SPECIFICATION SHEET

Identification:
Item: Distillation Column 2
No. required = 2
Tray type = Sieve tray
Function: To separate n-butyraldehyde from feed mixture
Operation: Continuous
Design Data:
Parameters

Values

Parameters

Values

Type of Column

Tray Column

Material of

Carbon Steel

Construction
Tray Type

Sieve Tray

Hole Diameter

5 mm

No. of Trays

51

Weir Length

1.82 m

Height of Column

22.536 m

Pressure
Drop/plate

709.263 Pa

Diameter of

2.33 m

Tray Thickness

5 mm

Tray spacing

0.45 m

Active Area

2.11 m2

Flooding

87 %

Reflux Ratio

16.6967

Column

Material Balance @ Distillation 2

N iso-

1383.05kg/

L Mixed
17.66

7063.81kg

O n5660.10kg/

(K)Compo
und
n-Butyral
iso-Butyral

79.656
20.337

Mass(kg/h
r)
5626.763
1436.62

n-Butanol

0.0052

0.370

Iso-Butanol

0.00087

0.0616

% Comp.

(N)Compo
und
n-Butyral
iso-Butyral
(O)Compo
und
n-Butyral
iso-Butyral

98.792
1.20

Mass(kg/h
r)
18.025
1368.493
Mass(kg/h
r)
5608.738
68.127

n-Butanol

0.0065

0.37

Iso-Butanol

0.00108

0.0616

Distillation Column 2
Butyraldehyde
1. Feed Operating line

% Comp.
1.3
98.7
% Comp.

q = Feed quality (

LL
)
F

V = Vapor-liquid leaving (Enriching section)

L = Vapor-liquid coming (Enriching section)

= Vapor-liquid leaving (Stripping section)

= Vapor-liquid coming (Stripping section)

97.92
kmol
Isob=20.7%

19.22
kmol
Isob=98.7%

78.7 kmol
Isob=1.2%
n-b =

Feed at Boiling Point = 66.77oC

q=1
Assumptions:

0.45 m plate spacing

100 mm pressure drop per plate
85% Flooding
At Minimum Liquid Rate, 70% turn down
Weir Height = 50 mm (assumed according to Coulsons suggest, see Page
589)
Hole Diameter =3 mm (assumed according to Coulsons suggest, see Page
589)
Plate thickness = 5 mm (assumed according to Coulsons suggest, see Page
590)

Nature of Feed

K=

Pvi
PT

WHERE

Pvi =Vapor Pressure Initial

PT =Total Pressure

AND

@ 66.36

Component
n-Butyraldehyde
IsoButyraldehyde
Total

Xf

K values

K Xf

0.797

0.98144

0.78220768

0.203

1.07324

0.21786772

1.00

1.0000754

Nature of Distillate
@ 64.258

Component
n-Butyraldehyde
IsoButyraldehyde
Total

Xd

K values

K Xd

0.013

0.92093

0.0132762

0.987

1.00112

0.98810544

1.00

1.00007753

Nature of Bottom
@ 73.4

Component
n-Butayraldehyde
IsoButyraldehyde
Total

Xb

K values

K Xb

0.988

0.990485

0.9885036

0.012

1.01383

0.012166

1.00

1.0006696

Vapor Pressure Equation Perrys CHE HB 8th ED (P in bar, T in Kelvin)

log P= A

B
T +C
Component

n-Butyraldehyde
Iso-Butyraldehyde

3.59112
3.87395

952.851
1060.141

-82.569
-63.196

Vapor Pressures (P in bar)

Component
n-Butyraldehyde
iso-Butyraldehyde

Feed
0.8704559
1.236486

Top
0.70756942
1.012942

Bottom
0.95846472
1.356903

values

(Vapor pressure ) Lk isoButyraldehyde

=
( Vapor pressure ) Hk nButyraldehyde

Component
n-Butyraldehyde
iso-Butyraldehyde

Feed
1
1.420504

top=

Where =relative volatility

Top
1
1.43158

bottom=

1.43158

Bottom
1
1.4157047

1.4157047

avg= top bottom = 1.43158(1.4157047)=1.42362

Calculations for the number of plates

Using Fenske Method (Eq 11.58 Coulson & Richardson Chemical Engineering Vol 2, 5 th Ed)
ln[(
n+1=

ln[(
n+1=

Xa Xb
)(
) ]
Xb d Xa w
ln ( avg )
0.987 0.988
) (
) ]
0.013 d 0.012 w
ln(1.42362)

nmin =20.2769 21 stages

Where a = iso-Butyraldehyde, b = n-Butyraldehyde

Calculating Minimum Reflux Ratio

Using Underwoods Method (Eq 11.114 Coulson & Richardson Chemical Engineering Vol 2, 5 th Ed)
AXfA aBXfB aCXfC
+
+
+ =1q
A aB C
nb X f nb isob X f isob
+
=1q
nb
isob
Assuming =1.308783237
1(0.797)
1.420504 (0.203)
+
=0
11.308783237 1.420501.308783237
axf

a =4.97545 x 1010 0

Accepted

Calculating Rmin
AXdA aBXdB aCXdC
+
+
+=Rmin+ 1
A aB C
nb X d nb isob X d isob
+
=Rmin+ 1
nb
isob

