Int ernat ional Journal of Multidisciplinary Research and Development

Volume: 2, Issue: 9, 733-741

Sep 2015 Design of a distillation column for palm oil Cracking
www.allsubjectjournal.com
e-ISSN: 2349-4182
p-ISSN: 2349-5979 Nwokedi IC, Ude CN, Igbokwe PK, Ugochukwu GC
Impact Factor: 4.342
Abstract
Nwokedi IC The design of a Distillation column is necessary for cracking of palm oil to produce oleochemicals. The
Department of Chemical proposed distillation column is to crack 500Kg per day of palm oil aimed at producing Fatty acid ethyl ester
Engineering, Nnamdi (oleochemicals). This figure was chosen as the basis of the design. Also the energy and material balance of
Azikiwe University, P.M.B. the distillation column was calculated. Finally the equipment design for the distillation column was carried
5025 Awka, Anambra state, out. The number of plates required is 17 plates with column diameter and height of 0.1m and 11.55m
Nigeria. respectively. The study shows the importance of a distillation column in cracking of palm oil which buttresses
the point that complete conversion of triglyceride to oleochemicals can be achieved with the aid of a
Ude CN fractionating column.
Engineering Research
Development and Production Keywords: Distillation column, material balance, energy balance, palm oil cracking, oleochemicals,
Department, Projects equipment design.
Development Institute,
PRODA, Emene, Enugu 1. Introduction
State, Nigeria. Oleochemicals are chemicals derived from oils and fats. They are analogous to petrochemicals
which are chemicals derived from petroleum [1, 2, 3, 4]. Oleochemicals or derivatives based on C12-
Igbokwe PK C14 and C16-C18 chain lengths have a variety of uses. The hydrolysis or alcoholysis of oils and fats
Department of Chemical formed the basis of the Oleochemicals industry [5, 6]. The five basic Oleochemicals are Fatty acids,
Engineering, Nnamdi Fatty Methyl esters and Ethyl esters, fatty alcohol, fatty nitrogen compounds and glycerol. The
Azikiwe University, P.M.B.
process of derivation or obtaining these chemical intermediates from palm oil requires high
5025 Awka, Anambra state,
temperature pyrolysis, alcoholysis, gasification or destructive distillation in the presence of a
Nigeria.
catalyst [7, 8, 9].
Ugochukwu GC
Engineering Research Nomenclatures
Development and Production VO Volumetric flow rate, m3/hr
Department, Projects X Conversion
Development Institute, MAO Initial mass flow rate, kg/hr
PRODA, Emene, Enugu Ρ Density, kg/m3
State, Nigeria. K Rate constant, g mol/min
T Temperature, K
P Power, kW
V Reactor volume, m3
H Height, m
L Baffle spacing, m
dO Baffle orifice diameter, m

2. Background to the study

The reactor is the starting point of the cracking process were the raw material which is the palm
oil is introduced at an ambient temperature and is heated to a certain temperature made possible
by the aid of a heat exchanger device embedded in the reactor thereafter the content of the reactor
is transferred to the distillation column where the different components in terms of the
oleochemicals are separated by the rectification and stripping sections of the column based on
their different boiling points. Material Balance is carried out which summarizes the sum of masses
Correspondence in the reactor and distillation column in conformity with the law of conservation of matter. The
Nwokedi IC Energy balance shows the heat effects of chemical reaction and physical transformation which
Department of Chemical
occurs in the equipment. The equipment design shows the various design specifications and
Engineering, Nnamdi
Azikiwe University, P.M.B.
conditions for the design of the distillation column in conformity with the standard design
5025 Awka, Anambra state, procedures and for the distillation column to function effectively. The basic procedure that will
Nigeria. lead to the yield of oleochemicals consists of pre-heating the palm oil (triglyceride) with the aid
of a heat exchanger, and then passed to the pump, and from the pump
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It is charged into the reactor which operates at a chosen Kinematic Viscosity is 39.6mm2/s at 38 oC,
temperature of 374 OC and atmospheric pressure, their after is Density is 0.9180g/cm3
transferred to the distillation column for separation of the Therefore Viscosity = Kinematic Visco. * Density = 39.6 *
different oleochemicals. 0.9180 = 36.3528
At room temp. Viscosity is 8.46Pa.s
3. Design Method for Distillation Column Ethyl propanoate- 0.426cP at 25oC
The geometric configuration is a proposed approach to design Stearic Acid- 176.50cP (160 oC), 9.04cP (75 oC), 7.79mPa.s (80
o
a Distillation (fractionating) column by maintaining dynamic C), 6.29m Pa.s (90 oC)
stability using various constants, McCabe-Thiele method of Linoleic Acid- 29.0cP (25 oC), 17.7cP (38 oC), 13.1cP (50 oC),
continuous distillation was used to achieve this purpose. 9.41cP (60 oC), 3.41cP (110 oC)

