NATIONAL UNIVERSITY OF HO CHI MINH CITYHO CHI MINH UNIVERSITY OF TECHNOLOGYFACULTY OF CHEMICAL ENGINEERINGDEPARTMENT OF UNIT OPERATIONS DESIGN PROJECT DISTILLATION SYSTEM FOR ACETONE-ACI
Acetone
Overview
Acetone, the simplest and smallest ketone, is a colorless liquid with a sweet odor and taste Highly flammable and quick to evaporate, it is also water-soluble Naturally occurring in plants, trees, and vehicle exhaust, acetone is a by-product of animal metabolism While typically found in minimal amounts in human urine and blood, elevated levels can be observed in diabetic patients.
It is an organic compound and has the formula CH3-CO-CH3 The chemical structure and physical properties are shown in the figure A 1 and table A 1.
Other names of acetone: 2-propanone, propanone, Dimethyl ketone.
Figure A 1: Acetone molecule Table A 1: Properties of Acetone
Acetone is a vital organic solvent utilized across various sectors, including industry, households, and laboratories It serves as a fundamental component in organic chemistry, primarily for the production of methyl methacrylate and bisphenol A In domestic settings, acetone is commonly found in nail polish removers and paint thinners In 2010, global production of acetone reached approximately 6.7 million tonnes.
Risks
EPA Safer Choice: Yellow triangle
Acetone is highly flammable: easily ignited by heat, sparks, or flames Vapors can form explosive mixtures with the surrounding air and can travel to the ignition source and flashback.
Acetone containers can explode when heated.
Acetone can be toxic when consumed at high doses However, the toxicity is in low order Other possible symptoms of acetone exposures are listed in the table A 2.
Mucous irritation Dermatitis (prolonged expose)
Table A 2: Risk of Acetone exposure
Acid acetic
Overview
Acetic acid, known as the second simplest carboxylic acid after formic acid, is a colorless liquid with the chemical formula CH3COOH This compound exhibits mild antibacterial and antifungal properties, enhancing fatty acid accumulation in cell membranes by increasing lipid solubility Consequently, it inhibits carbohydrate metabolism, leading to the death of the organism.
Other names of acid acetic: ethanoic acid, Ethylic acid, Acetic acid, glacial, or vinegar (no less than 4% acetic acid by volume)
The chemical structure and physical properties are shown in the table A 3 and figure A 2.
Figure A 2: Acid acetic chemical structure
Table A 3: Acid acetic chemical properties
Application
Acetic acid is a crucial chemical reagent and industrial compound, primarily utilized in the production of cellulose acetate, polyvinyl acetate, and various synthetic fabrics and fibers Additionally, it serves as an effective acidic food preservative in the food industry In domestic settings, diluted acetic acid is commonly employed as a descaling agent.
In 2016, the production of acid acetic was approximately 6.5 million metric tonnes, of which about 23% is made from recycling plants and the remainder is from methanol.
Risks
EPA Safer Choice: Green circle
Acid acetic may burn but do not ignite aggressively When heated, its vapor can form explosive mixtures with air It should be transported in a molten form (ERG, 2016)
Acetic acid is generally considered safe at low concentrations, but prolonged exposure to high levels (80 – 200 ppm) can lead to irreversible damage Symptoms of acetic acid exposure may include various health issues, as detailed in Table A.4.
Eye irritation (8 hrs exposure) Respiratory irritation
Nasal irritation (50 ppm) Dermatitis (prolonged expose)
Skin corrosive at high concentration Teeth erosion (Prolonged exposure)
Pharyngitis (Prolonged exposure) Bronchitis (Prolonged exposure)
Table A 4: Acid acetic exposure risks
Distillation of Acetone – Acid acetic binary mixture
Vapor-liquid phase diagram of Acetone-Acid acetic mixture
Equilibrium phase of liquid (𝑥), vapor (𝑦) by mol percentage and boiling point of a mixture of 2 compounds at 101.33 KPa (Acetone – Acid acetic):
Distillation overview
Distillation is a separation technique that differentiates compounds based on their volatility and boiling points This process involves the repeated evaporation and condensation of substances within a distillation column, allowing materials to transition between liquid and vapor phases multiple times.
Distillation differs from other separation methods as it does not introduce new compounds to the mixture; instead, both solvents and solutes evaporate, coexisting in varying ratios within the rectifying and stripping sections of the column This sets distillation apart from concentration processes, where only the solvent evaporates, leaving the solutes intact.
Figure A 1: Equilibrium curve of the acetone-acid acetic system
When doing distillation, several products are collected at the same time Ideally, the number of compounds in the initial mixture equals the number of products.
For a binary system (system with two different compounds), the two products are collected based on their volatility:
● The top product is mainly the compound with high volatility and traces of lower volatility compound.
● The bottom product is mainly the compound with low volatility and a little amount of higher volatility compound.
For the binary system of acetone-acid acetic:
● Bottom product: Mainly acid acetic
● The liquid phase goes from top to bottom with decreasing concentration of the high- volatility compound.
● The vapor phase goes from bottom to top with an increasing concentration of the high- volatility compound.
The temperature increases from bottom to top across the distillation column as the composition between the two phases change correspondingly
The mass transfer process occurs on each tray, facilitating the transition of high-volatility compounds between the liquid and vapor phases This process results in the collection of nearly pure high-volatility compounds in the top section after condensation, while more challenging-to-evaporate compounds are gathered in the bottom section as the bottom product.
Simple distillation is a technique that heats a liquid mixture to its boiling point and condenses the resulting vapors This method works best for mixtures with a boiling point difference of at least 25℃ However, due to the low purity of the distillate, simple distillation is primarily used for the initial separation of desired compounds from impurities.
Fractional distillation is a method used to separate liquid mixtures with close boiling points through multiple vaporization and condensation steps in a fractionating column, a process also referred to as rectification.
Steam distillation effectively separates heat-sensitive components from mixtures by passing steam through, which extracts volatile substances The resulting vapor is then condensed and collected as distillate, all while maintaining temperatures around the boiling point of water This method is particularly ideal for isolating essential oils and water-insoluble herbal distillates.
Vacuum distillation is an effective method for separating compounds that cannot be efficiently boiled at ambient pressure or risk decomposition By lowering the pressure, the boiling temperature is reduced, which not only saves time and energy but also prevents thermal degradation of the chemicals involved.
