Reflux drum total condensation

Cohimn pressure at the reflux drum is established so as to condense totally the overhead vapor or some fraction thereof. Flash-zone pressure is approximately 69 kPa (10 psia) higher. Crude-oil feed temper-... 

Derivatives or rates of change of tray and condenser-reflux drum hquid holdup with respecl to time are sufficiently small compared with total flow rates that these derivatives can be approximated by incremental changes over the previous time step. Derivatives of liquid enthalpy with respect to time eveiywhere can oe approximated in the same way. The derivative of the liquid holdup in the reboiler can likewise be approximated in the same way except when reflux ratios are low. 

Example 10 Calculation of Multicomponent Batch Distillation A charge of 45.4 kg mol (100 Ih-mol) of 25 mole percent heuzeue, 50 mole percent monochlorohenzene (MCB), and 25 mole percent orthodichloro-henzene (DCB) is to he distilled in a hatch still consisting of a rehoiler, a column containing 10 theoretical stages, a total condenser, a reflux drum, and a distillate accumulator. Condenser-reflux drum and tray holdups are 0.0056 and... 

Consider the binary batch distillation column, represented in Fig. 3.58, and based on that of Luyben (1973, 1990). The still contains Mb moles with liquid mole fraction composition xg. The liquid holdup on each plate n of the column is M with liquid composition x and a corresponding vapour phase composition y,. The liquid flow from plate to plate varies along the column with consequent variations in M . Overhead vapours are condensed in a total condenser and the condensate collected in a reflux drum with a liquid holdup volume Mg and liquid composition xq. From here part of the condensate is returned to the top plate of the column as reflux at the rate Lq and composition xq. Product is removed from the reflux drum at a composition xd and rate D which is controlled by a simple proportional controller acting on the reflux drum level and is proportional to Md-... 

A single feed stream is fed as saturated liquid (at its bubblepoint) onto the feed tray N,. See Fig. 3.12. Feed flow rate is F (mol/min) and composition is z (mole fraction more volatile component). The overhead vapor is totally condensed in a condenser and flows into the reflux drum, whose holdup of hquid is Mj) (moles). The contents of the drum is assumed to be perfectly mixed with composition Xo The liquid in the drum is at its bubblepoint Reflux is pumped back to the top tray (iVj-) of the column at a rate R. Overhead distillate product is removed at a rate D. 

Develop a mathematical model for the three-column train of distillation columns sketched below. The feed to the first column is 400 kg mol/h and contains four components (1, 2, 3, and 4), each at 25 mol %. Most of the lightest component is removed in the distillate of the first column, most of the next lightest in the second column distillate and the final column separates the final two heavy components. Assume constant relative volatilities throughout the system ai, CI2, and a3. The condensers are total condensers and the reboilers are partial. Trays, column bases, and reflux drums are perfectly mixed. Distillate flow rates are set by reflux drum... 

Reflux drum (holdup Mj> is assumed constant total condenser) ... 

Some of the stripping steam condenses in the overhead condenser, shown in Fig. 10.3. The condensed steam, which accumulates in the reflux drum, is totally refluxed back to the top tray of the stripper tower. 

The propane is totally condensed as it enters the reflux drum. 

Flgure 13.2 Total condensation below the reflux drum. 

Column pressure at the reflux drum is established so as to condense totally the overhead vapor or some fraction thereof. Flash-zone pressure is approximately 69 kPa (10 psia) higher. Crude oil feed temperature at flash-zone pressure must be sufficient to vaporize the total distillates plus the overflash, which is necessary to provide reflux between the lowest sidestream-product drawoff tray and the flash zone. Calculations are made by using the crude oil EFV curve corrected for pressure. For the example being considered, percent vaporized at the flash zone must be 53.1 percent of the feed. 

Component mole balances for total-condenser-reflux drum, trays, and reboiler, respectively ... 

Accumulators are not separators. In one application, an acciunulator placed after a total condenser provides reflux to a fractionator and prevents column fluctuations in flow rate from affecting downstream equipment. In this application the accumulator is called a reflux drum. A reflux drum is shown in Figure 6.3. Liquid from a condenser accumulates in the drum before being split into reflux and product streams. At the top of the drum is a vent to exhaust noncondensable gases that may enter the distillation column. The liquid flows out of the drum into a pump. To prevent gases from entering the pump, the drum is designed with a vortex breaker at the exit line. 

A fractionator separates dimethylformamide from water and acetic acid. The distillate contains a trace amount of acetic acid. Assuming that the fractionator uses a total condenser, estimate the diameter, length, and wall thickness of the reflux drum. Because the mixture contains acetic acid, use stainless steel (SS 316) for the drum. 

