Design of Distillation Column

DISTILLATION COLUMN
In industry it is common practice to separate a liquid mixture by distilling the components,
which have lower boiling points when they are in pure condition from those having higher
boiling points. This process is accomplished by partial vaporization and subsequent
condensation.

5.1 Distillation is defined as:

“Process in which a liquid or vapor mixture of two or more substances is separated into its
component fractions of desired purity, by
the application and removal of heat”.

5.2 Types of Distillation Columns:

There are many types of distillation columns, each designed to perform specific types of
separations, and each design differs in terms of complexity.

 Batch columns
 Continuous columns

5.2.1 Batch Columns:

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.

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5.2.2 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 and are the more common of the two types. We shall concentrate only on this
class of columns. Our process is for continuous column.

5.3 Choice between Plate and Packed Column:

Vapor liquid mass transfer operation may be carried either in plate or packed column. These
two types of operation are quite different. I have selected plate column for process because. The
relative merits of plate over packed column are as follows:

1. Plate column are designed to handle wide range of liquid flow rates without flooding.
2. If a system contains solid contents; it will be handled in plate column, because solid will
accumulate in the voids, coating the packing materials and making it ineffective.
3. Dispersion difficulties are handled in plate column when flow rate of liquid are low as
compared to gases.
4. For large column heights, weight of the packed column is more than plate column.
5. If periodic cleaning is required, man holes will be provided for cleaning. In packed columns
packing must be removed before cleaning.
6. For non-foaming systems the plate column is preferred.
7. Design information for plate column is more readily available and more reliable than that
for packed column.
8. Inter stage cooling can be provided to remove heat of reaction or solution in plate column.
9. When temperature change is involved, packing may be damaged.

5.4 Types of Plates:

There are three main types, sieve tray, bubble cap, valve tray. I’ve selected sieve tray because:
1. They are lighter in weight and less expensive. It is easier and cheaper to install.
2. Pressure drop is low as compared to bubble cap trays.
3. Peak efficiency is generally high.
4. Maintenance cost is reduced due to the ease of cleaning.

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Bubble cap tray

← Sieve Tray

Valve tray→

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5.5 Selection Criteria of Trays:

5.5.1 Cost:

Cost of plate depends upon material of construction used.

For mild steel, the ratio of cost between plates is

Sieve plate : valve plate : bubble-cap plate

3 : 1.5 : 1.0.
5.5.2 Capacity:

Sieve tray > valve tray > bubble-cap tray

5.5.3 Operating Range:

It is the range of liquid and vapor flow rates which must be above the weeping conditions and
below the flooding conditions. Operating range flexibility comparison is
Bubble cape tray > Valve tray > Sieve tray
For good design, sieve plate gives satisfactory operating range.

5.5.4 Pressure drop

Bubble-cap tray > valve tray > sieve tray

5.5.5 Sieve Tray

 Sieve plates are lighter in weight and less expensive. It is easier and cheaper to install.
 Pressure drop is low as compared to bubble cap trays.
 Maintenance cost is reduced due to ease of cleaning.
 If properly designed, sieve tray gives desired separation
 Simple to design.

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5.6 Components of Distillation Column:

A schematic of a typical distillation unit with a single feed and two product streams is shown
here.

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 A reboiler to provide the necessary vaporization for the distillation process. The liquid
removed from the reboiler is known as the bottoms product or simply, bottoms.
 Column internals such as trays/plates and/or packing which are used to enhance
component separations.’
 A condenser to cool and condense the vapor leaving the top of the column. The
condensed liquid that is removed from the system is known as the distillate or top product.
 A reflux drums to hold the condensed vapor from the top of the column so that liquid
(reflux) can be recycled back to the column. 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.
 In our process before reflux and getting product there is a two phase separator to
separate non-condensable gases.

