Batch Still Volume

Operating pressure

5618 lts
760 mmHg

Feed Composition
Component
Methanol
Water
IPA

%w/w
45%
10%
45%
100%

Properties of solvents
Component

Sp.gr

MW

Methanol
Water
IPA

0.78
1.00
0.79

32
18
60

Latent heat
Kcal/kg
263
510
159

Loading factor for Structured packing

Heating Medium
Saturated pressure
Saturated Temperature
Latent heat
Cost of Steam

Antonie Coefficient
A
B
C
8.08097

1582.271

239.726

8.07131

1730.63

233.426

8.1182

1580.92

219.62

1.75 m/s (kg/Cu.M)0.5

Steam
3
131
512
2.5

bar (g)
C
kcal/kg
Rs/kg

Main Condenser Cooling medium

Inlet temperature
Outlet temperature
Percentage of operating load
Cost of cooling water (Rs/TR)

Cooling water
32 C
37 C
85 %

Vent Condenser Chilling medium

Inlet temperature
Outlet temperature
Percentage of average operating load
Cost of cooling water (Rs/TR)

Chilled brine
-5 C
-3 C
15 %

Cost of Electricity

6 Rs/unit

Avg. Specific gravity of Methanol-Water feed mixture

Feed Quantity
Component
Methanol
Water
IPA

0.81

4546 kgs
wf
0.450
0.100
0.450
1.000

mass (kg)
2046
455
2046
4546

Mol. Wt
32
18
60

Moles
63.9
25.3
34.1
123.3

mol.fr
0.52
0.20
0.28
1.00

Recovery of Methanol as % of total Methanol in feed

Distillate Quantity
Component
Methanol
Water
IPA

% w/w
0.995
0.0025
0.0025
1.000

1994 Kgs
mass (kg)
1984.3
5.0
5.0
1994.3

Mol. Wt
32
18
60

Moles
62.0
0.3
0.1
62.3

Bottom residue Quantity

Component
Methanol
Water
IPA

97 %

mol.fr
1.00
0.00
0.00
1.00
2552 Kgs

% w/w
0.024
0.176
0.800

mass (kg)
61.37
449.62
2040.73

1.000

2551.7

Mol. Wt
32
18
60

Moles
1.9
25.0
34.0

mol.fr
0.031
0.410
0.56

60.9

1.000

Bubble Point calculation for distillate

Operating pressure of the column
Bubble temperature
Antonie Coefficient
mol. Fr
Component
x
A
B
C
Methanol
1.00
8.08097
1582.271
239.726
Water
0.00
8.07131
1730.630
233.426
IPA
0.001
8.11820
1580.920
219.620
1.00
Relative volatility of Methanol over water
Bubble Point Calculation for feed
Operating pressure of the column
Assumed temperature
mol. Fr
Antonie Coefficient
Component
x
A
B
C
Methanol
0.52
8.08097
1582.271
239.726
Water
0.20
8.07131
1730.63
233.426
IPA
0.277
8.1182
1580.92
219.62
1.00
Relative volatility of IPA over water
Bubble Point Calculation for final residue
Operating pressure of the column
Assumed temperature
mol. Fr
Antonie Coefficient
Component

760 mmHg
64.73 C
Vap. Pr
mol. Fr
y=Psat*x/P
mmHg
765.467487 1.0027
184.869534 0.0011
361.769632 0.0006
1.004
4.14

760 mmHg
75.6 C
Vap. Pr
mol. Fr
y=P
*x/P
mmHg
sat
1156.32676
0.789
295.82637
0.080
360.63103
0.131
1.000
3.91

760 mmHg
107.3 C
Vap. Pr
mol. Fr

mass
kgs
25.25
1.44
7.87
34.56

Component
Methanol
Water
IPA

x
0.031
0.410
0.558
1.000

A
8.08097
8.07131
8.1182

B
1582.271
1730.63
1580.92

C
239.726
233.426
219.62

y=Psat*x/P
mmHg
3322.4071
0.138
981.90041
0.530
360.63103
0.265
0.932

Relative volatility of Methanol over water

3.38

Average relative volatility, Alp

3.74

For a Total Condenser system

Nmin+1 = log(xDl/xDh)(xBh/xBl)/log(Alphaavg)

6
5 Not including reboilers

Minimum no. of trays, N

Minimum reflux ratio
(L/D)min = (1/(Alp-1))((xlD/xlB)-Alp(xhD/xhB))

15.06

Actual

(L/D)-(L/D)min

N-Nmin

Theoritical

Add Feed

with 60%

Reflux ratio

L/D+1

N+1

Total N

packing eff.

