CHAPTER V

DESIGN OF DISTILLATION COLUMN

5.1 INTRODUCTION
This chapter consists of the detail design of distillation column. The detail design of
distillation column would comprise of two different sections; (1) the chemical design, and (2)
mechanical design. Conceptual design section would include the steps taken in determining the
number of theoretical, minimal, and actual number of stages, column diameter and height, and
other supporting parameters.

The mechanical design however focuses upon the method in

calculating various dimension of the column inclusive of several safety aspects in designing the
shell, head and closures, gasket, bolts, flange and skirt support.
In the production of purified terephthalic acid, we use distillation column in order to
separate the acetic acid and water as the acetic acid will be recycling back to the feed stream at
the conversion reactor. Here, we use the multicomponent distillation column as it comprise of
three components which are water, acetic acid and p-xylene. The heavy key is the acetic acid
because it appears at the bottom and water is the light key as it appear at the top column. Tray
column is the distillation column type of choice based on several sound justifications. Where tray

column has various designs that used to hold up the liquid to provide better contact between
vapor and liquid, hence better separation. The tray that we use here is the valve trays,
perforations are covered by liftable caps. The principles of the valve tray like when the vapor
flows lifts the caps, thus self creating a flow area for the passage of vapor. The lifting cap directs
the vapor to flow horizontally into the liquid, thus providing better mixing than is possible in sieve
trays.
The advantages of distillation are its simple flowsheet, low capital investment and low risk.
The separation process has the ability to handle wide ranges of feed concentrations and
throughputs while producing a high-purity product. The equipment requirements for distillations
are small compared to those for most other separation processes like adsorption, membrane
separation and filtration. Equipment requirements for distillation column generally are a column, a
reboiler, a condenser and some relatively small ancillary equipment.
5.2 Chemical Design
5.1.1 Activity coefficient and K values
Using Wilson equation, the activity coefficient for water, acetic acid and p-xylene are calculated.
Table below shows the composition and mol fraction for the three components at the feed, top
and bottom stream from HYSIS simulation:
Table 5.1: The composition of components at the distillation column
Feed (f)
Tops (d)
Bottoms (b)
Composition
Mol
Composition
Mol
Compositio
Mol
fraction, xf
fraction, xd
n
fraction,xb
987.81
0.36
970.17
0.99
17.65
0.01
1756.77
0.63
9.8
0.01
1746.96
0.98
24.18
0.01
24.18
0.01
2768.76
1.00
979.97
1.00
1788.79
1.00

H2O
CH3COOH
C8H10
Total

Below is the equation developed by Wilson (1964) to calculate the liquid phase activity
coefficient:

[ ( ) ] [ (
n

ln k =1.0 ln

j=1

x j A kj

i=1

x i A ik

j=1

Where

x j A ij )

..(1)

k = activity coefficient for component k,

A ij , A ji = Wilson coefficients (A values) for the binary pair i,j,

n= Number of components
Assume the top stream (vapor) is ideal gas. So we consider the feed stream and bottom stream
(liquid) are non-ideal liquid.
System: H2O (1)
CH3COOH (2)
C8H10 (3)
Table 5.2: Values of activity model interaction parameters from HYSYS simulation
j
1
2
3
1
1.000
237.265
10999.734
i
2
528.965
1.000
-62.114
3
23194.363
1429.965
1.000
Table 5.3: Values of molar volume from HYSYS simulation
Molar volume(m3/kmol)
H2O
1.7883 x 10-2
CH3COOH
5.6641 x 10-2
C8H10
0.12371
Equation of Wilson from Perrys 7th Edition, page 13-21

v 2L
12 11
A 12= L exp
(2)
RT
v1

v 1L
2122
A 21= L exp
..(3)
RT
v2

Where

v iL = molar volume of pure-liquid component i

ij =

interaction energy between components i and j,

R= 1.98721 cal/gmol.K

( 12 11 ) =

cal/mol

ij = ji

Wilson coefficient (A values) for the binary pair i,j in the feed stream;

A 12=

( 5.6641 x 102 )
237.265
exp
2
( 1.98721 ) ( 383.15 )
( 1.7883 x 10 )

( 1.7883 x 102 )
528.965
exp
2
( 1.98721 ) ( 383.15 )
( 5.6641 x 10 )

2.3190

A 21=

0.1576

A 13=

( 0.12371 )

( 1.7883 x 10 )
2

exp

10999.734
( (1.98721
) ( 383 ) )

exp

23194.336
( ( 1.98721
) ( 383 ) )

exp

62.114
( 1.98721 ) ( 383 )

3.659 x 106

A 31=

( 1.7883 x 102 )
( 0.12371 )

8.4147 x 1015

A 23=

( 0.12371 )

( 5.6641 x 10 )

2.3698

A 32=

( 5.6641 x 102 )
( 0.12371 )

exp

1429.965
( 1.98721 ) ( 383 )

0.069
The liquid phase activity coefficient

is a function of pressure, temperature and liquid

composition. First, we calculate the activity coefficient for the three components at T=110C. And
for the rest at T= 120C, 125C, 130, 135C and 140C.
Sample of calculation for activity coefficient for the three components at T=110C by using
spreadsheet are shown below.

Activity coefficient for H2O at T=110C

H2O
CH3COO
H
C8H10

A interaction
CH3COO
H2O
H
C8H10
2.31930 3.67984E
1
044
-06
0.157613
2.369753
44
1
012
8.51547E 0.06999
-15
85
1

at the feed stream

j
1
1
i

2
3

feed

k
composi
tion

1
0.157613
44
8.51547E
-15
1
H2O

2
2.31930
044
1
0.06999
85

3
3.67984E
-06
2.369753
012
1

2
3
CH3COO
H
C8H10

0.36

0.63

0.01

Activity coefficient for H2O

Q1=x(j)*A(k,j)
k=1
j=1
j=2
j=3
1.461159 3.6798E
0.36
276
-08

sum Q1

1.82115
931

Q3=x(j)*A(i,j)
Q3

j=1

j=2
j=3
sum Q3
1.46115 3.67984E 1.821159
0.36
928
-08
313
0.056740
0.023697 0.710438
838
0.63
53
368
3.06557E 0.04409
0.054099
-15
905
0.01
053

i=1
i=2
i=3
Q2
=x(i)*A(i,k)/sumQ3
Q2
i=1
i=2
i=3
sumQ2

k=1
0.19767
628
0.13976
788
1.57E-15
3.37E-01

Gamma k = exp(1-ln(sumQ1)sumQ2)
Gamma
1.06511
H2O =
476

Activity coefficient for CH3COOH at T=110C

Activity coefficient for CH3COOH
Q1=x(j)*A(k,j)
k=2
j=1
j=2
j=3
0.0567
0.0236
41
0.63
98

sum Q1
Q3=x(j)*A(i,j)

0.7104
38

sum
j=2
j=3
Q3
0.6603
1.4E- 1.3717
0.7114
05
08
05
0.1121
0.0090 0.4058
26 0.2847
05
31
6.06E- 0.0199
0.0237
15
29 0.0038
29

Q3

j=1

i=1
i=2
i=3

Q2 =x(i)*A(i,k)/sumQ3

i=1
i=2
i=3
sum Q2

k=2
0.6086
94
1.5523
69
2.95E02
2.19E+
00

Gamma k = exp(1-ln(sumQ1)sumQ2)
Gamma
0.4279
CH3COOH =
75

Activity coefficient for C8H10 at T=110C

Activity coefficient for C8H10

Q1=x(j)*A(
k,j)
k=3

sum Q1

j=1
j=2
j=3
3.0656E
0.044
-15
099
0.01
0.05409
905

Q3=x(j)*A(
i,j)
sum
j=1
j=2
j=3
Q3
0.711
0.660
1.4E1.371
4
305
08
705
0.112
0.284
0.009
0.405
126
7
005
831
6.06E0.019
0.003
0.023
15
929
8
729

