SEPARATION TOWER DESIGN

EXPERT TEAM 4

PRESENT BY:
SUFI, RINA, HERA, DANIA, HASLENA, PULA, FAIZ
 DISTILLATION TOWER
OPERATING CONDITIONS
 DISTILLATION TOWER OPERATING
CONDITIONS
o PROXIMITY OF CRITICAL CONDITIONS SHOULD BE AVOIDED

o TYPICAL OPERATING P IS 1 TO 415 PSIA (29 BAR)

o FOR VACUUM OPERATION P > 5 MMHG

o NORMALLY TOTAL CONDENSER IS USED

(EXCEPT FOR LOW BOILING COMPONENTS AND WHERE VAPOR DISTILLATE IS DESIRED)

o PRELIMINARY MATERIAL BALANCE TO ESTIMATE THE DISTILLATE AND BOTTOM

PRODUCT COMPOSITIONS
 TOWER PRESSURE & CONDENSER TYPE
START
DISTILLATE AND Assume cooling water
BOTTOMS available at 90°F
COMPOSITIONS ARE
KNOWN OR PD : Dist P
ESTIMATED
Calculate bubble- PD < 215 psia PB : Bottom P
point pressure (PD) of (1.48 Mpa) PB=PD+10 psia
distillate at 120°F Use total condenser
(49°C) (reset PD to 30 psia if PD ,
30 psia)
PD > 215 psia
TB < bottoms
Calculate dew-point PD < 365 psia Estimate decomposition or
(2.52 Mpa) Calculate bubble-point critical temperature
pressure (PD) of bottom
temperature (TB) of
distillate at 120°F Use partial condenser pressure
bottom at PB
(49°C) (PB)
TB > bottoms
PD > 365 psia decomposition or critical
temperature
Choose a refrigerant
so as to operate Lower pressure PD
partial condenser at appropriately
415 psia (2.86 Mpa)
 OTHER THINGS TO BE CONSIDER

o IF TOP STREAM CONTAINS BOTH CONDENSABLE AND NON-CONDENSABLE COMPONENTS, THE

CONDENSER IS DESIGNED TO PRODUCE BOTH VAPOR DISTILLATE AND LIQUID DISTILLATE

o THE PD IS CALCULATED AT 120ºF FOR THE CONDENSABLE

COMPONENTS IN LIQUID DISTILLATE.

o FOR VACUUM OPERATION, THE VAPOR DISTILLATE IS SENT TO

VACUUM PUMP.

o IF REFRIGERANT IS USED, ALWAYS CONSIDER PLACING WATER-

COOLED PARTIAL CONDENSER AHEAD OF IT (TO REDUCE COOLANT REQUIREMENT)
TOWER OPERATING CONDITIONS
ABSORPTION TOWER STRIPPING TOWER

Favor high pressures and low Favor low pressures and high
temperatures temperature
Cool the feed gas and the absorbent Heat the feed liquid and the stripping
with CW or refrigerant agent

Inter-stage coolers can be added if Operates at near ambient pressure but

there is internal temperature rise not under vacuum

High compression cost: Not

economical to increase the feed gas
pressure
 DESIGN OF DISTILLATION TOWER

o WHAT TO DESIGN ??
o CONSIDER THE FOLLOWING SCENARIOS:
(TO MAINTAIN TOP PRODUCTS PURITY)

 AT TOTAL REFLUX RATIO

 MINIMUM NO. OF STAGES
 HIGH UTILITY COST

 AT MINIMUM REFLUX RATIO

 INFINITE NO. OF STAGES
 LOW UTILITY COST
 FENSKE-UNDERWOOD-
GILLILAND (FUG)
SHORTCUT METHOD FOR
ORDINARY DISTILLATION
 FENSKE-UNDERWOOD-GILLILAND (FUG)
SHORTCUT METHOD FOR ORDINARY
DISTILLATION
o VALID FOR SINGLE FEED, DISTILLATE AND BOTTOMS

o TO ESTIMATE:
 REFLUX RATIO
 NO. OF EQUILIBRIUM STAGES & FEED LOCATION.

o QUITE ACCURATE FOR IDEAL MIXTURES OF NARROW BOILING RANGE.

