Introduction:

Distillation is most common class of separation processes and properly of the

better-understand unit operation that uses the difference in relative volatilities
, or differences in boiling of the component to be separated, it is the most widely
used method of separation in the process industries Types of distillation column:

❖ Single flash vaporization.

❖ Packed towers.
❖ Plates towers.
a) Bubble cap towers.
b) Sieve pates.
c) Valve plates towers.
Sieve trays: Sieve trays offer several advantage over bubble-cap trays, and their
simpler and cheaper construction has led to their increasing use. The general
form of the flow on a sieve tray is typical of a cross flow system with perforation
in the tray taking the place of the more complex bubble caps. The key differences
in operation between these two types of tray should be noted. With the sieve
tray the vapor passes vertically through the holes into the liquid on the tray,
whereas with the bubble cap the vapor issues in an approximately horizontal
direction from the slots . With the sieve plate the vapor velocity through the
perforation must be greater than a certain minimum value in order to prevent
the weeping of the liquid stream down through the holes. At the other extreme,
a very high vapor velocity leads to excessive entrainment and loss off tray
efficiency.
Fluids:
-Feed stream:
At 4030 K, 2000 KPa.
Component Moleflow Mole% Mass flow Wt%
(kmol/h) (kg/h)

methanol 2516.10 0.2170066 80615.844 0.125340067

Comp A 428.05 0.0369181 24017.8855 0.037342577
Comp B 1817.511 0.1567552 101977.3431 0.158552542
Comp C 5172.917 0.4461496 290236.8929 0.451255111
Comp D 1660.00 0.1431703 146329 0.227509702
water 0 0 0 0
Total 11594.58 1 643176.9655 1
Feed stream composition.

-Top product stream: At400 o K, 1900KPa.

Component Mole flow Mole% Mass flow Wt%
(kmol/h) (kg/h)

methanol 2428.7308 0.246641 77816.57994 0.15750861

Comp A 428.0505 0.043468 24017.914 0.0486161
Comp B 1817.512 0.184579 101975.46 0.2064048
Comp C 5172.912 0.525310 290236.83 0.5874676
Comp D 0 0 0 0
water 0 0 0 0
Total 9847.236 1 494046.06 1
Top stream composition
-Bottom product stream:

At 440 o K, 1925.175 KPa

Component Mole flow Mole% Mass flow Wt%
(kmol/h) (kg/h)

methanol 87.36842 0.05 2799.284211 0.018770981

Comp A 0 0 0 0
Comp B 0 0 0 0
Comp C 0 0 0 0
Comp D 1660 0.95 146329 0.981229019
water 0 0 0 0
Total 1747.368 1 149128.2842 1

Bottom stream composition -Relative

volatility:
Component αfeed αtop αbottom Αav
methanol 1.186110 1.162297499 1.448866438 1.265758
Comp A 4.214615 4.270349142 3.743897719 4.076288
Comp B 4.281515 4.345063797 3.73236071 4.119647
Comp C 3.479708 3.515657126 3.194453855 3.396606
Comp D 1 1 1 1
water 0.381770 0.369823631 0.51937441 0.423656

Average relative volatility of composition.

Heavy and light key:

Heavy key: MTBE

Light key: methanol.

Type of tray:

Sieve tray.
5.1.5. Determination of minimum reflux ratio:

(1)
α= average Relative volatility of any component.
X= mole faction of component in Distillate.
Ø= Constant.
Rm = Minimum reflux ratio.

(2)
Where:
Zf= mole faction of component in feed stream.
q= feed quality

q=
HG=Enthalpy of gas at the feed dew point (KJ/Kmol) HL=Enthalpy
of liquid at the feed bubble point (KJ/Kmol)

HF=Enthalpy of feed at 403o K.

q=
Substitute in equation (2) to find (Ø)

+
Solving Ø By try &error:
Ø =1.047365
Substitute in equation (1) to find Rm:

Rm= 1.494995

Calculation of the actual ratio(R)

The rule of thumb is:

R = (1.2 ------- 1.5) R min
R=1.2Rm
=1.2×1.5 = 1.8
Calculation of the minimum number of theoretical stages:

=mole fraction of light key.

= mole fraction of heavy key.
= average relative volatility of light key.

Nmin= 26 stagess

Calculation of the number of theoretical stages:

From Gilland relation.

→ N=57.695 stages

Calculation of the column efficiency (E˳):

E˳= 0.5278-0.27511 log(αlk*μF)+0.04493(log(αlk* μF))2

μF=0.2161 E˳=69.29%
Calculation of the number of actual stages (Na):

Calculation of the height of the column (Ht):

Ht=N×C+ + 0.2 ×
C: tray spacing = 0.609(so as to ensue accessibility for cleaning)

0.8Ht = 84×0.3+= 27.69

Ht=34.6 m.

