating Velocity = 0.7*(Flooding Velocity) = 80 ft per hr

Area = 486/80 = 6 ft²

Diameter = 2.76 ft

Putting the provision for internal fittings

Diameter of the Column = 3 ft

Taking HETS = 8 ft

Height of Packing = 32 ft
 Putting the provision for Settling Zone and Re-distributor.

Height of the column = 46 ft

(∆ρ*σ³/μC*g)*(ρC/∆ρ)² = 3.7 exp 10

From the Graph

(σ/∆ρ*g)½ (μo* ρC/μC) = 7 exp 2

UO = 0.179 m/s

DROPLET CHARACTERISTIC VELOCITY:

(∆ρ*g/Pd*UO²)*[0.38dp-0.92(σ/∆ρ*g)½ = 0.95

From the Graph

UOˉ/UO[1- exp(-23.6dc)] = 0.55

UOˉ = 0.0984 m/s

UOˉ = Velocity of a single droplet relative to continuous phase.

Ud (dispersed phase velocity) = 0.008 m/s

Uc (continuous phase velocity)=0.0068m/s

DISPERSED PHASE HOLDUP:

Ud/ j + UC/(1-j) = ε* UOˉ(1-j)

j = 0.11

j = Fractional hold up (Amount of dispersed phase held up in the tower in the

form of droplets at steady state condition).

do(mean) = 0.92(σ/∆ρ*g)*0.50*(ε*UOˉ*j/Ud)

do = 0.0023 m
SPECIFIC AREA “a”:
a = 6 ε*j/do

= 270 m²/m³

For the Distributor, the opening size should be greater than do.

DISTRIBUTOR DESIGN:
Hole Diameter = 0.2. in

Hole Velocity = 0.75 ft/sec = 2700ft/hr

Triangular Pitch = 0.55 in

Total Hole Area = 587.53/2700 = 0.217 ft²

Plate area/Hole area = 2.21(0.55/0.20)² = 16.71

Plate Area = 16.71*0.217 = 3.62 ft²

No. of Holes = 0.217/2.2exp-4 = 1002

 SPECIFICATION SHEET:

Identification:
Item : Packed Extraction Column

Item No : C-1

No. required: 1

FUNCTION: To recover Aromatics from the mixture of Aliphatic and Aromatics

OPERATION: Continuous

Feed Solvent Raffinate Extract

Kg/hr Kg/hr Kg/hr Kg/hr
10000 20226 5412 24814

DESIGN DATA: Inside diameter = 0.92 m

No. of theoretical stages = 4 Flooding velocity = 9.25 m/hr

Height equivalent to theoretical stage INTERNALS:

= 2.4 m
Size and type 25.4mm, Pall
Height of packing section = 9.75 m rings

Total height of packing section = 9.75 Packing arrangement Dumped

m
Type of packing support Perforated
Total height of column = 12.1 m support
DESIGN OF HEAT EXCHANGER
 Design of Heat Exchanger:
A heat exchanger is a heat transfer device that is used for transfer of internal
thermal energy between two or more fluids available at different temperatures.
In most of the exchangers the fluids are separated by a heat surface and ideally
they don’t mix.

Usage:
Heat exchangers are used in process, food, power, petroleum, transportation, air
conditioning, refrigeration, cryogenics, heat recovery, alternate fuels and other
industries.

Classification Heat Exchanger:

In general industrial heat exchangers are classified according to there:

1: Construction

2: Transfer processes

3: Degrees of surface compactness

4: Flow arrangements

5: Pass arrangements

6: Phase of the process fluid

7: Heat transfer mechanism

A short description of classification of heat exchanger is

Classification According to Construction:

According to construction heat exchangers are:

1) Tabular heat exchanger(double pipe, shall and tube, coiled tube)

2) Plate heat exchanger(gas kited,spiral,plate coil, lamella)
 3) Extended surface exchangers(tube fin plate fin)
4) Regenerators (fixed matrix, rotary)

Classification According to Transfer Process:

These classifications are:

 Indirect contact (double pipe, shall and tube, coiled tube)

 Direct contact(cooling towers)
Classification According to Surface Compactness:
A compact heat exchanger incorporates a heat transfer surface having a high area
density, which is the ratio of heat transfer area (A) to its volume (V) it is
somewhat 700 sq meters per meter cube.

They can often achieve higher thermal effectiveness than shall and tube
exchangers. (95% vs. 60-80% for STHE) which makes them particularly useful in
energy intensive industries.

Classification According to Flow Arrangement:

The basic flow arrangements in heat exchanger are

1) Parallel
2) Counter flow
3) Cross flow
The choice of particular flow arrangement is dependent upon the required
exchanger effectiveness, fluid flow paths, packaging envelope, allow able
thermal stress, temperature levels etc.