o NOT FOR NON-IDEAL MIXTURES, AZEOTROPES AND MIXTURES OF WIDE-

BOILING RANGE (NEED TO USE RIGOROUS MODEL).
 FENSKE EQUATION: NMIN AT TOTAL
REFLUX
STEP 1:
USE FENSKE EQUATION TO DETERMINE MINIMUM NUMBER OF EQUILIBRIUM
STAGES (I.E. AT TOTAL REFLUX, D=0, R=∞)

D AND B ARE COMPONENT MOLAR FLOW RATES AT DISTILLATE AND BOTTOM

RESPECTIVELY. HK (HEAVY KEY), LK (LIGHT KEY), Α IS RELATIVE VOLATILITY
STEP 2:
ALSO USE FENSKE EQUATION TO DETERMINE THE DISTRIBUTION OF NON-KEY
COMPONENT BETWEEN DISTILLATE AND BOTTOM (D/B) STREAMS AT TOTAL REFLUX.
GOOD ESTIMATE FOR THE DISTRIBUTION (D/B) AT FINITE REFLUX CONDITIONS.
 UNDERWOOD EQUATION: RMIN, INFINITE
NO. OF EQUILIBRIUM STAGES
STEP 3:
USING UNDERWOOD EQUATION TO DETERMINE MINIMUM REFLUX RATIO (RMIN) THAT CORRESPOND
TO INFINITE NUMBER OF REFLUX RATIO (RMIN) THAT CORRESPOND TO INFINITE NUMBER OF
EQUILIBRIUM STAGES (N=∞).

SOLVE Ө BY TRIAL AND ERROR. NOTE: ΑHK (EQUALS 1) < Ө < ΑLK.

REFER C.J. GEANKOPLIS TEXTBOOK FOR DETAIL CALCULATIONS.

 GILLILAND CORRELATION: ACTUAL NO. OF
STAGES
STEP 4:
USING GILLILAND CORRELATION TO
ESTIMATE THE ACTUAL NUMBER OF
EQUILIBRIUM STAGES (N) AT A SPECIFIED
RATIO OF NUMBER OF EQUILIBRIUM STAGES
(N) AT A SPECIFIED RATIO OF R/RMIN.

NOTE: R = 1.1~1.5 RMIN

 FENSKE EQUATION: FEED LOCATION
STEP 5:
ESTIMATE THE FEED LOCATION BY USING FENSKE EQUATION.

CALCULATE NR,MIN FOR RECTIFYING SECTION (BETWEEN FEED AND DISTILLATE)

AND NS,MIN FOR STRIPPING SECTION (BETWEEN FEED AND BOTTOM).

ASSUME THAT, NR,MIN/NS,MIN =NR/NS; ALSO N=NR+NS.

KREMSER SHORTCUT METHOD
FOR ABSORPTION AND
STRIPPING
 KREMSER SHORTCUT METHOD FOR
ABSORPTION AND STRIPPING
• ESTIMATE MINIMUM ABSORBENT OR STRIPPING AGENT
• NUMBER OF EQUILIBRIUM STAGES FOR KEY COMPONENT FROM FEED

Absorption
𝐴𝑒 = 𝐿/𝐾𝑉 𝐴𝑒 = Effective absorption factor
𝐿 = Total molar liquid rate
𝐿𝑚𝑖𝑛 = 𝐾𝑘 𝑉𝑖𝑛 1 − ∅𝐴𝐾 𝑉= Total molar vapor rate
𝐾= k value from SRK equation
𝐴𝑒𝐾 − 1 (1 − ∅𝐴𝐾 )= Fraction of key component to be absorbed
∅𝐴𝐾 = 𝑁+1 𝑁 = No. of equilibrium stages
𝐴𝑒𝐾 − 1 𝐿𝑚𝑖𝑛 = Minimum molar absorbent flowrate
Note that: 𝐿 =1.5𝐿𝑚𝑖𝑛
 STRIPPING
𝑆𝑒 = 𝐾𝑉/𝐿 𝑆𝑒 =Effective stripping factor
𝐿 = Total molar liquid rate
𝑉= Total molar vapor rate
𝐾= k value from SRK equation
𝐿𝑖𝑛
𝑉𝑚𝑖𝑛 = 1 − ∅𝑆𝐾 (1 − ∅𝑆𝐾 )= Fraction of key component gas to be
𝐾𝑘 stripped
𝑁 = No. of equilibrium stages
𝐿𝑚𝑖𝑛 = Minimum molar absorbent flowrate
𝑆𝑒𝐾 − 1
∅𝑆𝐾 = 𝑁+1
𝑆𝑒𝐾 − 1
 EXAMPLE 13.1 (FOURTH EDITION PAGE 389)
THE FEED GAS TO AN ABSORBER AT 105ºF AND 400PSIA CONTAINS 150KMOL/HR
OF METHANE, 350KMOL/HR OF ETHANE, 250KMOL/HR OF PROPANE AND
50KMOL/HR OF N-BUTANE. THE ABSORBER IS TO ABSORB 90% OF THE N-BUTANE
WITH AN OIL AT 90ºF AND 50PSIA. WITH THE KREMSER EQUATION, DETERMINE THE
NUMBER OF STAGES REQUIRED AND THE AMOUNTS OF ABSORBED OF OTHER
THREE COMPONENTS IN THE FEED GAS.

