Equipment Design – Fourth Year Jwan T.

Hasan

Example 2: For the butane-pentane splitter defined by the compositions given in the
table below, estimate the minimum number of stages, the minimum reflux ratio, the
number of ideal stages needed, and the position of the feed point. The column will
operate at a pressure of 8.3 bar, with a reflux ratio of 2.5. The feed is at its boiling point.
The compositions:

Component αi fi di bi
Propane, C3 5 5 5 0
i-Butane, iC4 2.6 15 14.9 0.1
n-Butane, nC4 (LK) 2 25 24 1
i-Pentane, iC5 (HK) 1 20 1 19
n-Pentane, nC5 0.85 35 0.4 34.6
F = 100 D = 45.3 B = 54.7

Solution:
Minimum number of stages:

𝑥 𝑥 24 19
log [ 𝐿𝐾 ] [ 𝐻𝐾 ]
𝑥𝐻𝐾 𝑑 𝑥𝐿𝐾 𝑏 log [( 1 ) ( 1 )]
𝑁𝑚 = = = 8.8
log 𝛼𝐿𝐾 log 2

Minimum reflux ratio:

𝛼𝑖 ∗ 𝑥𝑖,𝑑
∑ = 𝑅𝑚𝑖𝑛 + 1
𝛼𝑖 − 𝜃

𝛼𝑖 𝑥𝑖,𝑓
∑ =1−𝑞
𝛼𝑖 − 𝜃

The feed is at its boiling point (𝑞 = 1)

𝛼𝑖 𝑥𝑖,𝑓
∴∑ =0
𝛼𝑖 − 𝜃
𝛼 ∗ 𝑥𝑓 𝛼 ∗ 𝑥𝑓 𝛼 ∗ 𝑥𝑓 𝛼 ∗ 𝑥𝑓 𝛼 ∗ 𝑥𝑓
( ) +( ) +( ) +( ) +( ) =0
𝛼 − 𝜃 𝐶3 𝛼 − 𝜃 𝑖𝐶4 𝛼 − 𝜃 𝑛𝐶4 𝛼 − 𝜃 𝑖𝐶5 𝛼 − 𝜃 𝑛𝐶5

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Equipment Design – Fourth Year Jwan T. Hasan

5 ∗ 0.05 2.6 ∗ 0.15 2 ∗ 0.25 1 ∗ 0.2 0.85 ∗ 0.35

+ + + + =0
5−𝜃 2.6 − 𝜃 2−𝜃 1−𝜃 0.85 − 𝜃
The value of 𝜃 must lie between the values of the relative volatility of the light and
heavy keys, and is found by trial and error.

For 𝜃 = 1.5:
𝛼𝑖 ∗ 𝑥𝑖,𝑓
∑ = 0.564 ≠ 0
𝛼𝑖 − 𝜃
𝜃 = 1.5 𝜃 = 1.3 𝜃 = 1.35
𝛼𝑖 ∗ 𝑥𝑖,𝑓 𝛼𝑖 ∗ 𝑥𝑖,𝑓 𝛼𝑖 ∗ 𝑥𝑖,𝑓
Comp. 𝑥𝑖,𝑓 𝛼𝑖 𝛼𝑖 ∗ 𝑥𝑖,𝑓
𝛼𝑖 − 𝜃 𝛼𝑖 − 𝜃 𝛼𝑖 − 𝜃
C3 0.05 5 0.25 0.071 0.068 0.068
iC4 0.15 2.6 0.39 0.355 0.3 0.312
nC4 0.25 2 0.5 1 0.714 0.769
iC5 0.2 1 0.2 − 0.4 − 0.667 − 0.571
nC5 0.35 0.85 0.3 − 0.462 − 0.677 − 0.6
0.022
∑ = 0.564 − 0.252
Close
enough

∴ 𝜃 = 1.35
𝛼𝑖 ∗ 𝑥𝑖,𝑑
𝑥𝑖,𝑑 𝛼𝑖 𝛼𝑖 ∗ 𝑥𝑖,𝑑
𝛼𝑖 − 𝜃
0.11 5 0.55 0.15
0.33 2.6 0.86 0.69
0.53 2 1.06 1.63
0.02 1 0.02 − 0.06
0.01 0.85 0.0085 − 0.017
2.393≅ 2.4

