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Example 11.11
Design the plates for the column specified in Example Take the minimum feed rate
11.2.
as 70 per cent of the maximum (maximum feed 10,000 kg/h). Use sieve plates.
Solution
As the liquid and vapour flow-rates
and compositions will vary up the
column, plate
designs should be made above and below the
feed point. Only the bottom plate will be
designed in detail in this example.
From McCabe-Thiele diagram,
Example 11.2:
Number of stages=16
Slope of the bottom operating line
5.0 =
Slope of top operating line 0.57 =
Top composition 94 per cent mol. 98 per cent
w/w.
Bottom composition -essentially water.
Reflux ratio =
1.35
Flow-rates
Mol.
=
weight feed =0.033 >x 58 +(1-0.033)18 = 19.32
Feed
A
13.000/19.32 –
672.9 kmol/h
mass balance on acetone gives:
Top product, D =672.9 x 0.033/0.94 = 23.6 kmol/h
Vapour rate,
An overall mass
V= =23.6(1+ 1.35)=
D(1 + R)
55.5 kmol/h
balance gives:
Bottom product, B =672.9- = 23.6
649.3 kmol/h
Slope the bottom operating line Lm/Vm=5.0
of
and V= L - B, from which:
vapour flow below feed, Vm=
162.3 kmol/h
liquid flow below feed, Lm= 811.6 kmo/h
Physical properties
Estimate base pressure, assume
column efficiency of 60 per
alent to one stage. cent, take reboiler as equiv
Number of
16- 1
real stages
0.6
=25
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580 CHEMICAL ENGINEERING
Assume 100 mmn water, pressure drop per plate.
Column pressure drop = × x 100 10- 1000 x 9.81 x 25 =24,525 Pa
Top pressure, 1 atm (14.7 lb/in') = x 101.4 10° Pa
Estimated bottom pressure = x 10 +
101.4 24,525
= =
125,925 Pa 1.26 bar
From steam tables, base temperature 106°C.
Pu=0.72 kg/m
=954 kg/m²
PL
Surface tension 57 103 Nm ×
Top, 989% w/w acetone, top temperature 57°C
From PPDS (see Chapter 8);
P= 2.05 kgm, pL=753 kgm
Molecular weight 55.6
Surface tension 23 d0-3 Nm
Column diameter
0.72
FLy bottom 5.0 =0.14 (11.82)
954
2.05
FLy top = 0.57 753
=0.03
Take plate spacing as 0.5 m
From Figure 11.27
base K=7.5 x 102
top K = 9.0 x 102
Correction for surface tensions
D.2
base K= x7.5 x 10=9.3x 10
580 CHEMICAL ENGINEERING
Assune 100 mm water, pressure drop per plate.
Column pressure drop 100x 10 x 1000 x 9.81 x 25 24,525 Pa
Top pressure, atmn (14.7 lblin') = 101.4 x 10° Pa
1
Estimated bottom pressure 101.4 x 10+ 24,525
125,925 Pa 1.26 bar
From steam tables, base temperature 106°C.
P, =0.72 kg/m
PL=954 kg/m³
Surface tension 57x 10- N/m
Top, 98% w/w acetone, top temperature 57°C
From PPDS (see Chapter 8):
P,=2.05kg/m, p =753 kg/m
Molecular weight 55.6
Surface tension 23 x 10-3 Nm
Column diameter
/0.72
Fy bottom= =0.14 (11.82)
5.0 954
2.05
Fy top = 0.57 753
=0.03
Take plate spacing as 0.5 m
From Figure 11.27
base K =7.5 x 10-2
top K =9.0 x 10-2
Correction for surface tensions
base K; =0) x 7.5 x 10-2 = 9.3 x 10-2
top K1 =0 23
x 9.0 x 102=9.3 x 10-2
954-0.72
base u=9.3 x 10
0.72
=3.38 m/s (1L81)
1753 2.05
top t =9.3 x 10 2,05
1.78 m/s
SEPARATIONCOLUMNS (DISTILLATION, ABSORPTIONAND EXTRACTION) 581
Design for 85 per cent flooding at maximum fow rate
base i, =3.38 x 0.85 2.87 m/s
top â, = 1,78 x 0.85 = 1.51 m/s
Maximum volumetric flow-rate
x
base = 162.3
0.72 x
18
3600
= L13 m'/s
top = 55.5 x 3600 =0.42 m/s
2.05 x
55.6
Net area required
bottom = 1.13
2.87
=0,40 n?
top =s 0.42
=0.28 m'
As first take downcomer area as 12 per cent of
trial total.
Column cross-sectioned area
base - 0.40 =0.46 m
0.88
0.28
top = 0.88 =0.32 m?
Column diameter
/0.46 x 4
base = =0.77 m
0.34 x 4
=0.64 m
top =
Use same diameter above and below feed, reducing the perforated area for plates above
the feed.
