Feeeesv2090009000009890909090920920092099 a SITPL Process Engineering A SIT MODULE - V Post Graduate Diploma in “PROCESS ENGINEERING” SUVIDYA INSTITUTE OF TECHNOLOGY © oz | 1207201 ested! for Training Pop AS or | 15.02.2008 ‘or Training vom DESCRIPTION oo REVIEWED BYMe ccccceose vee onesnecaveescenesve000arSITPL Process Engineering PREFACE SIT (Suvidya Insttute of Technology) is a leading provider of industrial training to meet the requirements of skiled manpower in the field of "OIL & GAS". Our aim is te develop skilled manpower in specialized field and to provide expert engineers to the industry, who are net only confident about their subject but ean also handle their job activities independently & efficiently. Si7 is a team of young, efficent, qualified and hardcore professionals wth broad spectrum of consultancy and industrial background. Our industrial training programmes are based on sound engineering principles & methodology, applicable code requirements and best industrial practices. We are awace that, "Engineer is the key person in the material progress of the world. Iti his engineering that converts the potential value of science into service by tanslating scientife knowledge into too's, resources and enaegy. Te make contributions of this kind the Engineer requires three things; the imagination to visualize the needs of society, an eye to appreciate what is possible, last and most important the technological and broad social understanding to bring his vision into reality. ‘Swit changes in global scenario and market, have transformed the dimensions of professionals in every Industry, The specialist from any field of engineering has to focus more and more narrowy on his specialized topies & work area rather than broad spectrum of faculty. This has heightened the chatenges of young & passionate Engineers. By realizing, this great obligation to build Technocrat Engineers and well-grounded Indian Work force, to ‘compete global requirements of industry, young, energetic, qualified, top notch professionals tram Software, ‘Consuttaney & Industrial background, we have formed a Consortium and laid the foundation of SIT. Keeping global competition in mind, SIT has designed professional courses which are a combination of theory, latest industrial practices and practical sessions. Our institute offers. numbers of courses to cover ‘wide spectrum of industrial aspects, which are recognized by industries. Syllabus covered in these courses is exactly ss per the global standards as well as latest werking requirements of various engineering companies. To develop proficient thinking skis in our participams we hhave adopted case study approach. ‘Course struchires are not at a dry accumulations of facts but it has way of thinking about possibie ‘ificuties, ways to find solutions of obviously puzziing problems, which make our students well equipped to be in lead roles. The overall stucture assesses the students against the requirements, which incuade key “thls, knowsedge tevel and execution power thal define competencesMM eocecsceesee sev eeseseeseseeeogeeeoeene@Pxaoseeesceveeere00¢0 cs cevecn00se0es « U® SITPL Process Engineering Our Faculty... SIT is slobally known for ite educational values and ethics. Cur faculty members are the experienced, leading professionals from top relevant organizations. These experts have the skill of ifusvating highly complex subject with an engaging combination of clartly & wit: This transforms complex engineering into easy leaming states. Practical sessions have been designed to set to rest all difficuties in classroom teaming. These sessions are vial paris of eur courses. Having attained tim teoting, our organization is very keen to be a livewire of Industry and offer consultancy services on various industrial & development Projects. Our Students nave made strong impact & carved niche aitference in the Industry. They are rendering their services to various Industries in India & Abroad. “Their every contribution to Industry has made us proud. ‘Our Services, ‘= Industry specifi Training in various disciptines of Engineering ‘= Corporate Training as per the Company requirement ‘= Ineplant Training facies. ++ Case Studies to develop rational thinking skit ‘= Seminars to update knowledge. ‘+ Industrial vist to develop visualization skis + Personality development and Mock Interviews to develop confidence. = Opportunity to work on Live Projects. ‘© Guidance to choose a right €areer ‘= Enhancing the non-technical students to bud up thelr Career. ‘Some of the companies where our students have made strong impact... ‘+ Ms, Petrofac Engineering India Ltd - Mumbai + Mis, Aker Solutions Pvt, Lid. — Mumbai + Ms, Toye Engineering India Lid, - Mumba Tecnimont ICB Pvt. Lid, ~ Mumbal Retance Engineering Associates Pvt Ltd - Mumbsi Bechtel india Pvt, Ltd, - Gurgaon Flour Daniel India Pvt.Ltd. - Gurgaon Mott MacDonald Pvt. Lic. - Mumbai UHDE India Ltd, Chemtex Engineering India Ltd. « Mumbai Jacobs Engineering India Ltd. - Mumbai + Mis, Larsen & Turbo Lid, Faridabad .....and many more in india and abroad, RRFEERREEE |veces