In industrial applications, selecting the right distillation equipment is crucial, with a key requirement being a large contacting surface between the two phases The two most widely used types of columns for this purpose are tray columns and packed columns.
A standing cylindrical-shaped shell includes many sections connected by flanges or welds. Materials are packed into the column randomly or in order.
The cylindrical shell features multiple trays strategically positioned along its length, each designed to optimize the interaction between vapor and liquid phases There are two primary types of trays utilized in this system.
● Sieve trays: Many holes or trenches are distributed evenly to the tray’s surface
● Bubble cap trays: There are caps of different shapes to increase the contact between two phases (valve, etc.)
Considering the advantages and disadvantages of each column, the bubble cap tray column emerges as the optimal choice for the simple distillation of the binary Acetone-Acetic Acid system.
Packed column Sieve tray column Bubble cap tray column
● Simple design ● Relatively low pressure- drops ● Relatively stable
● Low pressure-drops ● Highly efficient ● Highly efficient
● Easy to clean up ● Usually fewer trays
● Low stability ● Complicated design ● Complicated design
● Hard to operate, ● Unevenly distribution of liquid ● Expensive
Process flow diagram and process demonstration
The acetone-acetic acid mixture, with a 20% molar fraction of acetone at 25°C, is pumped from the storage tank into the pre-heater After being preheated to its bubble point, the saturated liquid is subsequently transferred to the distillation column at the feed tray.
A distillation column is composed of two main sections: the rectifying section and the stripping section In this column, the liquid phase flows downward while the vapor phase rises upward, facilitating contact between the two Vapor generated from the lower tray passes through bubble caps to interact with the liquid on the tray above This interaction leads to a mass transfer process within each tray, establishing a new equilibrium state continuously.
The concentration of more volatile compounds increases gradually along with the height of the tower as the temperature decreases and vice versa.
A condenser at the top section of the tower condenses vapor, with a portion of the liquid recirculated to enhance separation efficiency The remainder is cooled and collected as the top product, achieving a 99% molar fraction of acetone.
At the base of the tower, a high-volatility liquid product is directed into a reboiler, where a portion is vaporized and returned to the tower as reflux The remaining liquid is cooled and collected as the bottom product, primarily consisting of acetic acid.
MASS BALANCE 17 1 Mass balance
Initial data
Acetone molar fraction of feed stream x F 0.2
Acetone mass fraction of feed stream x F 0.1946
Acetone vapor molar fraction of feed y F 0.557
Acetone vapor mass fraction of feed y F 0.549
Top product molar flowrate T kmole/h 18.557
Top product mass flowrate T kg/h 1076.678
Acetone molar fraction of top product x T 0.99
Acetone mass fraction of top product x T 0.9897
Acetone vapor molar fraction of top product y T 0.999
Acetone vapor mass fraction of top product y T 0.999
Bottom product molar flowrate B kmole/h 81.443
Bottom product mass flowrate B kg/h 4883.322
Acetone molar fraction of bottom product x B 0.02
Acetone mass fraction of bottom product x B 0.0193
Acetone vapor molar fraction of bottom y B 0.065
Acetone vapor mass fraction of bottom y B 0.063
Mass balance equation for the whole column:
Top product molar flowrate T kmole/h 18.557
Bottom product molar flowrate B kmole/h 81.443
Reflux ratio
From the acetone-acid acetic Vapor-Liquid equilibrium diagram, x F =0.2 🡪 y F =0.557 According to (Eqt IX.24 [1])
From acetone-acid acetic Vapor-Liquid equilibrium diagram: x T
The practical reflux ratio is determined by the (Eqt IX.25 [1])
Figure A 2: acetone-acid acetic Vapor-Liquid equilibrium diagram
According to the (Ept IX.25a [3])
Properties of liquid and vapor phase
Average liquid phase composition in the column:
Average vapor phase composition in the column:
Based on the liquid-vapor equilibrium diagram of acetone-acid acetic, we obtain:
The average molar mass and density of vapor phase:
The average density of liquid phase:
● Rectifying section: x R = x R ,avg × M A x R, avg × M A +( 1−x R ,avg ) × M B
● Rectifying section: x S = x S ,avg × M A x S ,avg × M A +( 1− x S, avg ) × M B
Determine the theoretical number of trays and practical number of trays
3.1 Determine the theoretical number of trays
The feed stream is in saturated liquid state, this means the feeding line is a straight line at x=0.2.
In the diagram, the operating line for the rectifying section is positioned at x = 0.99, while the stripping section's operating line is set at x = 0.02 The "step off" equilibrium stages are depicted through the equilibrium curve and the operating lines, as shown in Figure 2.
According to the diagram, the theoretical number of trays is N theoretical trays, which equals the number of steps.
● 1 feed tray (the feed flow enters the column at the 7 th tray)
3.2 Determine the practical number of trays
The efficiency coefficient is the function of volatility and viscosity: η avg =f(αμ)
ENERGY BALANCE 26 1 Energy balance of the feed preheater
Energy balance of the distillation column
Based on the (Eqt IX.156, [1])
2.1 Energy supplied by super-heated water vapor in in reboiler (Eqt IX.157, [1]):
● D 2 ( kg h ) is the amount of super-heated water vapor supply.
● r 2 ( kg J ) is latent heat of vater at 5atm:r 2 !21( kJ kg ) , T 9.78℃
● C 2 T 2 is the specific heat and condensed temperature of water at 5atm.