5.7 Factors affecting Distillation Column Operation

5.7.1 Vapor Flow Conditions

Adverse vapor flow conditions can cause:

 Foaming
 Entrainment
 Weeping/dumping
 Flooding

5.7.2 Foaming:
Foaming refers to the expansion of liquid due to passage of vapor or gas. 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.
Whether foaming will occur depends primarily on physical properties of the liquid mixtures, but
is sometimes due to tray designs and condition. Whatever the cause, separation efficiency is
always reduced.

5.7.3 Entrainment:
Entrainment refers to the liquid carried by vapor up to the tray above and is again caused by
high vapor flow rates. It is detrimental because tray efficiency is reduced: lower volatile
material is carried to a plate holding liquid of higher volatility. It could also contaminate high
purity distillate. Excessive entrainment can lead to flooding.

5.7.4 Weeping/Dumping:
This phenomenon is caused by 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. That is the liquid on all trays will crash (dump) through to the
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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.

5.7.5 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
down comer, 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.

5.7.6 Reflux Condition:

Minimum trays are required under total reflux conditions, i.e. there is no withdrawal of
distillate. On the other hand, as reflux is decreased, more and more trays are required.

5.7.7 Feed Condition:

The state of the feed mixture and feed composition affects the operating lines and hence the
number of stages required for separation. It also affects the location of feed tray.

5.7.8 State of Trays and Packing:

Remember that the actual number of trays required for a particular separation duty is
determined by the efficiency of the plate. Thus, any factors that cause a decrease in tray
efficiency will also change the performance of the column. Tray efficiencies are affected by
fouling, wear and tear and corrosion, and the rates at which these occur depends on the
properties of the liquids being processed. Thus appropriate materials should be specified for tray
construction.

5.7.9 Column Diamete:

Vapor flow velocity is dependent on column diameter. Weeping determines the minimum vapor
flow required while flooding determines the maximum vapor flow allowed, hence column
capacity. Thus, if the column diameter is not sized properly, the column will not perform well.

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5.8-Design Steps of Distillation Column

 Calculation of minimum reflux ratio.

 Calculation of optimum reflux ratio.
 Calculation of theoretical no. of stages.
 Calculation of actual no. of stages.
 Calculation of diameter.
 Calculation of height.
 Calculation of no. of holes.
 Calculation of weeping and flooding.
 Calculation of pressure drop.

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Streams involved in Distillation Column

Stabilizer

5.9 Material Balance across Distillation Column:

Feed
COMPONEN Kg/hr mass Mass
T fraction COMPONENT Kg/hr Fraction
Water 2.095877 4.2074E-05 n-C7 5199.364 0.104375348
H2S 129.9035 0.002607765 i-C7 602.0374 0.012085682
C1 164.9759 0.003311832 22DM-P 2.867047 5.75549E-05
Db C2 1.573915 3.15958E-05 M-B 6.066237 0.000121778
C2 109.7214 0.002202617 n-C8 5631.111 0.113042503
Db C3 83.27675 0.00167175 db-C8 253.6585 0.005092102
C3 2314.562 0.046463989 i-C8 617.6902 0.012399907
Db iC4 134.5398 0.002700837 22DM-H 9.804628 0.000196824
iC4 462.4737 0.009283992 23DM-H 5.555933 0.000111533
nC4 3295.226 0.066150468 n-C9 6200.294 0.124468652
Db C5 3007.54 0.060375281 i-C9 891.2443 0.017891406
iC 5 272.5747 0.005471838 db-C9 234.6224 0.004709961
nC5 70.54097 0.001416084 n-C10 5870.263 0.117843393
CP 223.2878 0.004482422 db-C10 8.027153 0.000161142
23DMB 60.35506 0.001211606 22DM-O 337.8862 0.006782943
2MP 76.49376 0.001535585 n-C11 5764.763 0.115725526
3MP 38.08104 0.000764463 n PBz 823.1281 0.016523998
nC6 933.2214 0.018734082 db-C11 335.5354 0.006735751

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Benzene 373.001 0.007487861 n-C12 4001.741 0.080333493

