-

Static Equipment
C- Distillation Tower
Definition :
A process in which a liquid or vapour mixture of two or more substances is separated into its component
fractions of desired purity, by the application and removal of heat.

Distillation Process Types

 Batch
 Continuous
Batch Process
In batch operation, the feed to the column is introduced batch-wise. That is, the column is charged with a
'batch' and then the distillation process is carried out. When the desired task is achieved, a next batch of
feed is introduced.
Continuous Columns
In contrast, continuous columns process a continuous feed stream. No interruptions occur unless there is a
problem with the column or surrounding process units. They are capable of handling high throughputs
andare the most common of the two types. We shall concentrate only on this class of columns.
Types of Continuous Columns
Continuous columns can be further classified according to:
 The nature of the feed that they are processing,
 Binary column -feed contains only two components
 multi-component column -feed contains more than two components
 The number of product streams they have
 multi-product column -column has more than two product streams
 extractive distillation -where the extra feed appears in the bottom product stream
 azeotropic distillation -where the extra feed appears at the top product stream
 The type of column internals
 Tray column -where trays of various designs are used to hold up the liquid to provide better contact
between vapor and liquid, hence better separation
 packed column -where instead of trays, 'packings' are used to enhance contact between vapor and liq .
 Where the extra feed exits when it is used to help with the separation,

Basic Distillation Equipment And Operation

A typical distillation contains several major components:
 a vertical shell where the separation of liquid components is carried out
 column internals such as trays/plates and/or packings which are used to enhance component Sep .
 a reboiler to provide the necessary vaporization for the distillation process
 a condenser to cool and condense the vapourleaving the top of the column
 a reflux drum to hold the condensed vapourfrom the top of the column so that liquid (reflux) can be
recycled back to the column

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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147
Process Description

The liquid mixture that is to be processed is known as the

feed and this is introduced usually somewhere near the
middle of the column to a tray known as the feed tray.
The feed tray divides the column into a top (enriching or
rectification) section and a bottom (stripping) section.
The feed flows down the column where it is collected at
the bottom in the reboiler.

Heat is supplied to the reboilerto generate vapor. The

source of heat input can be any suitable fluid, although in
most chemical plants this is normally steam. In refineries,
the heating source may be the output streams of other
columns. The vapor raised in the reboiler is re-
introduced into the unit at the bottom of the column. The
liquid removed from the reboiler is known as the bottoms
product or simply, bottoms.

The vapour moves up the column, and as it exits the top of the
unit, it is cooled by a condenser. The condensed liquid is
stored in a holding vessel known as the reflux drum. Some of
this liquid is recycled back to the top of the column and this is
called the reflux. The condensed liquid that is removed from
the system is known as the distillate or top product.

Column Internals
Trays: stage wise process (used to hold up the liquid to give better separation)
• Sieve
• Valve
• Bubble cap

Packings: continuous process (packed columns are used to enhance contact between vapour & liquid)
• Random packings
•Structured packings

Tray Columns
Basic requirements of tray design:
• Intimate mixing between liquid and vapour streams for efficient exchange of components
• Provide sufficient liquid hold-up for high efficiency mass transfer
• Ability to handle desired rates of vapour and liquid flows without excessive liquid entrainment or
flooding
• Minimal pressure drop on each tray (especially important in vacuum operation)

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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147
Distillation Trays
Sieve tray: metal, diameter & number of holes are design considerations (cheep and simple)
Bubble Cap tray: has raised chimneys fitted over each holed, a cap covers the riser. There is a space
between riser and cap to allow the passage of vapour. The vapour rises through the chimney directed
downwards by the cap on discharging through slots in the cap bubbling through the liquid on the tray.

Valve Tray: perforations are covered by lift able caps, self creating a flow area for passage of vapour
through the liquid. The lifting caps direct the vapour to flow horizontally into the liquid (better mixing)

Which tray type?

Factors to consider :( Cost – Operation Range / Flexibility – Efficiency)
Generally sieve plates are satisfactory for many applications (except for low vapor flow rates)

Packed columns
Packing characteristics in operation:
• Large surface area for maximum vapour/ liquid contact
• High degree of turbulence to promote rapid, efficient mass transfer between phases
• Open structure for low resistance to vapour flow, hence low pressure drops
• Promote uniform liquid distribution on surface
• Promote uniform gas flow across column cross-section
Smaller packing: increased capital cost, higher pressure drop, increased surface area.
Packings- note will need more energy to drive vapour up the column when using packing.