2.2 Energy of liquid reflux stream (Eqt IX.158, [1]):
2.3 Energy of top vapor product (Eqt IX.159, [1]):
Specific heat of top vapor product: λ T =y F λ A +(1−y F )λ B
→{C A =2.415[ kg K kJ ] ∧r A R1.5 [ kJ kg ] C B =2.394 [ kg K kJ ] ∧r B = 402 [ kJ kg ]
→{λ A =r A +t T C A 25.09[ kJ kg ] λ B =r B +t T C B 98.60 [ kJ kg ] → λ T 24.96 [ kJ kg ]
2.4 Energy of bottom product (Eqt IX.160, [1]):
2.5 Energy the condensed water leaving the reboiler (Eqt IX.161, [1]):
2.6 Energy lost to the environment (Eqt IX.162 [1]):
2.7 The amount of super-heated water vapor needed to boil the bottom stream (Eqt
Energy balance of the overhead condenser
In case of completed condensed of top product, (Eqt IX.165 [1]):
● r T is latent heat of top product: r T R0.269( kJ h )
Energy balance of the overhead product cooler
In case of completed condensed of top product in the overhead condenser, (Eqt IX.166 [1])
Energy balance of the bottom product cooler
Heat of feed stream enter column Q F 5.237×10 6
Heat of liquid reflux stream enter column Q R 1.538×10 6 Heat of top vapor stream exit column Q T 4.126×10 6
Heat of bottom stream exit column Q B 4.743×10 6
Heat load for condenser Q con 1.62×10 6
Heat load for bottom product cooler Q cool 1 8.8981×10 5 Heat load for overhead product cooler Q cool 2 5.0435×10 5
Theoretical number of trays (feed: 4 th tray) N theo trays 10Practical number of trays (Feed: 9 th tray) N prac trays 24
Main equipment 33 1 Column diameter
Diameter of rectifying section
1.1.1 Average vapor flow rate inside the column
According to (Eqt IX.91 [1]) g R,avg =g T +g 1
● g T : amount of vapor goes out at the top of column [kg/h¿
● g 1 : amount of vapor entering the first stage of rectifying section [kg/h¿
● g R ,avg : average mass flowrate of the rectifying section [kg/h¿
Determine g T : according to (Eqt IX.92 [1]) g T =T(R+1)76.678×(1.892+1)113.752[kg/h]
Determine g 1 : According to (Eqt IX.93, IX.94, IX.95 [1])
● G 1 : the amount of liquid at the first stage of rectifying section
● r 1 : latent heat of the vapor mixture goes into the first tray of rectifying section
● r d : latent heat of the vapor mixture goes out of the top of the column
● t F =t 1 25[℃] → {r A H0.88[kJ/kg]r B @6.12[kJ/kg] (Table I.212 [3])
● t T V.2[℃] →{r A R1.5[kJ/kg]r B @2.00[kJ/kg] (Table I.212 [3])
Solving (I), we have: {g 1 630.71[kg/h]G 1 %54.03[kg/h]y 1 =0.43 Then: g R,avg =g T +g 1
1.1.2 Average vapor velocity inside the column
Vapor velocity in bubble cap distillation column, rectifying section (Eqt IX.105 [1])
● ρ R , x and ρ R, y : average density of vapor phase and liquid phase in rectifying section
Figure 1: The relation between tray’s diameter and tray’s distance data (p.184, [2])
Table 1: Trial results for tray’s diameter and tray’s distance, rectifying section h tray (m) (ρ R, v × ω R ) ave ( kg m 2 s¿¿ D (m)
Choose h tray =0.3(m) To avoid bubbling, the average velocity should equals 80% ít original value.
The diameter for rectifying section calculated from this height is D=1.1937(m) ⇒ Choose standard diameter: D=1.4(m)
Diameter of stripping section
1.2.1 Average vapor flow rate inside the column
According to (Eqt IX.96 [1]) g S,avg =g ' B +g' 1
● g' B : average vapor flow rate goes out of the stripping section [kg/h]
● g' 1 : average vapor flow rate goes into the stripping section [kg/h]
Determine g ' B : According (Eqt IX.97 [1]) g ' B =g 1 630.71[kg/h]
Determine g ' 1 : According to (Eqt IX.98, IX.99, IX.100 [1])
● G ' 1 : the amount of liquid at the first tray of stripping section
● r ' 1 : latent heat of the vapor mixture goes into the first tray of stripping section
● r 1 : latent heat of the mixture entering the first stage of rectifying section
● t F =t 1 25[℃] → {r A H0.88[kJ/kg]r B @6.12[kJ/kg] (Table I.212 [3])
● t ' 1 =t B 4.5[ ℃ ] → {r A G2[kJ/kg]r B @7.85[kJ/kg] (Table I.212 [3])
Solving (II), we have: {g ' 1 940.46[kg/h]G' 1 23.78[kg/h]x' 1 =0.0388 Then: g S,avg =g B +g' 1
1.2.2 Average vapor velocity inside the column
Vapor velocity in bubble cap distillation column, stripping section (Eqt IX.105 [1])
● ρ S, x and ρ S, y : average density of vapor phase and liquid phase in stripping section
Figure 2: The relation between tray’s diameter and tray’s distance data (p.184, [2])
Table 2: Trial results for tray’s diameter and tray’s distance, stripping section h tray (m) (ρ R, v × ω R ) ave ( kg m 2 s¿¿ D (m)
Choose h tray =0.3(m) To avoid bubbling, the average velocity should equals 80% ít original value.
The diameter for rectifying section calculated from this height is D=1.244(m) ⇒ Choose standard diameter: D=1.4(m)
Diameter of the column
D t =1.4[m] Then, the operating vapor velocity in the column will be: ω S, ave =0.0188 2 × g S, ave
Height of column
Height of the shell of the column (Eqt IX.54 [1])
● H shell : height of column shell [m]
● N prac : number of practical trays = 24 trays
To determine the final height of the shell, it is essential to consider the distance from the reboiler's vapor pipe to the first tray, as well as the distance from the reboiler's vapor pipe to the bottom.
