Process and Equipment Department

Contents
A. INTRODUCTION ................................................................................................................................1
1. General information.........................................................................................................................1
1.1. Definition ...................................................................................................................................1
1.2. Method .......................................................................................................................................1
1.3. Technological systems in use .....................................................................................................2
2. Materials introduction .....................................................................................................................3
2.1. Ethanol .......................................................................................................................................3
2.2. Water ..........................................................................................................................................5
2.3. Mixture of Ethanol-Water ..........................................................................................................5
B. TECHNOLOGICAL PROCESS ........................................................................................................7
1. Project ...............................................................................................................................................7
2. Project duty (the requirements and initial data) ...........................................................................7
3. Technological process and principle explanation ..........................................................................7
3.1. Technological process ................................................................................................................7
3.2. Principle explanation ..................................................................................................................7
3.3. Proposing....................................................................................................................................8
C. DESIGN AND CALCULATION ........................................................................................................9
1. Mass and energy balance .................................................................................................................9
2. Designing the main equipment ......................................................................................................16
2.1. Height of column ......................................................................................................................20
2.2. Length of volume ........................................................................ Error! Bookmark not defined.
3. Mechanical calculation for the main equipment .........................................................................24
3.1. Thickness of column ................................................................................................................24
3.2. Material of column ...................................................................................................................24
3.3. Flanges of column ....................................................................................................................24
4. Calculation and choosing subsidiary equipments .......................................................................24
4.1. Calculation ...............................................................................................................................24
4.2. Investment cost .........................................................................................................................24
D. CONCLUSION ...............................................................................................................................26
1. Output result...............................................................................................................................26
2. Advantages ..................................................................................................................................26
3. Disadvantages .............................................................................................................................26

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REFERENCES ...........................................................................................................................................27

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A. INTRODUCTION
1. General information
1.1. Definition
Distillation is the process of separating the components or substances from a
liquid mixture by selective boiling and condensation. Distillation may result in essentially
complete separation (nearly pure components), or it may be a partial separation that
increases the concentration of selected components of the mixture. In either case the
process exploits differences in the volatility of the mixture's components. In industrial
chemistry, distillation is a unit operation of practically universal importance, but it is a
physical separation process and not a chemical reaction.
1.2. Method
Laboratory scale distillation:
 Simple distillation: the vapor is immediately channeled into a condenser.
Consequently, the distillate is not pure but rather its composition is identical to the
composition of the vapors at the given temperature and pressure. That concentration
follows Raoult's law.
 Fractional distillation: For many cases, the boiling points of the components in the
mixture will be sufficiently close that Raoult's law must be taken into consideration.
Therefore, fractional distillation must be used in order to separate the components by
repeated vaporization-condensation cycles within a packed fractionating column. This
separation, by successive distillations, is also referred to as rectification.
 Steam distillation: is a method for distilling compounds which are heat-sensitive.
The temperature of the steam is easier to control than the surface of a heating element,
and allows a high rate of heat transfer without heating at a very high temperature. This
process involves bubbling steam through a heated mixture of the raw material. By
Raoult's law, some of the target compound will vaporize (in accordance with its partial
pressure). The vapor mixture is cooled and condensed, usually yielding a layer of oil and
a layer of water.

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1.3. Technological systems in use

 Although there is a lot of distillation equipment, all of them need to create
sufficient interfacial area.
 Tray column: is a cylindrical distillation equipment which has different tray
structure inside. In tray, vapor and liquid phase is contacted. Tray column can be:
- Sieve tray column: tray has many holes whose diameter is approximately 3-12mm,
total area of holes is accounted for 8-15% cross-sectional area of column.
- Bubble cap tray column: A bubble cap tray has riser or chimney fitted over each
hole, and a cap that covers the riser. The cap is mounted so that there is a space between
riser and cap to allow the passage of vapor. Vapor rises through the chimney and is
directed downward by the cap, finally discharging through slots in the cap, and finally
bubbling through the liquid on the tray.
- Packed column: is a cylindrical column which has packing inside to enhance phase
contact. The packaging can be arrange randomly or structured packaging.

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Table 1. Comparison of different types of distillation columns

Sieve tray column Bubble cap column Packed column

Advantage  Simple design  Steady, high mass  Simple design

 Low resistance transfer efficiency  Low resistance
 Easy cleaning  Less energy
 Less metal consumption =>
fabrication less tray
Disadvantage  High installation  Complex design  Low efficiency,
requirement  High resistance unsteady operation
 The diameter of  Hard to be scaled
the tower is so up to industry
large that it is  Difficult to control
distributed distillation process
unevenly on the through column
tray area

2. Materials introduction
2.1. Ethanol
The chemical compound ethanol, also known as ethyl alcohol or grain alcohol, is the
bio-alcohol found in alcoholic beverages. Ethanol's chemical formula is C2H5OH. MW =
46 Carbon unit.
 Physical properties and thermodynamic index
- Pure ethanol is a flammable, colorless liquid.
- Boiling point at 760 mmHg: 78.5° C
- Density: 0.7893 g/cm3 (at 20 °C)
 Chemical properties
All the chemical reactions occur at hydroxyl group (-OH) of ethanol which perform its
chemical properties.

