What is a Distillation Column?

Its Types, Working, and Components

In the vast landscape of chemical engineering, few processes stand as iconic and fundamental as distillation. At the
heart of this critical process lies the distillation column – a towering, cylindrical apparatus that plays a pivotal role in
separating and purifying mixtures, ranging from crude oil to alcoholic spirits. This article aims to demystify the
distillation column, exploring its inner workings, applications, and significance in various industries.

What is the Distillation Process?

Distillation is a separation technique that capitalizes on the differences in boiling points of components within a
mixture. When a mixture is heated, the component with the lower boiling point vaporizes first, rises through the
column, and condenses back into liquid form as it cools down. This vaporization-condensation cycle repeats, causing a
gradual separation of the mixture into its individual components. Distillation columns enhance this process by providing
ample surface area for efficient vapor-liquid contact and separation

What is a Distillation Column? Its Types, Working, and Components

What is a Distillation Column?

A distillation column resembles a tall vertical cylinder, often hundreds of feet high, equipped with an array of trays or
packing materials. These components aid in creating multiple vapor-liquid contact stages, maximizing the separation
efficiency. Fig. 1 shows a typical distillation column.

A distillation column is a tall, cylindrical static equipment used in chemical engineering and industrial processes to
separate and purify mixtures of liquid components based on their differing boiling points. The column facilitates the
process of fractional distillation, where the mixture is heated to cause vaporization of the component with the lowest
boiling point. As the vapor rises through the column, it comes into contact with liquid on trays or packing materials,
leading to equilibrium and separation of components. The condensed vapors, referred to as distillate, are collected and
further processed, while the remaining liquid, known as the bottoms, may contain the higher boiling point components.
Distillation columns are essential in various industries, including petroleum refining, chemical manufacturing,
pharmaceuticals, and beverage production, playing a crucial role in achieving product purity and quality.

Components of a Distillation Column

A distillation column is a complex apparatus composed of several key components that work in harmony to facilitate
the separation and purification of mixtures. These components ensure efficient vapor-liquid contact and separation.
The main components of a distillation column include:

Reboiler:
Located at the bottom of the column, the reboiler is responsible for heating the liquid mixture to initiate vaporization.
As heat is applied, the component with the lowest boiling point vaporizes and rises through the column.

Distillation Trays or Packing Materials:

These are situated within the column at specific intervals. They provide a surface area for vapor-liquid interaction,
promoting equilibrium between the vapor and liquid phases. Trays consist of perforated plates placed horizontally
across the column while packing materials (such as rings, saddles, or structured packing) increase surface area for
better separation efficiency.
Column Shell:
The cylindrical body of the distillation column provides structural support and houses the trays or packing materials. It
is designed to withstand the internal pressure and temperature conditions.

Vapor Outlets:
These are located at the top of the column and allow the separated vapor components to exit the column and proceed
to the condenser.

Condenser:
Positioned at the top of the column, the condenser cools down the vaporized components, causing them to condense
back into liquid form. This condensed liquid is then collected and referred to as the distillate.

Distillate Receiver:
This is a vessel or container that collects the condensed distillate from the condenser. It is designed to separate the
condensed liquid from any remaining vapor.

Reflux System:
The reflux system is responsible for returning a portion of the condensed liquid (distillate) back to the column. This
reflux helps maintain proper temperature and vapor-liquid equilibrium, improving separation efficiency.

Reflux Drum:
The reflux drum is a vessel that collects and temporarily stores the returning reflux liquid before it is reintroduced into
the column. It helps regulate the flow of reflux and prevents sudden disturbances in the column operation.

Bottoms Outlet:
Located at the bottom of the column, the bottom outlet allows the heavier components of the mixture to be withdrawn
as a liquid stream. This stream may contain the least volatile components.

Column Internals:
These include various accessories and devices used to optimize column performance, such as distributors for even
liquid distribution on trays, collectors for vapor distribution, and demisters to prevent the entrainment of liquid
droplets in the vapor stream.