V= 150+350+250+50= 800kmol/hr
Amount of key component to be absorbed= 1 − ∅𝐴𝐾 =90%=0.9
Avg. temp= (105ºF+ 90ºF)/2=97.5ºF
K value at 97.5ºF, 400psia=0.22
1) Calculate Lmin, 3) Calculate N ,

𝐿𝑚𝑖𝑛 = 𝐾𝑘 𝑉𝑖𝑛 1 − ∅𝐴𝐾 𝐴𝑒𝐾 − 1

∅𝐴𝐾 = 𝑁+1
𝐴𝑒𝐾 − 1
𝐿𝑚𝑖𝑛 = (0.22)(800) 0.9
=158kmol/hr
1.35−1
0.1=
Note that: 𝐿 =1.5𝐿𝑚𝑖𝑛 , 1.35𝑁+1 −1

L=1.5(158) N= 4
=237kmol/hr

2) Calculate 𝑨𝒆 ,

𝐴𝑒 = 𝐿/𝐾𝑉
𝐴𝑒 = 237/(0.22)(800)
=1.35
PLATE EFFICIENCY AND HETP
PAGE 503 (3RD EDITION)
 PLATE EFFICIENCY AND HETP
PLATE EFFICIENCY (EO) TO CONVERT NEQUILIBRIUM (EQUILIBRIUM STAGES) TO

ACTUAL TRAYS (NACTUAL).

HEIGHT EQUIVALENT TO A THEORETICAL PLATE (HETP) TO CONVERT

NEQUILIBRIUM TO PACKED HEIGHT.
PACKED HEIGHT = NEQUILIBRIUM (HETP)
IF A MORE ACCURATE ESTIMATE OF PACKED HEIGHT IS DESIRED,
CORRELATIONS OF EXPERIMENTAL MASS-TRANSFER COEFFICIENTS OF HEIGHT
TRANSFER UNITS SHOULD BE USED
 PLATE EFFICIENCY AND HETP

IN DISTILLATION, VISCOSITIES ARE GENERALLY LOW, OFTEN IN THE

RANGE 0.1 TO 0.2 CP AND OVERALL PLATE EFFICIENCY ARE
RELATIVELY HIGH , IN RANGE 50 TO 100%
ABSORBERS AND SOME STRIPPERS IS OFTEN IN THE RANGE 0.2 TO
2.0 CP AND OVERALL PLATE EFFICIENCY ARE IN THE RANGE 10 TO
50%

*cP is Liquid Viscosity-volatility Product

 PLATE EFFICIENCY

VERY APPROXIMATE PLATE EFFICIENCY:

• 70% FOR DISTILLATION
• 50% FOR STRIPPER
• 30% FOR ABSORBER
 HEIGHT EQUIVALENT TO A THEORETICAL
PLATE (HETP)
• VALUES OF HETP ARE USUALLY DERIVED FROM EXPERIMENTAL DATA FOR A
PARTICULAR TYPE AND SIZE OF PACKING.
• PACKING VENDORS/MANUFACTURERS CAN PROVIDE HETP VALUES
• TYPICAL VALUES:
FOR MODERN RANDOM PACKING: 2 ft
FOR STRUCTURED PACKING: 1 ft
• HETP AS A FUNCTION OF NOMINAL DIAMETER(Dp) OF RANDOM
PACKINGS AND SPECIFIC SURFACE AREA(a) AS RECOMMENDED BY
KISTER (1992).
TOWER DIAMETER
• Tower diameter is calculated to avoid flooding which is
liquid will fill the tower and leave with vapour at top
• Type of tower
– tray towers
– packed towers
• Tower diameter depends,
– Flow rate of vapour and liquid
– Properties of vapour and liquid

