İZMİR INSTITUTE OF TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING

CHE 312 SEPARATION PROCESSES

MALEIC ANHYDRIDE PRODUCTION AND DESIGN

Submitted by: Group 4

260202004 – Gökalp Bilgiç

260202040 – Helin Cemre Durak

260202048 – Ezgi Can

Submitted to:

Prof. Sacide Alsoy Altınkaya

T.A. Dr. Yaşar Kemal Recepoğlu

T.A. Dr. Merve Karabıyık

Spring, 2024
ACKNOWLEDGEMENT
We would like to express our sincere gratitude to our advisor; Prof. Sacide ALSOY
ALTINKAYA, as well as our teaching assistants; Dr. Yaşar Kemal Recepoğlu and Dr. Merve
Karabıyık for their supervision, support, and confidence.
ABSTRACT
This project targets the production of Maleic Anhydride (MAN) with a 95% purity level and an
annual capacity of 130,000 metric tonnes through a separation process. Initially, a stream
containing off-gases and MAN enters an absorption column where MAN is absorbed using
Dibutyl Phthalate (DBP) at an operational temperature of 140°C and pressure of 1 atm,
managing a gas phase flow rate of 1517.7 mol/s and a liquid phase flow rate of 520.92 mol/s.
Utilizing the McCabe-Thiele method, it was determined that 7 theoretical stages are necessary,
which, given an operational efficiency of 39%, equates to 18 actual stages. The absorption
column's design specifications include a diameter of 4.50 m and a length of 13.77 m, featuring
0.6 m plate spacing and 3 m disengagement spacing. A Fractional Entrainment value of 0.014,
well below the flooding limit of 0.1, and a negligible pressure drop of 1626.8 Pa confirm
efficient operation. Subsequently, the DBP-MAN stream enters the distillation column as a
saturated liquid at 187°C and 0.075 bar. A graphical solution yielded a minimum reflux ratio of
0.15, resulting in the determination of 4 stages, including a partial reboiler, via the McCabe-
Thiele method. The distillation column, designed with a length of 7.2 m and a diameter of 1.92
m, experiences a minimal pressure drop of 1021.08 Pa. The energy requirement for the reboiler
and condenser is approximately 18 MW, deemed suitable for the system. Comprehensive design
calculations underpin the effectiveness and efficiency of the separation and purification
processes, ensuring the consistent production of high-purity MAN.
TABLE OF CONTENT
ACKNOWLEDGEMENT ....................................................... Error! Bookmark not defined.
ABSTRACT............................................................................ Error! Bookmark not defined.
1. INTRODUCTION............................................................ Error! Bookmark not defined.
2. SELECTIONS ................................................................. Error! Bookmark not defined.
2.1. Solvent Selection for Absorption Column ..................... Error! Bookmark not defined.
2.2. Tray Type Selection for Absorption Column ................. Error! Bookmark not defined.
3. CALCULATIONS ........................................................... Error! Bookmark not defined.
3.1. Distillation Column Design........................................... Error! Bookmark not defined.
[Link] Balance .................................................................. Error! Bookmark not defined.
3.2.1. Enthalpy of Distillate ............................................... Error! Bookmark not defined.
3.2.2. Enthalpy of Feed ...................................................... Error! Bookmark not defined.
3.2.3. Enthalpy of Bottom Product ..................................... Error! Bookmark not defined.
3.3. Absorption Column Design .......................................... Error! Bookmark not defined.
[Link] .................................................................... Error! Bookmark not defined.
5. REFERENCES.................................................................... Error! Bookmark not defined.

LIST OF TABLES

Table 1. Molar Flow Rates and Compositions of Feed, Bottom and Top of the Distillation
Table 2. Mass Flow Rates and Compositions of Feed, Bottom and Top of the Distillation
Table 3. Equations of distillation and result values
Table 4 .Internal Design and Pressure Drop Calculation

Table 5. Mass Balance Calculations

Table 6. Equations of absorption and result values

Table 7. Flooding Calculations

Table 8. Internal Design and Pressure Drop Calculation

LIST OF FIGURES

Figure 1. Mass Balance Around Multistage Distillation Column

Figure 2. VLE Diagram for Minimum Reflux Ratio

Figure 3. VLE Diagram for 0.15 Reflux Ratio

Figure 4. Mass Balance Around Absorption Column

Figure 5. Equilibrium and Operating Line

Figure 6. Absorber column efficiencies (Eo)

Figure 7. Flooding velocity

Figure 8. Relation between downcomer area and weir length.

Figure 9. Oriffice Coefficient

 1. INTRODUCTION
The spread of plastic material production and the resulting release of garbage and residues into
the environment seems unstoppable for now. Fossil-based production of material flows poses
various threats such as pollution, climate change, resource depletion, ecosystem damage, as
well as consequences for human health. The plastics economy is supported by a large number
of consumers who participate in the cycle of raw materials, products and waste in different
[1]
ways. Globally, the use of resources derived from fuels is declining these days, with
sustainable, alternative energy and material sources gaining prominence. Concerns about
climate change draw industry attention to the need for greener manufacturing practices. Thus,
in the industrial context, biomass wastes are regarded as raw materials. The goal is to produce
maleic anhydride (MAN), so the biomass's hemicellulose content is used to first produce
furfural (FUR), and then the furfural is used to produce maleic anhydride. One type of chemical
compound in the furan class is maleic anhydride. It is a white or colorless solid with an
unpleasant smell. Maleic anhydride is used in the production of copolymers, resins and plastic
products, petroleum ingredients, agricultural and commercial materials, sheet specifications,
water purification compounds, flavor enhancers, sweeteners, and epoxy hardening
intermediaries. It is mostly used in the production of polyester resins that are unsaturated. Most
[2]
of the time, it is transported in a solid or molten state . Maleic anhydride production plants
operate on the basis of reactor units, separation and purification sections, feed preparation
sections, and energy recovery systems. This allows for the technologically and economically
feasible manufacturing of maleic anhydride while taking safety regulations, health concerns,
and financial considerations into [Link] most widely used industrial method for producing
[3]
maleic anhydride is catalytic oxidation of benzene or n-butane . Using the n-butane route,
maleic acid is first formed by oxidizing n-butane, and maleic anhydride is then formed by
dehydrating maleic acid. At high temperatures, a catalyst based on vanadium is usually used in
this process. An alternative method is the benzene route, which entails directly oxidizing
benzene to form maleic anhydride using a catalyst based on molybdenum, vanadium, or a
combination of the two. Additionally, this process runs at high temperatures. MAN is produced
by both routes as a vapor that is subsequently condensed and refined. Even though industry has
been using these techniques for a long time, this process should incorporate more
environmentally friendly and sustainable production methods, like using alternative catalysts
or renewable feedstocks. Utilizing furan derivatives derived from lignocellulosic biomass is
another method that is bio-based. Maleic anhydride can be produced from furan compounds. A
synthetic substance called furfural is made from biomaterials containing hemicellulose and
acid. As a possible source for the synthesis of biofuels and other biomaterials, it has drawn more
[4]
attention recently . The most common raw materials used to make furfural include wood,
nutshells, wheat straw, corn starch, and hazelnuts. In terms of viability, compatibility, and
environmental considerations, biomass-derived furfural is preferable to fuel-based materials
even though the latter is more difficult to obtain. This helps to make the process greener in the
first place. The selection of biomass as the process's raw material was made after taking
affordability, sustainability, and availability into account. It must not be used as provender and
be a waste of another [Link] raw materials that are obtainable domestically or even
from a particular region would be a wise strategy when looking for raw materials with the
highest hemicellulose content and taking availability into account. By employing green
engineering techniques to convert biomass wastes with appropriate amounts of hemicellulose
to furfural, it becomes easier to produce less hazardous products for the environment. The
conversion of biomass to furfural and furfural to maleic anhydride requires cooperative
processes.
 2. SELECTIONS