Pressure Relief System:

Distillation columns are operated under specific pressure conditions. A pressure relief system, such as safety valves
or rupture discs, is incorporated to ensure the column’s integrity in case of pressure build-up.

Working Principle: Fractional Distillation

The fundamental principle behind distillation is fractional distillation, which leverages the concept of equilibrium. As
the vapor rises through the column, it encounters the liquid on the trays or packing. The vapor-liquid equilibrium leads
to the separation of components, with the component of a lower boiling point vaporizing more readily and rising to a
higher tray. The trays or packing materials facilitate this equilibrium at multiple stages, enhancing the separation
efficiency. Fig. 2 below shows the typical products that are obtained from a crude distillation column at different
temperFig. 2: Typical Products from a Crude Distillation
Types of Distillation Columns

Distillation columns come in various types, each designed to address specific separation challenges and optimize
efficiency based on the characteristics of the mixture being processed. Here are some common types of distillation
columns:

Batch Distillation Column:

In batch distillation, a fixed amount of mixture is loaded into the column, processed, and then the products are
collected. It’s suitable for small-scale operations, research, and when dealing with mixtures that are difficult to
separate. Batch distillation is commonly used in the production of high-quality spirits and certain pharmaceuticals.

Continuous Distillation Column:

Continuous distillation columns manage an uninterrupted flow of feed. Only in the event of an issue with the column or
adjacent process equipment do interruptions occur. These columns excel at accommodating substantial throughput
and represent the more prevalent than batch distillation columns. Continuous Distillation columns can be further
divided into the following:

 Fractionating Column: This is the most common type of distillation column and is widely used in various industries.
It includes trays or packing materials to create multiple vapor-liquid equilibrium stages, enabling the separation of a
wide range of components based on their boiling points. Fractionating columns are extensively used in petroleum
refining, chemical manufacturing, and beverage production.
 Packed Distillation Column: These columns are filled with packing materials (such as rings, saddles, or structured
packing) that provide a large surface area for vapor-liquid interaction. Packed columns are often used for
applications where heat and mass transfer are critical, making them suitable for separating heat-sensitive or
difficult-to-distill mixtures.
 Azeotropic Distillation Column: This type of column is designed to handle azeotropic mixtures, where two or more
components have similar boiling points and form a constant-boiling mixture. Special techniques, such as the
addition of an entrainer or using extractive distillation, are employed to break the azeotrope and achieve effective
separation.
 Reactive Distillation Column:

In reactive distillation, chemical reactions occur simultaneously with the separation process. This integration of reaction
and separation allows for higher product yields, reduced equipment footprint, and improved energy efficiency. Reactive
distillation is commonly used in the production of chemicals, such as esters and biodiesel.

 Vacuum Distillation Column:

Vacuum distillation operates at reduced pressure to lower the boiling points of components, making it suitable for
separating heat-sensitive materials or reducing thermal degradation. Vacuum distillation is commonly used in the
refining of crude oil and in the production of high-quality products, such as essential oils.

 Steam Distillation Column:

This method involves the introduction of steam into the distillation process. Steam distillation is particularly useful for
separating volatile compounds from heat-sensitive materials, such as extracting essential oils from plants.
 Extractive Distillation Column:

In extractive distillation, an entrainer or solvent is added to the mixture to alter the relative volatility of the
components, making separation easier. This technique is often used for separating azeotropic mixtures or for
challenging separations that cannot be achieved through conventional distillation.

 Molecular Distillation Column:

Molecular distillation is a high-vacuum distillation process used to separate compounds with very high boiling points or
those that are thermally sensitive. It is commonly employed in the production of pharmaceuticals, edible oils, and other
high-value products.

Applications of Distillation Column

Distillation columns find applications across various industries, each with its unique requirements:

Petroleum Refining: In crude oil refining, distillation columns separate crude oil into fractions based on different boiling
points, yielding valuable products like gasoline, diesel, and jet fuel.

