Sulzer Chemtech

Tower Technical Bulletin

Troubleshooting distillation columns Part 1: The basics

Background
Properly designed and operated distillation columns can
provide long-term, trouble-free service. However, mechanical
failure, process upsets, and other factors can occur, preventing
the distillation system from achieving the expected design
performance.
Taking a tower off-line is time consuming and expensive; before
doing so it is important to have a good idea of what is causing
the problem. A systematic study of the column should be made
(often with the assistance of the column equipment provider).
After careful study, a tower inspection should be performed
to confirm the cause of the problem and to determine and/
or provide a proper solution. In emergency cases, expected
replacement equipment may need to be on site prior to the
column opening.
Understanding mass transfer fundamentals is critical
Knowledge of the column thermodynamic and hydraulic
functions is the key starting point. Any problem that develops
that does not allow the vapor and liquid to contact each other
in the manner for which the device was designed, or keeps the
vapor and liquid from separating after contact, will adversely
affect column performance. For example, the packing shown
below will not provide good flow or vapor/liquid contacting
efficiency because some of the packing is blocked off by fouling.

Where to start
Ask yourself the following questions:
What specifications are not being met? What could
happen internally to create this issue?
Is this a capacity problem? Has the column ever run
successfully at these rates? If not, the internals may be at
their capacity limit.
Have there been any upset conditions that may have
damage internals?

Working toward a solution

The simple checks should be made first. Check the instrumentation
to ensure that flows, levels, temperatures, and pressures are
correct. Check to make sure that feed compositions and analyses
are correct. Conduct a single gauge pressure survey and a
temperature survey as possible. Perform a mass balance across
the columna closure of 3-5% is normally considered acceptable.
Once you have this information, review the information with plant
engineering and operations. Consult with your equipment vendor
to further investigate the problem. Decide on the feasibility of a
column gamma scan. If practical, schedule a tower inspection at
the first opportunity in order to personally examine the internals.
In the meantime, the problem may be temporarily alleviated by
reducing rates, changing the reflux and reboiler duties, changing
the feed location, and increasing or decreasing the tower pressure.
The Sulzer Applications Group
Sulzer Chemtech has over 150 years of in-house
operating and design experience in process applications.
We understand your process and your economic drivers.
Sulzer has the know-how and the technology to design
internals with reliable, high performance.

Hydraulic evaluation
Symptoms of hydraulic flooding include excessive or
erratic pressure drop, reduced bottoms flow, reduced
column temperature profile, and excessive liquid
carryover. Conversely, low pressure drop is an indication
of missing trays or packing.

Sulzer Chemtech, USA, Inc.

8505 E. North Belt Drive | Humble, TX 77396
Phone: (281) 604-4100 | Fax: (281) 540-2777
Email: TowerTech.CTUS@sulzer.com
www.sulzer.com

Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee
of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application.