COLUMN DESIGN

2013. 03.18

SK E&C
INSTRUCTION

• What’s the last purpose of this instruction ?

• What’s the Unit Operation ?
• What’s the column ?
• Do you know how to define column internal
?
• How to operate the column system ?
• Can you complete the data sheet of column
?

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What’s Column ?

Column, Tower, Vessel, Drum, Pot, Reactor, Tank……

Column, Tower,Vessel, Drum, Pot, Reactor, Tank…

Vessel Tank
Column = Tower Vessel = Drum, Pot Tank
일정이 상압의 유체
상의 압
• Ex. Distillation Tower • Higher than Pressure 15 Psi, Dia • Ex. Storage Tank
력을 가
150mm
진 유체 Product Tank
Fractionation Tower
• Ex. Surge Vessel
Water Tank
Tray Tower
Knock Out Drum
• Except, Ball Tank
Packing Tower • Pot

• Reactor, Vessel

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Why Tray Tower?

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Why Tray Tower?

Be Economical

Tray Tower Packing Tower

Cost Pressure Drop

Fouling Efficiency
Corrosion Capacity

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Layout(Tray Tower)

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Layout(Tray Tower)

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Component(Tray)

Downcomer Area

Active Area
Free Area
Hole Area

Flow Path Length

Downcomer Width

Weir Height Downcomer

Clearance

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Component(Tray)

Sieve Valve

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Performance

Performance Curve
Vapor Velocity

Liquid Velocity

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Performance

Type Definition
• Condition in a liquid-vapor counterflow device (such as a distillation
Flooding column) in which the rate of vapor rise is such as to prevent liquid downflow,
causing a buildup of the liquid (flooding) within the device.

• Weeping is when liquid flows downward through the holes in a

Weeping
distillation tray.

• Where the droplets, instead of failing out into the downcomer carry up into
Blowing the holes of the tray above.

Entrainment • Same as blowing

• Dumping is liquid fall down continually through the hole area due to vapor-
Dumping liquid flow is too small compared to hole area. There is no mass transfer in
dumping situation

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Performance

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Performance

Flooding Type Definition

Jet • Dumping is liquid fall down continually through the hole area due to
vapor-liquid flow is too small compared to hole area. There is no mass
(Entrainment) transfer in dumping situation

• When the downcomer is insufficient to disengage the frothy vapor-

Downcomer
liquid mixture that enters.

System • When the actual capacity more than the design capacity

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COLUMN DESIGN

INTRODUCTION

COLUMNS / TOWERS

are fractional distillation equipment in which rising vapor

and falling liquid are brought into intimate contact to
separate the mixture into desired component parts.

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COLUMN DESIGN

WORK PROCEDURE

INPUT TO THE DESIGN OUTPUT TO THE DESIGN

1. Operating Conditions Data Sheet

 Pressure and Temperature  Skeleton / Drawing of Tower
 Flow Rate  Drawing of Internals
 Physical Properties  Operating / Design Conditions
 Etc.  Material of Construction
 Other Process Requirements
2. Performance Requirement
 Holding Time
 De-rating Factors
WORK STEPS
 Efficiency
 Pressure Drop
1. Prepare input data
 Etc.
2. Selection of Tray or Packing
3. Calculate tower diameter and
3. Mechanical Design Data
approximate height
 Design Conditions
4. Determine detail dimensions
 Codes / Standards
5. Prepare data sheet
 Material of Construction
 Condenser / Reboiler Type
 Etc.

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COLUMN DESIGN

GENERAL

BASIC PRINCIPLES

 Separation is based on differences in their

volatilities in a boiling liquid mixture

 The lightest products exit from the top and

the heaviest products exit from the bottom

 Flow of condensing liquid downwards in in

contact with hotter rising vapors provide a
driving force for separation

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COLUMN DESIGN

GENERAL

Main Components of Distillation Columns

1. Column / Tower

2. Column internals

3. Reboiler

4. Condenser

5. Reflux drum

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COLUMN DESIGN

TRAY vs PACKED TOWER

TYPES OF COLUMN INTERNALS

(a) Tray (b) Random Packing (c) Structured Packing

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COLUMN DESIGN
TRAY vs PACKED TOWER