Three types:
• Broken solids; cheapest, hardly used, non-uniformity in size, unreliable performance, high pressure drop
• Shaped packing/ random packing
• Structured packing
Various random shaped packing including:
• Rasching Rings: simple hollow ring, oldest, cheapest, most widely used, less effective, not necessarily
most economic. Can be made in various material and ceramic and carbon.
• Lessing Rings: Rasching Rings with partitions across its centre, increased surface area and strength.
Ceramic and metals

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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147
• Pall Rings: superior performance, highly effective give better wetting and distillation. Liquid smaller
pressure drop than Rasching under same conditions, available in metals, ceramics and plastics.
• Berl saddles: less free gas space better aerodynamic shape, ceramic or plastic.

Selection of random packing

Need to consider:(Type – Size – Material )

Packings versus Trays

A tray column that is facing throughput problems may be de-bottlenecked by replacing a section of trays
with packings. This is because:
 packings provide extra inter-facial area for liquid-vapor contact
 efficiency of separation is increased for the same column height
 packed columns are shorter than trayedcolumns
 Packed columns are called continuous-contact columnswhile trayedcolumns are called staged-contact
columnsbecause of the manner in which vapor and liquid are contacted.
 Plate towers can be designed to handle a wider range of liquid and gas flow-rates than packed towers.
 Packed towers are not suitable for very low liquid rates.
 The efficiency of a tray can be predicted with more certainty than the equivalent term for packing
 Plate towers can be designed with more assurance than packed towers.
 It is easier to make provision for the withdrawal of side streams from tray towers.
 If the liquid causes fouling, or contains solids, it is easier to make provision for cleaning in a tray
tower; man ways can be installed on the trays. With small diameter towers it may be cheaper to use
packing and replace the packing when it becomes fouled.
 For corrosive liquids a packed tower will usually be cheaper than the equivalent plate tower.
 The liquid hold-up is appreciably lower in a packed tower than a plate tower
 Packed towers are more suitable for handling foaming systems.
 The pressure drop per equilibrium stage (HETP) can be lower for packing than plates; and packing
should be considered for vacuum towers.
 Packing should always be considered for small diameter towers, say less than 0.6m, where trays
would be difficult to install, and expensive .

Towers Functions
Fractionating “Tower”
Is used in referring to a counter-current operation in which a vapor mixture is repeatedly brought in
contact with liquid having nearly the same composition as the respective vapors.
Atmospheric Distillation "Tower"
Is the first step in any petroleum refinery, in which the separation of the crude oil into various fractions.
These fractions may be products in their own right or may be feed stocks for other refining or processing
units.

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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147
 Vacuum Distillation "Tower"
Is used to reduce the temperature for the distillation of heat-sensitive materials and where very high
temperatures would otherwise be needed to distill relatively non volatile materials.

Stabilization "Tower"
It is a fractionation operation conducted for the purpose of removing high-vapor pressure components.

Splitting "Tower"
It is a simple distillation process, in which separation of naphtha into two streams before further
processing can take place
.

Stripping "Tower"

Is the process where the requirements, to strip a volatile component or group of similar components from a
relatively non-volatile solution or product by the action of stripping gas or steam.

Column Reboilers
There are a number of designs of re‐ boilers , they can be regarded as heat exchangers that are required to
transfer enough energy to bring the liquid at the bottom of the column to boiling point.

