CHAPTER 6 DESIGN OF EQUIPMENTS

DESIGN OF STRIPPING COLUMN

Before going in details of stripping column design first we see what is
stripping and what its industrial uses are.

STRIPPING
Unit operation where one or more components of a liquid stream are removed
by being placed in contact with a gas stream that is insoluble in the liquid stream.

OR

Stripping is a physical separation process where one or more components are

removed from a liquid stream by a vapor stream. In industrial applications the liquid
and vapor streams can have co-current or countercurrent flows. Stripping is usually
carried out in either a packed or tray column.

THEORY
Stripping works on the basis of mass transfer. The idea is to make the
conditions favorable for the more volatile component in the liquid phase to transfer to
the vapor phase. This involves a gas-liquid interface that the more volatile component
must cross.

EQUIPMENT USED FOR STRIPPING

Stripping is mainly conducted in trayed towers (plate columns) and packed
columns, and less often in spray towers, bubble columns and centrifugal contactors.

PLATE COLUMN
Packed columns consist of a vertical column with liquid flowing in from the
top and flowing out the bottom. The vapor phase enters from the bottom of the column
and exits out of the top. Inside of the column are trays or plates. These trays force the
liquid to flow back and forth horizontally while forcing the vapor bubbles up through
holes in the trays. The purpose of these trays is to increase the amount of contact area
between the liquid and vapor phases.

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PACKED COLUMN
Packed columns are similar to plate columns in that the liquid and vapor flows
enter and exit in the same manner. The difference is that in packed towers there are no
trays. Instead, packing is used to increase the contact area between the liquid and
vapor phases. There are many different types of packing used and each one its
advantages and disadvantages. The gas liquid contact in a packed bed column is
continuous, not stage-wise, as in a plate column. The liquid flows down the column
over the packing surface and the gas or vapor, counter-currently, up the column. In
some gas-absorption columns co-current flow is used. The performance of a packed
column is very much dependent on the maintenance of good liquid and gas
distribution throughout the packed bed, and this is an important consideration in
packed-column design.

CHOICE OF PLATE OR PACKED COLUMN

The choice between a plate and packed column for a particular application can
only be made with complete assurance by costing each design. However, this will not
always be worthwhile or necessary, and the choice can usually be made on the basis of
experience by considering main advantages and disadvantages of each type; which are
listed below:

1. Plate columns can be designed to handle a wider range of liquid and gas flow-
rates than packed columns.
2. Packed columns are not suitable for very low liquid rates.
3. The efficiency of a plate can be predicted with more certainty than the
equivalent term for packing (HETP or HTU).
4. Plate columns can be designed with more assurance than packed columns.
There is always some doubt that good liquid distribution can be maintained
throughout a packed column under all operating conditions, particularly in
large columns.
5. It is easier to make provision for cooling in a plate column; coils can be
installed on the plates.

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6. It is easier to make provision for the withdrawal of side-streams from plate

columns.
7. If the liquid causes fouling, or contains solids, it is easier to make provision for
cleaning in a plate column; manways can be installed on the plates. With small
diameter columns it may be cheaper to use packing and replace the packing
when it becomes fouled.
8. For corrosive liquids a packed column will usually be cheaper than the
equivalent plate column.
9. The liquid hold-up is appreciably lower in a packed column than a plate
column. This can be important when the inventory of toxic or flammable
liquids needs t be kept as small as possible for safety reasons.
10. Packed columns are more suitable for handling foaming systems.
11. The pressure drop per equilibrium stage (HETP) can be lower for packing than
plates; and packing should be considered for vacuum columns.
12. Packing should always be considered for small diameter columns, say less than
0.6 m, where plates would be difficult to install, and expensive.
Packed column is selected for our operation.