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+ Reaction of Hydrogen in Hydroxyl group

CH3-CH2-OH ↔ CH3-CH2-O- + H+
Dissociation constant of ethanol: 𝐾CH3−CH2−OH = 10-18  Ethanol is a neutral
substance.
Reacting with basic metal: CH3-CH2-OH + HO-SO3-H ↔ CH3-CH2O-SO3-H + H2O
+ Reaction occurs on the Hydroxyl group
Reacting with acid: CH3-CH2-OH + HX ↔ CH3-CH2-X + H2O
Reacting with Tricloride phosphate:
CH3-CH2-OH + PCl3 ↔ CH3-CH2-Cl + POCl + HCl
𝐴𝑙2 𝑂3 ,𝑡 𝑜
Reacting with Ammonia: CH3-CH2-OH + NH3 ↔ C2H5-NH3 + H2O
Reaction of esterification and dehydro:
𝐻2 𝑆𝑂4 ,>150𝑜 𝐶
2CH3-CH2-OH ↔ (CH3-CH2)2O + H2O
𝐻2 𝑆𝑂4 ,>150𝑜 𝐶
2CH3-CH2-OH ↔ CH2=CH2 + H2O

𝐶𝑢,200−300𝑜 𝐶
Hydrogen and oxidization reaction: CH3-CH2-OH ↔ CH3-CHO + H2O

 Application: Ethanol is aplied in more areas than Methanol. Because it can readily
dissolve in water and other organic compounds, ethanol also is an ingredient in a range of
products, from personal care and beauty products to paints and varnishes to fuel.
 Manufacturing methods: There are various ways to produce ethanol, such as:
hydrating Ethylene with H2SO4 as a catalyst, hydrolysing halogen derivatives with ester
of ethanol when heating with water and base as a catalyst, hydrating acetic aldehyde,….
In industry, ethanol is produced from the starch fermentation. In recent years, ethanol
production technology mainly uses yeast Saccharonyses cerevisiae for the fermentation:
C6H6O6 → C2H5OH + 2CO2 + 28 kcal
With: 95% input materials are converted into Ethanol and CO2
5% input materials are converted into subsidiary products (succinic acid, fuel,
methylic and other organic compounds…).

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2.2. Water
Water is the transparent, tasteless, odorless, and nearly colorless chemical
substance that is the main constituent of Earth's streams, lakes, and oceans, and
the fluids of most living organisms, and that is vital for all known forms of life, even
though it provides no calories or organic nutrients. Molecular formula: H2O. MW = 18
Carbon unit.
Water covers 71% of the Earth's surface, mostly in seas and oceans.

Water is an excellent solvent for a wide variety of chemical substances; as such it is

widely used in industrial processes, and in cooking and washing.

 Physical properties and thermodynamic index:

- Transparent, tasteless, odorless, and nearly colorless chemical substance.
- Boiling point: 100℃
- Specific gravity: 1 g/ml
2.3. Mixture of Ethanol-Water

Table 2. Liquid (x) – vapor (y) composition and boiling point of mixture of ethanol –
water at 760 mmHg

x(% 0 5 10 20 30 40 50 60 70 80 90 100
mole)

y(% 0 33.2 44.2 53.1 57.6 61.4 65.4 69.9 75.3 81.8 89.8 100
mole)

t(℃) 100 90.5 86.5 83.2 81.7 80.8 80 79.4 79 78.6 78.4 78.4

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100
95
90 Ethanol - Water System
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100

Figure 1. Ethanol – Water phase equilibrium line

100

T-x,y chart
95

90
T (oC)

85

80

75

70
0 20 40 60 80 100
x,y molar portion

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B. TECHNOLOGICAL PROCESS
1. Project
- Designing a distillation tower for EtOH/Water mixture with the
input flowrate of 300kg/h.
2. Project duty (the requirements and initial data)
- Input fficiency = 300kg/h
- Input concentration: 𝑥̅𝐹 = 15 wt %
- Output concentration: 𝑥̅𝐷 =70 wt %
- Bottom concentration: 𝑥̅𝐵 = 0.05 wt %
3. Technological process and principle explanation
Ethanol is an infinite solute in water. The boiling point of Ethanol at 760 mmHg is
78.37oC, while Water’s boiling temperature is 100oC. That big difference makes
distillation the most efficient method to collect ethanol with high purity.
Concentration method cannot be used as the components are volitile. Neither
absorption nor extraction method is utilitarian because it will make the process more
complex and the separation will be harder to proceed completely.

3.1. Technological process

3.2. Principle explanation

Mixture of Ethanol-H2O has concentration of 15 wt % as ethanol, temperature about

28oC in the containing tank (1). Then it is pumped into the heater (2) and heated until
71oC before entering distillation tower at the feed stage.

On the feeding stage, the aqueous mixture is mixed with the liquid from the rectifying
part. In the tower, vapour goes from bottom to up and meet the liquid phase moving
downward leading to the interconnection and exchanging phases. In the stripping part,
the aqueous phase retains less volatile component for the vapour phase at the bottom
vapourizes it. The temperature decreases gradually from bottom to upward, thus water
will condense, and the mixture collected at the top has the highest ethanol amount (70 wt
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%). This steam flows to the condenser (9) and be completely condensed. An amount of
liquid will flow to the top cooler to cool the top product till 35oC and retained in the top
product tank, the rest one will be refluxed back to the tower.