MCP 205.9457 0.004134285 db C12 828.403 0.01662989
CH 230.6476 0.004630167

Stabilized Naphtha
Mass Mass
COMPONEN Kg/hr Fraction COMPONENT Kg/hr Fraction
T

Water 2.095877 4.86421E-05 n-C7 5199.364 0.120669333

H2S 0 0 i-C7 602.0374 0.013972372
C1 0 0 22DM-P 2.867047 6.65398E-05
Db C2 0 0 M-B 6.066237 0.000140788
C2 0 0 n-C8 5631.111 0.130689514
Db C3 0 0 db-C8 253.6585 0.005887027
C3 0 0 i-C8 617.6902 0.01433565
Db iC4 0 0 22DM-H 9.804628 0.00022755
iC4 0 0 23DM-H 5.555933 0.000128945
nC4 35.589 0.000825967 n-C9 6200.294 0.143899393
Db C5 3001.285 0.069655272 i-C9 891.2443 0.020684424
iC 5 223.2878 0.00518217 db-C9 234.6224 0.00544523
nC5 60.35506 0.001400749 n-C10 5870.263 0.136239869
CP 223.2878 0.00518217 db-C10 8.027153 0.000186298
23DMB 60.35506 0.001400749 22DM-O 337.8862 0.007841824
2MP 76.49376 0.001775304 n-C11 5764.763 0.133791382
3MP 38.08104 0.000883803 n PBz 823.1281 0.019103551

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nC6 933.2214 0.021658651 db-C11 335.5354 0.007787265

Benzene 373.001 LPG
0.008656787 n-C12 4001.741 0.092874315
MCP 205.9457 0.004779686
COMPONENT Kg/hr db C12mass fraction
828.403 0.019225974
CH 230.6476
H2S 0.005352981
55.66426 0.010534
C1 0 0
Db C2 0 0
C2 49.05812 0.009284
Db C3 57.17613 0.01082
C3 1662.779 0.314671
Db iC4 117.0257 0.022146
iC4 393.8367 0.074531
nC4 2886.503 0.546253
Db C5 5.920795 0.00112
iC 5 46.4868 0.008797
nC5 9.73247 0.001842

HP
Component Mass Flow mass fraction
H2S 74.23921 0.051476
C1 164.9759 0.114391
Db C2 1.573915 0.001091
C2 60.66326 0.042063
Db C3 26.10062 0.018098
C3 651.7828 0.451934
Db iC4 17.51407 0.012144
iC4 68.63706 0.047592
nC4 373.1342 0.258724
Db C5 0.334026 0.000232
iC 5 2.800105 0.001942
nC5 0.453443 0.000314

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5.10 Design Calculations:

Light Key: Normal Butane
Heavy Key: Normal Pentane

Calculation of Minimum Reflux Ratio:

Using Underwood Equation;

n αi xF
∑ α −θ =1−q i

i=1 i
By iterations we find

θ = 177.5
Now using
n αixD
∑ α −θ =Rmin +1 i

i=1 i
We find

Rmin = 1.334

I used actual reflux ratio as 1.5 times the minimum reflux ratio
So,

R = 1.5 (1.334)
=2

Calculation of Minimum number of Plates:

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Using Fenske relation;

x LK x HK

N min =
ln
( )( )
x HK D x LK B

ln ( α LK / HK ) avg

Nmin = 12

Theoretical number of Stages:

Here I used Gilliland-Eduljee relation;

E0 =19 .2−57.8 log α avg μ L
N = 22

Location of Feed Plate:

Using Kirkbride relation;

2
N
log D =0 . 206 log
NB {( B
D )(
x HK
x LK )[
F
( x LK ) B
( x HK ) D ]}
We get
ND
=0 . 621
NB

As we know that;
N +N = 22
D B
Hence
N =8 N = 14
D B

Actual Number of Stages

Tray Efficiency;

