Distillation Tower Design

• As computer technology advances, the

fundamental aspects of plant design are
becoming a lost art. … N.P. Lieberman,
Refinery Manager, GHR Energy Inc., La
• The following steps are taken to design
and optimize a distillation tower:

R.A. Hawrelak, 22 Jan 02, CBE 497

(a) Select a Process Sequence
• Consider a five component feed as shown below.
Arrange in order of descending vapor pressure.

• C2 3
• C3 20
• C4 37
• C5 35
• C6 5
• Total 100 lb moles/hr
 Process Sequence Cont’d
• Make a split between C3 and C4
• Show this as C2, C3 / C4, C5, C6
• This called a depropanizer.
• C3 is identified as the light key.
• C4 is identified as the heavy key.
Establish Key Component Specs
• C3, light key composition in bottoms shall
be 1.0 mole %. (2.0% sales spec)
• C4, heavy key composition in the
overheads shall be 1.5 mole %. (3.0%
sales spec).
Set Up Mass Balance for Tower

Feed Feed Ohds Btms

C2 3 3
C3 lk 20 20 - Y Y
C4 hk 37 X 37 - X
C5 35 35
C6 5 5
100 23 + X - Y 77 + Y - X
 Mass Balance Equations

Light Key In Btms = 1.00%

Heavy Key In Ohds = 1.50%

Y 0.01 Eqn 1
77 + Y - X

X 0.015 Eqn 2
23 + X - Y
 Mass Balance Solution

Feed mf in Feed Ohds mf in Ohds Btms mf In Btms

C2 3 0.0300 3.00 0.1330
C3 lk 20 0.2000 19.23 0.8520 0.77 0.0100
C4 hk 37 0.3700 0.34 0.0150 36.66 0.4734
C5 35 0.3500 35.00 0.4520
C6 5 0.0500 5.00 0.0646
100 1.0000 22.56 1.0000 77.44 1.0000
 Obtain Antoine Constants
• Need Antoine constants for Vapor Pressure
• Vap Press, VP = 10^(A + B / (t°C + C))
psia

Component A B C
C2 5.0120015 -823.03103 328.18
C3 lk 4.3742477 -587.76681 248.90
C4hk 3.8201853 -367.50819 153.30
C5 4.0537542 -539.73661 169.60
C6 4.0165587 -545.39181 141.15
 Feed Conditions
• Temperature of feed = 225 deg F = 107.22
deg C.
• Pressure of feed = 264.7 psia
 Determine Bubble Point of Feed
Assume T, deg F = 212.5714318 T, Deg C = 100.317462
At Press = 264.7 psia

Component Moles/h, M VP, psia K = VP/P M*K

C2 3 1233.86 4.66133 13.98400
C3 lk 20 491.08 1.85523 37.10452
C4 hk 37 235.03 0.88790 32.85248
C5 35 113.27 0.42792 14.97726
C6 5 57.27 0.21635 1.08173
100.00 99.999999
 Determine Dew Point of Feed
Asssume T = 269.7699145 T, Deg C = 132.094397
At Press = 264.7 psia

Component Moles/hr, M VP, psia K = VP/P M/K

C2 3 1674.442 6.3258 0.4742
C3 lk 20 678.469 2.5632 7.8029
C4 hk 37 340.773 1.2874 28.7403
C5 35 183.966 0.6950 50.3600
C6 5 104.851 0.3961 12.6227
100.00 100.000001
 Assess Feed Condition
• Feed Bubble Point = 100.32 deg C
• Feed Temp = 107.22 deg C
• Feed Dew Point = 132.09 deg C
• Feed temp between Bubble Pt. and Dew
Pt.
• Feed must be in a two-phase V / L state.
• Special care will have to be taken for feed
distributor design on feed tray.
 Determine V / L for Feed
Assume V/L = 0.17114

1 2 3 4 5 6
Component Moles/hr, M K = VP/264.7 K(V/L) 1+K(V/L) L=1/4 V=1-5
C2 3 5.0000 0.856 1.856 1.617 1.383
C3 lk 20 2.0000 0.342 1.342 14.900 5.100
C4 hk 37 0.9700 0.166 1.166 31.732 5.268
C5 35 0.4800 0.082 1.082 32.343 2.657
C6 5 0.2500 0.043 1.043 4.795 0.205
100.00 85.387 14.613

