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Computer Aided Design of Distillation Column

Article  in  Journal of Applied Sciences Research · August 2015

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JOURNAL OF APPLIED SCIENCES RESEARCH

ISSN: 1819-544X EISSN: 1816-157X

JOURNAL home page: http://www.aensiweb.com/JASR 2015 Special; 11(17): pages 8-12.

Published Online 30 August 2015. Research Article

Computer Aided Design of Distillation Column

Banka Samidha R.
Dept. of Chemical Engineering, L. D. College of Engineering, Gujarat technological University, Ahmedabad, Gujarat, India.

Received: 23 June 2015; Accepted: 25 July 2015

© 2015 AENSI PUBLISHER All rights reserved

ABSTRACT

The paper is for software that deals with computation of detailed design of a distillation column. The platform used for developing the
software is MATLAB(Matrix Laboratory); a software package which is one of the most widely used tools in the engineering field today.
The methodology includes initial step of defining the basic correlations between input and output variables followed by the step of forming
the algorithm. Subsequently there is crucial step of developing a flowchart, writing the code and then testing it to remove any errors. The
program will be improved further continuously by adding on more modules to prepare robust and user friendly design software. The
invention is a self-made program in MATLAB for designing of distillation column. The program is a modular one i.e. it is broken into
several functions and in a step wise step determination of tower particulars. It contains about 30 different functions and a main program
named as "re4" that enables easy execution of all other functions. The functions also include a list of popular chemicals used in distillation
column along with its databank; there is also a provision for addition of data if chemical not present in data bank. The program is been tried
to made user friendly by providing provisions for user to enter various varying details such as plate spacing, type of tray, Material of
Construction, type of utility to be used, etc. The program is been designed for four component feed mixture, a binary mixture distillate and a
quaternary mixture residue. The program foremost starts calculation with molar liquid and vapor flow rates of enriching section. The
program computes tray material balances at the temperature given by user, thus providing the information that whether the given tray
temperature corresponds to feed tray or not. Similarly, it computes molar liquid and vapor flow rates of stripping section and thus bottom up
tray calculations are done. It also gives information about number of trays in enriching as well as stripping section and hence the total
number of trays. Next it calculates minimum number of trays using popular FUG(Fensky-Underwood- Gilliland’s) Method with Eduljee's
equation for Gilliland's correlation. It also calculates volumetric flow rate of vapor and its flooding velocity with the help of flooding
constant that user has to enter from the chart shown; given percentage of downcomer area, it will calculate the tray area and thus the tower
diameter. It also calculates the tray efficiency using O'Connell's Method and actual number of trays based on it. If user wants that it gives an
option for cost calculation too. Moving to cost calculation it calculates cost of construction of column based on material of construction
along with tower dimensions. It correspondingly calculates annual variable cost or precisely operating cost, thus giving the value of total
cost. Finally, it displays two output files one giving relationship between reflux ratio and theoretical stages and other giving details for cost
along with actual number of trays.
Keywords MATLAB, Multi-Component Distillation Column, Number of theoretical Stages, Lewis Matheson Method, Cost Optimization

INTRODUCTION The feed is fed in the tower and the product and the
by-product or waste is achieved may be from the top
Distillation is defined as a process in which a or bottom depending upon the system.
liquid or vapor mixture of two or more substances is The detail design of distillation column consists
separated into its component fractions of desired of mathematical operations based on input data,
purity, based on difference in volatility of operating conditions, reflux ratios, feed and product
components in a boiling liquid mixture. flow rates, etc. and computing output variables such
A distillation column is a long tower containing as column dimensions, number of trays, feed tray
of either number of trays or packings that is used for location, etc.[15]
either separation of various components from a MATLAB, a software package for high
mixture or for purification of a specific substance. performance numerical computation and

