DETERMINATION OF NUMBER OF IDEAL STAGES

By using Tiller-Tour equation, we can determine the number of theoretical stages.

𝑦 −𝑦 ∗
𝑙𝑜𝑔 (𝑦1 − 𝑦1 ∗ )
2 2
𝑁= 𝑦 −𝑦
𝑙𝑜𝑔 (𝑦 1∗ − 𝑦2 ∗ )
1 2

For,

0.0445 − 0.1033
𝑙𝑜𝑔 ( 0.3012 − 1.077 )
𝑁=
0.0445 − 0.3012
𝑙𝑜𝑔 ( )
0.1032 − 1.077

𝑁 = 1.934 = 5

DETERMINATION OF NUMBER OF ACTUAL STAGES

𝜌𝑠
𝑥 = 0.0062 ( )
𝜇𝑠 𝐾𝑀𝑠

0.7867
𝑥 = 0.0062 ( )
1.1041(39.04)(0.7867)

𝑥 = 2.0246

From the graph, the column efficiency is 0.43. Thus, the actual numbers of stages are:

2
𝐴𝑐𝑡𝑢𝑎𝑙 𝑆𝑡𝑎𝑔𝑒𝑠 = = 4.65 = 5
0.43
 Figure: Absorber column efficiencies (bubble-caps) (after O’Connell,1946)

PHYSICAL PROPERTIES

PLATE SPACING AND COLUMN DIAMETER

Plate Spacing = 0.5 m (Perry’s Chemical Engineering Handbook, 8th Ed., p.15-29)

Flooding Velocity = 80% (Sinnot, R.K. Coulson’s and Richardson’s Chemical, page 585)

Total Downcomer Seal Area = 20% (Sinnot, R.K. Coulson’s and Richardson’s Chemical, Figure 11.31 page
573)

TOP SECTION

Flow Parameter (𝑭𝑳𝑽 )

The flow parameter (FLG) represents the ratio of liquid and vapor kinetic energies. The liquid/gas ratio
L/G is based on the mass or molar flow rates. For this, we calculate the value of flow parameter at top
section.

𝐿 𝜌𝑣
𝐹𝐿𝑉 = √
𝑉 𝜌𝐿

(Fair Correlation Equation 14-89 p.14-37 Perry’s Chemical Engineering Handbook,8th Ed.)

8009.69 32.33
Flow Parameter (𝑭𝑳𝑽 ) = 37,471.37 √39.04

𝑭𝑳𝑽 = 𝟎. 𝟏𝟗𝟒𝟓 𝒎/𝒔

Capacity Parameter (𝑪𝒔𝒃𝒇 )

The capacity parameter can be determined by using Equation 14-90 of 8th Ed. Perry’s Chemical
Engineering Handbook:

𝐶𝑠𝑏𝑓 = 0.0105 + 8.127 𝑥 10−4 (𝑇𝑆 0.755 )𝑒𝑥𝑝[−1.463𝐹𝐿𝑉 0.842 ]

(Lygeros and Magoulas Equation 14-90 p.14-37 Perry’s Chemical Engineering Handbook, 8th Ed.)

𝐶𝑠𝑏𝑓 = 0.0105 + 8.127 𝑥 10−4 (0.5 𝑥 10000.755 )𝑒𝑥𝑝[−1.463(0.1945)0.842 ]

𝑪𝒔𝒃𝒇 = 𝟎. 𝟎𝟕𝟏𝟖𝟐 𝒎/𝒔

The value of the capacity parameter will be used to calculate the maximum allowable vapor velocity
through the net area of the plate.

Gas Velocity (𝑼𝒏𝒇 )

The design gas velocity (Un) is based on net area with the assumption of 80% of flooding.