TYPES OF PACKING
The principal requirements of a packing are that it should:

 Provide a large surface area: a high interfacial area between the gas and
liquid.
 Have an open structure: low resistance to gas flow.
 Promote uniform liquid distribution on the packing surface.
 Promote uniform vapor gas flow across the column cross-section.
Many diverse types and shapes of packing have been developed to satisfy these
requirements. They can be divided into two broad classes:

1. Packings with a regular geometry: such as stacked rings, grids and proprietary
structured packings.
2. Random packings: rings, saddles and proprietary shapes, which are dumped
into the column and take up a random arrangement.

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Grids have an open structure and are used for high gas rates, where low pressure
drop is essential; for example, in cooling towers. Random packings and structured
packing elements are more commonly used in the process industries.

RANDOM PACKING
The principal types of random packings are shown

Rasching Rings Pall Rings

Berl Saddles Intalox Saddles

Super Intalox Saddles Metal Hypac

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Raschig rings are one of the oldest specially manufactured types of random
packing, and are still in general use. Pall rings are essentially Raschig rings in which
openings have been made by folding strips of the surface into the ring. This increases
the free area and improves the liquid distribution characteristics. Berl saddles were
developed to give improved liquid distribution compared to Raschig rings. Intalox
saddles can be considered to be an improved type of Berl saddle; their shape makes
them easier to manufacture than Berl saddles. The Hypac and Super Intalox packings
shown in can be considered improved types of Pall ring and Intalox saddle
respectively.

Ring and saddle packings are available in a variety of materials: ceramics,

metals, plastics and carbon. Metal and plastics (polypropylene) rings are more
efficient than ceramic rings, as it is possible to make the walls thinner.

Raschig rings are cheaper per unit volume than Pall rings or saddles but are
less efficient, and the total cost of the column will usually be higher if Raschig rings
are specified. For new columns, the choice will normally be between Pall rings and
Berl or Intalox saddles.

The choice of material will depend on the nature of the fluids and the operating
temperature. Ceramic packing will be the first choice for corrosive liquids; but
ceramics are unsuitable for use with strong alkalies. Plastic packings are attacked by
some organic solvents, and can only be used up to moderate temperatures. So are
unsuitable for distillation columns. Where the column operation is likely to be
unstable, metal rings should be used, as ceramic packing is easily broken.

PACKING SIZE
In general, the largest size of packing that is suitable for the size of column
should be used, up to 50 mm. Small sizes are appreciably more expensive than the
larger sizes. Above 50 mm the lower cost per cubic meter does not normally
compensate for the lower mass transfer efficiency. Use of too large a size in a small
column can cause poor liquid distribution.

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Recommended size ranges are:

Column diameter Use packing size

<0.3 m <25 mm

0.3 to 0.9 m 25 to 38 mm

>0.9 m 50 to 75 mm

STRUCTURED PACKING
The term structured packing refers to packing elements made up from wire
mesh or perforated metal sheets. The material is folded and arranged with a regular
geometry, to give a high surface area with a high void fraction. A typical example is
shown below.

Structured Packing

Structured packings are produced by a number of manufacturers. The basic

construction and performance of the various proprietary types available are similar.
The advantage of structured packings over random packing is their low HETP
(typically less than 0.5 m) and low pressure drop (around 100 Pa/m). They are being
increasingly used in the following applications:

1. For difficult separations, requiring many stages: such as the separation of

isotopes.
2. High vacuum distillation.
3. For column revamps: to increase capacity and reduce reflux ratio requirements.
The applications have mainly been in distillation, but structured packings can
also be used in absorption; in applications where high efficiency and low pressure
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drop are needed. The cost of structured packings per cubic meter will be significantly
higher than that of random packings, but this is offset by their higher efficiency.

Selected packing is random because its cheaper and there are no difficult or
vacuum separation requirements.

