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Column Internals Explained

In the recent years, efforts have been made to design structured & random packings for mass
transfer columns more & more effectively. These developments are done to achieve greater
throughputs; lower pressure drops & better mass transfer efficiency. Column internals are also
playing important role for achieving the above targets & hence needs to be designed carefully
from both process & mechanical point of view. After the packed column hydraulics, column
internals needs to be designed. Packing internals include support plates, distributors,
redistributors, and bed-limiters, feed pipes, collector trays & mist eliminators.
a) Support Plate: The primary function of the packing support plate is to serve as a physical
support for the tower packing plus the weight of the liquid holdup. The packing support plate
must pass both the downwardly flowing liquid phase as well as the upwardly flowing gas phase.

Support Plate
For random packings, gas injection type of support plate is used. Gas injection type of support
plate provides the separate passage for liquid & gas. Support grid (made up of bars) is used to
support the structured packing. Support plates have a very high open area for gas & liquid
passage & do not add any significant pressure drop.

b) Bed Limiter: Bed limiters are commonly used with metal or plastic packings. The primary
function of these devices is to prevent expansion of the packed bed as well as to maintain the
bed top surface level. In towers, the packed bed will not fluidize over the entire surface, vapour
surges fluidize random spots on the top of the bed, so that after return to normal operation the
bed top surface is quite irregular. Thus the liquid distribution can be affected adversely by such
an occurrence.

Bed Limiter
Hold-down plates are weighted plates used with ceramic or carbon tower packings. With these
packings, it is especially important to prevent fluidisation of the packed bed top surface. The

hold down plate must rest freely on the top of the packed bed because beds of ceramic & carbon
packings tend to settle during operation. These plates usually act by their own weight to prevent
bed expansion. Weight (kg) of the hold down plates can be calculated by the pressure drop
across the packed bed (kg/m2) multiplied by the column cross sectional area (m2). They weigh
~ 95-120 kg per sq meter (20 lb to 30 lb per sq ft).

c) Collector trays: Whenever there is partial or total draw off in between two packed beds,
collector trays are used. However it has been noted that some packing vendors are always giving
collector trays in between two structured packing beds considering the high turbulence velocity

of liquid in structured packing.

Collector Tray

Since this type of tray frequently maintains a fairly high level of liquid (and consequently a
tremendous weight), special consideration should be given to its design. One consideration is the
placement of the draw nozzle. A flat chimney tray can be used with the nozzle located at tray
floor level, or a portion of the tray floor can be lowered to form a sump and the nozzle located at
the sump floor. Both designs require the same liquid head to force the design flow rate through
the nozzles. Therefore, locating the nozzle in a sump lowers the liquid level on the chimney tray
by an amount equal to the head requirements. This reduces the weight, which the tray must
support, but has little effect on residence time since that portion of the liquid depth
corresponding the head requirements should not be considered as residence time in most cases.

A chimney height of 6 12 is normally adequate for low liquid flow. 12 18 is usual for high
liquid flow if the draw nozzle is located in an inlet sump. All chimneys should have hats located a
sufficient space above the chimney to give a peripheral area of 1.25 times the chimney area. If a
leak-free design is required, the inlet sump should be seal-welded and gasketing used on the
chimney tray floor. A centre sump is preferred over a side sump, as some flow restriction can
occur at very high liquid rates due to the shorter weir lengths of side sumps.

d) Liquid distributor: From a process point of view liquid distributors are the most important
column internal devices. A distributor is required to uniformly distribute liquid at the top of a

packed tower. Liquid distributor must provide sufficient gas passage area to avoid a high
pressure drop or liquid entrainment.

An ideal distributor possesses the following attributes.


Uniform liquid distribution
Resistance to fouling
Proper turndown capability
Low gas pressure drop
Minimum height
Higher cross-mixing capability

Distribution quality: Quantifying the uniformity of liquid distribution is accomplished by


calculating the distribution quality (DQ) of a distributor based on the Moore & Rukovena model.
It relates the liquid load across the column area at the top of packed beds marking circles
proportional to the liquid flow through a particular orifice & then considering the irrigated,
overlapping, & un-irrigated areas of the circles.

An
ideal
liquid
distributor should have a DQ of 100%, but practical considerations restrict the DQ to about 95%

maximum. As per Moore & Rukovena model, a low DQ indicates a high degree of liquid
misdistribution & some portions of the column cross sectional area may be receiving
substantially different volumes of liquid when compared to other portions of the cross sectional
area. As the DQ decreases the number of stages that can be realized from a packed bed
decreases,
thus
decreasing
the
separation
efficiency.
Following guidelines are used for deciding the no. of points per m^2 for mentioned latest type of
packings.

Classification of liquid distributors: Liquid distributors are usually classified into pressure &
gravity
distributors.
Pressure Distributors: This type of distributors provides more open area for vapour flow & tend
to be less expensive, lighter, less robust & require smaller lead up piping than gravity type.
Disadvantages are high operating cost, susceptibility to plugging & corrosion & a relatively
inferior quality of distribution. Pipe arm & Spray type liquid distributors are the examples of
pressure
distributors.
Gravity Distributors: These are further classified as weir type & the orifice type. Both of these
types can handle large liquid flow rates. The weir type is generally one of the least troublesome
distributors, handle large liquid load & has excellent turndown capability. However it can usually
provide only a limited no. of drip points (minimum 30 no. of weirs per m^2), extremely sensitive
to
levelness
&
liquid
surface
agitation.