Classification According to Pass Arrangement:

A fluid is considered to have made one pass if it flows through a section of
heat exchanger through its full length once. There are either single pass multi
pass, in a pass multi arrangement the fluid is reversed and flows through the
 flow length two or more times. The pass multi arrangements are possible with
compact shall and tube and plate exchangers.

Classification According to Phase Fluid:

These classifications are made to the phase of the fluid I-e gas-gas, liquid-
liquid, gas-liquid etc.

Classification According to Heat Hransfer Mechanisms:

The basic heat transfer mechanism employed for heat transfer from one fluid to
another are

 Single phase convection, forces or free

 Two phase convection (condensation or evaporation) by force or free
convection
 Combined convection or radiation.

HEAT EXCHANGER SELECTION CRITERIA:

When selecting a heat exchanger for given duty the following points must
be considered

1) Operating pressure and temperature

2) Flow rates
3) Flow arrangements
4) Material of construction
5) Performance parameters—thermal effectiveness and pressure drops
6) Fouling tendencies
7) Types and phases of fluids
8) Maintenance, inspection, cleaning, extension, and repair possibilities
9) Overall economy
10) Fabrication technique
11) Intended applications
 SHELL AND TUBE HEAT EXCHANER:
The most commonly used heat exchanger is shell and tube type. It is the
“work horse” of industrial process heat transfer. These exchangers are
being used in 90% of the process industries now days.

Advantages of Shell and Tube Exchanger than other

Exchangers:
 It is used for high heat transfer duties.
 It occupies less space.
 Its maintenance is easy.
 It can be fabricated with any type of material depend up fluid properties.

Design of a Shell and Tube Heat Exchanger

Design Steps:
1. Define the duty:heat transfer rate,fluid flow rates,temperatures.
2. Collect together the fluid physical properties
required:density,viscosity,thermal conductivity.
3. Decide on the type of exchanger to be used.
4. Select a trial value for the overall coefficient,U.
5. Calculate the mean temperature difference,T(LMTD).
6. Calculate the heat transfer area required.
7. Design the exchanger layout.
8. Calculate the individual coefficients.
9. Calculate the overall coefficient and compare with the trial value.if the
calculated value differs significantly from the estimated value,substitute
the calculated for the estimated value and return to step 6.
10. Calculate the exchanger pressure drop;if unsatisfactory return to step 7 or
4 or 3,in that order of preference.
11. Optimise the design:repeat steps 4 to 10 as necessary,to determine the
cheapest exchanger that will satisfy the duty.
Design of a Shell and Tube Heat Exchanger:

C6H5 = 0.05 C6H5 = 0.05

C7H8 = 0.06 C7H8 = 0.06

C8H10 = 0.09 C8H10 = 0.09

C9H12 = 0.02 C9H12 = 0.02

C6H14 = 0.02 m = 24588 kg/hr C6H14 = 0.02

C7H16 = 0.01 cold fluid(mixture of C7H16 = 0.01

C4H8O2S = 0.75 heavy aromatics) C4H8O2S = 0.75

t1 = 90°C Heat t2=121°C

T2 = 100°C T1 =145°C
exchanger
C4H8O2S = 1.0 m = 17000 kg/hr C4H8O2S = 1.0

Hot fluid (sulfolane)

Composition of Cold Fluid:

COMPOUND Wt (Kg) Wt (lb) Wt Ratio

BENZENE 1242 2738 0.05

TOLUENE 1590 3505 0.06

XYLENE 2090 4608 0.09

PROPYL 466 1027 0.02

BENZENE

HEXANE 534 1177 0.02

HEPTANE 266 586 0.01

SULFOLANE 18400 40564 0.75

TOTAL 24588 54206 1

Design Calculations:
Hot fluid = Sulfolane

Cold fluid = Mixture of heavy aromatics.

Inlet temperature of cold stream t1 =90 °C

Outlet temperature of cold stream t2 =121 °C

Inlet temperature of hot stream T1 =145 °C

Outlet temperature of hot stream T2 =100 °C

Location of Fluids:
1. Cold fluid (heavy aromatics) : Tube Side
2. Hot fluid (Sulfolane) : Shell Side
Reasons:

1. The flow rate of cold fluid is less than that of hot fluid.
2. Both the fluids are non corrosive.

Exchanger Type:

R = (T1-T2)/(t2-t1)

R = (293-212)/(250-194)

= 1.45

S = (t2-t1)/(T1-t1)

S = (250-194)/(293-194)

= 0.56

F = 0.8

As R and S intersects each other in accordance with fig 17 so 2-4 exchanger is

imperative in this case.