Str. Packing

Random Pak

18.1

0.16

0.480

11

12

19

6.5

13.9

22.6

0.32

0.370

10

16

5.3

11.5

Note :

Packing Height (M)

1. For Structured packing, Packed ht is calculated considering 4 no. of theoritical

stages per mtr of Packing. Hpacking=N50% eff*4
2. For Random Packing, 1" Pall ring is considered and height of packing is calculated
considering HETP=1 (Ref. Ludwig Page no. 212, Table 9-36). HETP Act=HETPEst*1.5
and Hpaking=HETPAct*Ntotal
3. Use gilliland plot for entering values in (N-Nmin)/(N+1). Ref. Ludwig Vol-2 Page-11
Fig 8-14

Column diameter calculation

Option-1 : Considering MellaPak Structured Packing
Reflux ratio L/D
Internal reflux ratio L/V=R/(R+1)
Average molecular weight of Distillate
Duration of Batch distillation
Average rate of distillation collection
Molar flow rate of distillate
Liquid flowrate
Molar flow rate
mass flowrate
Vapour flowrate
Molar flowrate
Mass flowrate
Column operating pressure
Vapour density
Density of Liquid
Packing Loading Factor F
Column Cross Sectional Area
Diameter of the column

18.1
0.95
32
14.00
142
4.47
81
2574
85
2716
760
1.15
778.60
1.75
0.402
0.715

kg/kmol
hrs
kg/hr
kmol/hr
Kmol/hr
kgs/hr
Kmol/hr
kgs/hr
mmHg
kg/Cu.M
kg/Cu.M
m/s(kg/M3)1/2

Sq. M
M

Reboiler Heat Load Calculation

Boil-up rate
Latent heat of boiling liquid

2716.1 kgs/hr
263.0 Kcal/kg

0.71
0.75
0.07
48.61

Heat Load of Reboiler

Quantity of Steam required at 2 kg/cm 2 (g)
Total Steam consumption for I fractionation

785659.7 Kcals/hr
1534.5 kgs/hr
21482.9 kgs/batch

Condenser Load
Latent heat of condensing Methanol-water mix
Condenser load
Cooling water circulation rate at 6C temp. diff

263.0
714236.1 Kcals/hr
236.2 TR
142.8 Cu. M/hr

mass fr.
w/w
0.73
0.04
0.23
1.00

kgs/s
kgs/s
lb/Cu ft
lb/Cu ft

Avg. Specific gravity of IPA-Water feed mixture

Feed Quantity
Component
Methanol
Water
IPA

0.83

2551.725 kgs
wf
0.024
0.176
0.800
1.000

mass (kg) Mol. Wt

61
32
450
18
2041
60
2552

Moles
1.9
25.0
34.0
60.9

mol.fr
0.03
0.41
0.56
1.00

Recovery of IPA as % of total IPA in feed

75 %

Distillate Quantity

46 Kgs

Component
Methanol
Water
IPA

% w/w
0.995
0.0025
0.0025
1.000

mass (kg)
Mol. Wt
46.0
32
0.1
18
0.1
60
46.3

Moles
1.4
0.0
0.0
1.4

Bottom residue Quantity

Component
Methanol
Water
IPA

% w/w
0.006
0.179
0.814
1.000

mass (kg)
Mol. Wt
15.34
32
449.50
18
2040.62
60
2505.5

mol.fr
0.99
0.00
0.00
1.00
2505 Kgs

Moles
0.5
25.0
34.0
25.5

Bubble Point calculation for distillate

Operating pressure of the column
Bubble temperature
Antonie Coefficient
mol. Fr
Component
x
A
B
C
Methanol
0.99
8.08097 1582.271 239.726
Water
0.00
8.07131
1730.63 233.426
IPA
0.450
8.11820 1580.920 219.620
1.00
Relative volatility of Methanol over water
Bubble Point Calculation for feed
Operating pressure of the column
Assumed temperature
mol. Fr
Antonie Coefficient
Component
x
A
B
C
Methanol
0.03
8.08097 1582.271 239.726
Water
0.41
8.07131
1730.63 233.426
IPA
0.450
8.11820 1580.920 219.620
0.44
Relative volatility of IPA over water
Bubble Point Calculation for final residue
Operating pressure of the column
Assumed temperature
mol. Fr
Antonie Coefficient
Component
x
A
B
C

mol.fr
0.019
0.981
1.34
1.000

760 mmHg
59.85 C
Vap. Pr
mol. Fr
mmHg y=Psat*x/P
629.8955 0.8240
148.0068 0.0009
289.3007 0.1713
0.996
4.26

760 mmHg
89.63 C
Vap. Pr
mol. Fr
y=P
*x/P
mmHg
sat
1891.621
0.078
517.9063
0.279
1014.122
0.600
0.958
3.65