𝑅𝑚𝑖𝑛 + 1 = 2.4 → 𝑅𝑚𝑖𝑛 = 1.4

𝑅𝑚𝑖𝑛 1.4
= = 0.58
𝑅𝑚𝑖𝑛 + 1 2.4

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Equipment Design – Fourth Year Jwan T. Hasan

𝑅 2.5
𝑅 = 2.5 → = = 0.71
𝑅 + 1 3.5
From figure 6:

𝑁𝑚𝑖𝑛 8.8
= 0.64 → 𝑁 = = 13.75 ≅ 14
𝑁 0.64

For other reflux ratios:

𝑅 2 3 4 5 6
𝑁 15.7 11.9 10.7 10.4 10.1

Number of stages = 14

Number of plates = 14 − 1 = 13

By using Gilliland correlation:

1 + 54.4 𝑋 𝑋−1
𝑌 = 1 − 𝑒𝑥𝑝 [( ) ( 0.5 )]
11 + 117.2 𝑋 𝑋

𝑅 − 𝑅𝑚𝑖𝑛 2.5 − 1.4

𝑋= = = 0.314
𝑅+1 3.5

1 + 54.4 (0.314) 0.314 − 1

𝑌 = 1 − 𝑒𝑥𝑝 [( )( )]
11 + 117.2 (0.314) 0.3140.5

𝑌 = 1 − 𝑒𝑥𝑝[(0.3573) × (−1.224)] = 0.3543

𝑁 − 𝑁𝑚𝑖𝑛
= 0.3543
𝑁+1

𝑁 − 8.8
= 0.3543 → 𝑁 = 14
𝑁+1
2
𝑁𝑟 𝐵 𝑥𝑓,𝐻𝐾 𝑥𝑏,𝐿𝐾
log [ ] = 0.206 log [( ) ( )( ) ]
𝑁𝑠 𝐷 𝑥𝑓.𝐿𝐾 𝑥𝑑,𝐻𝐾

𝑥𝑓,𝑛𝐶4 = 0.25
𝑥𝑓,𝑖𝐶5 = 0.2

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Equipment Design – Fourth Year Jwan T. Hasan

𝑥𝑑,𝑖𝐶5 = 0.022
1
𝑥𝑏,𝑛𝐶4 = = 0.018
54.7
𝑁𝑟 54.7 0.2 0.018 2
log [ ] = 0.206 log [( )( )( ) ] = 0.206 log [0.65]
𝑁𝑠 45.3 0.25 0.022

𝑁𝑟
∴ = 0.91 → 𝑁𝑟 = 0.91 𝑁𝑠
𝑁𝑠

𝑁𝑟 + 𝑁𝑠 = 13 → 𝑁𝑠 = 13 − 𝑁𝑟 → 𝑁𝑠 = 13 − 0.91 𝑁𝑠

𝑁𝑠 = 13 − 𝑁𝑟

𝑁𝑠 = 13 − 0.91 𝑁𝑠 → 𝑁𝑠 = 6.8 ≅ 7

Example 3: a liquid feed of 100 mol/h at the boiling point is fed to a distillation tower
at 405.3 kPa. The composition in mole fractions as follow: n-butane (𝑥𝐴 = 0.4), n-
pentane (𝑥𝐵 = 0.25), n-hexane (𝑥𝐶 = 0.2), and n-heptane (𝑥𝐷 = 0.15). The liquid feed
is to be fractionated, so that 90% of the n-pentane (B) is recovered in the distillate and
90% of the n-hexane (C) in the bottoms. Calculate the following: (a) moles per hour
and composition of distillate and bottoms, (b) top temperature (dew point) of distillate
and boiling point of bottoms, (c) minimum stages for total reflux.