Calculation of LMTD:
 
 
 T2  t1   T1  t2  
ΔTo, log mean   
 ln  T2  t1  
 T t  
  1 2 

= 272.45°K
True LMTD:
LMTD = 272.45 °C

F = 0.8

True LMTD = 272.45 x 0.8

= 272.56 °K

Flow Rates

(Hot Fluid) ( Cold Fluid)

17000 kg/hr 24588 kg/hr

Caloric Temperatures:
∆tc/∆tn = T1-t1/T2-t2
∆tc/∆tn = 0.42
Kc =t2-t1/t1
Kc = 0.29
Now from fig 17 of DQ Kern

Fc = 0.38
Tc = T2+Fc(T1-T2)
Tc = 117 °C
tc = t1+Fc(t2-t1)
tc = 102 °C
Physical Properties Data at 102°C:

Comp Name Specific heat(Btu/lb.°F) Thermal condctivity Density

(Btu/hr.ft.°F) (lb/ft^3)
Benzene 0.462 0.066 47.62

Toluene 0.459 0.064 47.59

Xylene 0.456 0.063 48.78

Propyl benzene 0.48 0.061 47.72

Hexane 0.627 0.051 34.85

Heptane 0.597 0.056 36.76

Sulfolane 0.392 0.104 72.45

Physical Properties at 117°C:

 For sulfolane
 Specific heat(Btu/lb.°F) =0.398
 Thermal condctivity(Btu/hr.ft.°F) = 0.101
 Density(lb/ft^3) = 70.98
 Viscosity(lb/ft.hr) = 4.44
 Specific gravity = 1.22

Heat load Required:

Q = mCp(t2 – t1) = mCp(T1 – T2)

=376741 Watt
Heat Transfer Area:
A = Q/Ud Δt
Ud =199 Watt/ m².K (assumed.)

A = 376741/ (199 x 272)

= 6.96 m²

Heat Exchanger Specifications:

Now, let’s take

Tube length = 4.8ft

Tube O.D. = 1.5 inch

BWG 13, 1.875 inch triangular pitch,

Surface area / linear foot = 0.3925 ft² / lin. ft

No. of tubes = 1469/ 0.3925 ×16 = 233.92 tubes

(From nearest count, table 9)

No. of Tubes = 230

Shell ID dia. = 35 inch

Baffle Spacing = B = 7 inch

Shell Side Calculations:

Flow area = 0.0104 m²

Equivalent Dia.:

For triangular pitch (from fig 28)

De = 0.027 m
 Mass Velocity:

Gs = Ws / As

= 17000 / 0.0104

= 1634615 kg/hr.m²

Reynolds No.

Re.s = De Gs / 

= 9722

jH Factor: (from fig 28)

jH = 41

Prandtl No:

Pr = k(c / k) 1
̂ /3

= 0.26

Outside Heat Transfer Coefficient:


jH (c / k )0.33 ( )0.14

ho 
De

ho = 687 Watt/m². °K

Where

( / w) ̂0.14 = 1.01

Tube Side Calculations:
Flow Area

N t at '
as 
144n
n=4

Nt = 230 tubes

At = 1.47 per in² of tube (from table 10)

As = 0.0539 m²

Mass Velocity:

Gt = Wt / at

= 24588/ 0.0539

= 456178 kg/hr m²

Reynolds No.:

Re = De Gt / 

Re = 7430.68

jH Factor:

(from fig 26)

jH = 29

Prandtl No.:

Pr = k(c / k) 1/3

= 0.25
Inside Heat Transfer Coefficient:

0.14
 c    
1
3

jH k    
 k   w 
hi 
De

hi =367 Watt/m2. °C

Where

( / w) 0
̂ .14 = 1.0

Inside to Outside Heat Transfer Coefficient:

hio = hi × I.D./O.D.

= 367× (1.37/ 1.5)

= 335 Watt/ m² °C

Clean Overall Coefficient:

hio  ho
Uc 
hio  ho
Uc = 225 Watt/ m² °C

Corrected Overall Coefficient:

Q
Ud 
A  Tm
A = Nt a” L

= 230 × 16× 0.3925 = 133 m²

 Corrected Area = 133 m²

Ud = 204 Watt /m² °C

Corrected Overall coefficient =204 Watt /m² °C

Overall Dirt factor:

1 1
Rd  
Ud Uc

Rd = 0.00044 (m²) (°C) / Watt

This is in the allowable range.

Allowable rage is 0.000035-0.000053 (m²) (°C) / Watt

Shell Side Pressure Drop:

Shell-Side Pressure Drop relation

fGs 2 Ds ( N  1)
Ps 
5.22 1010  De  s  s
With:

f = 0.002 ft² / inch²

(from fig 29 of DQ Kern)

Gs = 1634615 kg /hr .m²

Ds = 0.88 m

N+1 = 12L/B = 27.43

s = 1.01
 De =0.09 m

s = 1.122

Now pressure drop can be calculated by above formula:

∆Ps = 45362 pa

This is in the allowable range.