According to Table IX.5 (p.170, [2]), with respect to the diameter D=1.4(m) and the distance between two trays h tray =0.3(m), we obtain:
● The number of trays between two flanges: 6
● The distance between two flanges: 2100 (mm)
Bubble cap calculation
The number of bubble caps per tray: n=0.1× D 2 d 2 h =0.1×1.4 2
Bubble cap’s thickness normally varies from 2 to 3 (mm), here we choose: δ cap =0.0025(m) According to equation IX.213 (p.236, [2]), the upper gap between riser and bubble cap is: h 2 =0.25× d h =0.25×0.1=0.025(m)
Height of bubble caps:h cap =h h +h 2=0.12+0.025=0.145(m)
According to equation IX.214 (p.238, [2]), bubble cap’s diameter is: d cap =√❑
The distance between slots varies from 0.003 to 0.004 (m), choose: c=0.003(m)
The gap between trays and edge of caps varies from 0¿0.025 (m), choose: S=0.02(m)
Height of slots varies from 0.01¿0.05 (m), choose:b=0.025(m)
Number of slots in each bubble cap, equation IX.216 (p.238, [2]) i=π c× ( d cap − 4 d ×b h 2 ) = 0.003 π × ( 0.145 − 4 × 0.1 0.025 2 ) G.12 ⇒ Choose 47 slots
48 −c=0.0065(m) Minimum distance between bubble caps: l 2.5+0.25× d cap I(mm)
According to equation IX.135 (p.192, [2]), the resistance of bubble cap tower is calculated by:
N practical : the practical number of trays
∆ P tray : resistance of each tray (N/m 2 )
According to equation IX.137 (p.192, [2]), dry tray resistance is calculated by:
Resistance coefficient is normally chosen as ξ=4÷5 (here, we choose ξ=4 ) ρ y :desity of vapor phase¿ ω 0 : velocity of vapor through slots (m/s)
V y : vapor flow in column (m 3 /h) g ytb : the average amount of vapor in column.
The number of bubble caps per tray: n g R, y, avg 372.23[kg/h] ρ R, y, avg =1.998[kg/m 3 ]
The number of bubble caps per tray: n ' =n g S , y , avg 785.59[kg/h] ρ S, y , avg =1.878[kg/m 3 ]
According to equation IX.138 (p.192, [2]), surface tension resistance is calculated by:
In which, σ: surface tension ¿ d eq :equivalent diameter of slots (m)
Assume that the slots are fully opened: d eq =4× f x Π (m)
In which, f x : surface area of slots; f x =b× a=0.025×0.0065=1.625×10 −4 (m 2 ) Π: perimeter of slots, Π=2×(b+a)=2×(0.025+0.0065)=0.063(m)
Average liquid flowrate through rectifying section:
Figure 3 Weir formula correction factor for segmental type weirs
According to equation IX.110a (p.185, [2]), height of liquid on overflow weirs is:
Height of liquid on slots normally varies from 0.015¿0.04(m), choose h 1=0.04(m) Height of overflow weirs on tray: h c =( h 1+b+S ) −∆=(0.04 +0.025 +0.02)−0.01085=0.07415(m)
Height of no foam liquid ontrays:h x =S+b
Total area of bubble caps on each tray: f=0.785× d cap 2 × n=0.785×0.145 2 ×19=0.3136(m 2 )
Figure 4 Area sections on trays
Area for installing bubble caps:
4 −2×0.136=1.268(m 2 ) According to equation IX.110 (p.185, [2]), height of foam layer on disk is calculated by: h b =(h¿¿c+∆−h x )×(F−f)× ρ x +h x × ρ b × f+(h ch −h x )× f × ρ b
F: area for installing bubble caps (m 2 ) f: total area of bubble caps on each tray (m 2 )
∆: height of liquid on overflow weirs (m) h x : (m) h cap : height of bubble caps (m) h c :height of overflow weirs (m)
According to equation IX.139 (p.194, [2]), hydrostatic resistance is calculated by:
In which, h r :height of slots;h r =b=0.025(m) ρ b :density of foam; normally ρ b '0.156(kg/m 3 ) g=9.81(m/s 2 ) h b :height of foam layer on disk (m)
Average liquid flowrate through stripping section:
Height of liquid on overflow weirs:
Height of overflow weirs on trays: h' c =( h 1+b+S ) −∆ ' =(0.04 + 0.025 +0.02)−0.0155=0.0695(m)
The distance between overflow weirs and below tray is chosen as 0.02 (m), total height of overflow weirs: H c =h+h c −0.02=0.3+0.072−0.02=0.352(m)
Height of bubble caps:h' cap =h cap =0.145(m)
Height of no foam liquid ontrays: h x =0.0325(m)
Total area of bubble caps on each tray: f ' =f=0.3136(m 2 )
Area for installing bubble caps: F ' =F=1.268(m 2 )
Height of foam layer on trays: h' b =(h¿¿c ' +∆ ' −h x )×(F−f)× ρ S, x +h x × ρ b ' × f+(h cap −h x )× f × ρ b '
Overall resistance of one rectifying tray:
Overall resistance of one stripping tray:
Total resistance of bubble cap column:
Flooding test
In order for the distillation column to work in normal working conditions, the distance between trays must satisfy the following restriction: h tray >h min #300×ρ y ρ x × ( n× π × d F × ω y cap ) 2 (m)
In which, h tray : distance between trays (m) h min : minimum distance between trays (m) ω y : vapor velocity (m/s)
MECHANICAL DESIGN 53 1 Body’s thickness
Maximum allowable working pressure (MAWP)
Head and bottom’s thickness
The head and bottom enclosure of the column is operated at the same working conditions with the body vessel Hence, the design pressure is also P D '.56 psi.
The head and bottom enclosure is made of stainless steel 304, with the ellipsoidal configuration 2:1. t min = P D D
C A : additional thickness for chemical corrosion, mm Assume that Acid acetic’s corrosion rate is 0.05 mm/year and the usage length is 20 years ⇒C A =1(mm).
C B : additional thickness for mechanical corrosion Assume that C B =1(mm).
C C : additional thickness for manufacturing error Assume that C C =1(mm).
2× h=2 🡪 Height of heat and bottom: h=D i
2.1 Maximum allowable working pressure (MAWP)
Flanges joining shell, head and bottom parts
Figure 6: Slip-on flange intersection
Flanges are important in joining parts of equipment together or joining equipment to equipment There are 3 kinds of commonly used flange:
● Slip-on flange: help joining equipment to equipment (by welding, casting, forging) This kind of flange mainly used for equipment operating at low and moderate pressure.
Lap-joint flanges are primarily utilized for connecting high-temperature pipes, particularly those crafted from colored metals and their alloys These flanges are essential when a more durable material is required than that of the equipment being joined.
● Threaded flange: mainly used for high-pressure operating equipment.
The flange that be used to join shell, head, bottom parts is slip-on flange (without neck) and made of stainless steel X18H10T.
