MASS TRANSFER TUTORIAL: DISTILLATION

EXAMPLE PROBLEM 2: MCCABE–THIELE METHOD

Four hundred and fifty lbmol/h (204 kmol/h) of a mixture of 60 mol% benzene
(LK) and 40 mol% toluene (HK) is to be separated into a liquid distillate and a
liquid bottoms product of 95 mol% and 5 mol% benzene, respectively. The
feed enters the column with a molar percent vaporization equal to the
distillate-to-feed ratio. Use the McCabe–Thiele method to compute, at 1 atm
(101.3 kPa): (a) Nmin, (b) Rmin, and (c) number of equilibrium stages N, for
R=Rmin *1.3, and the optimal feed-stage location.
Equilibrium data:
x 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
y 0.2 0.38 0.51 0.63 0.71 0.78 0.85 0.91 0.96 1

Solution

First calculate D and B. An overall material balance on benzene gives

0.60(450) = 0.95D + 0.05B …………………….1

A total balance gives: 450 = D + B ……………..2

Combining (1) and (2) and solving,
D = 275 lbmol/h, B = 175lbmol/h, and D /F = 0.611.
Thus, the molar vaporization of the feed is 61.1%.
Calculate the slope of the q-line:
VF/F = D/F =0,611, and q for a partially vaporized feed is

q-line equation is given by

Hence,

(a) In Figure below, where y and x refer to benzene, xD = 0.95 and xB = 0.05, the
minimum stages are stepped off between the equilibrium curve and the 45 0
line, giving Nmin = 6.7.
 Determination of minimum stages

(b) In Figure below, a q-line is drawn that has a slope of -0.637 and passes
through the feed composition (zF =0.60) on the 45o line. For Rmin, an operating
line for the rectifying section passes through the point x = xD =0.95 on the
45oline and through the point of intersection of the q-line and the equilibrium
curve (y =0.684, x = 0.465). The slope of this operating line is 0.55, which
from graph below is equals R/(R+1). Therefore, Rmin = 1.22.

Determination of minimum reflux

(c) The operating reflux ratio is 1.3Rmin =1.3(1.22) =1.59. The Rectifying
operating line(ROL) slope is
 R/(R+1) = 1.59/(1.59+1)=0.614
The two operating lines Rectifying operating line(ROL) and the q-line are
shown in Figure below, where the stripping-section operating line is drawn to
pass through the point x = xB = 0.05 on the 45o line and through the
intersection of the q-line with the rectifying-section operating line. The
equilibrium stages are stepped off, first, between the rectifying-section
operating line and the equilibrium curve, and then between the stripping-
section operating line and the equilibrium curve, starting from point A
(distillate composition) and finishing at point B (bottoms composition). For the
optimal feed stage, the transfer from the rectifying-section operating line to the
stripping-section operating line takes place at point P, giving N = 13:2
equilibrium stages, the feed going into stage 7 from the top, and N/Nmin
=13.2/6.7 =1.97. The bottom stage is the partial reboiler, leaving 12.2
equilibrium stages in the column. If the plate efficiency were 0.8, 16 trays
would be needed.

Determination of number of equilibrium stages and feed-stage location

Example problem 2: McCabe–Thiele Method for Column with a Sidestream.

A column equipped with a partial reboiler and total condenser, operating at
steady state with a saturated-liquid feed, has a liquid sidestream in the
rectifying section. Using the McCabe–Thiele assumptions: (a) derive the two
operating lines in the rectifying section; (b) find the point of intersection of the
operating lines; (c) find the intersection of the operating line between F and
LS with the diagonal; and (d) show the construction on a y–x diagram.
Solution
(a) By material balance over Section 1 in Figure below, Vn-1yn-1 = Lnxn + DxD.
For Section 2, VS-2 yS-2 =L’S-1xS-1 + LSxS + DxD. The two operating lines for
conditions of constant molar overflow become:

Distillation column with sidestream

(b) Equating the two operating lines, the intersection occurs at

(L – L’)x = LSxS and since L – L’ = LS, the point of intersection
becomes x = xS.
McCabe–Thiele diagram
 DISTILLATION TUTORIAL

1. A mixture of benzene and toluene containing 40 mole per cent benzene is to be

separated to give a product containing 90 mole per cent benzene at the top, and
a bottom product containing not more than 10 mole per cent benzene. The feed
enters the column at its boiling point, and the vapour leaving the column which is
condensed but not cooled, provides reflux and product. It is proposed to operate
the unit with a reflux ratio of 3 kmol/kmol product. It is required to find the number
of theoretical plates needed and the position of entry for the feed. The equilibrium
data at 100 kN/m2 is given below

x 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

y 0.2 0.38 0.51 0.63 0.71 0.78 0.85 0.91 0.96 1

2. Question 1 is now worked using the Mcabe Thiele method. Thus, with a feed
composition, xf = 0.4, the top composition, xd is to have a value of 0.9 and the
bottom composition, xw is to be 0.10. The reflux ratio, Ln/D = 3.
3. A mixture of water and ethanol containing 0.5 mole fraction ethanol is
continuously distilled in a plate column to give a product containing 0.95 mole
fraction and a waste of 0.02 mole fraction ethanol. It is proposed to withdraw 20%
of feed as side stream with a mole fraction of 0.6 ethanol. A reflux ratio of 2.5 is
applied. The feed enters at 80oC and has a rate of 100 kmol.h-1
Equilibrium data:

tb [oC] 120 115 110 105 98 94 86 81 77 75 73

X 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Y 0.0 0.27 0.42 0.51 0.59 0.67 0.75 0.82 0.89 0.95 1.0

