Continuous Distillation
Jose V Parambil
CB204 – Apr 2021 Continuous Distillation
Fractionation or Fractional Distillation
• In fractional distillation, part of the vapor formed from boiling liquid is condensed
and brought in direct contact with the rising vapor.
• Happens repeatedly over various plates or packed column.
• The vapor moving up gets enriched with the volatile component.
• The liquid moving down is stripped of the volatile component.
• Counter-transport of volatile and non-volatile components take place in each tray/region of
the column.
• The more volatile component absorbs the latent heat from the condensation of the less
volatile component.
• Enables greater degree of separation, even when relative volatility is almost unity.
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CB204 – Apr 2021 Continuous Distillation
Continuous Distillation Equipment
Condenser
• Consists of:
• Tray or packed column
• Reboiler Distillate
• Condenser (D, xD)
Feed
• Terminologies (F, zF)
• Top (D) and bottom (W) products
• Reflux and reflux ratio
• Part of column w.r.t. feed position
• Above: Enriching or rectification section
L V Bottom Product
• Below: Stripping section (W, xW)
Reboiler 3
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CB204 – Apr 2021 Continuous Distillation
Material & Energy Balance Equations (1)
Notations:
L & V → liquid and vapor flow rates [moles/time] above the feed (rectifying section)
𝐿ത & 𝑉ത → Liquid and vapor flow rate [moles/time] in stripping section.
Plate numbering starts from the top.
Subscript ‘n’ denotes property of the stream coming from the nth plate in rectifying section.
Subscript ‘m’ denotes property of the stream coming from the mth plate in stripping section.
Qc & QB are the condenser and reboiler heat loads.
F → Feed flow rate [moles/time].
zF is the mole fraction of the volatile component in feed.
xD & xw are mole fractions of the volatile component in distillate and residue.
D & W → distillate and residue flow rates [moles/time]
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CB204 – Apr 2021 Continuous Distillation
Material & Energy Balance Equations (2) Envelope 1
Considering envelope 1
Envelope 2 V1, y1 Qc
Total material balance,
Reflux ratio, 𝑅 = 𝐿0 /𝐷 L0, x0
1
D, xD
Component A balance,
n
Energy balance, Vn+1 Ln
yn+1 xn
Considering envelope 2
Total material balance,
Component A balance,
Energy balance,
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CB204 – Apr 2021 Continuous Distillation
Material & Energy Balance Equations (2)
Considering envelope 3
Total material balance,
Component A balance,
Energy balance,
𝑉ത𝑚+1 𝐿ത 𝑚
m 𝑦𝑚+1 𝑥𝑚
m+1
N 𝑉ത𝑁+1
QB W, xw
Envelope 3
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CB204 – Apr 2021 Continuous Distillation
Material & Energy Balance Equations (3) Envelope 1
Considering envelope 4
Envelope 2 V1, y1 Qc
Total material balance,
L0, x0
Component A balance,
1
D, xD
Energy balance,
Envelope 4
n
F, zF
f
m
m+1
N 𝑉ത𝑁+1
QB W, xw
Envelope 3
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McCabe-Thiele Method – Operating lines (1)
Considering Rectifying section
𝑉𝑛+1 𝑦𝑛+1 = 𝐿𝑛 𝑥𝑛 + 𝐷𝑥𝐷
Constant Molar Overflow assumption: The molar flow of liquid remains constant over
each section of the column, irrespective of the plate.
- True when the molar latent heat of vaporization of the components are almost equal
and molar heat of vaporization of the mixture is independent of the composition.
- Results in equimolar counter-diffusion between liquid and vapor phases.
- Most real liquid mixtures deviates <10% from this assumption.
- Implies 𝐿0 = 𝐿1 = . . . = 𝐿𝑛 = 𝑳 and 𝐿ത 𝑚 = 𝐿ത 𝑚+1 = . . . = 𝐿ത 𝑁 = 𝑳ത .
- Since molar liquid flow rate are the same, molar vapor flow rate should also be the
ഥ.
same in all plates. i.e., 𝑉1 = 𝑉2 = . . . = 𝑉𝑛 = 𝑽 and 𝑉𝑚 = 𝑉𝑚+1 = . . . = 𝑉𝑁 = 𝑽
- Note: everything has to be in mole-basis, not in mass-basis.