Q3
i=1
i=2
i=3
Q2
=x(i)*A(i,k)/sumQ3

i=1
i=2
i=3
sum Q2

k=3
6.22E01
3.67873
187
4.21E01
4.72E+0
0

Gamma k = exp(1-ln(sumQ1)sumQ2)
Gamma
0.44701
C8H10 =
595
Then, the values for the activity coefficient for various temperatures were calculated by using the
same method shown from the above. Then, we construct the graph to get the equation for the
activity coefficients.
Table 5.4: Activity coefficient for the three components at various temperatures
T (C)
110

1.0651

CH COOH

C H

0.4280

0.4470

10

120
125
130
135
140

1.0572
1.0535
1.0498
1.0462
1.0427

0.4247
0.4231
0.4216
0.4201
0.4186

0.4337
0.4274
0.4213
0.4154
0.4097

Gamma H2O
1.07
1.07

f(x) = - 0x + 1.15
R = 1

1.06
1.06

G1
Linear (G1)

1.05
1.05
1.04
1.04
1.03
100

105

110

115

120

125

130

135

140

145

Figure 5.1: Graph of activity coefficient for H2O versus T (C)

Gamma CH3COOH
0.43
0.43

f(x) = - 0x + 0.46
R = 1

0.43
0.42

G2

0.42

Linear (G2)

0.42
0.42
0.42
0.41
0.41
100

105

110

115

120

125

130

135

140

145

Figure 5.2: Graph of activity coefficient for CH3COOH versus T (C)

Gamma C8H10
0.45
f(x) = - 0x + 0.58
R = 1

0.44
0.43

G3
Linear (G3)

0.42
0.41
0.4
0.39
100

105

110

115

120

125

130

135

140

145

Figure 5.3: Graph of activity coefficient for C8H10 versus T (C)

For the non ideal system, we calculate the K values by using the equation below:

 i Pi
K i=
.(4)
P

Pi =

Where

P=

the pure component vapor pressure, N/m2

total system pressure

i= liquid-phase activity coefficient

The operating pressure of the distillation column is 1.97 atm = 1497.2 mmHg
For the calculation of the P saturation, we need the Antoine vapor pressure constants:
Table 5.5: Antoine constants
Antoine constants
Species

Range (C)
A
7.96681
7.38782
6.98820

H2O
CH3COOH
C8H10

log 10 P = A

B
1668.210
1533.313
1451.792

C
228.000
222.369
215.111

60 to 150
29.8 to 126.5
58.3 to 139.3

, P mmHg ,T .(5)
T +C

K values calculated by using the Antoine equations

constructed.

and then the graph for K values are

Table 5.5: K values at various temperatures

H2O
T (C)

P (mmHg )

120.0
130.0
140.0
146.5

1489.7
2027.7
2714.1
3253.2

CH3COOH

Ki

1.0524
1.0491
1.0458
1.0437

1.047
1.420
1.896
2.268

P (mmHg )
811.5
1087.4
1433.7
1702.3

C8H10

Ki

0.4263
0.4233
0.4203
0.4184

0.231
0.307
0.403
0.476

P (mmHg)
452.823
604.590
794.188
940.612

Ki

0.439
0.427
0.415
0.407

0.133
0.173
0.220
0.256

2.5
f(x) = 0 x^3.87
R = 1

K1
Power (K1)
Power (K1)

1.5

Power (K1)
K2

K Values
1

Power (K2)
Linear (K2)
Power (K2)

0.5

K3

f(x) = 0 x^3.62
R
f(x)==10 x^3.29

0
100.0

R = 1
120.0
130.0

110.0

Power (K3)
Power (K3)
140.0

150.0

Temperature

Figure 5.4: Graph of K values versus T (C)

5.1.2 Relative volatility
The relative volatility of two components can be expressed as the ratio of their K values:

ij=

Ki
..(6)
K HK
Temperature (C)
120.0
130.0
140.0
146.5
Average

H2O (LK)
4.5319
4.6216
4.7104
4.7676
4.6503

CH3COOH (HK)
1.0
1.0
1.0
1.0
1.0

C8H10
0.5749
0.5611
0.5472
0.5381
0.5566

5.1.3 Bubble and Dew point temperature

Estimation of bubble and dew points:
Bubble point

y i= K i x i=1.0 (7)
y

Dew point

x i= Ki =1.0 (8)
i

To estimate the dew and bubble points, assume that nothing heavier than the heavy key appears
in the tops and nothing lighter than the light key in the bottoms. The bubble point, dew point and
bubble feed point are calculated by using Goal Seek method (in Excel).
Bubble point calculation, bottoms at T= 177.09C;
T(C)
177.09

K H2O
4.804

H2O
CH3COOH
C8H10

K CH3COOH
0.966
Ki
4.804
0.966
0.482
sum

KC8H10
0.482

Kixb
0.048
0.947
0.005
1.000

Dew point calculation, tops at T= 118.13C;

T(C)
118.13

K H2O
0.992

H2O
CH3COOH
C8H10

K CH3COOH
0.218
Ki
0.992
0.218
0.125
sum

KC8H10
0.125

xd/Ki
0.998
0.002
1.000

Bubble point calculation, feed at T= 142.5C;

T(C)
142.5

K H2O
2.023

H2O
CH3COOH
C8H10

K CH3COOH
0.4274
Ki
2.023
0.427
0.230
sum

KC8H10
0.230

Kixf
0.728
0.269
0.002
0.999

5.1.4 Reflux ratio

For the calculation of minimum reflux ratio, the Underwood (1948) has been used.

ii ,d =R m +1 ..(7)
i

 i= the relative volatility of component i with respect to some reference component,

Where

Usually the heavy key,

Rm= The minimum reflux ratio

x i ,d = Concentration of component i in the tops at minimum reflux ratio
and is the root of the equation:

ii ,d =1q ..(8)
i

Where

x i ,f = concentration of component I in the feed, and q depends on the condition of the

feed

The value of must lie between the values of the relative volatility of the light and heavy keys,
and is found by trial and error.

H2O (LK)
CH3COOH (HK)
C8H10

fi

di

bi

4.6503
1.0000
0.5566
Total

987.81
1756.77
24.18
F = 2768.76

970.17
9.8
D = 979.97

17.65
1746.96
24.18
B = 1788.79

Calculate the minimum number of stages by using Fenske equation;

log
N m=

Where

[ ][ ]
x LK x HK
x HK d x LK
log LK

(9)

LK = average relative volatility of the light key with respect to the heavy key
x LK = Light key concentration
x HK = Heavy key concentration

log
N m=

][

970.17 1746.96
9.8 d 17.65 b
=5.9794 stages
log ( 4.6503)

Assume the feed is at its boiling point, q =1;

ii ,d =1q
i

ii ,d =0
i

x i ,f

i x i ,f

0.36
0.63
0.01

1.6591
0.6345
0.0049

= 1.16
0.4753
-3.9656
-0.0081

Try
= 1.152
0.4743
-4.1743
-0.0082

-3.4983

-3.7082

= 2.014
From equation 7;

x i ,d

i x i ,d

i xi , d
i

0.99
0.01

4.6038
0.01

1.7463
-0.0099
1.7364

Rm +1=1.7364
Rm=0.7364
Rm
0.7364
=
=0.42
( R m +1 ) ( 0.7364+1 )
Specimen calculation, for R = 1.0;

R
1
= =0.50
( R+1 ) 2

From figure 5.5 below,

= 2.014
0.6293
-0.6257
-0.0033
0.0003
close enough

Nm
=0.54
N
N=

5.9794
=11.07
0.54

Figure 5.5: Erbar-Maddox correlation

Recalculated for other reflux ratios;
R
0.8
0.9
1
1.2
1.5
1.8

R/(R+1)
0.44
0.47
0.50
0.55
0.60
0.64

Nm/N
0.26
0.44
0.54
0.68
0.74
0.78

N
23.00
13.59
11.07
8.79
8.08
7.67

The optimum reflux ratio is 1.5 and we take the reflux ratio of 0.8 which is between the minimum
reflux ratio and optimum reflux ratio. The number of stages required is 23 including the reboiler.