3.1 Equation of the reaction and mechanism Rate Constant Values

Equation for the reaction: K values of the cracking of palm oil in autoclave Batch reactor
Triglycerides Heat Fatty Acids + Fatty acid Temperature Rate constant
Methyl Ester + Glycerol [10] 623 0.0053gmol/min
Triglycerides Heat Ethyl propanate + Stearic acid 648 0.0021gmol/min
+ Linoleic acid + Ketene (octadecatrien-1-ol) 673 0.0060gmol/min

Mechanism 4. Results and Discussion

CH2 OCORI CH3 4.1 Material balance:
I I Plant capacity = 500kg/day
CHOCOCH2RII CH2 + RICOOH + RII COOH + Capacity = 500 = 62.5kg/hr
III
R CH = CHO 8
I I Considering 20% Safety factor
CH2 OCORIII COOC2H5 Plant through put = 20 x 62.5 = 75kg/hr
Triglyceride Ethyl Propanoate Stearic acid Linoleic acid 100
Ketene (octadecatrien-1-ol) Note: This safety factor takes care of material loss due to over
pressure and other losses
Figure 1: Reaction equation for cracking of vegetable oil [11].
RI = (CH2)16 CH3, From assumption, 95% of FAEE expected to be produced at
RII = (CH2)6 CH = CH (CH2)7 CH3 reactor is recovered as distillate
RIII = (CH2)7 CH = CH - CH2-CH = (CH2)4 CH3 FAEE is S2 = 75 x 100 = 78.95kg/hr
95 1
Assumptions Kmol of FAEE produced from reactor = mass = 78.95
1. 95% of FAEE produced at reactor is recovered as distillate. molar mass 102.13=0.733
2. For practical purpose, steady state condition is assumed Kmol of FAEE produced=0.773kmol/hr
3. Batch operation Conversion = kmoles of palm oil consumed x100
4. A day is assumed to be 8 hours kmoles of palm oil fed 1
5. 85% conversion
Basis: 1 day operation Similarly,
Plant capacity = 500kg/day Reactor Yield = kmoles of FAEE produced x 100
kmoles of palm oil fed 1
3.2 Calculation parameters used
Physical/Chemical Properties of Equation of Reaction: SC = stoichiometric factor = ratio of stoichiometric moles of
Density product to reactant = 1
Triglyceride- 0.928g/cm3
Ethyl propanoate- 0.8844g/cm3 Stoichiometric Equation of the Reaction:
Stearic Acid- 0.847g/cm3 at 70oC, 1.017g/cm3 at 17 oC Triglycerides => Ethyl propanoate (FAEE) + Stearic acid +
Ketene (octadecatrien-1-ol):1.08g/cm3 Linoleic acid + ketenes 0.95 = 0.773 x 1
Linoleic Acid- 0.90g/cm3 Kmole of palm oil converted 1

Vapour Pressure Kmoles of palm oil converted = 0.773 = 0.814kmol/hr

Triglyceride- Between 25-760mmHg 0.95
Ethyl propanoate- 35.90mmHg, 5.32kpa/27 oC, 44mmHg at Triglyceride fed = 0.814 = 0.958 kmoles
27.2 oC 0.85
Stearic Acid- 10mmHg at 21 oC, 1mmHg at 344.7oF, 5mmHg
at 408.2oF Kmoles of Stearic acid produced = 0.773, Kmoles of Linoleic
Ketene (Octadecatrien-1-ol): Greater than 1atm, 1.4*103kPa at acid produced = 0.773
25oC Kmoles of ketene produced = 0.773,
Linoleic Acid- 3.5mmHg at 25 oC, 1.0mmHg at 180 oC, Kmoles of triglyceride unconverted = 0.958-0.814 = 0.114
1.0mmHg at 176.5oF Mass of triglyceride fed to the reactor
Kmoles fed = 0.958, Molar mass = 846.26
Viscosity Mass of Triglyceride fed = 0.958 x 846.26 = 810.72kg/hr
Triglyceride- 15.9cSt at 40 oC Mass of triglyceride unconverted = (0.958-0.814) x 846.26 =
Also Palm Oil (Triglyceride) 121.86kg/hr