26
 1 Mass flow rate
4𝐺 2 of gas
𝐷𝑇 =
𝐴𝑑
(𝑓𝑈𝑓 )𝜋(1 − )𝜌𝐺 Density of
𝐴𝑇
gas
Fraction of flooding
velocity (0.75 –
0.85) 𝐷𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 𝐴𝑟𝑒𝑎
Flooding velocity, 𝑇𝑜𝑤𝑒𝑟 𝑖𝑛𝑠𝑖𝑑𝑒 𝑐𝑟𝑜𝑠𝑠 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎
Flow ratio parameter, 𝐹𝐿𝐺
𝐹𝐿𝐺 = 𝐿/𝐺 𝜌𝐺 /𝜌𝐿 0.5

𝐿 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑

𝐺 = 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 𝑜𝑓 𝑔𝑎𝑠
𝜌𝐺 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑔𝑎𝑠
𝜌𝐿 = 𝑑𝑒𝑛𝑠𝑖𝑡𝑦 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑

28
 Flooding velocity, 𝑈𝑓
Foaming factor
= 1 for non-foaming system
(typical distillation)
= 0.5-0.75 foaming system
(typical absorption)

𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑝𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟 = 𝐶𝑆𝐵 𝐹𝑆𝑇 𝐹𝐹 𝐹𝐻𝐴

Hole area factor

Use Figure = 1 (valve & bubble cap trays)
19.4 Surface tension factor = 1 (sieve tray 𝐴ℎ /𝐴𝑎 ≥ 0.1 )
𝐹𝑆𝑇 = 𝜎/20 0.2 = 5 𝐴ℎ /𝐴𝑎 + 0.5 sieve tray with 0.06 ≤
𝐴ℎ
≤ 0.1 )
𝐴𝑎
𝜎 is a surface tension in
dyne/cm
Exercise
19.4/13.4
32
 1
4𝐺 2 Mass flow rate of
𝐷𝑇 = gas
(𝑓𝑈𝑓 )𝜋𝜌𝐺
Fraction of flooding
velocity (0.70) Density of
gas
Flooding velocity
Flooding velocity,𝑈𝑓

𝐹𝑃 = packing factor (Table 19.1)

𝑔 = 32.2 ft/s2
𝜌𝐺 = density of gas
𝜌𝐿 = density of liquid
𝑌= Equation (19.15)
𝑓 𝜌𝐿 = Equation (19.17)
𝑓 𝜇𝐿 = Equation (19.18)
Leva flooding correlation,

 𝐹𝐿𝐺 = 𝐿/𝐺 𝜌𝐺 /𝜌𝐿 0.5

 Valid for Y = 0.01 to 10

Density function,
 Valid for density
ratio from 0.65 to
1.4

Viscosity function,
 Valid for viscosity
liquid from 0.3 to 20
cP
Exercise
19.6/13.6
By using simulator,
Liquid phase,
L = 77270 lb/hr
Density Liquid = 62.4 lb/ft3
Viscosity = 0.92 cP
Density water = 62.4 lb/ft3

Vapor phase,
G = 44540 lb/hr
Density = 0.0803 lb/ft3
PRESSURE DROP AND WEEPING
 PRESSURE DROP AND WEEPING
PRESSURE DROP :
 DRY TRAY PRESSURE DROP = DUE TO THE FLOW OF VAPOR
 HYDRAULIC PRESSURE DROP = DUE TO THE FLOW OF THE LIQUID
 PRESSURE DROP
• ΔP TRAY TOWER > ΔP RANDOM PACKING > ΔP STRUCTURED PACKING
THREE TYPE OF TRAY

SIEVE TRAY VALVE TRAY BUBBLE CAP TRAY

 PRESSURE DROP

• COULD BE EASILY ESTIMATED BY USING SIMULATORS.