Tube Side Pressure Drop:

Tube Side Pressure Drop relation

fG 2 Ln
Pt 
5.22 1010  D  s  
With:

f = 0.0003 ft² / inch²

(from fig 29)

Gt = 456178 kg /hr .m²

Dt = 0.034m

t = 1

s = 1.22

Now pressure drop can be calculated by above formula:

∆Pt = 54738 pa

Return pressure drop

V2/2g=0.09, ∆Pr= 4n/s *V2/2g = 10272 pa

 Total Pressure drop = 7.94+1.49 = 65010 pa

This is in the allowable range.

Specification Sheet:
Unit Shell & tube heat exchanger

No. of shell passes 2

No. of tube passes 4

Heat Transfer area 135 m²

Diameter of shell 0.54 m

Pitch(Square Pitch) 0.032 m

No. of tubes 230

Type of tube used 13 BWG

No of baffles &type (25%cut baffle)

Tube Length 4.8 m

OD & ID of tube 0.04m, 0.025 m

hi 367 Watt/m2. °C

ho 687 Watt/m². °K

hi,o 335 Watt/ m² °C

ΔP on shell 45362 pa

ΔP on tube side 65010 pa

DESIGN OF STRIPPER:
 DESIGN OF STRIPPER:

Stripping is a unit operation where one or more component of a liquid stream are
removed by being placed in contact with a gas stream that is insoluble in the
liquid stream.

It is the equipment use to strip solute from the liquid phase using gas phase.
It is an operation in which solute is separated from rich solvent on the basis of
difference in volatility in presence of suitable solvent.

Purpose of unit is to strip non-aromatics from rich solvent it contains normal

fractionating trays. Feed entered to the top of column is a combined stream of
rich solvent from the extractor through heat-exchanger plus added lean solvent
from recovery column.

The amount of lean solvent diverted to the stripper feed is determined by stripper
selectivity. High hydrocarbons concentration in stripper feed stream makes the
selective stripping of non-aromatic hydrocarbons more difficult.
Lean solvent is added to dilute this concentration.

The overhead vapors which contain the remaining non-aromatic hydrocarbon

that can not be tolerated in overhead are condensed and removed by water
stripping column, then enters to stripper receiver(V-1). From receiver it is vented
vent tank. The hydrocarbons (paraffin) is pumped from receiver and combined
with raffinate product of water stripping column. This is sent back to plate
forming unit for further processing. The stripper bottoms, which are partially free
of non-aromatic hydrocarbon, are sent to recovery column.
Choice between plate and packed column:

 Plate columns are designed to handle wide range of liquid flow rates
without flooding.
 Dispersion difficulties are easily handled in plate columns.
 For large column heights, weight of packed column is more than plate.
 For non foaming system plate column is preferred.
 When temperature change is involved packaging is damaged.
 Diameter is greater than 0.67m.
 Column is heighted as it comprises 26 stages.

GENERAL DESIGN STEPS:

 Establish separation basis

 Select operating conditions
 Obtain equilibrium data
 Calculate equilibrium stages
 Calculate column diameter
 Calculate column height
 Tray design
 OPERATING CONDITIONS

STREAM FLOERATES TEMPERATURE PRESSURE

kmol/hr °C kPa
FEED 236 121 149
TOP 10 109 136
BOTTOM 226 178 170
CALCULATION OF EQUILIBRIUM STAGES:

Selecting heptanes (C7H16) as key component on basis of relative volatility, first of

all calculate average stripping factor for C7H16.

STRIPPING FACTOR:

Si = Ki × (V/L)
V=entering vapor flow rate
L= entering liquid flow rate
K=vapor/liquid equilibrium ratio
FOR C7H16:
S C7H16 = (9.5×45.05)/236
S =1.82
For a stripping column, the stripping factor should be in the range of
(1.2 - 2.0).

Using Kremser-Edmister method:

SOLUTE FRACTION STRIPPED = (SiN+1-Si)/ (SiN+1 -1)

Where,
S = stripping factor
N = no. of equilibrium stages
Calculating percentage stripped of the key component in each stage.
Key component = C7H16
 % stripped
64.54
83.69 11 99.94
91.78 12 99.96
95.68 13 99.98
97.68 14 99.99
98.74
99.31
99.62
99.79
99.88

So, 14 theoretical stages would be sufficient to achieve 99.99% recovery.