5.1.5 Determine number of stages by using Lewis-Matheson method

Stage by stage calculations
Top down calculation
Assume total condensation with no subcooling;

y 1=x d =x o

H2O
CH3COOH
C8H10

xd

0.99
0.01
0.015

970.17
9.8
979.97

The temperature range from top to bottom of the column will be approximately 177.09 - 118.13C,
and the approximate ideal stages needed will be around 23 stages, so the temperature changes
from stage to stage can be expected to be around 2.56C. And we take the range around 2.03.0C.
Stage 1

Lo=R xD=0.8 x 979.97=783.976 kmol /hr

V 1=( R+1 ) D=1.8 x 979.97=1763.946 kmol /hr

Estimation of stage temperature and outlet liquid composition (x1)

y1
H2O
CH3COOH

0.99
0.01

Try T1 =119.93C
Ki
x1=yi/Ki
1.0186
0.972
0.2360
0.042
1.014
Close enough

Try 121.21C
Ki
x1=yi/Ki
1.0614
0.933
0.2452
0.041
0.974
Too low

Stage equations;

Lo +V 2=L1 +V 1 .(10)
Lo x o +V 2 y 2=L1 x 1 +V 1 y1 (11)
Lo ho +V 2 H 2=L1 h1 +V 1 H 1 .(12)

Normalised
, x1
0.958
0.042

h=f ( x , T ) .(13)

H=F ( x , T ) ..(14)
Where y2 is dependent on the liquid and vapor flows and as a first trial the liquid and vapor flows
are assume constant and equal to Lo and V1

Lo x o +V 2 y 2=L1 x 1 +V 1 y1
Lo x o +V 1 y 2=Lo x 1+V 1 y 1
V 1 y 2V 1 y 1=Lo x 1Lo xo
y
x
( 1x o )
( 2 y 1 )=Lo
V1
x
( 1x o )+ y 1
L
y2 = o
V1
Lo 783.976
=
=0.44
V 1 1763.946

H2O
CH3COOH

H2O
CH3COOH

xo
0.99
0.01

H2O

y1
0.99

x1
0.958
0.042

ho(To=118.13C)
hi
hixi
-278.8180
-276.0298
-473.5622
-4.7356
ho = -280.7654
H1(T1=119.93C)
Hi
Hiyi
-520.9774
-515.7676

xo
0.99
0.01

y2 = 0.71(x0-x1) + y1
0.976
0.024
1.000

x1
0.958
0.042

y2
0.976

h1(T1=119.93C)
hi
xihi
-278.6823
-267.0396
-473.3049
-19.7736
h1 = -286.8132
H2(T2=121.73C assumed)
Hi
yiHi
-520.9106
-508.3444

CH3COOH

0.01

-400.9994

-4.0100
H1 = -519.7776

0.024

-400.8608

Energy balance;

Lo ho +V 2 H 2=L1 h1 +V 1 H 1

( 783.976 ) (280.7654 )+ (518.0146 ) V 2=(286.8132 ) L1 + ( 1763.946 ) (519.7776 )

518.0146 V 2 +286.8132 L1 =696746.2832 .( a)
Lo +V 2=L1 +V 1
783.976+V 2=L1 +1763.946
V 2L1=979.97 .(b)
V 2=1797.904
L1=817.934
L1 817.934
=
=0.45
V 2 1797.904
Stage 2

Estimation of stage temperature and outlet liquid composition, (x2)

H2O

y2
0.976

Ki
1.0791

x2=y2/Ki
0.904

-9.6701
H2 = -518.0146

CH3COOH

y 3=

0.024

0.2491

0.097
1.001
Close enough

L1
( x x ) + y 2
V2 2 1

As the first trial take L/V as

L1 817.934
=
=0.46
V 1 1763.946
x2
0.904
0.097

H2O
CH3COOH

H2O
CH3COOH

x2
0.904
0.097

h2(T2=121.73C)
hi
hix2
-278.5466
-251.8951
-473.0470
-45.8163
h2 = -297.7115

x1
0.958
0.042

y3 = 0.45 (x2-x1) + y2
0.952
0.049
1.001

H3(T3=122.53C assumed)
y3
Hi
y3Hi
0.952
-520.8809
-495.6809
0.049
-400.7990
-19.6021
H3 = -515.2830

Energy balance;

L1 h1 +V 3 H 3=L2 h2 +V 2 H 2

( 817.934 ) (286.8132)+ V 3 (515.2830 )=L2 (297.7115 ) + ( 1797.904 ) (518.0146 )

515.2830 V 3 +297.7115 L2=696746.2535 .(c )
L1+V 3=L2+ V 2
817.934+V 3 =L2+ 1797.904
V 3L2=979.97 .. ( d )
V 3=1861.4475
L2=881.4775

L2 881.4775
=
=0.47
V 3 1861.4475

Stage 3
As the calculated liquid and vapor flows are not changing much from stage to stage, the
calculation will be continued with the value of L/V taken as constant at 0.45.

H2O
CH3COOH

Ki
1.1069
0.2550

Try T3 = 122.53C
x3 = y3/Ki
Normalized x3
0.860
0.860
0.192
0.140
1.052
Close enough

y4 =0.45(x3 x2) + y3
0.932
0.068
1.000

Stage 4

H2O
CH3COOH

Ki
1.1992
0.2749

Try T4 = 125.09C
x4 = y4/Ki
Normalized x4
0.777
0.777
0.249
0.223
1.026
Close enough

y5 =0.45(x4 x3) + y4
0.894
0.106
1.000

Stage 5

H2O
CH3COOH

Ki
1.2971
0.2958

Try T5 = 127.65C
x5 = y5/Ki
Normalized x5
0.689
0.689
0.357
0.311
1.047
Close enough

y6 =0.45(x5 x4) + y5
0.855
0.145
1.000

Stage 6

H2O

Ki
1.4008

Try T6 = 130.21C
x6 = y6/Ki
Normalized x6
0.610
0.610

y7 =0.45(x6 x5) + y6
0.819

CH3COOH

0.3179

0.456
1.067
Close enough

0.390

0.181
1.000

Stage 7

H2O
CH3COOH

Ki
1.5105
0.3411

Try T6 = 132.77C
x7 = y7/Ki
Normalized x7
0.542
0.542
0.530
0.458
1.072
Close enough

y8 =0.45(x7 x6) + y7
0.789
0.211
1.000

Stage 8

H2O
CH3COOH

Ki
1.6265
0.3655

Try T8 = 135.33C
x8 = y8/Ki
Normalized x8
0.485
0.485
0.578
0.515
1.063
Close enough

y9 =0.45(x8 x7) + y8
0.763
0.237
1.000

Stage 9

H2O
CH3COOH

Ki
1.7490
0.3912

Try T9 = 137.89C
x9 = y9/Ki
Normalized x9
0.436
0.436
0.606
0.564
1.042
Close enough

y10 =0.45(x9 x8) + y9

0.741
0.259
1.000

Stage 10

H2O
CH3COOH

Ki
1.8782
0.4181

Try T10= 140.45C

x10= y10/Ki
Normalized x10
0.395
0.395
0.620
0.605
1.014
Close enough

y11 =0.45(x10 x9) + y10

0.722
0.278

Stage 11
H2O
CH3COOH

Ki
2.0143
0.4464

x11= y11/Ki
0.359
0.622
0.981

Normalized x11
0.359
0.641

1.000

Close enough

ratio

LK 0.359
=
=0.56
HK 0.641

This is just below the ratio in the feed,

ratio

LK 0.36
=
=0.57
HK 0.63

So, the feed would be introduced at this stage.

