Chapter 7 Design of distillation column

In industry it is common practice to separate a liquid mixture by distillating the

components, which have lower boiling points when they are in pure condition from those
having higher boiling points. This process is accomplished by partial vaporization and
subsequent condensation

7.1 CHOICE BETWEEN PLATE AND PACKED

COLUMN
Vapour liquid mass transfer operation may be carried either in plate column or packed
column. These two types of operations are quite different. A selection scheme considering
the factors under four headings.
i) Factors that depend on the system i.e. scale, foaming, fouling factors,
corrosive systems, heat evolution, pressure drop, liquid holdup.
ii) Factors that depend on the fluid flow moment.
iii) Factors that depends upon the physical characteristics of the column and its
internals i.e. maintenance, weight, side stream, size and cost.
iv) Factors that depend upon mode of operation i.e. batch distillation, continuous
distillation, turndown, and intermittent distillation.
The relative merits of plate over packed column are as follows:
i) Plate column are designed to handle wide range of liquid flow rates without
flooding.
ii) If a system contains solid contents, it will be handled in plate column, because
solid will accumulate in the voids, coating the packing materials and making it
ineffective.
iii) Dispersion difficulties are handled in plate column when flow rate of liquid
are low as compared to gases.
iv) For large column heights, weight of the packed column is more than plate
column.

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Chapter 7 Design of distillation column

v) If periodic cleaning is required, man holes will be provided for cleaning. In

packed columns packing must be removed before cleaning.
vi) For non-foaming systems the plate column is preferred.
vii) Design information for plate column are more readily available and more
reliable than that for packed column.
viii) Inter stage cooling can be provide to remove heat of reaction or solution in
plate column.
ix) When large temperature changes are involved as in the distillation operations
tray column are often preferred because thermal expansion or contraction of
the equipment components may crush the packing.
x) Random-Packed Column generally not designed with the diameter larger than
1.5 m and diameters of commercial tray column is seldom less than 0.67m.
For this particular process, “TDI, Residues and ODCB”, I have selected plate column
because:
i) System is non-foaming.
ii) Temperature is very high i.e. about 250°C
iii) Diameter is greater than 0.67 meter.
iv) Height of the Column is very large.

7.2 CHOICE OF PLATE TYPE

There are four main tray types, the bubble cap, sieve tray, ballast or valve trays and the
counter flow trays. I have selected sieve tray because:
 They are lighter in weight and less expensive. It is easier and cheaper to install.
 Pressure drop is low as compared to bubble cap trays.
 Peak efficiency is generally high.
 Maintenance cost is reduced due to the ease of cleaning.
 Good flexibility in operation(Turndown ratio).

7.3 DESIGNING STEPS OF DISTILLATION

COLUMN
 Calculation of Minimum Reflux Ratio Rm.
 Calculation of optimum reflux ratio.

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Chapter 7 Design of distillation column

 Calculation of theoretical number of stages.

 Calculation of actual number of stages.
 Calculation of diameter of the column.
 Calculation of weeping point.
 Calculation of pressure drop.
 Calculation of thickness of the shell and head.
 Calculation of the height of the column.

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 Chapter 7 Design of distillation column

7.4 DESIGNING CALCULATIONS OF DISTILLATION

COLUMN (D-310)

SPECIFICATION SHEET
Identification:
Item Distillation column
Item No. D-310
No. required 1Tray type Sieve tray
Function: Separation of ODCB from TDI and Reaction Residues.
Operation: Continuous
Material handled
Feed Top Bottom
Quantity 36429.8 Kg/hr 30843.8 Kg/hr 5586 Kg/hr
Composition of 84.51% 99.78 % 0.5%
ODCB
Temperature 195 oC 160 oC 252.2oC

Design Data:
No. of trays = 29 Active holes = 15307
Pressure = 101.325 Kpa Weir height = 50 mm
Height of column = 14.6 m Weir length = 1.92 m
Diameter of column = 2.5 m Reflux ratio = 0.33:1
Hole size = 5 mm Tray spacing = 0.457 m
Pressure drop per tray = 1.36 Kpa Active area = 3.74 m2
Tray thickness = 5 mm Flooding = 80.3 %

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Chapter 7 Design of distillation column

Figure: 7.1

65
Chapter 7 Design of distillation column

1. NATURE OF FEED:
Pressure of column = P=101.325psi
At, Temperature=190oC
Light Key (lk) =ODCB
Heavy Key (hk) =TDI
At Temperature =195oC
Comp Xf Pv(PSI) K K*Xf
COCL2 0.0005 650 44.21769 0.022109
ODCB 0.8451 16.6 1.129252 0.954331
TDI 0.1362 2.43 0.165306 0.022515
RES 0.0182 0.0085 0.000578 1.05E-05
∑K*Xf 0.998965

As, Boiling Point (TB) is very close to feed temperature i.e. 190 oC it is assumed that feed
is saturated liquid at its boiling point so that q = 1

2. ESTIMATION OF TOP TEMPERATURE:

By a dew-point Calculation, ∑K/Xd = ∑Xd
Let at T=160 oC
Comp Xd Pv(PSI) K Xd/K
COCL2 0.0006 500 34.01361 1.76E-05
ODCB 0.9978 13.5 0.918367 1.086493
TDI 0.0016 1.8 0.122449 0.013067
∑K/Xd 1.009578