Rmin+1=

1(0.013)
1.43158( 0.987)
+
=10.46447
11.308783237 1.431581.308783237

Rmax=1.5 Rmin=1.5 ( 15.2315 )=15.6967

Theoretical Number of Plates
Using Gilliland Correlation - (Eduljee version, Hydro. Proc., Sept. 1975, p. 120)
RR min
R+1

1
N 23.7464
=0.75
N +1
15.699710.46447
15.6997+1

1
N31.36
=0.75
N +1

N=31.7333 32 plates

Plate Efficiency:
Equation 11.67 Richardson and Coulsons Chemical Engineering Vol. 6, 4 th Edition
Using OConnell Correlations

Efficiency=( 5132.5 log ( a a ) ) =( 5132.5 log ( 0.2976804 x 1.42362 ) )=63.1178

Actual Number of Plates

N actual =

N theo
Eo

N actual =

32
=50.6988 51 plates
0.631178

Location of Feed Plate

Equation 11.62 Richardson and Coulsons Chemical Engineering Vol. 6, 4 th Edition
Using Kirkbrides Equation:

N
log D =0.206 log[
NB

ND
=1.8314 ;
NB

N D =1.8314 N B

N D + N B =51
1.8314 N B +N B=51
N B =18.0123 19 th Plate thebottom

kmol
hr
kmol
19.2272
hr
78.7251

)(

0.797
0.203

)(

0.013 2
]
0.012

PHYSICAL PROPERTIES:
Assumed:
Pressure drop per plate = 100mm
iso-Butyraldehyde = 0.1 x 723 x 9.81 = 709.263 Pa
Column Pressure drop = 709.263 x 46 = 32,626.098 Pa
PressureBottom = 101325 + 32626.098 = 133,951.098 Pa
Top

Bottom

Column top pressure= 101325 Pa

Temperature= 64.1 C
=

1.3

= 793.8

Column Bottom pressure= 133951.098

Pa
Temperature= 73.4 C

kg
m3

kg
m3

(density of the mixture)

Surface tension,

= 29 x 10

-3

N
m

1.67

kg
m3
kg
m3

= 817

(density of the mixture)

kg
MWave = 72.11 m3

Liquid viscosity = 0.3095753 cP

kg
MWave = 72.11 m3
Top:

Bottom

Ln = R x D =15.6967(19.2272)

Lm = Ln + F = 301.8036 + 97.9529

= 301.8036

kmol
hr

Vn = Ln + D = 301.8036 + 19.2272
= 321.031

kmol
hr

= 399.7565

kmol
hr

Vm = Lm W = 424.4686 - 78.7251
=321.0314

kmol
hr

Tray spacing
Tray spacing is selected to minimize entrainment. A large distance between the
trays is needed in vacuum columns, where vapour velocities are high and excessive
liquid carryover can drastically reduce the efficiencies. Trays are 0.15m to 1.0m. A
trial tray spacing of 0.45m was selected.
Figure 11.27 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

Estimating column diameter:

FLV

Bottom

FLV

Top

8.0073448 1.67
6.4304373 817 = 0.056298

6.045294 1.3
6.430493 793.8

Bottom K1 = 0.08
Top K1 = 0.08

= 0.0380443

Flooding velocity
Equation 11.81 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

f Bottom

f Top

0.08

0.08

8171.67
1.67

m
s

= 1.7677

793.81.3
1.3

= 1.9752

m
s

Design for 85% flooding at maximum flow rate

Superficial velocity (Qn):

Bottom,

Top,

= 0.85 x 1.7677

= 0.85 x 1.9752

m
s = 1.5025

m
s = 1.679

m
s

m
s

Maximum volumetric flow rate (Qv):

Bottom =

Top =

Vn x MW
v x 3600

Vm x MW
v x 3600 =

321.031 x 72.11
= 3.85056
1.67 x 3600

321.031 x 72.11
= 4.9465
1.3 x 3600

Net area required:

Bottom =

Qv 3.85056
=
= 2.5626 m2
Qn 1.5025

m3
s

m3
s

Top =

Qv 4.9465
=
= 2.9461 m2
Qn 1.679

First trial, downcomer area is taken as 12% of the total downcomer area
Column cross-section area
Bottom =

