Distillation Modeling

CHEN 4470 Process Design Practice

Dr. Mario Richard Eden Department of Chemical Engineering Auburn University
Lecture No. 13 Design of Overhead Condensers and Air-cooled HX February 16, 2012 Material Developed by Dr. Jeffrey R. Seay, University of Kentucky - Paducah

Overview
Purpose of Overhead Condensers
Provide reflux flow to the top of a column and acts as an additional theoretical stage above the trays/packing

Types of Condensers
Knock-back reflux Total condenser Partial condenser

Proper condenser design is critical to the optimum operation of a column!

Knock-Back Condenser
This design is easy to operate, but difficult to achieve precise control. Condenser will be larger due to the bi-directional traffic on the process side.
2-Phase Flow Region

Condenser can be in the vertical or horizontal position.

- Horizontal Process on the shell side. - Vertical Process is on the tube side. Elevation is critical.

Partial Condenser
Vapor Distillate

Used when vapor product is required, or if non-condensible gases are present in the overhead product. Controlling the vapor stream split can be challenging. Condenser can be in the vertical or horizontal position. - Horizontal Process on the shell side. - Vertical Process is on the tube side.
Liquid Distillate

Elevation is not critical.

Total Condenser
Total condensers are used when no non-condensable gases are present. As with other condensers, vertical or horizontal operation is possible. Elevation is not critical for a total condenser. Subcooling of the reflux can be a problem with overhead condensers, especially with vertical designs.

Liquid Distillate

Condenser Design
Considerations
The overhead condenser is often a critical part of the control concept of a column Because distillation is based on VLE principles, the overhead condenser can be used to control the temperature and pressure in the column A later lecture will present some control concepts and strategies for overhead condensers Condensers in series can also be used to optimize utility consumption

Condensers in ASPEN Plus

Air-Cooled Heat Exchangers

Typical Air-Cooled Condenser
Process Out

Process In

V FD

V FD

Tube Detail

Design Equations:

Cp (TAir ,out TAir ,in ) Q U A Tlm m

U
1 k C Re m Pr 3 OD

Air-cooled HX are primarily used when no other cooling utilities are available on site

Note:

The surface area, A, includes the area of the fins! C and m are parameters based on the size of the fin.

Air-Cooled HX Design
Design Considerations
Natural convection in turndown cases Changing ambient air conditions Effect of precipitation on operation of unit Possibility of water-hammer inside tubes

Possible Control Parameters

Air flow across the tube bank Position of louvers on top of the unit Liquid level inside the tubes

Other Business
Next Lecture February 21
Equipment sizing and pinch analysis