Hence the Top-Temperature is Td=160 oC

3. ESTIMATION OF BOTTOM TEMPERATURE:

By Bubble-point Calculation ∑K.Xb=∑Xb
Trail at T=252.22 oC

Comp Xb Pv(PSI) K K*Xb

ODCB 0.005 59.8 4.068027 0.02034
TDI 0.879 16.35 1.112245 0.977663
RES 0.115 0.25 0.017007 0.001956
∑K*Xb 0.999959

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Chapter 7 Design of distillation column

Hence the Still Temperature is Ts=252.22 oC

4. DETERMINATION OF MININMUN REFLUX RATIO:

Since the relative volatility of light to heavy key is not constant so Colburn method is
used to fine out the Minimum reflux ratio.
This can be found by following relation

1  X lkD  X 
Rm     lk  hkD 
 lk  1  X lkR  X hkR 
Where
rF
X lkR 
(1  rF ) * (1   * X hF )
X lkR
X khR 
rF
Where ∑αXhF for every component heavier than the heavy key
In Our case the component heavier than the heavy key are reaction residues.
For that
α= (0.0011/2.78)=0.0004
So that ∑αXhF =` 0
rF=(XlkF/XhkF)
= (0.8451/0.136)
=6.22
At average temperature of column αlk = (17.9/2.8) = 5.85
XlkD=0.9987 and XhkD=0.0016
Then
XlkR = [6.22/ (1+6.22)] =0.861
XhkR= (0.862/6.24)=0.138
Rm = 0.22

5. CALCULATION OF OPTIMUM REFLUX RATIO:

Reflux Ratio = R=1.5*Rm
R = 1.5 * 0.22 = 0.33
Ln = R * D

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Chapter 7 Design of distillation column

Ln = 69.23 Kgmole/hr
Vn = Ln+D
= 276.6 Kgmole/hr
As, the feed is at its boiling point, q = 1
Lm = Ln+qF
= 305.41Kgmole/hr
Vm = L n – B
= 276.6 Kgmole/hr

6. MINIMUM NUMBER OF STAGES:

Using Fenske’s equation
 X lkD  X hkB 
  
X X
 hkD  lkB 
Nm 1   6
log  lk
Where  lk
is the average relative volatility of light to the heavy key.

7. NUMBER OF IDEAL STAGES:

Ideal number of Stages can be found by Lewis Matheson Method.
Average Temperature = 213.61 oC
Relative Volatilities at average column temperature:

Comp α
COCL2 144.34
ODCB 5.237
TDI 1
RES 0.00948

BELOW THE FEED PLATE:

The SOL Equations are

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Chapter 7 Design of distillation column

L   B 
Ym   m  X m 1    X B
 Vm   Vm 
Ym.ODCB = 1.106Xm+1 -0.00068
Ym,TDI = 1.106Xm+1 -0.119
Ym,RES = 1.106Xm+1 -0.01564
And other equations are
i * X i
Yi  For every component
( i * X i )

Comp Xb α*Xb Yb X1 α *X1 Y1

ODCB 0.005 0.02618 0.0288 0.02603 0.13633 0.1245
TDI 0.879 0.879 0.9699 0.958 0.9585 0.8753
RES 0.115 0.00109 0.0012 0.01482 0.00014 0.000128
∑ 0.999 0.9062 1 0.999 1.09 1

--- X5 α *X5 Y5 X6 α *X6 Y6 X7

--- 0.8037 4.207 0.958 0.844 4.421 0.969 0.8535

--- 0.1822 0.1822 0.0415 0.1413 0.141 0.0309 0.132

--- 0.0138 0.00013 0.00003 0.0137 0.00013 0.00002 0.0137

--- 0.999 4.389 1 0.999 1 1 0.9999

The plate 7 has composition very close to the feed plate so it is considered as feed plate.
ABOVE THE FEED PLATE:
The ROL equations are
 L  D
Yn 1   n  X n 1   Vn
 Vn 1   Vn 
Y n,ODCB = 0.248 X n+1 + 0.748
Y n,TDI = 0.248 X n+1 + 0.0012
Y n,COCl2 = 0.248 X n+1 + 0.00045

Comp X7 α *X7 Y7 X8 α *X8 Y8

COCL2 0.0005 0.0000155 0.000453 0.000014 0.002021 0.00045
DCB 0.853 0.9244 0.96 0.857 4.488218 0.9664

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Chapter 7 Design of distillation column

TDI 0.132 0.0755 0.0366 0.14292 0.14292 0.0307

RES 0.0137 0.00013 0.00013 0.000524 4.9E-06 1.0E-06
∑ 0.9992 1.000045 0.99718 1.000458 4.63316 0.9975

--- Y14 X15 α*X15 Y15 X16 α *X16 Y16

--- 0.00053 2.6×10-5 0.004 0.00054 3.1×10-5 0.00456 0.0058

--- 0.992 0.983 5.148 0.994 0.991 5.193 0.997

--- 0.005 0.011 0.016 0.003 0.083 0.008 0.002
--- 0 0 0 0 0 0 0
--- 0.999 1 5.169 0.999 1 5.020 1.002

The Plate 16 has nearly same composition as that of the top product so it is the last plate
from top to bottom.

