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Distillation, which is one of the oldest mass transfer operations, is reported to have
beeninvented in Alexandria in the first century AD. The early use was in the
production ofalcoholic beverages. The history of distillation has been described by
Forbes.It will be useful to distinguish between distillation and evaporation since in
the latter operationalso, the components in solution are separated by volatilizing
some of them. The major differenceis that in evaporation a solution containing a
volatile solvent and a non-volatile soluteis separated by vaporizing out a part or
whole of the solvent. Examplesare:evaporation of a sugar solution,evaporation of a
glycerol solution. But in distillation, the components have reasonable
volatilityExample: distillation of aqueous ethanol.Distillation is the most common
mass transfer operation in the process industries, particularlythe organic process
industries. The function of distillation may be separation of products froma
mixture, recovery of a product, or increasing the purity of a product. Distillation is
again the mostimportant operation in a petroleum refinery. A petrochemical
complex also uses a large numberof distillation columns. Sometimes, distillation
may be used in conjunction with a few other masstransfer operations. For example,
in an acrylonitrile plant, the productis separated from the reaction mixture by
absorption in water. The aqueous solution ofacrylonitrile leaving the absorption
tower is separated in a distillation column to produce aacrylonitrile of desired
purity. Similarly, the extract and raffinate streams from an extractioncolumn may
be further separated in a distillation column depending uponthe difference in
volatility of the components. Because of its importance and wide use in separation
of mixtures, distillation is called the workhorse of chemical industries. Despite the
advent of newer and advanced separation processes, distillation still remains the
most widely used separation technique of liquid mixtures and solutions. The
estimated cost of annual worldwide throughput of distillation columns was 524
billion dollars about ten years ago as reported by porter.
The perforated tray (also known as sieve plate) is a flat perforated metal
sheet. The hole diameter from 1.5 to 25 mm are very commonly used. The sieve
tray layout is a typical square or equilateral triangular pitch holes. The gas/vapor
flows upward through the perforation and disperses into the flowing liquid over the
plate. There is no liquid seal in case of trays without downcomer and the liquid
weeps (called weeping) through the holes at low flow rates, reducing the efficiency
of plate. For this reason, perforated tray has the lowest turndown ratio. perforated
tray construction is simple and relatively cheap.
This is the simplest type of cross-flow plate. The vapour passes up through
perforations in the plate; and the liquid is retained on the plate by the vapour flow.
There is no positive vapour liquid seal, and at low flow-rates liquid will “weep”
through the holes, reducing the plate efficiency. The perforations are usually small
holes, but larger holes and slots are used.
Schematic Diagram: -
Distillation column: -
The base of the distillation column contains a large volume of liquid, which is
mostly the liquid with higher boiling point (in our example, this would be water).
Out of the base flows some of this liquid, some of which is heated in the reboiler
and returned to the column. This is called the boil up, and is labeled V. The
remaining liquid is the bottom product, labeled B.
Some vapour escapes from the top of the column and is returned to a liquid state in
the condenser. Some of this liquid is returned to the column as reflux L, and the
remainder is the top product or distillate D.
Vapour and liquid phases on a given plate approach thermal, pressure and
composition equilibrium to an extent depending upon the efficiency of the plate.
Perforated Tray: -
In this tray the bubble caps are replaced by holes or perforations for entrance of the
gas into the liquid. The holes are of relatively small diameter. This is why the name
'perforated tray. For clean services, use of a hole diameter of inch is comm.
However, for liquids that foul or cause deposition, a hole diameter of ½ inch may
have to be used. In vacuum services, ¾-inch-hole diameter is preferred. Small
holes enhance tray capacity, reduce entrainment, reduce weeping promote froth
regime operation and exhibit better mass transfer characteristics. Holes are made
by punching rather than by drilling a tray sheet (small holes may have to made by
drilling) in order to reduce the labor cost These are arranged on an equilateral
triangular pitch or a square pitch. The pitch (i.e. the centre-to-centre distance
between the two adjacent holes) varies between 2.5dH and 5dH (3.8dH is
common), where dH is the hole diameter [as show marked on Figure] The rows of
holes are oriented normal to the direction of liquid flow A-sieve tray typically has
a free area of 6 to 10% [free area fraction-hole area/tower cross- section, less the
downcomer areal. The layout of a sieve tray, the downcomers and are shown in
Figure. The assembly of a sieve tray is shown in Figure the weirs and the
downcomers are shown in the figure.
Working Procedure: -
In a sieve tray as shown in the figure below, thevapour passes through a large
number of “holes” known as perforations (sieves) and emerges through the liquid
in a vertical direction.