The heat of vaporization is 32 000 KJ/Kmol

The specific heat capacity is 2500 KJ/Kmol K
4. A continuous fractionation column is required to separate a mixture of water and
methanol, containing 0.45 mol fraction methanol to give a product containing 0.75
mol fraction methanol and a waste of 0.02 mol fraction methanol. It is proposed to
withdraw 20% of the feed stream as a liquid side stream with 0.5 mol fraction
methanol.
Determine the operating lines for the different sections, the number of theoretical
stages required, and the position of the stage from which the side stream should
withdraw if the feed liquid is at its boiling point and a reflux ratio of 2.5 is used.
Use the McCabe thiele method.
Equilibrium Data:
X 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Y 0.0 0.27 0.42 0.51 0.59 0.67 0.75 0.82 0.89 0.95 1.0
5. For the separation of a mixture of benzene and toluene, considered in question 1,
xd = 0.9, xw = 0.1, and xf = 0.4. If the mean volatility of benzene relative to
toluene is 2.4, what is the number of plates required at total reflux?

6. The equilibrium data for n-pentane and n-hexane at atmospheric pressure

X 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Y 0.21 0.41 0.54 0.66 0.745 0.82 0.875 0.92 0.975 1

A mixture containing 0.52 mole fraction is to be distilled continuously to give a top

product 0.95mol fraction pentane and bottoms of 0.1 mol fraction pentane. A
relative volatility of 2 is used and feed is all liquid at its boiling point
a. Determine the number of ideal plates at total reflux
b. Determine the composition on the second plate from the top by Lewis sorrel
method
c. By the mcabe Thiel method determine the number of total plates required and
position of the feed

7. A continuous fractionating column is to be designed to separate 30 000kg/hr of a

mixture 40% benzene and 60% toluene into an overhead product containing
97% benzene and a bottom product containing 98% toluene. These percent are
by weight, a reflux ratio of 3.3 is to be used. The molar latent heats of
vaporisation are7360 and 7960 calories/gmol respectively Benzene and toluene
data are given in question 1 The feed has a bp of 95 degrees Celsius at a
pressure of 1 atm
a. Calculate the moles of overhead and bottom product per hour
b. Determine the number of ideal plates i. if the feed is liquid at 20 oC(specific
heat 0.44cal/goC) ii. If the feed is a mixture of 2/3 vapour and 1/3 liquid and in
all cases a total condenser is used

8. A mixture of benzene and toluene containing 40 mole per cent benzene is to

be separated to give a product containing 90 mole per cent benzene at the top,
and a bottom product containing not more than 10 mole per cent benzene. The
feed enters the column at its boiling point, and the vapour leaving the column
which is condensed but not cooled, provides reflux and product. It is proposed to
operate the unit with a reflux ratio of 3 kmol/kmol product. It is required to find the
number of theoretical plates needed and the position of entry for the feed. The
equilibrium data at 100 kN/m2 is given below

x 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

y 0.2 0.38 0.51 0.63 0.71 0.78 0.85 0.91 0.96 1

9. A mixture of water and ethanol containing 0.5 mole fraction ethanol is

continuously distilled in a plate column to give a product containing 0.95 mole
fraction and a waste of 0.02 mole fraction ethanol. It is proposed to withdraw 20%
of feed as side stream with a mole fraction of 0.6 ethanol. A reflux ratio of
1.3Rmin is applied. The feed enters at 80oC and has a rate of 100 kmol.h-1

Equilibrium data:
tb 120 115 110 105 98 94 86 81 77 75 73
[oC]
 X 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Y 0.0 0.27 0.42 0.51 0.59 0.67 0.75 0.82 0.89 0.95 1.0
The heat of vaporization is 32 000 KJ/Kmol
The specific heat capacity is 2500 KJ/Kmol K

10. A continuous fractionation column is required to separate a mixture of water and

methanol, containing 0.45 mol fraction methanol to give a product containing 0.75
mol fraction methanol and a waste of 0.02 mol fraction methanol. It is proposed to
withdraw 20% of the feed stream as a liquid side stream with 0.5 mol fraction
methanol.
Determine the operating lines for the different sections, the number of theoretical
stages required, and the position of the stage from which the side stream should
withdraw if the feed liquid is at its boiling point and a reflux ratio of 2.5 is used. Use
the McCabe thiele method.
Equilibrium Data:
X 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

Y 0.0 0.27 0.42 0.51 0.59 0.67 0.75 0.82 0.89 0.95 1.0

11. For the separation of a mixture of benzene and toluene, considered in question 1,
xd = 0.9, xw = 0.1, and xf = 0.4. If the mean volatility of benzene relative to
toluene is 2.4, what is the number of plates required at total reflux?

