Calculation for Number of

Plates in Distillation

Fahad Ali

DDP-SP13-BEC-017-A

Submitted to:

Dr.Fahad Rahman

SEPTEMBER 21, 2016

Methods to Determine the Number of Plates in Distillation

Introduction:
Distillation is a simple unit operation used for separation of components from their mixture. This
process is widely used although its efficiency is 10%. But it is economically cheap. During the
designing of distillation column finding the number of plates is main concern as it is a deciding
factor that how many stages required, pinch point determination, feed entry point, maximum reflux
required.(Sorensen, 2014)
These methods are discussed in this paper.
Lewis and Solely method of distillation
Before the work of Lewis hit and trial method is used for computing number of plates in distillation
column. Lewis and his student solely apply material and energy balance across distillation column
and gives equation for the determination of number of plates.(nirali, n.d.)
There are two equations
For rectifying unit

For stripping unit

Here n is the number of plate at which mass transfer is taking place. The value of n where
composition become equals to feed composition is the feed plate position. And the value of n
where composition become equal to bottom component is number of plates for stripping section.
The sum is the total number of theoretical plates required.(Manning et al., 1995)

Restrains in using this.

This method gives accurate results about number of plates, feed type, reflux ratio and minimum
reflux ratio required. But the calculation is very extensive and slight error changes the while
situation. But with the uses of computers this method again popularity as it is not hit and trial based
graphical base. A simulation of all equations is solved by computers and accurate answer can be
received. It can also be used for complex mixture and multi component systems if computer help
is taken. (Sorensen, 2014)

McCabe and Thiele method

It is a simply a graphical presentation of Lewis and solely method which gives direct results to
pinch point, minimum reflux, total reflux and number of plates just by drawing equilibrium data
which is obtained by experiments. Then by drawing top operating line and bottom operating line
one can determine how much stages are required in column.(Diwekar, 2011)

Limitations

This method very much declined after the use of computers now a day its only use for
analytical and visual study of column and get direct results about pinch point and refluxes.
Some other limitations are as follow;
It cant be used in cases where relative volatility is less than 1.3 and more than 5 as
equilibrium curve shrinks or expand out of scope.
This method for calculating number of plates more than 25.
It also fails when the operating reflux ratio is less than 1.1 times the minimum reflux ratio.
Also it is only applicable for binary component systems.

(nirali, n.d.)

Underwood and Fenske Equation

This is the shortest theoretical method used to obtained number of plates. The Fenske equation is
used to find minimum number of plates and Underwood equation is used to find minimum
reflux. This method gives direct results with less error.(Badger, 2001)
The equations are;
Fenske Equation

Underwood Equation

These equations can also be used for multi-component systems. In multi-components the
deciding factor is low key components and heavy key components. The equation modified for
multi-components is as follow;

Limitations:
One of the main limitation is the assumption that continuous molar flow rate which calculate
minimum reflux which is lower than actual value.(Distillation Design | Henry Kister, n.d.)

References:
1. Badger, 2001. Intro To Chem Engg. Tata McGraw-Hill Education.
2. Distillation Design | Henry Kister [WWW Document], n.d. URL
http://bookzz.org/book/2077569/2bf71c (accessed 9.20.16).
3. Diwekar, U., 2011. Batch Distillation: Simulation, Optimal Design, and Control, Second
Edition. CRC Press.
4. Manning, F.S., Thompson, R.E., (Ph.D.), R.E.T., 1995. Oilfield Processing of Petroleum:
Crude oil. PennWell Books.
5. nirali, n.d. Mass Transfer-II. Nirali Prakashan.
6. Sorensen, E., 2014. Chapter 5 - Design and Operation of Batch Distillation, in:
Distillation. Academic Press, Boston, pp. 187224.