The sieve tray has the simplest design among the various tray types. There are no
mechanical moving parts. There is no liquid seal and it is the passage of vapour
that efficiency prevents the loss of liquid through the sieves. A phenomenon
known as weeping – as shown in the figure below can occur at low vapour flow
and/or high liquid rates when the liquid height on the tray exceeds the tray pressure
drop.
Typical layout for sieve tray follows either a square hole pitch or equilateral
triangular hole pitch. Hole pitch is the centre-to-centre hole spacing.
Typical sieve sizes used industrially range from as small as 1/6-inch to 1-inch.
Small sieves are not suitable for fouling or corrosive services as they may be
susceptible to blockage, leading to excessive pressure drop and premature
flooding.
Small holes have better turndown characteristics because they reduce tray weeping
and therefore increase tray capacity. In terms of cost, larger holes are cheaper as
the holes can be punched, and there are fewer holes to be punched. Smaller holes
are more expensive as drilling may be required.
Industrial Application: -
Distillation column: -
Oil Refining
Desalinizing Water
Distilled Spirits
Liquor, beer and wine are produced after undergoing through several
stages of distillation which eliminates the additive and produce a final
distilled form of the spirits.
Other Applications
6160 lb 1 hr 0.454 Kg Kg
LWT = × × = 0.7768
hr 3600 second 1 lb Second
18160 lb 1 hr 0.454 Kg Kg
LWB = × × = 2.29
hr 3600 second 1 lb Second
9670 lb 1 hr 0.454 Kg Kg
VWT = × × = 1.22
hr 3600 second 1 lb Second
6670 lb 1 hr 0.454 Kg Kg
VWB = × × = 0.84
hr 3600 second 1 lb Second
Density-
Step 2: - Convert All Density From lb/(ft)3 To Kg/m3
lb 0.454 Kg 1 ft 3 Kg
ρLT = 507 × × (0.305 m) = 811.27
(ft)3 1 lb m3
lb 0.454 Kg 1 ft 3 Kg
ρLB = 44.6 × × (0.305 m) = 713.65
(ft)3 1 lb m3
lb 0.454 Kg 1 ft 3 Kg
ρVT = 0.178 × × (0.305 m) = 2.85
(ft)3 1 lb m3
lb 0.454 Kg 1 ft 3 Kg
ρVB = 0.19 × × (0.305 m) = 3.04
(ft)3 1 lb m3
Step 3: - Find Column Liquid-Vapour Factor for Top and Bottom and With
the Help of Figure 11.34 We Find the Value of K1 For Top and Bottom and
Convert Plate Spacing intometer from ft
L ρ 0.7768 2.85
FLVT = V WT × √ρ VT = × √811.27 = 0.038
WT LT 1.22
L ρ 2.29 3.04
FLVT = VWB × √ρ VB = × √713.65 = 0.180
WB LB 0.84
Vapour Velocity-
Step 7: - We Find Vapour Velocity at Flooding Point Based on Net Area for
Top and Bottom
VWT 1.22 m3
V̇T = = = 0.4280
ρVT 2.85 s
VWB 0.84 m3
V̇B = = = 0.2763
ρVB 3.04 s
Step 10: - Find Area onTop, Diameter on Top and Area onBottom, Diameter
on Bottom
V̇T = AT × uactual T
0.4280 = AT × 1.0795
π
AT = 0.3964 m2 = × dT 2
4
dT = 0.7106 m
V̇B = AB × uactual B
0.2763 = AB × 0.6545
π
AB = 0.4222 m2 = × dB 2
4
dB = 0.7333 m
Entrainment-
Entrainment can be estimated from the correlation given by Fair. which gives
the fractional entrainment (kg/kg gross liquid flow) as a function of the liquid-vapour
factor FLV, with the percentage approach to flooding as a parameter. The percentage
flooding is given by:
Step 11. Find Percentage Flooding for Top and Bottom and Fractional
Entrainment for Top and Bottom.
1.0795
(PFT ) =
1.27
(PFT ) = 85%
0.6545
(PFB ) =
0.77
(PFB ) = 85%
(FET ) = 0.095 = ΨT
(FEB ) = 0.0015 = ΨB
π
Column area = 4 × Dc 2 = 0.3968 m2 =Ac
Area-
AC =total column cross-sectional area
AD= cross-sectional area of downcomer
AN = net area available for vapour-liquid disengagement, normally equal
to Ac -Ad, for a single pass plate
AA= active, or bubbling, area, equal to Ac-2Ad for single-pass plates
AH= hole area, the total area of all the active holes
AP= perforated area (including blanked areas)
AAP = the clearance area under the downcomer apron
Step 12. Find Column Area,DowncomerArea, Net Area, Active Area and
Hole Area.
