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1
Solid handling
Vaccum system
2High liquid
rate
composition
Feed and
temperature
reduction
Revamps- The pressure drop
3
variable
translated into
can be capacity
energy gain or separation
improvement.
an
gain,
4Large diameter
columns
5
Performance prediction is easy
Corrosive system
6
Less weight saving in cost
foundations and
supports
7Interboilers, intercondensers,
cooling
colils, & side draw
8High turn down
requirements
ofFoaming
system
reducing
Low
liquid holdup for
polymerisation and
degradation.
Batch
Distillation
9
Chemical reactions
The industry, based on its experience, has standardised the type to be used in certain services. If this reference is
not available the guideline as per Appendix 1 are to be used
Types of Tray
The particular tray selection and its design can materially affect the performance of a given distillation,
absorption, or stripping system. Each tray should be designed so as to give as efficient a contact between the
vapour and liquid as possible, within reasonable economic limits.
Valve tray:
Valve trays are perforated sheet metal decks on which round, liftable valves are mounted. The vapour flows
through valves which are installed parallel to the outlet weir. Valve trays combine high capacity and excellent
efficiency with a wide operating range.
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Advantages:
Excellent liquid/ vapour contacting.
Higher capacity.
Higher flexibility than sieve trays.
Can handle higher loadings.
Low-pressure drop than bubble cap.
Sieve tray:
Sieve trays are flat perforated plate in which vapour rises through small holes in tray floor, & bubbles through
liquid in fairly uniform manner. They have comparable capacity as valve trays.
Advantages:
Simple construction Low entrainment,
low cost Low maintenance cost
Low fouling tendency
Disadvantages:
Less-flexible to varying loads than
other two types
Bubble cap tray:
Vapour rises through risers or uptakes into bubble cap, out through slots as bubbles into surrounding liquid on
tray. It is mainly used in special applications.
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Advantages:
Moderate capacity
Most flexible (high & low vap. & liquid rates)
Can provide excellent turndown.
Disadvantages:
High entrainment,
Baffle Tray
Baffle trays:
For a baffle tray column the gas flows upwards through the baffle openings and in doing so contacts the liquid
showering down from one baffle to the next. Baffle tray columns have almost same flooding capacity as cross
flow trays. Types of baffles used are disc & donut and segmental baffles for various column diameters.
Dual flow and baffle trays are used for fouling applications, solid / slurry handling services, corrosive services.
Proprietary types of trays:
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Sieve Tray
Valve Tray
Capacity
High
High
Efficiency
High
High
Turndown
~50%
~25-30%
Entrainment
Moderate
Moderate
Moderate
Cost
~1.2 times
Moderately High
Very High
Moderately High
Least
10%
Least
High
Low to moderate
High
Low to Moderate
~ 2-3 times of sieve
Low
Least
trays
sieve trays
Relatively High
7
8
9
10
11
Maintenance
Fouling
Tendency
Effects of
Corrosion
Design
information
Main
Application
Low
Low
Low
Well Known
Low
Low to
Moderate
Low to
Moderate
Low to
moderate
Proprietary,
but readily
available
High: Tends to
collect
Solids
High
Well Known
Extremely low
Often used
Where high Liquid
when turndownturndown is flow & Where
is not critical required
leakage must be
minimized
Extremely Low
Very Low
Some information
Available.Instability
can occur in large
dia. (>8 feet)
Capacity revamps,
Highly fouling and
corrosive services
Tray Parameters
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a)
http://seperationtechnology.com/distillation-column-tray-selection-1/
The numbers of flowpaths of liquid on tray are 1, 2, 3 or 4 as per liquid capacity requirement of column. From a
capacity viewpoint, a liquid rate greater than 6 gpm / inch of weir (weir loading), is the rate at which a higher
number of flow paths should be considered. The maximum allowable weir loading is 13 gpm/in of weir length.
If the weir loading exceeds this the tray needs redesign with higher number of passes.
b)
Tray spacing is the distance between two trays. Generally tray spacing ranges from 8 to 36 inches (200 mm to
900 mm). Prime factor in setting tray spacing is the economic trade-off between column height and column
diameter. Most columns have 600 mm tray spacing. Cryogenic columns have tray spacing of 200-300 mm.
c)
An outlet weir maintains a desired liquid level on the tray. As the liquid leaves the contacting area of the tray, it
flows over the tray weir to enter into the downcomer.
d)
This is the vertical distance between the tray floor and the bottom edge of the downcomer apron. The
Normalpractice is to use a downcomer clearance of 1/2 inch less than the overflow weir height to provide a
static liquid seal
e)
Inlet weirs and recessed seal pans are primarily used for achieving a downcomer seal in cases where a potential
positive sealing problem exists and clearance under downcomer is limited
f)
Downcomers:
Passage of liquid from the top tray to the bottom of tray occurs via downcomers. Downcomers are conduits
having circular, segmental, or rectangular cross sections that convey liquid from upper tray to a lower tray in a
distillation column.
