REPORT: DISTILLATION COLUMN DESIGN

Abhimanyu ,
Ankur Abhinav,
Ankit Sahu,
Pranjal Goswami

REPORT: DISTILLATION COLUMN DESIGN

Table of Contents
Problem Statement .......................................................................................... 3
Executive Summary ......................................................................................... 3
Design Process Overview................................................................................ 3
Process Description .......................................................................................... 4
Design of Distillation Column ............................................................................. 4
Thermodynamics ........................................................................................... 4
Equilibrium Data......................................................................................... 4
Vapor Liquid Equilibrium Data ...................................................................... 5
Preliminary Calculations ................................................................................. 5
Calculation of Tower Diameter (Fairs Method) .................................................. 8
Heat Exchangers: Condenser and Re-Boiler .................................................... 10
Condenser: .............................................................................................. 10
Re-boiler: ................................................................................................ 11
Height of Column ........................................................................................ 13
Thickness of Column Material........................................................................ 13
Thickness of Tori-spherical Head ................................................................... 14
Weight of Tower Material.............................................................................. 14
Cost Data ................................................................................................... 14
Evaluation of Annualized Fixed Cost and Annual Operating Cost: .................... 15
Optimization ............................................................................................... 15
Hydraulic Design ......................................................................................... 16
Bubble Cap Trays: .................................................................................... 16
Nozzles ................................................................................................... 16
Design of Support..................................................................................... 18
Pressure Drop Calculations ........................................................................... 20

REPORT: DISTILLATION COLUMN DESIGN

Problem Statement
A process stream of a mixture of benzene and toluene having 50 %(w/w)
composition of benzene has to be concentrated by Distillation. The distillate product
stream has to contain 95% (w/w) Benzene. The bottom product stream should
contain maximum 3% benzene in it. The operating pressure for the operation is 1.1
atm. Design the distillation column using data supplied and consulted reference
handbooks.

Executive Summary
This report consists of a detailed design of a binary distillation column to increase the
concentration of benzene from 50% (w/w) in the feed to 95% (w/w) under given
process conditions. The design procedure required determination of the optimum
reflux ratio and the corresponding number of stages required for achieving the
specified concentration of product.
The optimum value for R/Rmin was found to be 1.1. Calculations corresponding to this
ratio yielded the design of a distillation column which is 9.5 meters high, 2.7 meters
wide with 19 Bubble cap trays. Each bubble-cap tray consists of 166 openings
arranged in a triangular pitch.

Design Process Overview

The optimization was carried out based on economic considerations of the design.
The Annualized Fixed Cost and Operating cost for several reflux ratios were evaluated
and plotted. It must be noted that the optimization parameters include the cost of
column, trays, and heat exchange units only along with the utility costs.
Following the determination of an optimum reflux ratio, the type of tray was selected
after consideration of economic and operational parameters. Further, the theoretical
number of stages required was estimated graphically using McCabe-Thiele method.
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REPORT: DISTILLATION COLUMN DESIGN

The column height was then determined using the actual number of trays required
and a fixed tray spacing.
Next, the dimensions of the column heads were calculated followed by design
calculations for tray and nozzles. Hydraulic design for the column was done after
estimating the pressure drop. Check was made to avoid weeping, down-comer
flooding and entrainment conditions for the optimum design.
After the calculations, the support for column was designed using standard procedure
for supports of tall vessels. The data used in the design procedure were noted from
reliable sources acknowledged in the bibliography.

Process Description
The feed containing 50% (w/w) mixture of benzene and toluene is available at
ambient temperature.
**Incomplete

Design of Distillation Column

This section contains the detailed design process (mechanical and hydraulic) of
binary distillation tower for separation of benzene and toluene.

Thermodynamics
Equilibrium Data

x
y

1 0.82 0.66 0.50 0.38 0.28 0.15 0.06 0.0

1 0.92 0.83 0.72 0.60 0.45 0.30 0.13 0.0

[Provided Data]

REPORT: DISTILLATION COLUMN DESIGN

Vapor Liquid Equilibrium Data

The vapor-liquid equilibrium data can be obtained using Antoines Equation given as

Using the above equation, we obtain the T-x-y data.