Top =

2.5626
2
0.88 = 2.91204 m

2.9461
2
0.88 = 3.34785 m

Downcomer Area
Bottom = (0.12 x 2.91204) = 0.349445m2
Top = (0.12 x 3.34785) = 0.40174m2
Column diameter
Bottom =

Top =

4
2.91204

= 2.17275 m

4
3.34785 = 2.3297 m

Column Diameter should be use = 2.33 m

Liquid Flow pattern

Maximum Volume Flow Rate
Top =

Ln X MW 301.8036 x 72.11
=
= 0.0076156
l X 3600
793.8 x 3600

m3
s

Figure 11.28 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

Liquid Flow arrangement = f (Dc, Liquid Flow rate) = Cross flow Single pass

Provisional Plate Design

Column Diameter = 2.33 m
Column Area, Ac = 2.91204 m2
Downcomer Area, Ad = 0.40174 m2
Net Area, An = 2.9461 m2
Active Area, = Ac - 2 Ad = 2.91204 2(0.40174) = 2.10856 m2
Hole Area, Ah take 10% of Aa as first trial = 0.1 x 2.10856 = 0.2109 m2
Figure 11.31 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

From Graph;

lw
=0.78
Dc

Weir Length, lw = 0.78(2.33) = 1.8174 m

Weir Height = 50 mm (assumed according to Coulsons suggest, see Page
589)
Hole Diameter =5 mm (assumed according to Coulsons suggest, see Page
589)
Plate thickness = 5 mm (assumed according to Coulsons suggest, see Page
590)

Check weeping
Equation 11.85 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

Maximum Liquid Rate =

Lm X MW 399.7565 x 72.11
kg
=
=8.0073
3600
3600
s

Minimum Liquid Rate, at 70% turn down = 0.7 x

kg
s

8.0073

= 5.60514

maximum

how

minimum

how

8.0073
)3
817(1.8174)

750(

5.60514 23
750(
)
817(1.8174)

at minimum rate =

hw

how

= 23.0641 mm liquid

= 18.1832 mm liquid

= 50 + 18.1832 = 68.1832 mm

Figure 11.30 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

From Graph:

K2 = f(

hw

how ) = 30.75

Equation 11.84 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

30.750.90 (25.45)

h=
Actual minimum vapour velocity =

minimum vapor rate 0.7 x 3.85056

m
=
=12.7804
Ah
0.2109
s
Actual minimum vapour velocity > minimum vapour velocity, No weeping!

Plate pressure drop

Dry plate drop
Maximum vapour velocity through holes

h , max =

3.85056
m
=18.258
0.2109
s

Plate Thickness
Hole Diameter

= 1;

Ah
=0.1
Aa

Figure 11.34 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

From Graph: Co = 0.84

Equation 11.88 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

hd =51[

18.258 2 1.3
]
=38.339 mmliquid
0.84 817

Equation 11.89 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

hr =

12.5 x 103
=15.3mm liquid
817

Equation 11.90 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

ht =hd + ( h w + how ) + hr =38.339+ ( 50+18.1832 )+ 15.3=121.822 mm liquid

100 mm 121.822 ; Considerably Acceptable !

Downcomer Liquid Back-up

Figure 11.35 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

Downcomer pressure loss

Take

hap=hw 10=5010=40 mm liquid

Area under apron,

A ap=l w x h ap=1.8174 x 0.04=0.0727 m

Since: Ad = 0.40174 m2 >

A ap=0.0727 m2 ; So we choose

A ap

Equation 11.92 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

hdc =166 [

8.0073448 2
] =2.01698 mm
817 ( 0.0727 )

Equation 11.91 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

h
( w+ how )+h t +h dc=( 50+18.1832 ) +121.822+2.01698=192.0222mm
hb =
1
192.0222mm< ( plate spacing+ weir height )
2
192.0222mm< 1133.7 mm ; so 0.45 m plate spacing is acceptable !

Check Residence time

Equation 11.95 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

t r=

0.40174(0.1920222)(817)
=6.95 sec
8.0073448
7.87 seconds>3 seconds ; acceptable !

Check Entrainment
Equation 11.83; Figure 11.29 Coulson & Richardson Chemical Engineering Vol. 6, 4 th
Ed

n=

Q v 3.85056
m
=
=1.307
An 2.9461
s

Flooding=

n 1.307
=
x 100 =86.99 =87
f 1.5025

@ Flv Bottom =0.05894

From the Graph:

=f ( Flv B ) = 0.07

0.07>0.1 ; well below 0.1, Process are satisfactory

Trial Layout
Allowance:
50 mm unperforated strip round plate edge

2.33 m

1.82 m

50 mm wide calming zones

Figure 11.32 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

lw
=0.78;
Dc
theGraph , c =99
Angle subtended by the edge of the plate = (180 99) = 81

Mean length, unperforated edge strips = (2.09 0.05)