𝜎 0.2 𝜌𝐿 − 𝜌𝑉 0.5
𝑈𝑛𝑓 = 𝐶𝑠𝑏𝑓 ( ) ( )
20 𝜌𝑉

71.2 0.2 987.1 − 1.05 0.5

𝑈𝑛𝑓 = 0.07182 ( ) ( )
20 1.05

𝑼𝒏𝒇 = 𝟐. 𝟖𝟑𝟕 𝒎/𝒔

Linear Gas Velocity (Un)

𝑈𝑛 = 2.837(0.8)

𝑼𝒏 = 𝟐. 𝟐𝟔𝟗𝟔

(NPTEL Chemical Engineering Design II Module 7, page 10)

The maximum volumetric gas flow rate (Qmax) is used to calculate the net area required and this is used
to determine the total cross section area and the column diameter.

𝑘𝑔 1 𝑑𝑎𝑦 1 ℎ𝑟
37,471.37 𝑥 𝑥
𝑑𝑎𝑦 24 ℎ𝑟𝑠 3600 𝑠
𝑄𝑚𝑎𝑥 =
𝑘𝑔
1.05 3
𝑚

𝒎𝟑
𝑸𝒎𝒂𝒙 = 𝟎. 𝟒𝟏𝟑𝟎
𝒔
Net Area Required (A)

The Net Area (AN) is the cross sectional area (AT) minus the area at the top of the downcomer (ADT). The
net area symbolizes the smallest area available for vapor flow in the inter-tray spacing.

𝑄
𝐴=
𝑈𝑛

0.413
𝐴=
2.2696

𝑨 = 𝟎. 𝟏𝟖𝟐𝟎 𝒎𝟐

Total Tower Cross-Sectional Area (AT)

The total tower cross section area is the empty tower inside the cross sectional area without trays or
downspouts.

0.1820 𝑚2
𝐴𝑇 =
1 − 0.20

𝑨𝑻 = 𝟎. 𝟐𝟐𝟕𝟓 𝒎𝟐

Superficial Gas Velocity (Uv)

0.5
2 (𝜌𝐿 − 𝜌𝑉 )
𝑈𝑉 = (−0.17𝑙𝑡 + 0.27𝑙𝑡 − 0.047) [ ]
𝜌𝑉
0.5
(983.05 − 1.038)
𝑈𝑉 = (−0.17(0.5)2 + 0.27(0.5) − 0.047) [ ]
1.038

𝑼𝑽 = 𝟏. 𝟑𝟗𝟒𝟑 𝒎/𝒔

(Equation 11.79 page 557 Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume
6)

Column Diameter (Dc)

The column diameter is determined from the flooding correlation for a chosen plate spacing.

4𝑉𝑤
𝐷𝑐 = √
𝜋𝜌𝑉 𝑈𝑣

4(1.05)
𝐷𝑐 = √
𝜋(1.05)(1.3943)
 𝑫𝒄 = 𝟎. 𝟕𝟔𝟕𝟗 𝒎

(Equation 11.80 page 557 Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume
6)

Bottom Section

Flow Parameter (FLV)

The flow parameter (FLG) represents the ratio of liquid and vapor kinetic energies. The liquid/gas ratio
L/G is based on the mass or molar flow rates. For this, we calculate the value of flow parameter at top
section.

𝐿 𝜌𝑣
𝐹𝐿𝑉 = √
𝑉 𝜌𝐿

282.2 1.038
𝐹𝐿𝑉 = √
51,272.95 983.05

𝑭𝑳𝑽 = 𝟎. 𝟎𝟎𝟎𝟏𝟕𝟗 𝒎/𝒔

(Fair Correlation Equation 14-89 p.14-37 Perry’s Chemica Engineering Handbook,8th Ed.)

Capacity Parameter

The capacity parameter can be determined by using Equation 14-90 of 8th Ed. Perry’s Chemical
Engineering Handbook:

𝐶𝑠𝑏𝑓 = 0.0105 + 8.127 𝑥 10−4 (𝑇𝑆 0.755 )𝑒𝑥𝑝[−1.463𝐹𝐿𝑉 0.842 ]

𝐶𝑠𝑏𝑓 = 0.0105 + 8.127 𝑥 10−4 (0.5(1000)0.755 )𝑒𝑥𝑝[−1.463(0.000179)0.842 ]

𝑪𝒔𝒃𝒇 = 𝟎. 𝟎𝟗𝟗𝟏 𝒎/𝒔

The value of the capacity parameter will be used to calculate the maximum allowable vapor velocity
through the net area of the plate.