We have

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0. 566
N −N min R−Rmin
So, N +1 [(
=0 . 75 1−
R+1 ) ]
Eo = 74 %
Hence actual trays to be used will be
Nact = 29
Actual ND = 11
Actual NB = 18

Flow rates inside column:

Rectifying Section;

Ln = D×R
= 204 Kgmol/hr
Vn = Ln + D + overhead gases
= 344 Kgmol/hr

Stripping Section;

Lm = Ln + F
= 706 Kgmol/hr
Vm = L m – W
= 344 Kgmol/hr

Flooding Velocity in Stripping Section:

Flow Parameter; Lm ρV
F LV =

FLV = 0.44
√
V m ρL

Taking Plate Spacing = 0.8 m

From Graph B-1 Appendix B we get
K1 = 0.07
Now putting values in above relation we get Flooding velocity;

Uf = 0.25 m/sec

Column Cross sectional Area in Stripping Section:

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Taking Actual Operating Velocity to be 85% of the maximum flooding velocity we get
Operating Velocity = 0.21 m/sec
Vapor vol . Flow rate
Net Area=
Operating
2
Velocity
Net Area = 2.2 m
Taking Down-comer Area as 12% of total cross sectional area we get
Total Column cross sectional Area = Net Area/0.88
Ac = 2.5 m2

Column Diameter for Stripping Section:

area×4
Column Diameter =
√ π
DC = 1.78 m (5.82 ft)
Nearest available Standard = 1.83 m (6 ft)

Flooding Velocity in Rectifying Section:

Flow Parameter; Ln ρV
F LV =

FLV = 0.112
√
V n ρL

From previous Graph we get

K1 = 0.11
Now Flooding velocity;
ρ L−ρV
U f =K 1
√
ρV
Uf = 0.48 m/sec

Column Diameter for Rectifying Section:

Doing Similar Calculations for Rectifying Section we get,
Actual Operating Velocity = 0.41 m/sec
Net Area = 1.11 m2
Total Column cross sectional Area
Ac = 1.25 m2
Column Diameter = 1.26 m
Hence Two Diameters are well different from each other so we must use different Diameters for
both sections.
Nearest Standard available for Rectifying section = 1.37 m (4.5 ft)

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Tray Design for Stripping Section

Down-Comer Area = 0.12(Ac)
AD = 0.316
Active Area = Ac – 2AD
Aa = 2 m2
Hole Area = 0.07(Aa)
Take weir height = 38 mm
Plate Thickness = 3mm
Plate Spacing = 0.8m
Material of Construction = Stainless Steel

Weir Length:
As we have, Ad
×100=12
Ac
From Fig. 5.2 Appendix B we get
Lw
=0 .76
Dc
So,
Lw = 1.39 m

Weir Liquid Crest:

Using relation,
Lm
how =750
ρ L×Lw
how = 66 mm
( )
For minimum Crest use 70% of maximum flow
Lm
how ( min )=750
(
ρL ×Lw
×0 . 7
)
how(min) = 52 mm
Hence,
Min. Liquid Crest = hw + how = 90 mm

Weeping Check:
Using relation;
K 2 −0 . 9 ( 25 . 4−d h )
U min = 1/2
( ρv )
From Fig. 5.3 Appendix B ; K2 = 30.9
Hence we get,
Umin = 2.1 m/sec

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Actual minimum Vapor velocity through holes;

Vapor vol. flow rate
V act (min )= ×0 .7
Hole Area
V act(min) = 2.4 m/sec

Which is higher than min. required vapor velocity so there is no chance of weeping even at the
minimum possible vapor flow rate through column.

Area available for Perforations:

This area is actually that portion of the plate which is available for drilling perforations.
This area can be found by subtracting the Down-comer area, the area required to fix the plate
inside column with the column wall and the area left free of perforations to properly distribute
liquid over the plate.