• AMBIENT PRESSURE OR HIGHER; ΔP OF 0.10PSI/TRAY.
• VACUUM OPERATION ; NOT EXCESS 0.05PSI/TRAY OR USE PACK TOWER TO
LOWER ΔP.
 WEEPING

• Weeping occurs at low vapor flow rate

• Methods for checking are by using simulation.

• Weeping rate as high as 10% do not affect the tray

efficiency.
 MULTI-PASS TRAYS

• FOR DT > 4FT, LIQUID FLOW RATE > 500 GAL/MIN

• REDUCE DOWN COMER LIQUID LOAD AND REDUCE TRAY LIQUID LOAD
• INCREASE WEIR LENGTH
• SHORTER LIQUID FLOW PATH ACROSS THE TRAY.
 MULTI-PASS TRAYS

(a) Single-pass. (b) Two-pass. (c) Three-pass. (d) Four-pass. Flow- pass correction
 PRESSURE VESSEL AND TOWER
FOR DISTILLATION, ABSORPTION
AND STRIPPING
 EXAMPLE 22.12 (3RD EDITION), PG576

• AN ADIABATIC REACTOR CONSISTS OF A CYLINDRICAL VESSEL WITH ELLIPTICAL HEADS, WITH

AN INSIDE DIAMETER OF 6.5FT (78IN.) AND A TANGENT-TO-TANGENT LENGTH OF 40FT
(480IN.). GAS ENTERS THE REACTOR AT A PRESSURE OF 484 PSIA AND 800ºF. EXIT
CONDITIONS ARE 482PSIA AND 850ºF. THE VESSEL WILL BE ORIENTED IN A HORIZONTAL
POSITION. ESTIMATE THE VESSEL THICKNESS IN INCHES, WEIGHT IN POUNDS, AND PURCHASE
COST IN DOLLARS FOR A CE COST INDEX OF 550. THE VESSEL CONTAINS NO INTERNALS AND
THE GAS IS NON-CORROSIVE. THE BAROMETRIC PRESSURE AT THE PLANT SITE IS 14PSIA.
 PRESSURE VESSELS AND TOWERS FOR DISTILLATION, ABSORPTION AND STRIPPING

1) 𝑃𝑑 = EXP{0.60608 + 0.91615 LN𝑃𝑂 + 0.0015655[𝑙𝑛(𝑃𝑂 )]2 }

𝑃 𝐷
𝑑 𝑖
2) 𝑡𝑃 = 2𝑆𝐸−1.2𝑃 S DEPENDS ON DESIGN TEMPERATURE (𝑻𝒐 +50)
𝑑

FOR THICKNESS <1.25IN., E=0.85

FOR THICKNESS >1.25IN., E=1.0

3) W= Π(𝐷𝑖 + 𝑡𝑆 )(𝐿 + 0.80𝐷𝑖 ) 𝑡𝑆 Ρ

4) 𝐶𝑉 = EXP{8.9552 − 0.2330 LN 𝑊 + 0.04333[𝑙𝑛(W)]2 }

5) 𝐶𝑃𝐿 = 2005(𝐷𝑖 ) 0.20294

6) 𝐶𝑃 = 𝐹𝑀 𝐶𝑉 + 𝐶𝑃𝐿
 CHOOSING A VALUE FOR 𝑡𝑆

• ADD CORROSION ALLOWANCE OF 1/8 IN. TO WALL THICKNESS,𝑡𝑃

• CHECK THE RANGE OF THICKNESS
• CHOOSE A SUITABLE VALUE FROM THE RANGE OF THICKNESS

Thickness, inch Increment

3/16 to 1/2 1/16
5/8 to 2 1/8
9/4 to 3 1/4
PLATE AND PACKING
 PLATE
• VERTICAL TOWER ( ABSORPTION DISTILLATION, AND STRIPPING) UTILIZE TRAYS (PLATE) OR
PACKING
• TOTAL PURCHASE COST = COST PURCHASE,CP + COST INSTALLED TRAY,CT
CP = FMCV + CPL ……. EQN 16.52
CT = NTFNTFTTFTMCBT ………EQN 16.66