CHOICE OF RANDOM PACKING

Factors to be considered

1. Void fraction

2. Effective surface

3. Packing size

4. Maximum operating temperature

5. Mechanical strength

6. Material selection

Packing used here is 0.038m ceramic intalox saddle because

1. One of the most efficient packings

2. Little tendency to nest and block areas of bed

3. Gives a fairly uniform bed

4. Higher flooding point

5. Lower pressure drop

PACKING PROPERTIES

1.5"
Nominal size 0.038mm

Packing factor F 170 Specific gravity (g/cm3) 2.3

Package density (kg/m3) 580 Water absorption (%) <0.3

Free volume (%) 80 Acid resistance (%) >99.6

Surface area (m2/m3) 180 Max operating temp. 1100℃

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MATERIAL BALANCE

Component 10 17 11 19

Propylene 202 201.23 0.80

Hydrogen 549 1.88 547.27 3.64

n-Butanal 13726.88 266.37 13460.5

Iso-Butanal 315.94 8.83 307.11

CO 8163 48.64 8141.61 69.98

propane 44.40 43.76 0.633

Total 8712.00 14339.44 9201.94 13839.50

Material In = Material Out

Stream 10 + Stream 17 = Stream 11 + Stream 19

Total = 23041.44 kg/hr = Total = 23041.44 kg/hr

STRIPPER FEED (17) STRIPPED GAS (11)

Mass flow rate= 14339.44kg/hr Mass flow rate=9201.94kg/hr

Molar flow rate= 203.53kgmol/hr Molar flow rate= 574.1kgmol/hr

Mole Fraction: Mole Fraction:

Propylene: 0.023 Propylene: 0.0083

n-Butanal: 0.936 Hydrogen: 0.476

iso-Butanal: 0.021 CO: 0.506

Propane: 0.0049 N-butanal: 0.0064

Product (19)
STRIPPING GAS (10) Iso-butanal:.0.0021
Hydrogen: 0.0046 Mass flow rate= 13839.5 kg/hr
Mass flow rate= 8712kg/hr Propane: 0.0017
CO: 0.0085 Molar flowrate= 195.57kgmol/hr
Molar flowrate= 566.04kgmol/hr
Mole Fraction:
Mole Fraction:
N-Butanal: 0.956
Hydrogen: 0.484
Iso-Butanal: 0.0218
CO: 0.516
Propylene: 0.000097

Propane: 0.000073

Hydrogen: 0.0093
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CHAPTER 6 DESIGN OF EQUIPMENTS

PROCESS CONDITIONS

Stream Temperature (K) Mass Flowrate (kg/hr)

Liquid Inlet 313 14339.79

Liquid Outlet 388 13842

Gas Inlet 483 8712

Gas Outlet 317 9209

Components\Mole 10 17 11 19
fraction

Propylene 0.0236 0.00834 0.00009

Hydrogen 0.4849 0.00463 0.4767 0.00932

n-Butanal 0.9366 0.00644 0.9559

Iso-Butanal 0.02155 0.00021 0.02180

CO 0.5150 0.00853 0.50655 0.01278

Propane 0.00495 0.00173 0.00007

DESIGN APPROACH
1. Determining the diameter of column.

2. Determining the HETP of packing

3. Determining Number of transfer units for the required separation.

4. Determining the height of overall transfer units.

5. Determining the total height of column.

6. Determining the flooding velocity.

7. Verifying the pressure drop across the column.

8. Mechanical Design

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DIAMETER OF COLUMN
The column diameter is calculated by following formula
𝟎..𝟓
𝐆
𝐃 = 𝟏. 𝟏𝟐𝟖 ′
𝐆
G= Mass flowrate of gas

G’= Mass flux of gas

To find G’ first find the flow parameter X as followed

L= Mass flow rate of liquid stream

ρg = Density of gas

ρl = Density of liquid

x = 0.236

Pressure drop range for strippers and absorbers is 147Pa to 490Pa.

Pressure drop of 294 Pa/m of a packed bed is selected.

Value of gas mass flux G’ from figure 12 Chapter 1 Rule of thumbs for chemical
engineers 3ed.

G’=0.7 kg/m2 s Diameter of packed column is 0.603m.