T (oC)
X
y

85
0.772
0.896

90
0.524
0.772

95
0.404
0.626

100
0.257
0.457

105
0.127
0.259

Preliminary Calculations
Feed is saturated liquid mixture(saturation temperature = 92oC)
F = 75 ton/hr

= 871.28 kg/m3

F= 75000kg /hr => F = 86.1 m3/hr

Molecular Weight of feed (MF):
MF = xFMA + (1-xF)MB
= 0.5(78) + 0.5(92)
= 85 kg/kmol
F = 882.35 kmol/hr

REPORT: DISTILLATION COLUMN DESIGN

F=D+W
FxF = DxD + WxW
Given: xD = 0.95, xW = 0.03, xF = 0.5
D = 450.77 kmol/hr
W = 431.58 kmol/hr

Mavg|distillate = 0.95(78) + 0.05(92)

= 78.7 kg/kmol
Mavg|bottom =0.03(78)+ 0.97(92)
= 91.58 kg/kmol

D = 35475.6 kg/hr = 450.77 kmol/hr

W = 39524.1 kg/hr = 431.58 kmol/hr

Feed Stream
Distillate
Bottom Product

Molar Flow Rate

Mol. Weight

Mole Fraction

F = 882.35 kmol/hr
D = 450.77 kmol/hr
W = 431.58 kmol/hr

85 kg/kmol
78.7 kg/kmol
91.58 kg/kmol

xF = 0.50
xD = 0.95
xW = 0.03

Graphically, we obtain the minimum Reflux Ratio (Rmin )

Rmin = 1.043
Now, we consider R / Rmin = 1.1
R = 1.1473

REPORT: DISTILLATION COLUMN DESIGN

Enriching Section
Molar flow rate of liquid = L
L=R*D
L = 1.1473 * 450.77
L = 517.17 kmol/hr

Molar flow rate of vapour, V

V = (R+1)*D
= (1.1473 + 1)*450.77
V = 967.94 kmol/hr
Stripping Section
Molar flow rate of liquid = L
L = RD + F
L = (1.1473 * 450.77) + 882.35
L = 1399.52 kmol/hr
Molar flow rate of vapour, V
V = (R+1)*D
V = V
( Feed is saturated liquid)
V = V = 967.94 kmol/hr

REPORT: DISTILLATION COLUMN DESIGN

Calculation of Tower Diameter (Fairs Method)

benzene = 876.5 kg/m3 benzene = 866.9

L1

= 875.94 kg/m3

L1

= 867.15 kg/m3

Average liquid density,

kg/m3

= 871.54 kg/m3

Now,
PMD =

GDRT

(for vapor coming from tray 1)

GD

PMB =

GBRT

= 11.55 kg/m3

(for vapor coming from bottom tray)

GD

= 11.55 kg/m3

REPORT: DISTILLATION COLUMN DESIGN

Calculation of Operative Velocity

Using the viscosity data of the components and the operating flow rates of the
streams, the superficial velocity is obtained from the CSB vs FLV Graph (BK Dutta
P/194)
US,LV = 2.2 ft/s
Operating Velocity = 0.7(2.2) = 1.54 ft/s (Assuming Op. Vel. = 70% of superficial
velocity)

Operating Velocity = 0.47 m/s

Estimating Tower Diameter:
Vapor Flow rate, V = 967.94 kmol/hr
Mass flow rate of vapor (top) = V Mavg|distillate
= 76176.88 kg/hr
Mass flow rate of vapor (bottom) = V Mavg|bottom
= 88643.945 kg/hr
Average mass flow rate of vapor = 82410.4 kg/hr
Avg. density of vapor = 10.84 kg/m3
Volumetric flow rate of vapor = 7602.44 m3/hr

= 4.49 m2
Assuming frictional downcomer area,fd = 0.2
Cross Sectional area of Tower, AT = Aa/(1-fd)
AT = 5.62 m2
Diameter of Tower [Di] = 2.67 m
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REPORT: DISTILLATION COLUMN DESIGN

Heat Exchangers: Condenser and Re-Boiler

Condenser:
From T-x-y plot,
Dew point of vapor entering condenser = 83oC
Bubble point of distillate
= 81oC

Vapor
Dew Point = 83oC

Spent Cooling Water

45oC

Cooling Water
32oC

Condenser

Liquid
Bubble Point = 81oC

LMTD = 43.27oC
Enthalpy Balance:
VHV = QC + VHL
HV = xD[CPA(T-TD) + A] + (1 - xD)[CPB(T-TB)+B]

= Hv = 41789.82 kJ/kMol
(Reference temperature = 0oC)

