Distillation Modeling

CHEN 4470 – Process Design Practice

Dr. Mario Richard Eden

Department of Chemical Engineering
Auburn University

Lecture No. 14 – Design of Overhead Condensers and Air-cooled HX

February 26, 2013

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 • Condenser can be in the

Flow Region
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 • Elevation is not critical.

Distillate
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 In Process Out

V FD V FD

Tube Detail

Design Equations:

Q  U  A  Tlm  m  Cp  (TAir,out  TAir,in ) Air-cooled HX are primarily

used when no other cooling
k
U  C  Re m  Pr 3 utilities are available on site
1

OD

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 28

– Integration of design and control part I
– SSLW 322-340

• Individual Team Assignments

– Will be assigned over next two week period
– Choose one from the project description or
– Email me two sentences describing what you would like
to investigate and I will respond with the ”official”
problem statement.