Flash Fraction Vapor in Feed = 1-q = V / M = 0.14613121 V/L calc'd = 0.17114

V/L Ass'd = 0.17114
Diff = 0.00000
 Solve For Ø, The Underwood
Parameter
• Example In article by J.M. Ledanois,
Hydrocarbon Processing, April, 1981, P-
231
• Trial and error solution with as many
solutions as there are components.
• Solution is a Newton convergence method.
• Not all cases converge.
 Solve For Ø, The Underwood
Parameter, Cont’d
Next Ø 1.5976753 from Neqton Convergence

Assumed Ø = 1.5976753 Solution 2

1-q= 0.1461312 enter no. manually value from cell P55 - Fraction Vapor In Feed

Temp = 225 °F 107.22 °C Ist Estimate

Press, PT = 264.7 psia Eqn 13-43 Of Ø
Moles/Hr rel volatility Alpha*xFi Avg Alpha
Feed Fi xF1 Ki = VPi / PT Alpha i Alpha*xFi Aplha - Ø Adj Compts
C2 3 0.0300 5.0000 5.1546 0.155 0.043 3.6082
C3 lk 20 0.2000 2.0000 2.0619 0.412 0.888 1.5309
C4 hk 37 0.3700 0.9700 1.0000 0.370 -0.619 0.7474
C5 35 0.3500 0.4800 0.4948 0.173 -0.157 0.3763
C6 5 0.0500 0.2500 0.2577 0.013 -0.010

100 1.0000 ∑= 0.1461312 = 1-q

 Solve For Ø, The Underwood
Parameter, Cont’d
1-q= 0.1461312

Ist Estimate Final Est

Eqn 13-43 Of Ø Of Ø
Alpha*xFi Avg Alpha Avg Alpha
Feed Alpha*xFi Aplha - Ø Adj Compts Solution No. Ø Solutions
C2 0.155 0.043 3.6082 1 4.80084859
C3 lk 0.412 0.888 1.5309 2 1.59767531
C4 hk 0.370 -0.619 0.7474 3 0.64185818
C5 0.173 -0.157 0.3763 4 0.26706697
C6 0.013 -0.010

∑= 0.1461312 = 1-q
 Calc Minimum Reflux Ratio by
Underwood
• See Perry VI, Chem Eng HB, Page 13-36
• Solution For Minimum Reflux Ratio By
Solving For ∑ [Alpha*xDi / (Alpha - Ø)] =
L/D min. + 1
• Ø, The Underwood Parameter, was
determined above.
 Calc Minimum Reflux Ratio by
Underwood, Cont’d

Underwood parameter = 1.5977

Temp = 225 °F 107.22 °C
Pressure = 264.7 psia
Eqn 13-42
Alphai Alpha*xDi
Ohds Moles/hr xD1 Ki = VPi / PT Ki/K hk Alpha*xDi Aplha - Ø
C2 3.00 0.1327 5.0000 5.1546 0.684 0.192
C3 lk 19.30 0.8540 2.0000 2.0619 1.761 3.793
C4hk 0.30 0.0133 0.9700 1.0000 0.013 -0.022
22.6 1.0000 L/Dmin. + 1= 3.9635

L/D min. = 2.9635

 Determine Minimum No. Trays
by Fenske - Underwood
• Assume top and bottom pressure equal
feed pressure of 264.7 psia for now.
• Assume overhead distillate is removed as
a vapor from the condenser.
 Determine Minimum No. Trays by
Fenske – Underwood, Cont’d
Dew Point of Overhead Vapor Stream and Alpha of Keys

Temp = 118.3 °F 47.94 °C

Pressure = 264.7 psia

Ohds, D Moles/hr, M xD1 Ki = VPi / PT M/K

C2 3.00 0.1327 2.5180 1.19
C3 lk 19.30 0.8540 0.9364 20.61
C4hk 0.30 0.0133 0.3726 0.81
1.0000
22.6 22.61

Alpha Top = KC3 / KC4 = 2.51 For Distillate at 118 °F

 Determine Minimum No. Trays by
Fenske – Underwood, Cont’d
Bubble Point Of Bottoms Stream and Alpha of the Keys

Temp = 274.0 °F 134.44 °C

Press = 264.7 psia

Moles/hr, M xF1 Ki = VPi / PT M(K)

C3 lk 0.7 0.009044 2.6196 1.834
C4hk 36.7 0.474160 1.3189 48.405
C5 35 0.452196 0.7175 25.112
C6 5 0.064599 0.4119 2.060
MT = 1.000000
77.4 77.411