The designed pressure is choosen P ' =0.3( mm N 2 ) for safety issue
According to Table IX.5 (p.170, [1]), with respect to the diameter D=1.4(m) and the distance between two trays ∆ h trays 00mm, we obtain:
● The number of trays between two flanges: 8
● The distance between two flanges: 3650 (mm)
Then, number of flanges is: n flanges = N prac number of trays between2flanges+1$
The effectiveness of flange joining welds is primarily influenced by the gasket, which is crafted from a softer material compared to the flange itself As bolts are tightened, the gasket deforms to fill the uneven surfaces of the flange, ensuring a tight seal To guarantee optimal equipment sealing, we recommend using a 3mm thick asbestos rope gasket.
3.2 Diameter of pipe – Flange joining pipes
The flange is slip-on flange (without neck) and made of stainless steel X18H10T.
Feed flow rate: FY60[kg/h]
Density of feed liquid phase at t F 25[℃] and x A =0.1946, from (Table 2-32 [2])
D F =√❑ Choose: D F [mm], with l F 0[mm] (Table XIII.32, XIII.26 [1])
3.2.2 Vapor pipe on the top of the column
Vapor flow rate at the top column: g T 113.75[kg/h]
Density of vapor phase at t T V.2[ ℃ ] and y T =0.85877
Diameter of top vapor pipe:
D T =√❑ Choose: D T 0[mm], with l T 0[mm] (Table XIII.32, XIII.26 [1])
Density of reflux liquid phase at t T V.2[℃] and x T =0,9897, from (Table 2-32 [2])
D R =√❑ Choose: D R p[mm], with l R 0[mm] (Table XIII.32, XIII.26 [1])
3.2.4 Vapor pipe at the bottom of the column
Vapor flow rate at the into the first tray of the bottom: g ' 1 940 4[kg/h]
Density of vapor bottom product at t B 4.5[ ℃ ] and y B =0.063
Diameter of bottom vapor pipe:
D B =√❑ Choose: D B 0[mm], with l B 0[mm] (Table XIII.32, XIII.26 [1])
3.2.5 Liquid pipe at the bottom of the column
Bottom liquid flow rate: G ' 1 23 7[kg/h]
Density of liquid phase at t B 4.5[ ℃ ] and x B =0.0193
Diameter of bottom liquid pipe:
D R' =√❑ Choose: D R' [mm], with l R 0[mm] (Table XIII.32, XIII.26 [1])
Column’s support
The density of stainless steel 304 is ρy00(kg m 3 ).
4.2 Mass of head and bottom enclosures
2:1 ellipsoidal head/bottom ⇒A surface =1.084× D i 2=1.084×1.4 2 =2.125(m 2 ) m enclosures =2A surface tρ=2×2.125×0.005×79007.875(kg)
Number of flanges: n=6 (4 column flanges and 2 enclosure flanges) m flanges =n π
Cap’s outer diameter: d cap, o =d cap +2δ cap =0.145+2×0.0025=0.15(m)
Cap’s height: h cap =0.145(m) m caps =N ×n× π4[ ( d cap, o 2 −d cap 2 ) × h cap +d cap 2 × δ cap ] × ρv4.27 (kg )
Each tray features two overflow weirs: the longer weir serves as a downcomer, channeling liquid to the tray below, while the shorter weir regulates the liquid received from the tray above.
Short weir’s height: H w =0.072(m) m weirs =N × L c ×(H c +H w )× δ c × ρ#6.35(kg)
∑ ❑ ❑ m=m body +m enclosure + m flange + m tray +m liquid +m cap +m gas pipe + m weirs
Supporting stand
Supporting stands: column is supported on 4 stands
Supporting stands’ material: stainless steel 304
4 6717.06(N) Then, choose G c `000(N), applying (Table XIII.35 [1])
Lifting lug
Lugs are essential components attached to the head of a column, designed to facilitate the lifting of equipment during installation or maintenance Utilizing a pair of lugs ensures that the load is distributed evenly, enhancing safety and efficiency in the lifting process.
The lugs are constructed of stainless steel, grade SA-516
Erection weight of the vessel: W=( ∑ ❑ ❑ m−m liquid gX443.1( N )84.1(lbf))
Choose lugs that can withstand W000(lbf), applying (Table page 119 [7])
AUXILARY EQUIPMENT 67 1 Top vapor condenser
Top product cooler
Choose top product cooler tube-in-tube heat exchange equipment
Tubes are made by stainless steel X18H10T, which have:
● Cooling water inside inner tube with the size 16x2:
Cooling water inside tubes with: {t w ,1 %[℃]t w ,2 @[℃], then: t w ,avg '+40
2 2.5[℃] o Specific heat capacity: C w =4.18[kJ/kgK] (Table 2-53 [2]) o Density: ρ w 2.750[kg/m 3 ] (Table 2-32 [2]) o Dynamic viscosity: μ w =7.6257×10 −4 [Ns/m 2 ] (Table 2-313 [2]) o Thermal conductivity: λ w =0.61778[W/mK] (Table 2-315 [2])
● Top product inside outer tube with the size 25x2
Cooling water inside tubes with: {t T ,1 V.2[℃]t T ,2 5[℃], then: t T , avg V.2+35
2 F.5[℃] o C T =x T C A +( 1− x T ) C B =2.249[kJ/kgK] (Table 2-53 [2]) o ρ T =( ρ x T A + 1− ρ B x T ) −1 x0.712 [kg / m 3 ] (Table 2-32 [2]) o μ T =0.284×10 −3 [Ns/m 2 ] (Table 2-313 [2]) o λ T =x T λ A +( 1− x T ) λ B =0.165[W/mK] (Table 2-315 [2])