2.1. Solvent Selection for Absorption Column

The literature states that MAN absorption is accomplished by using dibutyl phthalate (DBP)
and di isobutyl hexahydro phthalate (DIBE). DIBE's weaker physicochemical properties, on
the other hand, would cause larger solvent losses, requiring an increased consumption rate,
and its cost is estimated to be up to 20% more per ton than DBP [5]. Furthermore, maleic
anhydride is soluble in DBP, while water and other gas stream constituents are not, based on
the Aspen data. In addition, DBP has less potential to harm the environment than other
solvents. Following a review of a number of factors, including availability and economic
viability as well as potential effects on human health and the environment, dibutyl phthalate
(DBP) was found to best satisfy all the requirements.

[Link] Type Selection for Absorption Column

Compared to packed columns, plate columns can be made to handle a larger variety of liquid
and gas flow rates. We have a large manufacturing capacity, therefore selecting the right kind
of column is essential. More trays can fit in each volume of a tray-type column. Higher
capacity absorption columns are made possible by this. Tray-type columns require less
maintenance and allow for more accurate estimation of a plate's efficiency than packaging-
related terms. Therefore, plate type column was selected to be used in the design.

The bubble cap tray, sieve deck tray, dual flow tray, valve tray, and baffle tray are the five
main types of tray columns. One of the drawbacks of bubble-cap trays is their high cost and
pressure decrease. Furthermore, bubble caps are not recommended because they are less
effective than sieves and valve trays. Consequently, bubble-cap is inappropriate.

Comparable in terms of cost, efficiency, and pressure drop are the valve and sieve tray. Trays
for valves are appropriate for somewhat larger capacities than trays for sieves. Because of
unique valves, the chance of clogging is intended to be minimized. Therefore, sieve tray type
is best option for this operation [6].

3. CALCULATIONS

3.1. Distillation Column Design

The solvent recovered from the distillation column is fed to the absorption column and is not
pure. This distillation receives a mixture of dibutyl phthalate (DBP) and maleic anhydride
(MAN) as feed. It is aimed to obtain 95% purity MAN with an annual capacity of 130,000
metric/tonnes from the multistage distillation [Link] assumptions for this unit are that the
system is a constant molal overflow. The feed temperature is 187 ᵒC, this value was found in
Aspen from Txy diagram at 0.075 bar. Recovery was set %99. Pure DBP and pure MAN have
boiling points of 340 ᵒC and 202 ᵒC, respectively. So, in the process,DBP is heavy key and
MAN is light key. Table 1 shows the flow rates and composition of distillation feed, bottom and
top parts.

Table 1. Molar Flow Rates and Compositions of Feed, Bottom and Top of the
Distillation
Molar Flow Rates (mol/s) Composition

Component Feed Bottom Top Feed Bottom Top

Dibutyl Phthalate (DBP) 475.87 474.1 1.102 0.9135 0.99 0.05

 Maleic Anhydride (MAN) 45.06 4.79 40.938 0.0865 0.01 0.95

Total 520.93 478.89 42.04 1 1 1

Table 2. Mass Flow Rates and Compositions of Feed, Bottom and Top of the
Distillation
Mass Flow Rates (g/s) Composition

Component Feed Bottom Top Feed Bottom Top

Dibutyl Phthalate 132453.6558 131960.994 306.73 0.9135 0.99 0.05

(DBP)

Maleic Anhydride 4418.5836 469.7074 4014.38 0.0865 0.01 0.95

(MAN)

Total 136872.24 132430.7014 4321.11 1 1 1

4321.11 g/s

4014.38 g/s MAN

306.73 g/s DBP

136872.24 g/s
Distillation
Column

4418.5836 g/s MAN

132453.6558 gg/s DBP

132430.7014 g/s
 469.7074 g/s MAN

131960.994 g/s DBP

Figure 1. Mass Balance Around Multistage Distillation Column

The mass flow rates of MAN and DBP in the determined compositions are shown in Figure 1
and mass balance is achieved.