DETERMINATION OF STAGE EFFICIENCY:

USING CORRELATION:
log E = 1.597 - 0.199log [(K*ML*µL)/ (ρL/16.02)]
- 0.0896[log {(K*ML*µL)/ (ρL/16.02)}] ²

Where,
E = stage efficiency,
K = equilibrium ratio
ML = molecular weight of liquid
µL = viscosity of liquid (cP),
ρL = density of liquid (kg/m3)

Putting all values in above equation

log E = 1.597-0.199log(1×114.37×1.085)/(1025/16.02)
-0.0896[log {(1×114.37×1.085)/(1025/16.02)}]
= 1.597 - 0.057 - 0.0073
E = 54.04%
Determination of Actual number of stages:
Nact = N/E
Nact = 26

Where,
N = theoretical no. of stages
Nact = actual no. of plates
E = stage efficiency

Diameter Evaluation:
First of all maximum allowable mass velocity through column is calculated by
Souder-Brown equation:

W = C [ρv (ρL - ρv)] 0.5

W = max. Allowable mass velocity

C = Factor (from graph)
ρv = vapor density
ρL = liquid density
FROM GRAPH
C = 610
CORRECT VALUE
C = 610×0.8
C = 488

NOW,
W = 1945 lb/ (ft².hr)
W = 9492 kg/ (m2.hr)
Now diameter on basis of vapor flow rate (V), is given by
D = [(4/π) (V/W)] 0.5
D = 0.926m
HEIGHT EVALUATION OF STRIPPER:
Height is given by the relation
Hc = (Nact-1) Hs + ΔH
Hc = [(26-1) ×0.508] +1.905
Hc = 14.6m

Tray Design
There are three main types of trays:
1- Bubble cap trays
2- Sieve trays
3- Valve trays

I have selected bubble cap tray because:

BUBBLE CAP TRAYS:

 More flexible for flow rates.
 No weeping problem.
 Entrainment is high but can be controlled by plate spacing.

SIEVE TRAYS:
 Usually not suitable for column under variable loads.
 Efficiency rapidly falls.
 Weeping problem.
 Design:

Tower inside diameter = 0.926m

Tray type = Cross flow
Tray Spacing = 0.508m
No. of down comers/ tray = 1

Caps data:
4 in standard cap size are selected so that all data about cap is fixed.
Cap OD = 0.1016m
Cap ID = 0.0984m

Down flow area (Adf):

It ranges from 10-20% of tower area
Thus for 15%of tower area 0.105m2

Liquid Distribution Area (Ala) End Wastage (Aew)

Ranges 8-20%of tower area Ranges from 7-22%

For 16% = 0.108m² For 15% = 0.105m2
No. of caps/tray (NC) = 27 Pitch = 60°Δ
No. of slots/cap (Ns) = 51 Spacing = 0.032m

Selected from table:

Width of slot (Ws) = 0.003m Height of slot (Hs) = 0.038m

Skirt height (s) = 0.006m Shroud ring height (hsr) = 0.006m
Riser OD = 0.069m Riser ID = 0.067m

Riser height above

the tray = 0.076m
Tray Details:

Length of outlet weir (IW) 0.625m

Height of weir above tray floor (hw) 0.073m
Height of slot above tray floor 0.051m
Height of bottom of down comer 0.069m
Riser slot seal 0.0508m
Pressure drop per tray (Top) 4.25mmHg
Pressure drop per tray (Bottom) 6.23mmHg
 SPECIFICATION SHEET:
Item : Stripper
No. required : 1
Tray Type : Bubble cap

Function : Separation of non-aromatics from rich solvent.

Operation : Continuous

TOP BOTTOM
Operating Temperature (°C ) 109 178
Operating Pressure (kPa) 136 170
Vapor rate (kmol/hr) 10 45
Liquid rate (kmol/hr) 236 270

Design Data:
No. of trays = 26
Diameter of column = 0.926m
Corrosion allowance = 2.0mm
No. of caps/tray = 27
Weir height = 76mm
Weir length = 0.9m
Shell thickness = 12mm
Tray spacing = 0.508m
Height of column = 14.6m
Cap size = 0.1m
DESIGN OF DISTILLATION
COLUMN:
 DESIGN OF DISTILLATION COLUMN:

In industry it is common practice to separate a liquid mixture by distillation

the components, which have lower boiling points when they are in pure condition
from those having higher boiling points. This process is accomplished by partial
vaporization and subsequent condensation.

CHOICE BETWEEN PLATE AND PACKED COLUMN:

Vapour liquid mass transfer operation may be carried either in plate

column. These two types of operations are quite different. A selection scheme
considering the factors in given below.

 Factors that depend on the system i.e. scale foaming, fouling actors,
corrosive systems, heat evolution. Pressure drop, liquid holdup.
 Factors that depend on the fluid flow moment.
 Factors that depends upon the physical characteristics of the column and
its internals i.e. maintenance, weight, side stream, size and cost.
 Factors the depend upon mode of operation i.e. batch distillation,
continuous distillation, turndown, intermittent distillation.