Component A B C
n-Butane 15.68151 2154.9 238.74
n-Pentane 15.8365 2477.9 233.21
n-Hexane 15.9155 2738.42 226.2
n-Heptane 15.877 2911.32 226.65

Solution: (a)
𝐹 =𝑊+𝐷
 For component B (n-pentane):
𝑥𝐵𝐹 = 0.25
𝑥𝐵𝐹 𝐹 = 0.25 × 100 = 25 mol/h

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Equipment Design – Fourth Year Jwan T. Hasan

22.5
𝑥𝐵𝐷 𝐷 = 0.9 × 25 = 22.5 mol/h → 𝑥𝐵𝐷 =
𝐷
2.5
𝑥𝐵𝑊 𝑊 = 0.1 × 25 = 2.5 mol/h → 𝑥𝐵𝑊 =
𝑊

 For component C (n-hexane):

𝑥𝐶𝐹 = 0.2
𝑥𝐶𝐹 𝐹 = 0.2 × 100 = 20 mol/h
2
𝑥𝐶𝐷 𝐷 = 0.1 × 20 = 2 mol/h → 𝑥𝐶𝐷 =
𝐷
18
𝑥𝐶𝑊 𝑊 = 0.9 × 20 = 18 mol/h → 𝑥𝐶𝑊 =
𝐷
Assume that no component D (heavy-non key) is in the distillate and no light component
A (light-non key) in the bottom, so:

 For component A (n-butane):

𝑥𝐴𝐹 = 0.4
𝑥𝐴𝑊 = 0 → 𝑥𝐴𝑊 𝑊 = 0
40
𝑥𝐴𝐹 𝐹 = 100 × 0.4 = 40 mol/h = 𝑥𝐴𝐷 𝐷 → 𝑥𝐴𝐷 =
𝐷

 For component D (n-heptane):

𝑥𝐷𝐹 = 0.15
𝑥𝐷𝐷 = 0 → 𝑥𝐷𝐷 𝐷 = 0
15
𝑥𝐷𝐹 𝐹 = 0.15 × 100 = 15 mol/h = 𝑥𝐷𝑊 𝑊 → 𝑥𝐷𝑊 =
𝑊

Feed, F Distillate, D Bottom, W

Comp.
𝑥𝐹 𝑥𝐹 𝐹 𝑥𝐷 = 𝑦𝐷 𝑥𝐷 𝐷 𝑥𝑊 𝑥𝑊 𝑊
A 0.4 40 0.62 40 0 0
B (LK) 0.25 25 0.349 22.5 0.07 2.5
C (HK) 0.2 20 0.031 2 0.507 18
D 0.15 15 0 0 0.423 15

∑=1 𝐹 = 100 1 𝐷 = 64.5 1 𝑊 = 35.5

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Equipment Design – Fourth Year Jwan T. Hasan

(b)

 Top temperature (dew point):

A value of 67°C will be estimated for the first trial

Component 𝑥𝐷 = 𝑦𝐷 𝐾𝑖 𝑦𝑖 /𝐾𝑖 𝛼𝑖 = 𝐾𝑖 /𝐾𝐻𝐾

A 0.62 1.75 0.354 6.73
B (LK) 0.349 0.65 0.537 2.5
C (HK) 0.031 0.26 0.1192 1
D 0 0.1 0 0.385

∑ = 1.0102

Or.

By using:
𝐵
ln 𝑝𝑖° = 𝐴 −
𝑇+𝐶

𝑝𝑖° in (mmHg), T in (°C )

Component 𝑥𝐷 = 𝑦𝐷 𝑝𝑖° 𝐾𝑖 = 𝑝𝑖° /𝑝𝑇 𝑦𝑖 /𝐾𝑖

A 0.62 5615.9414 1.84735 0.33561
B (LK) 0.349 2008.939 0.66084 0.5281
C (HK) 0.031 717.471 0.23601 0.1314
D 0 387.9199 0.12761 0

∑ = 0.99511

 Bottom temperature (bubble point):

For the bubble point of the bottoms, a temperature of 135°C is assumed for trial 1 →
∑ 𝐾𝑖 ∗ 𝑥𝑖 > 1 (check that). A second trial using of 132°C gives the final
temperature.