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COLUMN DESIGN

TRAY vs PACKED TOWER

COMPARISON OF TRAYS AND PACKINGS

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COLUMN DESIGN

TRAY vs PACKED TOWER

TYPICAL APPLICATIONS OF TRAYS AND PACKINGS

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COLUMN DESIGN

TRAYS

TYPES OF TRAYS
 Bubble cap Tray
 Sieve Tray
 Valve Tray
 Dual Flow Tray
 Baffle Tray
 High Performance Tray(ADV, MD, Ripple, Etc.)
 Others(Raindeck,ADE,MU)

Bubble Cap Tray

Valve Tray

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COLUMN DESIGN

TRAYS
COMPARISON OF TRAYS

Type Sieve Tray Valve Tray Bubble-cap Tray Dual Flow Tray
Capacity High High to Very High Moderate Very High

Efficiency High High Moderate High Low Than Other Type

Turndown About 2:1 About 4~5:1 Excellent Lower than Sieve Tray
Good at Low Liq.

Entrainment Moderate Moderate High Low to Moderate

Pressure Drop Moderate Moderate High Low to Moderate

Cost Low Slightly High Very High Low

Maintenance Low Low to Moderate Relatively High Low

Fouling Tendency Low Low to Moderate High Extremely Lower Suitable

for Fouling Service

Main Application Most Columns when Most Columns Low Liquid Highly Fouling Service
turndown is not critical

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COLUMN DESIGN

TRAYS

TRAY COMPONENTS
Outlet Weir
 Tray Deck Tray Deck

 Downcomer Downcomer

 Outlet Weir, Inlet Weir

Inlet Weir
 Recessed Sump

 Valve, Bubble Cap, Riser

Recessed Sump

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COLUMN DESIGN

PACKINGS

TYPES OF PACKINGS

 Random Packing

 Structured Packing

 Grid Packing

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COLUMN DESIGN

PACKINGS

PACKING COMPONENTS

 Distributor / Re-Distributor

 Bed Limiter

 Hold Down Grid

 Packing Support

 Collector Tray

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COLUMN DESIGN

PACKINGS
DISTRIBUTORS

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COLUMN DESIGN

PACKINGS

BED LIMITER

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COLUMN DESIGN

PACKINGS

PACKING SUPPORT

COLLECTOR TRAY

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COLUMN DESIGN

TOWER INTERNALS

TOP SECTION

1. Top Feed (Reflux) Nozzle

2. Top Manhole
3. Vapor Outlet

Example of Reflux Nozzle Detail Arrangement

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COLUMN DESIGN

TOWER INTERNALS

MIDDLE SECTION

1. Intermediate Feed Nozzle

2. Manhole
3. Draw-off Sump

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COLUMN DESIGN

TOWER INTERNALS
MIDDLE SECTION

Example of Draw-off Sump Arrangement

Example of Feed Nozzle Detail Arrangement

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COLUMN DESIGN

TOWER INTERNALS

BOTTOM SECTION

1. Vapor Inlet Nozzle

2. Manhole
3. Liquid Outlet
4. Bottom Sump

Vapor Inlet Nozzle Arrangement

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COLUMN DESIGN

TOWER INTERNALS

BOTTOM SECTION

Example of Bottom Sump and Liquid Outlet Nozzle Arrangement

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COLUMN DESIGN

SIZING
DESIGN CONSIDERATIONS

 Operation Pressure

 Determined by cooling medium temperature and desired

component separation
 Economical design to operate close to atmospheric
pressure

 Reflux Ratio and Number of Stages

 Optimum reflux ratio results in lowest total cost of

operation per unit time
 Primary parameters are the number of stages and the
reflux ratio

 Minimum Stages, Minimum Reflux Ratio and Number of

Stage

 Minimum number of stages required is at “total reflux”

 Minimum reflux an infinite number of stages is required
 Economic balance between operating cost and fixed
charges

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COLUMN DESIGN

SIZING

DIAMETER CALCULATION

1. Downcomer design velocity

Lowest value of the following:

VD = 250 x System Factor

VD = 41 x sqrt(DL – DV) x System Factor
VD = 7.5 x sqrt(Tray Spacing) x sqrt(DL – DV) x System Factor

Sample System Factors

Recommended Tray Space

Column Diameter Tray Spacing

~ 1200 mm ~ 450 mm
1200 mm ~ 7200 mm 600 mm ~ 900 mm

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COLUMN DESIGN

SIZING

DIAMETER CALCULATION

2. Vapor Capacity Factor

CAF = CAF0 x System Factor

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COLUMN DESIGN

SIZING
DIAMETER CALCULATION

3. Approximation of Column Diameter

where CFS = Vapor Rate, ft3/sec

where DT = Tower Diameter (fig. 19-14, GPSA)