Calming zone

Support Area

Ap = Active Area – Support

Area – Calming zone Area

Support Area:
Lw/Dc = 0.76
From Fig. 5.5 Appendix B;
θ = 99o

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Dc
r= +0 .025
2
r = 0.965
Arc length = r×θ
= 1.7 m
As = 2×Arc. × .05
= 0.17 m2

Calming zone Area:

From fig.
θc
a=r Sin
2
Putting values in above we get,
a = .74 m
Hence
Az = 4a × 0.05
= 0.15

Perforated Area:
Ap = Column Area – 2(Down-comer area) – Support area – Calming zone Area
= 1.7 m2

Number of Holes:
Single hole Area = π d
2
4 h
= 7.9 × 10-6 m2
No. of holes = Total hole area / single hole area
= 17682 holes

Hole Pitch;
Ah
=0.083
Ap
From Fig. 5.6 Appendix B
Lp
=3 .2
dh
So,
Lp = 10 mm

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Pressure Drop for Stripping Section:

There are three main sources of pressure drop

(a) Flow through holes
(b) Static head of liquid on plate
(c) Residual pressure drop

Total Pressure drop through a plate is thus the sum of the pressure drops from above three
sources.

Dry Plate Pressure Drop:

We know that,
2
u ρv

We have:
( )
hd = v
Co ρl

Ah
×100=8
and Ap
Plate thickness / hole diameter = 0.94
From Fig. 5.7 Appendix B we get:
Co = 0.82
Hence,
hd = 38.3 mm-liquid

Residual Head:
This is the head loss due to bubbling formation and other losses.
This is given by 3
12 . 5×10
hr =
ρL
hr = 23 mm-liq.

Total Pressure Drop:

Total head loss per plate = hd + hr + hw + how

ht = 165 mm-liq.
Pressure drop per plate = 9.81×10-3 × (ht) ×(ρL)
ΔP = 883 Pa

Hence,

Total Pressure drop in Stripping section;

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ΔPs = No. of plates in Stripping Section × ΔPp

= 16 Kpa

Down comer Backup:

Assuming that down comer is 6 mm below the weir level;
Then height of aperture thus formed is

hap= hw- 6
=32mm

Flow Channel at bottom of down comer;

Aap =hap×Lw
= 0.05m2
We know that,
Lmd 2
hdc =166 [ ]
ρc A m
So,
hdc =87.8
h b =h w +h ow +h t +h dc
we get
= 38+66.1+162+88
= 354mm

Residence Time:
Liquid residence time in down comer is given as

A d h bc ρ L
t r=
Lm
tr = 3.1 sec

Height of Stripping Section:

Hs = No of plates in Stripping section × Plate Spacing
+ Vapor Disengagement section
Hs = 16.3 m

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Tray Design for Rectifying Section:

Down-Comer Area = 0.12(Ac)

AD = 0.1769
Active Area = Ac – 2AD
Aa = 1.12 m2
Hole Area = 0.1(Aa) = 0.112 m2
Take weir height = 38 mm
Weir Length;
From Fig. 5.2 Appendix B we get
Lw/Dc = 0.76
So,
Lw = 1.12m

Weir Liquid Crest:

Using relation,
Ln
how =750
(
ρ L×Lw
how = 22 mm
)
For minimum Crest use 70% of maximum flow
Ln
how −min =750
how-min = 17 mm
(
ρ L×Lw )
×0. 7

Hence,
Min. Liquid Crest = hw + how = 55 mm

Weeping Check:
Using relation;
From Fig. 5.3 Appendix B K2 = 30.2

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K 2 −0 . 9 ( 25 . 4−d h )
U min = 1/2
( ρv )
Umin = 2.36 m/sec
Actual minimum Vapor velocity through holes;

Vapor vol. flow rate

V act (min )= ×0 .7
Hole Area
V act(min) = 2.9 m/sec
Which is higher than min. required.