The relative merits of plat over packed column are as follows

i. Plate column are designed to handle wide range of liquid flow rates
without flooding.
ii. If a system contains solid contents, it will be handled in plate column,
because solid will accumulate in the voids, coating the packing materials
and making it ineffective.
iii. Dispersion difficulties are handled in plate column when flow rate of
liquid are low as compared to gases.
iv. For large column heights, weight of the packed column is more than
plate column
v. If periodic cleaning is required man holes will be provided for cleaning.
In packed columns packing must be removed before cleaning.
vi. For non-foaming systems the plate column is preferred.
vii. Design information for plate column are more readily available and
more reliable than that for packed column.
viii. Inter stage cooling can be provided to remove heat of r3eaction or
solution in plate column
ix. When temperature change is involved, packing may be damaged.
x. For this particular process, “Benzene, Toluene, Xylene”,
xi. System is non foaming
xii. Temperature is high (145oC).

CHOICE OF PLATE TYPE:

There are four main tray types, the bubble cap, sieve, tray, valve trays and
the counter flow trays. We have selected sieve tray because.

 They are lighter in weight and less expensive. It is easier and cheaper to
install.
 Pressure drop is low as compared to double cap trays.
 Peak efficiency is generally high.
 Maintenance cost is reduced due to the ease of cleaning.
 DISTILLATION COLUMN DESIGN:

DESIGN STEP OF DISTILLATION COLUMN:

 Calculation of Minimum Reflux Ratio Rm.

 Calculations of Actual reflux ration.
 Calculations of theoretical number of stages.
 Calculations of actual number of stages
 Diameter of the column
 Calculation of weeping point
 Calculation of pressure drop
 Tray Design
 Calculation of thickness of the shell.

Feed Composition & Flow Rates (F):

Component Mass Flow Rate Molar Flow Rate Mol. Fraction

(Kg/hr) (kmol/hr)
Benzene 1171 15.02 0.288
Toluene 1560 16.95 0.325
Xylene 2011.8 18.98 0.364
Propyl Benzene 148.2 1.24 0.023
Total 4891 52.09 1.00

Top product composition and Flow Rate (D):

Component Mass Flow Rate Molar Flow Rate Mol. Fraction

Kg/hr (Kmol/hr)
Benzene 16.38 0.21 0.0056
Toluene 1528 16.61 0.448
Xylene 2011.8 18.98 0.512
Propyl Benzene 148 1.24 0.033
Total 3704 37.04 1.0
Relative volatilities (  ):

Component Feed Top Bottom Relative

Xf Xd Xw Volatility (  )
C3H6 0.288 0.983 0.0056 3.28
C7H8 0.325 0.015 0.448 1.0
C8H10 0.364 0.00132 0.512 0.6
C9H12 0.02 0.0 0.033 0.25

CALCULATION OF RMIN :

Using Underwood equation

 x  B x fB  C X fC
 
A f A
=1–q
 B   B   C 

As feed is at its bubble point so q = 1

By trial  = 1.61

Using equation of min. reflux ratio,

 A x d A  B x dB  C X dC
   R m 1
 A   B   C 

R min = 1.55

Rule of Thumb:

R = (1.5—1.5) Rm
 Take R = 1.3 Rmin

R = 2.1

Calculating Minimum No. of Stages, using Fenske’s equation:


 X   X  
In  A   B 
 X B  d  X A 
Nm    = 12
In ( AB ) av

USING LEWIS & MATHESON METHOD:

Above Feed plate:

Ln = RD = 2.1  15.06 = 31.62 kmol//hr

Vn = Ln + D = 46.68 kmol/hr

Below feed plate:

Lm = Ln + F = 31.62 + 52.09 = 83.71 kmol

Vm = Lm – W = 46.88 – 37.04 = 9.84 kmol/hr

Equation of Top Operating Line

Yn = (Ln/Vn) Xn+1 + (D/Vn) Xd

Evaluating for each component

Ym C6H6 = 0.678 Xm+1 +0.317

Ym C7H8 = 0.678 Xm+1 +0.005

Ym C8H10 = 0.678 Xm+1 + 0.0004

Ym C9H12 = Xm+1 + 0.678 Xm+1

Equation of Bottom Operating Line

Ym = (Lm/Vm)Xm+1- (W/Vm) Xw.

