Ministry of Higher Education
Higher Institute of Engineering and Technology in
New Damietta
Chemical Engineering Department
Higher Institute of Engineering and Technology in
New Damietta
Chemical Engineering Department
Report Name :
Submitted to : DR / Reham Atif
Name Code
Ahmed Mahmoud Elgarib 38-2020
Manal Mohamed Wehba 287-2020
Mariam Khaled Nafea 280-2020
I
THE CONTACT
Table of figure .......................................................................................................................................... III
Table of tables.......................................................................................................................................... III
Introduction: ............................................................................................................................................ IV
Classification of tray:................................................................................................................................. 1
focus Design of Trays: ............................................................................................................................... 1
Valve tray: ................................................................................................................................................. 2
Advantages: ...................................................................................................................................... 2
Disadvantages ................................................................................................................................... 2
applications: ...................................................................................................................................... 2
Sieve tray: ................................................................................................................................................. 3
Advantages: ...................................................................................................................................... 3
Disadvantages: .................................................................................................................................. 3
Applications: ..................................................................................................................................... 3
Bubble cap tray: ........................................................................................................................................ 3
Advantages: ...................................................................................................................................... 4
Disadvantages: .................................................................................................................................. 4
Applications: ..................................................................................................................................... 4
Other type of trays:................................................................................................................................... 4
Dual flow trays: ................................................................................................................................. 5
Baffle trays: ....................................................................................................................................... 5
Comparison between Common Conventional Trays. ............................................................................... 6
Tray Parameters........................................................................................................................................ 7
a) No. of passes (Np): ........................................................................................................................ 7
b) Tray Spacing (S): ............................................................................................................................ 7
c) Outlet Weirs (hw): ......................................................................................................................... 7
d) Downcomer Clearance (hcl):......................................................................................................... 7
e) Inlet Weirs & Recessed Seal Pans: ................................................................................................ 7
f) Downcomers:................................................................................................................................. 7
g) Downcomer width (Chord height, WDC): ..................................................................................... 7
h) Flow path length (FPL): ................................................................................................................. 7
i) Tray deck thickness (t): .................................................................................................................. 7
j) Hole pitch (P): ................................................................................................................................ 8
k) System (Derating) factors: ............................................................................................................ 8
l) Bubbling (Active) Area (AB):........................................................................................................... 8
m) % Hole Area: ................................................................................................................................ 8
n) Anti jump baffles:.......................................................................................................................... 8
Reference : ................................................................................................................................................ 9
II
Table of figure
Figure 1 :types of flow .............................................................................................................................. 1
Figure 2 :Valve tray ................................................................................................................................... 2
Figure 3 :Sieve tray ................................................................................................................................... 3
Figure 4 :Bubble cap tray .......................................................................................................................... 4
Figure 5 :Dual flow trays and baffle tray................................................................................................... 5
Table of tables
Table 1 :compare factore selection between trays & packings ............................................................... IV
Table 2 :Comparison between Common Conventional Trays. ................................................................. 6
III
Introduction:
Once the process design stage ends, the equipment design begins. This stage of design converts process
requirements into actual hardware.
One of the most prominent hardware’s used for mass transfer is tray. Tray columns are widely used in
various types of mass transfer operations. All the simulation results, which predict a certain number of
theoretical stages, can be converted to actual trays depending upon tray efficiency for a particular service.
In any conventional tray vapor rises through the liquid pool on the tray deck and then disengages from
the liquid in the space above the deck. Liquid enters the tray from a down comer above and leaves via a
down comer below.
Conventional Tray has three functional zones:
Active area for mixing vapor and liquid: This is the zone where mass transfer occurs.
Vapor space above the active area: This is the zone in which liquid is separated from vapor.
Down comer between trays. This zone has two functions, first moving liquid from one contacting tray to
another and second disengaging vapor from liquid.
Each of these zones takes up vertical and horizontal space in the tower.