Orifice distributors are usually of the pan/deck type or of the tunnel (trough) type. An orifice pan
distributor consists of a pan equipped with the circular or rectangular risers for vapour flow &
perforations in the pan for liquid flow. Orifice trough type distributors consist of parallel troughs
with perforations in the trough floors for liquid. Vapour rises in the space between the troughs.

The troughs are often interconnected by cross channels (called as parting box) that equalize
liquid levels in different troughs. These trough type liquid distributors provide more open area
for
vapour
flow
&
are
easier
to
support.
Orifice type may suffer from corrosion & plugging, but it can be designed with a large no. of drip
points to provide superior liquid distribution. Orifices are sized to maintain a minimum liquid
head at desired turndown conditions & to avoid distributor overflow during turn up condition.
Very
small
orifice
diameters
(<4mm)
are
avoided
to
prevent
fouling.
Selection of a liquid distributor: Specific liquid distributor for particular service is chosen by
considering the tower diameter, flow rate, turndown ratio, available height (in case of revamp) &
fouling
resistance.
Please refer the packing vendor catalogue for more details on liquid distributor models/types.

Following types of liquid distributors to be used in applications that are less demanding on
packing performance, such as heat transfer applications, absorption & stripping services.

Following are the some important design points of liquid distributor to be checked before
finalising
its
design.

Maximum & Minimum head: Maximum liquid head is the actual liquid head on the deck of the
distributor at turn up condition. The overall height (riser/trough) of the liquid distributor shall be
higher than this head by following formula.
Riser (Trough) height = {(Maximum head) 1.10 + 25} mm

It is always required to estimate the minimum head on the distributor at turndown condition. At
low liquid head there are chances of liquid vortexing & entrainment due to insufficient resistance
to orifices. Also if minimum heads are fallen short of, considerable misdistribution can occur.
Hence minimum liquid head on the distributor shall be around 35mm. It is always recommended
to use punched orifices in the direction of liquid flow instead of drilled orifices. Pressure Drop &
open area requirement for vapour: Liquid distributor must provide sufficient gas passage area as
per gas load to avoid a high-pressure drop or liquid entrainment. In case of very low open area
required for gas, a minimum of 12% open area is used. Pressure drop of liquid distributor shall
not exceed a value of 20mm WC. However it will depend upon gas load, liquid load & a particular
service.

% Flow variation: For low liquid loads & small column diameters, flow variation will increase
due to low liquid head. Flow variation is a strong function of mechanical points such as plate
levelness, distributor deck flatness as etc. Excessive flow variation will cause liquid
misdistribution on below packed bed, entrainment & hence needs to be minimised. Maximum of
12% flow variation is allowed for liquid distributor or redistributor.

Liquid redistributors: One of the main functions of a liquid redistributor is to remix the liquid
phase so as to bring the entire liquid flow onto the next lower bed at a more uniform
composition.

Deck type Liquid Redistributor


If liquid tight pans or boxes are used for a redistributor, gas riser covers & wall wipers must be
used. Whenever the liquid falls directly onto a deck type redistributor, the gas risers must be
provided with covers to prevent liquid from raining into this area of high vapour velocity. All
covers should have located a sufficient space above the risers to give a peripheral area of 1.25
times the
riser area.

Feed pipes: Process demand various feed to be introduced into the column at various locations.
The feed being introduced could be liquid only, liquid & vapour above a packed & vapour only
below a packed bed.

Liquid Feed Pipe


For liquid only feed devices, liquid is fed into the distributor via feed pipe & feed pipe design
depends upon distributor type, liquid flow rate, its operating range as etc. Each feed pipe meters
flow to one or more appropriate feed areas, matching the hydraulic requirements of the
distributor. Excessive turbulence, hydraulic jump & horizontal flow velocity in the liquid
distributor are eliminated in a feed pipe design. A submerged feed is recommended in all cases
in large towers with low or high flow rates. Submerging the feed maintains uniform liquid
temperature & reduces hydraulic jump of liquid in the distributor. Liquid feed pipes are designed
with a velocity of 1m/s to max 3.5m/s.

For liquid & vapour feed devices above a distributor, separating the two phases is of primary
response. The primary design factors are the feed flow rate, desired turndown, column height
needed for flashing vapour distribution & mixing of the inlet liquid with overhead liquid. Flashing
feed devices such as flash feed gallery, flash feed chamber or flashing feed pipe are used based

on the composition of vapour in liquid.

Flashing feed pipe


Vapour only feed devices are required for reboiler returns or to introduce vapour feed or to
introduce vapour or gaseous feed. If the column offers adequate pressure drop (> 4-5 mm of
WC per m of packed bed height), the packings themselves tend to mix the vapours. In the event
of very low pressure drop across the column (i.e. < 4-5); vapour channelling can become a
serious problem. The kinetic energy of the vapour (F factor) & its composition at the point of
introduction are the two main factors considered in designing the vapour entry device. Vapour or
gas feed pipes are designed with a velocity of max 20m/s.

ii) Vapour composition: When the vapour is introduced between packed beds, consider the
degree of mixing of the inlet vapour with rising vapour. If a gross mismatch of composition &/or
temperature exists, mixing of the two vapour optimizes packing performance above.
g) Mist Eliminator: In every process involving contact between liquid and flowing gas, tiny mist
droplets are carried away with the gas. This phenomenon is called entrainment. Mist eliminator
provides a large surface area in a small volume to collect liquid without substantially impeding
gas flow. It work on the principles of inertia whereby small droplets of liquid entrained in
vapours are coalesced into large drops & fall downward due to gravity.

Mist eliminators can be either demister pads (knitted or coknitted wire mesh for fine mist) or vane type separators.

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