From the initial part, the water flowrate inside inner tube:
Heat exchange surface is determined by heat exchange equation (Eqt V.2 [1])
● ∆ t log : log mean temperature difference
∆ t log =(t T , 1−t w ,2)−(t T ,2−t w ,1) ln ln( t t T ,1 T ,2 −t −t w , w, 2 1 ) = (56.2−40)−(35−25) ln ln( 56.2− 35−25 40 ) = 12.85
Overall heat transfer coefficient K is determined by this equation (Eqt V.5 [1])
● α w : heat transfer coefficient of water inside inner tube [W/m 2 K]
● α T : heat transfer coefficient of top product inside outer tube [W/m 2 K]
● ∑r t : thermal resistance by tube wall and fouling [m 2 K/K]
Determine heat transfer coefficient of tube
Velocity of top product outer tube: ω T = 4T π(D i 2−d o 2)ρ T
Then, Nusselt number will be determined by the equation (Eqt V.44 [1])
Nu T =0.021ε l ℜ 0.8 Pr T 0.43 ( Pr Pr wall T ) 0.25
● ε l =1: correction coefficient depended on Ren and ratio between tube length and tube diameter with ℜ T 6286.61and L/d i >50
● Pr T : Prandtl number of top product (V.35 [1])
● Pr T , wall : Prandtl number of top product at average temperature of tube wall
Heat transfer coefficient of top product inside outer tube α T =Nu T × λ T d ℜ #4.32×0.165
Heat load of cooling water [I]: q T =α T ( t T ,avg −t T ,wall ) = 7732.615 Pr wall 0.25 × ( 46.5 −t T , wall ) [W / m 2 ]
Where t T , wall : temperature of tube wall contacted with top product (outside tube)
Heat load through tube wall and fouling q t =t T , wall −t w ,wall
● t T , wall : temperature of tube wall contacted with top product (outside tube)
● λ t 5: Heat exchange coefficient of stainless steel [W/mK]
● r 1 =1/5000: Average heat resistance of fouling inside tube with water [m 2 K/W]
● r 2 =1/5000: Average heat resistance of fouling by top product [m 2 K/W]
Heat transfer coefficient of water inside inner tube
Velocity of water in innner tube: ω w = 4G w2 π d i 2 ρ w
Then, Nusselt number will be determined by the equation:
Nu w =0.021ε l ℜ w 0.8 Pr w 0.43 ( Pr Pr wall w ) 0.25
● ε l =1: correction coefficient depended on Ren and ratio between tube length and tube diameter with ℜ w 4430.63 and L/d i >50
● Pr w : Prandtl number of water at 32.5[℃]→ Pr w =5
● Pr w ,wall : Prandtl number of water at average temperature of tube wall
Heat load of cooling water [III]: q w =α w ( t w, wall −t w , avg ) = 13763.46 Pr w ,wall
Then: o C T =x T C A +( 1− x T ) C B =2.240[kJ/kgK] (Table 2-53 [2]) o μ T =0.291×10 −3 [Ns/m 2 ] (Table 2-313 [2]) o λ T =x T λ A +( 1− x T ) λ B =0.165[W/mK] (Table 2-315 [2])
We have: Pr T , wall =μ T , wall× C T ,wall λ T , wall =0.291×2.240
0,165 =3.952 From [I]: q T w32.615 3.952 0.25 ×(46.5−43.32)440.12[W/m 2 ] Neglecting the loss of heat load, then: q T =q t 440.12[W/m 2 ]
From [II]: q t =t T , wall −t w ,wall 5.14×10 −4 →17440.12C.32−t w , wall
2 8.838[℃], then Pr wall ≈4.5 From [III]: q w 763.46 4.5 0.25 ×(34.356−32.5)536.744[W/m 2 ]
46.63[W/m 2 K] c Heat exchange area and structure of equipment
Average heat exchanging surface area:
3600×12.85×1246.63=0.8739[m 2 ] Length of heat exchanging tube:
The top product cooling equipment is tube-in-tube heat exchange, with tube length L [m] that is separated in 10[pass], each line has a length of 2[m]
Reboiler
Choose bottom product boiler as Kettle type boiler
Heat exchange tubes are made by stainless steel X18H10T, with the size for code 80 tube (Table 12.1 [8])
Heating stream is vapor at 5atm inside the tubes, from (Table I.212 [3])
Bottom product stream has temperature of
2 5.25[℃] From the energy balance section, we have
Q rb =r w × D 2 39×2121=2.204×10 6 [ kJ h ] = 612.144 [kW ] a Thermal conductivity
Heat exchange surface is determined by heat exchange equation (Eqt V.2 [1])
● ∆ t log : log mean temperature difference
Overall heat transfer coefficient K is determined by this equation (Eqt V.5 [1])
● α w : heat transfer coefficient of steam inside tubes [W/m 2 K]
● α T : heat transfer coefficient of bottom product outside tubes [W/m 2 K]
● ∑r t : thermal resistance by tube wall and fouling [m 2 K/K]
Heat exchange coefficient of vapor
With A: coefficient depended on physical characteristic to temperature of water
The heat exchange coefficient of water is influenced by the arrangement of tubes, specifically when arranged in a hexagonal shape consisting of 130 tubes In this configuration, the number of tubes along the diagonal line of the hexagon is denoted as b tubes, as detailed in Table V.11.