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REPORT: DISTILLATION COLUMN DESIGN

HL = xDCPA(T-To) + (1 - xD)CPB(T-To)

= Hv = 11004.5 kJ/kMol
(Reference temperature = 0oC)
Condenser Heat Load = V(HV - HL)
QC = 8277317.944 J/s

Ucondenser*A*(LMTD) = Qc
Ucondenser = 851 W/m2K
Acondenser = 224.79 m2 (area of condenser)
mcw * Cpw

T = Qc

mcw = 152.11 kg/s

Mass of cooling water req. in 1 year = 4490287.2 m3/year
(Assuming plant operation to be 8200 hrs/year)

Re-boiler:
Vapor
Dew Point = 110oC

Condensed Water
160oC

Re-Boiler

Saturated Steam
160oC @ 5 atm(g)

Bottom Liquid
Bubble Point = 109oC

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REPORT: DISTILLATION COLUMN DESIGN

LMTD = 50.50oC
Enthalpy Balance:
FHF + QB = QC + DHD + WHW
HF = xFCPA(T-To) + (1 xF)CPB(T-TB)

= HF = 13374.96 kJ/kMol
(Reference temperature = 0oC)

HW = xWCPA(T-To) + (1 xW)CPB(T-To)

= HW = 16930.45 kJ/kMol
(Reference temperature = 0oC)
HD = HL = 11004.5 kJ/kMol
.(from previous calculations)

Re-Boiler Heat Load = QB

QB = 30264290.72 kJ/hr
ms* = QB
steam = 2758 kJ/kg
ms = 10973.27 kg/hr
Mass of cooling water req. in 1 year = 89980849.86 m3/year
(Assuming plant operation to be 8200 hrs/year)

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REPORT: DISTILLATION COLUMN DESIGN

Ure-boiler*A*(LMTD) = QB
Ure-boiler = 1845.45 W/m2K
Are-boiler = 90.2 m2 (area of condenser)

Height of Column
The number of stages required for desired concentration of product is estimated
graphically using the McCabe Thiele Method for the above calculated parameters.
No. of actual stages = 19
Selected tray spacing = 18 = 0.457 m
(top spacing= 0.4m ; bottom spacing 0.85m)
Height of column = (19-1)*0.457 + 0.4 + 0.85
= 9.476 m

Thickness of Column Material

(Reference Process Equipment Design | B.C. Bhattacharya)
f = allowable stress = 98.1 x 106 N/m2 (IS:2825-1969)
J = 0.85

t = 1.7 mm + 2 mm(corrosion allowance)

t = 3.7 mm
Next standard thickness available = 5mm

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REPORT: DISTILLATION COLUMN DESIGN

Thickness of Tori-spherical Head

(Reference Process Equipment Design | B.C. Bhattacharya)
f = allowable stress = 98.1 x 106 N/m2 (IS:2825-1969)
J = 0.85

t = 5.34 mm + 2 mm(corrosion allowance)

t = 7.34 mm
Next standard thickness available = 8 mm

Weight of Tower Material

Volume of material = 0.5784 m3
Mass of Tower material = 4540.4 kg
Mass of Tower material (including trays) = 1.3 * 4540.4 = 5902.6 kg

Cost Data
Following are the costs for material and utilities.
Particulars
Cost of Steel
Cost of Cooling Water
Cost of Steam
Cost of fabrication

Cost
9690 INR/MT
320 INR/1000m3
485 INR/MT
60% of Material Cost

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REPORT: DISTILLATION COLUMN DESIGN

Evaluation of Annualized Fixed Cost and Annual Operating Cost:

Particulars

Cost

Cost of Cooling Water per Year (INR/Year)

Cost of Steam per year (INR/Year)
Cost of Tower Materail (INR)
Cost of Condenser

Rs. 14,36,927
Rs. 4,36,42,840
Rs. 82,241
Rs. 20,07,949
Rs. 18,45,226

Cost of Boiler
Total Fixed Cost(Without Piping/Insulation)
Total Fixed Cost(INR)
Annual Fixed Cost (INR/year)
Annual Operating Cost (INR/year)
Total Annual Cost (INR/Year)

Rs. 39,35,417
Rs. 53,12,813
Rs. 9,03,178
Rs. 4,50,79,768
Rs. 4.59,82,946

Optimization
Following the calculations of one value of R/Rmin the annual cost was evaluated
programmatically for all other values of R/Rmin
R/Rmin
1.1
1.2
1.3
1.4
1.5
1.6
1.7