Bottom up calculation
The calculation for the bottom up will be shown for the reboiler and bottom stage, assuming
constant molar overflow. With the feed at its boiling point and constant molar overflow the base
flows can be calculated as follows:

V ' =V o =1763.946 kmol/hr

'

L =Lo + FEED=783.976+ 2768.76=3552.736 kmol /hr

V ' 1763.946
=
=0.50
L' 3552.736

H2O
CH3COOH
C8H10

xb

0.99
0.01
0.015

970.17
9.8
24.18
1788.79

Reboiler
xb
H2O
CH3COOH

0.010
0.977

Try To =177.09C
Ki
yb=Kixb
4.6105
0.045
0.9679
0.945
0.991
Close enough

Try 174.53C
Ki
yb=Kixb
4.3576
0.043
0.9181
0.897
0.940
Too low

Material balance:
'

'

x B 1 L = y B V +x B B

x B 1=

V'
B
yB+ ' xB
'
L
L

x B 1=

1763.946
1788.79
y +
x
3552.736 B 3552.736 B

x B 1=0.5 y B+ 0.5 x B

Stage 1 from Base (B1)

H2O
CH3COOH

xb1
0.028
0.961

Ki
4.3576
0.9181

T1=174.53C
Normalized
yb1=Kixb1
yb1
0.121
0.120
0.882
0.880
1.003
1.000

xb2=0.50(yb1-yb)+xb1
0.066
0.952
1.019

Stage 2
T2 = 171.97C

H2O
CH3COOH

xb2
0.065
0.935

Ki
4.1152
0.8703

yb2=Kixb2
0.268
0.814
1.082

normalised
yb2
0.248
0.752
1.000

xb3
0.129
0.871
1.000

normalised
yb3
0.411
0.589
1.000

xb4
0.210
0.790
1.000

normalised
yb4
0.555

xb5
0.283

Stage 3
T3 = 169.41C

H2O
CH3COOH

xb3
0.129
0.871

Ki
3.8829
0.8243

yb3=Kixb3
0.500
0.718
1.218

Stage 4
T4 = 166.85C

H2O

xb4
0.210

Ki
3.6604

yb4=Kixb4
0.769

normalised
xb2
0.065
0.935
1.000

CH3COOH

0.790

0.7801

0.616
1.386

0.445
1.000

0.717
1.000

normalised
yb5
0.648
0.352
1.000

xb6
0.329
0.671
1.000

normalised
yb6
0.695
0.305
1.000

xb7
0.353
0.647
1.000

normalised
yb7
0.716
0.284
1.000

xb8
0.363
0.637
1.000

normalised
yb8
0.725
0.275
1.000

xb9
0.367
0.633
1.000

normalised
yb9
0.728

xb10
0.369

Stage 5
T5 = 164.29C

H2O
CH3COOH

xb5
0.283
0.717

Ki
3.4476
0.7376

yb5=Kixb5
0.974
0.529
1.504

Stage 6
T6 = 161.73C

H2O
CH3COOH

xb6
0.329
0.671

Ki
3.2441
0.6968

yb6=Kixb6
1.067
0.468
1.535

Stage 7
T7 = 159.17C

H2O
CH3COOH

xb7
0.353
0.647

Ki
3.0497
0.6577

yb7=Kixb7
1.075
0.426
1.501

Stage 8
T8 = 156.61C

H2O
CH3COOH

xb8
0.363
0.637

Ki
2.8640
0.6202

yb8=Kixb8
1.040
0.395
1.435

Stage 9
T9 = 154.05C

H2O

xb9
0.367

Ki
2.6869

yb9=Kixb9
0.987

CH3COOH

0.633

0.5843

0.370
1.357

0.272
1.000

0.631
1.000

normalised
yb10
0.728
0.272
1.000

xb11
0.369
0.631
1.000

normalised
yb11
0.727
0.273
1.000

xb12
0.369
0.631
1.000

Stage 10
T10 = 151.49C

H2O
CH3COOH

xb10
0.369
0.631

Ki
2.5180
0.5499

yb10=Kixb10
0.928
0.347
1.276

Stage 11
T11 = 148.93C

H2O
CH3COOH

ratio

xb11
0.369
0.631

Ki
2.3571
0.5170

yb11=Kixb11
0.870
0.326
1.196

LK 0.369
=
=0.58
HK 0.631

This is just above the ratio in the feed,

ratio

LK 0.36
=
=0.57
HK 0.63

So, the assume concentration of the keys in the bottom products mesh with the top down
calculation. By using the stage by stage calculation, the distillation column has 23 stages
including the reboiler with reflux ratio of 0.8
5.1.6 Plate efficiency
The overall plate efficiency can be obtained from the correlation given by OConnell (1946).

Eo =5132.5 log ( a a ) ..(15)

Where

a=the molar average liquid viscocity , mNs /m2

a=average relative volatility of thelight key

The OConnell correlation was based on data for bubble-cap trays, and it was stated to predict
90% of the efficiency data to within 10%. For sieve and valve trays, its predictions are likely to
be slightly conservative since our design of distillation column we use the valve trays.
From HYSYS simulation, for the feed composition, molar average viscosity = 0.8627 mNs/m2
Average relative volatility light key = 4.6503

a a=( 0.8627 ) ( 1.855 )=4.01

Figure
5.6: Plate efficiencies (bubble caps) (OConnell)
From the graph above, the efficiency, Eo (%) = 0.35

Eo =

number of ideal stages

number of real stages

0.35=

23
number of real stages

number of real stages=65.71=66 stages

5.1.7 Physical properties

From HYSIS simulation, these data are obtained:
Table 5.1 Properties of liquid phase and gas phase
Parameter

Top

Density (kg/m3)
Volume Flowrate (m3/hr)
Volume Flowrate (kmol/hr)
Molecular Weight (kg/kmol)
Surface Tension, (kg/s2)
Viscosity, (kg/ms)

Liquid phase
930.60
18.02
0.055
0.2295

Vapor phase
1.102
72760.41
4449.61
18.02
0.013

Bottom
Liquid phase
Vapor phase
910.500
3.571
118.57
1781.41
60.60
61.41
0.018
0.152
0.0084

5.1.8 Plate Spacing

The overall height of the column will depend on the plate spacing. Plate spacing from 0.15m to
1m are normally used. The spacing chosen will depend on the column diameter and operating
conditions. For our design, we choose the normal height between the trays which is 700mm
(0.7m) and at the feed location, the spacing is larger, can be up to 1m. A larger spacing will be
needed between certain trays to accommodate feed and side-streams arrangements, and for
manways.
5.1.9 Column Diameter
Table 5.2: Flowrates at the distillation column