8. EFFICIENCY OF THE COLUMN:

The efficency of the column is given by the following empirical relation
Eo  51  32.5 Log (  a * a )

Where μa = Average viscosity of the feed = 0.1456

αa = Average relative volatility of light to heavy key = 5.29
Then,
Eo = 56%

9. ACTUAL NUMBER OF STAGES:

Actual number of stages = Ideal number of stages/Eo
= 16/0.56
Actual number of stages = 29
Sieve Trays are used.

10. CALCULATION OF COLUMN DIAMETER:

Top Conditions Bottom Conditions
Ln =69.23Kgmole/hr Lm = 305.41 Kgmole/hr
Lw =10178.45 Kgs/hr Lw =59226.02 Kgs/hr
Vn = 276.6 Kgmole/hr Vm = 276.6 Kgmole/hr
Vw =40687.85 Kgs/hr Vw =53641.04 Kgs/hr

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Chapter 7 Design of distillation column

Average mol.Wt. = 147.01 Kg/Kgmol Average mol. wt=193.923

T = 175o C Kg/Kgmol
Liquid density = dL = 1306 Kg/m3 T = 252.22o C
Vapor density = dV = 4 Kg/m3 Liquid density = dL = 1202 Kg/m3
Vapor density = dV = 4.5 Kg/cm3

Flooding Velocity:

L  d
Flv   w  v
 Vw  d l
Where,
dv = 4.5 Kgs/ m3
dl = 1202 kg/m3
Flv = 0.0675
From figure11.27, Coulson and Richardson, 6th Ed.
At 18 inch spacing or 0.457 m
K1 = 0.08
0 .2
dl  dv   
U c  K1  
d v  20 

Where,
σ=surface tension of the system = 4.14dynes/cm
Uc = 0.952 m/s
Let, flooding = 80%
Uc* = 0.8 * 0.952
= 0.762 m/s
Maximum volumetric flow rate of vapors :
Vw
qv 
dv
= 3.31 m3/s
Net area required:
qv
An  
Uc

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Chapter 7 Design of distillation column

= 4.33 m2
Column Cross sectional Area:
An
Ac 
0.88
= 4.92 m2
Diameter:
4 * Ac
Dc 

= 2.5 m
The calculated diameter at the top of column is 1.95m.As the diameter is more in bottom
so calculations are carried out on the basis on bottom. Use same diameter at top while
reducing the perforation area at the top.

Downcomer Area:
Ad = 0.12*Ac
= 0.59 m2

Net Area:
An = Ac – A
= 4.33 m2

Active Area:
Aa = Ac-2Ad
= 3.74 m2

Hole Area:
Lets by trial its 11% of Aa
Ah = 0.11*0.579
= 0.41 m2
Weir height = hw = 50mm
Plate thickness = 5mm
Hole diameter = dh = 5mm

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Chapter 7 Design of distillation column

11. WEEP POINT

Weir Length:
Factor (Ad/Ac)*100 = 12 At (Ad / Ac) * 100 = 12
From Graph b/w (Ad/Ac)*100 vs. lw / Dc on page # 572 by “Coulson and
Richardson’s”, 6th Ed.
lw / Dc = 0.77
lw = 1.92 m
Weir Liquid Crest:
Maximum liquid rate=Lw=-46632.05/3600=16.45Kgs/sec
Minimum liquid rate= Lw*=16.45*0.7
(at 70% turn down) =11.5kgs/sec
2/3
 Lw 
how (max)  750 
 d w  lw 
how (max) = 27.778mm
how (min) = 21.88mm
At minimum liquid rate,
hw + how = 50 + 21.88
= 71.88 mm
From graph 11.30, page # 571,”Coulson and Richardson” Vol. 6
At hw + how = 71.88 mm
K2 = 30.6 mm
Weep point:

U h (min) 
 K 2  0.9(25.4  d h )
o .5
dv
= 5.76 m/s
Actual Uh (min) based on active hole area is given as:
 Vw 
Actual U h (min)  0.7 
 d v  Ah 
= 5.65 m/s

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Chapter 7 Design of distillation column

As, actual minimum velocity is less than Uh(min) , so we change the hole area so that
Actual Uh (min) becomes well above Uh(min) .
Another Trial for Hole Area: (8% of Aa)
Aa = 3.74 m2
Ah=0.08*3.74=0.3m2
So, Actual Uh (min) = 7.72 m/sec
Since Actual Uh (min) is well above Uh (min) so our new trial is correct

12. PLATE PRESSURE DROP

Dry Plate Pressure Drop:
Maximum vapor velocity through holes
 Vw 
U h (min)     11 .037m / sec
 d v  Ah 
(Ah / Aa) * 100 = (0.23/2.87)*100
= 8.02
From figure 11.34, 6th Ed. “Coulson and Richardson’s” ,At (Ah/Aa)*100=8.02, When
Plate thickness to plate dia ratio is 1.
Then, Co = 0.83
2
U   dv 
hd  51 h   
 Co   dl 
= 33.76 mm liquid
Reisdual Drop:
12.5  103
hr 
dl

= 10.4 mm liquid
Total Plate Pressure Drop:
ht  hd  hr  (ho  how )

= 116.04 mm liquid
3
Pt  9.81 10  ht  dl

= 1368.3Pa = 1.36 KPa

13. RESIDENCE TIME

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Chapter 7 Design of distillation column

Downcomer Liquid backup/ Liquid height in downcomer:

