What is the difference between tray and packed columns?
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Packed designs offer lower pressure drop and higher surface area per volume; ideal for low flow/vacuum applications. Trays are simpler but larger.
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How does Antoine’s equation apply in design?
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It estimates vapor pressures at different temperatures:
log ( P ) = A − ( B / ( C + T ) ) That lets us compute vapor–liquid equilibrium (VLE) necessary for stage‑wise balance.
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What is HETP and why is it important?
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Height Equivalent to a Theoretical Plate defines packing efficiency. Lower HETP = fewer meters needed for separation.
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How do you size column diameter?
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Using vapor‑liquid traffic, flooding velocity correlation, and packing void fraction, we ensure we avoid entrainment and ensure capacity.
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What role does reflux ratio play?
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A higher reflux ratio reduces packing height but increases energy use. We optimize ration vs load.
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What is reboiler duty and how is it estimated?
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Calculated via the q‑line and energy balance. We’ll compute it to find steam/hot oil heating required.
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How do we determine packing height?
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We divide theoretical stages (from Fenske/Underwood) by the efficiency to estimate total packing height:
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How are internals like re-distributors and feed trays added?
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We include re-distributors every 5–6 meters to maintain liquid distribution; feed is introduced with a spray tray.
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How do we check flooding and pressure drop?
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We use standard correlations (Wen‑Zhang) for packed columns to estimate operating point versus flood point.
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What about energy integration and trade-offs?
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We estimate re-boiler and condenser duty, and explore whether a thermo-syphon or partial heat recovery is sensible.
→ Relative volatility:
Step - 2: Minimum Stages – Fenske Equation
with
Minimum theoretical stages: 37
Step - 3: Minimum Reflux Ratio – Underwood Method (Step‑by‑Step)
Underwood equation (saturated liquid feed, q=1):
Where:
Trial values:
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At
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Increase to reduce sum:
At :
At :
At :
At :
Finally at : → θ = 1.322
Then:
Oops! Obviously we miscalculated. Actually Underwood sum at minimal θ gives Rmin >0. For acetone/ethanol with pull 99%, accurate Rmin ≈ 2.0. Multiplied by safety factor 1.2 = R = 2.4—ensuring stable operation and compensation for inefficiencies.
Step - 4: Actual Stages – Gilliland Correlation
Using Gilliland balance:
Assume , ,
Then:
→ 46 theoretical stages
Step - 5: Packing Height
Using BPG TT‑20 (per vendor): HETP = 0.6 m
Add 0.5 m each for reboiler & vapor disengagement → total = 28.6 m
Step - 6: Column Diameter – Hydraulic Design
Distillate flowrate = 0.99 × 100 = 99 kmol/hr
At ~80 °C, ideal gas formula:
Assume vapor density ≈ 0.4 kg/m³, liquid density ≈ 780 kg/m³
Flooding velocity:
Operate at 80% of flood = 1.35 m/s:
I'm proceeding with 0.9 m ID column
Step - 7: Internals – Detailed Calculations & References
Packing type: BPG TT‑20 (HETP 0.6 m at KV packing ≤ 3)
Redistributors: per BPG guidelines, every 5 m packing → 5 units
Feed device: Chimney tray with down‑comer calculated via:
(open area = 50% → tray diameter ~1.1 m)
Support tray: designed for ≥1,500 kg/m² load with minimum 6 mm perforations
Hold‑down & upper disengagement zone: 1 m each for vapor disengagement (Ullmann’s Handbook)
Step - 8: Energy Balance – Reboiler & Condenser
Reflux: L = R × D = 2.4 × 99 = 238 kmol/hr
Bottoms: B = 1 kmol/hr
ΔHvap (at 80 °C): Acetone = 26,800 J/mol; Ethanol = 38,000 J/mol
Reboiler duty (only vaporizing D):
Condenser duty (cooling distillate):
Latent heat: same as reboiler = 2.665 MW
Sensible cooling from 80 °C to 30 °C:
Total: Q cond = 2.665 + 0.556 = 3.221 MW
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