Area available for Perforations:

Ap = Active Area – Support Area – Calming zone Area

Support Area:
Lw/Dc = 0.76
From Fig. 5.5 Appendix B;
θ = 99o
Dc
r= +0 .025
2 m
r = 0.71
Arc length = r×θ
= 1.23 m
As = 2×Arc. × .05
= 0.123 m2

Calming zone Area

From fig.
θ
a=r Sin c
2
a = .54 m
Az = 4a × 0.05
= 0.11 m2

Perforated Area:

Ap = Column Area – 2(Down-comer area) – Support area – Calming zone Area

= 0.9 m2

Number of Holes:
π
= d2
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 Design of Distillation Column

Single hole Area

= 7.9 × 10-6 m2
No. of holes = Total hole area / single hole area
= 14162 holes

Hole Pitch;

Ah
=0. 126
Ap
From Fig. 5.6 Appendix B
Lp
=2 .7
dh
So,
Lp = 8.5 mm

Pressure Drop
There are three main sources of pressure drop
(a) Flow through holes
(b) Static head of liquid on plate
(c) Residual pressure drop

Total Pressure drop through a plate is thus the sum of the pressure drops from above three
sources.

Dry Plate Pressure Drop:

We know that,
2
u ρv

We have:
hd =51 v
( )
C o ρl
Ah
×100=12. 6
Ap
and Plate thickness / hole diameter = 0.94
Therefore from Fig. 5.7 Appendix B we get:

Co = 0.86
Hence,
hd = 35 mm-liquid

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Residual Head:
This is the head loss due to bubbling formation and other losses.
This is given by
3
12 . 5×10
hr =
ρL
hr = 24 mm-liq.

Total Pressure Drop

Total head loss per plate = hd + hr + hw + how
ht = 123.4 mm-liq.
Pressure drop per plate = 9.81×10-3 × (ht) ×(ρL)
ΔPt = 640 Pa
Total Pressure drop in Stripping section;
ΔPR = No. of plates in Stripping Section × ΔPt
= 7.1 Kpa

Down comer Backup:

Assuming that down comer is 6 mm below the weir level;
Then height of aperture thus formed is
hap= hw- 6
=32 mm
Flow Channel at bottom of down comer;
Aap =hap×Lw
= 0.05 m2
Now,
Ln
hdc =166 [ ]2
ρc A ap
hdc =4 mm-liq.
Hence
h b =h w +h ow +h t +h dc
= 182 mm-liq

Residence Time:
Liquid residence time in down comer is given as

A d h bc ρ L
t r=
Ln

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tr = 6 sec

Height of Rectifying Section:

HR = No of plates in Rectifying section × Plate Spacing
+ Vapor Disengagement section
Hs = 9.7 m

Total Pressure Drop in Column:

Total Pressure drop in column is the sum of pressure drops in two sections,
Total ΔPT = ΔPs + ΔPR

ΔPT = 23 Kpa

Total Column Height:

Column height = height of stripping section + height of rectifying section
Hc = Hs + HR
= 26 m

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Equipment :- V-02
Operation:- Continuous
Function:- Stabilization of Naphtha

Design Data
No. of trays = 29 Column Height = 25.6 m
Efficiency=76% R=2
Stripping Section Rectifying Section
Diameter =1.83 m Diameter = 1.37 m
Height =16.22 Height = 9.4 m
No. of holes per tray = 17682 No. of holes = 14162
Pressure drop = 15.9 Kpa Pressure Drop = 7.1 Kpa
Weight Height = 38 mm Weir Height = 38 mm
Weight Length = 1.39m Weir Length = 1.12 m
Tray Spacing = 0.8 m Tray Spacing = 0.8 m
Hole Diameter = 3.175 mm Hole Diameter = 3.175 mm
2
Total Hole Area = 0.14 m Total Hole Area = 0.11 m2
Down Conner Area = 0.32 m2 Down Comer Area = 0.18 m2
Column Cross sectional Area =2.63 m2 Column Cross Sectional Area = 1.48 m2

Specification Sheet

Stabilization of Naphtha Page 92