Let, hap= hw-10
= 40 mm = 0.04m
Area under apron = hap*lw
Aap = 0.04*1.92
= 0.0768m2
As Aap is less than Ad = 0.59m2
2
 Lw 
h dc  166   
 d l  Aap 
 
=5.27mm
H D  H t  H dc  (ho  how )

= 116.04 + 5.27+ (71.88)

=193.2 mm=0.2m
Since,
HD < 0.5*(Tray spacing +Weir height)
0.200<0.253
So, tray spacing is acceptable.
Residence Time:
Ad  hbc  d l
tr 
Lw
= 8.26 sec
As residence time is greater than 3 sec, so satisfactory

14. ENTRAINMENT
Un
Uv   100
Uc
Where
Vm
Un 
d v  Ah
= 0.764 m/s
Uv = 80.3 % (Our Assumption is correct.)

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Chapter 7 Design of distillation column

Flv = 0.0675
From Graph 11.29, 6th Ed. “Coulson and Richardson”
Fractional entrainment= ψ = 0.052
As, entrainment is less than 0.1, process is satisfactory.

15. PLATE SPECIFICATIONS

Use Sectional type construction, Allow a total of 100mm allowance on diameter for
extension of tray ring type supports into the tower. This reduces the available tray area.
Allow 125mm clearance (no holes) between downcomer and first row of holes.
Since lw//Dc = 0.77 From Graph 11.32 ,6th Volume, “ Coulson and Richardson”
Lh/Dc = 0.18 Lh = 0.45m
Area of the segment of the circle-2 (The circle excluding the allowance for ring
construction) with chord (made by the distance b/w downcomer and first row of holes).
Diameter of circle-2 = 2500-100 = 2400 mm = 2.4 m
Radius of circle-2 = 1.2 m
Height of the chord = 1.2 – (1.25-0.45-0.125)
= 0.525 m
Chord height / Circle-2 dia. = 0.525/2.4 = 0.218 m
Reffering to Perry’s Handbook, Page 32, 3rd ed.
Area of unperforated strips (Chords) = 0.13  (2.4)2 = 0.747 m2
Area of circle-2 = 4.52 m2
Area available for perforation = Ap = 4.52 – 0.747 – 0.747 = 3.026 m2
Ah/Ap = 0.3/3.026
= 0.088
From Graph 11.33, 6th Ed., Coulson and Richardson l p/dh = 3.2
(satisfactory i.e. b/w 2.5—4.0)
Hole Pitch:
lp/dh = 3.2
lp=16mm Triangular
Number Of Holes per plate:
 2
Area of one hole = a h  dh
4

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Chapter 7 Design of distillation column


ah  0.005 2 = 1.96 × 10-5 m2
4
Ah
Number Of Holes = n 
ah

Number Of Holes = 15307

16. HEIGHT OF THE COLUMN

No. of plates = 29
Tray spacing = 0.457 m
Distance between 29 plates = 0.457  29 = 13.25 m
Top clearance = 0.7 m
Bottom clearance = 0.5 m
Tray thickness = 5 mm/plate
Total thickness of trays = 0.005  2.9= 0.145 m
Total height of column = 13.25+ 0.7 + 0.5 + 0.145
Ht = 14.6m

17. MATERIAL OF CONSTRUCTION

SHELL:
Diameter of the tower =Di = 2500 mm = 2.5 m
Working/Operating Pressure = 1.01325 bar =101.325 Pa
Design pressure = 1.1×Operating Pressure = 1.1×101.325 = 111.4575 KPa
Working temperature = 252.22 ºC
Design temperature = 1.1×252.22=577.7 ºC
Shell material = Stain steel Type-317
Permissible tensile stress (ft) = 73.100 MN/mm2
Insulation material = Mineral wool
Insulation thickness = 50 mm
Density of insulation = 130 kg/m3
HEAD - TORISPHERICAL DISHED HEAD:
Material = Stain steel Type-317
Allowable tensile stress = 73.100 MN/mm2
SUPPORT SKIRT:

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Chapter 7 Design of distillation column

Height of support = 5000 mm = 5000 m

Material – Carbon Steel

18.SHELL MINIMUM THICKNESS

Considering the vessel as an internal pressure vessel.
P  Ri
ts  C
 f t  J   0 .6 P
Where ts = thickness of shell, mm
P = design pressure, Pa
Ri = Radius of shell, m
ft = permissible/allowable tensile stress, MN/m2
C = Corrosion allowance, 3mm
J = Joint factor
Considering Double welded butt joint in fully radio graphed with backing strip
J= 100% = 1.00
Thus,
ts = 3.26mm
Taking the thickness of the shell = 9 mm (Standard)

19. HEAD DESIGN

Type: Torispherical head
Thickness of head:
P  Rc  0.885
th  C
 ft  J   0.1P
Where th= thickness of head
P = internal design pressure, Pa
Rc = Crown radius = Diameter of shell ,m
Including corrosion allowance take the thickness of head = 3 mm
th= 3.23 mm
Thickness of head=8mm (Standard)

20. STRESSES DUE TO COMBINED LOADINGS

Dead weight of Vessel

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Chapter 7 Design of distillation column