g)
Flow path length is the distance between the inlet downcomer & outlet downcomer. The minimum limit for
flow path length is 400 mm in order to provide good contacting between vapour and liquid. This is also
necessary for the mechanical reason of providing tray manway.
i)
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Trays normally used in commercial service need a minimum material thickness to provide structural strength
(personnel walk on them during installation) and corrosion allowance. A thickness of 10 to 12 gauge (2.5 to 3.5
mm) is customary for carbon steel, while 12 to 14 gauge (1.9 to 2.5 mm) is used for stainless steel trays (in
general no C.A. for SS)
j)
Centre to centre distance between holes is called pitch. Normal practice is to use a hole pitch to hole diameter
ratio between 2.2 to 3.8.
k)
Derating factors are often closely related to the foaming tendency of the system. Higher the foaming tendency,
the lower is the Derating factor. System factors are used in three of the rating correlations (jet flood, down comer
backup flood, down comer choke) to account for system effects on hydraulic capacity limits. It includes both
foaming effects and high vapour density.
l)
Bubbling area is the column area, which is actually available for vapour bubbling through liquid. It can be
defined as column area minus downcomer areas, downcomer seal & large calming zones.
m) % Hole Area:
This is the ratio of hole area to bubbling area. The default practice is to target a hole area of 8 to 10 % of
bubbling area for pressure services. The acceptable range for percentage hole area is 5 % to 15 %. However for
some critical services, we can go % hole area up to 17-17.5% provided that weeping is under control. Hole areas
below 5 % are not used.
n)
Anti jump baffles plates suspended vertically above centre or off centre downcomers, which stops liquid
jumping from one deck onto the opposite deck, flow path
Tray Hydraulic Parameters
Following are the some important output parameters of tray hydraulics.
a)
Flood:
Jet Flood:
In spray regime operation flooding is brought about by excessive vapour flow, causing excessive liquid to be
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entrained in the vapour up the column. In froth and emulsion flows regimes operation excessive froth
entrainment in the vapour up the column causes jet flooding.
Down-comer Back-up Flood:
Occurs when the pressure available for a given height of liquid and froth in the downcomer cannot overcome the
total pressure drop across the tray This pressure imbalance causes the froth in the downcomer to start backing-up
until it reaches the tray above, causing an increased accumulation of liquid on it. It requires high liquid and
vapour loads.
Downcomer Choke Flood:
The mechanism by which this type of flooding occurs is one related to frictional pressure losses in the
downcomer becoming excessive. In addition, the vapour carried into the downcomer must separate from the
liquid and then flow counter-current to the liquid entering the downcomer. When the combination of vapour
exiting and the liquid entering becomes excessive, the downcomer entrance is choked causing the liquid to
backup on the tray. It requires relatively high liquid rates, surpassing a velocity limitation on the downcomer.
b) Weeping/Dumping
The pressure exerted by the vapour is insufficient to hold up the liquid on the tray. Therefore, liquid starts to leak
through perforations.
c) Pressure Drop:
Pressure drop is an important consideration while designing a tray. It becomes more critical for the vacuum
systems than the high-pressure systems. The tray pressure drop is viewed as the sum of the pressure drop
through the valves or sieves and pressure drop through the aerated liquid on the tray deck.
d) Turndown ratio:
Turndown ratio defines the range of vapour load between which the column can operate without substantially
affecting its primary separation objective (i.e. fractionation efficiency) or over which acceptable tray
performance is achieved. The tray efficiency stays at or above the design value throughout the turndown range.
Tray Sizing
The sizing procedure is an iterative calculation. A preliminary design is set, and then refined by checking
against the performance correlations until an adequate design is achieved. The sizing calculations are performed
at the point where column loading is expected to be highest and lowest for each section, i.e.,
i) The top tray
ii) Above every feed, product drawoff, or point of heat addition or removal.
iii) Below every feed, product drawoff, or point of heat addition or removal.
iv) The bottom tray.
v) At any point in the column where the calculated vapour or liquid loading peaks
The sizing is done at all above load points and also detailed sizing is checked at all above load points. All design
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parameters given in the design procedure below are calculated at all above load points at turndown and turn-up
loads so that the feasibility of design for varied loads is tested.
a) Preliminary determination of tower area:
The methods used for determining tower diameter are:
C Factor Method
Nomograph Method
FRI Tray design handbook
However in this technical guideline we are describing method using C-Factor Method.
C-Factor Method:
The following calculations are done at all the loading points mentioned above and diameters are found
separately. If the difference in calculated diameter at different sections exceeds 20 percent, different diameters
for the sections are likely to be economical. The section having different diameter should be at least 20ft in
length else same diameter can be maintained.
i. Tray Area
Assume appropriate values for following parameters (based on system requirements) for preliminary diameter
calculation.
dH = Hole diameter, inches ( to inch) S = Tray spacing, inches (18 24)
hct = Clear Liquid height at the transition from the froth to spray regime, in of liquid.