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CB204 – Apr 2021 Continuous Distillation
McCabe-Thiele Method – Operating lines (2)
Operating line for the rectifying section hence becomes,
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CB204 – Apr 2021 Continuous Distillation
McCabe-Thiele Method – Operating lines (3)
For the stripping section,
𝐿ത 𝑚 𝑥𝑚 = 𝑉ത𝑚+1 𝑦𝑚+1 + 𝑊𝑥𝑊
𝑉ത 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑣𝑎𝑝𝑜𝑟 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑝𝑒𝑟 𝑡𝑖𝑚𝑒
Boil-up ratio of a reboiler can be defined as, 𝑅𝑉 = =
𝑊 𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑙𝑖𝑞𝑢𝑖𝑑 𝑙𝑒𝑎𝑣𝑖𝑛𝑔 𝑝𝑒𝑟 𝑡𝑖𝑚𝑒
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CB204 – Apr 2021 Continuous Distillation
McCabe-Thiele Method – No. of plates
𝑦1 = 𝑥𝐷
Mole fraction of A in vapor
Mole fraction of A in vapor
𝑦2
𝑦3
𝑥𝐷
𝑅+1 𝑦𝑁
𝑦𝑁+1
𝑥𝑊
𝑥2 𝑥1 𝑥𝐷 𝑥𝑊 𝑥𝑁 𝑥𝑁−1
Mole fraction of A in liquid Mole fraction of A in liquid
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CB204 – Apr 2021 Continuous Distillation
Feed quality and q-line
• Parameters of feed that affect the function of the column include flow
rate, composition, physical state, and thermal condition.
• Feed can be as liquid, gas, or a mixture.
• Also, feed can be cold, saturated, or superheated.
• Types
• Cold liquid
• Saturated liquid
• Partially vaporized mixture
• Saturated vapor
• Superheated vapor
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CB204 – Apr 2021 Continuous Distillation
Feed Quality
𝐿 𝑉 𝐿 𝑉 𝐿 𝑉
𝐹 𝐹 𝐹
𝐿ത 𝑉ത 𝐿ത 𝑉ത 𝐿ത 𝑉ത
Super cooled liquid Saturated liquid Partially vaporized
𝐿 𝑉 𝐿 𝑉
𝐹 𝐹 𝐿ത − 𝐿
𝑞=
𝐹
𝐿ത 𝑉ത 𝐿ത 𝑉ത
Saturated vapor Superheated vapor
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CB204 – Apr 2021 Continuous Distillation
q-line (1) 𝑉, 𝐻𝑉,𝑓
Material balance over the feed plate, 𝐿, 𝐻𝐿,𝑓−1
𝐹, 𝐻𝐹
Since stripping and rectifying sections meet at the feed
plate, both the operating lines should be satisfied.
From rectifying section: 𝑉𝑦 = 𝐿𝑥 + 𝐷𝑥𝐷 (2) ത 𝐻𝑉,𝑓+1
𝑉,
From stripping section: ത = 𝐿ത 𝑥 − 𝑊𝑥𝑊
𝑉𝑦 (3) 𝐿ത , 𝐻𝐿,𝑓
(2)-(3) give,
Dividing (1) by F,
Dividing (4) by F,
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CB204 – Apr 2021 Continuous Distillation
q-line (2) 𝑉, 𝐻𝑉,𝑓
Energy balance gives, 𝐿, 𝐻𝐿,𝑓−1
𝐹, 𝐻𝐹
Assuming that the enthalpy change in phase as it passes
through the feed plate is negligible,
ത 𝐻𝑉,𝑓+1
𝑉,
𝐿ത , 𝐻𝐿,𝑓
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CB204 – Apr 2021 Continuous Distillation
Feed line or q-line
𝑞=1
Mole fraction of A in vapor
𝑐𝑝𝐿 𝑇𝑏 − 𝑇𝐹
For subcooled liquid, 𝑞 =1+
𝜆𝑉
𝑞=0
𝑐𝑝𝑉 𝑇𝐹 − 𝑇𝑑
For superheated vapor, 𝑞=−
𝜆𝑉
𝑧𝐹 Tb & Td are bubble point and
Mole fraction of A in liquid dew point of feed, respectively.
𝑞 𝑧𝐹 Note: Operating lines of rectifying and stripping sections will
𝑦= 𝑥−
𝑞−1 𝑞−1 intersect along with q-line in a single point.
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CB204 – Apr 2021 Continuous Distillation
Optimum Feed position
Mole fraction of A in vapor
M Theoretical number of trays = 8 – 1 = 7
Optimal feed position = 4th tray
N
𝑥𝐷
𝑅+1
If feed is given before 4th tray → early feed entry
If feed is given after 4th tray → delayed feed entry
𝑥𝑊 𝑧𝐹 𝑥𝐷 Feed has to be given between MN.
Mole fraction of A in liquid
If the feed is liquid, it has to be fed above the
feed tray and below it if the feed is vapor.