Thermal Syphon Reboiler

Kettle Type Reboiler

Fired Heater Reboiler

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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147
Kettle Type Reboiler :
In this reboiler, the bottom product from the tower flows to the bottom of the reboiler and comes in
contact with the hot coils which are heated by steam or another heating medium. Part of the liquid is
vaporized and returns back to the tower. It is this hot vapor that passes up through the trays to fractionate
the product on each tray. Stated another way, the heat drives the tower. The liquid that is not vaporized
passes over the weir plate behind the tube bundle and is level controlled out of the reboiler.
The thermal syphon Reboiler
The thermal syphon reboiler uses convection alone to produce circulation. The bottom product flows to
the bottom of the reboiler by gravity. The addition of heat causes some of the liquid in the reboiler to
vaporize and the remaining heated liquid expands. The mixture of vapor and hot liquid in the reboiler has
a much lower relative density than the bottom liquid and a thermal syphon flow is produced.
Fired Heater Reboiler
The flow through the fired heater type reboiler must be positive to prevent overheating of the tubes in the
heater. The fractionator bottom pump circulates allor nearly all, of the bottom product through the
reboiler. A positive flow through all passes of the reboiler is very critical and the controls must be
interlocked so flow failure will shut down the burners to the heater. In some operations the fired heater
will supply heat to more than one fractionator.
Column Condensers
Liquid-vapor contact in the top of the tower is required to purify the overhead product and to condense
any bottom product that is being driven overhead. The condensing of someor all, of the overhead product
is accomplished by cooling the overhead product in a heat exchanger.
The overhead condenser may use any of the following for a cooling medium:
1. "Fin Fan Cooler", which is a heat exchanger containing finned tubes to increase the heating surface.
Air is forced across the tubes by fans, hence the name "Fin Fan".
2. "Water Cooled Condensers", in which the overhead product temperature may be controlled by
regulating the flow of cooling water through the condenser. This method may be employed to condense
all or part of the overhead product.

Partial Condensers :
The partial condenser is best used when there is a large difference in
the overhead vapor compositions. For example when there is a small
amount of methane and hydrogen mixed in a propylene stream, like
in the propylene towers. The partial condenser condenses the
propylene and leaves the methane and hydrogen as a vapor to be
vented from the overhead receiver.

Total Condensers
Total condensers are used to condense all the vapor product
coming from the top of the fractionator. The reflux and the
condensed product are essentially of the same composition and
control is maintained by regulating the amount of cooling
medium passing through the condenser. Total condensers are
commonly used in condensing LPG and heavier products.

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Hot Vapor By Pass Condenser
The hot vapor by pass condenser is best utilized when there is the potential for large changes of overhead
vapor composition. The vapor by pass can be used to maintain the pressure in the tower system when the
light components are lower than design. The hot vapor by pass condenser also has a lower installed cost
due to the heat exchanger being installed on the ground level.

Column Reflux
The word reflux is defined as "flowing back". Applying it to distillation tower, reflux is the liquid flowing
back down the tower from each successive stage.

Kinds of Reflux
A. Cold Reflux
Cold reflux is defined as reflux that is supplied at temperature a little below that at the top of the tower.
Each pound of this reflux removes a quantity of heat equal to the sum of its latent and sensible heat
required to raise its temperature from reflux drum temperature to the temperature at the top of the tower.

B. Hot Reflux
It is the reflux that is admitted to the tower at the same temperature as that maintained at the top of the
tower. It is capable of removing the latent heat because no difference in temperature is involved.
C. Internal Reflux
It is the reflux or the overflow from one plate to another in the tower, and may be called hot reflux
because it is always substantially at its boiling point. It is also capable of removing the latent heat only
because no difference in temperature is involved.

D. Circulating Reflux
It is also able to remove only the sensible heat which is represented by its change in temperature as it
circulates. The reflux is withdrawn and is returned to the tower after having been cooled.

E. Side Reflux
This type of reflux (circulating reflux) may conveniently be used to remove heat at points below the top
of the tower. If used in this manner, it tends to decrease the volume of vapor the tower handles.
Reflux Ratio
It is defined as the amount of internal reflux divided by the amount of top product. Since internal hot
reflux can be determined only by computation. Plant operators usually obtain the reflux ratio by dividing
actual reflux by the top product. It is denoted by R which equals L/D.
The Importance of Reflux Ratio
In general, increasing the reflux improves overhead purity and increases recovery of the bottom product.
The number of stages required for a given separation will be dependent upon the reflux ratio used.

Total Reflux
Total reflux is the conclusion when all the condensate is returned to the tower as reflux, no product is
taken off and there is no feed.

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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147
At total reflux, the number of stages required for a given separation is the minimum at which it is
theoretically possible to achieve the separation and total reflux is carried out at:
 Towers start-up
 The testing of the tower
Minimum Reflux
At minimum reflux, the separation can only be achieved with an infinite number of stages. This sets the
minimum possible reflux ratio for the specified separation.
Optimum Reflux Ration
Practical reflux ratio will lie between the minimum for the specified separation and total reflux. The
optimum value will be the one at which the specified separation is achieved at the lowest annual cost
(steam or vapor). For many systems, the optimum value of reflux ratio will lie between 1:2 to 1:5 times
the minimum reflux ratio.