From Txy diagram bubble point of feed mixture, condenser inlet temperature and reboiler inlet
temperature are found 187 ᵒC, 122 ᵒC and 232 ᵒC, respectively. According to the bubble point
of mixture, feed temperature was set to 187˚C since feed stream is saturated liquid. It is
requested that the input feed be saturated liquid. The formula for feed quality is as follows:

(1 + 𝐶𝑝,𝐿𝑚𝑖𝑥 ∗ (𝑇𝑏𝑢𝑏𝑏𝑙𝑒 − 𝑇𝑓𝑒𝑒𝑑 ))

𝑞=
𝜆𝑚𝑖𝑥

𝑇𝑏𝑢𝑏𝑏𝑙𝑒 = 𝑇𝑓𝑒𝑒𝑑

(1+𝐶𝑝,𝐿𝑚𝑖𝑥 ∗0)
𝑞= 𝜆𝑚𝑖𝑥

𝜆𝑀𝐴𝑁 /𝜆𝐷𝐵𝑃 ≈ 1

𝑞=1 (Constant molar overflow)

According to this formula,for q is 1, T bubble must be equal to T feed. So, the feed temperature is
set as 187 ˚C is equal to bubble temperature of inlet mixture.
 Figure 2. VLE Diagram for Minimum Reflux Ratio

When the two operating lines touch the equilibrium line, a ‘’pinch point’’ at y=0.86 and x=0.09
occurs, where the number of steps required becomes infinite. From the equation below,
minimum reflux ratio was determined.

𝑅𝑚
= (𝑥𝐷 − 𝑦)/(𝑥𝐷 − 𝑥)
𝑅𝑚 + 1

𝑅𝑚
= (𝑥𝐷 − 0.86)/(𝑥𝐷 − 0.09)
𝑅𝑚 + 1

𝑅𝑚 = 0.1

𝑅 = 1.5𝑅𝑚

𝑅 = 0.15

After the reflux calculation, the enriching line was drawn according to enriching line operating
equation. Since our feed is saturated liquid, q=1. After the enriching line, q=1 line is drawn, and
the two lines are tried to intersect and finally the stripping line is drawn. For 0.15 reflux ratio
example graph which drawn by Mc-Cabe Thiele method was shown.

According to the graph drawn by the Mc-Cabe Thiele method, 5 stages were found. Since the
last stage is a partial reboiler, the number of stages is found to be 4.
 Figure 3. VLE Diagram for 0.15 Reflux Ratio.

Table 3. Equations of distillation and result values

Equation Description Value

𝑃𝛼0 ∗ 𝛾 𝑃 = 𝑜𝑝𝑒𝑟𝑎𝑡𝑖𝑛𝑔 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 ,0.075 (𝑏𝑎𝑟)

𝐾𝛼 =
𝑃
𝑃𝛼0 = 𝑣𝑎𝑝𝑜𝑟 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑜𝑓 𝑙𝑖𝑔ℎ𝑡 𝑘𝑒𝑦, 0.677 (𝑏𝑎𝑟) 𝐾𝛼 = 9.03

𝛾 = 𝑎𝑐𝑡𝑖𝑣𝑖𝑡𝑦 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡, 1

𝐾𝛼 = 𝐾 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 𝑙𝑖𝑔ℎ𝑡 𝑘𝑒𝑦

𝐾𝛼 𝛼𝛼 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑣𝑜𝑙𝑎𝑡𝑖𝑙𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑖𝑔ℎ𝑡 𝑘𝑒𝑦

𝛼𝛼 =
𝐾𝑏𝑎𝑠𝑒
𝐾𝑏𝑎𝑠𝑒 = 𝑠𝑢𝑚 𝑜𝑓 𝐾 𝑣𝑎𝑙𝑢𝑒𝑠 𝑜𝑓 𝑙𝑖𝑔ℎ𝑡 𝑎𝑛𝑑 ℎ𝑒𝑎𝑣𝑦 𝑘𝑒𝑦𝑠 𝛼𝛼 = 0.986

𝐾𝛽 = 𝐾 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 ℎ𝑒𝑎𝑣𝑦 𝑘𝑒𝑦, 0,1255

𝐸0 = 51 − 32.5log(𝜇𝛼 𝛼𝛼 ) 𝛼𝛼 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑣𝑜𝑙𝑎𝑡𝑖𝑙𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑖𝑔ℎ𝑡 𝑘𝑒𝑦

𝜇𝛼 = 𝑡ℎ𝑒 𝑚𝑜𝑙𝑎𝑟 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑙𝑖𝑞𝑢𝑖𝑑 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦, 𝐸0 = 60.24 %

0.5268 (𝑚𝑁𝑠/𝑚 2)

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠 𝑁𝑖 = 4

𝐸0 =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠
𝐸0 = 0.60 𝑁𝑟𝑒𝑎𝑙 = 6.64 ≈ 7

𝐻 = 𝑁𝑟𝑒𝑎𝑙 ∗ 𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔, 0.6

+ 𝑑𝑖𝑠𝑒𝑛𝑔𝑎𝑔𝑒𝑚𝑒𝑛𝑡
 𝑑𝑖𝑠𝑒𝑛𝑔𝑎𝑔𝑒𝑚𝑒𝑛𝑡, 3 𝐻 = 7.2

𝐻 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 (𝑚)

𝐿𝑤 𝜌𝑣 𝐿𝑤 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 , 138.525 (𝑘𝑔/𝑠)

𝐹𝐿𝑉 = √
𝑉𝑤 𝜌𝐿
𝑉𝑤 = 𝑣𝑎𝑝𝑜𝑟 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 9.272(𝑘𝑔/𝑠) 𝐹𝐿𝑉 = 0.68

𝜌𝑣 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒 , 1.758 (𝑘𝑔/𝑚 3)

𝜌𝐿 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑝ℎ𝑎𝑠𝑒 , 847.197 (𝑘𝑔/𝑚 3 )

𝐹𝐿𝑉 = 𝑓𝑙𝑜𝑤 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟

𝜌𝐿 − 𝜌𝑣 𝜌𝑣 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒 , 1.758 (𝑘𝑔/𝑚 3)

𝑢𝑓 = 𝐾1 √
𝜌𝑣
𝜌𝐿 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑝ℎ𝑎𝑠𝑒 , 847.197 (𝑘𝑔/𝑚 3 ) 𝑢𝑓 = 1.315

𝐾1 = 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑓𝑎𝑐𝑡𝑜𝑟 , 0.06 (𝑓𝑟𝑜𝑚 𝑓𝑙𝑜𝑤 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟 𝑔𝑟𝑎𝑝ℎ)

𝑢𝑓 = 𝑓𝑙𝑜𝑜𝑑 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, (𝑚/𝑠)

̅̅̅̅̅̅̅̅ 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 , 0.75

4𝑉(𝑀𝑊 𝑉)
𝐷=√
𝜋𝜂𝜌𝑣 (𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛)𝑢𝑓𝑙𝑜𝑜𝑑 (3600)
𝜂 = 𝑤𝑒𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 0.9 𝐷 = 1.92