NP = Number of Flow Passes

where GPM = Liquid Load for same tray, gpm

FF = Design Percent of Flood (normally 0.8)

if ADM < 11% AAM, use 11% of AAM or 2xADM, whichever is smaller

use either ATM, whichever is smaller

 Calculated Column Diameter

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COLUMN DESIGN

SIZING
HYDRAULICS DESIGN PROCEDURE
c. Outlet Weir Height
A. Design Condition d. Downcomer Clearance Area
a. Determine Vapor-Liquid Load e. Bubbling Area
- Vapor Flow rate f. Free Area
- Liquid Load
b. Determine Physical Property C. Preliminary Performance Checks
- Vapor Density a. Capacity : Determine Safety factors
- Liquid Density - Limiting Capacity
- Liquid Viscosity - % Flooding of Active Area
- Liquid Surface Tension - % Flooding of Downcomer
- Foaming Factor - Pressure Drop
b. Lower Limits
B. Preliminary Estimate of Tower Size - Weeping
a. Assume Tray Spacing - Dumping
b. Compute Approximate Tower Diameter c. Entrainment
c. Compute Minimum Downcomer Area at Top - Vapor rate (ratio of Valve Open)
d. Estimate Downcomer Area at Bottom d. Efficiency
e. Assume one Path Tray
f. Prepare Preliminary Tray Layout D. Adjust design where necessary to obtain satisfactory
safety factors
C. Design Considerations
a. Valve Type Selection and Layout F. Repeat Performance Checks
b. Outlet Weir Length

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COLUMN DESIGN
JOB NO. :
CUSTOMER / USER:
DESCRIPTION
I. TRAY GEOMETRY:
Tow er I.D., mm
Tow er Area, m2
No. of Passes
Side DC Width, top/btm, mm.
Ctr. DC Width, top/btm, mm.
O/C DC Width, top/btm, mm.
Area Side DC, top/btm, m2.
Area Ctr. DC, top/btm, m2.
Area O/C DC, top/btm, mm.
Active Area, m2.
Free Area, m2.
Avg Flow Path Length, mm.
Weir Height, mm.
Weir Notch Depth, mm.
LWI for HOW
Dow ncomer Clearance, mm.
Dow ncomer Radius, mm.
Hole Size, mm
Punch Direction
Hole Area, m2
Percent Hole Area, %
Tray Deck Thickness, mm.
Tray Deck Material
PRELIMINARY & CONFIDENTIAL
TRAY DESIGN OUTPUT
SIEVE TRAY HYDRAULIC RATING SUMMARY PRO BASETRAYTM
ITEM NO. : BY:
TOWER NAME : PAGE :
II. PROCESS LOADINGS: 1 2 3 4 5 6
Case
0.00 Vapor Rate, kg/hr
Vapor Density, kg/m3
/ Vapor Rate, m3/s
/ Liquid Ratre, kg/hr
/ Liquid Density, kg/m3
/ Liquid Rate, liter/min
/ Viscosity, cp
/ Surface Tension, dyne/cm
Tray Spacing, mm.
System Factor
III. HYDRAULIC PERFORMANCE:
V Load / Act. Area, m/s
Capacity Factor x SF
% FRI Constant V/L
% DC Flood
DC Back-up, mm. Clear liq.
Weir Loading, liter/min-cm
VH2 DV/DL
Dry Tray Pressure Drop, mm. liq.
Liquid Crest Ht., mm.
Pressure Drop per Tray, mm. liq.
Pressure Drop per Tray, mmHg
% Jet Flood Eqn. 13
% System Limit Flood
% Aerated DC Flood
% Weep Point
% 25% Leakage Point
% Dump Point
ENT at Design (lb/lb Vapor)
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COLUMN DESIGN

SIZING

INTERPRETING TRAY HYDRAULICS

 % (Jet)Flooding : 20% ~ 80%

 DC Flooding : Max. 80%(60% @High Press. System)

 DC Back-up : > 60% of TS(40% @ Vap. Den. >= 3 lb/ft3)

