Distillation Column Explained
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Article
Introduction
Distillation Columns use a heating and cooling process
to separate two (or more) mixed components (liquids
and/or gas) into their respective separate or original
states. In simple terms, this process is achieved by
heating the mixed liquid components to a temperature
that is in-between their respective boiling points,
thereby boiling off the lower temperature liquid in order
to separate them by evaporation.
Refinery Distillation Columns
History
The Distillation process is one of the oldest and most
commonly used separation and purification methods. Its
historical links date back to the Romans, Arabs, Chinese,
Indians, and Babylonians of Mesopotamia more than
5000 years ago, where evidence of perfume and alcohol
Distillation was recorded on the Akkadian tablets (circa.
1200BC), on through to the medieval period, and
subsequently to the 19th century Industrial Revolution
where the more contemporary applications were
developed.
Whiskey Still
Continuous Distillation Column
There are many types of distillation column designs, such
as the ‘batch’ column or ‘continuous’ column. A basic
batch column is where the input feed (liquid/gas
component) is distilled entirely and then another batch
of feed is added to the column and processed in turn. A
continuous column has a constant input and output
stream which facilitates a much higher throughput, and
the process does not stop unless maintenance or a
repair is required.
Both types of columns have specific application relating
to the separation of two or more liquid/gas
components, and both incorporate varying levels of
complexity and associated equipment to facilitate the
overall distillation process.
What are the main parts of a distillation
column?
A typical Continuous Distillation Column has several
components to facilitate the overall process. These four
main components are:
Column (incorporating the enriching and
stripping sections), where the liquid/gas phase
separation takes place.
Reboiler (heat exchanger), which provides the
heat energy to partially vaporise the columns input
feed (liquid) for the separation (distillation) process
to take place. The input feed flows into the centre of
the column and down through the stripping
section to the base, before entering the reboiler
where the feed liquid is heated to generate the feed
vapour (through evaporation). This feed vapour
travels up through the column by convection, to
continue the feed components separation process.
Condenser, which cools and condenses the
separated and enriched feed vapour at the top of
the column before it enters the reflux drum.
Reflux drum, which collects the condensed feed
vapour (as a liquid), and splits it into two streams, 1.
the distillation process output (distillate), and 2.
the reflux drums recycled liquid (reflux), which is
fed back into the top of the column, to further
enrich and purify the distillate.
General Distillation Column Main Components
In order to make this process more efficient, the
distillation column usually has a series of stacked plates
or trays inside the column. These plates have circular
perforations, and/or corrugated metal packings, to
improve the liquid/vapor contact surface area and
therefore the feed liquid evaporation process
efficiency. This type of column is called a fractionating
distillation column and supports the
removal/separation of several components (liquid or
gas) at different levels in the column.
Fractionating Distillation Column
Basic Distillation Column Operation and
Terminology
The feed components that are to be processed in the
distillation column are introduced near to, or at, the
centre of the column, into a central tray/plate known as
the feed tray (plate).
Distillation Column Process Flow Diagram
This central feed tray divides the column into a top
(enriching) section and a bottom (stripping) section. The
feed liquid flows into the column and across the
tray/plate, then down through the column (by gravity)
through to the next tray/plate via its downcomer
conduit, where the enriched feed liquid ‘vapour
component’ is stripped out through the distillation
process as it rises through the feed liquid. The remaining
feed liquid falls down the column and collects at the
column’s base, then flows back into the reboiler which
vaporises the lighter component into the feed liquid
vapour component. This vapour then continues the
distillation process as it rises to the top of the column,
through the column tray plates where it comes into
contact with the feed liquid, stripping the lighter
component (vapour) out and becoming more enriched as
it does so. At the base of the column the ‘heavy’ (not
vapourised) feed liquid product is removed from the
column as the ‘bottoms’ component.
Distillation Column Liquid and Vapour Flow Paths
The reheated feed vapour, flowing back into the base of
the column from the reboiler, is enriched as it rises up
through the column and ‘contacts with’ the falling feed
liquid, before exiting the column at the top, into the
cooling condenser. This condensed liquid then enters a
holding vessel known as the reflux drum.
Distillation Column and Reflux Drum
A proportion of this reflux drum liquid i.e. the reflux
ratio, is recycled back into the top of the column, further
enriching and purifying it through contact with the feed
vapour component that is rising up through the column
plates. Finally, the condensed feed vapour component
which is now cooled into liquid form by the condenser
and reflux drum system, is the column output (distillate)
that is recovered through the overall distillation process.
Distillation Column Operating Profile
There are certain operating parameters and trends
which are common to the distillation column process,
and an appreciation of these aspects will assist in gaining
a general understanding of the process. In simple terms
the column design (diameter and height, number of
trays/plates, packers etc.) and the operating
parameters (temperature, pressure, feed liquid input
stage etc.) are optimised by the designers to achieve an
overall internal vapour liquid equilibrium (balance),
based on the volatility (boiling points) of the feed liquid
components. Distillation Column Operating Profile.
Temperature and Pressure
The general temperature profile within the column is that
it is hotter at the top and cooler at the base. For example,
in a simple process that has a feed liquid with two
components, the temperature at the base of the column
is slightly cooler than the boiling point of the heavier feed
component, and the temperature at the top is slightly
higher than the boiling point of the lighter component, as
it is desired to create an environment for a vapour -
liquid balance within the column. At the base of the
column, we require the heavy feed component to remain
as a liquid and the lighter component to remain as a gas
until it reaches the top of the column, before entering
the condenser and reflux drum. To control these
temperatures, the reboiler heat exchanger temperature
is adjusted to control the bottoms heavy feed component
temperature; the reflux drums ‘return’ flow rate (flow
back to the top of the column) is used to control the
lighter components temperature at the top of the
column.
The columns overall pressure gradient is ‘higher’
pressure at the base and ‘lower’ at the top. This gradient
is determined by the feed stage liquid (input) falling
down through the column tray plates and impeding the
rising vapour flowing up through the feed liquid.
In general, for a steady state distillation process the
pressure gradient of the column is kept as constant as
possible, using the reboiler temperature and reflux drum
flow to control the composition of the light and heavy
components streams.
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