eeseovoeecetesesveseneeeseenese®@vse00e00000093000008909093000000000 0 STL Process Engineering ‘Objectives of these Courses... ** Tovidentity the basic vocabulary and to introduce the major concepts of design + To provide & understand the basic requirements for design as per the intamational cades & standards, + Tounderstand how to design eost effective new installation + Tounderstand how to create cost effective design in trouble shooting as well as while improving existing system ‘SPECIALISED COURSES OFFERED BY US WHO CAN ATTEND: = Piping Engineering = Mechanical, Chemical & Production Engineers + Advanced Pipe Stress Analysis + Mechanical/Chemical Engineering’ Piging Engineers + HVAC = Mechanical & Production Engineers. Process Engineering een tneenfhemical Engineers, *+ Mechanical Design of Frocess Equipment - Mechanical / Production Engineers ‘= Structural Engineering. ~ Civil 'Structural Engingers, ‘= Electrical Engineering + Electrical Engineers ‘= Instrumentation & Control ~ Instrumentation f Electronics Engineers. Water & Waste Water Engineering. = Engineers, BSc & Msc ‘+ Engineering Design & Dratting. > HSC + Piping Design & Dratting ~ IT1+ Mechanical Draughtsman TOGETHER WE WILL BRING NEW DIMENSIONS TO ENGINEERING A\SsIT ‘SUVIDYA INSTITUTE OF TECHNGLoGY ®Mee eeegeeooeveoveeeseeeese88 2009000098080Peeaseevesesseosesesveaeeneaoen000n a a ei SPL - Process Engineering INDEX CONTENTS Page Nos. 1. SEPARATION COLUMNS (DISTILATION, ABSORPTION }.. 2. SCRUBBER DESIGN... 3. VAPOUR LIQUID SEPARATORS... 4. BE-EG-UE109 GUIDE FOR VESSEL SIZING 5. DESIGN OF GRAVITY DECANTER... 6, DESIGNING ENTRAINMENT SEPARATION VESSELS......... 7. DESIGN OF CYCLONE SEPARATOR-GAS SOLID SEPARATION. 8. AREA CLASSIFICATION... ates 9. OISD-STD-118. 208 40, SCALE UP TECHNIQUES. si 30 44, REACTOR SIZING & AGITATOR DESIGN. 233 42. VACUUM PUMP: CAPACITY: 237 43. PNEUMATIC CONVEYING DESIGN.. 4d. EJECTOR.PUeecoeeeceooececeeeesseseseesenasnenn0n 9sm. Pracess Engroming A SIT SUVIDYA INSTITUTE OF TECHNOLOGY © SEPARATION COLUMNS DISTILATION, ABSORPTION) Fosnonnscvennseeenec00009 0000000000000Preece eceeo ces esses eseeeeesennenaenyCosesesveeesessenecesengseasse0en0dw SITPL Process Engineering Separation Columns (Distillation, Absorption) 11.1, INTRODUCTION ‘This chapter covers the design of separating columns. Though the emphasis is on distil- lation processes, the basic construction features, and many of the design methods, also apply to other multistage processes; such as stripping, absorption and extraction. Distillation is probably the most widely used separation process in the chemical and allied industries; its applications ranging from the rectification of aleobol, which has been practised since antiquity. to the fractionation of crude oil. Only a brief review of the fundamental principles that underlie the desigm procedures ‘will be given; a fuller discussion can be found in Volume 2, and im other text books: King (1980), Hengstebeck (1976), Kister (1992). |A good understanding of methods used for correlating vapour-Fiquid equilibrium data is essential to the understanding of distillation and other equilibrium-staged processes; this subject was covered in Chapter 8. In recent years, most of the work done 1o develop reliable design methods for distillation pment has heen carried out by a commercial organisation, Fractionation Research {av organisation set up with the resources to carry aut experimental work on full- ize columns, Since their work is of a proprietary nature itis oot published in the open fiterature and it has not been possible to refer to their methods in this book. Fraction- tion Research's design manuals will, however, be available to design engineers whose cconipanies are subseribing members of the organisation. ce Distillation column design “The design of a distillation column ean be divided into the Following steps: . Specify the degree of separation sequired: set product specifications. Select the operating conditions: batch oF continuous: operating pressure. | Select the type of contacting device: plates or packing. Determine the stage and reflux requirements the number of equilibrium stages. Size the column; diameter, number of real stages. Design the column internals: plates, distributors, packing supports. Mechanical design: vessel and internal fittings. 1p will be to determine the stage and reflex requirements. This is ‘imple procedure when the feed is a binary mixture, but complex ap pePPe ‘The principal a relativelySITPL and difficult task when the feed contains more than twe components (multicomponent systems). 