Distillation Column:

Flow rate = 856 kg/hr

(Assuming the distillation column can operate for 6hrs)

Storage Capacity = 5136 kg
Mass(capacity )
Volume =
ρ
The feed is 10 percent methanol and 90 percent water so the total density would be 958)
5136 kg
=
958
= 5.36 m3
Maximum operating volume = 0.85x 5.3
= 4.5 m3
Design Calculation
Mass flow rate of feed = 856kg/hr=36 kmol/hr
Molecular weight of methanol = 32 kg/kgmol
Molecular weight of water = 18 kg/kgmol
Boiling point of water = 100 C
Boiling point of methanal = 64.5 C
The more volatile component is methanal
The concentration of methanal in the feed is given as
14
% Of MeOH in the feed = *100
36
= 38%
Assumptions
Requirements for separation are as follows;
 An overhead product containing 99.9% MeOH
 A bottom product containing 99% water.

Molecular weight of Methanol = 32 kg/kgmol

Molecular weight of water = 18 kg/kgmol
 38
32
The amount of methanol in the feed in mole fraction; Xf = =0.25
38 62
+
32 18

99.
32
The amount of methanol in the distillate in mole fraction; = =0.999
99 0.1
+
32 18

0.1
32
The amount of methanol in the bottom in mole fraction; = =0.001
0.1 99
+
32 18
Mass balance:
Applying overall material balance around the distillation column
Where F = Feed Flow rate in kgmol/hr
F = D + W……….
Where F = 856 Kg/hr,
856 = D + W
Component balance
XFF = XDD + Xw W ………..

xf = 0.25, xD
= 0.999 and xW
= 0.01
(856 * 0.25) = 0.999D + 0.001W
214 = 0.999D + 0.001W
D = 856– W
214 = 0.999(856– W) + 0.001W
214 = 855-0.999 W +0.001 W
214 = 855-0.999 W
W = 640
D = 216 kg/hr
Rmin graph
From the graph

Figure 5. 1 VLE diagram of water and methanol

XD− y
Using the slope line of the ROL i.e. S=
XD−x
Where xD = 0.999
Y = 0.61
X = 0.25
Δs = 0.999-0.61/0.990-0.25
= 0.519
Rmin / Rmin + 1 = slop
Rmin / Rmin + 1 = 0.519
(Rmin+1)0.519 = Rmin
0.519 Rmin + 0.519 = Rmin
0.519 = 0.480 Rmin
Rmin = 0.92
Calculating the operating reflux ratio, the optimum in reflux ratio will lie between 1.1 to 1.5
times, the optimum in reflux ratio [Rmin]
Assuming the reflux ration [R] is 1.6 times the Rmin
R = 1.6 * Rmin
R = 1.6 * 0.92
R = 1.45
Calculation of the actual total number of trays required :
Steps in determining the number of stages
1. Draw the VLE Diagram curve

2. Draw the Diagonal line

3. Indicate the xw, xf and xd on the y=x line

4. Calculate the slope of q line [-q/(1-q)] and the q-line from (xF, xF)

5. Calculate B and D from overall balances

6. Calculate flow rates at top and bottom sections

7. Step off to know the amount of the practical stages required

 Figure 5. 2: number of plates calculation

The number of stages is 23 stage (Theoretical)

Reboiler is stage 23
Number of plates (23-1) = 22 plates
The optimum feed location is stage 16 (theoretical)
Calculating of liquid and vapor amounts in both section
Rectifying section
L
R =
D
L
1.45 =
216
L = 313
As we know according to constant molar over flow = L=L=313
Vn = Lo + D
Vn = 313+216
= 529
As the feed is saturated liquid the feed will be equal to liquid in the feed trey plus the input feed
Lm = F + Ln
Lm = 856 +313
= 1169
Vm = Vn
Vm = 529
Table 5. 1: Vapor and liquid density calculation