Gas Velocity (𝑼𝒏𝒇 )

The design gas velocity (Un) is based on net area with the assumption of 80% of flooding.

𝜎 0.2 𝜌𝐿 − 𝜌𝑉 0.5
𝑈𝑛𝑓 = 𝐶𝑠𝑏𝑓 ( ) ( )
20 𝜌𝑉
 44.29 0.2 983.05 − 1.038 0.5
𝑈𝑛𝑓 = 0.0991 ( ) ( )
20 1.038

𝑼𝒏𝒇 = 𝟑. 𝟓𝟕𝟏𝟖 𝒎/𝒔

Linear Gas Velocity (Un)

𝑈𝑛 = 3.5718 (0.8)

𝑼𝒏 = 𝟐. 𝟖𝟓𝟕 𝒎/𝒔

(NPTEL Chemical Engineering Design II Module 7, page 10)

The maximum volumetric gas flow rate (Qmax) is used to calculate the net area required and this is used
to determine the total cross section area and the column diameter.

𝑘𝑔 1 𝑑𝑎𝑦 1 ℎ𝑟
51,272.95 𝑥 𝑥
𝑑𝑎𝑦 24 ℎ𝑟𝑠 3600 𝑠
𝑄𝑚𝑎𝑥 =
𝑘𝑔
1.038 3
𝑚

𝒎𝟑
𝑸𝒎𝒂𝒙 = 𝟎. 𝟓𝟕𝟏𝟕
𝒔

Net Area Required (A)

The Net Area (AN) is the cross sectional area (AT) minus the area at the top of the downcomer (ADT). The
net area symbolizes the smallest area available for vapor flow in the inter-tray spacing.

𝑄
𝐴=
𝑈𝑛

0.5717
𝐴=
2.857

𝑨 = 𝟎. 𝟐𝟎𝟎 𝒎𝟐

Total Tower Cross-Sectional Area (AT)

The total tower cross section area is the empty tower inside the cross sectional area without trays or
downspouts.

𝑁𝑒𝑡 𝑎𝑟𝑒𝑎 𝑟𝑒𝑞𝑑

𝐴𝑇 =
1 − % 𝑜𝑓 𝑡𝑜𝑡𝑎𝑙 𝑑𝑜𝑤𝑛𝑐𝑜𝑚𝑒𝑟 𝑎𝑟𝑒𝑎

0.200
𝐴𝑇 =
1 − 0.20
 𝑨𝑻 = 𝟎. 𝟐𝟓 𝒎𝟐

Superficial Gas Velocity (Uv)

0.5
2 (𝜌𝐿 − 𝜌𝑉 )
𝑈𝑉 = (−0.17𝑙𝑡 + 0.27𝑙𝑡 − 0.047) [ ]
𝜌𝑉
0.5
(983.05 − 1.038)
𝑈𝑉 = (−0.17(0.5)2 + 0.27(0.5) − 0.047) [ ]
1.038

𝑼𝑽 = 𝟏. 𝟑𝟗𝟗𝟓 𝒎/𝒔

(Equation 11.79 page 557 Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume
6)

Column Diameter (Dc)

The column diameter is determined from the flooding correlation for a chosen plate spacing.

4𝑉𝑤
𝐷𝑐 = √
𝜋𝜌𝑉 𝑈𝑣

(Equation 11.80 page 557 Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume
6)

4(1.038)
𝐷𝑐 = √
𝜋(1.038)(1.3995)

𝑫𝒄 = 𝟎. 𝟗𝟎𝟏𝟕 𝒎

Selection of Liquid-flow Arrangement

Liquid flow arrangement is used to pick what type of plate dependeing on the liquid flow rate and
diameter. The selection can be determined by using Figure 11.28 of Coulson and Richardson’s.