11.2, CONTINUOUS DISTILLATION: PROCESS DESCRIPTION ‘The separation of liquid mixtures by distillation depends on differences in volatility between the components. The greatcr the relstive volatilities, the easker the separation. ‘The basic equipment required For continuous disilation is shown in Figare 11.1. Vapour Hows up the column and tiquid eounter-currently down the columa. The vapour and liquid fire browght into comtaet on plates. or packing. Part of the condensate from the condenser je retmed to thee top of the column ko provide liquid flow above the Feed pesint (refi), fait part of the Hiquid Grom the Biase of the column is vaporised im the rehoier and returned to prowide tse vapour Now. a o Figwe 11.1 Duttatisn ootaren 141 Basie columa (0) Suhipte feds and side stream, In the Section below the food, the more volatile components are sxipped from the liquid and this is known as the stripping section. Above the feed, the concentration of the more ‘volatile components is increased and this is called the enrichment, or more commonly, the reciifging section. Figure 11.1a shows a column producing two product streams, referred to as fps and Bottoms, from a single feed, Columns are occasionally used with more than one feed, ane! with side steams withdrawn at points up the coluran, Figtre 11.1, “This does not alter the hasic operation, but complicates the analysis of the process, to some estent Process Engheering Ceeeeeeecoeceseceeeeeseeeseeeeeeseee os agSvseeseseseoss covesesensseanso0enas SIP. Process Engineering ithe process requirement isto strip a volatile component from a relatively non-volatile solvent, the rectifying section may be omitted, and the column would thea be called a steipping column, In some operations, where the top product is required as a vapour, only sufficient liquid is condensed to provide the reflux flow to the column, and the condenser is referred to as a partial condenser. When the liquid is totally condensed, the liquid retumed to the column will have the same composition as the top product. I a partial condenser the reflux will be in equilibrium with the vapour leaving the condenser. Virtually pure top ‘and bottom products can he obtained in a single column from a binary feed, but where the feed contains more than {wo components. only a single “pure™ product can be produced. ther from the top oF battom of the column. Several columns will be needed to separate imponent feed into its constituent parts, 11.2.1, Reflux considerations ‘The reflux ratio, A. is normally defined as: ea flow retest as ets = How of top product taken off ‘The number of stages required far a given separation will be dependent on the reflux ratio used. in an operating column the effective reflux ratio will be increased by vapour condensed, within the column duc to heal leakage through the walls. With a well-lagged colume the heat foss will be small and no allowance is normally made for this increased flow in. design calculations. If a column is poorly inculated. changes in the internal reflux duc vo auudden changes in the extemal conditions, such as a sudden rain storm, ean have s noticeable effect oa the eolumn operation and control. Total reflux ‘Total reflux js the condition when all the condensate is remmed to the column as reflux: no product is taken off and there is no feed. ‘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. Though sot a practical operating condition, it is a useful guide to the likely number of stages that will Be ceded. | ‘Columns are often started ap with no product take-off andl operated. at total refhus till steady conditions. are attained. The testing of columns is also conveniently carried out at rotal reflux. Minimum nium reflux os [As the reflux ratio is reduced a pinch point Will occur at which the separation can ‘only be schieved with an infinite number of stapes. This scts the minimum possible reflux eatio for the specified separation.Process Engineering Optimum retiux ratio Practical reflux ratios will lic somewhere between the minimum for the specified separation and joint reflux. ‘The designer must select a value at which the specified separation is achieved at minimum cost. Increasing the reflux reduces the aumber of stages required, fd hicnex the eapital cast, but increases the service requirements (steam and. water) andl the operating casts, The optimum reflux ratio will be tkat which gives the lowest annual Operating cost. No hard and fast roles can be given for the selestion of the design reflux fitio, but for many systems the optimum will lie between 1.2 to 1.5 times the minignum ratio. or new designs, where the eatie cannot Be decided on from past experience, the effect ‘of reflux ratio on the number of siages can be investigated using the short-cut desiga methexts given in this chapter, This will usually indicate the best of value f0 use in mont imber of stages will be very dependent on the accuracy of the vapour-liquid equilibrium data available. If the data are suspect a higher than nermial ati should be selected to give more confidence in the design. 11.2.2, Feed-point location ‘The precise location of the feed point will affect the number of stages required for a specified separatign and the subsequent operation of the column. As a general rule. the feed should enter the column at the point that gives the best match hetwecn the feed ‘The precise location of the feed point will affect the number of stages required for a. specifica separation and the subscquent operation of the column. As a general rule, the feed should enter the column at the point that gives the hest match between the feed composition (vapour and liquid if two phases) and the vapour and liquid streams in the column. In practice, it is wise to provide two or three feed-point nozzles located round the predicted feed point te allow for uncertainties in the design calculations and data, and possible changes in the feed composition after startup. 