Position Temperature Density-of Density of Methanol

. (C) H2O(Kg/M3) (Kg/M3)
liquid liquid vapor
Feed 0.25 77 973 0.27 7.42 2.01
Distillate 0.995 65 980.53 0.165 752 1.12
Residue 0.0016 99 958.10 0.586 713 4.34

Density of liquid at feed point at 77 C

= 973*0.75+742*0.25
= 915
Density of vapor at feed point at 77 C
= 0.27*0.899+1.12*0.0978
= 0.434
Density of liquid at distillate at 65 C
= 752
Density of vapor at distillate at 65 C
= 1.12
Density of liquid at residue at 99 C
= 958.10
Density of vapor at residue at 99 C
 = 0.586

Table 5. 2: densities of liquid mixture

Temperature (oC) Density of Liquid mixture Density of vapour mixture

(Kg/m3) (Kg/m3)
77 982 0.434
65 752 1.12
99 958.10 0.586
Rectifying section densities
Rectifying is working between 77 to 65 temperature so its density will be its average

Density of liquid at rectifying section is

= (982.29+752)/2
= 867
Density of vapour at rectifying section
= (0.434+1.12)/2
= 0.777
Stripping section densities
Stripping section is working between 77 to 99 temperature so its density will be its average

Density of liquid at stripping section

= (752+958.10)/2
= 855.05
Density of vapours at stripping section
= (1.12+0.586)/2
= 0.853
Diameter of rectifying section
Calculating flooding factor

Flv =
L
V √ Pv
Pl
Flv =
√
313 0.777
529 867
Flv = 0.017

Figure 5. 3 vapor liquid factor graph

Table 5. 3: Try Spacing’s

Tray spacing Flv factor

0.15 0.040
0.25 0.050
0.30 0.060
0.45 0.080
0.60 0.11

Assuming tray spacing = 0.15 m

According to graph
K1=0.040

Uf = K1
√ pl− pv
pv

Uf = 0.040
√ 867−0.777
0.777
= 1.33 m/s
Dc = diameter of column
Ac = cross sectional area of column
Ad = down comer area
Aa = actual active area
Ah = area of hole
An = net area
Ua = Actual vapor velocity through the column
An = Ac- Ad
Assume
Ad = 12 % of Ac
An = Ac- 0.12Ac
An = 0.88Ac

Assume 80% flooding condition Ua = 0.80Uf

Ua = 0.80*1.33
= 1.06 m/s
Calculating average molecular weight when moisture is 50% methanal
32*.50+18*0.50=25
529∗25
V =
3600
= 3.6 m/s
An = Un/UA
3.6
An =
1.06
= 3.3 m2
Now
An = 0.88 Ac
3.3 = 0.88 Ac
= 3.882
Π Dc
Ac =
4
Dc = √0.126*4/Π
 = 2.2 m

Table 5. 4 parameters at different tray spacings

Tray spacing Diameter Height Area

0.15 2.2 ---- 3.8

Diameter of stripping section section:

Flv =
L
V √ Pv
Pl

=
313 0.853
√
529 855.05
= 0.018
Assuming tray spacing= 0.15 m
According to graph
K1 = 0.040

Uf = K1
√ pl− pv
pv

Uf = 0.040
√ 855.05−0.853
0.853
= 1.265 m/s
Assume 80% flooding condition Ua =.80Uf
Ua = 0.80*1.265
= 1.01m/s
V = 3.6
3.6
An =
1.012
= 3.6