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HEIGHT EQUIVALENT OF THEORETICAL PLATE (HETP)

HETP is calculated as

HETP =

Where

A= Size of packing = 38mm

σ= Surface tension of liquid = 29.2 mN/m

µ= Overall viscosity of feed stream = 0.000414 Pa s

HETP = 0.0357m

NUMBER OF TRANSFER UNITS (NTU)

Number of transfer units is calculated as followed.

𝟏 𝐱 𝟐 − 𝐲𝟏
𝐍𝐭𝐨𝐭𝐚𝐥 = 𝐥𝐧 𝟏 − 𝛃 +𝛃
𝟏−𝛃 𝐱 𝟏 − 𝐲𝟏
Where

β=L/HG = 0.0045

L=Molar liquid flow rate = 203 kmol/hr

G=Molar gas flow rate = 566 kmol/hr

H=Henry’s Law Constant = 79.52 Pa/mol fraction

x2=Solute contents in liquid inlet stream mol fraction = 0.0083

x1=Solute contents in liquid exit stream mol fraction = 0.00009

y1=Solute contents in gas at bottom mol fraction =0

Ntotal= 4.5 ~ 5

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HEIGHT OF OVERALL GAS TRANSFER UNIT (HOG)

Height of overall gas transfer unit is calculated as followed.

𝟏
𝛃−𝟏
𝐇𝐨𝐠 = 𝐇𝐄𝐓𝐏
𝐥𝐧 𝟏 𝛃

Hog = 1.45m

COLUMN HEIGHT
Packing height is calculated as followed

Htotal = Hog x Ntotal

Htotal = 7.28m

Giving 0.457m allowance for disengagement of vapors at top and at bottom

for liquid. Htotal = 8.194 m

FLOODING VELOCITY
Flooding velocity requires the calculation of the superficial velocity that is
given as

Vog = G/Aρg

Vog = 5.88m/s

As general rule superficial velocity is 40% to 60% of the flooding velocity.

Taking superficial velocity as 60% of the flooding velocity, then the flooding velocity
is given as

VF = 9.8m/s

CHECK FOR PRESSURE DROP

For pressure drop calculation we required flow factor and gas mass velocity.

𝐋 𝛒𝐠
Flow factor X is calculated as
𝐆 𝛒𝐥

X = 2.66

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Gas mass velocity is calculated with following formula.

Where

mv = Mass flow rate of gas stream

A = Area of column
m
G v
A
G = 0.703 kg/m2 s

Now the Y ordinate of figure 12 Chapter 1 Rule of thumbs for chemical engineers 3ed
is calculated by the given formula.

𝐆′ 𝟐𝐅𝛍𝟎.𝟏
𝐘=
𝛒 𝐠 𝛒𝐥 − 𝛒𝐠 𝐠 𝐜

Y = 0.723

Value of pressure drop for this value of Y is 294Pa/m of packing height.

MECHANICAL DESIGN
THICKNESS OF SHELL
Material selection: Stainless Steel 304

Shell thickness is calculated as given below

ts =Thickness of shell

p=Design pressure = O.P. × 1.1 = 55.265 N/mm2

D=Inside diameter = 0.602 m

f=Design stress = 145 N/mm2

J=Joint efficiency = 85%

c= Corrosion allowance = 2mm

ts = 82mm

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SHELL WEIGHT
Shell weight is calculated as

Shell Weight = Volume of shell × Density of shell material

Shell weight = 12670 kg

HEAD SELECTION AND THICKNESS

2:1 Elliptical head has been selected because it is used for high pressure requirements
and its manufacturing is easy as compared to other types. Material of construction is
low alloy steel.

Thickness of elliptical head is calculated with following formula

𝐩𝐃𝐢
𝐭𝐡 =
𝟐𝐟𝐉 + 𝟎. 𝟐𝐩

Where
th =Thickness of head

p =Design pressure = O.P. × 1.1 = 55.25N/mm2

Cs=Stress concentration factor = 1.77

Rc=Crown Radius = 0.602m

F =Design stress = 240N/mm2

J =Joint efficiency = 85%

C = Corrosion allowance =2

th = 83 mm

HEAD WEIGHT
Weight of elliptical head is calculated as

𝟒𝛑 𝐃𝐨 − 𝐃𝐢 𝐡𝐨 − 𝐡𝐢 𝐜
𝐖 = 𝛒𝐦
𝟑
W = 58kg

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SUPPORT DESIGN
Type of support selected is skirt type support for vertical vessels. Material of
construction is construction stainless steel SS-301.