Assumption: The starting values for these can be dH=1/4, S=24, h ct=2
Calculate C-Factor (CSB) using following Kister and Haas Correlation:
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iv. Downcomer Area Calculation Calculate downcomer area (AD) from clear liquid velocity in downcomer
VCL
Value of VCL obtained from table below. No derating factor is required for this calculation, as VCL values have
taken care of foaming
Table: Recommended VCL values for different foaming tendencies
VCL in downcomer, ft/s
Foaming
18-in
24-in
30-in
Tendency Example
Spacing Spacing Spacing
Low
0.5-0.6
0.4-0.5 0.5-0.6
0.4-0.5
0.3-0.4 0.4-0.5
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High
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0.2-0.3
0.2-0.25 0.20.25
b)
Downcomer Layout:
Check the % of Downcomer area with respect to tower area:
The Fractional area should around 10% but avoid less than 8% in normal circumstances. Note that AD should in
no circumstance be less that 5% of AT
Net Area (AN):
The total tower cross-section area AT less the area at the top of the downcomer (sometime refer to as free area,
the term free area.)
The net area represents the smallest area available for vapour flow in the inter-tray spacing.
AN = AT - AD
Bubbling (Active) area (AB):
The total cross-section area AT less the area at the inlet & outlet downcomer is called as bubbling area.
AB = AT - ADT - ADB
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? = sin-1(h/R)
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D = ASECT- ATRI
The side downcomer area can be calculated as that for single pass tray. It should be noted that side down-comers
are on both sides.
Center downcomer calculations can be done as follows in similar manner as side down-comer:
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? = sin-1 (h/R)
w = 2*R COS (?1) or w = 2*(R2 h2)0.5
? = 2*(?/2- ?)
Sector area = ASECT = ? R2 * ? / (2 * ?)
Area of center downcomer = Area of circle -2*area of sector + 2*Area of Triangle Area of downcomer = ?*R2
2* ASECT + h1*w1
In case of more than two pass trays we have to define one more parameter, i.e. off-center downcomer location
from centerline. This needs to be done on a case-by-case basis.
Liquid Flow Path Length (FPL):
ForSinglePassTray:
FPL= (tray diameter) minus (side DC width of the tray) minus (bottom width of DC of tray above)
Where,
w1dc
w2dc
w3dc
w4dc
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C) Detailed Design
Flooding Check:
The flooding check is performed using following Correlations:
1. Kister and Haas correlation.
2. Downcomer choke-Koch correlation
3. Fairs correlation
4. Smith et al. correlation
1. Jet Flood: Kister and Haas correlation
This correlation possess following advantage:
It gives a close approximation to the effects of physical properties, operating variable, and tray geometry
on the flood point.
-
It was derived from a much wider database of commercial and pilot-scale column data.
It can predict sieve and valve tray entrainment flooding within 15 and 20 percent respectively.
Factors
Flooding Mechanism
Tray Type
Pressure
Gas Velocity
Liquid Load
Gas Density
Liquid Density
Surface Tension
Liquid Viscosity
Tray Spacing
Hole Diameter
Fractional Hole Area
Weir Height
Applicability
Entrainment (Jet) flood only
Sieve or Valve trays only
1.5-500 psia
1.5-13 ft/s
0.5-12 gpm/in of outlet weir
0.03-10 lb/ft3
20-75 lb/ft3
5-80 dyne/cm
0.05-2.0 cP
14-36 in
1/8-1 in
0.06-0.20
0-3 in
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ii. Clear Liquid height at the transition from the froth to spray ((hct)
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Sr.No
Factors
Applicability
Flooding Mechanism
Tray Type
Hole size
Weir height
1
2
3
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4. Hydraulic checks
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If the value of actual flow parameter exceeds 0.0208 then the regime of operation is emulsion.
iii. Froth-Spray Transition Check:
Porter and Jenkins correlation for the froth to spray transition.
Where,
Lw weir length in inches, AB Active area ft2
p pitch in inches
hc clear liquid height, inches
5. Entrainment:
If entrainment is excessive, column diameter or tray spacing are usually increased. As recommended value, the
entrainment from the tray should not exceed about 0.10 lb liquid entrained per pound of liquid flow.
Methods to determine Entrainment:
Fairs entrainment correlation
This method holds good for froth and emulsion regime. However it is less accurate for spray regime. For a trays
operating at a high liquid to vapour ratio, 0.1 lb of liquid entrained per pound of liquid is an excessive quantity
of entrained liquid.
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Crystallization Process
Design Distillation System
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Operations of Distillation System
Other Unit Operations
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