Wv  C v  m Dm g ( H v  0.8 Dm )t  10 3

Where
Wv = Total weight of the shell, excluding internal fittings such as plates
Cc = A factor to account for the weight of the nozzles, manways, internal supports, etc;
which can be taken as 1.15 for the distillation column
Hv = Height or length b/w tangent lines (the length of cylindrical shell),m,
g = Gravitational acceleration, 9.81 m/sec2
t = Thickness of the shell wall, mm
ρm = Density of vessel material, Kg/m3
Dm = Mean diameter of vessel = (Di + t × 10-3), m.
= (2.5 + 9 × 10-3) = 2.509 m
Wv  1.15  3.14  1161  7850  9.81(2.5  0.8  2.509)9 10 3

= 103.47 KN
Weight of contacting plates
Contacting plates, steel, including typical liquid loading, 1.2 KN/m 2 plate area = 1.2 ×
2.94 = 5.88 KN
No. of plates = 29
Total weight of contacting plates = 29 × 5.88 = 170.52 KN
Weight of insulation
Mineral wool density = 130 Kg/m3
Approximate volume of insulation = π × 2 × 14.6 × 50 × 10-3 = 4.60 m3
Insulation weight = 4.6 × 130 × 9.81 = 5.8 KN
Double this to allow for attachment fittings, sealing, and moisture absorption. i.e. = 12
KN
Total weight of insulation = 170.52 + 12 + 103.47 = 286 KN
Wind Loading
Take dynamic wind pressure as 1280 N/m2
Mean dia. Including insulation = 2.5 + 2 ( 9 + 50 ) × 10-3 = 2.62 m
Loading per linear meter = Fw = 1280 × 2.62 = 3353.6 N/m
3353.6
Bending moment at the bottom of the tangent line = M   14.6 2
2

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Chapter 7 Design of distillation column

= 357426.68 Nm
Analysis of Stresses
At bottom tangent line
Pressure stress
Longitudinal stress and Circumferential stress due to internal pressure are
PDi
L   7.74 N / mm 2
2t
PDi
h   15.5 N / mm 2
4t
Dead weight stress
The direct stress δw due the weight of the vessel, its contents, and any attachments. The
stress will be tensile (positive) for points below plane of the vessel supports and
compressive (negative) for points above the supports.
W
w 
 ( Di  t )  t
286
w   4.03N / mm 2 (Compressive because we are considering bottom
 ( 2500  9)  9
tangent line)
Bending Stress
Bending stresses resulting from the bending moments to whic the vessel is subjected.
Bending moments will be caused by the following loading conditions:
1. The wind load on the tall self-supported vessels.
2. Seismic (earthquake) loads on the tall vessel.
3. The dead weight and wind loads on piping and equipment which is attached to the
vessel, but offset from the vessel centre line.
The bending stresses will be compressive or tensile depending upon location and are
given by
M  Di 
b     t
Iv  2 
Where M is the total bending moment at the plane being considered and l v the second
moment of area if the vessel about the plane of bending.

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Chapter 7 Design of distillation column

Iv 

64
 4
D o  Di
4
 Do  2500  2  9  2518mm


Iv 
64
 25184  2500 4   5.58mm 4

3574226.68  10 3  2500 
b     9   8.06 N / mm 2
5.58  10 3
 2 
The resultant Longitudinal stress is
 z  L  w  b

Since δw is compressive and there for negative.

δz (up-wind) = 7.74 -4.03+ 8.06 = + 11.77 N/mm2
δz (down-wind) = 7.74 – 4.03 – 8.06 = -4.35 N/mm2

15.5

11.77 4.35

15.5

Up-wind Up-wind

The greatest difference b/w the principal stresses will be on the downward side
15.5 – (- 4.35) = 19.85 N/mm2 well below the maximum allowable stress (73.1N/mm2)
Check Elastic stability(buckling)

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Chapter 7 Design of distillation column

Critical buckling stress

t
 c  2  10 4 
Do

9
 c  2  104   71.5 N / mm 2
2518
The maximum compressive stress will occur when the vessel is not under pressure is 8.06
+ 4.35 = 12.41 N/mm2 well below the critical buckling stress.
 Design is satisfactory

7.5 CONDENSERS
A condenser is a two-phase flow heat exchanger in which heat is generated from the
conversion of vapor into liquid (condensation) and the heat generated is removed from
the system by a coolant. The basic types of condensers are shown:

Types of Condensers:

 Steam Turbine Exhaust Condensers/surface condensers

 Plate Condensers
 Air-Cooled Condensers
 Direct Contact Condensers
 Shell & tube type
Selection of suitable Condenser Configuration :
Four Condenser Configuration are Possible
1) Horizontal with condensation in shell side.
2) Horizontal with condensation in tube side.
3) Vertical with condensation in the shell.
4) Vertical with condensation in the tubes.
Horizontal shell side and vertical tube side are the most commonly used types of
condensers.
In a vertical tube condenser, about 60% of the vapors condense in the upper half
section of the tubes. The heat transfer coefficients for horizontal arrangement are about

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Chapter 7 Design of distillation column

three times more than the vertical arrangement. Maintenance and structural supports for
vertical condensers may be costly and considerably much more difficult. On the other
hand if it is desired not only to condense the overhead product but also to sub cool the
condensate, vertical condenser is admirably suitable. A horizontal condenser with the
condensation inside the tubes is rarely used as a process, but it is the usual arragment for
heaters and vaporizers using condensing steam as the heating medium.
In this process, I have selected horizontal configuration with the condensation inside
the shell based upon above mentioned considerations.