Liquid Volumetric Flow Rate in Top Section =

Liquid Volumetric Flow Rate in Bottom Section =

Liquid-flow Arrangement: Single Pass, Reverse Flow, Sieve Plate

*Selection of liquid flow arrangement*

 Figure: Selection of liquid-flow arrangement

Provisional Plate Design

Since the column diameter (m) is known, we can now calculate the column crosssection area (AT),
downcomer area (AD), net area (AN), and the active area (AA). The active area is the available area for
vapor flow just above the tray floor.

The weir length (lW) is based on the ratio of active area and the downcomer area. The graph shown in
Figure 11.28 of Coulson and Richardson’s shown the relationship between weir length-downcomer and
active area-downcomer area.

Weir heights (hW) ranges from 40 to 90 mm are common applications for the columns operating above
the atmospheric pressure. The plate hole diameter (dh) from 3 to 12 are commonly used. The bigger
sizes are susceptible to weeping. The holes may be drilled or punched and the plate is fabricated from
stainless steel and other alloys than carbon steel. The center-to-center distance between two adjacent
holes is called the hole pitch (Ip). Perforations can be arranged in square or equilateral triangle arrays
with respect to the vapor flow direction.

Column Cross-Sectional Area (AT)

𝜋(0.8224)2
𝐴𝑇 =
4
 𝑨𝑻 = 𝟎. 𝟓𝟑𝟑𝟎 𝒎𝟐

Downcomer Area (AD)

𝐴𝐷 = (0.20)(0.5330)

𝑨𝑫 = 𝟎. 𝟏𝟎𝟔𝟔 𝒎𝟐

Net Area (AN)

𝐴𝑁 = 𝐴 𝑇 − 𝐴𝐷

𝐴𝑁 = ( 0.5330 + 0.1066 ) 𝑚2

𝑨𝑵 = 𝟎. 𝟔𝟑𝟗𝟔 𝒎𝟐

Active Area (AA)

𝐴𝐴 = 𝐴 𝑇 − 2𝐴𝐷

𝐴𝐴 = 0.5330 − 2(0.1066)

𝑨𝑨 = 𝟎. 𝟑𝟏𝟗𝟖 𝒎𝟑

Weir Length (lw)

𝑙𝑤 = 0.77𝐷𝑐

Weir Height (hw)

Hw = 40 mm
(Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume 6, page 572)

Hole Diameter (dh)

Dh = 3 mm

(Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume 6, page 573)

𝑙𝑝 3
=
𝑑ℎ
√0.15
0.9

Lp = 7.345

Total Hole Area (Ah)

𝐴ℎ = 0.15 (𝐴𝐴 )

𝐴ℎ = 0.15 (0.3198)

𝑨𝒉 = 𝟎. 𝟎𝟒𝟕𝟗𝟕 𝒎𝟐

Plate Thickness (tp)

𝑡𝑝 = 3 𝑚𝑚

(Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume 6, page 573)

Hole Pitch Pattern: Equilateral Triangle

(Sinnott, R.K. Coulson’s and Richardson’s Chemical Engineering Design Volume 6, page 574)

𝑡𝑝 3 𝑚𝑚
= =1
𝑑ℎ 3 𝑚𝑚

Checking for Weepage

The upward vapor flow through the plate perforation prevents the liquid from leaking through the tray
perforation. When at low vapor flow rates, the liquid starts to leak through the perforation and it is
called weeping. The weeping tendency increases with increasing fractional hole area and liquid flow
rates.

The maximum and the minimum liquid flow rate are calculated first to measure the weir crest (hWC).
Weir crest is the height of the liquid to overcome the weir height.

The total liquid height is the summation of the weir height and the minimum weir crest. With this, we
can correlate the height with the weep point constant (K2) to determine the minimum weep point
velocity. A graph from Coulson and Richardson’s (Figure 11.30) is used for the value of K2. The weep
point vapor velocity is the minimum value for stable operation.