AH = 0.1 × Aa
AH = 0.03008 m2
This is defined by the below graph
AD
∗ 100 = 10
AC
Length of weir-
Lw = 0.711×0.73
= 0.51903 m
= 519.03 mm
C0=0.84
This is defined by the below graph
Step 14. Find Maximum Vapour Velocity Through Holes and Dry Plate
Pressure Drop (Head of Liquid).
Pressure Drop-
Step 15. Find Plate Residual Pressure Drop (Head of Liquid) And Height of
Liquid Crest Over Downcomer Weir.
The pressure drop over the plates is an important design consideration. There are
two main sources of pressure loss: that due to vapour flow through the holes (an
orifice loss), and that due to the static head of liquid on the plate. A simple additive
model is normally used to predict the total pressure drop. The total is taken as the
sum of the pressure drop calculated for the flow of vapour through the dry plate (the
dry plate drophd); the head of clear liquid on the plate (h W +hOW); and a term to
account for other, minor, sources of pressure loss, the so-called residual loss hr. The
residual loss is the difference between the observed experimental pressure drop and
the simple sum of the dry-plate drop and the clear-liquid height. It accounts for the
two effects: the energy to form the vapour bubbles and the fact that on an operating
plate the liquid head will not be clear liquid but a head of “aerated” liquid froth, and
the froth density and height will be different from that of the clear liquid.
Residual head-
Methods have been proposed for estimating the residual head as a function of
liquid surface tension, froth density and froth height. However, as this
correction term is small the use of an elaborate method for its estimation is
not justified, and the simple equation proposed by Hunt et al. can be used:
This equation is equivalent to taking the residual drop as a fixed value of 12.5 mm
of water (1/2 in.)
ht = hd + hw + how + hr
ht =25.9780+45+24.840+17.5156
=113.3337 mm liquid
where hap is height of the bottom edge of the apron above the plate.
hdc= head loss in the downcomer (mm)
Step 17. Take Values of Maximum Liquid Flow Rate andDowncomer Cross-
Sectional Area.
Kg
Maximum Liquid Flow Rate = 2.29
s
Step 18. Find Head Loss in Downcomer And Height of Liquid Backed-Up
inDowncomer.
Aap = hap× Lw
= 40× 519.03
= 0.02076 m2
Ad = 0.048 m2
Aap< Ad
Lwd = max. liq flow rate
= 2.29 kg/s
2
2.29
hdc = 166 [ ]
713.65 × 0.02076
= 3.9660 mm liquid
hb = hw + how + ht + hdc
=45 + 24.8401 + 113.3337 + 3.9660
= 186.9398 mm liq.
Residence time-
Sufficient residence time must be allowed in the downcomer for the entrained
vapour to disengage from the liquid stream; to prevent heavily “aerated”
liquid being carried under the downcomer.
No. of holes-
Ah 0.03008
Number of Holes = π = π = 1531 Holes
4
× d2h 4
× (d)2
Efficiency-
Step 21: - Take the Values of Liquid Viscocity And Liquid Diffusivity
and Find Surface Tension Number (Dg), Liquid Schmidt Number
(Sc), Fractional Area, Reynolds Number and Percentage Efficiency by
Van Winkle's Method.
μL 9 × 10−4
Sc = = 811.27 ×1.24 × 10−9 = 894.6546
ρL × DLK
= 0.07(13.3807)0.14(894.6546)0.25(2029.40)0.08
= 76.1460%
Plate Specification: -
Result: -
We get the Efficiency of distillation column is 76.14604% by van winkle’s method and Total
pressure drop of plate is 795.4386 Pa. We get the number of holes is 1531 and residence time is
2.7963 sec. For sieve tray according to find out diameter and given flow rate.
Conclusion: -
According to given flow rate and diameter of the holes in the sieve tray found by us if the
number holes is increased it will cause flooding ,if decreased it will lead to weeping.
Sieve Tray are simple metal plates with hole in them. Its has more efficiency as compared to
bubble cap tray. It has wide operating range and maintenance, cost factor is comparatively less.
Acknowledgement: -
We would like to express special thank of gratitude to Dr. Arijit Ganguly, who give us the
golden opportunity to do this wonderful project of design tray of distillation column on sieve tray.
we came to know about so many new things we are really thankful to him. Our thanks and
appreciations also got to collage in developing the project and people who have willingly helped
us out with their abilities.
References: -
1.R.K. Sinnott, Coulson & Richardson’s Chemical Engineering: Chemical
Engineering Design (vol. 6), Butterworth-Heinemann, 5th edition.
2. Robert E. Treybal, Mass Transfer Operations, McGraw-Hill, Inc., 3rd ed. 1981.
3. www.researchgate.net/publication/296574027_designing_Sieve
tray_distillation_columns
4. Binay k. Dutta,Principal of mass transfer and separation Process.