7.6 DESIGN CALCULATIONS OF CONDENSER

(E-312)
SPECIFICATION SHEET
Identification: condenser
No. Required = 1
Function: Condense vapor mixture of (COCL2,ODCB,TDI) by removing the
latent heat of vaporization
Operation: Continuous
Type: 1-2 Horizontal Condenser
Shell side condensation
Heat Duty = 11202300 KJ/hr
Tube Side: Tubes: OD:19 mm , 16 BWG
Fluid handled cold water 224 tubes each 2.4 m long
Flow rate = 88907.14 Kg/hr 2 passes
Pressure = 506.6Kpa 24 inch triangular pitch
Temperature = 30oC to 60oC pressure drop = 8.04 Kpa
No. of tubes = 224

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Chapter 7 Design of distillation column

Shell Side: Shell: ID = 0.438 m

Fluid handled (COCL2=0.06%,ODCB 1 passes
=99.78%,TDI=0.16%) Baffles spacing 0.8 m
Flow rate= 40687.86 Kg/hr Pressure drop = 24.3 Kpa
Pressure = 61.88 Kpa
Temperature= 160oC
Utilities: Cold water
UD assumed = 850 W/m2 oC UC calculated = 1274.6 W/m2 oC
Calculated dirt factor = 0.00039 Allowed dirt factor = 0.00032

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Chapter 7 Design of distillation column

DESIGN STEPS:

T1= 160oC T2= 160oC

t2= 60 oC t1= 30oC

Inlet temperature of the process stream = T1 = 160 oC

Outlet temperature of the process stream = T2 = 160 oC
Inlet temperature of the water = t1 = 30 oC
Outlet temperature of the water = t2 = 60 oC
Molar flow rate of the process stream = Vn = 276.6 Kgmole/hr
λ of Process Stream = 40500 KJ / Kgmole

1.HEAT LOAD
Q = Vn(  )
Q = 276.6 (40500)
Q = 11,202,300 KJ/hr
Mass flow rate of cooling water
Q
w
C p Δt

11202300

(1)(60  30)

= 88907.14 Kg/hr

2.LMTD
(T1  t 2 )  (T2  t1 )
LMTD 
T t
Ln 1 2
T2  t 1

= 114.34 oC

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Chapter 7 Design of distillation column

3.ASSUEMED CALCULATIONS
Value of UD Assumed
UD = 850 W/m2 oC
Heat Transfer Area
Q
A
U D  LMTD

= 32.017 m2
Tube Specifications
Assume Configuration is 1 shell side passes and 2 tube side passes
Tube length = L = 2.4 m
Tube O.D. = 19 mm
Tube Pitch = PT = 24 mm Triangular
Baffle spacing = B = 0.8 m (25% segmental cut baffles)
Clearance = C = PT - B = 5 mm
Outer surface per linear meter =at= 0.06m2
A
No. of Tubes 
at  L

No. of tubes = 222

From Table 10 on “Process Heat transfer” by DQ Kern, By the nearest count
No. of tubes = Nt = 224
Corrected UD
Q
UD 
N t  L  at  LMTD

= 843.7 W/m2 oC

4.CALCULATIONS OF FILM COEFFICIENTS

Tube Side Calculations: Cold Fluid
Flow Area
Flow area/tube = at  = 0.0002 m2

N t  at
at  = 0.0224 m2
n

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Chapter 7 Design of distillation column

Mass Velocity
Gt = W/at
= 3969068.75 Kg/hr-m2
Water Velocity
V = Gt / 3600
= 1.1 m/sec
At ta = 45 oC
 = 0.66×10-3Pa.sec
I.D of tube = 15.7 mm
Reynold No.
Ret = DGt/
= 26226.6
From figure 25 on Kern hi = 5678.3 W/m2-oC
I.D
hio = hi 
O.D
hio = 4692 W/m2-oC

Shell Side Calculations: Vapors

Flow Area
ID  C  B
as 
PT

= 0.073 m2
Mass Velocity
W
Gs 
as

= 557367.94 Kg/hr-m2

Loading
W
G   2/3
L  Nt

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Chapter 7 Design of distillation column

276.6  147.1
G  
2.4  224 2 / 3
= 459.6 Kg/hr-m2
Assumption
ho = 2000 W/m2- oC
ho
tw  ta  (Tv  t a )
(hio  ho )
2000
t w  45  (160  45)
( 4692  2000)

= 79.4 oC
Film Temperature
Ta  t w
Tf =
2
= 119.7 oC
Physical Properties at Tf
Thermal conductivity kf = 383.22 micro-cal/sec-cm-oC
Specific gravity Sf = 1.2
Viscosity f = 0.31 cp
From Figure(12.9) on Kern,
h = ho calculated = 1750 W/m2-oC
Based upon a new value of h = ho , This would give a new value of h o , tw and tf.
But that value would be nearly same as one read from the graph.
Clean Overall Coefficient
h io h o
UC 
h io  h o
= 1274.6 W/m2-oC
Design Overall Coefficient Calculated
UC  UD
Rd 
UCUD

= 0.00039
Allowable dirt factor Rd = 0.00032 (Satisfactory)
4.PRESSURE DROP CALCULATIONS

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Chapter 7 Design of distillation column