̅̅̅̅̅̅̅̅
(𝑀𝑊 𝑉 ) = 𝑚𝑜𝑙𝑒𝑐𝑢𝑙𝑎𝑟 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒 , 191.796 (𝑔

/𝑚𝑜𝑙)

𝑉 = 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒 𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, 48.346 (𝑚𝑜𝑙/𝑠)

𝐷 = 𝑐𝑜𝑙𝑢𝑚𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , (𝑚)

𝜋𝐷 2 𝐻 𝐷 = 𝑐𝑜𝑙𝑢𝑚𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , (𝑚)

𝑉=
4
𝐻 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑜𝑙𝑢𝑚𝑛 (𝑚) 𝑉 = 20.88

𝑉 = 𝑣𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡𝑜𝑤𝑒𝑟 (𝑚 3)

𝐻/𝐷 𝐷
𝑟𝑎𝑡𝑖𝑜 𝑐𝑎𝑛 𝑏𝑒 1: 3 − 1: 20 𝑟𝑎𝑛𝑔𝑒 (𝑟𝑒𝑓)
𝐻
3.7

It is necessary to use overall efficiency to find the actual tray numbers. A quick estimate of the
overall column efficiency can be obtained from the correlation given by O’Connell (1946) [7].

The overall column efficiency is correlated with the product of the relative volatility of the light
key component (relative to the heavy key) and the molar average viscosity of the feed, estimated
at the average column temperature. Values such as activity coefficient, vapor pressure of light
key, the molar average liquid velocity specified in Table 3 were taken from Aspen at 0.075 bar
and average column temperature. After finding overall tower efficiency (60.24%), actual
number of stage calculation was performed to evaluate the tower height. The actual number of
 stages is 7. The disengagement height is the height added to the starting height of the estimated
[8]
column. The disengagement values of most columns are generally 3 m long . Therefore,
disengagement is set to 3 m while tray spacing is set to 0.6 m by considering the number of
stages. The height of the distillation column was calculated as 7.2 m. Afterwards; tower
diameter calculation was performed and was found 1.92 m. For every case, propose a fraction
of 0.75[7]. Therefore, weld efficiency (η) and fraction were set to 0.9 and 0.75, respectively. The
volume of the distillation column was found to be 20.88 m3 and finally H/D ratio was
determined 3.7.

Table 4 .Internal Design and Pressure Drop Calculation

Equation Description Value

𝜋𝐷 2 𝐷 = 𝑐𝑜𝑙𝑢𝑚𝑛 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , (𝑚) 𝐴𝑡 = 2.90

𝐴𝑡 =
4
𝐴𝑡 = 𝑡𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡𝑜𝑤𝑒𝑟 , (𝑚 2)

𝐴𝑎 = 𝐴𝑡 (2𝜂 − 1) 𝐴𝑎 = 𝑎𝑐𝑡𝑖𝑣𝑒 𝑎𝑟𝑒𝑎 , (𝑚 2) 𝐴𝑎 = 2.32

𝜂 = 𝑤𝑒𝑙𝑑 𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦, 0.9

𝑛𝜋𝑑ℎ2 𝑑ℎ = ℎ𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 5 (𝑚𝑚)

𝐴ℎ = ∗ 10−6
4
𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 ℎ𝑜𝑙𝑒𝑠 𝑛 = 11822

𝐴ℎ = ℎ𝑜𝑙𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡𝑜𝑤𝑒𝑟 0.232 (𝑚 2)

𝐴ℎ
0.05 < < 0.15 , 0.1
𝐴𝑎

𝐴ℎ 𝑑ℎ 2 𝑑ℎ = ℎ𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 , 5 (𝑚𝑚)

= 0.907 [ ]
𝐴𝑎 𝑃𝑇
𝐴ℎ 𝑃𝑇 = 15.05
= 0.1
𝐴𝑎

𝑃𝑇 = 𝑡ℎ𝑒 ℎ𝑜𝑙𝑒 𝑝𝑖𝑡𝑐ℎ , (𝑚𝑚)

𝐿̇
2/3
𝐿̇ = 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 , 0.163 (𝑚 3/𝑠)
ℎ𝑜𝑤 = 7507 [ ]
𝜌𝐿 𝐿𝑤
𝜌𝐿 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑝ℎ𝑎𝑠𝑒 , (𝑘𝑔/𝑚 3 ) ℎ𝑜𝑤 = 1.92

𝐿𝑤 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑤𝑒𝑖𝑟 , (𝑚)

ℎ𝑜𝑤 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑤𝑒𝑖𝑟 𝑐𝑟𝑒𝑠𝑡 , (𝑚𝑚)

𝐺̇ 𝐴ℎ = ℎ𝑜𝑙𝑒 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡𝑜𝑤𝑒𝑟 , 0.232 (𝑚 2)

𝑢ℎ =
𝜌𝑣 𝐴ℎ
𝜌𝑣 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒, (𝑘𝑔/𝑚 3) 𝑢ℎ = 22.73

𝐺̇ = 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑔𝑎𝑠 , (𝑚 3/𝑠)

 𝑢ℎ = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓𝑔𝑎𝑠 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑡ℎ𝑒 ℎ𝑜𝑙𝑒𝑠 , (𝑚/𝑠)

1 2 𝜌𝑣 2 𝜌𝑣 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒, (𝑘𝑔/𝑚 3)

ℎ𝑜 = 51 ( ) 𝑢
𝐶𝑜 𝜌𝐿 ℎ
𝜌𝐿 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑝ℎ𝑎𝑠𝑒 , (𝑘𝑔/𝑚 3 ) ℎ𝑜 = 99.88

𝑢ℎ = 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 𝑜𝑓𝑔𝑎𝑠 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑡ℎ𝑒 ℎ𝑜𝑙𝑒𝑠 , (𝑚/𝑠)

𝐶𝑜 = 𝑡ℎ𝑒 𝑜𝑟𝑖𝑓𝑖𝑐𝑒 𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡, 0.74

𝐺̇ 𝐴𝑎 = 𝑎𝑐𝑡𝑖𝑣𝑒 𝑎𝑟𝑒𝑎 , (𝑚 2) 𝐹𝐺𝑎 = 1.71

𝐹𝐺𝑎 =
𝐴𝑎 √𝜌𝑣
𝜌𝑣 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒, (𝑘𝑔/𝑚 3)