H2O
CH3COOH
C8H10
Total

feed, fi
987.81
1756.77
24.18
2768.76

distillate, di
970.17
9.8
0
979.97

Flow-rates

Liquid flowrate at the rectifing section , Ln=R x D

( 0.8 ) ( 979.97 )=783.98 kmol /hr
Vapor flowrate at therectifing section ,V n =Ln+ D
783.98+979.97=1763.9460 kmol/hr

bottom, bi
17.65
1746.96
24.18
1788.79

Liquid flowrate at the stripping section , Lm' = Ln+ F

783.98+2768.76=3552.7360 kmol /h r

Vapor flowrate at the stripping section , V m' =Lm' W

3552.73601788.79=1763.9460 kmol/h r
Lm' 3552.7360
Slope of bottom operating line ( BO L ) , ' =
=2.01
V m 1763.9460
Slope of bottom operating line (TOL ) ,

R
=0.44
( R+ 1 )

The liquid-vapor flow factor FLV is given by

F LV =

Where

LW
VW

LW =

V
..(1)
L

liquid mass flowrate, kg/s

V W = Vapor mass flowrate, kg/s

F LV bottom=

F LV top=

LW
VW

LW
VW

V
3.571
=2.01
=0.126
L
910.5

V
1.102
=0.44
=0.015
L
930.60

Take plate spacing as 0.7 m

Figure 5.7: K1 value versus Flooding velocity, FLV

From figure above;

base K 1 =0.08
top K 1=0.135
Correction for surface tensions
0.2

[ ]

K 1=
0.02

.(2)

0.018
base K 1 =
0.02

top K 1=

0.055
0.02

0.2

x 0.08=0.0783

0.2

x 0.135=0.1653

The flooding velocity can be estimated from the correlation given by Fair (1961);

uf =K 1

Where

L v
..(3)
v

uf = flooding vapor velocity, m/s, based on the net column cross-sectional area
K 1= A constant obtained from figure 5.3

base u f =0.0783
top u f =0.1653

910.53.571
=1.25 m/s
3.571

930.61.102
=4.80 m/s
1.102

Design for 90% flooding at maximum flow rate;

base u^ v =1.25 x 0.90=1.12m/ s

top u^ v =4.80 x 0.90=4.08 m/s
Maximum volumetric flowrate

base=

( 1763.9460 ) (60.60)
=8.32m 3 / s
( 3.571 ) (3600)

top=

( 1763.9460 ) (18.02)
=8.01 m3 /s
(1.102 ) ( 3600)

Net area required

bottom=

8.32
=7.40m2
1.12

An

top=

8.01
=1.96 m2
4.08

As first trial take downcomer area as 12 percent of total.

Column cross sectional area

base=

top=

7.40
2
=8.41 m
0.88

1.96
2
=2.23 m
0.88

Column diameter

base=

top=

8.41 x 4
=3.27 m

2.23 x 4
=1.69 m

Use same diameter above and below feed, reducing the perforated area for plates above the
feed.
From Chemical Process Equipment Selection and Design by Stanley M.Walas, page 622, the
nearest standard vertical vessel (ASME Code) internal diameter is 3.30 m.
So, internal column diameter taken is 3.30 m.
5.1.10 Thickness column
For a cylindrical shell the minimum thickness required to resist internal pressure can be
determined using equation below:

e=

Pi D i
(4)
2 f Pi

Where

D i= internal diameter (mm)

Pi= internal pressure (N/mm2)
f = design stress (N/mm2)

For vessels under internal pressure, the design pressure is taken 10 percent above the normal
working pressure to avoid spurious operation during minor process upsets as well as the design
temperature.

Internal pressure , P i=( 0.2 ) ( 1.1 )=0.22 N /mm

Internaltemperature ,T i=( 177.1 ) ( 1.1 )=194.81 C

Internaldiameter , D i=3300 mm
From Coulson & Richardsons Chemical Engineering Series Volume 6, page 812, the typical
stresses for plate for various materials are shown in the table below:

Table 5.3: Typical design stresses for various material of plate

We select the material of Stainless steel 18Cr/8Ni, Ti stabilized (304).

Then the design stress, f (N/mm2) = 135.519

e=

Pi D i
(5)
2 f Pi

( 0.22 )(3300)
=2.68 mm=3 mm
2 ( 135.519 )0.22

Corrosion allowance = 4 mm
Take the thickness of the column = 3 + 4 = 7 mm
From Chemical Process Equipment Selection and Design by Stanley M.Walas, page 622, the
nearest standard vertical vessel (ASME Code) thickness is 8 mm.
So, the thickness of the column diameter taken is 8 mm.
Then, the outside diameter = 3.308 mm

5.1.11 Liquid flow pattern

maximum liquid flowrate=

( 3552.7360 )( 60.60 )
=0.066 m3 / s
( 910.5 ) (3600 )

From figure 5.4 below, the plate diameter is outside the range, but it is clear that a single pass
plate can be used.

Figure 5.8: Selection of liquid flow arrangement

5.3.6 Provisional plate design

Columndiameter , D c =3.30 m

Columnarea , A c =( )

3.27 2
=8.55 m2
2

( )

Downcomer area , A d =( 0.12 ) ( 8.40 )=1.03 m2 ,at 12 percent

Net area , A n=A c A d=7.53 m2
Active area, Aa =A c 2 Ad =8.402 ( 1.01 ) =6.50 m2
2

Hole area , A h take 10 percent A a as first tria l=( 6.50 ) ( 0.1 )=0.65 m

From figure 5.9 below,

A d 0.12Lw
=
=0.76
Ac
Dc

Figure 5.9: Relation between downcomer area and weir length

So ,the weir length , L w =2.508 m

Take weir height = 50 mm
Hole diameter = 5 mm
Plate thickness = 5 mm
5.3.7 Number of holes
2
0.005
(
)
Area of one hole=
=1.9635 x 105 m2
2

number of holes=33105.6=33101 holes

5.3.8 Cheek weeping

Maximumliquid rate=

( 3552.7360 ) (60.60)
=59.80 kg /s
3600

Minimum liquid rat , ate 70 turndown= (59.80 )( 0.7 )=41.86 kg/ s

5.3.9 Weir liquid crest

The height of the liquid crest over the weir can be estimated using the Francis weir formula. For a
segmental downcomer this can bewritten as;

how =750(

Where

Lw 23
) (6)
L lw

l w = weir length (m)

how = weir crest, mm liquid
Lw = liquid flowrate, kg/s
2

maximum how =750(

59.80
) 3 =66.14 mm liquid
( 910.5 )( 2.508)

2
41.86
minimum h ow =750(
) 3 =41.86 mm liquid
( 910.5 ) (2.508)

at minimum rate hw +how =66.14 +41.86=118.29 mm

From figure 5.10 below, K2 = 31.15;
Then the minimum design vapor velocity is calculated by using the equation below;

u h=

[ K 20.90(25.4d h) ] .(7)
1

( v ) 2
Where

u h= minimum vapor velocity through the holes (based on the area), m/s
d h=

hole diameter, mm

K 2= a constant, dependent on the depth of clear liquid on the plate

u h=

[ 31.150.90(25.45)]
( 3.571 )

1
2

=6.77 m/s

Figure 5.10: Weep point correlation

minimum vapor rate=

( 1763.9460 )( 60.60 )
=8.32m 3 /s
( 3.571 )( 3600 )

actual min vapor velocity=

( 0.7 )( 8.32 )
=8.95 m/ s
0.65

So, minimum operating rate will be above weep point.

