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Distillation columns can typically be described by the schematic diagram shown to the right.
A column contains N trays, each of which is at a particular temperature and pressure. Vapour-liquid
equilibrium is established across each of these trays, with a vapour flow rate of V and liquid flow rate
of L. A feed stream of molar flow F, mole fraction composition z i and quality q (q=0 is a saturated
vapour; q=1 is a saturated liquid) is fed to the column at an optimized tray N FEED. The vapour from
the top of the column (molar flow rate V) is totally condensed, with part of the condensate returned to
the column (molar flow rate L) and part removed as a distillate product (molar flow rate D with mole
fraction composition xi,DIST). Similarly, the liquid from the bottom of the column is partially reboiled
back to the column, with the remaining liquid portion removed as a bottoms product (molar flow rate
B with a mole fraction composition xi,BOT). Unlike in a flash drum, the product distillate and bottoms
streams are NOT themselves in equilibrium, only the vapour and liquid compositions of each single
tray.
Distillation processes are frequently used in industry to do perform well-defined separations, often
using a cascade of columns in sequence to achieve the desired product compositions. As a result,
it's important we find a way to design columns to meet specific product stream specifications. A
variety of methods can be used, the most obvious of which is performing tray-by-tray balances within
the column. Since each tray is at a constant pressure, this essentially amounts to performing a flash
calculation on each single tray up and down the column. While computer simulation programs can
do such calculations, they are very cumbersome and difficult to do with a spreadsheet. However, we
can use shortcut methods to estimate the number of trays and external (L/D) and internal (L/V) reflux
ratios required to produce product streams of specified compositions.
In designing a column, we can identify two practical limiting cases for the reflux ratios L/V and L/D:
(1) L=V; that is, we do not take any distillate (or bottoms) product
In this case, we need a minimum number of trays to perform the separation since we have no incoming or outgoing flow. This
predicted using the Fenske equation, expressed either in terms of the mole fractions (x) of components A and B or the fractio
in the distillate and bottom stream. Here, A is the light key component (ie. a component present in both the distillate and botto
and B is the heavy key component (ie. a component present in both the distillate and bottoms but recovered primarily in the bo
two components whose recovery in the distillate and/or bottoms is specified in the problem in a multi-component distillation pro
N min =
ln
{( ) ( ) }
xA
xB DIST
/
xA
xB BOT
N min=
ln
{ ( FR A ) DIST ( FR B )BOT
[ 1( FR A )DIST ][ 1( FR B )BOT ] }
ln AB ln AB
The parameter AB in these equations is the relative volatility of A with respect to B, which (assuming ideal conditions) can be e
yA P A
xA
PA
where PA* and PB* are the vapour pressures of components A and B (from Antoin
P
AB= =
yB P B PB
xB P
yA P A
xA P PA
AB= =
yB P B PB
xB P
A key assumption to this approach is that the relative volatility is constant throught the entire column, despite the fact that a ran
different trays. Several approaches are taken to get the "best" estimate of this average relative volatility; in this spreadsheet, t
calculated and the partial pressure ratio at the midpoint of these temperatures is used.