Nearest standard pipe size (BS 1600): outside diameter 812.8 mm (32 in): standard
wall thickness 9.52 mm: inside diameter 794 mm.
Liquid flow pattern
×18
811.6
Maximum volumetric =4.3 x 10- m/s
3600 ×954
liquid rate
The plate diameter is outside the range of Figure 11.28, but it is clear that a single pass
plate can be used.
Provisional plate design
Column diameter D =0.79 m
Column area A, 0.50 m
Downcomer area A =0.12 x (0.50 = 0.06 m, at 12 per cent
Net area A, A-A, =0.50 -0.06 =0.44 m
582 CHEMICAL ENGINEERING
Active area A, =A, -2A =0.50–0,12 =0.38 m?
Hole area A, take 10 per cent A, as first trial =0.038 m
Weir length (from Figure 11.31) = 0.76 x 0.79=0.60 m
Take weir height 50 mm
Hole diameter 5 mm
Plate thickness 5 mm
Check weeping
Maximum liquid rate - (811.6 x 18
kg/s
3600=4.06
Minimum liquid rate, at 70 per cent turn-down=0.7 x 4.06 = 2.84 kg/s
4.06 23
maximum ho =750 =27 mm
954 x 0.06 liquid (11.85)
minimum h= 750
954
2.85
x 0.60
2/3
=22 mm liquid
at minimum rate h +ho =50 + 22 =72 mm
From Figure 11.30, K; =30.6
-5)
u (min)
30.6-0.90(25,4
(0.72)4/2
=14 m/s (11.84)
actual minimum vapour velocity = minimum vapour rate
A
0.7x 1.13
20.8 mn/s
0.038
So minimum operating rate will be well above weep point.
Plate pressure drop
Dry plate drop
Maximum vapour velocity through holes
1.13
0.038
= 29.7 m/s
From Figure
Co =0.84
11.34, for plate thickness/hole dia. = 1, and A/A, A,/A, =0.I.
h =51 29.7)
0.84)
0.72
=48 mm liquid
(188)
954
residual head
10
h, = 12.5
954
x
-13.1 mm liquid
(11.89)
SEPARATION COLUMNS (DISTILLATIoN, ABSORPTION AND EXTRACTION) 583
total plate pressure drop
h, =48 + (50 + 27) + 13 =138 mm liquid
Note: 100 mm was assumed to calculate the base pressure. The calculation could be
repeated with a revised estimate but the small change in physical properties will have
little effect on the plate design. 138 mm per plate is considered acceptable.
Downcomer liquid back-up
Downcomer pressure loss
Take hap =
10 40 mm.
h =
Area under apron, A,ap 0.60 40 x = 10= 0.024 m?.
As this is less than A = 0.06 m use Aup in equation 11.92
hac = 166
954
4.06
x 0.024
=5.2 mm (11.92)
say 6 mm.
Back-up in downcomer
hy =(50+27) +138 +6 =221 mm (11.91)
0.22 m
0.22 <(plate spacing + weir height)
so plate spacing is acceptable
Check residence time
0.06 ×0.22 x 954
=3.1s (I1.95)
t,=
4.06
>3 s, satisfactory.
Check entrainment
1.13
=2.57 m/s
0.44
2.57
per cent flooding
76
3.38
FLy = 0.14, from Figure l1.29, 0.018, well below 0.1.
design of 85. the column diameter
As the per cent looding is well below the figure
could be reduced, but this would increase the pressure drop.
Trial layout
50 mm
Use cartridge-type construction. Allow 50 mm unperforated strip round plate edge:
wide calming zones.
584 CHEMICAL ENGINEERING
50 mmn
50mm
Perforated area
From Figure 11.32, at /D, 0.6/0.79=0.76
8 =99
angle subtended by the edge of the plate = 180 99 =81
mean length, unperforated edge strips (0.79-50x 10-)X 81/180 = 1.05 m
area of unperforated edge strips 50 % 10 x L05 = = 0.053 m?
mean length of calming zone, approx. - weir length + width of unperforated strip
=0.6+50 % 10 = 0.65 m
area of calming zones = x 50 ×10)=
2(0.65 m 0.065
total area for perforations, Ap = 0,053-0.065=
0.38 - 0.262
=
m
An/A, 0.038/0.262 = 0.145
From Figure 11.33, 1,/d,= 2.6; satisfactory,within 2.5 to 4.0.
Number of holes
Area of one hole 1.964 x 10-5 m?
0.038
Number of holes = 1.964 x 10-5
=1935
Plate specification
50mm
50mmn
40mm
50mm
Turn-down 70 per cent max rate
Plate No.
Mild steel
Plate I.D. 0.79 m Plate material
Mild steel
5 mm Downcomer material
Hole size
12.5 mm A Plate spacing
m
0.5
Hole pitch
Plate thickness 5mm
Total no. holes KPa
1935 Plate pressure drop 140 mm liquid 1.3
Active holes
Blanking area