Top Section

Maximum liquid flow rate

0.15
𝑚𝑚𝑎𝑥 = (3)√
0.9

𝒎𝒎𝒂𝒙 = 𝟏. 𝟐𝟐 𝒌𝒈/𝒔

Minimum liquid flow rate

𝑘𝑔
𝑚𝑚𝑖𝑛 = 0.7(1.22 )
𝑠

𝒎𝒎𝒊𝒏 = 𝟎. 𝟖𝟓𝟒 𝒌𝒈/𝒔

(NPTEL Chemical Engineering Design II Module 7, page 24)

Maximum weir crest (hwc)

2
𝐿𝑤𝑐 3
ℎ𝑤𝑐 = 750 ( )
𝐿𝑤 𝜌1
2
1.22 3
ℎ𝑤𝑐 = 750 ( )
0.401(987.1)

𝒉𝒘𝒄 = 𝟏𝟓. 𝟖𝟖𝟏 𝒎𝒎

(Francis Weir Formula Equation 11.85 page 572 Sinnott, R.K. coulson’s and Richardson’s Chemical
Engineering Design Volume 6)

Minimum weir crest (hwc)

2
𝐿𝑤𝑐 3
ℎ𝑤𝑐 = 750 ( )
𝐿𝑤 𝜌1
2
0.854 3
ℎ𝑤𝑐 = 750 ( )
(0.4011)(987.1)

𝒉𝒘𝒄 = 𝟏𝟐. 𝟓𝟐𝟎 𝒎𝒎

 ℎ𝑤𝑐 + ℎ𝑤 = 15.881 + 12.520 = 𝟐𝟖. 𝟒𝟎𝟏 𝒎𝒎

Using fig (Weep-point correlation), Coulson & Richardson Chemical Engineering Vol 6, 4th Ed., p.571)

Figure: Weep-point correlation (Eduljee,1959)

Minimum vapor velocity at the Weep point (Umin)

𝐾2 − 0.9(25.4 − 𝑑ℎ )
𝑈𝑚𝑖𝑛 =
𝜌𝑣 1/2

29.7 − 0.9(25.4 − 3)
𝑈𝑚𝑖𝑛 =
(1.05)1/2

𝑼𝒎𝒊𝒏 = 𝟗. 𝟑𝟏𝟎 𝒎/𝒔

(Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design Volume 6, Equation 11.84 page
571)

Actual Minimum Vapor Velocity At Minimum Flow Rate (Uop)

0.7𝑄𝑚𝑎𝑥
𝑈𝑜𝑝 =
𝐴𝐻

0.7(0.4130)
𝑈𝑜𝑝 =
0.04797
 𝑼𝒐𝒑 = 𝟔. 𝟎𝟐𝟕 𝒎/𝒔

(NPTEL Chemical Engineering Design II Module 7, page 24)

Bottom Section

Maximum liquid flow rate

𝒎𝒎𝒂𝒙 = 𝟎. 𝟎𝟎𝟑𝟑 𝐤𝐠/𝐬

Minimum liquid flow rate

𝑚𝑚𝑖𝑛 = 0.7(0.0033)

𝒎𝒎𝒊𝒏 = 𝟎. 𝟎𝟎𝟐𝟐𝟗 𝒌𝒈/𝒔

Maximum weir crest (hwc)

2
0.00327 3
ℎ𝑤𝑐 = 750 ( )
0.4011(983.7)

𝒉𝒘𝒄 = 𝟎. 𝟑𝟎𝟕𝟏 𝒎𝒎

Minimum weir crest (hwc)

2
0.00229 3
ℎ𝑤𝑐 = 750 ( )
(0.4011)(983.7)

𝒉𝒘𝒄 = 𝟎. 𝟐𝟒𝟐𝟐 𝒎𝒎

ℎ𝑤𝑐 + ℎ𝑤 = 0.3071 + 0.2422 = 𝟎. 𝟓𝟒𝟗𝟑 𝒎𝒎

(Using fig.11.30 (Weep-point correlation), Coulson & Richardson Chemical Engineering Vol 6, 4th Ed., p.
571)

K2 = 29.85

Minimum vapor velocity at the Weep Point (Umin)