𝐺̇ = 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑔𝑎𝑠 , 5.27 (𝑚 3/𝑠)

𝐹𝐺𝑎 𝑓𝑜𝑢𝑛𝑑 𝑡𝑜 𝑜𝑏𝑡𝑎𝑖𝑛 𝑎𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟

ℎ𝑎 = 𝑄𝑝 (ℎ𝑤 + ℎ𝑜𝑤 ) ℎ𝑤 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑤𝑒𝑖𝑟, 12 (𝑚𝑚)

ℎ𝑜𝑤 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑤𝑒𝑖𝑟 𝑐𝑟𝑒𝑠𝑡, (𝑚𝑚) ℎ𝑎 = 9.05

𝑄𝑝 = 𝑎𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 , 0.65

ℎ𝑎 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 , (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

ℎ𝑇 = ℎ𝑜 + ℎ𝑎 ℎ𝑜 = 𝑑𝑟𝑦 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝, (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

ℎ𝑎 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑔𝑎𝑠 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑎𝑒𝑟𝑎𝑡𝑒𝑑 𝑙𝑖𝑞𝑢𝑖𝑑, ℎ𝑇 = 108.93

(𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

ℎ𝑇 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑔𝑎𝑠 𝑠𝑖𝑑𝑒 , (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

𝐾2 − 0.90(25.4 − 𝑑ℎ ) 𝐾2 = 30.2
𝑢ℎ𝑚 =
𝜌𝑣 0.5
𝑑ℎ = ℎ𝑜𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 5 (𝑚𝑚) 𝑢ℎ𝑚 = 8.9

𝜌𝑣 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑝ℎ𝑎𝑠𝑒, 1.758 (𝑘𝑔/𝑚 3)

𝑢ℎ𝑚 = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 ℎ𝑜𝑙𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 , (𝑚/𝑠)

ℎ𝑑𝑐 = ℎ𝑤 − 10 ℎ𝑤 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑤𝑒𝑖𝑟, 12 (𝑚𝑚) ℎ𝑑𝑐 = 2

ℎ𝑑𝑐 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑠𝑖𝑑𝑒,

(𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

𝐴𝑝𝑒 = 𝐿𝑤 ℎ𝑑𝑐 ∗ 10−3 ℎ𝑑𝑐 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑖𝑛 𝑙𝑖𝑞𝑢𝑖𝑑 𝑠𝑖𝑑𝑒, 𝐴𝑝𝑒 = 0.003
(𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

𝐿𝑤 = 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑤𝑒𝑖𝑟 , 1.48 (𝑚)

𝐴𝑝𝑒 = 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝑎𝑡 𝑡ℎ𝑒 𝑒𝑛𝑡𝑟𝑎𝑛𝑐𝑒 , (𝑚 2)

2
𝐿̇ 𝐿̇ = 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 , 0.163 (𝑚 3/𝑠)
ℎ𝑝𝑒 = 166 [ ]
𝜌𝐿 𝐴𝑝𝑒
𝜌𝐿 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑝ℎ𝑎𝑠𝑒 , 847.197 (𝑘𝑔/𝑚 3 ) ℎ𝑝𝑒 = 3.88

𝐴𝑝𝑒 = 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝑎𝑡 𝑡ℎ𝑒 𝑒𝑛𝑡𝑟𝑎𝑛𝑐𝑒 , (𝑚 2)

ℎ𝑝𝑒 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 , (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

ℎ𝑑 = ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑜 + ℎ𝑎 + ℎ𝑝𝑒 ℎ𝑤 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑤𝑒𝑖𝑟, 12 (𝑚𝑚)

ℎ𝑜𝑤 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑤𝑒𝑖𝑟 𝑐𝑟𝑒𝑠𝑡 , (𝑚𝑚) ℎ𝑑 = 122.86

ℎ𝑜 = 𝑑𝑟𝑦 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝, (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑) ∆𝑃 = 9.81 ∗ 10−3 ∗ ℎ𝑑 ∗ 𝜌𝐿

ℎ𝑎 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑔𝑎𝑠 𝑡ℎ𝑟𝑜𝑢𝑔ℎ 𝑎𝑒𝑟𝑎𝑡𝑒𝑑 𝑙𝑖𝑞𝑢𝑖𝑑, ∆𝑃 = 9.81 ∗ 10−3 ∗ 122.86 ∗ 847.197
(𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)
∆𝑃 = 1021.08 𝑃𝑎
ℎ𝑝𝑒 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝, (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)

ℎ𝑤 + ℎ𝑜𝑤 + ℎ𝑇 + ℎ𝑝𝑒 ℎ𝑤 = ℎ𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑤𝑒𝑖𝑟, 12 (𝑚𝑚)

ℎ𝑑𝑎 =
𝑄𝑝
ℎ𝑜𝑤 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑤𝑒𝑖𝑟 𝑐𝑟𝑒𝑠𝑡, (𝑚𝑚) ℎ𝑑𝑎 = 189.02

ℎ𝑝𝑒 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝, (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑) 1

ℎ𝑑𝑎 ≤ ∗ 𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔(0.6) ∗ 103
2
ℎ𝑇 = 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝑑𝑟𝑜𝑝 𝑖𝑛 𝑡ℎ𝑒 𝑔𝑎𝑠 𝑠𝑖𝑑𝑒 (𝑚𝑚 𝑙𝑖𝑞𝑢𝑖𝑑 ℎ𝑒𝑎𝑑)
ℎ𝑑𝑎 ≤ 300
𝑄𝑝 = 𝑎𝑒𝑟𝑎𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟 , 0.65

ℎ𝑑𝑎 = 𝑑𝑜𝑤𝑛 𝑐𝑜𝑚𝑒𝑟 𝑏𝑎𝑐𝑘 𝑢𝑝 , (𝑚𝑚)

For mechanical design of distillation column, Table 4 has sample calculations. The calculation
was made from Sinnot’s book and class notes. One of the considerations that should not be
neglected while constructing a distillation column is pressure drop. The following procedure
was used to calculate the pressure drop. In Table 4 pressure drop, and internal design equation
can be seen.