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Calculation of Mass of Ketene (Octadecatrien-1-ol) compd mass composition (%) (Kg/hr)

Produced
From the stoichiometric equation, 1 kmole of ketene is Inlet Stream
produced along with 1 kmole of FAEE, 1 kmole of Stearic acid Triglyceride (Mass: 810.72kg/hr, Composition: 100%)
and 1 kmole of Linoleic acid.
Hence, total kmoles of ketene produced = 0.773 Outlet Streams
Molar mass of ketene = 223.42kg/kmol, Mass of ketene = 0.773 Compound Mass (kg/hr) Composition (%)
x 223.42= 172.72kg/hr Ethyl Propanoate (FAEE) 78.95 9.74
Stearic acid 219.9 27.14
Calculation of Mass of Stearic Acid Produced Linoleic acid 216.79 26.76
From stoichiometric equation, 1 kmole of stearic acid was Ketenes 172.7 21.32
produced. Triglyceride Unconverted 121.86 15.04
Hence total kmol of stearic acid produced = 0.773 Total 810.2
Molar mass of stearic acid = 284.48kg/kmol, Mass of Stearic
acid = 0.773 x 284.48 = 219.9kg/hr Table 1: Summary of material balance on reactor
Reactor Quantity
Calculation of Mass of Linoleic Acid Produced
Mol. wt
From the stoichiometric equation, 1 kmole of Linoleic acid Stream Component
Kg/kmol
Kmole/hr Kg/ hr
produced. S1 (Input) Triglyceride 846.26 0.958 810.72
Hence total kmoles of linoleic acid produced = 0.773 ΣS1 810.72
Molar mass = 280.45kg/kmol., Mass of Linoleic acid = 280.45 S2 FAEE (Ethyl
x 0.773 = 216.79kg/hr 102.13 0.773 78.95
(Output) propanoate)
Stearic acid 284.48 0.773 219.9
Material Balance Summary Linoleic acid 280.45 0.733 216.79
Ketenes 223.42 0.773 172.7
Triglyceride
846.26 0.144 121.86
Unconverted
ΣS2 810.2
Input, ΣS1 = 810.72 kg/hr, Output, ΣS2 = 810. 2 kg/hr
compd Mass S2 composition (%) (Kg/hr)

For Fractionating Column

Table 2: Summary of material balance on distillation column 4.2 Energy Balance

Mol. Wt Quantity
Stream Component Kg/kmol Kmole Kg/hr
S4 FAEE 102.13 0.734 75
Linoleic acid 280.45 0.00546 1.53
76.53
S5 FAEE 102.13 0.0387 3.95
Stearic acid 284.48 0.773 219.9
Linoleic acid 280.45 0.768 215.26
Ketene 223.42 0.773 172.7
Triglycerides 846.26 0.144 121.86
733.67 Assumptions
Output = ΣS4 + ΣS5 = 810.2 kg/hr 1. Steady State Operation
2. Datum Temperature

Hence, the input to the reactor

Triglyceride = 810.72kg

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H1 = MCpT1, = 810.72 x 2425.78 x 303 = 595888.39KJ/hr = Q = H2 – H1 = 931.997 - 595.888 = 336.109 MJ/hr

595.888 MJ/hr Heat added to the reaction for cracking of the palm oil =
Effluents, from the reactor 336.109MJ/hr = 336109KJ/hr
Ethyl propanoate = 78.95kg/hr, Stearic acid = 219.9kg/hr, Power = 336109 x 103 = 93363.6W
Linoleic acid = 216.79 kg/hr 60 x 60 = 93.3636 KW
Ketene = 172.7kg/hr, Triglyceride uncovered = 121.86 kg/hr
Q = Hout - Hin Energy Balance Summary
Heat output, Hout = ΣmcpT = (mcpT) + (mcpT) + (mcpT) +
(mcpT) + (mcpT) + Ethyl stearic Linoleic Ketene
Unconverted propanoate acid acid Triglyceride

a. Head output for Ethyl propanoate = mcpT = 78.95 x 1.920

x 647 = 98074.848 = 98.074KJ/hr
b. Heat output for Stearic acid = mcpT = 219.9 x 2359.42 x
647 = 335687.183KJ/hr
c. Heat output for Linoleic acid = mcpT = 216.79 x 2884.27
x 647 = 404556.738KJ/hr Table 3: Summary of energy balance on reactor
d. Heat output for Ketene = mcpT, Hout = 172.7 x 3.568 x 647 Input Output
= 398.677KJ/hr H1: 595888 H2: 931997
e. Heat output for unconverted Triglyceride = mcpT = 121.86 Q: 336109 -
x 2425.78 x 647 = 191256.791KJ/hr 931997 931997
Total Heat output = 931.997MJ/hr