NT = NO. Tray
FNT = Factor no. tray
2.25
𝐹𝑁𝑇 = ,if NT< 20 ……. Eqn 16.68
1.0414 𝑁𝑇
FNT = 1 ,if NT> 20
CBT = 468exp(0.1482Di) ……………Eqn 16.67
 EXAMPLE 16.13
• A DISTILLATION COLUMN IS TO BE USED TO SEPARATE ISOBUTANE FROM N-BUTANE. THE
COLUMN, WHICH IS EQUIPPED WITH 100 SIEVE TRAYS, HAS AN INSIDE DIAMETER OF 10 FT (120
IN.) AND A TANGENT-TO-TANGENT LENGTH OF 212 FT (2,544 IN.). OPERATING CONDITIONS
ARE 110 PSIA AND 150OF AT THE BOTTOM OF THE TOWER AND 100 PSIA AND 120OF AT THE
TOP. THE MATERIAL OF CONSTRUCTION IS CARBON STEEL. THE BAROMETRIC PRESSURE AT THE
PLANT LOCATION IS 14.5 PSIA. ESTIMATE THE PURCHASE COST OF THE DISTILLATION COLUMN
AT A CE INDEX OF 600.
• FIND DESIGN PRESSURE:

PD = EXP (0.6068 + 0.91615[ LN(PO)] + 0.0015655[LN(PO)]2)....

EQN 16.61
*UNIT PO = UNIT IN PSIG
PO = THE OPERATING PRESSURE, BASED ON THE HIGHER PRESSURE
= 110PSIA – 14.5PSIA (BAROMETRIC PRESSURE) = 95.5PSIG
PD = EXP (0.6068 + 0.91615[ LN(95.5)] + 0.0015655[LN(95.5)]2)
= 123 PSIG
• THE DESIGN TEMPERATURE MAY BE TAKEN AS THE HIGH OPERATING TEMPERATURE PLUS 50OF.

150 OF + 50 = 200 OF
• TP = WALL THICKNESS IN INCHES TO WITHSTAND THE INTERNAL PRESSURE

………………….. EQN 16.60

 PD = INTERNAL DESIGN GAUGE PRESSURE IN PSIG,

 DI =INSIDE SHELL DIAMETER IN INCHES,
 S = MAXIMUM ALLOWABLE STRESS OF THE SHELL MATERIAL AT THE DESIGN TEMPERATURE
IN POUNDS PER SQUARE INCH
 TDESIGN = 200 F
 S = 15000 PSI
 E = FRACTIONAL WELD EFFICIENCY.
 ASSUME WALL THICKNESS < 1.25 IN
 E = 0.85

• TW = THE NECESSARY THICKNESS IN INCHES TO WITHSTAND THE WINDLOAD OR EARTHQUAKE
AT THE BOTTOM OF THE COLUMN

……….. EQN 16.62

 DO = THE OUTSIDE DIAMETER OF THE VERTICAL VESSEL IN INCHES

 ASSUMING A WALL THICKNESS OF 1.25 INCHES
 DO = 120 IN (INNER DIAMETER) + 1.25 IN = 122.5 IN
 L = THE TANGENT-TO-TANGENT VESSEL HEIGHT IN INCHES
 S = THE MAXIMUM ALLOWABLE STRESS IN POUNDS PER SQUARE INCH.

• TV = AVERAGE THICKNESS (COMPUTED FROM THE AVERAGE OF THE THICKNESS AT THE TOP, TP,
AND THE THICKNESS AT THE BOTTOM, TP + TW.
𝑡𝑝 +(𝑡𝑝 +𝑡𝑤 )
 TV =
2
0.582+(0.582+0.889)
 TV =
2
= 1.027 IN.