(1) L/Dmin - the external reflux ratio at which the specified separation is just achieved with an infinite number of trays
As we continue to take more and more product off the top, we reduce the amount of product returned to the column and conse
molecule stays within the column. Eventually, we reach a point where an "infinite" number of stages is required to separate the
specifications. This minimum external reflux ratio L/D min can be predicted using the Underwood equations given below:
To solve these equations, we first find the value of the parameter which satisfies equation (1). We can then substitute this va
calculated based on the feed flow and composition and the specified mole fractions and/or fractional recoveries of the compon
3. These equations can be used for any number of different components within the column; however, if solved in this fashion (
assume that any light or heavy non-key components (ie. components with relative volatilities higher and lower than the light an
either do not distribute at all (ie. all light non-key ends up in the distillate and all heavy non-key in the bottoms) or distribute acc
N
CBmin
( FR C )DIST =
( FR B ) BOT N
+ CBmin
1( FR B )BOT
We can then use these extreme results (ie. the minimum possible number of trays and the minimum possible external reflux ra
reflux ratio required in a real column using the Gilliland correlation. A design value for L/D is first specified, usually as some fa
1.05 and 1.25). The following values are then calculated and fit to the correlation developed by Gilliland:
L
D
( L D) min
N N min
x= Abscissa=
L y=
D
+1 N +1
We can therefore solve for N as well as the optimum feed location in a real column, based on the N/N min
N F=N F ,min
( ) N
N min N F ,min =
ln
{( ) ( )}
xA
xB DIST
/
zA
zB
ln AB
Practically, the Fenske-Underwood-Gilliland approach gives rough, first-pass estimates of the number of stages required to pe
assumption of constant relative volatility can be inaccurate in some cases, particularly in columns with highly non-ideal compo
Stage-by-stage calculations can be performed graphically using the McCabe-Thiele method. In this approach, the y vs x VLE
eliminating the uncertainty regarding the constant relative volatility estimate. This means we need to perform dew or bubble p
equilibrium data; in this spreadsheet, we use an ideal bubble point calculation to produce this data. The curve is then fit to a fo
to give us an algebraic expression for the y vs x equilibrium line, allowing us to calculate its intercepts with the other lines. On
lines:
q 1
y A= xA+ z
q1 1q A , FEED
Feed Line: q 1
y A= xA+ z
q1 1q A , FEED
L L
Top Operating Line:
( )
y A= x A + 1 x A , DIST
V V
L L
y = x +(1 ) x
Bottom Operating Line:
A A A , BOT
V V
We also plot the simple y=x line on the graph. A typical McCabe-Thiele plot is shown below (with the polynomial y vs x VLE fit
Starting at the specified mole fraction of component A (the lighter component) in the distillate on the y=x line, we can step dow
equilibrium data curve and either the top or bottom operating lines as our step limits. The top operating line is used when the c
the x value of the feed line - y vs x VLE curve intercept; the bottom operating line is used at mole fractions below the intercept.
column with any specifications (ie. we are not limited to total reflux or minimum reflux). However, by setting L/V equal to one, w
check that the Fenske calculation of Nmin is accurate. In the case of minimum reflux, we can obviously not plot an infinite numb
method; however a "pinch point" will be visible on the graph in which the operating and equilibrium lines touch.
This spreadsheet will allow you to use both the Fenske-Underwood-Gilliland and the McCabe-Thiele approach to design distill
Cells with a red triangle in the upper right-hand corner have comments which will give you more information about what the va
value for that variable.
UT METHODS
V D
xi,DIST
1
L
V
NFEED
F
zi
L
q
B
xi,BOT
Dx A , DIST
FR A ) DIST ( FR B )BOT
R A )DIST ][ 1( FR B )BOT ] } where
( FR A ) DIST = Fz A
Bx A , BOT
( FRB ) BOT = Fz A
(assuming ideal conditions) can be estimated as:
uct returned to the column and consequently reduce the total time an average
r of stages is required to separate the components according to the column
rwood equations given below:
(3)
Lmin =V min D
on (1). We can then substitute this value into (2) to calculate V min. D can be
r fractional recoveries of the components. L min can be calculated using equation
mn; however, if solved in this fashion (ie. with a single value of ), it is required to
es higher and lower than the light and heavy key components respectively)
n-key in the bottoms) or distribute according to the Fenske equation prediction:
e minimum possible external reflux ratio) to predict the number of trays and
is first specified, usually as some factor of (L/D) min (typical values are between
ed by Gilliland:
d on the N/N min scaling and the Fenske optimum feed prediction:
od. In this approach, the y vs x VLE relationship is plotted directly on the graph,
we need to perform dew or bubble point calculations to generate the y vs x
this data. The curve is then fit to a fourth-order polynomial expression in order
s intercepts with the other lines. On the same graph, we plot three additional
ow (with the polynomial y vs x VLE fit)
ate on the y=x line, we can step down the curves, using the y vs. x VLE
top operating line is used when the component A mole fraction is greater than
at mole fractions below the intercept. This method can be used to design any
owever, by setting L/V equal to one, we can use the McCabe-Thiele diagram to
an obviously not plot an infinite number of stages using the McCabe-Thiele
quilibrium lines touch.