 Velocity Under DC : Max. 0.45 mps

 Dry Pressure Drop : Should not exceed 15% of TS, 10% is conservative

 Aerated DC Back up : > 75% of TS

 Weir Loading : > 6~8 gpm/inch weir

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COLUMN DESIGN

QUICK GUIDE

TRAY COLUMNS

 Tray Spacing : 12 ~ 36 inch

 Min. Dia. For Tray Column : 750 mm(Except for Cartridge Type)

 No. of Passes(Min. Dia., ft)

2-P(5), 3-P(8), 4-P(10), 5-P(13)

 Weir Height : Min. ¾ inch ~ 15% of TS

 Flow Path Length : Min. 18 inch

 DC Clearance – Weir Height = ½ inch(Prefer)

 Hole Fraction(Sieve Tray) : 4 ~ 14 %

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COLUMN DESIGN
TRAY DATA SHEET SAMPLE TOWER DATA SHEET SAMPLE
PAGE OF PAGE 2 OF 3
PROJECT NO. PROJECT NO.
PROJECT NAME PROJECT NAME
ITEM NO. Q'TY ITEM NO. Q'TY
TRAY LOADING SERVICE TOWER SERVICE
DOC. NO. REV. DOC. NO. REV.
1 Vessel Number 1 TYPE & DIMENSION
2 Vessel Name or Service 2 VESSEL
3 Operating Case 3 Type:
4 Number of Trays on the Section 4 I.D: mm
5 Quantity of Trays 5 TL-TL: mm
on contained therein are the property of SK Engineering & Const. Co. Ltd (SKEC). They are merely loaned and shall not be disclosed to others or reproduced in any manner without written permission of SKEC.

on contained therein are the property of SK Engineering & Const. Co. Ltd (SKEC). They are merely loaned and shall not be disclosed to others or reproduced in any manner without written permission of SKEC.
6 Type of Tray 6 OPERATING CONDITIONS C V
7 Tow er Internal Diameter, mm 7 Fluid Name
8 Tray Spacing, mm 8 Specific Gravity
9 Number of Passes 9 Pressure kg/cm2G
10 Allow able Pressure Drop per Tray, kg/cm2 10 Temperature ℃ 100

1000
11 Allow able Leakage Thru Tray, kg/h 11 DESIGN CONDITIONS M1
R
12 Tightness Requirements 12 Temp.
100 10
13 13 Int. Press. kg/cm2G @ ℃

5 SPCS@450 = 2250
14 9
14 Ext. Press. @ ℃
15 Condition at Tray No. 15 MDMT ℃ 8

SEE SHT #3
16 Vapor to Tray 16 Postw eld Heat Treatment
7
17 Flow Rate, kg/h 17 Insulation
18 Molecular Weight 18 Fire Proofing 6
19 Temperature, ℃ 19 Type of Head
5
20 Pressure, kg/cm2g 20

700
Compressibility Factor 21 A
21

350
22 CORROSION ALLOWANCE 4
22 Density, kg/m3

3 SPCS@600 = 1800
23 Liquid from Tray 23 Shell mm

9800 T/T
24 Flow Rate, kg/h 24 Heads mm 3

25 Temperature, ℃ 25
26 Density, kg/m3 26 SPECIAL CONDITION 2

27 Viscosity, cP 27
28 Surface Tension, dynes/cm 28 1
29 Operating Range Maximum, % 29 NOZZLE SCHEDULE RR

750
30 Minimum, % 30 Mark Q'ty Size Facing Rating Description
31 Vapor System Factor, FSV 31
32 Liquid System Factor, FSL 32 L1 1300 I.D. D2

33 Max Flooding , % 33 HLL

4050
L2
34 Turndow n Requirement, % 34
35 Furnish Seal Pan below Bottom Tray ? Yes No 35 L3

36 Adjustable Weirs Required ? Yes No 36

M2
37 Gaskets Required ? Yes No Material : 37
LLL

250
38 Tray Material : Corrosion Allow ance, mm : 38 L4 D1SO

39 Valve Material : Corrosion Allow ance, mm : 39

40 NOTE 40 B

41 41

3000 SKIRT
VORT EX
42 42
BREAKER
43 43
E
44 44
45 45 8-M56 ANCHOR
BOLT S
46 46
WIT H T YPE II
47 47 SUPPORT 1318 O.D. SKIRT
48 48 LUGS PER
49 49 MATERIAL SPECIFICATIONS BADGER ST D
50 50 Shell / Heads
51 51 Internal
52 52
53 53 NOTE

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PILOT PROJECT TRAINING – COLUMN DESIGN

END

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