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CB204 – Apr 2021 Continuous Distillation
Total Reflux and Minimum Number of Stages
If the entire liquid from a total condenser is passed down back into column,
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CB204 – Apr 2021 Continuous Distillation
Fenske’s equation for minimum trays (1)
Writing the relative volatility relationship in the total reboiler,
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CB204 – Apr 2021 Continuous Distillation
Fenske’s equation for minimum trays (2)
Similarly, moving up each tray at a time, finally, for the top most tray,
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CB204 – Apr 2021 Continuous Distillation
Minimum Reflux Ratio
P
Mole fraction of A in vapor
P
𝑥𝐷
𝑥𝐷 𝑅𝑚 + 1
𝑅𝑚 + 1
𝑥𝐷
𝑅𝑚 + 1 P
𝑥𝑤 𝑥𝐷 𝑥𝑤 𝑥𝐷 𝑥𝑤 𝑥𝐷
Mole fraction of A in liquid Mole fraction of A in liquid Mole fraction of A in liquid
Pinch point on rectifying section Pinch point on stripping section
With maximum reflux ratio, number of plates reduced.
As reflux ratio decreases, number of theoretical plates increases – up to infinity.
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CB204 – Apr 2021 Continuous Distillation
Example 7.1
A mixture of water and methanol containing 40 mol% methanol is to be
separated continuously in a tray tower at a rate of 150 kmol/h. The
distillate needs to be 90% pure and the bottom product cannot have more
than 5% methanol. If the reflux ratio is fixed at 2 and the feed is saturated
vapour, determine the following: boil-up ratio, number of actual trays
required is the overall efficiency is 60%, and the temperature in each tray.
The equilibrium data and the bubble point of the mixture are as below.
x 0.0 0.02 0.04 0.06 0.08 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 0.95 1.00
y* 0.00 0.13 0.23 0.30 0.37 0.42 0.58 0.67 0.73 0.78 0.82 0.87 0.92 0.96 0.98 1.00
T 100 96.4 93.5 91.2 89.3 87.7 84.4 78.0 75.3 73.1 71.2 69.3 67.6 66 65 64.5
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CB204 – Apr 2021 Continuous Distillation
Example 7.2
Determine the number of stages required to separate a mixture of benzene
and toluene containing 40 mole% benzene into a distillate containing 96
mole% benzene and a bottoms containing 5 mole% benzene. The feed is a
two-phase mixture at saturation condition consisting of 50 mole% liquid.
The process is carried out at 1 atm. The condenser employs cooling water
at 35 °C and the overall column efficiency is about 50%. Equilibrium data
is provided below. Optimal reflux ratio has been found to be 1.3 times the
minimum reflux ratio.
x 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
y* 0.00 0.22 0.35 0.49 0.60 0.68 0.76 0.83 0.93 0.96 1.00
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CB204 – Apr 2021 Continuous Distillation
Ponchon-Savarit Method (1) Envelope 1
Considering envelope 2
Envelope 2 V1, y1 Qc
Total material balance,
Component A balance, L0, x0
1
D, xD
Energy balance,
n
Vn+1 Ln
yn+1 xn
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CB204 – Apr 2021 Continuous Distillation
Ponchon-Savarit Method (2) 𝐷′ = (𝑥𝐷 , 𝑄𝐷′ )
𝐷′
From (1) & (2),
𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦
𝑉2 𝑉1 𝑄𝑐
=
𝐷
𝐿2 𝐿1
𝐷
𝐷 = (𝑥𝐷 , 𝐻𝐷 )
𝑉1 = (𝑦1 , 𝐻𝑉,1 )
𝐿1 = (𝑥1 , 𝐻𝐿,1 )
𝑥𝑊 𝑥𝐹 𝑥𝐷
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CB204 – Apr 2021 Continuous Distillation
Ponchon-Savarit Method (3) 𝐷′ = (𝑥𝐷 , 𝑄𝐷′ )
𝐷′
Similarly, for the stripping section, 𝑉𝑁+1
𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦
𝑉𝑁
𝑉2 𝑄𝑐
𝑊
𝐷
𝑄𝐵 𝐿2 𝐿1
𝑊 𝐷
𝑊′
𝐷 = (𝑥𝐷 , 𝐻𝐷 )
𝑉1 = (𝑦1 , 𝐻𝑉,1 )
𝐿1 = (𝑦1 , 𝐻𝐿,1 )
𝑥𝑊 𝑥𝐷
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CB204 – Apr 2021 Continuous Distillation
Ponchon-Savarit Method (4)
𝐷′
𝑉𝑁+1
𝐸𝑛𝑡ℎ𝑎𝑙𝑝𝑦
𝑉𝑁
𝑊 𝑉2
𝐹 𝐿2 𝐿1
𝐷
𝑊′
𝑥𝑊 𝑥𝐹 𝑥𝐷
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CB204 – Apr 2021 Continuous Distillation
Example 7.3
A distillation tower is used to separate 100 kmol/h of a benzene-toluene
solution containing 50 mol% benzene into a distillate product containing
95 mol% benzene and bottom product containing 95 mol% toluene. The
column is operated at 101.3 kPa. The feed is partially vaporized and is
1/3rd vapour and 2/3rd liquid. Determine:
a) Minimum number of plates (α=2.39)
b) Minimum reflux ratio.
c) Number of plates if operating reflux ratio is 30% in excess of the
minimum.
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