3.3. Proposing

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C. DESIGN AND CALCULATION

 Equipment requirement:
- Working pressure: P = 1 atm
- Distillation tower: bubbles cap
 Initial data
- Input mixture:
o Ethanol: C2H5OH, Tb = 78.37oC
o Water: H2O, Tb = 100oC
- Feed flowrate: 𝐺𝐹 = 300 (𝑘𝑔/ℎ)
- Input concentration: 𝑥̅𝐹 = 15 𝑤𝑡%
- Distillation concentration: 𝑥̅𝐷 = 70 𝑤𝑡%
- Bottom concentration: 𝑥̅𝐵 = 0.5 wt %
1. Mass and energy balance
1.1. Mass balance
Converting from mass flowrate to molar flowrate for feed
o MEthanol = 46 molecular mass of Ethanol
o MWater = 18 molecular mass of Water

𝐺𝐹 ×𝑥̅𝐹 𝐺𝐹 ×(1−𝑥̅𝐹 ) 300×0.15 300×(1−0.15)

𝐹= + = + = 15.14 (kmol/h)
MEthanol MWater 46 18

Converting from mass portion to molar portion

̅𝐹
𝑥 0.15
𝑀𝐸𝑡ℎ𝑎𝑛𝑜𝑙 46
𝑥𝐹 = ̅𝐹
𝑥 ̅𝐹
1−𝑥 = 0.15 1−0.15 = 0.065 (mol/mol)
+ +
𝑀𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑀𝑊𝑎𝑡𝑒𝑟 46 18

̅𝐷
𝑥 0.7
𝑀𝐸𝑡ℎ𝑎𝑛𝑜𝑙 46
𝑥𝐷 = ̅𝐷
𝑥 ̅𝐷
1−𝑥 = 0.7 1−0.7 = 0.48 (mol/mol)
+ +
𝑀𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑀𝑊𝑎𝑡𝑒𝑟 46 18

̅𝐵
𝑥 0.005
𝑀𝐸𝑡ℎ𝑎𝑛𝑜𝑙 46
𝑥𝐵 = 𝑥̅𝐵 ̅𝐵
1−𝑥 = 0.005 1−0.005 ≈ 1.96×10-3 (mol/mol)
+ +
𝑀𝐸𝑡ℎ𝑎𝑛𝑜𝑙 𝑀𝑊𝑎𝑡𝑒𝑟 46 18

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𝐹 =𝐵+𝐷 15.14 = 𝐵 + 𝐷
{  {
𝐹 × 𝑥̅𝐹 = 𝐵 × 𝑥̅𝐵 + 𝐷 × 𝑥̅𝐷 15.14 × 0.065 = 𝐵 × 1.96 × 10−3 + 𝐷 × 0.48
𝑘𝑚𝑜𝑙 𝑘𝑔
𝐵 ≈ 13.14 ( ) = 237.24 ( )
ℎ ℎ
{ 𝑘𝑚𝑜𝑙 𝑘𝑔
𝐷 ≈ 2.00 ( ) = 62.73 ( )
ℎ ℎ

1.2. Reflux ratio

1.2.1. Minimum reflux ratio

According to Table Vapour (x) – Liquid (y) phase and boiling temperature of EtOH/H2O
system at 760 mmHg (Table 2). Using leveling method, we have:

𝑥̅𝐹 = 0.065 (mol/mol)  𝑦𝐹∗ = 0.375 (mol/mol)

𝑥𝐷 −𝑦𝐹∗ 0.48−0.365
Minimum reflux ratio: 𝑅𝑚𝑖𝑛 = = = 0.383
𝑦𝐹∗ − 𝑥𝐹 0.365− 0.065

1.2.2. The operation reflux ratio

R = 1.3 × 𝑅𝑚𝑖𝑛 + 0.3 = 0.798

𝑥𝐷 𝑅 0.48 0.798
Rectifying operation line: 𝑦𝑛+1 = + × 𝑥𝑛 = + × 𝑥𝑛
𝑅+1 𝑅+1 0.798+1 0.798+1

 𝑦𝑛+1 = 0.267 + 0.444 × 𝑥𝑛

𝑅+𝑓 𝑓−1
Stripping line: 𝑦 = ×𝑥− × 𝑥𝑊
𝑅+1 𝑅+1
𝐹 15.14
With: 𝑓 = = = 7.57
𝐷 2
0.798+7.57 7.57−1
𝑦 = ×𝑥− × 0.002 = 4.654𝑥 − 7.31 × 10−3
0.798+1 0.798+1

1.3. Theoritical stages

To determin the number of theoritical stages, we need to determin three lines:
o Rectifying operation line: 𝑦𝑛+1 =0.267 + 0.444 × 𝑥𝑛
o Feed line
o Stripping line crossing (𝑥𝐵 , 𝑥𝐵 = 𝑦𝐵 ) and the intersection point of the feed line
and the rectifying line

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0.9

0.8

0.7

0.6

0.5

0.4

0.3

0.2

0.1

0
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Figure 2. Number of theoritical stages

1.4. Practical stages
1.4.1. Average efficiency of tower determination

To determine the practical stages, we need to determine the average efficiency of tower.

ƞ1 + ƞ2 + ƞ3 +. . +ƞ𝑛
ƞ𝑎𝑣𝑒 =
𝑛
 ƞ1, ƞ3, ƞ3,…, ƞn: efficiency at different stage and concentration.
 n: number of stage efficiency
 ƞave is a function of the relative volatility of mixture and the kinetic viscosity of the
liquid: ƞave = f(α,μ)

𝑦∗ 1−𝑥
Volatility of distillation formula: 𝛼 = ×
1−𝑦 ∗ 𝑥

 y*, x are the equilibrium concentration of the volatile component in vapour and
liquidd phases respectively.

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1 𝑦𝑖
Viscosity of the mixture: =∑
𝜇 𝜇𝑖

 μ: the mixture viscosity; yi: molar portion of volatile component in the mixture; μ:
viscosity of the component in the mixture.