Total Annual Cost

INR 4,66,46,436
INR 4,98,86,241
INR 5,20,47,051
INR 5,42,07,792
INR 5,63,69,152
INR 5,85,29,777
INR 6,06,90,341
The Optimum R/Rmin was found to be 1.1
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REPORT: DISTILLATION COLUMN DESIGN

Hydraulic Design
Bubble Cap Trays:
Bubble cap trays selected for the binary distillation column. Following is the
calculation for Cap distribution
Tower Diameter = 2.67 m
Ref. B.D. Smith
Selected: Carbon Steel 4 in. bubble caps
Downflow area = 10% of Tower cross-section
Liquid Distribution area = 5% of Tower cross-section
End Wastage = 10% of Tower cross-section

Allocated bubble cap area = 100- (2x10 2x5 2x10)

= 0.5 * 5.62 m2

Cap- distribution:
Pitch = D + Clearance
= 4 + 1.5
= 5.5 inch
No. of Bubble (caps arranged in triangular pitch) = 166
Nozzles
Feed Nozzle :
Feed rate = 86.1 m3/hr
Velocity = 1.5 m/s
Flow area required = 0.016 m2
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REPORT: DISTILLATION COLUMN DESIGN

Taking NPS = 6 SC 40
OD = 0.168 m
ID = 0.161 m
Area = 0.02 m2
Velocity = 1.2 m/s
Top Nozzle:
Vapor Flow rate = 7602.44 m3/hr
Velocity = 25 m/s
Flow area required = 0.0845 m2
Taking NPS = 14 SC 40
OD = 0.355 m
ID = 0.346 m
Area = 0.094 m2
Velocity = 22.5 m/s
Bottom Nozzle:
Bottom Product Flow rate = 46.6 m3/hr
Velocity = 1 m/s
Flow area required = 0.0127 m2
Taking NPS = 5 SC 40
OD = 0.141 m
ID = 0.134 m
Area = 0.094 m2
Velocity = 22.5 m/s

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REPORT: DISTILLATION COLUMN DESIGN

Design of Support
Cylindrical skirt support is selected as the vessel support.
Skirt height = 2 m
Minimum weight of vessel with two heads and shell,
Wmin = 44.62 kN
Now,
Wmax = Wshell + Winsulation + Wwater_during_test + Wattachments
Wmax = 249.734 kN

Period of vibration at minimum dead weight, Tmin

Tmin < 0.5 s

K2 = 1

Period of vibration at maximum dead weight, Tmax

Tmax < 0.5 s

K2 = 1

Evaluation of Wind Load

PW = K1K2 p H D
Hence, PW,min = 21.58 kN
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REPORT: DISTILLATION COLUMN DESIGN

PW,max = 22.786 kN

Minimum wind moment MW,min = PW,min

= 123.826 kJ

Maximum wind moment MW,max = PW,max

= 130.746 kJ

Now,
ZWM,min =

, where t is thickness of skirt.

zwm(min) = 22.06/t kN/m2

zwm(max) = 23.3/t kN/m2

Minimum and maximum dead load stresses:

zw(min) = Wmin/dt = 5.29/t kN/m2
zw(max) = 29.63/t kN/m2

Maximum tensile stress

z(tensile) = zwm(min) - zw(min) = 16.77/t kN/m2
Substituting, z(tensile) = fJ = 67200 kN/m2
Equating, 67200 = 16.77/t
t= 0.249 mm

Maximum compression load

z(compression) = zwm(max) - zw(max) = 52.93/t kN/m2
z(compressive) = 0.125E

= 9314456 t kN/m2

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REPORT: DISTILLATION COLUMN DESIGN

Equating, 9314456 t =52.93/t

t= 2.384 mm
Following IS: 2825-1969, minimum corroded skirt thickness is 7 mm.
Providing 1 mm corrosion allowance, a standard 8 mm thick plate can be used for
skirt.

Pressure Drop Calculations

Pressure drop Tray

v = 10.84 kg/m3
l = 871.54 kg/m3
Q = vapor flow rate in fps = 74.5 ft3/sec
Ar = riser area = 5.53 ft2
ht = 3.39
Total pressure drop across Column = 64.5 of liq
= 0.138 atm

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