Energy around Distillation (Fractionating) Column

For effective separation, care is taken in fixing the temperature Boiling point of bottom product mixture, BPmb
at the bottom and top of the column. BPmb = 0.301(383) + (0.295 x 230) + (0.237 x 374.23) + (0.167
Determination of top and Bottom product temperatures x 818.7) = 408.55 oC

Table 4: Boiling points of some fatty acids and ester Boiling point of top product mixture, BPmt
BPmt = (0.98 x 98.9) + (0.02 x 230) = 101.52 oC
Compound Boiling Point
Ethyl propionate (propanoate) 98.9oC
Specific heat capacity of component using several group
Linoleic acid 230oC contributions methods by Riham and Doraiswamy (1965) [12]
Stearic acid 383oC for organic compounds Coulson and Richardson vol.6
Ketene (octadecatrien-1-ol) 374.227oC Cp = a + bT + CT2 + dT3
Triglyceride 818.7oC Enthalpy of the feed, H3 = H2 = 931997. 463kJ/hr
Enthalpy of the distillate H4 = ∑MCpdT = ∆∑XdCp∆T
Boiling point of mixture, BPm = ΣXmBPc Temperature of 105 oC
Where BPm = boiling point of mixture, Xm = mass fraction of F = D + B, F = 810.2kg/hr, D =76.53kg/hr, B=729.72kg/h
each component
BPc = boiling point of each component

Table 5: Summary of specific heat capacity calculation for top products

Compound mi (kg/hr) Xd = mi/mT Cp (ks/kgk) ∆T(k) xdCp∆T KJ/kg.hr
Ethylpropanoate 75 0.98 1.487 75 8197.088
Linoleic acid 1.53 0.02 1.779 75 4.083
8201.171

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Top column Temperature Enthalpy of liquid reflux, if reflux ratio of 2 is assumed

The temperature at the top of the column is to be above the top R = Ln/D, Ln =RD, Ln = 2D = 2 x 76.53 = 153.06kg/hr
products boiling point Bpm = 101.52 oC but below the entry Vn = Ln + D = 153.06 + 76.53: Vn = 229.59kg/hr
point of the feed, which is 374 oC, so far effective separation, Hence, HLN = Ln ∑ XdCp ∆T = 153.06 x 1.492 x (410 -105) =
105 oC top column/ product 69651.4896kJ/hr
Temperature is chosen Hvn = ∑mcp ∆T + Vn λav
H4 = 76.53 x 8201.171 = 627635.62kJ = 627.635MJ/hr Where λav = average latent heat of vaporization = ∑xf λ¡

Table 6: Summary of latent heat of vaporization calculation of bottom product

Compound Xf λi (KJ/kg) Xf λI (kJ/kg)
Ethyl propanoate 0.0974 96.837 9.4319
Linoleic acid 0.2676 82.011 21.946
Stearic acid 0.2714 134.63 36.54
Ketene 0.2132 164.5 35.07
Triglyceride 0.1504 96.74 14.55
117.5309

From Coulson and Richardson volume 6 Hvn = 8568.5 + 117.5309 = 8568.031KJ/hr

λv = constant Hvn = QC + H4 + HLN, where QC = Hvn - H4 - HLn
Tb = 8686.031 - 627635.62 - 69651.4896 = -688719.07KJ/hr, QC
λv = Latent heat of vaporization, kJ/kmol, Tb = normal boiling = -688.719 MJ/hr
point, K Enthalpy of bottom, H5 = B∑ Xb Cp ∆T
For organic liquids the constant can be taken as 100 T = 410 oC (683k)

Table 7: Summary of specific heat capacity calculation for bottom products

Compound mi (kg/hr) xb Cp (kT/Kg) ∆T (k) ∑XbCp∆T (Ks/kg)
Stearic acid 219.9 0.301 2.935 380 73821.6
Linoleic acid 215.26 0.295 2.747 380 66286.88
Ketene 172.7 0.2367 3.53 380 54833.87
Triglyceride 121.86 0.167 2.45 380 18946.27
213888.62
H5 = 729.72 x 213888.62 = 156078808.8kJ/hr
Taking overall Energy Balance
H3 + QB = H4 + H5 + QC, QB = H4+ H5 + QC -H3
= 627635.62 + 156078808.8 – 688719.07- 931997.463
QB =15646316KJ/h, QB =156463.156MJ/hr