Shell side:
Reynolds No.
At Ta G = 0.011 cp
De = 0.014 m ( From Graph 28 on Kern )
Res = DeGs/G
= 197018.2
For Res = 197018.2 From Graph 29 on Kern
Friction factor for shell side f = 0.0012 ×144 = 0.1728 ( making dimensionless)
No. of crosses, N + 1 = L/B = 3
Density = ρ = 4 Kg/m2 (by using ideal gas equation)
S = specific gravity = 0.004
2
1 f  G s  Ds  ( N  1)
Ps  
2 2.54  1011  De  s
= 24.3 KPa = 3.5 PSI
Pressure Drop (Tube Side)
Reynolds No.
For Ret = 26226.6
Friction factor for tube side f = 0.00012 ×144 = 0.0173 (making dimensionless)

f  G 2t  L  n
Pt  11
2.54  10  D  s
= 3.2 KPa
4 n V2
Pr    w
s 2g

= 4.84 KPa
PT  Pt  Pr = 3.2 + 4.84 = 8.04 KPa = 1.2 PSI

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Chapter 7 Design of distillation column

7.7 REBOILERS
Reboilers are used with the distillation columns to vaporize a fraction of bottom product:
whereas in a vaporizer essentially all the feed is vaporized.
Three principal types of reboiler are used:
1. Forced circulation, in which the fluid is pumped through the exchanger, and the vapor
formed is separated in the base of the column.
2. Thermosyphon, natural circulation, Vertical exchangers with the vaporization in the
tubes, or horizontal exchangers with the vaporization in the shell. The liquid circulation
through the exchanger is maintained by the difference in the density between the two
phase mixture of vapors and liquid in the exchanger and the single-phase liquid in the
base of the column.
3. Kettle type, Fig. 7.2: in which boiling takes place in the pool of liquid with which tubes
are immersed: there is no circulation of liquid through the exchanger. This type is also,
more correctly, called a submerged kettle reboiler.

Fig. 7.2: Kettle reboiler

In some applications it is possible to accommodate the bundle in the base of the column,
saving the cost of the exchanger shell but that arrangement is not used for large capacity.
Choice of Type

90
Chapter 7 Design of distillation column

The choice of the best type of reboiler for a given duty will depend upon the factors like
nature of the process fluid, particularly its viscosity and propensity to fouling, the
operating pressure: vacuum or pressure and the equipment layout, particularly the head
room available.
In this process Ketlle Type reboiler is selected as a best choice due to following reasons.
 The system is not fouling.
 It has a high residence time.
 High rate of vaporization, about 90 per cent of feed is vaporized.
 Relatively less costly.

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Chapter 7 Design of distillation column

7.8 DESIGN CALCULATIONS OF REBOILER

(E-313)
SPECIFICATION SHEET
Identification: Reboiler
No. Required = 1
Function: To vaporizethe bottom product of distillation column.
Operation: Continuous
Type: Kettle type
Heat Duty = 11202300 KJ/hr
Tube Side: Tubes: OD:19 mm , 16 BWG
Fluid handled utility fluid: Dimethyl 224 tubes each 2.4 m long
siloxane 2 passes
Flow rate = 247422.47 Kg/hr 24 inch triangular pitch
Pressure = 400Kpa pressure drop = 22.4 Kpa
Temperature = 326oC to 304oC No. of tunes = 506
Shell Side: Shell: ID = 1.08 m
Fluid handled (ODCB Tube bundle dia. = 0.6 m
=0.5%,TDI=87.9%, Residues = 11.5%) 1 passes
Flow rate= 5586 Kg/hr Pressure drop = Negligible
Pressure = 105 Kpa
Temperature= 252.22oC
Utilities: Thermal fluid: Dimethyl siloxane
UD assumed = 596 W/m2 oC UC calculated = 736 W/m2 oC
Calculated dirt factor = 0.00032 Allowed dirt factor = 0.00032

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Chapter 7 Design of distillation column

DESIGN STEPS:

T1= 326oC T2= 304oC

t2= 252.22 oC t1= 252.22oC

Inlet temperature of the utility fluid stream = T1 = 326 oC

Outlet temperature of the utility fluid stream = T2 = 304 oC
Inlet temperature of the process fluid = t1 = 252.22 oC
Outlet temperature of the process fluid = t2 = 252.22 oC
Molar flow rate of the process stream = Vn = 276.6 Kgmole/hr
λ of Process Stream = 40500 KJ / Kgmole

1.HEAT LOAD
Q = Vn(  )
Q = 276.6 (40500)
Q = 11,202,300 KJ/hr
Mass flow rate of Dimethlyl siloxane
Q
W
C p Δt

11202300

(1)(326  304)

= 227422.47 Kg/hr

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Chapter 7 Design of distillation column

2.LMTD
(T1  t 2 )  (T2  t1 )
LMTD 
T t
Ln 1 2
T2  t 1
= 62.13 oC

3.ASSUEMED CALCULATIONS
Value of UD Assumed
UD = 596 W/m2 oC
Heat Transfer Area
Q
A
U D  LMTD

= 83.2 m2
Tube Specifications
Assume Configuration is 1 shell side passes and 2 tube side passes
Tube length = L = 2.4 m
Tube O.D. = 19 mm
Tube Pitch = PT = 24 mm Triangular
Outer surface per linear metre=at= 0.06m2
A
No. of Tubes 
at  L