Alpha Btm = KC3 / KC4 = 1.99 For Btms at 274°F

Determine Minimum No. Trays by
Fenske – Underwood, Cont’d
• Determine geometric Average Alpha
between top and bottom of the tower.
• Geometric Avg = (Alpha Top*Alpha
Btm)^0.5
• Avg Alpha = ((2.51)(1.99))^0.5 = 2.23
Determine Minimum No. Trays by
Fenske – Underwood, Cont’d

• Min. Trays = LN((C3 lkD / C4 hkD)*

(C4 hkB / C3 lkB)) / LN(Alpha Avg)

• Minimum No. Trays, Sm = 10.11

Determine Trays versus Reflux
Ratio by Gilliland Method
• Use Chang equation to represent Gilliland.
• Huan Yang Chang, HC Proc, Oct 1981, P-146
• A partial condenser and a reboiler represent two
theoretical trays.
• No. trays = S – 2.
• Assume the economic reflux ratio is 1.2 times
the minimum reflux ratio,
• Plot the results.
 Determine Trays versus Reflux
Ratio by Gilliland Method, con’d
L/D Min. = 2.9635 Sm = 10.11
L/D = 3.56
Chang Factor = (S - Sm) / (S + 1) = 1 - EXP(1.49+0.315*C-1.805/C^0.1)
where C = (L/D - L/Dmin) / (L/D + 1)
Chang Factor
A B C (S - Sm) By Chang
L/D L/D - L/Dmin B/(A +1) (S + 1) S N=S-2
3.1 0.14 0.0333 0.65 30.30 28.30
3.2 0.24 0.0563 0.59 26.29 24.29
3.3 0.34 0.0783 0.56 24.07 22.07
3.56 0.59 0.1301 0.49 20.97 18.97
4 1.04 0.2073 0.43 18.39 16.39
4.5 1.54 0.2794 0.38 16.81 14.81
6 3.04 0.4338 0.29 14.53 12.53
Plot of Trays Versus Reflux Ratio
Reflux Versus Number of Trays

40.00

35.00

30.00

25.00
Number of Trays

20.00 Example

15.00

10.00

5.00

0.00
2.00 2.50 3.00 3.50 4.00 4.50 5.00 5.50 6.00 6.50
Reflux Ratio, L/D
 Determine Feed Tray Location
Feed Tray Location By Kirbride Equation
Oil And Gas Journal, Oct. 20, 1980, P-138, by Henry Y. Mak

Feed Tray Location = EXP[0.206*LN(B/D*fhk/flk*((blk/B)/(dhk/D))^2)]

B = 77.44 fhk = 37 dhk = 0.34

D = 22.56 flk = 20 blk = 0.77

Kirbride Feed Tray Location = 1.25 = # trays above fd / # trays below fd

No theoretical trays = 19

Trays Above = 10.55 11 10

Trays Below = 8.45 8 final selection 9
Ratio A/B = 1.25 1.38 1.11
 Determine Reflux Flow & Comp’n
Temp = 118.65 °F 48.14 °C
Pressure = 264.7 psia
L/D = 2.963 L= 66.868
Comp of Reflux
Mole Frac Dew Pt. Liq Reflux Stream,
Ohds, D Moles/hr, M y, D Ki = VPi / PT M/K x=y/K mole/hr, L
C2 3.00 0.1330 2.5246 1.19 0.05266 3.522
C3 lk 19.23 0.8520 0.9392 20.47 0.90724 60.666
C4hk 0.34 0.0150 0.3741 0.90 0.04009 2.681
1.0000
D= 22.5641 22.5641 1.00000 66.868
 Calculate Overhead Vapor Flow
from Top Tray = 19

Minimum Reflux Ratio = 2.963

D= 22.56 moles/hr
L = (2.963)(D) = 66.868 moles/hr.
V=L+D= 89.432 moles/hr
 Calc Vapor Composition from
Top Tray 19
Temp = 118.65 °F 48.14 °C
Pressure = 264.7 psia
Comp of Reflux Vapour Vapor
Mole Frac Dew Pt. Liq Reflux Stream, Stream Comp'n
Ohds, D Moles/hr, M y, D Ki = VPi / PT M/K x=y/K mole/hr, L moles/hr, V mole frac
C2 3.00 0.1330 2.5246 1.19 0.05266 3.522 6.52 0.0729216
C3 lk 19.23 0.8520 0.9392 20.47 0.90724 60.666 79.89 0.893316
C4hk 0.34 0.0150 0.3741 0.90 0.04009 2.681 3.02 0.0337624
1.0000
22.5641 22.5641 1.00000 66.868 89.432 1.00000
Show Molar Balance Around
Top Tray 19
Top Tray n, Assume equal molar flow
Molar balance = V18 = V19 + L19 - L