The distillation column used in this study is designed to separate a binary mixture of methanol and water, which enters as a feed stream with flow rate F oi and composition Xp between the rectifying and the stripping section, obtaining both a distillate product stream D oi with composition Ad and a bottom product stream 5vo/ with composition Ab. The column consists of 40 bubble cap trays. The overhead vapor is totally condensed in a water cooled condenser (tray 41) which is open at atmospheric pressure. The process inputs that are available for control purposes are the heat input to the boiler Q and the reflux flow rate L oi. Liquid heights in the column bottom and the receiver drum (tray 1) dynamics are not considered for control since flow dynamics are significantly faster than composition dynamics and pressure control is not necessary since the condenser is opened to atmospheric pressure. 

A stream containing benzene, toluene, and biphenyl is to be separated in a distillation column to produce purified benzene in the distillate. The separation will take place in an existing column with a total condenser, a partial reboiler, and several optional feed locations. The feed stream is of fixed flow rate, composition, and thermal conditions. The entire feed may be introduced at any one of the available feed trays, but may not be split and introduced at more than one feed tray. The condenser pressure is controlled by an inert gas flowing in and out of the reflux drum. Using column modules representation, determine the degrees of freedom for this operation, and recommend a set of specifications to define the column performance. 

As an exercise, the reader is invited to demonstrate that both for condenser and reboiler, the degrees of freedom are (A +4), identical with a flash. Typically, the specifications are input stream N. + 2) variables plus two others. Outlet pressure is usually imposed. The remaining variable may be liquid or vapour fraction, including bubble-point liquid (1=1), dew-point vapour (1=0), or sub-cooled liquid or superheated vapour (unusual). The above specifications enable to compute the duty Q, but this may be given also as specification. Note also that in steady state flowsheeting the reflux drum is included in the simulation of condenser. The type of condenser (partial, total, or sub-cooled liquid), as well as the type of reboiler (kettle or thermosyphon) does not change the analysis. 

For preliminary design, column operating pressure and type condenser can be established by the procedure shown in Fig. 12.4, which is formulated to achieve, if possible, reflux drum pressures Pp between 0 and 415 psia (2.86 MPa) at a minimum temperature of 120°F (49°C) (corresponding to the use of water as the coolant in the overhead condenser). The pressure and temperature limits are representative only and depend on economic factors. Both column and condenser pressure drops of 5 psia are assumed. However, when column tray requirements are known, more refined computations should allow at least 0.1 psi/tray for atmospheric or superatmospheric column operation and 0.05 psi/tray pressure drop for vacuum column operation together with a 5 to 2 psia condenser pressure drop. Column bottom temperature must not result in bottoms decomposition or correspond to a near-critical condition. A total condenser is used for reflux drum pressures to 215 psia. A partial condenser is used from 215 psia to 365 psia. A refrigerant is used for overhead condenser coolant if pressure tends to exceed 365 psia. 

When vapor is totally condensed, a cylindrical, horizontal reflux drum is commonly employed to receive the condensate. Equations (13-9) and (13-11) permit estimates of the drum diameter and length Ly by assuming an optimum LylD of four and the same liquid residence time suggested for a vertical drum. 

The advantages of the system are fast response and the ability to run the condenser and reflux drum at a lower pressure than the column. The latter may be a distinct advantage when the colunrn is revamped to operate at higher pressure. Because of its fast response, at least one designer (258) feels that this is the best method when tight pressure control is required with total condensers. Others (e.g., 77, 164) do not favor this scheme because of its high costs and its potential problems during low-rate operation. 

The control of partial condenser columns is more complex than total condenser columns because of the interaction among the pressure, reflux-drum level, and tray-temperature control loops. Both pressure and level in the reflux dmm need to be controlled, and there are several manipulated variables available. The obvious are reflux flow, distillate flow, and condenser heat removal, but even reboiler heat input can be used. In this section, we explore three alternative control structures for this type of system, under two different design conditions (1) a large vapor distillate flow rate (moderate RR) and (2) a very small vapor distillate flow rate (high RR). 

If the column is designed with a vapor distillate product, the column operates with a reflux drum pressure of 210psia, which gives a reflux dram temperature of 110°F and permits the use of cooling water in the condenser. If a total condenser were used, the column pressure would have to be 230 psia to give a reflux dram temperature of 110 °F. Of course, higher ethane concentrations in the feed would increase the difference between the operating pressures of total and partial condenser columns. 

A viable alternative is to place a large total trap-out tray below the condenser that can serve as an internal reflux drum. Liquid reflux can be taken from this trap-out tray and fed to the top tray through a control valve. This modihed system requires additional column height, which means higher capital investment. But its dynamic controllability is much better. 

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