Faculty M Elamaran PNM-CG Prepared by Production-CG Team CONTENTS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Introduction
Basics of distillation
History of distillation
Types of distillation
Videos
Fractionating equipments INTRODUCTION TO REFINERY PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Hydrocarbon molecules in crude do NOT meet customer needs SEPARATION PROCESSES (Primary Processes) CONVERSION PROCESSES (Secondary Processes) FINISHING PROCESSES (Secondary Processes)
Segregate the molecules Rearrange the molecules Remove Contaminants MARKETABLE PRODUCTS UNIT OPERATIONS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 1.Fluid flow processes, including fluids transportation, filtration, and solids fluidization.
2. Heat transfer processes, including evaporation, condensation, and heat exchange.
3. Mass transfer processes, including gas absorption, distillation, extraction, adsorption, and drying.
4.Thermodynamic processes, including gas liquefaction, and refrigeration.
5.Mechanical processes, including solids transportation, crushing and pulverization, and screening and sieving. UNIT OPERATIONS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 1. Combination.
2. Separation Distillation comes under this.
3. Reaction. BASICS OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future EVAPORATION ORDINARY EVAPORATION IS A SURFACE PHENOMENON - SOME MOLECULES HAVE ENOUGH KINETIC ENERGY TO ESCAPE FROM THE LIQUID. THE PROCESS OF EVAPORATION IN A CLOSED CONTAINER WILL PROCEED UNTIL THERE ARE AS MANY MOLECULES RETURNING TO THE LIQUID AS THERE ARE ESCAPING. AT THIS POINT THE VAPOUR IS SAID TO BE SATURATED AND THE PRESSURE OF THAT VAPOUR (EXPRESSED IN mmHg) IS CALLED SATURATED VAPOUR PRESSURE. IF THE LIQUID IS OPEN TO THE AIR, THEN THE VAPOUR PRESSURE IS SEEN AS PARTIAL PRESSURE ALONG WITH OTHER CONSTITUENTS OF THE AIR. BASICS OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future THE TEMPERATURE AT WHICH VAPOUR PRESSURE IS EQUAL TO THE ATMOSPHERIC PRESSURE IS CALLED THE BOILING POINT. SINCE THE VAPOUR PRESSURE IS LOW IN ORDINARY EVAPORATION AND THE PRESSURE INSIDE THE LIQUID IS EQUAL TO ATMOSPHERIC PRESSURE PLUS THE LIQUID PRESSURE, BUBBLES OF VAPOUR CAN NOT FORM INSIDE THE BULK LIQUID. AT BOILING POINT, VAPOUR PRESSURE IS EQUAL TO ATMOSPHERIC PRESSURE, BUBBLES FORM AND VAPORIZATION BECOMES A VOLUME PHENOMENA. SINCE THE MOLECULAR KINETIC ENERGY IS GREATER AT HIGHER TEMPERATURE, MORE MOLECULES CAN ESCAPE THE SURFACE AND THE SATURATED VAPOUR PRESSURE IS CORRESPONDINGLY HIGHER.
BASICS OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future VAPOUR PRESSURE OF A LIQUID AT A PARTICULAR TEMPERATURE IS THE EQUILIBRIUM PRESSURE EXERTED BY MOLECULES LEAVING AND ENTERING THE LIQUID SURFACE.
SOME IMPORTANT POINTS REGARDING VAPOUR PRESSURE:
ENERGY INPUT RAISES VAPOUR PRESSURE VAPOUR PRESSURE IS RELATED TO BOILING A LIQUID IS SAID TO BOIL WHEN ITS VAPOUR PRESSURE EQUALS THE SURROUNDING PRESSURE THE EASE WITH WHICH A LIQUID BOILS DEPENDS ON ITS VOLATILITY LIQUIDS WITH HIGH VAPOUR PRESSURES (VOLATILE LIQUIDS) WILL BOIL AT LOWER TEMPERATURES THE VAPOUR PRESSURE AND HENCE THE BOILING POINT OF A LIQUID MIXTURE DEPENDS ON THE RELATIVE AMOUNTS OF THE COMPONENTS IN THE MIXTURE DISTILLATION OCCURS BECAUSE OF THE DIFFERENCES IN THE VOLATILITY OF THE COMPONENTS IN THE LIQUID MIXTURE BASICS OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future