• FIND PLATE THICKNESS, TS

 ADD A CORROSION ALLOWANCE OF 1/8 IN.
 THICKNESS = 1.027+0.125 = 1.152 IN.
 THEREFORE, TS = 1.25 IN.
• FIND WEIGHT, W
 …………… EQN 16.59
 DI , TS, L IN INCHES.
 W = (3.14)(120+1.25)(2544+0.8(120))(1.25)(0.284)
 W= 356,800 IB
• FIND PURCHASE COST OF VERTICAL TOWER, CV

 CV = EXP { 10.5449 - 0.4672 [IN (W)] + 0.05482[IN(W)]2} …………. EQN 16.57
 CV = EXP { 10.5449 - 0.4672 [IN (356 800)] + 0.05482[IN(356 800)]2}
= $ 753,400

• FIND COST FOR PLATFORM AND LADDER, CPL


 CPL = 341 (DI)0.63316 (L)0.80161 ……….. EQN 16.58
 DI & L IN FEET
 CPL = 341 (10)0.63316 (212)0.80161 =107 300

• FIND PURCHASE COST AT INDEX 600 FOR TOWER, PLATFORM AND LADDER
 CP = FMCV + CPL ……. EQN 16.52
 FM = 1 (FROM TABLE 16.26)
 CP = (600/567)[1(753 000)+107 300]
 CP = 910 800
• FIND COST TRAY
 CT = NTFNTFTTFTMCBT ………EQN 16.66
 NT = 100 TRAY
 FNT = 1 ( SINCE NT > 20)
 FTT = 1 (FROM TABLE)
 CBT = 468EXP(0.1482DI) ……………EQN 16.67
 DI IN FEET
 CBT = 468EXP[0.1482(10)] = 2060 PER TRAY
 COST TRAY AT INDEX 600
CT = 100(1)(1)(2060)(600/567)
= 218 000

• FIND TOTAL COST

 910 800 + 218 000 = 1 130 000
 PACKING
• PACKINGS FOR TOWERS ARE CLASSIFIED AS DUMPED (RANDOM) OR STRUCTURED.
• TOTAL PURCHASE COST OF THE PACKED TOWER BECOMES:
…….EQN 16.69
FM = FACTOR OF MATERIAL CV = COST VERTICAL TOWER
CPL = COST PLATFORM AND LADDER VP = VOLUME OF PACKING
CPK = INSTALLED COST OF PACKING CDR = INSTALLED COST OF HIGH LIQUID DISTRIBUTOR
 EXAMPLE 16.14
• A DISTILLATION COLUMN HAS TWO SECTIONS. THE ONE ABOVE THE FEED IS 14 FT IN INSIDE
DIAMETER WITH A 20-FT HEIGHT, 15 FT OF WHICH IS PACKED WITH STRUCTURED PACKING OF
THE CORRUGATED-SHEET TYPE. THE BOTTOM SECTION IS 16 FT IN DIAMETER WITH A 70-FT
HEIGHT, 60 FT OF WHICH IS PACKED WITH 4-IN. CASCADE MINI-RINGS. THE COLUMN IS MADE
OF CARBON STEEL, BUT BOTH PACKINGS ARE OF STAINLESS STEEL. THE COLUMN WILL OPERATE
UNDER VACUUM WITH CONDITIONS OF 55 KPA AND 60OC AT THE TOP AND 60 KPA AND
125OC AT THE BOTTOM. A TOTAL OF FOUR LIQUID DISTRIBUTORS OR REDISTRIBUTORS WILL BE
USED. ESTIMATE THE F.O.B. PURCHASE COST OF THE COLUMN, INCLUDING INSTALLED PACKINGS,
DISTRIBUTORS, AND REDISTRIBUTORS, FOR A CE COST INDEX OF 600. THE BAROMETRIC
PRESSURE IS 100 KPA.
• FIND DESIGN PRESSURE:
 PD = THE MAXIMUM PRESSURE DIFFERENCE BETWEEN THE INSIDE AND OUTSIDE OF THE VESSEL

= 100KPA – 55KPA = 45KPA = 6.5 PSIG

• THE DESIGN TEMPERATURE MAY BE TAKEN AS THE HIGH OPERATING TEMPERATURE PLUS 50OF.

125OC = 257 OF
257OF + 50 = 307 OF
• FIND WALL THICKNESS FOR VACUUM CONDITION
 ……. EQN 16.63

 EM = MODULUS OF ELASTICITY
 T AT 307 OF , EM = 28.9 X 106
 TOTAL LENGTH, L = 20+70 = 90 FT
 AT TOP SECTION ASSUME DI=DO = 14 FT = 168 IN
  AT BOTTOM SECTION, ASSUME DI=DO = 16 FT = 192IN
6.5 (90) 0.4
𝑡𝐸 = 1.3(192) = 1.09 IN
28.9 × 106 (16)

 TOTAL THICKNESS, TV = TE + TEC

 THE VALUE OF TE THE FOLLOWING CORRECTION, TEC, .... EQN16.64
 ALL UNIT IN INCHES
 TOP SECTION

 TV = 1.01 + 0.11 = 1.12 IN.