Selection Guide for Tray Column:
The factors discussed below influence the choice between trays & packings. As these are guidelines for
selection of trays or packings for a particular service, it is recommended to analyze each design case on
its own merit for selection.
Table 1:compare factore selection between trays & packings
No. System Favoring Tray Column System Favoring Packed
Column
1 Solid handling Vacuum system
2 High liquid rate Low pressure drop application
3 Feed composition and variabletemperature Revamps- The pressure drop Reduction can
be translated intocapacity gain, an energy
gain or
separation improvement.
4 Large diameter columns Small diameter columns< 900
mm
5 Performance prediction is easy Corrosive system
6 Less weight saving in cost Foaming system
foundations and supports
7 Interboilers, intercondensers,cooling coils % Low liquid holdup for reducing
side draw polymerization and degradation.
8 High turn down requirements Batch Distillation
9 Chemical reactions
The industry, based on its experience, has standardised the type to be used in certain services. If this
reference is not available the guideline as per Appendix 1 are to be used
Classification of tray:
The main requirement of a tray is that it should provide intimate mixing between the liquid and vapour
streams, that it should be suitable for handling the desired rates of vapour and liquid without excessive
entrainment or flooding, that it should be stable in operation, and that it should be reasonably easy to erect
and maintain. In many cases, particularly with vacuum distillation, it is essential that the drop in pressure
over the tray should be a minimum. The arrangements for the liquid flow over the tray depend largely on
the ratio of liquid to vapour flow. Three layouts are shown in Figure 11.50, of which the cross-flow
arrangement is much the most frequently used. Considering these in turn:
Figure 1:types of flow
(a) Cross-flow. Normal, with a good length of liquid path giving a good opportunity for mass transfer.
(b) Reverse. Downcomers are much reduced in area, and there is a very long liquid path. This design is
suitable for low liquid-vapour ratios.
(c) Double-pass. As the liquid flow splits into two directions, this system will handle high liquid vapour ratios.
The liquid reflux flows across each tray and enters the downcomer by way of a weir, the height of which
largely determines the amount of liquid on the tray. The downcomer extends beneath the liquid surface on
the tray below, thus forming a vapour seal. The vapour flows upwards through risers into caps, or through
simple perforations in the tray.
focus Design of Trays:
Before proceeding for the design of a tray tower, the Design Specialist needs the following data from his
process counterpart:
1. Vapor Loads entering the trays and its properties viz. temperature, pressure, mol. wt. &
compressibility factor.
2. Liquid Loads leaving the tray and its properties viz. density, viscosity, surface tension etc.
3. Allowable pressure drop per tray.
4. Turn down/ turn up requirement
5. Foaming tendency
6. Material of construction
7. Fouling Characteristics
8. Any special requirements like heat transfer etc.
1
Types of tray:
The particular tray selection and its design can materially affect the performance of a given distillation,
absorption, or stripping system. Each tray should be designed so as to give as efficient a contact between
the vapour and liquid as possible, within reasonable economic limits.
Valve tray:
Valve trays are perforated sheet metal decks on which round, liftable valves are mounted. The vapour
flows through valves which are installed parallel to the outlet weir. Valve trays combine high capacity and
excellent efficiency with a wide operating range.as show in Figer2
Figure 2:Valve tray
Advantages:
• Excellent liquid/ vapour contacting.
• Higher capacity.
• Higher flexibility than sieve trays.
• Can handle higher loadings.
• Low-pressure drop than bubble cap.
Disadvantages
• Higher pressure drop than sieve tray
• 20% more expensive than sieve tray
• more likely to foul or plug in case of dirty mixtures
applications:
• Offer high capacity & good efficiency
• Good turndown characteristics
• Maximum application-widely used in almost all applications.
• Cheaper and simple in fabrication.
2
Sieve tray:
Sieve trays are flat perforated plate in which vapour rises through small holes in tray floor, & bubbles
through liquid in fairly uniform manner. They have comparable capacity as valve trays.