5.3.10 Plate pressure drop
Dry plate drop

Maximum vapor velocity through holes

u h=

8.32
=12.79 m/s
0.65

For plate thickness/hole diameter = 1.0, and Ah/Ap = Ah/Aa = 0.1

From figure 5.7 below, Co = 0.84

Figure 5.11: Discharge coefficient, sieve plates

The pressure drop through the dry plate can be estimated using expressions derived for flow
through orifices.
2

[ ]

u
hd =51 h
Co

v
..(8)
L

12.79
hd =51
0.84

3.571
=46.39 mm liquid
910.5

Residual head
3

hr =

1.25 x 10
..(9)
L

1.25 x 103
hr =
=1.37 mmliquid
910.5
Total plate pressure drop

ht =hd + ( how +h w ) + hr ..(10)

ht =46.39+ (118.29 ) +1.37=166.05mm liquid
5.3.11 Downcomer liquid backup
The downcomer area and plate spacing must be such that the level of the liquid and froth in the
downcomer is well below the top of the outlet weir on the plate above. If the level rises above the
outlet weir the column will flood.
The back-up of liquid in the downcomer is caused by the pressure drop over the plate (the
downcomer in effect forms one leg of a U-tube) and the resistance to flow in the downcomer
itself;

Figure 5.12: Downcomer liquid backup

In terms of clear liquid the downcomer back-up is given by:

hb =( hw +h ow ) + ht +h dc .. (11 )
hb = downcomer back-up, measured from plate surface, mm,

where

hdc = head loss in the downcomer, mm.

The main resistance to flow will be caused by the constriction at the downcomer outlet, and the
head loss in the downcomer can be estimated using the equation given by Cicalese(1947).

hdc =166

[ ]

Lwd
..(12)
L Am

where

Lwd = liquid flow rate in downcomer, kg/s,

A m = either the downcomer area Ad or the clearance area under the

downcomer

A ap ; whichever is the smaller, m2.

The clearance area under the downcomer is given by:

A ap=hap l w ..(13)
Where

hap= is height of the bottom edge of the apron above the plate. This height is

normally set at 5 to 10 mm (1/4 to in) below the outlet weir height:

5
hap=hw ( 10 mm ) ..(14 )
Take

hap=hw 10
66.1410=56.14 mm

=0.141m
( 56.14
1000 )

Area under apron,

A ap=( 2.508 )

As this is less than

A d =1.00 m2 , use A ap

59.80
hdc =166
=0.60 mm , say 1 mm
(910.5)(0.141)
Backup in downcomer

hb =( 118.29 ) +166.05+1.0=285.33 mm=0.29 m

1
0.22< ( plate spacing+weir height )
2
1
0.22< ( 0.7+0.05 )
2
0.22<0.375
So, plate spacing is acceptable
Check residence time
Sufficient residence time must be allowed in the downcomer for the entrained vapor to disengage
from the liquid stream; to prevent heavily aerated liquid being carried under the downcomer.
A time of at least 3 seconds is recommended.
The downcomer residence time is given by:

t r=

A d h bc L
..(15)
Lwd
where

t r= residence time, s,

hbc = clear liquid back-up, m.

t r=

( 1.03 )( 0.29 ) (910.5)

=4.5 s
59.80

 3 s , satisfactory
5.3.12 Check entrainment
Entrainment can be estimated from the correlation given by Fair (1961) figure 5.13 which gives
the fractional entrainment (kg/kg gross liquid flow) as a function of the liquid-vapor factor FLV,
with the percentage approach to flooding as a parameter. The percentage flooding is given by
equation below,

percentage flooding=

uv =

un actual velocity(based on net area)

.(16)
uf

8.32
=1.10 m/s
7.53

percent flooding=

1.10
x 100=88.50
1.25

F LV =0.126
From figure 5.14, = 0.03, well below 0.1
As the percent flooding just below the design figure of 90%, the column diameter would be the
same.

Figure 5.13: Entrainment correlation for sieve plates

5.1.13 Trial layout

Use cartridge-type construction. Allow 50 mm unperforated strip round plate edge; 50 mm wide
calming zones.

Figure 5.14: View of plate

5.1.14 Perforated area
The hole sizes used vary from 2.5 to 12 mm; 5 mm is the preferred size. Larger holes are
occasionally used for fouling systems.
From figure 5.15 below,

lw
=0.76, c =99
Dc
Angle subtended by the edge of the plate=180 99=81

Mean length ,unperforated edge strips= 3.30

area of unperforated edge strips=

50
81
()
=4.59 m
1000
180

) ( )

50
( 1000
) ( 4.59 )=0.230 m

meanlength of calming zone , weir length+width of unperforated strip

50
( 1000
)=2.558 m

2.508+

area of calming zone=2 2.558 x

50
( 1000
))=0.2558 m

total area for perforations , A p =6.500.230.2558=6.015 m

Ah 0.64
=
=0.108
A p 5.902

Figure 5.15: Relation between angle subtended by chord, chord height and chord length
From figure 5.16,

lp
=2.8, satisfactory , within2.5 4.0
dh

Figure 5.16: Relation hole area and pitch

5.1.15 Summary of chemical design
Parameters
1. Column Sizing
Tray Spacing (m)
Internal column diameter, Dc (m)
Area of column, Ac (m2)
Thickness of column (mm)
Number of tray
Material of tray and column
Operating pressure
Operating Temperature
2. Provisional plate design
Plate thickness (mm)
Total plate pressure drop (mm liquid)
Down comer area, Ad (m2)
Net Area, An (m2)
Active area, Aa (m2)
Hole area, Ah (m2)
3. Weir Design
Weir Length, lw (m)
Weir Height, hw (mm)
Maximum weir liquid crest:, how (mm liquid)
Minimum weir liquid crest:, how (mm liquid)
4. Weep Point

Data
0.70
3.30
8.55
8.00
66
Stainless steel
0.2 N/mm2
118-177C
5
166.05
1.03
7.53
6.50
0.65
2.508
50
66.14
41.86

Minimum Uh (m/s)
Actual Uh (m/s)

8.32
8.95

5. Hole Design
Hole diameter (mm)
Hole area (m2)
Number of holes

5
1.9635 x 10-5
33101

5.2 Mechanical Design

5.2.1 Height Column

Column Height=( no of stage1 ) ( Tray spacing ) +2 ( tray spacing )

+ ( no of stage1 ) ( thicknessof plate ) ..(17)
( 661 )( 0.7 m ) +2 ( 0.7 m )+ ( 661 ) ( 0.005 )
47.23 m
Rule of thumb: Add 1.2m at top of column for vapor release and 1.8m for reboiler return for the
height of the column.
So, the column height = 47.23 + 1.2 + 1.8 = 50.23 m
Allow, 2 m for clearance height = 50.23 + 2 = 52.23 m
5.2.2 Design of domed end
Design temperature and pressure is taken as 10% above the operating temperature and
pressure.

N
0.2
=0.22 N /mm
( 110
)
100 (
mm )

Design Pressure=

( 177.1 )=194.81 C
( 110
100 )

Design Temperature=

From table 5.3, the design stress is 135.519 N/mm2 and the tensile strength is 540 N/mm2.
i) Try a standard dished head (torispherical head);

crown radius , Rc =Di =3.3 m

knuckle radius , R k =6 Rc =0.198m
A head of this size would be formed by pressing: no joints, so J = 1.