V19 = 89.4324 V19 = L + D

Reflux L
Tray 19 66.868

L19
66.868 Liq fr Tray 19

V18 = 89.4324
 Calc Dew Pt of Vapor Fr T19
and Liquid Comp’n Fr T19
Temp = 126.5378 °F 52.52 °C
Pressure = 264.7 psia
Comp of
Mole Frac Dew Pt. Liq fr Tray n
Ohds, V Moles/hr, V y, V Ki = VPi / PT M/K x=y/K
C2 6.52 0.0729 2.6753 2.44 0.02726
C3 lk 79.89 0.8933 1.0035 79.61 0.89022
C4hk 3.02 0.0338 0.4091 7.38 0.08252
1.0000
89.4324 89.4325 1.00000
Moles/hr, V 89.4324
Diff = 0.0001
 Vapor Comp’n From Tray 18

Vapor, V19 Reflux, L L19 Comp L19 Flow Vap, V18 Vap, V18
moles/hr moles/hr mole fr moles/hr moles/hr mole frac
C2 6.52 3.52 0.0273 1.82 4.82 0.0539
C3 lk 79.89 60.67 0.8902 59.53 78.75 0.8806
C4hk 3.02 2.68 0.0825 5.52 5.86 0.0655

89.43 66.87 1.0000 66.87 89.43 1.0000

 Calc Dew Point of Vapor V18
Temp = 133.0915 °F 56.16 °C
Pressure = 264.7 psia

V18 Mole Frac Dew Pt.

Vap V18 Moles/hr, M y, V18 Ki = VPi / PT M/K
C2 4.82 0.0539 2.8044 1.72
C3 lk 78.75 0.8806 1.0587 74.39
C4hk 5.86 0.0655 0.4394 13.33
1.0000
89.4326 89.4326
Moles/hr V18 89.4326
Diff 0.0001
 Design Data For Top of Tower
Vap, V18 L19 Flow Liq Density
MW lb/hr lb/hr lb/cf
C2 30.07 145 55 22.2
C3 lk 44.10 3,473 2,625 31.6
C4 hk 58.12 340 321 35.1
3,958 3,001 31.80

MW = 44.26 44.87

Dew Point of Vapor from Tray 18 = Vapour to Top Tray 19

Temp = 133.0915 Deg F

Pressure = 264.7 psia

Vapor Density = (MW)(Psia) / (10.73) / (Deg Rankine) = 1.841 lb/cf

 Input Shortcut Tower Dia. (FWG)
Input Data
Vapor To Tray, V, lb/hr = 3,958 CFS Vapor = 0.60 CFS Vapor = V / DV / 3600
Vapor Density, Dv, lb/cf = 1.841
Liquid From Tray, L, lb/hr = 3,001 USGPM = 11.76 USGPM = L / DL / 60 * 7.481
Liquid Density, DL, lb/cf = 31.80
System Factor, SF = 1.00 FWG 4900 / 5, Table 1b Non Foaming System
Tray Spacing, TS, Inches = 18 Assume 18 inches or 24 inches as a First Try. 24 inch TS is preferred.
Spray Ht. / Tray Spacing, = 50.00% Assume 70% as a default value.
Assume Minimum Valves / AA = 8 No. Valves / sf AA A Higher value, eg 13, may lead to an unsuitable, smaller to
Downcomer Flood, % DCF = 50.00% Assume 60% as a default value.

Preliminary Sizing
Downcomer Area (One Side), sf = 0.14 DCA = (L*7.481 / DL /60)/(7.5*TS^0.5*(DL-Dv)^0.5*SF) / %DC Flood
Active Area, AA, sf = 1.39 AA = V/3600/Dv/(((((TS*SH/TS)-4.5213)/4.3662)*DL/Dv)^0.5)*78.5/(No Valves /
Tower Area sf = 1.66 AT = AA + 2*DCA
Tower Dia, ft. = 1.45 D = (AT*3/p)^0.5

Select Tower Diam = 2.00 ft. (next 6" increment)

 Shortcut Method by Dr Prakash
Kv = 0.04070 by Kv = -0.17*(TS)^2+0.27*(TS)-0.047 where TS is in meters
cm/s = 0.01691 cm/s by cfs/3.2808^3
vel = 0.16419 m/s by Vmax =Kv(DL-DV/DV)^0.5, the Souder Eqn
A= 0.103 sm cm/s / m/s
D metric = 0.362 m D = (sm/.785)^0.5
D English = 1.188 ft D = m*3.2808
 Check Tower Mole Balance
89.43 22.56