THE BOILING POINT DIAGRAM SHOWS HOW THE EQUILIBRIUM COMPOSITIONS OF THE COMPONENTS IN A LIQUID MIXTURE VARY WITH TEMPERATURE AT A FIXED PRESSURE. CONSIDER AN EXAMPLE OF A LIQUID MIXTURE CONTAINING 2 COMPONENTS (A AND B) - A BINARY MIXTURE. IN THIS EXAMPLE, A IS THE MORE VOLATILE COMPONENT AND THEREFORE HAS A LOWER BOILING POINT THAN B. THE DEW-POINT IS THE TEMPERATURE AT WHICH THE SATURATED VAPOUR STARTS TO CONDENSE. THE BUBBLE-POINT IS THE TEMPERATURE AT WHICH THE LIQUID STARTS TO BOIL. BASICS OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future FOR EXAMPLE, WHEN A SUBCOOLED LIQUID WITH MOLE FRACTION OF A=0.4 (POINT A) IS HEATED, ITS CONCENTRATION REMAINS CONSTANT UNTIL IT REACHES THE BUBBLE- POINT (POINT B), WHEN IT STARTS TO BOIL. THE VAPOURS EVOLVED DURING THE BOILING HAS THE EQUILIBRIUM COMPOSITION GIVEN BY POINT C, APPROXIMATELY 0.8 MOLE FRACTION A. THIS IS APPROXIMATELY 50% RICHER IN A THAN THE ORIGINAL LIQUID. THIS DIFFERENCE BETWEEN LIQUID AND VAPOUR COMPOSITIONS IN EQUILIBRIUM IS THE BASIS FOR DISTILLATION OPERATIONS. BASICS OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future DISTILLATION IS ACHIEVED BY THE APPLICATION AND REMOVAL OF HEAT. THE SEPARATION OF COMPONENTS FROM A MIXTURE BY DISTILLATION DEPENDS ON THE DIFFERENCE IN BOILING POINTS OF THE INDIVIDUAL COMPONENTS, CALLED RELATIVE VOLATILITY. WHEN A MIXTURE OF TWO OR MORE LIQUIDS IS HEATED AND BOILED, THE VAPOR HAS A DIFFERENT COMPOSITION THAN THE LIQUID. FOR EXAMPLE, IF 10% MIXTURE OF ETHANOL IN WATER IS BOILED, THE VAPOR WILL CONTAIN OVER 50% ETHANOL. DISTILLATION IS BASED ON THE FACT THAT THE VAPOUR OF A BOILING MIXTURE WILL BE RICHER IN THE COMPONENTS THAT HAVE LOWER BOILING POINTS. THE CONDENSATE WILL CONTAIN MORE VOLATILE COMPONENTS. AT THE SAME TIME, THE ORIGINAL MIXTURE WILL CONTAIN MORE OF THE LESS VOLATILE MATERIAL. BASICS OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future THE VAPOR CAN BE CONDENSED AND BOILED AGAIN, WHICH WILL RESULT IN AN EVEN HIGHER CONCENTRATION OF ETHANOL. DISTILLATION OPERATES ON THIS PRINCIPLE. REPEATED BOILING AND CONDENSING IS A CLUMSY PROCESS, HOWEVER, THIS CAN BE DONE AS A CONTINUOUS PROCESS IN A DISTILLATION COLUMN. IN THE COLUMN, RISING VAPORS WILL STRIP OUT THE MORE VOLATILE COMPONENT, WHICH WILL BE GRADUALLY CONCENTRATED AS THE VAPOR CLIMBS UP THE COLUMN DISTILLATION CONSUMES ENORMOUS AMOUNTS OF ENERGY . BOTH IN TERMS OF COOLING AND HEATING REQUIREMENTS IT CAN CONTRIBUTE TO MORE THAN 50% OF PLANT OPERATING COSTS.
HISTORY OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future USE OF DISTILLATION DATES BACK IN RECORDED HISTORY TO ABOUT 50 B.C.
INDUSTRIAL EXPLOITATION OF THIS SEPARATION PROCESS STARTED IN 12TH CENTURY WHEN IT WAS USED TO PRODUCE ALCOHOLIC BEVERAGES.
BY THE 16TH CENTURY, DISTILLATION WAS BEING USED IN THE MANUFACTURE OF VINEGAR, PERFUMES, OILS AND OTHER PRODUCTS.
EARLY DISTILLATION WAS BASICALLY BATCH STILLS TO PRODUCE ETHANOL.
NEXT WAS A SERIES OF STILLS WITH A CONTINUOUS FEED THAT FLOWED THROUGH THE SERIES. HISTORY OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future HISTORY OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future HISTORY OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future THE NEXT PROGRESSION WAS TO PLACE THE STILLS IN A COLUMN AND INTERCHANGE THE VAPOUR AND LIQUID TO IMPROVE RECOVERY.
EARLY SMALL TOWERS HAD ONE OR TWO LARGE BUBBLE CAPS PER TRAY.
THE LIQUID AND VAPOUR TRAVELLED THROUGH THE CENTRE OF COLUMN AND MIXED ON THE OUTER RING OF BUBBLE CAP.