Table 3. Determination of average efficiency and practical number of stage

No. of tray 1 2 3 4
xethanol, mol/mol 0.48 0.136 0.049 0.02
T, oC 80.16 85.312 90.58 96.2
x, wt% 0.7023 0.2869 0.1164 0.0496
ρEtOH, kg/m3 734.848 729.954 724.949 719.61
ρW, kg/m3 971.888 968.282 964.594 960.66
ρmix, kg/m 3
886.736 785.417 746.538 728.678
x (volume
0.8474 0.3087 0.1198 0.0502
fraction)
y*, mol/mol 0.48 0.327 0.221 0.138
μEthanol, cP 0.4341 0.4061 0.3773 0.3467
μWater, cP 0.3558 0.3343 0.3145 0.2956
μMix, cP 0.4200 0.3536 0.3209 0.2978
αF 1.000 3.087 5.506 7.845
αF μMix 0.420 1.091 1.767 2.336
ƞ, % 62.5 48.0 42.75 40.25

∑ ƞ = 193.5%

ƞ𝑎𝑣𝑒 = 48.375

 μEthanol, μWater, cP (Table 9 and 6)

 ρEtOH, ρW, kg/m3 (Table I.2, page 9)
 T, oC (Table IX.2a, page 148)

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1.4.2. Practical stages determination

𝑛𝑡ℎ 4
Therefore, the number of practical stages: 𝑛𝑝 = = = 8.269 ≈ 9 𝑠𝑡𝑎𝑔𝑒𝑠
ƞ𝑎𝑣𝑒𝑟 0.48375

Rectifying stages: 4 stages

Stripping stages: 4 stages
Feed stage: 1 stage (6th stage).
1.5. Energy balance
1.5.2. Energy balance for the feed heater

𝑄𝐷1 + 𝐷𝑓 = 𝑄𝐹 + 𝑄𝐶1 + 𝑄𝐿1 , J/h

Energy from the inlet hot steam, QH1:

𝑄𝐻1 = 𝐷1 1 = 𝐷1 (𝑟1 + 𝜃1 𝐶1 ), J/h

At: P = 1 atm.
 D1 - vapour steam flowrate, kg/h;
 r1 – latent heat, r1 = 2264 kJ/kg; (Bảng 49)
 1 – heat quantity of hot steam, kJ/kg;

 1 – temperature of condensed water, 1 = 99.61oC; (Bảng 42)

 C1 – specific heat of condensed water, C1 = 4.2282 J/kg.C.

Heat energy from the inlet feed stream, Qf:

𝑄𝑓 = 𝐹. 𝐶𝑓 . 𝑡𝑓 = 29497.5 kJ/h

 F – feed flowrate, F = 300 kg/h;

 Cf – heat capacity of the feed mixture, with:
𝐶𝐸𝑡𝑂𝐻 = 2.5375 𝑘𝐽/𝑘𝑔. 𝐶
{ → 𝐶𝑓 = 𝑥̅𝐹 × 𝐶𝐸𝑡𝑂𝐻 + (1 − 𝑥̅𝐹 ) × 𝐶𝑊𝑎𝑡𝑒𝑟 = 3.933 𝑘𝐽/𝑘𝑔𝐶
𝐶𝑊𝑎𝑡𝑒𝑟 = 4.179𝑘𝐽/𝑘𝑔. 𝐶
 tf – inlet temperature of feed, tf = 25 oC.

Heat energy lost by feed outlet stream, QF:

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𝑄𝐹 = 𝐹. 𝐶𝐹 . 𝑡𝐹 = 109335.348 kJ/h

 CF – specific heat capacity of feed at the outlet, with;

𝐶𝐸𝑡𝑂𝐻 = 3.360 𝑘𝐽/𝑘𝑔. 𝐶
{ → 𝐶𝑓 = 𝑥̅𝐹 × 𝐶𝐸𝑡𝑂𝐻 + (1 − 𝑥̅𝐹 ) × 𝐶𝑊𝑎𝑡𝑒𝑟 = 4.0812 𝑘𝐽/𝑘𝑔𝐶
𝐶𝑊𝑎𝑡𝑒𝑟 = 4.2086𝑘𝐽/𝑘𝑔. 𝐶

 tF –temperature of feed after going through the heater, tF = 89.3 oC.

Heat energy lost by the condensed water QC1

𝑄𝐶1 = 𝐺𝐶1 𝐶1 𝜃1 = 𝐷1 𝐶1 𝜃1 = 15634.71 kJ/h

 GC1 = D1 – flowrate of the condensed water by the hot steam, kg/h.

Energy lost into the surrounding environment equally to 5% consumed heat

𝑄𝐿1 = 0.05𝐷1 𝑟1 = 4202.2104 kJ/h
The amount of the necessary vapour to heat the feed to the boiling temperature:
𝑄𝐹 −𝑄𝑓 +𝑄𝐶1 +𝑄𝐿1 𝐹(𝐶𝐹 .𝑡𝐹 −𝐶𝑓 .𝑡𝑓 )
𝐷1 = = = 37.122, 𝑘𝑔/ℎ
1 0.95𝑟1

1.5.3. Energy balance calculation for condenser of the top product

𝑃(𝑅 + 1)𝑟 = 𝐺𝑛 𝐶𝑛 (𝑡2 − 𝑡1 ), 𝑘𝑔/ℎ

The consumed amount of cold water Gn

𝐷 (𝑅 + 1)𝑟
𝐺𝑛 = = 4355.344 𝑘𝑔/ℎ
𝐶𝑛 (𝑡2 − 𝑡1 )

 D is the top product flowrate, D=62.73 kg/h;

𝑡1 +𝑡2
 Cn – specific heat capacity of cold water at = 32.5℃, Cn = 4.177 kJ/kgC;
2

 r – Latent heat of water at 32.5oC, r = 2419.431 kJ/kg;

 t2, t1 – Outlet and inlet of condensed water, t1 = 25oC, t2 = 40oC;
 R is the reflux ratio, R=0.798.
1.5.4. Energy balance of the distillation tower
The total amount of the inlet energy is equal to the total outlet:

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𝑄𝐷2 + 𝑄𝐹 + 𝑄𝑅 = 𝑄𝑊 + 𝑄𝑦 + 𝑄𝑥𝑞 + 𝑄𝑛𝑔2 , kJ/h

Heat energy from the inlet hot steam QD2:

𝑄𝐷2 = 𝐷2 2 = 𝐷2 (𝑟2 + 𝜃2 𝐶2 ), kJ/h

Choose: Steam flows in at P = 1 atm

 D2 – The necessary amount of the steam to heat the solution at the bottom, kg/h;
 r2 – Latent heat, J/h; r2 = 2264 kJ/kg;
 2 – Temperature, 2 =99.1 oC,

 C2 - Specific heat capacity of condensed water, C2 = 4.2282 kJ/kgC.