Ym C6H6 = 1.79 (Xn+1) – 0.0043

Ym C7H8 = 1.79 (Xn+1) – 0.0354

Ym C8H10 = 1.79 (Xn+1) – 0.4

Ym C9H12 = 1.79 (Xn+1) – 0.02

By stage to stage calculations

No. of plates = 12

Rebioler acts as one plate, so

Actual no. of trays = 11

Feed plate = 5th from bottom

COLUMN EFFICIENCY:

Average temperature of column = (85+145) = 115oC

Molar Avg. feed viscosity at average temperature =  ave = 0.244 Cp

(relative volalitly of key component)   ave = 3.28  0.224 = 0.65

From O’ Connel Correlation

E = 51 - 32.5 log (   )

= 60 %

So, No. of actual trays = 14/0.6 = 20

COLUMN PRESSURE DROP:

Assume 100 mm. liq pressure drop per plate

Pt =  L *9.81 *ht *10-3 *Na

Where

Pt = total pressure drop (Pa)

ht = Total plate pressure drop (mm liquid)

Pt = Density of liquid at 25oC

Na = actual no. of plates

By putting Values in above eq.

Pt = 2015 Pa

Top pressure = 121.6*103 pa

Estimated bottom pressure = 123605 Pa

= 1.22 atm
LIQUID VAPOUR FLOW FACTORS:

L   0.5
Flv   m   t 
 Vm    t 

Where

Lm = liquid flow rate (kg/sec)

Vm = vapour flow rate (kg/sec)

Tbottom = 145oC

Av. Mol. Wt. = 100.2 kg/k.mol

Lm = 2.3 kg/sec, Vm = 1.29 kg/sec,  v = 3.1 kg/m3,  L = 790 kg/m3

Putting values we get FLV = 0.11

FLOW VELOCITIES:

 L  V
U r  K1
V

Ur = flooding vapour velocity

   0.2
Corrected K1 = K1  
 0.02 

K1 constant from fig

Where  = surface tension

By “Sudgen Parachor” method

 P (   
4

   Ch L V  *10 
12

 M 

Where

Pch = Sudgen sparachors constant and

M = mol.wt

From fig. K1 = 0.085

Pch = 54.2

 = 50 mj/m2 = 5* 10-2 N/m

Therefore K1 = 0.096 and

Uf = 1.855 m/s

Designing at 85% flooding at maximum flow rate

Uv = 0.85*Uf = 1.32 m/s

Maximum volumetric flow rate

Vn = 46.6 kmol/hr = 0.013 Kmol/sec

Vn  M .wt
Max Volumetric flow rate =
V

= 0.52 m3/sec
NET AREA REQUIRED:

max . vol. flow rate

A
Uv

A = 0.42m2

COLUMN CROSS-SECTIONAL AREA:

Taking down comer area as 12% of total

A
Ac   0.48m 2
0.88

COLUMN DIAMETER:

4  Ac
D


D = 0.81 m

LIQUID FLOW PATTERN:

Ln  M .wt
Max. Volumetric flow Rate =
3600   L

Where Ln = liquid flow rate (k mol/hr)

 L = density of liquid (Kg/m3)

Putting values

Ln = 31.6 k mol/hr,  L = 790 Kg/m3), M = 100.2 kg/kmol

So max. volumetric Flow rate = 1.11* 10-3 m3/*sec

From fig. 3.2 it is clear that cross flow single pass plate is used

PROVISIONAL PLATE DESIGNING:

Sieve Plate Is Selected

Column Dia = Dc = 0.81 m

Column Area = Ac = 0.48 m2

Downcomer Area = Ad = 0.12 Ac = 0.057 m2 (12% of Ac)

Net Area = An = Ad = 0.422 m2

Active Area = Aa = Ac – Ad = 0.366m2

Ah = hole area (Total) Aa  0.1 = 0.0366 m2 (10% of Aa)

Form fig

Iw/Dc = 0.76

Where Iw = weir length = 0.6 Im

Take weir height = hw = 50 mm

Hole diameter = dh = 5 mm

Plate thickness = 5 mm

CHECK WEEPING:

Lm  M .wt
Max. liquid flow Rate =
3600
Where

Lm =Liquid flow rate below feed plate (k mol/hr) = 83.7 k mol/hr

M. wt = 100.2

Therefore Max. Liquid flow Rate = 2.32 kg/sec

Max. Liquid flow Rate at 70% turndown = 0.7*3.62 = 1.63 kg/sec

WEIR LIQUID CREST:

 Lw 
how  750  
 Iw  L 

Where

How = weir crest, (mm liquid)

Iw = weir length = 0.65m

Lw = liquid flow rate = 1.63 lg/sec

 L = liquid density = 790 kg/m3

So we get

How = 16.2, (mm liquid)

At minimum rate

Hw + how = 66.2 mm liquid

Weep point
 a) Minimum vapour velocity through holes

U h=
K 2  0.90(25.4  d h ) 
1
(v ) 2

 v = vap. Density = 3.1 kg/m3

Dh = hole dia = 5 mm

K2 = coinst. = 30.3

U h = 7.8 m/s

b) Actual minimum vapour flow velocity

min .vap flow rate

Ua 
Ah

0.7  0.52
  9.8 m / sec
0.0366

Since the total minimum vapour rate is above weep point. So no weeping occurs.