more information about what the variable in the cell means or how to select a
ANTOINE EQUATION COEFFICIENTS
B
P =10
( A
T C )
Use the numbers in column B to choose your components in the subsequent spr
C
291.809
222.309
225.000
199.817
229.664
154.683
247.885
206.049
219.888
239.711
241.942
173.427
168.279
228.066
255.189
241.593
226.409
224.000
216.000
227.400
207.701
223.148
226.232
194.738
197.056
229.060
222.927
252.616
228.799
214.192
221.667
196.434
240.337
226.184
173.368
217.000
238.612
213.091
203.454
334.765
194.366
244.124
260.714
28.097
216.823
219.783
224.867
228.477
260.418
230.000
219.726
244.914
249.336
221.969
191.944
274.369
233.286
221.723
204.842
201.783
227.600
201.808
205.814
209.100
211.625
213.022
231.541
229.564
161.330
233.344
174.954
198.463
197.527
217.724
228.594
214.979
214.985
219.693
302.769
209.197
209.197
226.655
235.000
228.000
214.827
213.872
215.110
TWO-COMPONENT DISTILLATION: ESTIMATION OF RELATIVE VOLATILITY
Antoine's Equation Coefficients for Ethanol Antoine's Equation Coefficients for Water2
A= 8.1122 B
A= 7.96681
B= 1592.864
P =10
( A
T C ) B= 1668.21
P =10
B
( A T C )
C= 226.184 C= 228
Component A should be the more volatile of the two components (higher P*(T) value) - switch the components if this is not the case.
Pressure 760 mm Hg
TBP= 92.116 C
PTOTAL= 583.8104061499 mm Hg Bubble T Equation: PTOTAL=x 1 P1 (T bp )+x 2 P2 (T bp )
P1* 25.641 mm Hg
P2* 558.169 mm Hg P1*+P2* 583.810 mm Hg
y1 0.044
y2 0.956
Pressure 760 mm Hg
TDP= 98.777 C y P y P
xi 1.0333 Dew T Equation: x i= P1 (TTOTAL) + P2 (TTOTAL) =1
x1 1 dp 2 dp
0.009
x2 1.024
0 0
Estimate the Relative Volatility of the Two Components 1 1
xA PTOTAL TBP, C yA
0.0 1097.3513 110.6 0.000
0.1 1056.5918 106.1 0.197
0.2 1019.2441 102.1 0.357
0.3 985.1738 98.5 0.489
0.4 954.1272 95.1 0.599
0.5 925.8149 92.1 0.692
0.6 899.9436 89.3 0.772
0.7 876.2460 86.8 0.841
0.8 854.4733 84.4 0.901
0.9 834.4103 82.2 0.954
1.0 815.8669 80.1 1.000
COLUMN DESIGN EQUATIONS - TWO COMPONENTS
AB 2.46 BB 1
AA 1 BA 0.406504065
zA, FEED 0.5 Ethanol zB, FEED 0.5 Water2
Fenske Equation
Problem A: Given: fractional recovery of A in distillate and Problem B: Given: mole fraction of A or B in distillate and
B in bottoms bottoms product
N min=
ln
{ ( FR A ) DIST ( FR B )BOT
[ 1( FR A )DIST ][ 1( FR B )BOT ] } ln
{( ) ( ) }
xA
xB DIST
/
xA
xB BOT
ln AB N min =
ln AB
FRA, DISTILLATE 0.95 Ethanol xA, DISTILLATE 0.979269497 Ethanol
FRB, BOTTOM 0.95 Water2 xB, BOTTOM 0.99462004 Water2
Underwood Equation
VFEED 0
AB Fz A BB FzB
1.7299967254 V FEED= + =F( 1q )
VFEED, TEST 99.998936924 AB BB
D 50 AB Dx A , DIST BB Dx B , DIST
VMIN 156.64310222 V min= +
LMIN
AB BB
106.64310222