Heat energy from the reflux stream QR:

𝑄𝑅 = 𝐺𝑅 . 𝐶𝑅 . 𝑡𝑅 = 14095.916 kJ/h

 Gr – reflux stream flowrate: 𝐺𝑅 = 𝐷. 𝑅 = 50.059 kg/h

Heat energy lost by the out steam at the top of the tower Qy:
𝑄𝑦 = 𝐷 (1 + 𝑅)𝑑 = 155307.1127 kJ/h

 D – latent heat of the steam at the top, J/kg;

𝑑 = 1 𝛼1 + 2 𝛼2 = 1376.976 𝑘𝐽/𝑘𝑔

 1, 2 – Specific heat quantity of the component 1 and 2 at top, with:

𝜆1 = 𝑟𝐸𝑡𝑂𝐻 + 𝐶𝐸𝑡𝑂𝐻 𝜃𝐷 = 1104.4396 𝑘𝐽/𝑘𝑔
 {
𝜆2 = 𝑟𝑊𝑎𝑡𝑒𝑟 + 𝐶𝑊𝑎𝑡𝑒𝑟 𝜃𝐷 = 2644.194 𝑘𝐽/𝑘𝑔
 rEtOH , rWater, CEtOH, CWater at D = 80.16oC;
 α1, α2 – mass portion of components 1 and 2 in vapour at top of tower.

Heat energy lost by the outlet bottom product QW:

𝑄𝑊 = 𝑊. 𝐶𝑊 . 𝑡𝑊 = 99862.465 kJ/h

 W – Bottom product flowrate, W = 237.24 kg/h;

 Cw – specific heat capacity of the bottom product, Cw = 4.2254 kJ/kgC, with:

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 CEtOH = 3.5143 kJ/kgC,

 CWater = 4.229 kJ/kgC.
 tw – temperature of the bottom product, tw = 99.62 oC.

Heat energy brought out by the condensed water Qc2:

𝑄𝐶2 = 𝐺𝐶2 . 𝐶2 . 𝜃2 = 25664.981 kJ/h

 Gngt = D2 – the amount of the condensed water, kg/h;

 2, C2 – specific heat capacity J/kgC, and temperature of the condensed water, oC.

Heat loss into the surrounding environment Qxq2 takes over 5% heat consumed at
bottom:

′
𝑄𝑥𝑞2 = 0.05𝐷2 𝑟2 = 6933.591 kJ/h
Therefore, the necessary amount of the steam to boil the mixture at the bottom of the
tower:

𝑄𝑦 + 𝑄𝑊 − 𝑄𝐹 − 𝑄𝑅
𝐷1 = = 61.2508 𝑘𝑔/ℎ
0.95𝑟2
2. Designing the main equipment
2.1. Diameter of column

𝑔𝑡𝑏
𝐷 = 0.0188√
(𝜌𝑦 𝜔𝑦 )𝑡𝑏

 ωytb – the average velocity of vapor in tower, m/s;

 gtb – the average flowrate of vapor in tower, kg/h;
 (ρyωy)tb – the average velocity of vapor in tower, kg/m2.s.
2.1.1. Diameter of rectifying section
It can be approximately calculated by the average of the total amount of the outlet vapor
on the top stage and the inlet vapour at the bottom stage.
𝑔𝐷 +𝑔1 112.789+83.708
𝑔𝑎 = = = 98.248 𝑘𝑔/ℎ
2 2

The amount of outlet vapor at the top gD

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𝑘𝑔
𝑔𝐷 = 𝐷 × (𝑅 + 1) = 112.789( )
ℎ
 D – The bottom product, D = 62.73 kg/h;
 R – Reflux ratio, R = 0.798.
The amount of inlet vapor at rectifying section

𝑔1 = 𝐺1 + 𝐺𝑃 𝐺1 = 20.978 𝑘𝑔/ℎ
{𝑔1 𝑦̅1 = 𝐺1 𝑥̅1 + 𝐺𝑃 𝑥̅𝑃 ↔ { 𝑔1 = 83.708𝑘𝑔/ℎ
𝑔1 𝑟1 = 𝑔đ 𝑟đ 𝑦̅1 = 0.561% → 𝑦1 = 0.333 𝑚𝑜𝑙/𝑚𝑜𝑙

 𝑦̅1 – mole fraction of vapor at the first stage of rectifying section;

 x1= xF = 0.065  𝑥̅1 = 𝑥̅𝐹 = 0.15%;
 𝑥̅𝑃 = 𝑥̅𝐷 = 0.7%;
 G1 – The amount of liquid on the first stage of rectifying section, kg/h;
 r1 – latent heat of the inlet mixture vapor at the first stage in rectifying section,
kJ/kg.
𝑟1 = 𝑟𝐸𝑡𝑂𝐻 𝑦̅1 + (1 − 𝑦̅1 )𝑟𝑊 𝑟 = 1489.879 𝑘𝐽/𝑘𝑔
{ ↔{1
𝑟𝐷 = 𝑟𝐸𝑡𝑂𝐻 𝑦̅𝐷 + (1 − 𝑦̅𝐷 )𝑟𝑊 𝑟đ = 1104.304 𝑘𝐽/𝑘𝑔