LATER WHEN THE TRAY EFICIENCY BECAME MORE IMPORTANT, FLOW ON THE TRAY BEGAN TO BE STUDIED AND SEVERAL TYPES OF TRAYS AND CHANGED FLOW PATTERNS WERE DEVELOPED.
TRAY COLUMNS APPEARED IN THE SCENE IN THE 1820s ALONG WITH FEED PREHEATING AND USE OF INTERNAL REFLUX. HISTORY OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future TYPES OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Based on system composition:
Binary distillation Multi component distillation
Based on Operation Mode:
Batch distillation Continuous distillation TYPES OF DISTILLATION PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Based on Extra feed:
Extractive distillation: Extra feed component leaves with the bottom product. Azeotropic distillation: Extra feed component leaves with the top product.
Based on Separation:
Stripping Removes lighter from heavier component Rectification Removes heavier from lighter component Fractionation Separates lighter and heavier. Complex fractionation separates into 3 or more components. VIDEOS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future
A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT Faculty M Elamaran PNM-CG Prepared by Production-CG Team COMPONENTS OF FRACTIONATION EQUIPMENT PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Distillation columns are made up of several components, each of which is used either to transfer heat energy or enhance material transfer. A typical distillation contains several major components:
A vertical shell where the separation of liquid components is carried out.
Column internals such as trays/plates and/or packings which are used to enhance component separations.
A reboiler to provide the necessary vaporization for the distillation process .
A condenser to cool and condense the vapour leaving the top of the column
A reflux drum to hold the condensed vapour from the top of the column so that liquid (reflux) can be recycled back to the column COMPONENTS OF FRACTIONATION EQUIPMENT PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future COMPONENTS OF FRACTIONATION EQUIPMENT PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future
The liquid mixture that is to be processed is known as the feed and this is introduced usually somewhere near the middle of the column to a tray known as the feed tray. The feed tray divides the column into a top (enriching or rectification) section and a bottom (stripping) section. The feed flows down the column where it is collected at the bottom in the reboiler.
COMPONENTS OF FRACTIONATION EQUIPMENT PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future The condenser, reboiler and the column internal are termed as Stages, where ideally vapour and liquid equilibrium is established, if given enough residence time.
A vessel filled with a mixture of two components is said to be in equilibrium if the number of light molecules escaping from the liquid is equal to the number returning to the liquid. REBOILER PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Heat is supplied to the reboiler to generate vapour. The source of heat input can be any suitable fluid, although in most chemical plants this is normally steam. In refineries, the heating source may be the output streams of other columns. The vapour raised in the reboiler is re-introduced into the unit at the bottom of the column. The liquid removed from the reboiler is known as the bottoms product or simply, bottoms.
REBOILER TYPES PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Types of Reboiler:
1. Vertical Thermo-Syphon Reboiler.
2. Horizontal Thermo-Syphon Reboiler
3. Kettle Reboiler.
4. Furnace
CONDENSER PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future The vapour moves up the column, and as it exits the top of the unit, it is cooled by a condenser. The condensed liquid is stored in a holding vessel known as the reflux drum. Some of this liquid is recycled back to the top of the column and this is called the reflux. The condensed liquid that is removed from the system is known as the distillate or top product. CONDENSER TYPES PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future A. Partial Condenser The partial condenser is best used when there is a large difference in the overhead vapour composition. For e.g. when there is a small amount of methane and hydrogen mixed in a gasoline stream, the partial condenser condenses the gasoline and leaves the methane and hydrogen as a vapour to be vented from the overhead reflux drum. B. Total Condenser The total condenser is best used when there is small difference in the overhead vapour composition. The overhead vapour can be condensed at approximately same temperature. CONDENSER TYPES PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future C. Hot vapour bypass condenser The hot vapour bypass condenser is best utilized when there is a potential for large changes in the overhead vapour composition. The vapour bypass can be used to maintain the pressure in the tower system when the light components are lower than design.
COLUMN INTERNALS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future TRAYS PACKINGS TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Trays
A tray essentially acts as a mini-column, each accomplishing a fraction of the separation task.
The more trays there are, the better is the degree of separation .
Overall separation efficiency will depend significantly on the design of the tray.
Trays are designed to maximize vapour-liquid contact by considering the liquid distribution and vapour distribution.
TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Vapour and liquid mixes to form a froth.
Mass transfer occurs within the froth.
The froth overflows across a weir.
The vapour disengages and move to the tray above.
The bulk liquid flows down the down comer to next tray.
The steps are repeated in the next tray.