Fractionating Column

Table 8: Summary of energy balance across distillation column

Input stream (KJ/hr) Output stream (KJ/hr)
H3=H2 931997 -
H4 - 627635
H5 - 156078808.8
QC - 688719
QB 156463156 -
157395162 157395162.8

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4.3 Equipment design calculations for the reactor

A) Detailed Design of Fractionating Column
From Material Balance

Table 9: Summary of overall material balance

Feed Top Bottom
Component Mass (kg) Composition (%) Mass (kg) Composition (%) Mass (kg) Composition (%)
FAEE 78.95 9.74 75.0 98.0 3.95 0.538
Ketenes 172.7 21.32 - - 172.7 23.67
Stearic acid 219.9 27.14 - - 219.9 30.1
Linoleic acid 216.79 26.76 1.53 2 215.26 29.5
Triglyceride 121.86 15.04 - - 121.86 16.7
810.2 100 76.53 100 733.67 100

NB: Top is assumed to be the last plate in the column while bottom is the first plate.

Overall material Balance Feed point

F=D+B To get the feed point, we use kirkbride’s empirical equation [1]
F = Mass of feed mixture, D = mass of top product, B Log (Nr/Ns) = 0.206 log [(B/D) * (Xf,B/Xf,A) * (Xb,A/Xd,B) 2]
= mass of bottom product This equation is used considering the bottom product to be at
FAEE is assumed to be the light key while linoleic acid is high the bottom and top product at the last plate
key B = mass of bottom product = 733.67 kg/hr
Taking the composition material balance over FAEE, Fxf, A = D = mass of top product = 76.53 kg/hr
Dxd, A + Bxb, A Xf,B = mass fraction of linoleic acid in the feed mixture = 0.2676
Where XF, A = mass fraction of FAEE at the feed Xf, A = mass fraction of FAEE in the feed mixture = 0.0974
Xd, A = mass fraction of FAEE at the top, Xb, A = mass Xb, A = mass fraction of FAEE in the bottom product = 0.00538
fraction of FAEE at the bottom Xd, B = mass fraction of linoleic acid in the top product = 0.02
Log (Nr/Ns) = Nr = 1.14Ns
Number of stages The number of stages excluding the reboiler (bottom)
Calculating the minimum number of stages using Fenske Nr + Ns = 16, 1.14Ns + Ns = 16
Equation Ns = 8 plates