The average density of vapor phase:

𝑦1 + 𝑦𝐷 0.333 + 0.646 𝑚𝑜𝑙
𝑦𝑎,𝐸𝑡𝑂𝐻 = = = 0.49
2 2 𝑚𝑜𝑙
 𝑇 = 86.573 oC
[𝑦𝑎,𝐸𝑡𝑂𝐻 𝑀𝐸𝑡𝑂𝐻 + (1 − 𝑦𝑎,𝐸𝑡𝑂𝐻 )𝑀𝑊 ]273
𝜌𝑦𝑎 = = 1.082 𝑘𝑔/𝑚3
22.4 × 𝑇
 MEtOH, MW – molecular weight of Ethanol and Water;
 T – average operation temperature of rectifying section, T = 359.573K;
𝑚𝑜𝑙
 𝑦𝑎,𝐸𝑡𝑂𝐻 - mole fraction concentration of Ethanol, 𝑦𝑎,𝐸𝑡𝑂𝐻 = 0.49
𝑚𝑜𝑙

The average density of aqueous phase:

𝑥1 + 𝑥𝑅 0.065 + 0.48
𝑥𝑎,𝐸𝑡𝑂𝐻 = = = 0.2725 → 𝑥̅𝑎,𝐸𝑡𝑂𝐻 = 0.489 %
2 2
 𝑡𝑥̅𝑎 = 82.1125℃

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𝑥̅𝑎,𝐸𝑡𝑂𝐻 1 − 𝑥̅𝑎,𝐸𝑡𝑂𝐻 −1 0.489 1 − 0.489 −1 𝑘𝑔

𝜌𝑥̅𝑎 = ( + ) =( + ) = 837.7472 3
𝜌𝑎,𝐸𝑡𝑂𝐻 𝜌𝑎,𝑊 𝜌𝑎,𝐸𝑡𝑂𝐻 𝜌𝑎,𝑊 𝑚
 𝜌𝑥̅𝑎 - The average density of liquid, kg/m3;
 𝜌𝑎,𝐸𝑡𝑂𝐻 – The average density of Ethanol and Water at aqueous phase,
𝑘𝑔
𝜌𝑎,𝐸𝑡𝑂𝐻 = 732.99 ;
𝑚3
𝑘𝑔
 𝜌𝑎,𝑊 - The average density of Water at aqueous phase, 𝜌𝑎,𝑊 = 970.520 ;
𝑚3

 𝑥̅𝑎,𝐸𝑡𝑂𝐻 - The average weight fraction of Ethanol in aqueous phase.

The velocity of vapor in rectifying section:
𝑘𝑔
(𝜌𝑦 𝜔𝑦 ) = 0.065𝜑[𝜎]√ℎ𝜌𝑦𝑎 𝜌𝑥̅𝑎 , 𝑠
𝑎 𝑚2
 h – Distance among the stages, m;
 φ[σ] depends on the surface tension:
 σ < 20 dyn/cm => φ[σ] = 0.8
 σ > 20 dyn/cm => φ[σ] = 1

10−3 𝑁 𝑑𝑦𝑛
𝜎𝐸𝑡𝑂𝐻 = 20.789 × = 20.789
o 𝑚 𝑐𝑚
From 𝑡𝑥̅𝑎 =82.1125 C: { 10−3 𝑁 𝑑𝑦𝑛
𝜎𝑊 = 62.209 × = 62.209
𝑚 𝑐𝑚

Hence, surface tension of the aqueous phase, ignoring the influence of the concentration:

1 1 −1 𝑑𝑦𝑛
𝜎𝑎 = ( + ) = 15.582
𝜎𝐸𝑡𝑂𝐻 𝜎𝑊 𝑐𝑚

 Choose: φ[σ] = 0.8

 h = 0.25 m

The velocity of vapor phase in rectifying section:

𝑘𝑔
(𝜌𝑦 𝜔𝑦 ) = 0.065𝜑[𝜎]√ℎ𝜌𝑦𝑎 𝜌𝑥̅𝑎 = 0.783 .𝑠
𝑎 𝑚2

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𝑔𝑡𝑏
Diameter of rectifying section: 𝐷 = 0.0188√ = 0.211𝑚
(𝜌𝑦 𝜔𝑦 )𝑎

2.1.2. Diameter of stripping section

- The amount of inlet vapor at rectifying section
𝑔′𝑛 + 𝑔′1 𝑔1 + 𝑔′1 𝑘𝑔 ′
𝑔′𝑡𝑏 = 𝑜𝑟 𝑔′𝑡𝑏 = = 68.919 (𝑔 𝑛 = 𝑔1 )
2 2 ℎ
𝐺′1 = 𝑔′1 + 𝐺𝑤 𝐺′1 = 291.37 𝑘𝑔/ℎ
{𝐺′1 𝑥̅ ′1 = 𝑔′1 𝑦̅𝐵 + 𝐺𝐵 𝑥̅𝐵 ↔ { 𝑥̅ ′1 = 0.01%
𝑔′1 𝑟′1 = 𝑔′𝑛 𝑟′𝑛 = 𝑔1 𝑟1 𝑔′1 = 54.13 𝑘𝑔/ℎ
 𝐺′1 - The amount of liquid on the first stage of stripping section, kg/h;
 GB – Flowrate of bottom, GB = 272.34 kg/h;
 ̅ 1 = 𝑦̅𝐵 – weight fraction of vapor at bottom, 𝑦′
𝑦′ ̅ 1 = 0.0333% ;

 r’1 – Latent heat of latent heat of the inlet mixture vapor at the first stage in
stripping section,