C s=

( )

Rc
1
3+
.(18)
4
Rk

1
3.3
3+
4
0.198

1.7706

The thickness of this head;

e=

Pi R c C s
2 fJ + Pi ( C s 0.2 )

(19)

0.22 N /mm2 3300 mm 1.7706

2(1) ( 135.519 N /mm2 ) +0.66 N /mm2 ( 1.77060.2 )

4.725 mm
ii) Try a standard ellipsoidal head;

e=

P i Di
..( 20)
2 Jf 0.2 Pi

0.22 N /mm2 3300 mm

2(1) ( 135.519 N /mm2 )0.2 ( 0.22 N /mm2 )

2.679 mm

III) Try a standard flat head;

e=C p De

Pi
(21)
f

Use a full face gasket;

C p =0.4 ,

De =bolt diameter
approximate 1.7 m

e=0.4 1.7 103

0.22 N /mm2
( 135.519 N /mm2 )

21.40 mm
From the calculations, the flat head shows the inefficiency of a flat cover. It would be better to use
a flanged domed ahead. So, from the two domed head, the ellipsoidal head is the most
economical. Take the thickness of the ellipsoidal head as same as cylindrical section which is 8
mm.
5.2.3 Dead weight of vessel
For preliminary calculations the approximate weight of a cylindrical vessel with domed ends, and
uniform wall thickness, can be estimated from the following equation:

W v =240C v Dm ( H v + 0.8 Dm ) t (22)

Where,

W v = total weight of shell, excluding internal fitting such as plates, N,

C v = factor to account for the weight of nozzle, manways and internal supports;
1.08 for vessels with only a few internal fittings,
1.15 for distillation columns, or similar vessels, with several manways, and with
plate support rings, or equivalent fittings,

H v = height, or length, between tangent lines (the length of the cylindrical section),
m,

Dm=
t =

mean diameter of vessel

( Di +t x 103 ) , m

wall thickness, m

This calculation can give the rough estimation of the weight of this vessel with uniform
thickness. For the thickness for the vessel, we use the calculated thickness of 8 mm.

W v =240 ( 1.15 )( 3.30+0.008 ) ( 52.23+0.8 ( 3.30+ 0.008 ) ) 8

7743.08 N =7.743 kN

Weight of plates:

3.3

plate area=
4

weight of a plate= 1.2

kN
( 8.55 m2 ) =10.26 kN
2
m

(Where 1.2 is factor for contacting plates, steel including typical liquid loading in kN/m2)

66 plates=( 66 )( 10.26 )=677.16 kN

Weight of insulation:

mineral wool density=130 kg /m3

approximate volume of insulation=( ) ( 3.30 )( 52.23 ) ( 0.075 ) =40.611 m 3
weight=( 40.611 ) ( 9.81 )( 130 ) =51791.208 N
double this value allow fittings=103582.417 N =103.582kN
Total weight ;
Shell=7.743 kN

Plates=677.16 kN
Insulations=103.582 kN

Total=788.485 kN
5.2.4 Wind loading

1
dynamic wind pressure= C d a U w 2
2
for smooth cylinder =0.05 U w

design for 160

km
=( 0.05 ) (160)=1280 N /m 2
hr

Therefore, take wind pressure as 1280 N/m2

mean diameter , including insulation=3.30+2 ( 8+75 ) x 103=3.466 m

Loading ( per linear meter ) , F w =( 1280 )( 3.466 )=4436.48 N /m
Bending moment at bottom tangent line:
Where

x=H v =52.23 m(column height )

M x =F w

(52.23 )2
x2
=( 4436.4 )
=6051189.49 Nm
2
2

( )

5.2.5 Analysis of stress

At bottom tangent line:
Pressure stresses:

L=

h=

PD ( 0.2 )( 3300 )
=
=20.63 N /mm2
4t
4 (8)

PD ( 0.2 )( 3300 )
=
=41.25 N /mm2
2t
2 (8)

Where,

P=operating pressure( 0.2 N /mm 2)

D=column diameter (3.30 m)

t=thickness(8 mm)
Dead weight stress:

w =

Wv
( D i +t ) t

788485
2
=9.484 N / mm
( 3300+8 ) 8

Bending stress:

Do=3300+ 2 ( 8 )=3316 mm
I v=

( D 4 Di4 )= 64 ( 3316 433004 ) =1.137 x 1011 mm4

64 o

6051189.49 x 103 3300

2
b =
+8 = 88.22 N /mm
11
2
1.137 x 10

The resultant longitudinal stress is:

z= L + w b
w is compressivetherefore negative
z (upwind ) =20.639.484 +88.22=+ 99.37 N /mm

z (upwind ) =20.639.48488.22=77.07 N /mm2

The greatest difference between the principal stresses will be on the downwind side:
2
h z ( downwind )=41.25 (77.07 ) =118.32 N /mm

Well below the maximum allowable design stress.

5.2.6 Check elastic stability (buckling)

Critical buckling stress , c =

t
200000
8
=
(
)=292.03 N /mm
(
)
D
3316
3 ( 1v )
3 (1 ( 0.3 ) )
2

When the vessel is not under pressure (where the maximum stress occur):

maximum stress= w + b=9.484+88.22=97.704 N /mm2

The maximum stress is well below the critical buckling stress. Therefore, design is satisfactory.
5.2.7 Design for skirt support
Material of construction for skirt support is stainless steel.

Design stess=135.519 N /mm2

Youn g' s modulus=210000 N /mm2
The maximum dead weight load on the skirt will occurs when the vessel is full with acetic acid.

( 4 D H ) g
2

Approximate weight , W =

( 4 ( 3.3 m ) ( 52.23 m ))( 910.5 mkg )(9.81 ms )

2

3990127.235 N =3990.127 k / N

Weight of vessel=788.485 kN
total weight=3990.127+788.485=4778.612 kN

Wind loading , F w =4436.48 N /m

Take skirt support as 3 m height,
Bending moment at base skirt;

M s=F w

( H v + H skirt )
2

= ( 4436.48 )

( 52.23+3 )2
2

6766414.82 N =6766.42 kNm

Take the skirt thickness same as the cylindrical thickness which is 8 mm.

bs=

4 Ms
( D cyl +t cyl ) t cyl D cyl

4 6766.42 106 Nmm

( 3300 mm+8 mm ) 3300 mm 8 mm

98.651 N /mm2

ws (test )=

W
( D cyl +t cyl ) t cyl

3990.127 10 3
( 3300+8 ) 8
2

47.993 N / mm

ws (operating)=

W
( Dcyl + t cyl ) t cyl

788.485 10 3
( 3300+8 ) 8

9.484 N / mm2
The test condition is with the cylindrical full of the slurry for hydraulic test. In estimating total
weight, the weight of slurry in the cylindrical has been counted twice. The weight has not been
adjusted to allow for this as the error is small, and on the safe side.

Maximum s ( compressive )=98.651+ 47.993=146.644 N /mm2

Maximum s ( tensile )=98.6519.484=89.167 N /mm2
Take the joint factor 1.0. The criteria for design;

s ( tensile ) f s J sin
89.167 1.0 135sin 90

50.307 135

s ( compressive ) 0.125 E

t cyl
sin
D cyl

( )

146.644 0.125 210000

8
( 3300
) sin 90

146.644 63.636

Both criteria are satisfied; hence add 2 mm for corrosion allowance to give the thickness of skirt
support 10 mm.
5.2.8 Base ring and anchor bolts
Approximate pitch circle

D (b)=Di +2 ( t+ t insulation )
3300+2(8+75)

3466 mm
Circumference of bolt circle

3466

Number of bolt required, at minimum recommended bolt spacing,

3466
=18.15
600

Closest multiple of 4, Nb = 20 bolts

Take bolts design stress fb = 125 N/mm2 (typical design value)

M s=6766.42 kNm
Take W = operating value = weight of cylinder = 788.485 kN

Ab=

1
Nb f b

4Ms
W
Db

1
4 6766.42 10
(788.485 103 )
20 125
3.466

2808.17 mm2
Bolt root diameter;

Dbolt =

2808.17 4

59.80 mm
Hence from the bolt size = nominal diameter (BS 4190: 1967) the bolt that is going to be used is
M64 with root area = 2680 mm2;
Total compressive load on the base ring per unit length;

Fb =

4 Ms
D

2
cyl

W
D cyl

4 4 6766.42 103 788.485 103

=4956637.1572412.74
3.466
( 3.466 )2

4884224.406 N /m=4884.22kN /m
Bearing pressure range is 3.5 N/mm2 to 7 N/mm2. Therefore the bearing pressure was taken as 5
N/mm2.
The minimum width of the base ring is;

Lb =

Fb
1
3
f c 10
3

4884.22 10
=976.84 mm
3
5 10

9.9898 mm
Actual width required;

Lr +t cyl +50 mm

 152+ 8+50=210 mm
Where Lr is taken from table 5.17 (Coulson & Richarson page 852);

Lr=the distance theedge of the skirt the edge of the ring .