Nm = log (XA/XB) D - (XB/XA) B Feed point is at the 8 plates from the bottom
Log XAB Column Diameter
The principal factor that determines the column diameter is
XAB = relative average volalility of FAEE – linoleic acid the vapour flow- rate. The vapour velocity must be below that
XB = mass fraction of linoleic acid, XA = mass fraction of FAEE which would cause excessive liquid entrainment or a high
XA,b = 0.00538, XB,b = 0.295
Relative volatility, X = Vapour pressure of FAEE pressure drop. The equation given below, this is^based on the
Vapour pressure of linoleic acid well-known Sounders and Brown equations. Lowenstein
(1961) [14], can be used to estimate the maximum allowable
Nm = 11 plates (stages) superficial vapour velocity and hence the column area and
Reflux Ratio diameter. 
From separation process principles by Seader and Ernest J. Uv = (- 0.171L2t + 0.27Lt – 0.047) (ρL– ρv/ ρv) ½
Henley (2006) [13], we assumed internal reflux Where Uv^ = Maximum allowable velocity vapour based on
the gross column cross-sectional area, m/s, Lt = plate spacing,
Rm = 1 (Xd,,A/Xf,A)- XAB( Xd,B/Xf,B) in (range 0.15- 0.6) m 
(XAB -1) Assuming 0.5m spacing
Xf,A = mass fraction of FAEE in the feed mixture = 0.0974 ρv = Density of FAEE = 0.884g/cm3 = 884.4kg/m3
Xf,B = mass fraction of linoleic acid in the feed mixture = ρL = Density of linoleic acid = 0.90g/cm3 = 900kg/m3
0.2676 Uv = (-0171 x 0.52 + 0.27 x 0.5 – 0.047) (900-884.4/900)½
Xd,A = mass fraction FAEE at the top = 0.98 Uv^ = 0.04525 x (0.132) 
Xd,B = mass fraction of linoleic acid at the top = 0.02
Uv^ = 0.00597m/s 
Rm = 8.76, Assuming R = 1.5 Rm = 1.5 x 8.76 = 13.14
Diameter of the column, DL = D^C = 0.095m = 0.1m
Actual Number of stages/ plates
From Gilliland correlation
(R -Rm) / (R +1) = (13.14-8.76) / (8.76 + 1) = 0.449 Area = d2 = 3.142 x 0.12 = 0.0078m2
Using the graph showing the empirical relation between reflux 4 4
ratio R and number of plates n, in which only the minimum Column Area, Ac = 0.00786m2
reflux ratio and the number of plates at total reflux nm are equal.
Fig. 11.42, Coulson and Richardson’s vol.2 Determination of Column Height
However, tracing 0.449 to number of plate’s axis, we have 0.3 Height of the column, Hc (Nreal-1) x Ip x Disengagement height
i.e. N-Nm/ N + 2 = 0.3 Where HC = Column height
N = 17 plates (Actual number of plates = 17 plates) Ip = plates or stage spacing
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From McCabe and Smith the top & bottom disengagement Where Un = minimum vapour velocity through the holes based
height for distillation column are 4ft at top and 6ft at bottom. on the hole area m/s dh = hole diameter, K2 = constant
If plates spacing is 0.5, 1foot = 0.3048 metres U^n = 27 - 0.90(25.4 - 5) = 0.291m/s 
Hc = (17-1) x 0.5 + 10 (0.3048) (884.4) 1/2 
Hc = 11.55m
Actual minimum vapour velocity = minimum vapour rate
Provisional Plate Design for Sieve Tray Ah
Column diameter, Dc = 0.1m
Maximum volumetric flow-rate base = Vm/ ρL = 0.0375/900 =
Column Area, Ac = 0.00786m2
4.17 x 10-5 m/s
Downcomer area = 12% of column area (Coulson &
Actual minimum vapour velocity = 0.7 x 4.17 x10-5= 0.049m/s
Richardson Vol.6)
0.000597
Ad = 0.12 + 0.00786 = 0.000943m2
So minimum operating rate will be well above weep point
Net area, An = Ac - Ad= 0.00786 - 0.000943 = 0.00692m2
Active area, Aa =Ac – 2Ad = 0.0078 - 2(0.000943) = 0.00597m2,
Plate Pressure Drop, Dpt
Aa = 0.00597m2
Dry Plate drop
From Coulson and Richardson’s Vol.6
Maximum vapour velocity through holes, Uh = 4.17x10-
Assume the Hole area, Ah as 10% of active area, Aa at first trial 5
/0.0005 = 0.0698m/s
Ah = 0.1 x 0.00597 = 0. 000597m2
From fig 11.34, Coulson and Richardson’s vol.6 for plate
thickness/ hole diameter = 1 and (Ah/Ap) = (Ah/Aa) = 0.1
Weir Length Orifice coefficient, CO = 0.84
(From figure 11.31 Coulson & Richardson)
lw = 0.76 x 0.1 = 0.076m
hd = 51 (uh/CO)2 (ρv/ ρL) = 51 x (0.0698/0.84)2 x (884.4/900)
= 0.346mm liquid
Weir Height
The height of the weir determines the volume of liquid on the
Residual head, hr = 12.5 x 103 = 12.5 x 103 = 13.89mm liquid
plates and is an important factor in determining the plate
ρL 900
efficiency.
A high weir will increase the plate efficiency but at the expense
Total plate pressure drop, ht = hd + (hw + how) + hr = 0.346 +
of a higher plate drop. For column operating above atmospheric
(5.6 + 7.10) + 13.89
pressure, the weir height will normally be between 40mm to
ht = 26.936mmliquid
90mm; 40mm to 50 is recommended [1].
∆Pt = ρght = 237.8Pa, ∆pt = 0.238 kPa
Weir height = 50mm, Hole diameter = 5mm, Plate thickness =
5mm
Downcomer Liquid Back-Up
The downcomer area and plate spacing must be such that the
Check Weeping level of the liquid and froth in the downcomer is well below the
D = 76.53kg/ (8 x 60 x 60) = 0.00266kg/s top of the outlet weir on the plate. If the level rises above the
Vn = D (1+R) = 0.00266 (1+13.14) = 0.0376kg/s outlet weir the column will flood. The back-up of liquid in the
Ln = DR = 0.00266 x 13.14 = 0.035kg/s downcomer caused by the pressure drop over the plate (the
F = 0.028kg/s downcomer in effect forms one leg off a U-tube and the
Lm = Ln + F = 0.035 + 0.028 = 0.063kg/s resistance to flow in the downcomer itself)
Vn = Lm – B = 0.063 – 0.0255 = 0.0375kg/s
Ln = Liquid flow rate above feed composition, Vn = Vapour Downcomer Pressure Loss
flow-rate above feed composition Take hap = hw – (5 to 10mm)
Lm = Liquid flow rate below feed composition, Vm = Vapour Where hap = height of the bottom edge of the apron above the
flow-rate below feed composition plate. This height is normally set at 5 to 10mm below the outlet
Maximum liquid rate = 0.063kg/s weir height
Minimum liquid rate at 70% turn down = 0.7 x 0.063 = hap = hw - 10 = 50 -10 = 40mm
0.0441kg/s Area under, Aap = hap Іw
Maximum height of the liquid crest over the weir can be Where Іw = weir length = 0.076m
estimated using the Francis weir formula, for a segmented Aap = 0.76 x 40 x10-3 = 0.00304m2
dowcomer. This can be written as: Since Aap = 0.00304m2 is less than Ad in equation below
how = 750 (Lm/ρLІw)2/3 hdc = 166 (Lmd/ ρLAm)2
Where Іw = weir length, m, how = weir crest, mm liquid Where hdc = head loss in the downcomer, mm
Lm = liquid flow rate (kg/s), ρ = liquid density = 900kg/m3 Lmd = liquid flow rate in downcomer (below the feed
composition), kg/s
Minimum, how = 750 0.0441 2/3 = 5.6mm Am = either the downcomer area, Ad or the clearance
900 X 0.076 area under the downcomer Aap whichever is the smallest,
m2(value calculated already from provisional plate design of
Maximum, hw = 750 0.063 2/3 = 7.10mm sieve tray)
900 X 4 x 0.076 Lmd = 0.063kg/s (value gotten from check weeping)
Am = 0.000943m2 (value gotten from provisional plate
At minimum rate hw + how = 7.10 +5.6 = 12.70mm liquid
design)
From fig 11.30 Coulson and Richardson vol. 6 weep correlation
hdc = 166[0.063/(900 x 0.000943)]2 = 0.915mm =
k2 = 27.0
approximately 1mm
Un^(min) = k2 – 0. 90 (25.4 - dh)
(ρv)1/2
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Back-up in downcomer Hole Pitch