 BOTTOM SECTION
 TEC= (90)(12)[0.18(192)-2.22] X 10-5 -0.19 = 0.16 IN
 TV = 1.09 + 0.16 = 1.25 IN.

• FIND PLATE THICKNESS, TS

 ADD A CORROSION ALLOWANCE OF 1/8 IN.
 TOP SECTION
 THICKNESS = 1.12+0.125 = 1.245 IN.
 THEREFORE, TS = 1.25 IN.
 BOTTOM SECTION
 THICKNESS = 1.25+0.125 = 1.375 IN.
 THEREFORE, TS = 1.375 IN.
• FIND PURCHASE COST OF VERTICAL TOWER, CV
 SINCE, IT HAS TWO SECTION
• THE BASE COST FOR THE TWO SECTIONS IS : …. EQN 16.70

• FIND WEIGHT
• ……………. EQN 16.59

 DI , TS, L IN INCHES.
 W1 = (3.14)(168+1.25)(1080+0.8(168))(1.25)(0.284)
 W1= 229 112 IB
 W2 = (3.14)(192+1.375)(1080+0.8(192))(1.375)(0.284)
 W2= 292 499 IB
• CV
 CV = EXP { 10.5449 - 0.4672 [IN (W)] + 0.05482[IN(W)]2} …………. EQN 16.57
 AT TOP SECTION
 CV1 = EXP { 10.5449 - 0.4672 [IN (229 112 )] + 0.05482[IN(229 112 )]2}
=$ 503 400
 AT BOTTOM SECTION
 CV1 = EXP { 10.5449 - 0.4672 [IN (292 499 )] + 0.05482[IN(292 499 )]2}
=$ 627 069
20 503400 +70(627069)
𝐶𝑉 = = $ 599 587
20+70
• FIND COST FOR PLATFORM AND LADDER, CPL
 CPL = 341 (DI)0.63316 (L)0.80161 ……….. EQN 16.58
 DI & L IN FEET
 AT TOP SECTION
 CPL1 = 341 (14)0.63316 (90)0.80161 =66 800
 AT BOTTOM SECTION
 CPL1 = 341 (16)0.63316 (90)0.80161 =72 726
 USING SAME EQN 16.70,
20 66 800 +70(72 726)
 𝐶𝑃𝐿 = 20+70
= $ 71 409

• FIND VOLUME PACKING, VP

𝜋𝐷2 ℎ
𝑉 = , D= INNER DIAMETER, FT H= HEIGHT PACKING, FT
4
 AT TOP SECTION
𝜋 14 2 (15)
 𝑉𝑃1 = = 2 310 𝑓𝑡 3
4
 AT BOTTOM SECTION
𝜋 16 2 (60)
 𝑉𝑃2 = = 12 060 𝑓𝑡 3
4
• FIND INSTALLED COST OF PACKING, CPK
 AT TOP SECTION, USE STAINLESS STEEL
 CPK = $285/ FT3 .
 AT BOTTOM SECTION, IT INSTALL 4-IN CASCADE MINIRING IN STAINLESS STEEL
 CPK = $50/ FT3 FROM TABLE 16.27

• FIND INSTALLED COST OF HIGH LIQUID DISTRIBUTOR

 HAS 4 DISTRIBUTOR
 ASSUME ONE HAS A DIAMETER OF 14 FT,
WHILE THE OTHER THREE HAVE A DIAMETER OF 16 FT.
𝜋 (14)2
 TOP AREA = = 154𝑓𝑡 2
4
𝜋 (16)2
 BOTTOM AREA = = 201𝑓𝑡 2
4
 A DISTRIBUTOR COST IS $140/ FT2
 CDR = 154(140)+3(201)(140) = $105 900
• TOTAL COST PURCHASE AT INDEX 600
•
• CP = (600/567)[(1.0)(599 587) + 71 409 +(2130(285) +12 060(50)) + 105 900]

= $ 2 102 588
‐ ANY QUESTION?