Determination of the feed plate location (m):

D=9847.2118Kmol/h B=1747.368 Kmol/h

m=

m=22 stage
The feed enter the column at tray no 22 from the Bottom.
Calculation of the tower diameter(D):

The following areas terms are used in the plate design procedure:
At=Total column cross- sectional area,
Ad=cross-sectional area of down comer,
An=Net area available for vapor-liquid disengement, normally equal to Ac-Ad for
a single pass plate,
Aa= Active or bubbling, area, equal to Ac-2Ad for single- pass plates,
Ao=Hole area, the total area of all the active holes,
Ap= perforated area (including blanked areas),
Aap= The clearance area under the down comer apron.
-Top diameter calculation:

UF
Where:
= floading vapor velocity (m/s) based on the net column cross sectional area
.
K=constant

FLV
Where:
= the vapor liquid flow
= Liquid mass flow rate kg/s
= Vapor mass flow rate kg/s
Top Diameter calculations:

From ideal gas law: PV= nRT

Design velocity (U)= 80% of ( )

U = 0.8* 0.753 = 0.602m/s

= 0.12
= − 0.12 = 0.88

D=
-Bottom diameter calculations:

Ideal gas law:PV= nRT

At FLV= O.261 and spacing 60 mm

Design velocity (U) = 80% of flooding velocity ( )

0.8× 0.178 = 0.1424m/s

Down comer area =12% from total area=0.88

D=
Taking the bottom diameter for the entire tower since it is the greatest diameter.

2
= 1.36
= 0.12

=0.12×1.36=0.1632
2

2. o =
= 1.36 – 2(0.1632) = 1.0336
2.
0.1× = 0.10336

2.
= 0.07× = 0.07 × 1.36 = 0.0952
 =Preformatted area:
When down comer area = 0.12×

Where : Weir length.

=0.75×D= 0.75 × 1.3172=0.9879 M

Angle subtended at plate edge by imperforated strip=180- 98=82

Calming zones width=50mm
Mean Length, imperforated edage strips

= (1.3172 −50×10−3 ) π × ( ) = 1.813 m

Area of imperforated edge strips= 50 * 10−3 × 1.813 = 0.0906 2

Mean length of calming zone = (1.3172−50*10

Area of calming zone =2(0.9563*50*10−3 ) = 0.09563 2

Total area for perforatins, = 1.336− 0.0906 −0.09563 = 0.8473 2

Where : hole pitch.

2.716 are satisfactory, within 2.5 to 4.0.

Determination of fractional entrainment (ϕ):

=0.261 and 80% flooding ϕ= 0.09(well below 0.1).

e= =160.973kg/h.

Weeping point:

Weeping will occur when (min) < (min) calculated.

Taking 70% turn down.

(min) = 0.7× = 0.7 ×2.3175 = 1.624 m/s.

(min) calculated
=5mm
2is a function of ( + (min))
: weir hight = 23 mm

(min): minimum weir crest =750×

= o.7×17724.98 = 12407.486kg/h.

(min) calculated =
Weeping will not occur.
Pressure drop calculation:

∆P = 9.81 × ×10−3×

At = 12.198%&

= 23mm

= 21.31+36.23+23+17.16=97.7mm

∆P= 9.81 ×97.7×10−3×728.228

= 0.007 bar/tray.
Down comer liquid back up: For safe design

and to avoid flooding

= ×
= -10mm
23-10=13mm

=0.9879 ×10−3×13=0.013mm

=97.7+36.23+23+4.67=201.83mm

(0.3+23×10−3) =0.323m.
no floading will occure.
5.1.18. Down comer residence time:

4.8>3 so it is acceptaple 5.1.19,

Thickness calculation:
- columan thickness:

Highest operating temperature is 166.850C. Design stress at 166.850C

= 111 N/ 2.

Joint efficiency = 0.85.

e=
Corrosion allowance 2mm.
=2.01357 .

-Head thickness:
- Ellipsoidal heads:

e=
-Tori spherical head

e=
Stress concentration factor for torispherical head

Crown radius.

=no less than 0.6

=knukle radius

J =1(No joint in head).

E = 0.01224mm.
Ellipsoidal heads IS recommended since it has the smallest thickness
 =0.011 .

Parameter Value
Tower diameter 1.3172m
Tray spacing 0.30
Tower Height 34.6m
Total area(cross sectional area)
1.36 2
Down comer area
0.1632 2
Net area
1.19 2
Active area
1.0336 2
Hole area
0.10336 2
Number of theoretical stages 57.695 stages
Tower efficiency 69.29%
Plate thickness 0.005m
Weir height 0.005m
Weir length 0.987m
Hole diameter 0.005m
Fractional entrainment 0.09
Weeping velocity 1.5m/s
Total presser drop head 0.007 bar
thickness Of column 2.01357mm
thickness Of head 0.011mm
Material balance around distillation column (T-901):

F7=F8 + F9
11594.53-1747.37=9847.21=F9

Methanol balance:
M7F7=M8F8 + M9F9
2516.10-87.37=2428.73=M7F7=M7F9

Com B & C balance:

BF7=BF8 + BF9

428.05=0+ISO9F9 , B9F9=428.05

Other butane balance:

C7 F7=C8 F8 + C9F9
6990.43= 0+C9 F9
C9 F9=6990.43

F9=F10
F10 = 6990.4
Energy balance around distillation column
(T901):

Q r − Q c = H9 + H8 − H 7

H9 = HD9 + HM9 + HA9 + H1−B9 + H2−C9 − HW9

PT = 19 bar.
T= 313.3°K (bubble point).

HD9 = MD
MD9 from material balance calculation = 0.00Kmol/h.
HD7 = 0.00KJ/h.

HM9