1.

Introduction

The general structure of a chemical process

Preparation
of
raw materials

Reaction

Purification
of
products

Recycle
Unit operations:
-Heating
-Size reduction
-Mixing
-...

Unit operations:
-Cooling
-Distillation
-Extraction
-Drying
-...

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation

Continuous flash distillation

Distillat
e
D, yD
Demister

Feed
F, xF
Heater
Bottom product
B, xB
Flash drum

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation
Continuous flash distillation

Balance line:
Equilibrium line

y
f=0

0<f<1

f 1
x
x F
f
f

D
F

yD

f=1

xB

xF

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation
Continuous distillation with reflux

G, y1

Q*C

Distillate
D, xD

Reflux
R,xD
Feed
F, xF
Q*H

Bottom product
B, xB
Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation
Distillation of a binary mixture in a column with reflux ; the feed is at boiling point temperature
The McCabe-Thiele Method to determine the number of theoretical stages

Equilibrium line

1
Balance line
of rectifying
section

3
Balance line
of stripping
section

xD
v 1

xB

xF

xD

4 theoretical stages = 3 theoretical trays + reboiler

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation

The McCabe-Thiele-Method is used for theoretical stages

y1 xD
v
xD
y2
x1
v 1
v 1

v
xD
y3
x2
v 1
v 1

Stage 1

x1 x equi y1
Stage 2

x2 x equi y2
Stage 3

and so on....until
bottom concentration
is reached.

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux ; various feed conditions

The feed line

y
e>1
e=1

e 1

0<e<1

xD
v 1

e<0

With the given reflux ratio

h0 F hF
hV

e is determined by the
thermodynamical state
of the feed

e=0

xB

e
x
x F
e 1
e 1

xF

xF
e

xD

e = 0 and e < 0 is not possible!

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

The feed line

e>1
e=1
y

0<e<1

xD
v 1

xD
v 1 mod

e=0
e<0

xB

xF

xF
e

xD

With increased reflux e = 0 and e < 0 become possible

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

Minimal reflux ratio vmin

y
e
anc
l
a
B

xD
vmin 1

line

Feed line

xB

xF

xF
e

xD

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

Minimal reflux ratio vmin

xD
vmin 1

xB

xF

xF
e

xD

The balance line cannot cut the equilibrium line !

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

Minimal number of theoretical stages

1
y

xB

xD

Minimal number of theoretical stages is nth,min = 3

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

costs

The optimal reflux ratio

Total costs

Cost
minimum

Energy
Equipment

vmin

vopt

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

Energy (heat) consumption of a column

Heat balance for the condenser

.

Q C DhD RhR GhG

G

Q*C

Reflux R

R
D
hD hR

v
Distillate D

hG hD hV
.

Q C (1 v) D hV
Feed F

Heat balance for the column

.

Q*H

Q H DhD BhB FhF Q C

.

QH ~ v
.

Bottom product B

QC ~ v

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

Overall tray efficiency and Murphree efficiency

Reasons for an efficiency below 100%:

Short contact time of vapour and liquid phase
Entrainment of liquid droplets with high vapour flows
(backmixing of the liquid phase)
Forward mixing of the liquid phase with low vapour flow rates
(raining)
Overall efficiency, average value of the whole column

nth

nreal
Murphree efficiency, value for one plate

yn yn 1
M equi
yn yn 1
Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

Overall tray efficiency and Murphree efficiency

Murphree efficiency, value for one plate

yn yn 1
M equi
yn yn 1
ynequi
yn
yn 1

Fundamentals of Chemical Process and Reaction Technology - Unit Operations

2. Distillation of a binary mixture in a column with reflux

Column design

Material balances
Feed line
Minimal reflux
Number of theoretical stages and feed stage
Number of practical stages or height of packing
Heat balances
Column diameter (optimal efficiency)
Plate distance (entrainment!)
Downcomer

Fundamentals of Chemical Process and Reaction Technology - Unit Operations