760 mmHg
83.25 C
Vap. Pr
mol. Fr
y=P
*x/P
mmHg
sat

mass
kgs
2.51
5.03
36.03
43.57

mass fr.
w/w
0.06
0.12
0.83
1.00

Methanol
Water
IPA

0.019
0.981
0.450
1.000

8.08097
8.07131
8.11820

1582.271
1730.63
1580.920

239.726
233.426
219.620

1520.317
403.9464
791.4122

Relative volatility of Methanol over water

3.76

Average relative volatility, Alp

4.00

For a Total Condenser system

Nmin+1 = log(xDl/xDh)(xBh/xBl)/log(Alphaavg)
Minimum no. of trays, N

7
6

Minimum reflux ratio

(L/D)min = (1/(Alp-1))((xlD/xlB)-Alp(xhD/xhB))

54.05

0.038
0.521
0.469
1.028

Actual

(L/D)-(L/D)min

N-Nmin

Theoritical

Add Feed

with 50%

Reflux ratio

L/D+1

N+1

Total N

packing eff.

Str. Packing

Random Pak

64.9

0.16

0.480

12

13

26

8.7

15.6

18.0

-1.90

0.180

16

5.5

9.9

Note :

Packing Height (M)

1. For Structured packing, Packed ht is calculated considering 4 no. of theoritical

stages per mtr of Packing. Hpacking=N50% eff*4
2. For Random Packing, 1" Pall ring is considered and height of packing is
calculated considering HETP=1 (Ref. Ludwig Page no. 212, Table 9-36). HETP
=HETPEst*1.5 and Hpaking=HETPAct*Ntotal
Act
3. Use gilliland plot for entering values in (N-Nmin)/(N+1). Ref. Ludwig Vol-2 Page11 Fig 8-14

Column diameter calculation

Option-1 : Considering MellaPak Structured Packing
Reflux ratio L/D
Internal reflux ratio L/V=R/(R+1)
Average molecular weight of Distillate
Duration of Batch distillation
Average rate of distillation collection
Molar flow rate of distillate
Liquid flowrate
Molar flow rate
mass flowrate
Vapour flowrate
Molar flowrate
Mass flowrate
Column operating pressure
Vapour density
Density of Liquid
Packing Loading Factor F
Column Cross Sectional Area
Diameter of the column

64.9
0.98
32
1.00
46
1.45
94
3000
96
3046
760
1.17
778.60
1.75
0.447
0.755

kg/kmol
hrs
kg/hr
kmol/hr
Kmol/hr
kgs/hr
Kmol/hr
kgs/hr
mmHg
kg/Cu.M
kg/Cu.M
m/s(kg/M3)1/2

Sq. M
M

Reboiler Heat Load Calculation

Boil-up rate
Latent heat of boiling liquid
Heat Load of Reboiler

3046.4 kgs/hr
263.0 Kcal/kg
881203.6 Kcals/hr

0.83 kgs/s
0.85 kgs/s
0.07 lb/Cu ft
48.61 lb/Cu ft

Quantity of Steam required at 2 kg/cm 2 (g)

Total Steam consumption for II fractionation

1721.1 kgs/hr
1721.1 kgs/batch

Condenser Load
Latent heat of condensing Methanol-water mix
Condenser load
Cooling water circulation rate at 6C temp. diff

263.0
801094.2 Kcals/hr
264.9 TR
133.5 Cu. M/hr

Avg. Specific gravity of Methanol-Water feed mixture

Feed Quantity
Component
Methanol
Water
IPA

2505 kgs
wf
0.006
0.179
0.814
1.000

mass (kg) Mol. Wt

15
32
450
18
2041
60
2505

Moles
0.5
25.0
34.0
59.5

Recovery of Methanol as % of total Methanol in feed

Distillate Quantity
Component
Methanol
Water
IPA

% w/w
0.007
0.001
0.992
1.000

% w/w
0.001
0.813
0.185
1.000

mol.fr
0.01
0.42
0.57
1.00
95 %
1954 Kgs

mass (kg)
Mol. Wt
14.6
32
2.0
18
1938.6
60
1954.2

Moles
0.5
0.1
32.3
32.9

Bottom residue Quantity

Component
Methanol
Water
IPA

0.83

mass (kg)
Mol. Wt
0.8
32
447.5
18
102.0
60
550.3

mol.fr
0.01
0.00
0.98
1.00
551 Kgs

Moles
0.0
24.9
1.7
26.6

Bubble Point calculation for distillate

Operating pressure of the column
Bubble temperature
Antonie Coefficient
mol. Fr
Component
x
A
B
C
Methanol
0.01
8.08097 1582.271 239.726
Water
0.00
8.07131
1730.63 233.426
IPA
0.450
8.11820 1580.920 219.620
0.02
Relative volatility of Methanol over water
Bubble Point Calculation for feed
Operating pressure of the column
Assumed temperature
mol. Fr
Antonie Coefficient
Component
x
A
B
C
Methanol
0.01
8.08097 1582.271 239.726
Water
0.42
8.07131
1730.63 233.426
IPA
0.450
8.11820 1580.920 219.620
0.43
Relative volatility of IPA over water
Bubble Point Calculation for final residue
Operating pressure of the column
Assumed temperature
mol. Fr
Antonie Coefficient
Component
x
A
B
C

mol.fr
0.001
0.935
0.06
1.000

760 mmHg
101.92 C
Vap. Pr
mol. Fr
mmHg y=Psat*x/P
2816.131 0.0513
813.9177 0.0035
1590.328 0.9416
0.9965
1.95