𝑟′1 = 𝑟𝐸𝑡𝑂𝐻 𝑦̅′1 + (1 − 𝑦̅′1 )𝑟𝑊 ↔ 𝑟 ′ 1 = 2306.688 𝑘𝐽/𝑘𝑔;

 rEtOH = 813.5356, kJ/kg at t = 99.62oC.

 rWater = 2358.0443kJ/kg at t = 99.62oC.
The average density of vapor phase:
𝑦′1 + 𝑦′𝑛 0.01328 + 0.0333 𝑚𝑜𝑙
𝑦𝑎,𝐸𝑡𝑂𝐻 = = = 0.17314
2 2 𝑚𝑜𝑙
 𝑇 = 95.046℃
[𝑦𝑎,𝐸𝑡𝑂𝐻 𝑀𝐸𝑡𝑂𝐻 + (1 − 𝑦𝑎,𝐸𝑡𝑂𝐻 )𝑀𝑊 ]273
𝜌𝑦𝑎 = = 0.7566 𝑘𝑔/𝑚3
22.4 × 𝑇
 MEtOH, MW – molecular weight of Ethanol and Water;
 T – average operation temperature of rectifying section, T = 368.046oC;
 𝑦𝑎,𝐸𝑡𝑂𝐻 - mole fraction concentration of Ethanol.
The average density of aqueous phase:
𝑥′1 + 𝑥′𝑛 0.00394 + 0.065 𝑚𝑜𝑙
𝑥𝑎,𝐸𝑡𝑂𝐻 = = = 0.03447 → 𝑥̅𝑎,𝐸𝑡𝑂𝐻 = 0.0836%
2 2 𝑚𝑜𝑙
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𝑡𝑥̅𝑎 = 93.4507℃
𝑘𝑔
 𝜌𝑎,𝐸𝑡𝑂𝐻 = 722.22
𝑚3
𝑘𝑔
{𝜌𝑎,𝑊 = 962.5845 𝑚3

𝑥̅𝑎,𝐸𝑡𝑂𝐻 1 − 𝑥̅𝑎,𝐸𝑡𝑂𝐻 −1 𝑘𝑔
𝜌𝑥̅𝑎 = ( − ) = 936.525 3
𝜌𝑎,𝐸𝑡𝑂𝐻 𝜌𝑎,𝑊 𝑚
The velocity of vapor in rectifying section:
𝑘𝑔
(𝜌𝑦 𝜔𝑦 ) = 0.065𝜑[𝜎]√ℎ𝜌𝑦𝑎 𝜌𝑥̅𝑎 = 0.692 𝑠
𝑎 𝑚2
 h – Distance among the stages, m;
 φ[σ] depends on the surface tension:
 σ < 20 dyn/cm => φ[σ] = 0.8
 σ > 20 dyn/cm => φ[σ] = 1

𝜎𝐸𝑡𝑂𝐻 =
From 𝑡𝑥̅𝑎 = oC: { 𝜎 =
𝑊

Hence, surface tension of the aqueous phase, ignoring the influence of the concentration:

1 1
𝜎𝑎 = ( + )−1 =
𝜎𝐸𝑡𝑂𝐻 𝜎𝐸𝑡𝑂𝐻

Choose: φ[σ] = 0.8

h = 0.25 m

The velocity of vapor phase in rectifying section:

𝑘𝑔
(𝜌𝑦 𝜔𝑦 ) = 0.065𝜑[𝜎]√ℎ𝜌𝑦𝑎 𝜌𝑥̅𝑎 = 0.692 𝑠
𝑎 𝑚

𝑔𝑡𝑏
Diameter of rectifying section: 𝐷 = 0.0188√ = 0.188 𝑚
(𝜌𝑦 𝜔𝑦 )𝑡𝑏

2.2. Height of column

𝐻 = 𝑁𝑝 × (𝐻𝑠 + 𝛿 ) + (0.8 ÷ 1) = 3.068𝑚 ≈ 3.1𝑚

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 Np – Number of practical stage, Np = 9 trays;

 δ – Thickness of each stage, δ = 2mm = 0.002m;
 0.8 ÷ 1 – The allowed distance at top and bottom of equipment, choose 0.8;
 Hs – Distance among stages, Hs = 0.25m.
 Checking the minimum distance among trays:
𝜌𝑦 𝐹 × 𝜔𝑦
ℎ𝑚𝑖𝑛 = 23300 × ×(
𝜌𝑥 𝑛×𝜋×
2.3. Calculation for details of bubbles cap
2.3.1. Diameter of riser
Choose: dr = 50 mm.
2.3.2. Number of cap on each stage:
𝐷2
𝑛 = 0.1 × 2 ≈ 2 𝑏𝑢𝑏𝑏𝑙𝑒 𝑐𝑎𝑝𝑠. Choose n = 3
𝑑ℎ

 D – The inner diameter of column, D = 0.21m;

 dr – The diameter of riser, dr = 0.05m.
2.3.3. Height of cap above the riser
ℎ2 = 0.25 × 𝑑𝑟 = 0.0125𝑚
2.3.4. The diameter of cap
𝑑𝑐 = √𝑑𝑟2 + (𝑑𝑟 + 2𝛿𝑐 )2 = 0.073𝑚
 δc – Thickness of cap, usually choosing δc = 2 ÷ 3 mm. Choose δc = 1.5 mm;
2.3.5. The distance between the stage surface and foot of cap
𝑆 = 15𝑚𝑚
2.3.6. The height of the liquid between the cap and riser
ℎ1 = 20 𝑚𝑚
2.3.7. The parameters for slot
 Height of slot: hs = 10 mm = 0.01m;
 Width of slot: ws = 3 mm = 0.003m;
 Distance between two slots, c = 3mm = 0.003m;