The following equation gives the pressure drop for one tray in Pascal.

∆𝑃 = 9.81 ∗ 10−3 ∗ ℎ𝑑 ∗ 𝜌𝐿

∆𝑃 = 9.81 ∗ 10−3 ∗ 122.86 ∗ 847.197

∆𝑃 = 1021.08 𝑃𝑎

After calculating the total pressure drop, it is observed that the pressure drop through the column
can be neglected.

𝑢ℎ > 𝑢ℎ𝑚 must be provide to prevent weeping.

𝑢ℎ = 22.73 𝑚/𝑠

𝑢ℎ𝑚 = 8.9 𝑚/𝑠

𝑢ℎ > 𝑢ℎ𝑚
The minimum hole velocity is less than the hole velocity in this system so inequity is satisfied
weeping does not occur.

3.2. Energy Balance

Sample calculation have done for condenser. Cp and latent heat of vaporization values are taken
from ASPEN. Cp and latent heat of vaporization values are taken at (T+T ref )/2 ᵒC and 0.075 bar
for each condition. Saturated liquid enthalpy formula is given below with refer to distillate. For
feed and bottom streams enthalpy can be write same formula with different value at C p and T.
Tref is 0 ᵒC. Details can be found in the Excel file.

𝑇𝑓𝑒𝑒𝑑 = 187ᵒC

𝑇𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 = 122ᵒC

𝑇𝑏𝑜𝑡𝑡𝑜𝑚 = 232ᵒC

3.2.1. Enthalpy of Distillate

Saturated Vapor Enthalpy

𝐻1 = 𝑦1,𝑀𝐴𝑁 [𝜆𝑀𝐴𝑁 + 𝐶𝑝𝑉,𝑀𝐴𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 ) + 𝑦1,𝐷𝐵𝑃 [𝜆𝐷𝐵𝑃 + 𝐶𝑝𝑉,𝑀𝐴𝑁 (𝑇1 − 𝑇𝑟𝑒𝑓 )]

𝐻1 = 91870,43 𝑘𝐽/𝑘𝑚𝑜𝑙

Saturated Liquid Enthalpy

ℎ𝐷 = 𝑥𝐷,𝑀𝐴𝑁 𝐶𝑝𝐿,𝑀𝐴𝑁 (𝑇𝐷 − 𝑇𝑟𝑒𝑓 ) + (1 − 𝑥𝐷,𝑀𝐴𝑁 )𝐶𝑝𝐿,𝐷𝐵𝑃 (𝑇𝐷 − 𝑇𝑟𝑒𝑓 )

ℎ𝐷 = 31061.66 𝑘𝐽/𝑘𝑚𝑜𝑙

𝑚𝑜𝑙
𝑉 = 48.346 = 0.048346 𝑘𝑚𝑜𝑙/𝑠
𝑠

𝑄𝐶 = 𝑉 ∗ (ℎ𝐷 − 𝐻1 )

𝑄𝐶 = −2939.86 𝑘𝐽/𝑠

3.2.2. Enthalpy of Feed

ℎ𝐹 = 𝑧𝐹,𝑀𝐴𝑁 𝐶𝑝𝐿,𝑀𝐴𝑁 (𝑇𝐹 − 𝑇𝑟𝑒𝑓 ) + (1 − 𝑧𝐹,𝑀𝐴𝑁 )𝐶𝑝𝐿,𝐷𝐵𝑃 (𝑇𝐹 − 𝑇𝑟𝑒𝑓 )

ℎ𝐹 = 84451.866 𝑘𝐽/𝑘𝑚𝑜𝑙
3.2.3. Enthalpy of Bottom Product
ℎ𝐵 = 𝑥𝐵,𝑀𝐴𝑁 𝐶𝑝𝐿,𝑀𝐴𝑁 (𝑇𝐵 − 𝑇𝑟𝑒𝑓 ) + (1 − 𝑥𝐵,𝑀𝐴𝑁 )𝐶𝑝𝐿,𝐷𝐵𝑃 (𝑇𝐵 − 𝑇𝑟𝑒𝑓 )

ℎ𝐵 = 114563,973 𝑘𝐽/𝑘𝑚𝑜𝑙

𝑚𝑜𝑙
𝐹 = 520.93 = 0.52093 𝑘𝑚𝑜𝑙/𝑠
𝑠

𝑚𝑜𝑙
𝐷 = 42.04 = 0.04204 𝑘𝑚𝑜𝑙/𝑠
𝑠

𝑚𝑜𝑙
𝐵 = 478.89 = 0.47889 𝑘𝑚𝑜𝑙/𝑠
𝑠

𝑄𝑅 = 𝐷 ∗ ℎ𝐷 + 𝐵 ∗ ℎ𝐵 − 𝐹 ∗ ℎ𝐹 − 𝑄𝑐

𝑄𝑅 = 15115.72 𝑘𝐽/𝑠

3.3. Absorption Column Design

In maleic anhydride (MAN) purification process, absorption column was used to separate
maleic anhydride from off-gas. After total mass balance was performed on the system which
is shown in figure X, y1 and (L/V)min were found by setting 99% recovery for absorption.
(L/V)min value was multiplied by 1.5, which is the most appropriate value as a result of
literature researches, and the actual (L/V) ratio was found. Then mass balance was performed
on the absorber to find xN. The equations used in the operations are given in table below.
 Figure 4. Mass Balance Around Absorption Column

Table 5. Mass Balance Calculations

Equations Definitions Value

yN+1: MAN composition of
𝑦𝑁+1 = 𝑦1 ∗ 𝑟𝑒𝑐𝑜𝑣𝑒𝑟𝑦 inlet gas 𝑦1 = 0.0003
y1: Outlet gas composition
of MAN
𝑥𝑁∗ : 𝐸qulibrium
𝑦𝑁+1 concentration in liquid phase 𝑥𝑁∗ = 0.1398
𝑥𝑁∗ =
𝐻𝐵 /𝑃
P: Pressure
𝐿 𝑦𝑁+1 − 𝑦1 𝑥0 :Man composition of inlet 𝐿
(𝑉)𝑚𝑖𝑛 :0.229
( )𝑚𝑖𝑛 =
𝑉 𝑥𝑁∗ − 𝑥0 solvent
𝐿 𝐿 L: Solvent flow rates 𝐿
( ) = ( )𝑚𝑖𝑛 ∗ 1.5 ( ) = 0.388
𝑉 𝑉 V: Off-gas molar flow rate 𝑉