Table 5.4: Anchor Bolt Chair Design) bolt size use is M24 bolts (BS 4190: 1967),

Actual bearing pressure on concrete foundation;

'

f c=

4884.22 103
2
=23.26 N /mm
3
210 10

The minimum base ring thickness;

t b=Lr

3 f 'c
3 ( 23.26 )
=152 mm
=107.31 mm , round off 110 mm
fr
140

Take the skirt bottom diameter as 3 m;

Skirt base angle,

s =tan 1

3.0
1
( 3.02.0 )
2

=80.5

Keep the skirt thickness the same as that calculated for the cylindrical skirt. Highest stresses will
occur at the top of the skirt; where the values will be close to those calculated for the cylindrical
skirt. Sin 80.5= 0.99, so this term has little effect on the design criteria.
5.2.9

Design of stiffness ring

Take rings

= 75 mm wide

Rings

= 10 mm deep

Plate spacing

= 0.7 m

Take design pressure as 1 bar external or 105 N/m2

So, the load per unit length of the ring
5

( )

Fr =Pe L s=

10 N
( 0.7 m )=70000 N /m
2
m

Taking Youngs modulus, E

= 210000 N/mm2 = 2.1 x 1011 N/m2

Factor of safety = 6
The second moment of area of the ring to avoid buckling is given by,

P c Ls =

24 E l r
3

D r x factor of safety
lr

Where,

= second moment of area of the ring cross-section

Dr
= diameter of the ring (approximately equal to the shell outside diameter) = 3.5 m

70000 N / m=

11
24 ( 2.1 x 10 ) (l r )
3

(3.5 m ) (6)

l r=3.573 x 106 m4
For the rectangular section, the second moment of area is given by:

I=

breath x depth 3
12

lr
So,

for the support rings

( 0.01 ) ( 0.075 )3

=3.516 x 107 m4
12

And the support rings is adequate size to be considered as a stiffening

Ring,

L 0.7 m
=
=0.212
D o 3.3 m

D o 3300 mm
=
=412.5
t
8 mm

From figure 5.17 below,

Figure 5.17: Collapse coefficients for cylindrical shell

K c =100
Pc =K c E(

t 3 (
8 3
11
2
5
2
) = 100 ) ( 2.1 x 10 N /m ) (
) =2.99 x 10 N /m
Do
3300

This is above the maximum design pressure of 1.0 x 105 N/m2. So, design of the support rings to
support the plate is satisfied.

5.2.10 Flange design

Optimum diameter of flange can be calculating using equation:

d , optimum=260 G

0.52

0.37

mix

i)

Feed Inlet
From HYSYS simulation,

Feed inlet , G=129500 kg /h=35.97 kg/ s

mix =944.5 kg /m3

d , opt=260 (35.97 kg/ s )0.52 (944.5 kg /m3 )0.37=132.81 150
From figure 5.18 below,
Nom
.
size
150
ii)

Pipe
o.d

Flange
b

Raised face
d4
f

168.3

265

18

44

202

Bolting
No.

M16

Drilling
d2
18

Boss
d3

225

185

Boss
d3

110

80

Top column inlet

From HYSYS simulation,

top column outlet ,G=15740 kg /h=4.372 kg /s

mix =931.2 kg/m3

d , opt=260 ( 4.372 kg/ s )0.52 (931.2 kg /m3 )0.37=44.63 50
From figure 5.18 below,
Nom
.
size
50

iii)

Pipe
o.d
60.3

Flange
b

Raised face
d4
f

140

14

28

90

Bolting
No.
M12

Bottom column inlet

From HYSYS simulation,

topcolumn outlet ,G=113800 kg /h=31.61 kg /s

Drilling
d2
14

mix =910.9 kg /m3

d , opt=260 (31.61 kg /s )0.52 (910.9 kg /m3 )0.37=125.86 125
From figure 5.18 below,
Nom
.
size
50

Pipe
o.d

Flange
b

Raised face
d4
f

139.7

240

18

44

178

Bolting
No.
M16

Figure 5.18: Typical standard flange design

5.2.11 Manhole Design

Drilling
d2
18

Boss
d3

200

160

Man ways or manhole is the opening design on the cylindrical vessel for letting
personnel in and out of the vessel to perform routine maintenance and repair. We are going to
determine the reinforcement requirements for a 600 mm diameter manhole opening in a
2

cylindrical pressure vessel 3.3 m in diameter subjected to an internal pressure of 0.22 N /mm
2

The shell and the nozzle allowable stress are 135.519 N /mm .

Let say the shell and manhole

thickness are 8 mm and 18 mm, respectively.

Minimum required shell thickness;

t rs=

Pi D i
2 Jf Pi
2

0.22 N /mm 3300mm

2 ( 1 ) (135.519 N /mm2)( 0.22 N /mm2 )

2.68 mm
Minimum required manhole thickness;

t rn=

Pi D i
2 Jf Pi
0.22 N /mm2 600 mm
2 ( 1 ) (135.519 N /mm2)( 0.22 N /mm2 )

0.487 mm
The limit parallel to the surface of the shell is the larger of two quantities,

a t s +t n +0.5 d=8+18+1650=1676 mm
b d=600 mm
Parallel to the shell the limit is therefore 600 mm.

The limit normal to the surface of the shell measured inward or outward is typically set as the
smaller of (a) 2.5ts or (b) 2.5tn. The limit normal to the surface of the shell is the smaller of (a) 2.5 t s
or (b) 2.5 tn. Therefore the limit is;

2.5 ( 8 mm )=20 mm
The reinforcement area required is;

A r =d t rs
600 ( 2.68 mm )=1608 mm2
The reinforcement area available in the shell, A1;

A 1=( 2 dd ) ( t s t rs )=600 ( 82.68 ) =3192mm 2

The reinforcement area available in manhole wall is available in two parts A21 and A22;

A 21=2 ( 2.5 t s )( t st rn ) =2 (2.5 8 ) ( 80.487 )=300.52 mm2

2

A 22=2 ( 2.5 t s )( t s )=320 mm

The total area available for reinforcement At;

A t =A 1 + A21 + A 22=3812.52 mm2

Figure 5.19: Reinforcement scheme for the manhole

References
1. Plant Design and Economics for Chemical Engineers, 5th Edition, Max S.Peters, Klau
D.Timmerhaus, Ronald E.West, Mc Graw Hill, page 754 - 823
2. Handbook of Separation Process Technology, Ronald W.Rousseau, 1987, page 229-331
3. Process Plant Design, J.R. Backurst, J.H. Harker, Heinemann Educational Books London,
page 102-201
4. Chemical Engineering Design, Volume 6, R K Sinnot, Coulson & Richardsons Chemical
Engineering Series