11.2.3. Selection of column pressure Except when column opcrating-pressure will be to ensure that the dew point of the di that which ean be easily obtained with the plant cooling Water. The maximum, summer, of cooling Water is usually taken as. 30°C. If this means that high pressures will be needed, the provision of refrigerated brine cooling should be considered. Vacuum operation is uscd to reduce the column temperatures for the distiflation of heat-sensitive ind where very high temperatures would otherwise be needed to distil relatively materials, culating the stage ancl reflux requirements it is usual to take the operat pressure a5 constant throughout the column, In vacuum columns, the column pressure mop will he a significant fraction of the total pressure and the change in pressure up the column should be allowed for when calculating the stage temperatures. This may require {tial and errer calculation, as clearly the pressure drop cannot be estimated before ait mate of the number of stages is Te feeceeeeseeceeeeceeesceteaeseoeeeeecaggTosooocesceosve000 00200 0000000000000 ‘SITPL Process Engineering It is comvenicat to carry out the analysis in lerris of equilibrium stages” 1s 29 equilibcium stage (ibeoretial plate) the liquid and vapour strcamy leaving the sagt ne hen to be io equilibrism, and their compouitions are deizrmined by the vapour Tigeid equilibrium relatioaship for the system (see Chapter 8). In terms of equilibriure comuanss: we ht ange “The performance of real sages i eeated to an equillsium stage by the concer of pice Taacte for plate contactors, pd “height of an equivalent thecretrat plate” for packed otuma. Ta adlcion 10 the equations arising from the material and cncies talances ovet stage. und de cealibeam relationships there wil be 2 four refatonship, the wemmation Dunties for a hiquid and vapour compositions Pe ee ae “These four equalions ave the so-ealled MESH cquations forthe stage: Materiat atace, Equitoriien Seonmatina and Heal (e0ergy) talsnee, equations. MESH equations “an Se atten for each singe, and for the reboiler and condenser, The solution of this set of Teiieas forma the banis of the rigorous methods that Rave heen developed for te iis for aged separation processes 44.3.2. Dew points and bubble points “To eatimate the Suge. and the condenser aod reboiler temperatures. procedares are required for calculating dew and bubble points. By defiaition, a saturated liquid is at its bubble ia temperature Will cause 2 bobbie of vapour \o form). and 2 saturate’ Cipou iat fs dew pouot (any drop ia temperature will cause 4 érop of liquid «0 frm). ‘Dow points and bubble points can be calculated from a knowleege of the vapost-liqad equilibeiom fot the system. In terms of equilibrium constaats, the Subtle point is defied by the equation: butte potas Sn ku Le (tsa sod dew past: x= Ee to (a1se For cwilticomposest mixtures the teespersture that satisfies these equations. at « give system pressure, must be found by trial and error For biaary systems the equations can be solved more read compositions are not indcpendeat; fixing one fixes the other. welnn mel ‘yermuse the component née (11.685 "7SITPL 11.3.3. Equilibrium flash calculations In an cquilitwium flash. process a feed stream is separated into liquid and vapour streams at equilibrium, The composition of the streams will depend oa the quantity of the feed ‘aporisce (Rlashed), The equations uscd for equilibrium Mast calculations are developed below and a typical calculation is sown in Example 11.1 Flash ealculations are offen needed fo determine the condition of the feed to a dist column and, oceasionally. 10 determine the flow of vapour from the reboiler, or condenser if a partial condenser is used. Single-stage flash distillaion processes are used to make a coarse separation of the light components in a feed: often as. a preliminary sigp before a multicomponent distillation column, as in the distillation of crude oil. Figure 11.3 shows a typical cquilibriumn fash process. The equations describing this process are wy fe Ly Figure 11.3. Mash aieuttaboa Material balance, for any component, i ain Energy bbalanee, total stream onthalpiex: Flys Vit+ Lh asy If the vapour-fiqaid equilibrium relationship is expmessed in terms of equilibvium constants, equation 11.7 can be write ina amore useful frm: VA + bs muff from which L= sand, soilaly fa veer Z atl.10) Vi os mieteeeeeceteoeeceetoeeoeneeeeeeees se agSCS SBSESOFA OF ECAFCATHFOHOVF9R2990909000 ‘STPL “The groups incorpor have a general significance in separation process calculations. The group L/V'K;, is known as the absorption factor 4. and is the ratio of the mols of any component in the liquid stream to the mols in the vapour stream, Tho yroup VK; /L is called the stripping factor Sand is the reciprocal of the absorption facior Efficient techniques for the solution of the trial and error calculations necessary in multicomponent flash calculations are given by several authors; Hengstcbeck (1976) and King (1980). Example 11.1 A feed to a column has the composition given in the table below, and is at a pressure of 14 bar and a temperature of 60°C. Calculate the flow and composition of the liquid and vapour phases, Take the equilibrium data from the Depriester charts given in Chapter 8. kmolh x Feed ethane (C2) 2% 0.25 propane (Cy) 2 0.25 isobutane GCs) 200.25 mepemtane (ns) 200.25 Solution For two phases to exist the flash temperature must Ife between the bubble point and dew point of the mixture. Foon equations TH Sa and 1 1Sbe Check feed condition Ky wR ee G3 098 ‘007 c 13. 