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𝜋 𝑑𝑟2
 No of slot for each cap: 𝑖 = (𝑑𝑐 − ) = 11 slots
𝑐 4ℎ𝑠

 Height of liquid on the neck

2
𝑄𝐿 3
ℎ𝑙𝑛 = 2.84 × 𝐸 × ( ) , 𝑚𝑚
𝐿𝑛
 QL – Average flowrate in tower, m3/h
𝐺𝑥
𝑄𝐿 =
𝜌𝑥
 Ln – Length of neck, m. Usually, Ln = (0.6 – 0.76)D.
Choose Ln =
 E – correct factor for neck, determined by:
𝑄𝐿 𝐿𝑛
𝐸 = 𝑓( , )
𝐿2.5
𝑛 𝐷
E=
 hln =
Calculation for the height of neck
ℎ𝑐 = (ℎ1 + 𝑏 + 𝑆) − ∆ℎ
 h1 – Height of liquid level on the slot, mm;
 b – Height of slot, m;
 S – Distance from the tray surface to the foot of bubble cap, mm (S = hsc);
 h – Height of liquid level on the neck, mm (h = hln)
 Calculation for the Gradient of height of liquid level on trays
∆= 𝐶𝑔 × ∆′ × 𝑛
n – number of line of cap, n = ;
’ – Gradient of height of liquid level over a line;
Cg – Correct factor for vapor flowrate
Calculation for correct factor of vapor flowrate:
Determination of average width of tray

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𝐴
𝑊𝑡 =
𝑙
 A: Surface area for tray installed with bubble caps, m2;
 l – Distance between two weirs, m.
2.4. The resistance of column
𝑁
∆𝑃 = 𝑁𝑝 × ∆𝑃𝑡 ,
𝑚2
 Np – Number of practical rectifying stage, Np = 4 trays ;
 Pt – Total resistance of a tray, N/m2.
∆𝑃𝑡 = ∆𝑃𝑑 + ∆𝑃𝑠 + ∆𝑃ℎ
2.4.1. Resistance of dry trays Pd
𝜌𝑦 𝜔𝑜2 𝑁
∆𝑃𝑑 = 𝜉 ,
2 𝑚2
 ξ – Resistance factor usually ξ = 4.5 ÷ 5. Choose ξ = 4.5;
 ρy – Density of vapor phase, ρy = 1.082 kg/m3;
𝑄𝐺 𝑚
 ωo – Velocity through the slot, 𝜔𝑜 = =
𝑛×𝑖×𝑎×𝑏 𝑠

2.4.2. Resistance of surface tension Ps

4𝜎 𝑁
∆𝑃𝑠 = ,
𝑑𝑒 𝑚 2
 σ – Surface tension, σ = N/m2;
 de – Equivalent diameter of slot, m.
 When fully opens:
4𝑓𝑥
𝑑𝑒 =
П
 ƒx – Free surface area of slot, 𝑓𝑥 = 𝑎𝑏 = 𝑚2
 П – Perimeter of slot, П = 2 × (𝑎 + 𝑏) = 𝑚
2.4.3. Resistance of the liquid on tray (hydrolysis resistance)
ℎ𝑠 𝑁
∆𝑃ℎ = 𝜌𝑓 𝑔 (ℎ𝑓 − ),
2 𝑚2
 hs – Height of slot, hs = b = m;

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 ρf – Density of foam, usually ρf = (0.4 ÷ 0.6) ρx, kg/m3;

 hf – Height of foam, m;
(ℎ𝑛 + ∆ − ℎ𝑥 )(𝐹 − 𝑓)𝜌𝑥 + ℎ𝑥 𝜌𝑓 𝑓 + (ℎ𝑐 − ℎ𝑥 )𝑓𝜌𝑏
ℎ𝑓 =
𝑓𝜌𝑏
 hn - Height of neck, m;
 hx – Height of liquid (no foam) on tray, m;
ℎ𝑥 = ℎ𝑠𝑐 + ℎ𝑠𝑠 + (𝑏 − ℎ𝑜 ) =
 F – Surface of tray for bubble caps installation, m2;
 ρf – Density of foam, usually ρf = 0.4 ÷ 0.6 kg/m3;
 ƒ – Total surface area of bubble caps on tray, 𝑓 = 0.785𝑑𝑠2 𝑛, 𝑚2 ;
 n – Number of caps on tray;
 ds – Outer diameter of cap, m;
 ρx – Average density of aqueous phase, kg/m3;
 hs – Height of cap, m.
  - Height of liquid phase on vách chảy tràn, m;
2
𝐺𝑥 3
∆= 0.00284 × 𝐾 × ( ) , 𝑚
𝑙…
 Gx – Flowrate of aqueous phase, m3/h;
 lc – Length of cửa chảy tràn, m;
 K – Factor determined according to figure IX.22/p.185.
 g – Gravity acceleration, m/s2.
3. Mechanical calculation for the main equipment
3.1. Thickness of column
3.2. Material of column
3.3. Flanges of column
4. Calculation and choosing subsidiary equipments
4.1. Calculation
4.2. Investment cost

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D. CONCLUSION
1. Output result
2. Advantages
3. Disadvantages

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REFERENCES

www.worldofmolecules.com

https://en.wikipedia.org/wiki/Water

http://www.sciencelab.com/msds.php?msdsId=9927321

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