hb = (hw + how) + ht + hdc = (50 + 7.10) + 26.94 + 1 The hole pitch (distance between the hole centre) Іp should not
hb = 8.504mm = 0.08504 be less than 2.0 hole diameter and the normal range will be 2.5
0.08504 < ½ (plate spacing + weir height) to 4.0 diameter within the range the pitch can be selected to
So plates spacing is acceptable give the number of active holes required for the total hole area
Check residence time specified.
Ratio of hole area to perforated area = (Ah/Ap) =
tr = Adc x hbc x ρL = 0.000943 x 0.08504 x 900 (0.00597/0.00597) = 0.1
Lmd 0.063 =1.15s From fig 11.33, Coulson and Richardson Vol. 6 Lp/ dh = 2.75
This is satisfactory, within 2.5 to 4.0
The residence time in Downcomer, tr = 1.15s
Lp = 2.75dh = 2.75 x 5 = 13.75mm
Perforated Area Hole pitch = 13.75mm
The area available for perforation will be reduced by the
obstruction caused by the structural members (the support rings Hole pitch arrangemented selected = Equilateral Triangular
and beams), and by the use of calming zones. Downcomer selected = segmental or chord
Calming zones are unperforated strips of plates at the inlet and This is due to its simplicity and cheapness. The apron is usually
outlet sides of the plate. The width of each zone is usually made vertical, but may be sloped to increase the plate area available
the same; recommended values are below 1.5m diameter, for perforation.
75mm above, 100mm.
The width of the support rings for sectional plates will normally Number of Holes on the Plate
be 50 to 75mm; the support ring should not extend into the Number of holes = hole area/area of one hole
downcomer area. A strip of unperforated plate will be 6ft round Area of hole = dh2 = 3.142 x (5x10-3)2 = 1.964x10m2
the edge of cartridge type trays to stiffen the plate. 4 4
The unperforated area can be calculated from the plate
geometry. The relationship between the weir chord length, Number of holes = 0.000597/1.964x10-5 = 30.4 holes =
chord height and the angle subtended by the chord is given in 31holes
fig 11.32, Coulson and Richardson Vol.6 from
Figure 11.32, at Iw/Dc = 0.076/0.1=0.76, θc = 99 0C Fractionating Column
Angle subtended by the edge of the plate = 180-99 = 81o The column consists of a cylindrical structure divided into
Mean length, unperforated edge strips = (0.1-50 x 103) x sections by series of perforated trays or plate (sieve plate),
(81/180) = 0.0707 which permit the upward flow of vapour. The liquid reflux
Area of unperforated edge strips = 50 x 10-3 x 0.0707 = flows across each tray, over a weir and a down comer to the
0.00354m2 tray. The vapour rising from the top tray passes to a condenser
Mean of Calming zone = weir length + width of unpreforated and then through an accumulator or reflux drum and a reflux
strip = 0.076 + 50x10-3 = 0.126m divided, where part is withdrawn as the overhead product and
Area of calming zone = 2 (0.126 x 50 x10-3) = 0.0126m2 the remainder is returned to the tray as reflux.
Total mean for perforation, Ap = 0.00397 – 0.00334 =
0.00063m2