Figure 3:Sieve tray
Advantages:
• Low fouling tendency
• easy to manufacture
• Inexpensive
• considerable design information is available
• efficiency is good at design condition
Disadvantages:
• Less-flexible to varying loads than other two types
• turndown is poor (efficiency falls below the design condition)
• not flexible
Applications:
• System where high capacity near design are to be maintained in continuous service.
• Poor turndown characteristics as compared to valve trays .
• Suitable for Liquid-liquid extraction applications
Bubble cap tray:
Vapour rises through risers or uptakes into bubble cap, out through slots as bubbles into surrounding
liquid on tray. It is mainly used in special applications.
3
Figure 4:Bubble cap tray
Advantages:
• Moderate capacity
• Most flexible (high & low vap. & liquid rates)
• Can provide excellent turndown.
Disadvantages:
• High entrainment, High fouling tendency
• High cost
• High pressure drop
Applications:
• Suitable for all services, except extremely coking, polymer formation or other high fouling
conditions.
• Used for extremely low flow conditions i.e. good turndown characteristics & offer maximum
flexibility in flow range
Other type of trays:
• Baffle Trays / Shed deck
• Ripple Tray
• Disc and Donut tray
• Dual Flow tray
4
Dual flow trays:
A dual flow tray is a sieve tray with no downcomers. This tray operates with liquid continuously weeping
through the holes. Due to the absence of downcomers, dual flow tray gives more tray area hence a greater
capacity than any of the common tray types. They are ideal for revamp where if some efficiency can be
sacrificed for more capacity. They are least expensive to make and easiest to install and maintain.
Figure 5:Dual flow trays and baffle tray
Baffle trays:
For a baffle tray column the gas flows upwards through the baffle openings and in doing so contacts the
liquid showering down from one baffle to the next. Baffle tray columns have almost same flooding
capacity as cross flow trays. Types of baffles used are disc & donut and segmental baffles for various
column diameters.
Dual flow and baffle trays are used for fouling applications, solid / slurry handling services, corrosive
services.
5
Comparison between Common Conventional Trays.
Table 2:Comparison between Common Conventional Trays.
No. Factors Sieve Tray Valve Tray Bubble-Cap Dual Flow Tray
Tray
1 Capacity High High Moderately High Very High
2 Efficiency High High Moderately High Least
3 Turndown ~50% ~25 - 30% 10% Leats
4 Entrainment Moderate Moderate High Low to
Moderate
5 Pressure Drop Moderate Moderate High Low to
Moderate
6 Cost Low ~1.2 times sieve ~2-3 Times of Least
trays Sieve
7 Maintenance Low Low to Relatively High Low
Moderate
8 Fouling Low Low to High: Tends to Extremely Low
Tendency Moderate Collect Solids
9 Effects of Low Low to High Very Low
Corrosion Moderate
10 Design Well known Proprietary but Well Known Some info.
Information readily available available.
Instability can
occur in largedia.
(>8 feet)
11 Main Application Often used when Where high Extremely low Capacity revamps,
turndown is not turndown is liquid flow & Highly foulingand
critical required where leakage corrosive
must be services
minimized
6
Tray Parameters
a) No. of passes (Np):
The numbers of flowpaths of liquid on tray are 1, 2, 3 or 4 as per liquid capacity requirement of column.