760 mmHg
92.268 C
Vap. Pr
mol. Fr
y=P
*x/P
mmHg
sat
2065.415
0.022
572.3232
0.316
1120.287
0.663
1.0015
1.96

760 mmHg
84.096 C
Vap. Pr
mol. Fr
mmHg y=Psat*x/P

mass
kgs
0.70
5.69
39.80
46.19

mass fr.
w/w
0.02
0.12
0.86
1.00

Methanol
Water
IPA

0.001
0.935
0.450
0.936

8.08097
8.07131
8.11820

1582.271
1730.63
1580.920

239.726
233.426
219.620

1565.789
417.7193
818.3564

Relative volatility of Methanol over water

1.96

Average relative volatility, Alp

1.96

For a Total Condenser system

Nmin+1 = log(xDl/xDh)(xBh/xBl)/log(Alphaavg)
Minimum no. of trays, N

12
11

Minimum reflux ratio

(L/D)min = (1/(Alp-1))((xlD/xlB)-Alp(xhD/xhB))

10.38

0.002
0.514
0.485
1.0004

Actual

(L/D)-(L/D)min

N-Nmin

Theoritical

Add Feed

with 50%

Reflux ratio

L/D+1

N+1

Total N

packing eff.

Str. Packing

Random Pak

12.5

0.15

0.485

23

24

48

16.2

29.1

35.0

0.68

0.230

15

16

32

10.8

19.5

Note :

Packing Height (M)

1. For Structured packing, Packed ht is calculated considering 4 no. of theoritical

stages per mtr of Packing. Hpacking=N50% eff*4
2. For Random Packing, 1" Pall ring is considered and height of packing is
calculated considering HETP=1 (Ref. Ludwig Page no. 212, Table 9-36). HETP
=HETPEst*1.5 and Hpaking=HETPAct*Ntotal
Act
3. Use gilliland plot for entering values in (N-Nmin)/(N+1). Ref. Ludwig Vol-2 Page11 Fig 8-14

Column diameter calculation

Option-1 : Considering MellaPak Structured Packing
Reflux ratio L/D
Internal reflux ratio L/V=R/(R+1)
Average molecular weight of Distillate
Duration of Batch distillation
Average rate of distillation collection
Molar flow rate of distillate
Liquid flowrate
Molar flow rate
mass flowrate
Vapour flowrate
Molar flowrate
Mass flowrate
Column operating pressure
Vapour density
Density of Liquid
Packing Loading Factor F
Column Cross Sectional Area
Diameter of the column

12.5
0.93
0
24.00
81
317.23
3953
1015
4270
1096
760
0.01
6.82
1.75
1.904
1.557

kg/kmol
hrs
kg/hr
kmol/hr
Kmol/hr
kgs/hr
Kmol/hr
kgs/hr
mmHg
kg/Cu.M
kg/Cu.M
m/s(kg/M3)1/2

Sq. M
M

Reboiler Heat Load Calculation

Boil-up rate
Latent heat of boiling liquid
Heat Load of Reboiler

1096.0 kgs/hr
2.5 Kcal/kg
2979.9 Kcals/hr

0.28 kgs/s
0.30 kgs/s
0.00 lb/Cu ft
0.43 lb/Cu ft

Quantity of Steam required at 2 kg/cm 2 (g)

Total Steam consumption for III fractionation

5.8 kgs/hr
139.7 kgs/batch

Condenser Load
Latent heat of condensing Methanol-water mix
Condenser load
Cooling water circulation rate at 6C temp. diff

2.5
2709.0 Kcals/hr
0.9 TR
0.5 Cu. M/hr

Trebayal Illutration 9.8

Basis
5000 kg/hr solution
ComponentMol wt
wt %
mol/hr
Mol%
Methanol
32
50%
78.125
0.36 Xf
Water
18
50% 138.8889
0.64
217.0139
1.00
Average Mol feed rate
23.04 kgmol/hr
kg/hr
Distillate
Xd
2606
Methanol
0.95
0.914
Water
0.05
1
Residue
Xw
2394
Methanol
0.01 0.00565
Water
0.99
1
Mass balance
kmol/hr
kg/hr
So,
F 217.0139
5000
D
84.617
2606
W 132.397
2394