Tower Problem Solving

1. Foaming
2. Entrainment
3. Weeping / Dumping
4. Flooding
5.Downcomer / Flooding
Foaming
 Foaming refers to the expansion of liquid due to passage of vapor or gas, caused by high vapor flow
rates.
 Although it provides high interfacial liquid-vapor contact, excessive foaming often leads to liquid
buildup on trays. In some cases, foaming may be so bad that the foam mixes with liquid on the tray
above.
 Whatever the cause, separation efficiency is always reduced.
Entrainment
 Caused by excessively high vapor flow rates.
 Entrainment refers to the liquid carried by vapor to the tray above.
 It is detrimental because tray efficiency is reduced: lower volatile material is carried to a plate
holding liquid of higher volatility.
 Excessive entrainment can lead to flooding.

Flooding
 Flooding is brought about by excessive vapor flow, causing liquid to be entrained in the vapor up the
column.
 The increased pressure from excessive vapor also backs up the liquid in the downcomer, causing an
increase in liquid holdup on the plate above.
 Depending on the degree of flooding, the maximum capacity of the column may be severely reduced.
 Flooding is detected by sharp increases in column differential pressure and significant decrease in
separation efficiency.
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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147
Weeping/Dumping
 Caused by excessively low vapor flow.
 The pressure exerted by the vapor is insufficient to hold up the liquid on the tray. Therefore, liquid
starts
 to leak through perforations.
 Excessive weeping will lead to dumping - the liquid on all trays will crash (dump) through to the
base of the column (via a domino effect) and the column will have to be re-started.
 Weeping is indicated by a sharp pressure drop in the column and reduced separation efficiency.

Downcomer Flooding
 Caused by excessively high liquid flow and/or a mismatch between the liquid flow rate and the
downcomer area.
 This can be avoided by ensuring that the downcomer back-up (level) is below 50% of the tray
spacing. This can be checked by performing tray sizing using a process simulator.
 If necessary, design multipass trays (see later).

. Distillation Important Notes

 To Control Tower Temperature:
 Reflux Ratio
 Temperature Gradient
 Reflux Ratio
 When reflux ratio is increased, the amount of reflux increases. The top product will therefore be
purer. In general, the higher the reflux ratio, the fewer the number of trays required for a given
separation. However, too high a ratio may cause flooding in the tower resulting in poor separation
and causing 'off-spec' products throughout the system. The reflux rate is normally controlled by a
temperature controller in the vapour outlet which operates a control valve in the reflux pump
discharge. An increase in tower top temperature will cause the valve to open, increasing the reflux
rate, and vice versa.

 Two points to consider

 A minimum number of plates (stages) required at total reflux.
 There is a minimum reflux ratio below which it is impossible to obtain the desired
 Temperature Gradient
 if feed and bottom temperatures are too high, too much heavy vapour will rise up the tower and
put side-stream products off-spec. This condition, combined with high reflux rate will again lead
to flooding and poor separation. Opposite conditions can lead to liquid starvation across the trays
and again, a very upset process will result.
 High top temperature will result in heavy components in the overhead product.
 Low top temperature will result in a lighter top product.
 The operating parameters to be selected by the designer include:
 Operating pressure
 Reflux ratio
 Feed condition
 feed stage location
 type of condenser
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 How Pressure Control Works
 Distillation pressure control uses either mass or energy balances around the unit. Mass methods
control pressure by regulating the amount of flow into or out of the tower.
 Energy methods regulate the heat flow into and out of the tower.
 In general, mass flow methods control the tower vapor inventory. This may be directly by
throttling the vapor rate out of the system or indirectly by manipulating downstream equipment
that evacuates gas from the system.
 Energy methods control the heat flux in the overhead condenser.
 Coning
 Poor vapor-liquid contact occrs due to the vapor forming jets
 increasing the number of stages will improve separation..!!!
 These strangely shaped pieces are supposed to impart good Vapor liquid contact when a
particular type is placed together in numbers, without causing excessive pressure drop
across a packed section. This is important because a high pressure drop would mean that
 Distillation Column Design
 Pease Follow the basis of sizing distillation columns using the McCabe-Thiele graphical design
methodology .
 Nmin This corresponds to total reflux and Nminis determined by Fenske equation
 Please Follow Flash Calculations
 Drwaing Tower over view is very important

 Troubleshooting

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Process Engineer at Gulf Of Suez Pet. Mobile: +02 01091217147