From a capacity viewpoint, a liquid rate greater than 6 gpm / inch of weir (weir loading), is the rate at
which a higher number of flow paths should be considered. The maximum allowable weir loading is 13
gpm/in of weir length. If the weir loading exceeds this the tray needs redesign with higher number of
passes.
b) Tray Spacing (S):
Tray spacing is the distance between two trays. Generally tray spacing ranges from 8 to 36 inches (200
mm to 900 mm). Prime factor in setting tray spacing is the economic trade-off between column height
and column diameter. Most columns have 600 mm tray spacing. Cryogenic columns have tray spacing of
200-300 mm.
c) Outlet Weirs (hw):
An outlet weir maintains a desired liquid level on the tray. As the liquid leaves the contacting area of the
tray, it flows over the tray weir to enter into the downcomer.
d) Downcomer Clearance (hcl):
This is the vertical distance between the tray floor and the bottom edge of the downcomer apron. The
Normalpractice is to use a downcomer clearance of 1/2 inch less than the overflow weir height to provide
a static liquid seal
e) Inlet Weirs & Recessed Seal Pans:
Inlet weirs and recessed seal pans are primarily used for achieving a downcomer seal in cases where a
potential positive sealing problem exists and clearance under downcomer is limited
f) Downcomers:
Passage of liquid from the top tray to the bottom of tray occurs via downcomers. Downcomers are
conduits having circular, segmental, or rectangular cross sections that convey liquid from upper tray to a
lower tray in a distillation column.
g) Downcomer width (Chord height, WDC):
It is maximum horizontal distance between tower wall and weir.
h) Flow path length (FPL):
Flow path length is the distance between the inlet downcomer & outlet downcomer. The minimum limit
for flow path length is 400 mm in order to provide good contacting between vapour and liquid. This is also
necessary for the mechanical reason of providing tray manway.
i) Tray deck thickness (t):
Trays normally used in commercial service need a minimum material thickness to provide structural
strength (personnel walk on them during installation) and corrosion allowance. A thickness of 10 to 12
gauge (2.5 to 3.5 mm) is customary for carbon steel, while 12 to 14 gauge (1.9 to 2.5 mm) is used for
stainless steel trays (in general no C.A. for SS)
7
j) Hole pitch (P):
Centre to centre distance between holes is called pitch. Normal practice is to use a hole pitch to hole
diameter ratio between 2.2 to 3.8.
k) System (Derating) factors:
Derating factors are often closely related to the foaming tendency of the system. Higher the foaming
tendency, the lower is the Derating factor. System factors are used in three of the rating correlations (jet
flood, down comer backup flood, down comer choke) to account for system effects on hydraulic capacity
limits. It includes both foaming effects and high vapour density.
l) Bubbling (Active) Area (AB):
Bubbling area is the column area, which is actually available for vapour bubbling through liquid. It can be
defined as column area minus downcomer areas, downcomer seal & large calming zones.
m) % Hole Area:
This is the ratio of hole area to bubbling area. The default practice is to target a hole area of 8 to 10 % of
bubbling area for pressure services. The acceptable range for percentage hole area is 5 % to 15 %. However
for some critical services, we can go % hole area up to 17-17.5% provided that weeping is undercontrol.
Hole areas below 5 % are not used.
n) Anti jump baffles:
Anti jump baffles plates suspended vertically above centre or off centre downcomers, which stops liquid
jumping from one deck onto the opposite deck, flow pa
8
Reference :
1. Baratt, R., G. Vacca, and A. Servida, “Neural Network Modeling of Distillation
Columns,” Hydrocarbon Processing, June 1995, p. 35
2. Barber, A. D., and E. F. Wijn, “Foaming in Crude distillation Units,” IChemE Symp.
Ser., 56, 1979, p. 3.1/5
3. Bali, V. K., and A. K. Maheshwari, “Case Study of CO2 Removal System Problems/Failures in
Ammonia Plant,” Ammonia Plant Safety, 39, AIChE, 1999, p. 285
4. LatimerR.E. Distillation of Air Chem Eng Prog (1967)
5. BiddulphM.W.Multicomponent distillation simulation-distillation of air AIChEJ(1975)
6. Biddulph, M.W. and Dribika, M.M. Distillation efficiencies on a large sieve plate with small
diameter holes AIChEJ
7. Andersen, A. E., and J. C. Jubin, “Case Histories of the Distillation Practitioner,” Chem. Eng.
Prog., 60(10), 1964, p. 60.