Corresponding Author: Banka Samidha R., Dept. of Chemical Engineering, L. D. College of Engineering, Gujarat
technological University, Ahmedabad, Gujarat, India.
Ph: +91 8401417439 E-mail: samidhab1@yahoo.co.in
9 Banka Samidha R., 2015 /Journal Of Applied Sciences Research 11(17), Special, Pages: 8-12
visualization, is one of the most widely used tools in
the engineering field today. Its broad appeal lies in
its interactive environment, which features hundreds
of built-in functions for technical computation,
graphics and animation. In addition, MATLAB
provides easy extensibility with its own high level
programming language.
This project focuses on combining the attributes
of MATLAB and the detail design procedure of
distillation column by following a step by step
approach of developing the program. Initial step is of
defining the basic correlations between input and
output variables followed by the step of forming the
algorithm. Subsequently there is crucial step of
writing the code and then testing it to remove any
errors. The program can be improved further
continuously by adding on more and more new
features into it. [13]
1.2 Why Lewis Matheson Method?
The various reasons of using Lewis Matheson
method are as follows:
1. It is applicable for both binary as well as
multicomponent distillation, unlike McCabe Thiele
or Ponchon Savriot methods which are applicable for
only two component separation.
2. It gives the number of theoretical stages without
specifying equilibrium stages, which is not possible
with Thiele Geddes Method.
3. It does not require data from graphs that are
cumbersome to draw as in Enthalpy Concentration or
Ponchon Savriot method.
4. Also plotting such rigorous graphs in MATLAB
are difficult and the software is inefficient to read the
required values itself.
5. Also some methods have steps that together
form a loop during calculations, in such case the
required result may not be given or there is a chance
of failure of program, this is not a problem with
Lewis Matheson Method.
6. Also use of computers facilitates an easier and
convenient use of this method.
1.3 MATLAB:
1.3.1. Introduction to MATLAB [13]:
MATLAB® is a high-level language and
interactive environment for numerical computation,
visualization, and programming. Using MATLAB,
you can analyse data, develop algorithms, and create
models and applications. The language, tools, and
built-in math functions enable you to explore
multiple approaches and reach a solution faster than
with spread sheets or traditional programming
languages, such as C/C++ or Java™. You can use
MATLAB for a range of applications, including
signal processing and communications, image and
video processing, control systems, test and
measurement, computational finance, and
computational biology. More than a million
engineers and scientists in industry and academia use
MATLAB, the language of technical computing.
1.3.2. Key Features:
 High-level language for numerical computation,
visualization, and application development
 Interactive environment for iterative exploration,
design, and problem solving
 Mathematical functions for linear algebra,
statistics, Fourier analysis, filtering, optimization,
numerical integration, and solving ordinary
differential equations
 Built-in graphics for visualizing data and tools
for creating custom plots
 Development tools for improving code quality
and maintainability and maximizing performance
 Tools for building applications with custom
graphical interfaces
 Functions for integrating MATLAB based
algorithms with external applications and languages
such as C, Java, .NET, and Microsoft® Excel®
1.4 Cost Estimation:
As soon as final process design stage is
completed, it becomes to make accurate cost
estimations because detailed equipment
specifications and definite plant facility information
are available.
Evaluation of costs in the preliminary design
phases is referred to as pre-design cost estimation.
Such estimates should be capable of providing a
basis for company management to decide whether
further capital should be invested in the project.
Fixed costs, direct production costs for raw
materials, labour, maintenance, power, and utilities
must all be included along with costs for plant and
administrative overhead, distribution of the final
products, and other miscellaneous items.
A traditional economic definition of capital is “a
stock of accumulated wealth.” The capital needed to
supply the required manufacturing and plant facilities
is called the fixed-capital investment (FCI)., while
that necessary for the operation of the plant is termed
the working capital (WC). The sum of the fixed-
capital investment and working capital is known as
the total capital investment (TCI). The fixed-capital
portion may be further subdivided into
manufacturing fixed-capital investment, also known
as direct cost, and nonmanufacturing fixed-capital
investment, also known as indirect cost. [10]
Fixed Cost Calculation in terms of design of
Distillation Column:
CT = f1*Cb + N*f2*f3*Ct + Cp1
N = number of trays
Cb = exp[7.123 + 0.1478(ln W) + 0.02488(ln W) 2 +
0.01580(L/D) ln(Tb/Tp)],
(9020<W<2,470,000 lbs of column exclusive of
nozzles and skirts)
Ct = 375.5 exp(0.1739D), 2<D<16 ft tray diameter
10 Banka Samidha R., 2015 /Journal Of Applied Sciences Research 11(17), Special, Pages: 8-12
Cp1 = 204.9D0.6332L0.8016, 2<D<24, 57<L<170 ft
(platforms and ladders)
f4 = 2.25/(1.0414)N, when the number of trays N is
less than 20
2.1. Problem for Program Test – I:
The program has been tested for "Example 8.11"
of "Process Engineering and Design by Prof. S. B.
Thakore and B.I.Bhatt." [15]
2.2. Problem for Program Test – II:
The verification of diameter function with
"Example 8.13" of "Introduction to Process
Engineering and Design" by "Prof. S. B. Thakore and
B. I. Bhatt" [15]
3. Discussion:
The program has been successfully tested for
above mentioned Problems.
3.1. Assumptions:
Following assumptions are made for the coding
and usage of method:
1. All the physical properties, for example density,
viscosity, etc., of the components involved remain
unaltered during the process.
2. Molar flow rate of liquid and vapour is constant
throughout the column.
3. Molar latent heat of vaporization of liquid phase
is equal to molar latent heat of condensation of vapor
phase. Hence moles of liquid vaporized over each
theoretical stage are equal to moles of vapor
condensed on that stage.
4. Molar flow rate of liquid and vapors in enriching
section (L and V) and also in stripping section (Ĺ and
Ṽ) remains constant.
5. Temperature of each tray is known.
6. Partial vapor pressures and bubble point and
dew point calculations are made.
3.2. Advantages of such Program:
1. It saves time and energy that is otherwise wasted
in pen and paper method.
2. Gives accurate answers, corrected up to four
decimal places.
3. Programs can be coded as per case specific or
user specific.
4. Complex equations and iterations can be solved
easily.
5. It is Stage by stage calculations is easy.
6. It can be well utilized for academics and
teaching purposes and a base for research studies.
3.3. Limitations of current Program:
1. It is very case specific.
2. Lewis Matheson method is not suitable for
problems involving multiple feeds, and side-streams,
or where more than one column is needed.
3. It is insufficient for real tower designing.
4. Certain bugs and error may occur due to system
incompatibility.
5. Cannot enable junk inputs and inappropriate
inputs.
6. Still lacks in extreme robustness and user-
friendliness.
7. The program does not account for any
contingency or undesired activity occurring during
process or in column.
4. Conclusion:
This program works well for design of
distillation column. It reduces time and efforts and
can be utilized by students, teachers, industrial
equipment developers and researchers.
This program can be used as base for extensive
coding and further detailing of distillation column.
5. Future Scope:
5.1 In Programming:
The following things can be thought for
improvement in coding:
1. A more generalized program can be made.
2. Can be made yet more robust and user friendly.
3. Input control and specification can be made.
4. Program can be extended for other details
required for complete designing of distillation
column.
5. Separate modules can be formed regarding
various different calculations. For example: For
Reflux Ratio, For Number of stages, etc.
6. Databank related to widely used chemicals in
distillation is created but can be extended.
7. Graphical User Interface (GUI) can be used.
8. Other methods can also be tried for the same.
9. Complete software for distillation column
design, operation calculation and learning can be
made.
5.2 Column Designing:
1. We can go for detail designing of distillation
column i.e.
a. If the feed mixture contains more than two
components, then select two key components from
all the components of feed mixture.
b. Decide the operating pressure of distillation
column and determining the vapour liquid
equilibrium data.
c. Specifying the degree of separation required.
d. In case of multi-component distillation, deciding
the distribution of key components and distribution
of non-key components in distillate and residue.
2. Real design considerations:
a. Safety Considerations can also be taken into
account.
b. Programs can be developed which can manage
operations.
c. Design of head, support and other mechanical
parts can be incorporated.
 11 Banka Samidha R., 2015 /Journal Of Applied Sciences Research 11(17), Special, Pages: 8-12