81
( 180
)=2.884 m

Area of unperforated edge strips = 0.05

x 2.884=0.1442 m

Mean length of calming zone, approximately =

l w +width of unperforated

1.8174+0.05=1.8674 m
Area of calming zones =

2 (1.8674 x 0.05 )=0.187 m2

Total area for perforateions,

A p=2.108560.14420.187=1.77736 m

Figure 11.33 Coulson & Richardson Chemical Engineering Vol. 6, 4 th Ed

Ah 0.2109
=
=0.11866
A p 1.77736

From the Graph,

lp
=2.85 ; s atisfactory , within 2.5 4.0
Dh

lp
=2.85 ; l p=2.85 ( 5 mm )=14.55 mm , Hole pitch
Dh
Area of Single Hole:

D2 (0.005)
h=
=
=0.000019635 m2
4
4
Total no. of holes:

Ah
h

nT =

0.2109
0.000019635

No. of holes/plate

= 10,741.05

10,742holes

10,742
51

= 211 holes

MECHANICAL DESIGN
Design Pressure (Mpa)
Allowable Stress (Tube Sheet
Material) (Mpa)
Nozzle ID, Shell (m)
Joint Effienciency
Corrosion Allowance (m)

0.1013
25
4.75
0.254
0.8
0.002

Shell Thickness Calculation

Equation to be found at Chapter 2.3.1 NPTEL Chemical Engineering Chemical
Engineering Design - II

Ts=

pDs
+c
fj0.6 p
0.101325 Mpa(2.33 m)

= 4.75 Mpa ( 0.8 )0.6 (0.101325 Mpa)

Torrispherical head Calculation

Th=

pRiW
+c
(2 fj0.2 p)

For Torrispherical head Ri =Ds

+0.002 m=0.06514 m=65.14 mm

Equation to be found at Chapter 2.3.2 NPTEL Chemical Engineering Chemical

Engineering Design - II

1
Ri
W = (3+
)
4
ri

For Torrispherical Head

Ri
1
=
ri 0.06

1
1
W = (3+
)=1.77
4
0.06
Th=

0.101325 Mpa (1.165 m)(1.77)

+0.002 m=0.02794 m=27.94 mm
(2 ( 4.75 Mpa )( 0.85 ) 0.2 ( 0.101325 Mpa ))

Channel Cover Diameter and thickness

Channel cover diameter = Shell Outside diameter = 2.39514 m
Equation to be found at Chapter 2.3.3 NPTEL Chemical Engineering Chemical
Engineering Design - II

Tcc=

Dc C 1 p
10 f

Tcc=

2.39514 0.25(0.101325 Mpa)

=0.00803 m=8.03 mm
10( 4.75 Mpa)
So :

Column Height=(N actual1)( Plate spacing)+ Mechanical Design

( 511 ) ( 0.45 ) + ( 0.03597 )=22.536 m

Nozzles (Number of Nozzles = 6)

1. Feed Inlet

Nozzle Diameter =0.1 D=0.1 ( 2.33 m ) =233 mm 9.17 =254 mm

t n=

p Dn
+c
2 fj p
f =4.75 Mpa

p=0.101325 Mpa
c=2 mm

j=0.85
0.101325
t n=

N
( 254 mm )
2
mm

N
N
2 4.75
( 0.85 )0.101325
2
2
mm
mm

t n=6.23 mm 0.25 =6.35 mm

2. Reflux

Nozzle diameter = 254 mm 10 =254 mm

t = 6.35 mm
3. Overhead Vapor Oulet gas out

Nozzle diameter = 254 mm 10 =254 mm

t = 6.35 mm
4. Bottom Out

Nozzle diameter = 152.4 mm 6

f =4.75 Mpa

p=0.133951 Mpa
c=2 mm

j=0.85

t n=

p Dn
+c
2 fj p

+2 mm

0.133951
t n=

N
( 152.4 mm )
2
mm

N
N
2 4.75
( 0.85 )0.133951
2
mm
mm2

t n=4.571 mm 0.18

5. Reboiler Return

Nozzle diameter = 152.4 mm 6

t = 4.57 mm

COSTING (Distillation Column 2)

+ 2 mm

Column Cost Estimation including installation and auxiliaries

(Fig14-84 Perrys Chemical Engineers HB 8th Ed)

D c =2.39514 m=94.297 inch

Column Height =22.536 m=73.94 ft

Cost ( $ ) per foot height =4000 $

Cost ( $ )=4000 $ x 73.94 ft =295,748 $=Php13,308,661.42
Using Equipment Index Factors; Marshall & Swift/Boeckh, LLC (Marshall & Swift)
Year

Average

2012
1979

295,748 $ ( 1979 )

424.1
222.301

424.1 (2013 )
=564,220.2545 $=Php 25,389,911.45
222.301 ( 1979 )