66.87 reflux
Tray 19

89.43 66.8684

14.61
Feed Tray Molal Balance
100.00 Flashing feed 74.82 Feed Tray Feed In = 241.69
Feed Out = 241.69
85.39

74.82 152.26

Tray No. 1

Vapour to Tray No. 1 = 74.82 152.26 Liquid From Tray No. 1

In equilibrium with bottoms
Note: Tower simulation usually assume this config
Reboiler for the reboiler. In actual practice it is not quite like this
See tower sketch for reason

77.44 Composition From Btms Bubble Pt.

 Calc Bubble Point of Bottoms
Temp = 273.757833 °F 134.31 °C
Pressure = 264.7 psia

y = K(x)
Mole Frac Bub Pt. Vap to Tr 1
Btms, B Moles/hr, M x, B Ki = VPi / PT M*K mole frac
C3 lk 0.77 0.0100 2.6163 2.03 0.02616
C4 hk 36.66 0.4734 1.3171 48.29 0.62359
C5 35.00 0.4520 0.7162 25.07 0.32371
C6 5.00 0.0646 0.4110 2.06 0.02654
1.0000
77.4359 77.4358 1.00000
77.4359
-0.0001
 Vapor Rate To Tray 1
y = K(x)
Vap to Tr 1 Vap to Tr 1 Molecular Vap to Tr 1
Btms, B mole frac Moles/hr, V1 Weight lb/hr
C3 lk 0.02616 1.96 44.10 86
C4 hk 0.62359 46.66 58.12 2,712
C5 0.32371 24.22 72.15 1,747
C6 0.02654 1.99 86.18 171

1.00000 74.82 63.04 4,717

 Final Vapor & Liquid Data to Tr 1

Btms, B Vap to Tr 1 Liq Fr Tray 1 Molecular Liq Fr Tray 1 Liq Dens

Btms, B moles/hr Moles/hr, V1 Moles/hr Weight lb/hr lb/cf
C3 lk 0.77 1.96 2.73 44.10 120 31.6
C4 hk 36.66 46.66 83.32 58.12 4,842 35.1
C5 35.00 24.22 59.22 72.15 4,273 37.2
C6 5.00 1.99 6.99 86.18 602 40.7

77.44 74.82 152.26 9,838 36.31

Temp = 273.76 Deg F

Press = 264.70 psia

Vapor Density = (MW)(Psia) / (10.73) / (Deg Rankine) = 2.119 lb/cf

Tower Diameter For Bottom Tray 1
Vapor To Tray, V, lb/hr = 4,717 CFS Vapor = 0.62
Vapor Density, Dv, lb/cf = 2.119
Liquid From Tray, L, lb/hr = 9,838 USGPM = 33.78
Liquid Density, DL, lb/cf = 36.31
System Factor, SF = 1.00 FWG 4900 / 5, Table 1b
Tray Spacing, TS, Inches = 18 Assume 18 inches or 24 inches as a Firs
Spray Ht. / Tray Spacing, = 50.00% Assume 70% as a default value.
Assume Minimum Valves / AA = 8 No. Valves / sf AA A Higher value, eg 1
Downcomer Flood, % DCF = 50.00% Assume 60% as a default value.

Preliminary Sizing
Downcomer Area (One Side), sf = 0.36 DCA = (L*7.481 / DL /60)/(7.5*TS^0
Active Area, AA, sf = 1.45 AA = V/3600/Dv/(((((TS*SH/TS)-4.5
Tower Area sf = 2.17 AT = AA + 2*DCA
Tower Dia, ft. = 1.66 D = (AT*3/p)^0.5

Select Tower Diameter 2 ft. (next 6" incremen

 Shortcut Method by Dr Prakash
For Bottom of Tower

Kv = 0.04070 by Kv = -0.17*(TS)^2+0.27*(TS)-0.047 where TS is in meters

cm/s = 0.01751 cm/s by cfs/3.2808^3
vel = 0.16348 m/s by Vmax =Kv(DL-DV/DV)^0.5, the Souder Eqn
A= 0.107 sm cm/s / m/s
D metric = 0.369 m D = (sm/.785)^0.5
D English = 1.212 ft D = m*3.2808
 Tray Efficiency
O'Connell and Drickamer / Bradford Tray Efficiencies
Basis, Perry VI, p 18-14, & Ludwig, Applied Process Design For Chemical Plant Design