𝐿 𝑦𝑁+1 − 𝑦1 𝑥𝑁 : Man composition of 𝑥𝑁 = 0.0865

( )=
𝑉 𝑥𝑁 − 𝑥0 outlet solvent
After finding all input and output values, the operating line equation was found. The
theoretical number of stages calculated by using the McCabe Thiele method together with the
equilibrium data. Operating line equation given below:

𝐿 𝐿
𝑦𝑗+1 = ( ) ∗ 𝑥𝑁 + [𝑦1 − ( ) ∗ 𝑥0
𝑉 𝑉

𝑦 = 0.388𝑥 + 0.0003

When the equilibrium line and operating line were drawn, the theoretical number of stages
was found by applying the McCabe Thiele method. There are 7 theoretical stages in total.

Figure 5. Equilibrium and Operating Line

Then max. allowable vapour velocity was found to calculate column diameter and column
height. In order to find the actual number of trays, the correlation factor was first found 0.918
and then the plate efficiency was read from figure 5. In actuality, there are 18 trays. The
disengagement height of an estimated column is the height that is added to its initial height. 3
Meters is the disengagement value for the majority of columns [9]. Disengagement is set to 3
meters, and tray spacing is set to 0.6 meters, all while accounting for the amount of steps.
Also, viscosity and densities taken from Aspen Plus. The height of the column calculated as
13.76 m. The diameter of the column was found to be 4.508 metres.
 Table 6. Equations of absorption and result values

Equations Definitions Value

𝑢𝑣 = (−0.171𝑙𝑡2 + 0.27𝑙𝑡 𝑢𝑣 : Max. allowable vapour
(𝜌𝐿 − 𝜌𝑉 ) velocity (m/s) 𝑢𝑣 = 1.52
− 0.047) [ ]
𝜌𝑉 𝑙𝑡 :Plate spacing 0.6 m
ρL: liquid density (kg/m3 )
ρv: gas density (kg/m3 )
𝐷𝑐 : Column diameter m
4 ∗ 𝑉𝑤
𝐷𝑐 = √ 𝑉𝑤 : Mass flow rate of gas 𝐷𝑐 = 4.508
𝜋 ∗ 𝜌𝑉 ∗ 𝑢𝑣
phase (kg/s)
x: Correlation factor
𝜌𝐿 𝜇: Viscosity of solvent 𝑥 = 0.918
𝑥 = 0.062 [ ]
𝜇 ∗ 𝐾 ∗ 𝑀𝑠
𝐾:Equlibrium constant for
the solute 𝑀𝑠 :Molecular
weight of solvent (DBP:
274.34 kg/mol)
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠 𝐸𝑜 : Efficiency of plate (read Nreal = 18
𝐸𝑜 =
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠 from table 0.39)
𝐻: Column Height (m)
𝐻 = 𝑁𝑟𝑒𝑎𝑙 ∗ 𝑙𝑡 + 𝑑𝑖𝑠. 𝑣𝑎𝑙𝑢𝑒 𝑙𝑡 : Plate spacing 0.6 m 𝐻 = 13.76
Disengagement value: 3 m
 Figure 6. Absorber column efficiencies (Eo)

The vapour velocity upper limit is fixed by the flooding state. High plate efficiencies require a
high vapour velocity, which is typically between 70 and 90 percent of the velocity that would
result in floods [7]. In order to calculate the flooding velocity, the liquid-vapour flow factor
was first found and the K1 value was read from figure 7. Flooding velocity was found to be
2.56. After this, pergantage flood 75.42 was found, which is the desired between 70 and 90. In
addition, the fractional entrainment was found to be 0.014, which is below the upper limit 0.1.
The calculations are shown in table 7 below.

Table 7. Flooding Calculations

Equations Definitions Value

𝐿𝑤 𝜌𝑉 𝐹𝐿𝑉 : Liquid-vapor flow

𝐹𝐿𝑉= √
𝑉𝑤 𝜌𝐿 factor 𝐹𝐿𝑉= 0.172
𝐿𝑤 : Liquid flow rate (kg/s)
 𝑉𝑤 : Vapor flow rate (kg/s)

𝑢𝑓 : Flooding vapour
(𝜌𝐿 − 𝜌𝑉 )
𝑢𝑓 = 𝐾1 √ 𝑢𝑓 = 2.56
𝜌𝑉 velocity (m/s)
𝐾1 : A constant obtained 0.09
from figure X.
𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 𝑢𝑛 : Actual velocity (1.92
𝑢𝑛 (𝐴𝑐𝑡𝑢𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦) m/s) 𝑃𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔
=
𝑢𝑓 = 75.42

Figure 7. Flooding velocity.

Table X provides sample estimates for the mechanical design of the distillation column.
Firstly, the downcomer area, active area, net area and hole are were found. Hole diameter is
set as 5 mm and downcomer area is set as 12%. These parameters were taken from sinnot
design book as the most suitable parameters for interior design. After that weir lengt
calculated thanks to figure X and weir crest was found. Also, dry plate drop, weir crest, weir
height and residual head calculated to find total drop. The total drop examined in table X.
Pressure drop is also calculated with the total drop. It was found to be 0.016 bar, this level is
negligibly low.
Table 8. Internal Design and Pressure Drop Calculation