PLATE PRESSURE DROP:

a. Maximum vapour velocity through holes

max . volmetric flow rate

Uh =
Ah

0.52
17.2 m / sec
0.0366

b. Pressure Drop Through Dry plate

 u  
h d  51  h  2 v
co  L

Where,

Co, orifice coefficient

Putting all of these values

Hd = 34.3 mm liq

c. Residual head

12.5  10 3
hr
L

= 15.3 mm liq

d Total Pressure Drop

ht = gd + (hw + how) + hr

where

hd = pressure drop through dry plate, hw = weir height

how = weir liquid crest (max), and hr = residual head

putting values

ht = 121.2 mm liq.

This is close to the assumed value of pressure drop, so is accepted.

 DOWN COMER BACK UP:

a Down comer pressure loss

take

hap = hw – 10

where hw = weir height = 50 mm

there fore hap -= 40mm

b Area Under Apron

Aap = hap Iw

Where

Hap = height of bottom edge of apron above plate, Iw = weir length

So Aap = 0.026m2

b Head loss in down comer

2
 L 
hdc 166  wd 
  L Am 

Where

Hdc = head loss in down comer (mm)

Lwd = Liquid flow rate in down comer = 2.32 kg/s

So
Hdc = 2.4 mm

c Backup in downcomer

h bc – hdc + (hw + how max ) + ht

putting values of

hw = 50mm, hdc = 2.4 mm, how max = 19.7 mm and ht = 121.2 mm

we get

h bc = 193.3 mm = 1.193m

0.179 < ½ (plate spacing + weir height)

0.193 > 0.275

So our late spacing 0.5 in is acceptable

DOWNCOMER RESIDENCE TIME:

A h  
tr   d bc L 
 L wd 

Where

Tr = down comer residence time sec

Hbc = dead liquid backup m

Lwd = liquid flow rate in Down comer

Putting values
 Tr = 4.25 sec

> 3 (satisfactory)

CHECK ENTRAINMENT:

Un
% flooding =
Ur

Where

Un = actual velocity based upon net area

Uf = flooding Velocity

Max. volumetric flowrate

Un 
net area required ( An )

Put values

Max. volumetric Flow rate = 0.58 m3/sec

An = 0.422m2 and Un = 1.37 m/s

Since Uf = 1.855 m/s

Therefore % flooding 74%

From Fig. at Fiv = 0.016 fractional entrainment i.e. = 0.084

Which is well below 0.1 ()maximum value of fractional entrainment)

NUMBER OF HOLES:

Dia of hole (D) = 50 mm = 0.05 m

Area of Single whole (A1) =  /4D2= 1.96* 10-5 m2

Total no. of Holes = Ah/A1 = 1867

HEIGHT OF DISTILLATION COLUMN:

No. of Plates = 20

Tray Spacing = 0.5 m

Distance between 20 plates = 20* 0.5 = 10 m

Take

Top Clearance = 0.5 m

Bottom Clearance = 0.5 m

Plate Thickness = 5mm / plate = 5*10-3 m/plate

Total thickness of plates = 5* 10-3*20 = 0.1 m

Total column height = 10 + 0.5 + 0.5 + 0.1 = 11.1 m

 MECHANICAL DESIGN:

Shell material = carbon steel

Sieve plate material = stainless steel 316

Operating pressure = 1.2 atm

Taking design pressure 40% more than operating pressure then

Design pressure = 1.68 atm

= 0.168 MPa

Shell diameter = 0.81 m

Shell Height = 11.1 m

 P 
Shell thickness = ts=    Di  C
2 f jP

Where

P = design pressure = 0.168 MPa

J = joint efficiency = 0.85

C = corrosion allowance for carbon steel = 2mm = 2*10-3 m/yr

Dt = internal diameter

Ts = 0.046m = 46 mm
 SPECIFICATION SHEET
Identification

Item Distillation column

No. required 1

Tray type Sieve tray

Function: Separation of Benzene from aromatics

Operation: Continuous

MATERIAL HANDLED

Feed Top Bottom

Quantity 125.5 Kgmol/hr 86.2 kmol/hr 39.47 kmol/hr

Temperature 110oC 85oC 145oC

Design Data

No. of trays = 20 Hole area/active area = 0.10

Pressure = 1.2 atm Weir length = 0.61 m

Height of column = 11.1 m Weir height = 50 mm

Diameter of column = 0.81m Reflux ration = 2.1

Hole size = 5 mm Tray spacing = 0.5 m

Tray thickness = 5 mm No. of holes = 1867