(L/D)MIN 2.1328620444 Lmin =V minD
Problem A: Given: fractional recovery of A in distillate and Problem B: Given: mole fraction of A or B in distillate and
B in bottoms - calculate mole fractions bottoms product - calculate fractional recoveries
{( ) ( )}
xA zA A , DIST
ln / ( FR A ) DIST = Fz ( FRB ) BOT = Fz A
xB DIST zB A
N F ,min =
ln AB
Gilliland Correlation
Keep copying the four-row block at the end (ie. A134-->F137) until you have found the total number of equilibrium trays
xB line
0.05 0
0.05 1
1
f(x) = - 0.4209902342x^4 + 1.4215879197x^3 - 2.1647615018x^2 + 2.1634435115x + 0.000394172
0.8
0.6
yA
0.4
0.2
0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
xA
xA,BOT y vs. x VLE Polynomial Fit: xA,DIST
VLE Equilibrium Line y = x Line Top Operating Line Bottom Operating Line Feed Line
THRE-COMPONENT DISTILLATION: ESTIMATION OF RELATIVE VOLATILITY
Antoine's Equation Coefficients for Toluene Antoine's Equation Coefficients for Cumene Antoine's Equation Coefficients for Benzene
A= 6.95805 B
A= 6.93619 A= 6.89272 B
B= 1346.773
P =10
( A T C ) B= 1460.31
B
( AT C ) B= 1203.531
P =10
( A T C )
C= 219.693 C= 207.701 P =10 C= 219.888
z1, FEED 0.3 Toluene z2, FEED 0.3 Cumene z1, FEED 0.4 Benzene
Partial Pressure Temperature = 50.000 C Partial Pressure Temperature = 50.000 Partial Pressure Temperature = 50.000 C
P1*(T) 92.114 mm Hg P2*(T) 18.600 mm Hg P1*(T) 271.236 mm Hg
Pressure 760 mm Hg
TBP= 100.306 C
PTOTAL= 759.9999997241 mm Hg Bubble T Equation: PTOTAL=x 1 P1 ( T bp )+ x 2 P2 ( T bp )+ x 3 P3 ( T bp )
P1* 168.459 mm Hg
P2* 47.006 mm Hg P1*+P2* 623.866 mm Hg
P3* 408.401
y1 0.270
y2 0.075
y3 0.655
Pressure 760 mm Hg
TDP= 123.942 C
xi y P y P y P
x1
1.0000 Dew T Equation:
x i= P1 (TTOTAL) + P2 (TOTAL +
3 TOTAL
T ) P (T )
=1
0.208 1 dp 2 dp 3 dp
x2 0.668
x3 0.123
Partial Pressure Temperature = 112.124 C Partial Pressure Temperature = 112.124 C Partial Pressure Temperature = 112.124 C
P1*(T) 792.987 mm Hg P2*(T) 234.543 mm Hg P2*(T) 1852.492 mm Hg
AB 3.3809878333 BB
AA 1 BA
zA, FEED 0.3 Toluene zB, FEED
Fenske Equation
Underwood Equation
xA, DISTILLATE
Lmin =V min D
0.4073130243 Toluene
xB, BOTTOM 0.9490748234 Cumene
xC, DISTILLATE 0.5712494481 Benzene Dx A , DIST
Nmin, feed 2.4171043403
( FR A ) DIST = Fz A
Gilliland Correlation
1 CB 7.89830348
0.295771546 CA 2.33609343
0.3 Cumene zA, FEED 0.4 Benzene
=
ln
{ ( FR A ) DIST ( FR B )BOT
[ 1( FR A )DIST ][ 1( FRB )BOT ] }
ln AB
N
CBmin
)DIST =
( FR B ) BOT N
+ CBmin
1( FR B )BOT
AB Fz A BB FzB CB FzC
= + + =F( 1q )
AB BB CB
AB Dx A , DIST BB Dx B , DIST CB DxC , DIST
+ +
AB BB CB
V min D N F ,min =
ln
{( ) ( )}
xA
xB DIST
/
zA
zB
ln AB
Dx A , DIST Bx A , BOT
ST
= ( FRB ) BOT = Fz
Fz A A