Professional Documents
Culture Documents
Process Analysis
Chapter 1 Chapter 4
Fundamentals Column Operating Pressure
Chapter 2 Chapter 5
Two-Product Columns Column Capacity and Efficiency
Chapter 3
Multiproduct Columns
CHAPTER 1
Fundamentals
I
n this chapter, the basic knowledge necessary to understand
an operating distillation unit is discussed. More details on the
subjects treated in this chapter are found in various texts oriented
to distillation design [14]. The approach, followed in most chapters
of the book, is based on the assumption that the distillation unit is in
operation.
Separation Factor
Distillation is a separation process based on the different boiling
points of the various components. The relative volatility is the
parameter that characterizes the separation factor, and it derives from
the equilibrium between vapor and liquid phases:
Ki = yi/xi (1-1)
K j = y j/x j (1-2)
3
4 Chapter One
and
The relative volatility aij for the ideal mixture is formally independent
from pressure and composition and shows moderate sensitivity
to temperature as Pi0 and Pj0 move in the same direction with the
temperature.
Consider that the boiling temperature TiBP depends on total
pressure P, as from Eq. (1-8) for Pi0 = P:
Figure 1-1 Vapor pressure trends with temperature for C3, iC4, and nC4 components.
Nonideal Systems
Many mixtures show nonideal behavior in the liquid phase. In such
cases, Eq. (1-4) is modified to include the liquid activity coefficient g
i:
pi = Pyi = i P
i0 xi (1-10)
6 Chapter One
and
and
Figure 1-3 T-xy and x-y diagrams for ideal and nonideal mixtures.
8 Chapter One
Figure 1-4 Equilibrium stages (a) to (e) and nonequilibrium stages (f) and (g).
9
Fundamentals
Sequence of Stages
Ideal stages can be combined and arranged as shown in Fig. 1-8. This
arrangement reproduces the rectifying section of a simple distillation
column. The rectifying section is located above the feed stage, and its
name derives from the fact that composition of vapor flow becomes
richer of the light component going upward; as consequence, the
liquid flow becomes richer of the heavy component going down. The
total molar balance around the top envelope in Fig. 1-8 indicates that
in the rectifying section, the interstage vapor flow is always greater
than the corresponding liquid flow Vj L j 1 = D and that all
interstage differences between vapor and liquid are constant and equal
to the distillate product D. Maintaining the distillate D constant, any
change of liquid flow Lj-1 requires an equal change of vapor flow Vj.
12 Chapter One
Figure 1-8 Equilibrium-stage sequence representing the rectifier column on the right.
The effect of the increase of the vapor flow on the equilibrium stage is
shown in Fig. 1-9a and b, using separation between nC4 and nC5 as an
example. The operating parameter that characterizes such change is the
interstage L/V ratio that increases in the rectifying section. Figure 1-9
also shows that an increment of the L/V ratio, from 0.665 to 0.715, gives
L
an increment of nC4 molar flux JC4 from liquid to vapor phase from
11.53 to 17.61 kmol/h, with the enrichment of nC4 in the vapor phase
from 8.6 to 11.2 percent.
Figure 1-9 L/V ratio effect on equilibrium-stage separation in the rectifying section.
13
Fundamentals
Figure 1-10 Equilibrium-stage sequence representing the stripping column on the right.
14 Chapter One
The total molar balance around the bottom envelope of Fig. 1-10
indicates that in the stripping section, the interstage liquid flow is
always greater than the corresponding vapor flow, independent of the
feed status Lj Vj + 1 = B and that the interstage flow difference
between liquid and vapor is constant and equal to the bottom product B.
Maintaining B constant, any change of liquid flow Li requires an equal
change of vapor flow Vj + 1 . The effect of the increment of the vapor flow
to the equilibrium stage in this section is shown in Fig. 1-11a and b, using
the same separation between nC4 and nC5 as example. The operating
parameter that characterizes such change is the interstage L/V ratio
that decreases in the stripping section. Figure 1-11 also shows that a
reduction of the L/V ratio from 1.44 to 1.32 causes the increment of C5
V
molar flux JC5 from vapor to liquid phase from 7.56 to 14.01 kmol/h,
with an enrichment of C5 in the liquid phase from 21.3 to 27.2 percent.
Vn + 1 = Vn = Vn 1 = V
Ln + 1 = Ln = Ln 1 = L
Kn + 1 = Kn = Kn 1 = K
V yn 1 = V yn + L( xn xn + 1 ) (1-16)
and the stage equilibrium equation is
yn = K xn (1-17)
The application of Eqs. (1-16) and (1-17) to top stage N, considering
that yout = K xN and rearranging, gives
( )
2
( yN 2 yN 1 )/( yout K xin ) = L /K (1-20)
V
( )
V
N
( yin y1 )/( yout K xin ) = L /K
(1-21)
N
( yin yout )/( yout K xin ) = [(L/V )/K ]i (1-22)
1
or, more clear for the scope:
N N
( yout yin )/( K xin yin ) = [(L/V )/K ]i/1 + [(L/V )/K ]i (1-23)
1 1
Equation (1-23) shows that the enrichment of a component in a
group of equilibrium stages depends on the L/V ratio as far as the
operating variables are concerned.