First we find maximum dead weight of vessel when full of water.

Max. Dead weight = 25.5 kN

Weight of column = 202 kN

Weight of Packing = 2.364 kN

Wind Loading

𝐰𝐱 𝟐
𝐌𝐬 =
𝟐
Where

w= Dynamic wind pressure = 2790N/m2

x= Length of column = 9.11m

Ms = 69813 N

Take test thickness of support say 220mm.

Tensile strength of support

𝟒𝐌𝐬
𝛔𝐛𝐬 =
𝛑 𝐃𝐬 + 𝐭 𝐬 𝐃𝐬 𝐭 𝐬

Where

Ms = Wind loading

Ds = Inside diameter of shell

ts = Thickness of support

σbs= 0.81 N/mm2

Test compressive strength of support

𝐖
𝛔𝐰𝐬 (𝐭𝐞𝐬𝐭) =
𝛑 𝐃𝐬 + 𝐭 𝐬 𝐭 𝐬

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Where

W= Dead weight of column when full of water

σws (test) = 0.044 N/mm2

Operational compressive strength of support

𝐖
𝛔𝐰𝐬 (𝐨𝐩𝐞𝐫𝐚𝐭𝐢𝐧𝐠) =
𝛑 𝐃𝐬 + 𝐭 𝐬 𝐭 𝐬

Where

W= Total weight of column

σws (operational) = 0.359 N/mm2

Maximum tensile strength of support

𝐌𝐚𝐱 𝛔𝐬 𝐓𝐞𝐧𝐬𝐢𝐥𝐞 = 𝛔𝐛𝐬 − 𝛔𝐰𝐬 (𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧𝐚𝐥)

Max σs (Tensile) = 770 kPa

Maximum compressive strength of support

𝐌𝐚𝐱 𝛔𝐬 𝐂𝐨𝐦𝐩𝐫𝐞𝐬𝐬𝐢𝐯𝐞 = 𝛔𝐛𝐬 − 𝛔𝐰𝐬 (𝐓𝐞𝐬𝐭)

Max σs (Compressive) = 455 kPa

Check for taken thickness of support

Following two conditions must be satisfied.

1.

𝛔𝐬 (𝐓𝐞𝐧𝐬𝐢𝐥𝐞) < 𝐟𝐬 𝐉𝐬𝐢𝐧𝛉𝐬

Where

fs= Design stress = 240N/mm2

J= Joint efficiency = 85%

θs=Base angle (normally taken as 90°)

0.0226 < 0.770

Condition 1 is satisfied.

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2.

E= Young Modulus of elasticity = 11.35 N/mm2

0.455 < 0.518

Condition 2 is satisfied.

So thickness of support = 220mm

PACKING SUPPORT
The best design of packing support is one in which gas inlets are provided
above the level where the liquid flows from the bed; such as the gas-injection type.
These designs have a low pressure drop and no tendency to flooding. They are
available in a wide range of sizes and materials: metals, ceramics and plastics.

Gas-injection type packing support

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LIQUID DISTRIBUTER
The pan-type construction provides liquid level balance. Vapor passage is provided by
circular gas risers as well as around the periphery of the pan.

Pan-type distributer with bottom holes

SPECIFICATION SHEET

Name of equipment Stripper

Type Packed column

No. of equipment 1
Type of packing 0.038m ceramic Intalox saddles
Material of construction Low alloy steel 950X
Diameter of column 0.602m
Area of column 1.138m2
NTU 5
Hog 1.45m
Height of column 9.11m
Weight of shell 12671kg
Pressure drop 294Pa/m of packing

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