Chemical Production: Distillation is vital in the production of chemicals, pharmaceuticals, and specialty chemicals,
enabling the separation and purification of complex mixtures.

Beverage Industry: Distillation columns are integral to producing alcoholic beverages like whiskey, vodka, and gin. They
separate alcohol from fermented mixtures to create high-proof spirits.

Environmental Applications: Distillation columns play a role in environmental processes such as water purification and
wastewater treatment, removing impurities through separation.
Example Data for Deethanizer Column:

Feed Composition:

 Methane (CH₄): 90%

 Ethane (C₂H₆): 10%

Operating Conditions:

 Pressure: 1.5 MPa (1500 kPa)

 Reboiler Heat Duty: 200 kW
 Condenser Duty: 150 kW
 Reflux Ratio: 3:1 (meaning 3 parts of condensed liquid are returned as reflux for every 1 part of product sent to
the overhead)

Desired Separation:

 Top Product (Overhead): Mainly Methane (CH₄)

 Purity: 98% CH₄

 Bottom Product: Mainly Ethane (C₂H₆)

 Purity: 95% C₂H₆

Step-by-Step Example of the Deethanizer Column Process:

1. Feed Input:
 We are feeding a mixture of 1000 kmol/h of a gas stream containing 90% methane and 10% ethane
into the deethanizer column.

Feed composition:

 Methane (CH₄): 90% of 1000 kmol/h = 900 kmol/h

 Ethane (C₂H₆): 10% of 1000 kmol/h = 100 kmol/h

The total flow rate of the feed = 1000 kmol/h.

2. Reboiler Duty:

 The reboiler provides heat to the column to vaporize the liquid. Here, we assume that the reboiler duty
is 200 kW, which heats the liquid at the bottom of the column. This heat will separate the mixture into
vapor and liquid phases.

3. Vapor-Liquid Separation:

 As the mixture moves upward through the column, the components with lower boiling points
(methane) will move toward the top, while components with higher boiling points (ethane) will stay
toward the bottom.

4. Overhead Product (Top Product):

 After vapor condensation in the condenser, the overhead vapor is mostly methane (CH₄), with a purity
of 98%. The liquid condensed from the overhead vapor is sent as reflux to the column.

 Overhead Product Composition: 98% CH₄, 2% C₂H₆

Flow rate of the overhead product:

 Methane: 98% of 950 kmol/h (estimated flow rate from the top section) = 931 kmol/h
 Ethane: 2% of 950 kmol/h = 19 kmol/h

The total overhead product flow = 950 kmol/h (after condensation and reflux).

5. Bottom Product:

 After the ethane-rich liquid reaches the bottom of the column, it is removed as the bottom product,
which has a purity of 95% ethane (C₂H₆).

 Bottom Product Composition: 95% C₂H₆, 5% CH₄

Flow rate of the bottom product:

 Ethane: 95% of 50 kmol/h = 48 kmol/h

 Methane: 5% of 50 kmol/h = 2.5 kmol/h

The total bottom product flow = 50 kmol/h.

6. Reflux:

 The reflux ratio is 3:1, meaning that for every 1 part of distillate removed (overhead product), 3 parts
are returned as reflux.

Flow rate of reflux:

 Reflux = 3 × 950 kmol/h (overhead product) = 2850 kmol/h.

7. Summary of Material Balance:

 Feed: 1000 kmol/h (900 kmol/h CH₄ + 100 kmol/h C₂H₆)

 Overhead Product: 950 kmol/h (931 kmol/h CH₄ + 19 kmol/h C₂H₆)
 Bottom Product: 50 kmol/h (48 kmol/h C₂H₆ + 2.5 kmol/h CH₄)
 Reflux: 2850 kmol/h (mostly methane-rich liquid)
Deethanizer Column Internals (Example Data):

Tray Level Composition (CH₄) Composition (C₂H₆) Flow Rate (kmol/h)