Table 10: Summary of Fractionating Column Design

Minimum no. of plates: 11 plates
Actual no. of plates: 17 plates
Feed point: 8 plates
Column diameter: 0.1m
Area of column: 0.00786m2
Column Height: 11.55m
Weir Height: 50mm (0.5m)
Hole diameter: 0.05m
No. of holes per plate: 31 holes
Plate thickness: 0.05m
Hole pitch: 13.75mm
Hole pitch arrangement: Equilateral triangle
Column wall thickness: 4.0463mm
Type of plate: Sieve plate

Conclusion References
The design for a distillation column follows an appropriate 1. Sinnott, R.K. Coulson and Richardson’s Chemical
methodology based on the McCabe-Thiele method of column Engineering Series, “Chemical Engineering Design”,
design. Other criteria employed to take into account are the type volume 6, 4th edition, Butterworth – Heinemann, 2005,
of plate and number of plates. The number of plates required is 243-247, 634 – 692.
17 plates with column diameter and height of 0.1m and 11.55m 2. Coulson, J. and Richardson, J. “Chemical Engineering –
respectively. The study shows the importance of a distillation Design (SI units), Volume 6”, Pergamon Press, Oxford,
column in cracking of palm oil which buttresses the point that 1983, 273-280.
complete conversion of triglyceride to oleochemicals can be
achieved with the aid of a fractionating column.
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International Journal of Multidisciplinary Research and Development
 

3. Saunders, E.A.D. “Heat Exchangers: selection Design and

Construction, Scientific and Technical”, Longman press
Inc., N.T., 1988, 421-493.
4. Coulson, J. and Richard, J. “Chemical Engineering – Fluid
flow. Heat Transfer and Mass”, Pergamon Press, Oxford,
1999, 242-252.
5. Kister, H.Z. “Distribution Design (1st Edition ed.).”
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6. Morel, F.M.M., Hudson, R.J.M. and Price, M. “Limitation
and Movement of Heat in Machines and Exchangers”,
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7. Peters, M.S., Timmerhaus, K.D., and West, R.E. “Plant
Design and Economics for Chemical Engineers”,
MCGraw-Hill, New York, 2003, 331-352.
8. Giddings, J.C. “Chemical Engineering, Man and
Environmental Change”, Canfield Press, San Francisco,
C.A. 1973, 106-133.
9. Gupka, S.K. and Sharma, P. “Trends in Heat Exchangers
and Heat Exchangers and Maintenance”, today and
tomorrow’s printers and publication, New Delhi, India,
1978, 128-129.
10. Tan, Y.L., Mohamed, A.R. and Bhatia, S. “Catalytic
Conversion of Palm Oil to Fuels and Chemicals”.
Canadian Journal of Chemical Engineering, 1999, 77, 156-
162.
11. Chang, C.C. and Wan, S.W. “China’s Motor Fuels from
Tung Oil”. Ind. Eng. Chem., 1947, 39, 1543-1548.
12. Rihani, D. N. and Doraiswamy, L. K. Ind. Eng. Chem.
Fundamentals 4, 17.
13. Estimation of heat capacity of organic compounds from
group contributions, 1965.
14. Seader, J.D., Henley, E.J., Roper, K.D. Chemical and
Biochemical Operations. J. Wiley and Sons, 3rd Edition,
2006, New York.
15. Lowenstein, J. G. Ind. Eng. Chem. 53 (Oct.) 44A. Sizing
distillation columns, 1961

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