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Equipment Design – Fourth Year Jwan T. Hasan

Component 𝑥𝑤 𝐾𝑖 𝐾𝑖 ∗ 𝑥𝑖 𝛼𝑖 = 𝐾𝑖 /𝐾𝐻𝐾
A 0 5 0 4.348
B (LK) 0.07 2.35 0.1645 2.043
C (HK) 0.507 1.15 0.58305 1
D 0.423 0.61 0.25803 0.53

∑ = 1.00558

(c) Minimum number of stages:

𝑥 𝑥
log [ 𝐿𝐾 ] [ 𝐻𝐾 ]
𝑥𝐻𝐾 𝑑 𝑥𝐿𝐾 𝑏
𝑁𝑚 =
log 𝛼𝐿𝐾
𝛼𝐿,𝐷 = 2.5 (𝑇 = 67°C at the top)

𝛼𝐿,𝑊 = 2.04 (𝑇 = 132°C at the bottom)

𝛼𝐿,𝑎𝑣. = √𝛼𝐿,𝐷 𝛼𝐿,𝑊 = √2.5 × 2.04 = 2.258

0.0349 0.507
log [( )( )]
𝑁𝑚 = 0.031 0.07 = 5.404 (stages)
log 2.258

The distribution or compositions of the other components can be calculated using:

𝑥𝑖𝐷 𝐷 𝑁𝑚 𝑥𝐻𝐷 𝐷
= (𝛼𝑖,𝑎𝑣. )
𝑥𝑖𝑊 𝑊 𝑥𝐻𝑊 𝑊

𝛼𝐴,𝑎𝑣. = √𝛼𝐴,𝐷 𝛼𝐴,𝑊 = √6.73 × 4.393 = 5.409

𝑥𝑖𝐷 𝐷 𝑁𝑚 𝑥𝐻𝐷 𝐷 0.031(64.5)

= (𝛼𝑖,𝑎𝑣. ) = (5.409)5.404 = 1017
𝑥𝑖𝑊 𝑊 𝑥𝐻𝑊 𝑊 0.507(35.5)

𝑥𝐴𝐹 𝐹 = 40 = 𝑥𝐴𝐷 𝐷 + 𝑥𝐴𝑊 𝑊

𝑥𝐴𝐷 𝐷 = 1017 𝑥𝐴𝑊 𝑊

𝑥𝐴𝑊 𝑊 = 0.039, 𝑥𝐴𝐷 𝐷 = 39.961

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Equipment Design – Fourth Year Jwan T. Hasan

𝛼𝐷,𝑎𝑣. = √0.385 × 0.530 = 0.452

𝑥𝐷𝐷 𝐷 𝑁𝑚 𝑥𝐻𝐷 𝐷 0.031(64.5)

= (𝛼𝐷,𝑎𝑣. ) = (0.452)5.404 = 0.001521
𝑥𝐷𝑊 𝑊 𝑥𝐻𝑊 𝑊 0.507(35.5)

𝑥𝐷𝐹 𝐹 = 15 = 𝑥𝐷𝐷 𝐷 + 𝑥𝐷𝑊 𝑊

𝑥𝐷𝐷 𝐷 = 0.023, 𝑥𝐷𝑊 𝑊 = 14.977

Feed, F Distillate, D Bottom, W

Comp.
𝑥𝐹 𝑥𝐹 𝐹 𝑥𝐷 = 𝑦𝐷 𝑥𝐷 𝐷 𝑥𝑊 𝑥𝑊 𝑊
A 0.4 40 0.6197 39.961 0.0011 0.039
B (LK) 0.25 25 0.3489 22.5 0.0704 2.5
C (HK) 0.2 20 0.031 2 0.5068 18
D 0.15 15 0.0004 0.023 0.4217 14.977

∑=1 𝐹 = 100 1 𝐷 = 64.484 1 𝑊 = 35.516

By using the new distillate composition and repeating the bubble and dew point
temperature calculation, we obtained values are very close to the values obtained when
the trace amount of D in the distillate and A in the bottom were assumed as zero. Hence,
the dew point remains 67°C and the bubble point is 132°C. If either the bubble- or dew-
point temperature had changed, the new values would then be used in a recalculation
Nm.

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