3. One can try other methods also such as: 5. Esmaeil Atashpaz Gargari, Farzad
a. Methods for binary distillation like: Hashemzadeh, Ramin Rajabioun, Caro Lucas,
i. McCabe – Thiele Method 2008. Colonial competitive algorithm: A novel
ii. Ponchon – Savriot Method approach for PID controller design in MIMO
b. Shortcut Methods distillation column process International Journal
i. Fensky-Underwood-Eduljee’s method of Intelligent Computing and Cybernetics, 1(3).
ii. Smith Brinkley method 6. Gilliland’s correlation chart (modified by Liddle
c. Rigorous Methods in 1968) from “Separation Process Engineering”
i. Thiele – Geddes Method by Wankat, 2007.
ii. Matrix methods 7. Houcque, D., 2005. Introduction to MATLAB for
4. Figurative: Engineering Students, North-western University,
a. One can add more graphs. (version 1.2, August 2005), Chap.1,4,6
b. One can go for diagrammatical view of designed http://www.mccormick.northwestern.edu/docs/ef
column. irst/matlab.pdf
c. One can use pictorial view for representing 8. Ignacio E. Grossmann, Mark M. Daichendt,
various sections of distillation column. 1996. New trends in optimization-based
approaches to process synthesis, Computers &
Acknowledgement Chemical Engineering, 20(6-7): 665-683, Fifth
International Symposium on Process Systems
I am very thankful Prof. S. M. Dutta (HoD – Engineering.
Chemical Engineering Dept., Governement 9. Marius Olteanu, Nicolae Paraschiv, Otilia
Engineering College, Bhuj, Gujarat ) for guiding us Cangea, 2010. Modeling Gilliland Correlation
throughout the work. He helped me in crossing all using Genetic Programming, Int. J. of
the hurdles in the way of project by getting the Computers, Communications & Control, V(5):
answer to the problems. He also taught me how to 837-843.
approach a problem. The interest taken by him for 10. Max S. Peters, Klaus D. Timmerhaus, Ronald E.
the successful completion of this project was worth West, 2011. Plant Design and Economics for
high appreciation as it served as a motivation for me Chemical Engineers, 5th ed., McGraw-Hill, New
to work on this project with heavy efforts. York.
I would also like to thank all the respective 11. McCabe, W.L., J.C. Smith, P. Harriot, 2005.
faculty members for their kind support in completion Unit Operations of Chemical Engineering,7th
of this project. ed. McGraw-Hill, New York.
I am deeply indebted to various authors whose 12. Perry, R.H., J.O. Maloney, 2008. Perry's
material was used in preparation of this project and Chemical Engineers' Handbook, 8th ed.,
hence acknowledge them in the references list. McGraw-Hill, New York.
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their constant support and motivation throughout the Oxford University Press, Switzerland, Chap. 1,
process of making this project. 2, 4.
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Appendix – Output Window (Sample)*

*Not all output windows are shown.

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