Feed Tray 90% 10% 1000
Tray 1 88% 12% 850
Tray 2 80% 20% 700
Tray 3 70% 30% 550
Tray 4 60% 40% 400
Tray 5 50% 50% 250
Tray N 95% 5% 950 (top)
Bottom Tray 5% 95% 50 (bottom)

Conclusion:

 The deethanizer column is designed to achieve a high separation efficiency of methane and ethane, where the
methane is concentrated at the top and the ethane at the bottom.
 The separation is based on the relative volatilities of methane and ethane. By adjusting the operating
conditions (e.g., reflux ratio, reboiler heat duty), the purity of both products (methane and ethane) can be
controlled.
Types of Column Internals

Column internals are the devices that interact and separate, used in industrial columns. These columns use a variety of
components to perform their job, including trays (at time referred to as plates) and packing. They are used in the
biofuel, energy, gas processing, petrochemical, refining, waste water treatment, water well, and many other industries.
Following is more insight into the various types of column internals and their uses.

Structured Packing

Structured packing is typically available in four different types, each with its own benefits:

1. Gauze – This is a high efficiency, corrugated-type packing often used for fine chemical distillation. It is not
recommended in applications that may result in fouling, the accumulation of unwanted material on solid
surfaces. Gauze packing is a good choice for uses such as vacuum distillation with low liquid rates where it is
critical to minimize pressure drop.

2. Grid – It provides extended operation in fouling applications. Corrugated sheet metal or stamped blades connect
into panels with cross rods. Both options offer large open areas for accommodating fouling and are highly
durable. Grid packing offers a smooth surface constructed of much thicker material than normal sheet metal
packing and can be used in services with low liquid loadings. This includes crude vacuum column wash sections,
FCC main fractionator slurry pump around beds, and to replace structured packing where fouling is a concern.

3. Knitted – It uses multi-strand cables composed into high-density mesh that can be rolled into one-piece layers
that fit small diameter columns. Knitted packing can also be wrapped back and forth into bricks for use in column
many ways. It provides high mass transfer efficiency at a higher pressure drop than woven gauze.

4. Sheet Metal – Surface textured sheet metal is used to create corrugated packing with a wide range of
corrugation sizes and angles without the use of more expensive wire gauze. It can handle a much wider range of
vapor and liquid rates along with process services.
Random Packing

As the name implies, random packing is dumped into a column’s section and permitted to fall in irregularly. Random
packing also has a number of options including Pall rings, high performance saddle rings, Superblend, Raschig, and
others. It costs less than structured packing but offers more weight drop and has lower productivity and more
limitations.

Trays (Plates)

Column internal trays are used in distillation and to separate mixtures. There are a number of options in trays for
various applications. Conventional trays provide time-proven, cost effective operations for the contact of vapor and
liquid. This process allows thermodynamics and chemical reactions to accomplish a number of mass transfer
applications. High performance trays are a good choice for more advanced processes such as washing applications,
natural gas drying, the Rectisol washing process, the fractionating of fatty acids, and hold up time for reactions.

AMACS supplies packing, replacement-in-kind trays, and tray parts for all sorts of column internals. We are a reliable
source for complete trays, partial panels or various types of packing installed in most existing towers. Our team is
known for its quick delivery for towers with a diameter of up to 20 feet and tray decks up to 1/4″ thick in many
common stocked alloys.
Feed and Product Specifications

 Feed composition: Determine the composition of the feed stream (typically a mixture of hydrocarbons,
including methane, ethane, propane, and heavier components).
 Desired separation: Identify the purity or recovery goals for the products. For example, ethane may need to be
separated from the feed stream with a certain purity.
 Operating conditions: Temperature, pressure, and flow rates of the feed stream, as well as the required
product streams.

2. Column Sizing

To determine the diameter and height of the column, you need to account for the vapor and liquid flow rates and the
desired separation efficiency. This requires mass and energy balances, and sometimes trial-and-error through design
correlations (like the Fenske equation for ideal separation).