The interstage liquid and vapor flows are not univocally
defined when the ratio L/V is specified, but they are defined when
17
Fundamentals
the material balance is defined. Indicating with Vrect and Lrect the
generic interstage vapor and liquid flow in the rectifying section of
Fig. 1-8, the material balance around the generic envelope shown in
Fig. 1-10 gives
with
heatrequiredtovaporizeonemoleoffeed
q=
feedmolarlatentheatofvaporization
If the feed stream is saturated liquid, q = 1 and Vrect Vstr ; if the feed
stream is saturated vapor, q = 0 and Vrect Vstr + F . On the basis of
Eqs. (1-24b) and (1-25b), Lstr /Vstr and Lrect /Vrect are not independent
of each other. However, the parameter q that determines the
relationship between Vstr and Vrect is an operating variable in many
units, as discussed in Chap. 2.
The analysis of the equilibrium-stage sequence has shown that
only two parameters define the separation in the sequence: L/V ratio
18 Chapter One
and D (or B). The fact that L/V ratios above and below the feed stage
are related leads to the conclusion that only two parametersL/V
ratio in one section and D (or B)are necessary to set the column
performance. The way the two parameters are usually defined is
indirect through other sets of variables: (Vstr and D), (Vstr and Lrect),
and (Vstr and B). In Chap. 2, these concepts are applied extensively to
the analysis of two-product distillation columns.
J i , n = V ( yi , n yi , n 1 )
to the net interphase flux of same component for the ideal stage
Ji*, n = V ( yi*, n yi , n 1 )
Thus,
Ji , n = KG ahL yi , n (1-29)
where
KG = overall mass transfer coefficient
a = vaporliquid interfacial area per unit of liquid holdup
on tray active area
hL = total liquid holdup on tray active area
yi , n = average driving force on the tray, depending mainly
on liquid and vapor flow and on flow model on the
tray
Equations (1-28) and (1-29) have been introduced with the scope
of emphasizing the dependence of tray efficiency on mass transfer
parameters. A more rational approach to relate mass transfer parameters
to tray efficiency defining vapor and liquid flow models is illustrated
in Chap. 5. The parameters appearing in Eq. (1-29), being dependent
on the tray fluid dynamics, are subject to variation with the operating
variables. More details on stage efficiency and fluid dynamic regimes
related to operating conditions are presented in Chap. 5.
Figure 1-15 shows the comparison between an ideal stage and a
tray with 80 percent Murphree vapor efficiency in terms of stream
composition and internal component flux. In this example, molar
21
Fundamentals
Figure 1-15 Separation comparison between ideal stage and tray with 80 percent
efficiency (Murphree).
liquid and vapor flows are not constant so that heat transfer between
the two phases on the stage needs to occur.
From the perspective of separation understanding, the concepts
described earlier regarding the effects of L/V ratio on staged cascade
enrichment and stage efficiency maintain their validity even when the
assumption of constant molar flow is not fully respected. In such cases,
a complexity is added at the level of interphase transfer phenomena
because of simultaneous mass and heat transfer. The calculation of tray
efficiency from basic transfer phenomena becomes much more complex.
Continuous Devices
In the past several decades, following the appearance on the market
of high-performance packings, continuous vaporliquid devices have
22 Chapter One
H = neq
t HETP (1-30)
( p p p
)
HETP = Ji*, n/ KG a p hL yi (1-31)
where
KGp = overall mass transfer coefficient for packing
ap = vaporliquid interfacial area per unit of liquid holdup
hLp = total liquid holdup per unit of packing height
yip = a verage driving force depending mainly on liquid and
vapor flow and flow model along the packing bed
Equation (1-31) has been written to show that for packings, the
performance parameter HETP also strongly depends on packing
23
Fundamentals
Separation Energy
In distillation, the separation energy is usually supplied in the
form of heat that generates the main internal vapor flow(s). In
operating columns, the energy consumption is a key parameter
whose trade-off with the material balance leads to maximum
economic benefits.
Some concepts regarding the energy cost of separation are
now introduced, but only for the purpose of comparing different
process schemes. Heat supplied can be evaluated in terms of net
work consumption, defined as the difference between the work that
could have been obtained with a reversible heat engine from the heat
supplied to the distillation unit and the work that could be obtained
in a reversible heat engine from the heat leaving the unit. Both heat
engines have a sink at ambient temperature Ta.
With reference to Fig. 1-17, the work that can be obtained from
reboiler heat is
Figure 1-17 Column input and output of energy and material streams.
24 Chapter One
can be written as
(1-41)
where
Tch = temperature of chilling water to the overhead
condenser
Tc2 = temperature of the condensing medium to the side
condenser that can be much higher than Tch
The scheme is more efficient from the energy point of view as Tc2
and Qcond,2 are higher. Also for this scheme, the temperature profile
determines the energy efficiency. Figure 1-22 shows a favorable
temperature profile that occurs when very light components are in
the distillate product, which would require too-high pressure to be
condensed with an ambient temperature medium. Moreover, the
27
Fundamentals
Literature
1. Smith, B.D., Design of Equilibrium Stage Processes, McGraw-Hill, New York,
1963.
2. King, C.J., Separation Processes, 2d ed., McGraw-Hill, New York, 1980.
3. Kister, H.Z., DistillationDesign, McGraw-Hill, New York, 1992.
4. Stichlmair, J.G. and Fair, J.R., DistillationPrinciples and Practice, Wiley-VHC,
New York, 1998.