Then, from (Diagram V.20 [1]) ε avg =0.45→α condense =ε avg α w =0.45α w
Heat load outside of wall tube (I): q w =α w ( t w −t w ,wall ) Y.3239 × A × ( 149.78−t w , wall ) 0.75
Heat load through tube wall and fouling q t =t W , wall −t B, wall
● t B, wall : temperature of tube wall contacted with bottom product (outside tube)
● λ t 5: Heat exchange coefficient of stainless steel [W/mK]
● r 1 =1/5000: Average heat resistance of fouling inside tube with water [m 2 K/W]
● r 2 =1/5000: Average heat resistance of fouling by top product [m 2 K/W]
Heat exchange coefficient of bottom product
Heat exchange coefficient of bottom product is determined by this equation (bubbling fluidized boiling model) (V.89 [1]) α B =7.77×10 − 2 × ( ρ B ρ − B, vap ρ B, vap r ) 0.033 ( σ ρ B B ) 0.333 μ 0.45 B λ C B 0.75 0.117 B q B 0.7 T B ,avg 0.37
● ρ B ,vap =1.883[kg/m 3 ] μ B [x B loglog ( μ Et ) +(1−x B )log log ( μ w ) ] =0.38×10 −3 [Ns/m 2 ] (Table 2-313 [2])
Head load of bottom product (III): q B =α B ( T B,wall −T B,avg ) =1.801 × q B 0.7 ( T B,wall − T B,avg ) [W / m 2 ]
Neglecting the loss of heat load, then: q w =q t =3.36×10 4 [W/m 2 ]
6.24×10 −4 →t B ,wall 8.01[℃] From (III): q B =1.801× q B 0.7 ( T B, wall −T B, avg ) q B = 0.3 √ 1.801 ×(128.01−115.25) ¿3.45×10 4 [W/m 2 ]
6.73[W/m 2 K] b Heat exchange area and structure of equipment
Average heat exchanging surface area:
17.64×946.736.6546[m 2 ] Choose the total number of tubes: nb
Length of heat exchanging tube:
The reboiler is kettle heat exchanger, with tube length L=8.5[m], with 62tubes
Preheater
Choose horizontal shell-tube condenser
Inside tubes are made by stainless steel X18H10T with L=H=1.5[m]
● Feed stream inside tubes with the size for code 80 tube (Table 12.1 [8])
{d o =1.050 [ ¿ ] =0.02667[m]d i =0.742 [ ¿ ] =0.01885[m]δ d =0.154 [ ¿ ] =0.00392[m] Feed stream inside tubes with: {t F,1 %[℃]t F, 2 25[℃], then: t F ,avg %+93.25
2 59[℃] o C F =x F C A +( 1− x F ) C B "38.7[J/kgK] (Table 2-53 [2]) o ρ F =( x ρ F A + 1 −x ρ B F ) −1 0.7 [ kg/m 3 ] (Table 2-32 [2]) o μ F =0.56×10 −3 [Ns/m 2 ] (Table 2-313 [2]) o λ F =x F λ A +( 1− x F ) λ B =0.165[W/mK] (Table 2-315 [2])
● Heating stream outside tubes with the size for code 80 tube
Heating stream is vapor at 2at outside tubes, then:
Flow rate of feed: FY60[kg/h]
Flow rate of steam: D 2 u9.316[ kg h ] =0.211 [ kg s ] b Thermal conductivity
Heat exchange surface is determined by heat exchange equation (Eqt V.2 [1])
● ∆ t log : log mean temperature difference
∆ t log =( t w −t F ,1 ) − ( t w −t F,2 ) ln ln( t t w w −t −t F ,1 F ,2 ) ¿(120.33−25)−(120.33−93.25) ln ln( 120.33 120.33 −93.25 −25 ) T.23
Overall heat transfer coefficient K is determined by this equation (Eqt V.5 [1])
● α w : heat transfer coefficient of steam [W/m 2 K]
● α T : heat transfer coefficient of feed stream inside tubes [W/m 2 K]
● ∑r t : thermal resistance by tube wall and fouling [m 2 K/K]
Heat exchange coefficient of feed stream
Choosing the velocity of feed product: ω F =0.5[m/s]
Then, the number of tubes is: n' F = 4F π ω F d i 2 ρ F
Then, the practical number of tubes is: n F 7[tubes]
Then, Nusselt number will be determined by the equation (V.40 [1])
Nu F =0.021ε l ℜ 0.8 F Pr F 0.43 ( Pr Pr F, wall F ) 0.25
● ε l =1: correction coefficient depended on Ren and ratio between tube length and tube diameter with ℜ T 803.32 and L/d i >50
● Pr F : Prandtl number of feed (V.35 [1])
● Pr F ,wall : Prandtl number of feed at average temperature of tube wall Then:
Heat transfer coefficient of feed inside inner tube α F =Nu F × λ F d i = 200.175×0.165
Heat load of cooling water [I]: q F =α F ( t F, wall −t F ,avg ) = 1752.2
Heat load through tube wall and fouling q t =t w ,wall −t F , wall
● t T , wall : temperature of tube wall contacted with steam (outside tube)
● λ t 5: Heat exchange coefficient of stainless steel [W/mK]
● r 1 =1/5000: Average heat resistance of fouling inside tube [m 2 K/W]
● r 2 =1/5000: Average heat resistance of fouling be feed stream [m 2 K/W] Then [II]: q t =t B, wall −t F ,wall 6.24×10 −4 [W/m 2 ]
Heat exchange coefficient of vapor
With A: coefficient depended on physical characteristic to temperature of water
The heat exchange coefficient of methanol is influenced by the arrangement of tubes, specifically when arranged in a hexagonal configuration with 62 tubes, where the number of tubes in the diagonal line of the hexagon is 9.
Then, from (Diagram V.20 [1]) ε avg =0.45→α w' =ε avg α w =0.45× α T
We have (III): q w =α w ' ( t w −t w , wall ) 3.08 × 0.45 × A × (120.32951−t w ,wall ) 0.75 ¿q w =α w ' ( t w −t w , wall ) Y.87 × A × (120.32951−t w ,wall ) 0.75
Neglecting the loss of heat load, then: q w =q t @589.24[W/m 2 ]
Then, we have: Pr F ,avg =μ F, avg C F, avg λ F, avg =4.707 (V.35 [1])
1189.59 e5.34[W/m 2 K] c Heat exchange area and structure of equipment
Average heat exchanging surface area:
54.23×655.34.3[m 2 ] Length of heat exchanging tube:
Bottom product cooler
Choose top product cooler tube-in-tube heat exchange equipment
Tubes are made by stainless steel X18H10T, which have:
● Cooling water inside inner tube with the size 42x2:
{d o =0.042[m]d i =0.038[m]δ d =0.002[m] Cooling water inside tubes with: {t w ,1 %[℃]t w ,2 E[℃], then: t w ,avg %+45
2 5[℃] o Specific heat capacity: C w =4.18[kJ/kgK] (Table 2-53 [2]) o Density: ρ w 2.750[kg/m 3 ] (Table 2-32 [2]) o Dynamic viscosity: μ w =6.92×10 −4 [Ns/m 2 ] (Table 2-313 [2]) o Thermal conductivity: λ w =0.63[W/mK] (Table 2-315 [2])
● Bottom product inside outer tube with the size 70x2
Cooling water inside tubes with: {t B ,1 4.5[℃]t B,2 5[℃], then: t B, avg 4.5+35