Assume avergae column conditions at Feed temp = 225 Deg F

Liq Visc Vap Press Vap Pre Ratio

Comp Xi, Feed cP (Xi)(cP) psia Alpha lk/hk (Alpha lk/hk)(Xi)
C2 0.03000 0.02 0.0006
C3 lk 0.20000 0.06 0.0120 529.40 2.0619 0.2270
C4 hk 0.37000 0.1 0.0370 256.76
C5 0.35000 0.15 0.0525
C6 0.05000 0.16 0.0080
1.00000 0.1101 = X For Drickamer

O'Connell Y = 0.2270

Drickamer Y = 0.1101
 Tray Efficiency cont’d
Box A
O'Connell Tray Efficiency = 70.39% Perry VI, Fig 18-23a

Perry VI, Eqn 18-14 Tray Eff'y = IF Y > 4, (46.514*(Y)^-0.2052)/100 63.06%

IF Y > 1 Tray Eff'y = (48*(Y)^-0.228)/100 67.31%
IF Y > 0.45 Tray Eff'y = (48*(Y)^-0.2797)/100 72.67%
Else, Tray Eff'y = (49.83*(Y)^-0.233)/100 Ans --> 70.39%

Drickamer Tray Eff'y = 76.43% Drickamer Tray Eff'y = -27.3*LN(Drickamer Y / 1.81) / 100
Ludwig, Applied Process Design For Chemical Plant Design
And Petroleum Plant, Vol Ii, Gulf Publishing, Circa 1960.

Recommend Use Average = 73.41% (O'Connell + Drickamer) / 2

 Actual No. of Trays & Feed Tray
Location
No. Theoretical Trays = 19

Traty Efficiency = 73.41%

Actual Trays = 26

Kirbride Feed Tray Ratio = 1.25

Trays above Feed = 15

Feed Tray Location = 11

Selected Feed Tray Ratio = 1.3636 vs 1.25 by Kirbride

 Tower Dimensions
26 3 ft. top trat to top tan line

14 spcs at 1.5 ft./spc

52 ft. Tan to Tan 21 ft.

12
11 3 ft. feed tray space

10 spcs at 1.5ft/sp
15 ft.
1

10 ft. to first tray

10 ft. shirt
 Vessel Specs

Vessel Specs

Operating pressure = 264.7 psia Check Flange Ratings

Design Pressure = 300 psia
Max Operating temp = 273.758 deg F Flg Rating, psig 300 (150/300/400/600)
Design temp = 650 deg F Flg Press, psig 541 Flgs O.K.
Material = SA-516 Gr 70 Des Temp, °F = 650 deg F
Corrosion allowance = 0.0625 inches.
Cost of Towers Database v1.1
Tag No., T - 100
Description Depropanizer
Flow Sheet No. 1000
No. Eqt Items 1
90 Actual Cost
90 Est'd Cost
Tower Type Tray Tower
Tower Dia., ft 2
T-T Length, ft 52
Design Press, psig 300
Corr Allow, in. 0.0625
Yield Eff'y 0.85 10% X-RAY
Tower Material No. (26) 4 SA-516 Gr 70
Tray Option (4) 1 Valve
No Trays 26
Tray Mtl No. 1 T-410 SS
Packing Option
Packing Ht, ft.
Tray Cost-88
Cost Estimate for Tower with Trays
Select Tower No., T- 301 (1 to 16 in Tower dB) Time Period 2001
dB Item No. 9 Fab Eqt Index 454
Description Depropanizer CND$/US$ 1.54
Flowsheet No. 0 Duty US>CAN 1
No. Eqt Items 1
90 Actual Cost 0 Shell Cost = $79,204 Shop Fab
90 Est'd Cost 0 Tray Cost = $9,268 Shop Installed
Tower Type Tray Tower Platforms = $8,218 Shop Installed
Tower Dia., ft 2 Tot Tower Cost = $96,690
T-T Length, ft 52
Design Press, psig 300
Back Calc'd des press = 306.06996 psig
Corr Allow, in. 0.0625
Yield Eff'y 0.85 10% X-RAY
Tower Material No. 4 SA-516 Gr 70
Tray Option 1 Valve
No Trays 26
Tray Mtl No. 1 T-410 SS
Packing Option 0 #N/A
Packing Ht, ft. 0
Tray Cost-88 0
Btm Wall Thickness = 0.53125 Inches
Top Wall Thickness = 0.3125 Inches
Vessel Wt = 5,800 lbs
Skirt Ht = 12 ft.
Skirt Wt = 2,345 lbs Assuming 3/4" Thk
Tray Wt = 980 lbs Assuming 10 ga. Wt.
Total Tower Wt = 9,125 lbs
 Shortcut
Method for
Packed
Towers
 Ekert Packing Factors
Some Ekert Wet Dumped Packing Factors, SF/Cf, for shortcut method Note:

Diam. Inches 0.625 0.75 1.00 1.50 2.00

Material
Ceramic Super Intalox 60 30
Plastic Super Intalox 33 21
Ceramic Intalox Saddles 145 98 52 440
Metal Hy-Pak Rings 42 18
Plastic Pall Rings 97 52 40 25
Metal Pall Rings 70 48 28 20
Ceramic Berl Saddles 170 110 65 45
Ceramic Raschig Ring 380 255 155 95 65
Plastic Tellerettes 40 20
Plastic Mapak 32
User Choice - See Perry VI, P-18-23

Select Packing Factor = 155 sf/cf FP for shortcut method only

 Approximate HETP
• From Tray Tower design, TS = 18 inches.
• For Approximated Packed Tower Design assume
one HETP = one Tray Spacing.
• HETP = 18 inches.
• Determine Tower Dimensions as for a Trayed
Tower.
• Allow 6 ft. for feed tray and top tray for liquid
distributer.
• No packing height should exceed 20 ft.
• If packing height exceeds 20 ft., must
redistribute liquid which adds another 6 ft.
 FRI Packed Tower V1.2
FRI Packed Tower **FRIPT** Version 1.0, 14 Nov 93

Case Study =Bottom of Tower Example for CBE 497 Dwg No. = Example from Perry III
By = RAH Tag No. = CBE - 497

Input Data

Liquid Flow = 9,933 lb/hr Packing Factor = 155 sf/cf

Liquid Density = 36.31 lb/cf Packing Type No. = 18
Liquid Viscosity = 0.08 Centipoise Packing Type = Ceramic Raschig Rings / Wet Packed
Vapor Flow = 4,812 lb/hr Packing Size = 1 Inches
Vapor Density = 2.117 lb/cf
Vapor Viscosity = 0.01 Centipoise
No. Theoretical Trays = 19
Tower I.D. = 2.00 ft.
S = mG/L Factor = 1.01 Minimum Value = 1.01
 FRI Packed Tower Results For
2 ft. Diameter Tower

From Generalized Eckert Pressure Drop Correlation Shortcut Method

X = (WL/WG)(RHOG/RHOL)^0.5 = 0.4984
Y = (G)^2(FP)/(gc*RHOG*RHOL) = 0.0113
At X above, Y Flooding = YF = 0.0444
% Flood At (X,Y) = (Y/YF)^0.5*100 = 50.56%
Eckert Presure Drop = 0.20 Inches H2O/ft. DP = 3.87 In. H2O
 FRI Packed Tower Results For
1.5 ft. Diameter Tower

From Generalized Eckert Pressure Drop Correlation Shortcut Method

X = (WL/WG)(RHOG/RHOL)^0.5 = 0.4984
Y = (G)^2(FP)/(gc*RHOG*RHOL) = 0.0358
At X above, Y Flooding = YF = 0.0444
% Flood At (X,Y) = (Y/YF)^0.5*100 = 89.88%
Eckert Presure Drop = 1.77 Inches H2O/ft. DP = 35.14 In. H2O
 FRI Detailed Method for
Designing a Packed Tower
• Select a Packing Factor from 18 selected
packing types.
• FRI have determined the design factors
which are too numerous to list here.
• FRI Packed Tower V1.2 will use this
packing data and the other data in the
shortcut method to design % Flood and
estimate the HETP.
 FRI Detailed Method For PT
From New FRI Packing Correlations, Reports 92, 94, and 95, 1984 Detailed Method

FS Factor = (V)(RHOG)^0.5 = 0.29 Top tower = 6 ft.