An = 0.88Ac
3.6 = 0.88Ac
Ac = 4
Then
Dc = √4*4/Π

Dc 2.2

Number of Holes in a tray at the Rectifying section

AA = Ac-2Ad
AA = Ac-(0.12*2Ac)
AA = Ac-0.24Ac
AA = 0.76Ac

Ac = 4
AA = 0.76(4)
AA = 3
Assume holes area is 15% of active area
An = 0.15AA
An = 0.15(3)
= 0.45
Taking hole size to be 10mm in order to avoid entrainment
Hole diameter = 5 x 10-3 m
2
π∗0.005
Area of holes =
4
= 0.007
Ah
Number of holes in a plate¿
Ahi
0.45
=
0.007
= 64 holes
Number of Holes in a tray at the stripping section section:
AA = Ac-2Ad
AA = Ac-(0.12*2Ac)
AA = Ac-0.24Ac
AA = 0.76Ac
Ac = 3.8
AA = 0.76(3.8)
AA = 2.8
Assume holes area is 15% of active area
An = 0.15AA
An = 0.15(2.8)
=0.42
Taking hole size to be 10mm in order to avoid entrainment
Hole diameter = 10 x 10-3 m
2
π∗0.005
Area of holes =
4
= 0.007

Ah
Number of holes in a plate¿
Ahi

0.42
=
0.007

= 64 holes
Calculation of Column Efficiency
the "Van Winkle's Correlation", the efficiency of the column can be calculated thus:
Emv = 0.07Dg0.14Sc0.25Re0.08

where Dg: surface tension number = (δL/μLUv)

Uv = superficiel vapeur Velocity
δL = liquid surface tension
μL = liquid viscosity
Sc = liquid Schmidt number = (μL/ρLDLK)
ρL = liquid density
Dlk = liquid diffusivity, light key component
Re = Reynolds number = (hwUvρv/μ[Link])
Hw = weir height
Ρv = vapor density

minimum and maximum temperature inside the column are 99 C and 65 C then we can find the
average temperature of the column
99+65
Average temperature of the column is = =*82C
2
Assuming the physical properties of the liquid equal to the properties of the water the

Surface tension of the liquid at 82C = 0.109 N/m

Superficial velocity is considered to be equal to height Ua
Uv = UA
Uv = 1.33 m/s
μL = 355 x 10-6 Ns/m2

calculating average densities of liquid and vapors in column

p v + p ' v 0.777+0.853
pv1 = = =0.815
2 2
p L + p ' L 867+855.05
pL1 = = =861
2 2
DLK = 5*10-9 m2/s
At 1 Atm pressure the weir height is taken 40_90 mm

HW= weir height (the height of the side of plate)

Therefore, we consider to be 50 mm

Hw = 50 mm

Fractional Area Calculation

area of the holes

Fractional area =
total ColumnCross Area
 0.54 +0.42
2
F.A =
3.88+ 4
2
= 0.1138
Surface Tension Number Calculation
δl
Dg =
µl∗U v
0.109
= −6
355 x 10 ∗1.33
= 230
Liquid Schmidt Number Calculation
µl
Sc =
pl v∗D LK
−6
355 x 10
= −9
5∗10 ∗861
= 82
Reynold Number Calculation
H w U v p v1
Re =
π l∗FA
−3
50∗10 ∗1.33∗0.851
= −6
355 x 10 ∗0.1138
= 1400
Emv = 0.07Dg0.14Sc0.25Re0.08
= 0.07(230)0.14820.2514000.08
= 0.805*100
= 80%
The efficiency of the column ≈ 80%
Calculation of Actual Number of stages required
The number of theoretical stages required = 23 stages
The theoretical stages calculation is based on a 100% efficient column.
But the actual efficiency of the column is 80%
The number of actual stages is calculated thus:
 number of theortical stages
Emv=
actual stages
23
=
0.80
= 28
Calculation of Height of the column
Height of column =Hc ={Nactual-1} Hs+ ΔH+ plates thickness
Actual number of plates, Nactual = 28
Tray spacing, Hs = 0.15 m
ΔH =0.5 m (each for liquid hold up and vapour disengagement)
Plate thickness is assumed to be 5mm
Total thickness of trays = 0.005 x 28
=0.14m
Height of column; Hc = [28 - 1] x 0.15 + 0.5 + 0.140
Hc = 4.9
Calculation of the Actual Feed Location
From the McCabe-Thiele stepping method;
The theoretical optimum feed tray location is stage 16
To calculate the actual feed tray location the stage number is divided by the column efficiency
16
Therefore, actual feed tray location =
0.80
= 20
= 20th stage