2 t.75[℃] o C B =x B C A +( 1− x B ) C B =2.292[kJ/kgK] (Table 2-53 [2]) o ρ B =( x ρ B A + 1− ρ B x B ) −1 = 982.751 [ kg/ m 3 ] (Table 2-32 [2]) o μ B =0.585×10 −3 [Ns/m 2 ] (Table 2-313 [2]) o λ T =x T λ A +( 1−x T ) λ B =0.161[W/mK] (Table 2-315 [2])
From the initial part, the water flowrate inside inner tube:
Heat exchange surface is determined by heat exchange equation (Eqt V.2 [1])
● ∆ t log : log mean temperature difference
∆ t log =(t B ,1−t w ,2)−(t B,2−t w ,1) ln ln( t t B,1 B,2 −t −t w ,2 w ,1 ) =(114.5−45)−(35−25) ln ln( 114.5−45 35 −25 ) 0.69
Overall heat transfer coefficient K is determined by this equation (Eqt V.5 [1])
● α w : heat transfer coefficient of water inside inner tube [W/m 2 K]
● α T : heat transfer coefficient of top product inside outer tube [W/m 2 K]
● ∑r t : thermal resistance by tube wall and fouling [m 2 K/K]
Determine heat transfer coefficient of tube
Velocity of top product outer tube: ω B = 4B π(D i 2−d o 2)ρ B
Then, Nusselt number will be determined by the equation (Eqt V.44 [1])
Nu T =0.021ε l ℜ 0.8 Pr 0.43 B ( Pr Pr wall B ) 0.25
● ε l =1: correction coefficient depended on Ren and ratio between tube length and tube diameter with ℜ T 6286.61and L/d i >50
● Pr T : Prandtl number of top product (V.35 [1])
● Pr T , wall : Prandtl number of top product at average temperature of tube wall
Heat transfer coefficient of top product inside outer tube α B =Nu B × λ T d ℜ 14.523×0.161
Heat load of cooling water [I]: q B =α B ( t B,avg −t B, wall ) = 2109.92 Pr wall 0.25 × ( 74.75 −t T ,wall ) [W / m 2 ]
Where t T , wall : temperature of tube wall contacted with top product (outside tube)
Heat load through tube wall and fouling q t =t B, wall −t w ,wall
● t B, wall : temperature of tube wall contacted with top product (outside tube)
● λ t 5: Heat exchange coefficient of stainless steel [W/mK]
● r 1 =1/5000: Average heat resistance of fouling inside tube with water [m 2 K/W]
● r 2 =1/5000: Average heat resistance of fouling by top product [m 2 K/W]
Heat transfer coefficient of water inside inner tube
Velocity of water in innner tube: ω w = 4G w1 π d i 2 ρ w
Then, Nusselt number will be determined by the equation:
Nu w =0.021ε l ℜ w 0.8 Pr w 0.43 ( Pr Pr wall w ) 0.25
● ε l =1: correction coefficient depended on Ren and ratio between tube length and tube diameter with ℜ w 3115 and L/d i >50
● Pr w : Prandtl number of water at 35[℃]→ Pr w =4.8
● Pr w ,wall : Prandtl number of water at average temperature of tube wall
Heat load of cooling water [III]: q w =α w ( t w, wall −t w , avg ) = 13479.3 Pr w, wall
Then: o C B =x T C A +( 1− x T ) C B =2.134 [ kJ / kgK ] (Table 2-53 [2]) o μ B =0.821×10 −3 [Ns/m 2 ] (Table 2-313 [2]) o λ B =x B λ A +( 1−x B ) λ B =0.167[W/mK] (Table 2-315 [2])
We have: Pr T , wall =μ T , wall× C T ,wall λ T , wall =0.821×2.134
0,167 49 From [I]: q B !09.92 10.49 0.25 ×(74.75−67.5)17.07[W/m 2 ] Neglecting the loss of heat load, then: q T =q t 17.07[W/m 2 ]
From [II]: q t =t T , wall −t w ,wall 5.14×10 −4 →8617.07g.4−t w ,wall
2 e.185[℃], then Pr wall ≈4.5 From [III]: q w 479.3 4.4 0.25 ×(62.97−35)85.69[W/m 2 ]
1172.39 g7.96[W/m 2 K] b Heat exchange area and structure of equipment
Average heat exchanging surface area:
3600×30.69×677.96.879[m 2 ] Length of heat exchanging tube:
The top product cooling equipment is tube-in-tube heat exchange, with tube length L[m] that is separated in 5[pass], each line has a length of 2[m]
SUMMARY 92 1 Mass balance
Energy balance
Heat of feed stream enter column Q F 5.237×10 6
Heat of liquid reflux stream enter column Q R 1.538×10 6 Heat of top vapor stream exit column Q T 4.126×10 6
Heat of bottom stream exit column Q B 4.743×10 6
Heat load for condenser Q con 1.62×10 6
Heat load for bottom product cooler Q cool 1 8.8981×10 5 Heat load for overhead product cooler Q cool 2 5.0435×10 5
Heat load for reboiler Q rb 2.204×10 6
Main column
Size parameters of the column
Height of the shell H shell m 9.5
Total height of the column H m 10.2
Size parameters of the bubble caps
Diameter of bubble caps d cap m 0.145
Height of bubble caps h cap m 0.145
Number of bubble caps 1 tray N 19
Number of hexagons formed by holes a 2
Thickness of column shell S cell mm 5
Thickness of head and bottom S H/B mm 5
Diameter of pipe – Flange joining pipes
Vapor pipe on the top of the column
Vapor pipe at the bottom of the column
Liquid pipe at the bottom of the column
H mm 450 h mm 226 s mm 18 l mm 110 d mm 34
Auxiliary equipment
Type: horizontal shell-tube condenser type TH Inner tubes: cooling water (25℃→40℃)
Outside the tubes: top vapor product (56.2℃) Length: 3m
Type: tube-in-tube heat exchanger Inner tubes: cooling water (25℃→40℃)
Inside outer tube: top condensed product (56.2℃→35℃)
Reboiler Type: Kettle heat exchanger
Inner tubes: heating steam (149.78℃−5atm¿
Outside the tubes: bottom product (114.5℃→116℃¿Length: 8.5m
Type: vertical shell-tube condenser type TH Inner tubes: feed stream (25℃→93.25℃)
Outside the tubes: heating steam (120.33℃−2atm¿ Length: 2m
Type: tube-in-tube heat exchanger Inner tubes: cooling water (25℃→45℃)
Inside outer tube: top condensed product (114.5℃→35℃) Total ength: 10m
Conclusion
The distillation of an acetone-acetic acid mixture using a bubble cap distillation column offers various advantages and disadvantages Given that this process operates at high temperatures with flammable acetone, it is crucial for operators to adhere to strict safety protocols to mitigate risks and protect both the plant and personnel.
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