033 a9 ics 0438 058, nts «016004 1.56 Els E240 therefore the feed is a two phase mixture. aProcess Engineering “v= Ler Liv =2.80 for L/V. The ealentated values Hengstobock’s method is used to find the third trial value ith a line at 45° (ealeulated = are plotied against the assumed values and the intereept ascurmed) gives the new trial value, 24. ya vv w= (Fay — Vite 052 on 0.30 0.23 0.13 030 0.08 033 Veg = 2358 1.0 1.00 E = 2358 = S642 kmol/h, LIV calcula $6.42 /23.58 2.39 close enough tothe assumed value of 2.4. Adiabatic flash In many flash processes the feed stream is at a higher pressure than the fash pressure tnd the heat for vaporisation is provided by the enthalpy of the feed. In this situation the fash temperature will not be known and must be found by tial and error. A temperature must be found at which both the material and cneegy halanees are satisfied. 11.4. DESIGN VARIABLES IN DISTILLATION It was shown in Chapter 1 that to carry out a design calculation the designer must specify ‘values for a certain number of independent variables to define the problem completely, and that the case of calculation will often depend on the judicious choice of these design variables. In manual calculations the designer cad use intuition in selecting the design variables and, as he proceeds with the calculation, can define other variables if it becomes clear that 7% Ce eoeeFCeCeeoeeseceeotoboeteaeeseeveee se ogT42SFsSF2HH2 FH T2HHHHTFORTGHTFHRBE990900 ‘SITPL ‘Process Enginmering the problem is not sufficiently defined. He can also start again with a new set of design variables if the calculations become tortuous. When specifying a problem for a computer method jt is essential that the problem is compl i In Chapicr 1 it was showa that the number of independent variables for any problem is equal to the difference between the total number of variables and the number of finking. equations and ather relationships. Examples of the application of this formal procedure for determining the number of independent variables in separation process calculations are given by Gilliand and Reed (1942) and Kwauk (1956). For a multistage, multicomponent, colume, there will be a set of material and enthalpy balance equations and equilibrium relationships for each stage (the MESH equations), and for the reboiler and condenser, for each component, If there are more than a few stages the task of counting the variables and. ‘equations becomes burdensome and mistakes ane very likely to be made. A simpler, more practical, way to determine the number of inlependent variables ts the “description rule” procedure given by Hanson ef af, (1962). Their description rule states that to determine 2 Separation process completely the number of independent variables which must be set (by the designer) will equal the number that are set in the construction of the column or that ‘can be controlled by extemal means in its operation, The application of this rule requires the designer to visualise the column in operation and list the number of variables fixed by the column construction; thase fixed by the process; and those that have to be controlled for the column to operate steadily and produce product within specification, The method is best illustrated hy considering the operation of the simplest type of column: with one feed, no side streams, a total condenser. and a reboiler. The construction will fix the number of stages above and below the feed point (Iwo variables). The feed composition ‘und total enthalpy will be fixed by the processes upstream (1 + (a — 1) variables, where a is the number of components). The feed rate, column pressure and condenser and reboiter duties (cooling water and steam flows) will be controlled (four variables). 6 1 of variables fixed = 2414 (1-1) +4 Total num ‘To design the column this number of variables must be specified completely to define the problem, but the same variables need not be sclected. “Typically. in a design situation, the problem will he to determine the number of stages required at a specified reflux ratio and column pressure, for a given feed, and with the product compositions specified in terms of two key components and one product flow- rate, Counting up the number of variables specified it will be seen that the problem is completely defined: Feed flow, composition, emthalpy +@-D Reflux (sets 4.) 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