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Layers in the Process Design
Design for overall utility systems
including the plant site
UTILITY SYSTEM
Heat exchanger networking to
HEAT RECOVERY minimize energy consumption
SEPARATION R&D on separation & purification
for product quality, recovery,
REACTION
cost , etc.
CHEMISTRY
R&D on the chemistry for
optimum: conditions,
topologies, type, etc.
BUSINESS
R&D + Economic decision into
which chemical route
A corporate decision into what
business area to FOCUS 2
Separation Design
Purpose of separation
Separate unreacted reactants, byproducts, inert from products
Purify products to meet specification
Recovery toxic or polluted materials
Separation design
Identify the separation requirements
Select separation methods
Size separation units
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Separation Methods Distillation
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Separation Methods Gas Absorption
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Separation Methods Stripping
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Separation Methods Liquid-Liquid
Extraction
Liquidliquid extraction also known as solvent extraction and
partitioning, is a method to separate compounds based on
their relative solubilities in two different immiscible liquids,
usually water and an organic solvent. It is an extraction of a
substance from one liquid into another liquid phase.
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Separation Methods Adsorption
Mechanism: adsorbability
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Separation Methods Membrane
Mechanism: Permeability
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Separation Methods Crystallization
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Example: Select the separation method
Remove acid gas (CO2, H2S) from flue gas Absorption (amine) (with stripping)
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Distillation Column Design
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Basic Understandings Phase Diagram
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Phase Diagram Example
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Basic Understandings Tray Operation
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McCabe-Thiele Method - Equilibrium
Curve
The Figure (right) showed a typical equilibrium curve for a
binary mixture on x-y plot. It contains less information than the
phase diagram (i.e. temperature is not included), but it is most
commonly used. It is useful for graphical design in determining
the number of theoretical stages required for a distillation
column.
Expressed by relative volatility
A binary mixer has equilibrium curve as: y = 2.08x / (1+1.08x), whats the
relative volatility? In saturated liquid, if the light component takes 40 mol%,
whats the light component mol% in the saturated vapor at the same T, P?
What are the mol% of the corresponding heavy component in sat. liquid and
vapor?
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McCabe-Thiele Method - Rectifying
Section Operating Line (ROL)
Overall Mass Balance (Right figure): Vn+1 = Ln + D
Component Balance: Vn+1 yn+1 = Ln xn + D xD
(Ln + D) yn+1 = Ln xn + D xD
Assume
L1 = L2 = .......... Ln-1 = Ln = Ln+1 = L = constant
V1 = V2 = .......... Vn-1 = Vn = Vn+1 = V = constant
Introducing Reflux Ratio R = L / D,
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McCabe-Thiele Method Staircase for
theoretical stages
By plotting the operating line on the equilibrium curve, we
can graphically construct using the "staircase" construction
to determine the number of theoretical stages required for
the separation in the rectifying section.
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McCabe-Thiele Method Stripping
Section Operating Line (SOL)
Example: figure out the SOL equation
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McCabe-Thiele Method Feed Line (q-
line)
Overall material balance: L' = L + q F, V = V' + (1-q) F
Rectifying section : V y = L x + D xD
Stripping section : V' y = L' x - B xB
At the feed point where the two lines operating lines intersect:
( V - V' ) y = ( L - L' ) x + D xD + B xB
V - V' = ( 1 - q ) F
L - L' = - q F
In addition, from component balance around the entire column:
F xF = D xD + B xB
Thus, ( 1 - q ) F y = - q F x + F xF
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McCabe-Thiele Method Feed Line (q-
line)
For a given feed condition, xF and q are fixed,
therefore the q-line is a straight line with slope
-q / (1-q) and intercept xF / (1-q).
If x = xF , then y = xF. i.e. the q-line passes
through the point (xF, xF) on the 45o diagonal.
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McCabe-Thiele Method Three Lines and
Theoretical Stages
The number of theoretical stages is then the
number of triangles that can be drawn between
these operating lines and the equilibrium curve.
The last triangle on the diagram represents the
reboiler.
http://www.separationprocesses.com/Distillation/
DT_Animation/McCabeThiele.html
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McCabe-Thiele Method Examples
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Reflux Ratio vs. Number of Theoretical Trays
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Overall Efficiency and Plate Efficiency
where ye is the composition of the vapor that would be in equilibrium with the
liquid leaving the plate.
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Tray Types
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Plate Liquid Flow Pattern
& Active Area
Liquid flow patterns on cross-flow trays: (a) single
pass; (b) reverse flow; (c) double pass.
An approximate criterion for selecting the liquid flow
pattern is the liquid volumetric flow rate per unit
weir length, which should ideally be in the range 5 to
8 litres/s per m (2 to 3 gpm/in).
Active area (bubbling area): liquid vapor contact
with valve/bubble-cap/hole
For single pass, active area = A 2Ad
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Column Sizing
Plate spacing: 24 or 2 as rule of
thumb.
Column diameter: a function of vapor Plate spacing
flowrate (and liquid flowrate)
Small diameter high vapor flow
prevent liquid flow flooding
Large diameter low vapor flow
liquid drop from holes weeping
Downcomer: area, length, height Downcomer
clearance
Weir height
Weir height
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An Example of Tray Column Design:
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General Procedure
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Determine D and B
D+B = F
DxD+BxB = FxF
D = 10,200 lb/hr
B = 89,800 lb/hr
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Determine Rmin
(x1, y1)
(x1, y1)
(x1, y1) is the pinch point.
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Determine R and number of theoretical
stages
R = 3 Rmin in this case (typically R is only 1.2-1.5 Rmin)
Draw steps to determine Nth
Calculate Eo
Eo = 0.52782 0.27511log10() + 0.044923[log10()]2
= 0.324
Calculate Nr = (Nth-1)/Eo = 46
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Preliminary sizing of
Column Diameter
ACFS (actual cubic feet per second = 101
GPM = 228.2
TS = 24
SF = 1
TSF = 1
=3
= 228
GPM 24 1
Ad = 1.31
175 TS SF
H = 8
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Detailed Sizing
Read Chart E to get chord Length
Lweir = 3
Bubbling area
Ab = At-Adt-Adb-Ae
At-2Ad = 9.95 sqrt
d o w n c o m e r c le a r a n c e
CFM (air equivalent)
=
= 5078
P due to valve:
Type A: 4.2 in H2O
Type To: 2.0 in H2O
P due to liquid on
tray:
GPM/Lweir=76 GPM/ft
P 2 in liquid
= 2x59.3/62.4
= 1.9 inch H2O
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Packed Column for Absorption and
Stripping
Which is absorption? Which is stripping?
Vapor L iq u id Vapor L iq u id
A y A
i
x i
yi
xi yi
xi
y
x
M a s s t r a n s fe r f r o m t h e liq u id M a s s tr a n s fe r fro m th e g a s
to th e g a s p h a s e to t h e liq u id p h a s e
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y out x in y
Absorption Sizing yin O p e r a tin g lin e
y x y out
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Example
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