Key calculations for column sizing:

 Flooding Velocity (V_flood): This is the maximum vapor velocity that can pass through the column before the
liquid begins to flood. It depends on column diameter, packing type, and properties of the fluid.
 Minimum Fluidization Velocity (V_min): This is the minimum velocity at which the liquid and vapor phases are
in equilibrium.
 Column diameter: Can be calculated using the following formula:

 Number of stages (trays or packing): For tray columns, the number of stages can be calculated using the
McCabe-Thiele method or a more detailed method involving the use of equilibrium data for the separation. For
packed columns, use the height equivalent to a theoretical plate (HETP) to determine the number of theoretical
plates.

3. Tray or Packing Selection

The choice between trays and packing depends on several factors such as the physical properties of the feed, column
height, and pressure drop considerations.

 Trays: Common types include sieve trays, valve trays, and bubble-cap trays. Tray columns are usually preferred
for larger diameter columns, or when a large number of stages are required.
o Tray spacing: Typically 18-24 inches.
o Tray design: Design is based on the vapor and liquid traffic, with tray area sized to ensure proper
vapor-liquid contact.
 Packing: For packed columns, structured or random packing can be chosen depending on the required
efficiency and pressure drop.
o Packing material: Materials like stainless steel, ceramic, or plastic are common.
o Packing size and type: These can be calculated based on required surface area per volume and liquid
hold-up to ensure mass transfer efficiency.

4. Reboiler and Condenser Design

  Reboiler Duty: Determines how much heat needs to be supplied to the column bottom to vaporize the bottom
product. It’s typically based on the heat of vaporization for the components being separated.
 Condenser Duty: The condenser will condense the overhead vapor to return as a liquid reflux or product.
 Reflux ratio: The ratio of liquid reflux to the distillate product flow rate is crucial for determining the separation
efficiency.

5. Hydraulic Design Considerations

 Pressure drop: Ensure that the column design minimizes excessive pressure drops, which can lead to flooding
or inefficiency. This is important for both trays and packing.
 Vapor and liquid flow rates: These should be balanced to ensure good contact between the two phases,
promoting efficient mass transfer.

6. Column Height (or Number of Theoretical Plates)

The total height of the column is determined based on the desired separation. This is often done by determining the
number of theoretical plates required (for trays) or the required height equivalent to a theoretical plate (HETP) for
packing.

The number of theoretical plates can be calculated using the Fenske equation for ideal separations:

7. Thermodynamic Analysis

 Vapor-Liquid Equilibrium (VLE): Accurate VLE data is crucial for any separation design. Software such as Aspen
Plus or HYSYS is often used for detailed phase equilibrium calculations.
 Thermodynamic models: Choose the appropriate model for phase behavior (e.g., Peng-Robinson, Soave-
Redlich-Kwong).

8. Operational Conditions

 Operating pressure and temperature: The deethanizer typically operates under pressure conditions that are
determined by the desired separation and the thermodynamic properties of the components.
 Operating range: Ensure the design allows for operational flexibility within expected fluctuations in feed
composition, flow rates, and pressure.

9. Additional Design Considerations

 Vibration and mechanical stability: Considerations to prevent column vibration or structural issues at
operational velocities.
 Corrosion resistance: Selection of materials resistant to corrosion due to exposure to hydrocarbons.
 Access and maintenance: Ensure that trays, packing, or internals are accessible for maintenance and that the
column is designed for efficient cleaning.
Example of Deethanizer Column Design Specifications:

 Feed stream: A natural gas mix (methane, ethane, propane, etc.).

 Product separation: Ethane purity > 95% in the distillate.
 Reflux ratio: 3:1.
 Column type: 20 trays (or structured packing).
 Diameter: 3 meters (calculated based on vapor flow rate).
 Pressure: 2 MPa (for the specific separation).
 Height: 60 meters (number of trays or packed height).

This is a high-level approach, and actual designs require detailed thermodynamic analysis, simulation, and iterative
calculation. If you have specific feed data or parameters, I can help you walk through the calculation process or
simulate a design more closely.