No. of tubes = 466

From Table 10 on “Process Heat transfer” by DQ Kern, By the nearest count
No. of tubes = Nt = 506
1/ 
N 
Dia. Of the tube bundle = Db  Do  t 
 C 
Where C and Δ are the typical constants, for triangular pitch C = 0.249 and Δ = 2.21
1 / 2.21
 506 
Db  0.019   0.6
 0.249 

From “Unit operations of chemical engineering “ by Chattopadhayay

Tube bundle to shell dia ratio. = 1.8 ( when heat flux is greater than 40 KW )
I.D. of Shell = ID = 0.6 × 1.8 = 1.08 m

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Chapter 7 Design of distillation column

4.CALCULATIONS OF FILM COEFFICIENTS

Tube Side Calculations: Dimethyl siloxane

Flow Area
Flow area/tube = at  = 0.0002 m2

N t  at
at 
n
= 0.0506 m2
Mass Velocity
Gt = W/at
= 1358.27 Kg/sec-m2
Water Velocity
V = Gt / 
= 1.82 m/sec
At ta = 45 oC
 = 0.43×10-3Pa.sec
ID of tube = 15.7 mm
Reynold No.
Ret = DGt/
= 50000
From “Chemical Engineering Progress” July-1994
hi = 1567.2 W/m2-oC
I.D
hio = hi 
O.D
hio = 1295 W/m2-oC

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Chapter 7 Design of distillation column

Shell Side Calculations: Vapors

Assumption
ho = 1703.5 W/m2- oC
ho
tw  ts  (Ta  t s )
(hio  ho )
2000
t w  252.22  (315  252.22)
( 4692  2000)

= 279.33oC
Δtw = 279.33-252.22 = 27.22 oC
From graph 11.5 on Kern h = ho calculated = 1703.5 W/m2-oC
Clean Overall Coefficient
h io h o
UC 
h io  h o
= 736 W/m2-oC
Design Overall Coefficient Calculated
UC  UD
Rd 
UCUD

= 0.00032
Allowable dirt factor Rd = 0.00032 (Satisfactory)

4. PRESSURE DROP CALCULATIONS

Pressure Drop (Tube Side)
Reynolds No.
For Ret = 50000 From graph 26 on Kern
Friction factor for tube side f = 0.00018 ×144 = 0.026 (making dimensionless)
S = 672/1000 = 0.67

f  G 2t  L  n
Pt  11
2.54  10  D  s
= 9.16 KPa

96
Chapter 7 Design of distillation column

4 n V2
Pr    w
s 2g

= 13.5 KPa
PT  Pt  Pr = 9.16 + 13.5 = 22.6 KPa = 3.25 PSI

5. CHECK FOR MAXIMUM HEAT FLUX

Heat flux on the basis of estimated area is
Q 3111750
  34.16 KW / m 2
A 506  0.06  3
Satisfactory as it is less than the Maximum Heat Flux 20,000 BTU/hr.ft2
Or 68 KW/m2

7.9 NOMENCLATURE
Aa = Active Area
Ad = Downcomer Area
Ah = Hole Area
An = Net Area available for vapor liquid disengagement
Ac = Column Area
Aap =Area of Apron
Ah = Hole Area
Ap = Area of Perforations
as = Area of shell
a//t = Flow area
at = Flow area per tube
B = Baffle Spacing
C = Clearance b/w tubes
Cp = Specific Heat Capacity
Co = Orifice coefficient
D = Inside diameter of tubes
De = Equivalent diameter of shell
Ds = Inside diameter of shell
Dc = Column diameter
dl = Density of liquid

97
Chapter 7 Design of distillation column

dv = Density of Vapors
dh = Hole diameter
Pt =Total Pressure Drop,Pa(N/m2)
Eo =Overall column Efficiency
F = Flow rate of feed
Flv = Liquid Vapor flow rate factor
f= Friction Factor
Gt = Tube side mass velocity
Gs = Shell side mass velocity
hi , ho = Inside and Outside film coefficient
hio = Value of hi when referred to the tube ,OD,Btu/hr.ft2.oF
Hv = Heat of vaporization
hap = Height of Apron
Ht =Height of Column
HD=Height of liquid back up in Downcomer
hd = Pressure drop through dry plate
hdc = Head Loss
hk = Heavy Key
hr = Residual head
Hs = Plate spacing
ht = Total plate pressure drop,mm liquid
hw = Weir height
how = weir crest
ID = Internal Diameter
K1 =Constant obtained from figure
K2 = Constant obtained from figure
lk= Light Key
Lm = Molar liquid flow rate of top
Ln = Molar flow Rate of liquid at top
Lw = Flow Rate of liquid at bottom
lw = Weir Length

98
Chapter 7 Design of distillation column

L = Tube Length,ft
LMTD = Log Mean Temperature Difference
m= Mass flow rate of vapors
n = Number of passes
OD = Outer Diameter
PT = Tube Pitch
ΔP, ΔPt, ΔPr = Total,tube,return pressure drop
ΔPs = Pressure drop of shell
Rmin =Minimum Reflux
Rd = Combined dirt factor
Re = Reynolds number,dimensionless
s= Specific Gravity
tr = Residence time
Uc = Vapor velocity
Uc* = Flooding vapor velocity
Uhmin = Minimum vapor velocity through holes
UC,UD = Clean overall coefficient for condensation,desuperheating
Vm = Mean Molal vapor flow rate of top and bottom
Vn = Vapor Flow Rate at top
Vw = Vapor Flow Rate at bottom

99