12. The equilibrium data for n-pentane and n-hexane at atmospheric pressure
X 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Y 0.21 0.41 0.54 0.66 0.745 0.82 0.875 0.92 0.975 1

A mixture containing 0.52 mole fraction is to be distilled continuously to give a top

product 0.95mol fraction pentane and bottoms of 0.1 mol fraction pentane. A relative
volatility of 2 is used and feed is all liquid at its boiling point
a. Determine the number of ideal plates at total reflux
b. By the mcabe Thiel method determine the number of total plates required and
position of the feed
c. Determine the composition on the second plate

13. A continuous fractionating column is to be designed to separate 30 000kg/hr of a

mixture 40% benzene and 60% toluene into an overhead product containing
97% benzene and a bottom product containing 98% toluene. These percent are
by weight, a reflux ratio of 3.3 is to be used. The molar latent heats of
vaporisation are7360 and 7960 calories/gmol respectively Benzene and toluene
data are given in question 1 The feed has a bp of 95 degrees Celsius at a
pressure of 1 atm
a. Calculate the moles of overhead and bottom product per hour
b. Determine the number of ideal plates i. if the feed is liquid at 20oC(specific
heat 0.44 cal/goC) ii. If the feed is a mixture of 2/3 vapour and 1/3 liquid and in
all cases a total condenser is used.

14. 1000 kg/hr of a mixture containing 42 mole percent heptane and 58 mole percent
ethyl benzene is to be fractionated to a distillate containing 97 mole percent
 heptane and a residue containing 99 mole percent ethyl benzene using a total
condenser and feed at its saturated liquid condition. The enthalpy-concentration
data for the heptane-ethyl benzene at 1 atm pressure are as follows:

xheptane 0 0.08 0.18 0.25 0.49 0.65 0.79 0.91 1.0

yheptane 0 0.28 0.43 0.51 0.73 0.83 0.90 0.96 1.0

Hl (kJ/kmol) x 24.3 24.1 23.2 22.8 22.05 21.75 21.7 21.6 21.4
10-3

Hv (kJ/kmol) x 61.2 59.6 58.5 58.1 56.5 55.2 54.4 53.8 53.3
10-3
Calculate the following:
a. Minimum reflux ratio
b. Minimum number of stages at total reflux
c. Number of stages at reflux ratio of 2.5
d. Condenser duty
e. Reboiler duty
15. A total of 100 gm-mol feed containing 40 mole percent n-hexane and 60 percent
n-octane is fed per hour to be separated at one atm to give a distillate that
contains 92 percent hexane and the bottoms 7 percent hexane. A total condenser
is to be used and the reflux will be returned to the column as a saturated liquid at
its bubble point. A reflux ratio of 1.5 is maintained. The feed is introduced into the
column as a saturated liquid at its bubble point. Use the Ponchon-Savarit method
and determine the following: Minimum number of theoretical stages The minimum
reflux ratio The heat loads of the condenser and reboiler for the condition of
minimum reflux.
a. Minimum number of theoretical stages
b. The minimum reflux ratio
c. The heat loads of the condenser and reboiler for the condition of
minimum reflux.
d. The quantities of the distillate and bottom streams using the actual
reflux ratio.
e. Actual number of theoretical stages
f. The heat load of the condenser for the actual reflux ratio
g. The internal reflux ratio between the first and second stages from the
top of tower.
STUDY QUESTIONS
1. What equipment is included in a typical distillation operation?
2. What determines the operating pressure of a distillation column?
3. Under what conditions does a distillation column have to operate under
vacuum?
4. Why are distillation columns arranged for countercurrent flow of liquid and
vapor?
5. Why is the McCabe–Thiele graphical method useful in this era of more
rigorous, computer-aided algebraic methods used in process simulators?
6. Under what conditions does the McCabe–Thiele assumption of constant
molar overflow hold?
7. In the McCabe–Thiele method, between which two lines is the staircase
constructed?
8. What is meant by the reflux ratio? What is meant by the boilup ratio?
9. What is the q-line and how is it related to the feed condition?
10. What are the five possible feed conditions?
11. In the McCabe–Thiele method, are the stages stepped off from the top
down or the bottom up? In either case, when is it best, during the stepping,
to switch from one operating line to the other? Why?
12. Can a column be operated at total reflux? How?
13. How many stages are necessary for operation at minimum reflux ratio?
14. What is meant by a pinch point? Is it always located at the feed stage?
15. What is meant by subcooled reflux? How does it affect the amount of
reflux inside the column?
16. Is it worthwhile to preheat the feed to a distillation column?
17. Why is the stage efficiency in distillation higher than that in absorption?
18. What kind of a small laboratory column is useful for obtaining plate
efficiency data?