USGPM = 34.11 USGPM Feed tray - 6 ft.
USGPM / SF = 10.86 USGPM/sf Btm packing =9 ft.
a / Epsilon^3 factor = 146.08 sf/cf Top packing 12 ft.
Packing Height = 19.42 Ft. btm tower = 12 ft.
Packing Volume = 61.01 Cu. ft. Tan - tan = 42 ft.
Skirt = 10 ft.
Dry Packing Pressure Drop = 0.46 In. H2O / ft. Dry DP = 9.01 In. H2O
Wet Packing Pressure Drop 0.67 In. H2O / ft. Wet DP = 13.05 In. H2O

Maximum Allowable Vapor Rate For Calculated HETP = 9,150 lb/hr

% Load or % Capacity = 4812 / 9150 = 52.59%

Maximum Stable Or Flood Vapor Rate At Unknown HETP = 12,279 lb/hr skirt ht. = 12 ft.
% Flood = 4812 / 12279 = 39.19%
 FRI HETP Values for 2 ft. Diam.
FRI Vapor And Liquid Transfer Unit Values

Vapor Back Mixing Transfer Unit = HDUG = 3.53 Inches

Liquid Phase Transfer Unit = HTUL = 4.56 Inches
Vapor Phase Transfer Unit = HTUG = 4.19 Inches
Overall Gas Phase Transfer Unit = HTOG = 12.33 Inches

At Above Design Vapor / Liquid Rates, HETP = 12.27 Inches

HETP Message = Within 20% to 80% Capacity Limits Total Height of packing = 19.42 ft.

HETP Calculations (Good Only Between 20% to 80% Of Capacity

And For Level, FRI Tubed Drip Pan Distributor.)
 Packed Tower Cost Estimate
Select Tower No., T- 302 (1 to 16 in Tower
TimedB)
Period 2001
dB Item No. 10 Fab Eqt Index 454.00
Description Depropanizer CND$/US$ 1.54
Flowsheet No. 0 Duty US>CAN 1.00
No. Eqt Items 1
90 Actual Cost $0 Shell Cost = $61,120 Shop Fab
90 Est'd Cost $0 Packing Cost = $1,406 Field Installed
Tower Type Packed Tower Platforms = $7,319 Shop Installed
Tower Dia., ft 2 Tot Tower Cost $69,845
T-T Length, ft 42
Design Press, psig 300
Back Calcd Design Pressure, psig = 6.07
Corr Allow, in. 0.0625
Yield Eff'y 0.85 10% X-RAY
Tower Material No. 4 SA-516 Gr 70
Tray Option 0 #N/A
No Trays 0
Tray Mtl No. 0 #N/A
Packing Option 1 Ceramic Raschig Rings, 1 in
Packing Ht, ft. 21
Tray Cost-88 $0
Btm Wall Thickness = 0.4375 Inches
Top Wall Thickness = 0.3125 Inches
Vessel Wt = 4,482 lbs
Skirt Ht = 12 ft.
Skirt Wt = 2,345 lbs Assuming 3/4" Thk
Packing 0 Packing Installed In Field
Total Tower Wt = 6,827 lbs
 Summary
Shortcut Shortcut Detailed
Trays Pkd Twr Pkd Twr
Diameter 2 2 2
Shell t-t 52 53 45
No. Theo Tr 19 19 19
Efficiency 73.41%
No. trays 26
Tray Spg 18
HETP, inches 18 12.27
Pkg ht. 29 21

Shell Cost $79,204 $80,441 $61,120

Tr/Pkg Cost $9,268 $1,942 $1,406
Platforms $8,218 $8,345 $7,319
Total $96,690 $90,728 $69,845
Word of Caution – Trayed Towers
• Towers with trays are huge mixing
devices. Any slight restriction will cause
flooding.
• Three controlling factors:
• (1) % Flood by Liquid and Vapor Load
• (2) % Spray Height by number of holes.
• (3) % Downcomer flood.
• Trays must be level and well supported.
Word of Caution – Trayed Towers
• Vendors will often quote towers with many
holes to reduce diameter and obtain the
bid.
• Later on detailed design, they find they
must reduce holes for specified diameter.
• This increases spray height beyond
acceptable level and entrainment will be
too high.
• Buyers must be aware of all design details.
Word of Caution – Packed Towers
• Packed towers are low pressure drop
systems. Flows don’t always go where
they should.
• HETPs offered by vendors are optimistic.
• Vendors claim a wide range of operation.
• In actual practice there is a narrow range.
 Word of caution – Packed
Towers cont’d
• Uniform liquid distribution is difficult.
• If packing ht. Exceeds 20 ft.. Liquid must
be redistributed. This adds cost.
• Vapor is easily misdirected to walls.
• Vapor distributors are often required.
Good Luck On Your Distillation
Tower Design
• Presented to CBE 497
• 22 Jan 02
• R.A. Hawrelak