LIQUID AND VAPOR FLOW IN TRAY COLUMN PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Each tray has 2 conduits called down comers: one on each side. Liquid falls by gravity through the down comers from one tray to the tray below. A weir ensures there is always some liquid (holdup) on the tray and is designed such that the holdup is at a suitable height, e.g. such that the bubble caps are covered by liquid. Vapour flows up the column and is forced to pass through the liquid via the openings on each tray. The area allowed for the passage of vapour on each tray is called the active tray area. LIQUID FLOW PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Single pass Double Pass TRAY TYPES PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future 1. BAFFLE TRAYS
2. SIEVE TRAYS
3. VALVE TRAYS
4. BUBBLE CAP TRAYS
5. HIGH EFFICIENCY TRAYS TRAY TYPES- BAFFLE TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Baffle Tray
Baffle trays are trays of low fouling potential with low efficiency. They have open areas approaching 50 % where a high efficiency tray will have open area less than 15 %.
Three major types of baffle trays are
A. Shed decks B. Side to side trays C. Disc and Donut trays TRAY TYPES- SIEVE TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Flat perforated plate
Vapor issues from holes to give multi-orifice effect
Simple in structure easy to fabricate
Turn down ratio is around 2:1
Pressure drop is moderate
Not suitable for operation under variable loads
TRAY TYPES- VALVE TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Valve can be round or rectangular with or without caging structure
Vary high capacity tray
Turndown ratio5:1
pressure drop Moderate (earlier designs somewhat higher recent design same as sieve tray)
Around 20%higher cost then sieve tray
TRAY TYPES- VALVE TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future CAGED VALVE FIXED VALVE FLOATING VALVE TRAY TYPES- BUBBLE CAP TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Perforated plate with riser around the hole
Cap in the form of inverted cups over the riser
excellent turn down ratio
Good at extreme low liquid rates
Pressure drop is high TRAY TYPES- BUBBLE CAP TRAYS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future PACKED COLUMNS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Random and structured Packed columns generate a mass transfer area by providing a large surface area over which the liquid can transfer heat and mass to the vapour.
Packing utilizes a continuous contacting principle to separate products. A major advantage to packed column is the reduction in pressure across the column.
Typically the column pressure drop for a packed column is less than that of a trayed column because of % open area.
Typical percent open area of a trayed column is 8 to 15 %, whereas a packed column can approach 50 %. Liquid accumulation for a packed column is lower than a trayed column.
Another advantage of packed column is reduced foaming. Packing generates thin films instead of fine droplets for mass and heat transfer, reducing entrainment when foaming agents are present.
The introduction of vapour and liquid to the packing is very important. Trays will normally equalize whatever mal-distribution is developed by vapour and liquid feeds. PACKED COLUMNS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future TRAY VS PACKED COLUMNS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Sl. No Description Trays Random Packing Structured Packing 1 Pressure Drop High Low Lower 2 Fouling Service Yes No No 3 Feed Point Flexibility Yes Difficult Difficult 4 Liquid Hold up Considerable Small Small 5 Cleaning Easy Difficult difficult 6 Cost Low Low/Medium High COLUMN PROBLEMS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Foaming
Foaming refers to the expansion of liquid due to passage of vapour or gas. Although it provides high interfacial liquid-vapour contact, excessive foaming often leads to liquid buildup on trays. In some cases, foaming may be so bad that the foam mixes with liquid on the tray above. Whether foaming will occur depends primarily on physical properties of the liquid mixtures, but is sometimes due to tray designs and condition. Whatever the cause, separation efficiency is always reduced.
COLUMN PROBLEMS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Entrainment
Entrainment refers to the liquid carried by vapour up to the tray above and is again caused by high vapour flow rates. It is detrimental because tray efficiency is reduced: lower volatile material is carried to a plate holding liquid of higher volatility. It could also contaminate high purity distillate. Excessive entrainment can lead to flooding. COLUMN PROBLEMS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Weeping/Dumping
This phenomenon is caused by low vapour flow. The pressure exerted by the vapour is insufficient to hold up the liquid on the tray. Therefore, liquid starts to leak through perforations. Excessive weeping will lead to dumping. That is the liquid on all trays will crash (dump) through to the base of the column (via a domino effect) and the column will have to be re-started. Weeping is indicated by a sharp pressure drop in the column and reduced separation efficiency. COLUMN PROBLEMS PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future Flooding
Flooding is brought about by excessive vapour flow, causing liquid to be entrained in the vapour up the column. The increased pressure from excessive vapour also backs up the liquid in the down comer, causing an increase in liquid holdup on the plate above. Depending on the degree of flooding, the maximum capacity of the column may be severely reduced. Flooding is detected by sharp increases in column differential pressure and significant decrease in separation efficiency. QUERIES PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future PARADEEP REFINERY PROJECT A Sunrise Project for a Sunshine Future