Equations Definitions Value

𝜋𝐷2 𝐷: Diameter of the tower m
𝐴𝑐 =
4 𝐴𝑐 : Cross sectional area of 𝐴𝑐 = 15.95
tower m2
𝐴𝑑 :The downcomer area
𝐴𝑑 = 𝐴𝑐 ∗ 0.12 (%12 of Ac) m2 𝐴𝑑 = 1.91
𝐴𝑎 : Active area of column
𝐴𝑎 = 𝐴𝑐 − 2𝐴𝑑 m2 𝐴𝑎 = 12.13
𝐴𝑛𝑒𝑡 : Net area of column
𝐴𝑛𝑒𝑡 = 𝐴𝑐 − 𝐴𝑑 m2 𝐴𝑛𝑒𝑡 = 14.04
𝐴ℎ𝑜𝑙𝑒 : Hole area of column
𝐴ℎ𝑜𝑙𝑒 = 𝐴𝑎 ∗ 𝛽 m2 𝐴ℎ𝑜𝑙𝑒 = 1.21
𝛽: Hole corelation chosen
0.1.
𝐴𝑑 Found to read figure 8.
∗ 100
𝐴𝑐 12
𝑙𝑤 𝑙𝑤 : Weir length m
0.77 =
𝐷𝑐 𝐷𝑐 : Diameter of the column 𝑙𝑤 = 3.47
m
𝐿𝑤 2/3 ℎ𝑜𝑤 : Weir crest mm
ℎ𝑜𝑤 = 750 [ ]
𝜌𝑉 𝑙𝑤 𝑙𝑤 : Weir length m ℎ𝑜𝑤 = 90.98
ρv: gas density (kg/m3)
𝐿𝑤 : Liquid flow-rate (kg/s)
12.5 ∗ 103 ℎ𝑟 : Residual head mm
ℎ𝑟 =
𝜌𝐿 𝜌𝐿 : Liquid density (kg/m3 ) ℎ𝑟 = 12.79
𝑢ℎ : Minimum vapor
𝑢ℎ velocity m/s 𝑢ℎ = 11.47
[𝐾2 − 0.90(25.4 − 𝑑ℎ )] 𝐾2 : Coefficient read from
=
(𝜌𝑉 )1/2 figure.
 𝑑ℎ : Diameter of hole, 5 mm
ρv: gas density (kg/m3)
ℎ𝑑 : Dry plate drop mm
𝑢ℎ 2 𝜌𝑉 𝑢ℎ : Minimum vapor ℎ𝑑 = 15.15
ℎ𝑑 = 51 [ ]
𝐶𝑜 𝜌𝐿 velocity m/s
𝐶𝑜 : Orifice Coefficient 0.74
read from figure 9
ℎ𝑜𝑤 : Weir crest mm
ℎ𝑡 = ℎ𝑑 + ℎ𝑟 + ℎ𝑜𝑤 + ℎ𝑤 ℎ𝑑 : Dry plate drop mm ℎ𝑡 = 168.87
ℎ𝑤 : Weir height mm
ℎ𝑟 : Residual head mm
𝛥 𝑃: Pressure Drop Pa
𝛥 𝑃 = 9.81 ∗ 10−3 ℎ𝑡 𝜌𝐿 ℎ𝑡 : Total drop mm 𝛥 𝑃 = 1626.8

Figure 8. Relation between downcomer area and weir length.

Figure 9. Oriffice Coefficient
4. CONCLUSION
In this project, it is aimed to obtain 95% purity MAN with an annual capacity of 130,000
metric/tonnes from the multistage distillation [Link] stream containing off-gases and
MAN first entered the absorption column. The stream containing DBP and MAN coming out
of the absorption column entered the distillation column to obtain MAN of the desired
[Link] anhydride will be separated from the off-gas using an absorption column with
DBP as the solvent. Absorption column is operated at 140 degrees with a pressure of 1 atm.
When mass balance was performed, it was found that the gas phase was 1517.7 mol/s and the
liquid phase was 520.92 mol/s. In the calculations made using the McCabe Thiele method, the
theoretical 7 stages were found. In these stages operating with 39% efficiency, the actual
number of stages was calculated as 18. In addition, the diameter of the absorption column was
found to be 4.50 m, while the column length was found to be 13.77 m with 0.6 m plate spacing
and 3 m disengagement spacing. In the internal design of the column, Fractional Entrainment
was found to be 0.014. Since the upper limit for flooding is accepted as 0.1, it is predicted that
there is no overflow in the column. Also, with 168.87 mm liquid total drop, the pressure drop
was found to be 1626.8 Pa. This is so small that it can be neglected. DBP-MAN stream coming
from the absorber entered the distillation column as saturated liquid at 187 degrees and 0.075
bar. According to the minimum reflux ratio obtained with the graphical solution, the reflux ratio
was found to be 0.15. In the MAN-DBP equilibrium graph at 0.15 reflux ratio, the number of
stages was found to be 4 by subtracting the partial reboiler using the McCabe Thiele method.
By setting parameters such as disengagement and tray spacing, the length of the column was
calculated as 7.2 m and its diameter as 1.92 m. The internal design of the column was completed
by calculating the necessary parameters. The procedure followed sequentially ended with the
determination of pressure drop, which is an important parameter in separation column design.
The total pressure drop found as 1021.08 Pa , it is observed that the pressure drop through the
column can be neglected. In addition, the energy value required for the operation of the reboiler
and condenser was calculated as approximately 18 MW and this value was deemed acceptable
for the system.
Figure 10. Production Schema
5. REFERENCES
[1] Cucciniello et al., Maleic anhydride from bio-based 1-butanol and furfural: a life cycle
assessment at the pilot scale, Green Chem., 2023,25, 5922-5935

[2] National Center for Biotechnology Information (2023). PubChem Compound Summary for
CID7923,Maleic anhydride. Retrieved from
[Link]
[3] Production Technologies of Maleic anhydride. PRODUCTION TECHNOLOGIES OF
MALEIC ANHYDRIDE. (n.d.). [Link]
[4] Romero-García, A. G., Prado-Rúbio, O. A., Contreras-Zarazúa, G., Ramírez-Márquez, C.,
& Segovia-Hernández, J. G. (2019). Simultaneous design and controllability optimization for
the reaction zone for furfural bioproduction. In Computer aided chemical engineering (Vol. 46,
pp. 133-138). Elsevier.)

[5] Gmbh, S., & KG, C. (n.d.). ANALYSIS OF ALTERNATIVES.

[6] RASCHIG (2015). Fractination Trays. Retrieved from FractionationTray Technology
Bulletin [Link] ([Link])
[7] Sinnott, R. A. Y. (2014). Chemical engineering design (Vol. 6). Elsevier.

[8] Wankat, P. C. (2012). Separation process engineering. Pearson Education.

[9] Shi, S., Guan, W., Kang, L., & Lee, Y. Y. (2017). Reaction kinetic model of dilute
acidcatalyzed hemicellulose hydrolysis of corn stover under high-solid conditions. Industrial
& Engineering Chemistry Research, 56(39), 10990-10997