29.85 − 0.9(25.4 − 3)
𝑈𝑚𝑖𝑛 =
983.71/2
 𝑼𝒎𝒊𝒏 = 𝟎. 𝟑𝟎𝟗𝟏 𝒎/𝒔

Actual Minimum Vapor Velocity At Minimum Flow Rate (Uop)

0.7(0.5717)
𝑈𝑜𝑝 =
0.0480

𝑼𝒐𝒑 = 𝟖. 𝟑𝟑𝟕 𝒎/𝒔

PLATE PRESSURE DROP

Top Section

Maximum vapor velocity (Umax)

Dry plate pressure drop is a function of maximum vapor velocity and the orifice coefficient. The vapor
velocity is calculated using this equation:

𝑄𝑚𝑎𝑥
𝑈𝑚𝑎𝑥 =
𝐴𝐻

0.4130
𝑈𝑚𝑎𝑥 =
0.0480

𝑼𝒎𝒂𝒙 = 𝟖. 𝟔𝟎𝟒 𝒎/𝒔

 Figure: Discharge coefficient, sieve plates (Liebson et al., 1957)

Minimum dry plate pressure drop (hd)

The orifice coefficient is a function of ratio between the hole area (Ah) to perforated area (AP) and
between the plate thickness to hole diameter ratio, which assumed to be 1. Figure 11.34 shows the
correlations of the three variables, and the value of the orifice coefficient.

𝐶𝑜 = 0.95

Dry plate pressure drop (hd) occurs due to friction within dry short holes. The maximum dry plate
pressure drop is computed using this equation:

𝑈𝑚𝑎𝑥 2 𝜌𝑉
ℎ𝑑 = 51 ( )
𝐶𝑜 𝜌𝐿

8.610 2 1.05
ℎ𝑑 = 51 ( )
0.95 987.1

𝒉𝒅 = 𝟒. 𝟒𝟓𝟔 𝒎𝒎

(Equation 11.88 page 576 Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design Volume
6)

Residual head (hr)

The residual pressure drop results from the surface tension as the gas releases from a perforation. This
simple equation can be used to estimate the residual head with reasonable accuracy.
 12.5𝑥103
ℎ𝑟 =
𝜌𝑙

12.5𝑥103
ℎ𝑟 =
983.7

𝒉𝒓 = 𝟏𝟐. 𝟕𝟏 𝒎𝒎

(Hunt Equation 11.88 page 577 Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design
Volume 6)

Total plate pressure drop

The total pressure drop is given by:

ℎ𝑡 = ℎ𝑑 + (ℎ𝑤𝑐 + ℎ𝑤 ) + ℎ𝑟

ℎ𝑡 = 4.456 + (0.2422 + 0.3071) + 12.71

𝒉𝒕 = 𝟏𝟕. 𝟕𝟏𝟓 𝒎𝒎

Bottom Section

Maximum vapor velocity (Umax)

𝑄𝑚𝑎𝑥
𝑈𝑚𝑎𝑥 =
𝐴𝐻

0.5717
𝑈𝑚𝑎𝑥 =
0.0480

𝑼𝒎𝒂𝒙 = 𝟏𝟏. 𝟗𝟏 𝒎/𝒔

Minimum dry plate pressure drop

𝐶𝑜 = 0.95

Residual head (hr)

12.5𝑥103
ℎ𝑟 =
𝜌𝑙

12.5𝑥103
ℎ𝑟 =
983.7

𝒉𝒓 = 𝟏𝟐. 𝟕𝟏 𝒎𝒎
Total plate pressure drop

ℎ𝑡 = ℎ𝑑 + (ℎ𝑤𝑐 + ℎ𝑤 ) + ℎ𝑟

ℎ𝑡 = 12.71 + 40.30 + 8.475

𝒉𝒕 = 𝟔𝟏. 𝟒𝟗 𝒎𝒎

Checking:

Head of Top:

∆𝑃𝑡 = 9.81 𝑥 10−3 ℎ𝑡 𝜌1

∆𝑃𝑡 = 9.81 𝑥 10−3 (0.0015)(983.7)

∆𝑷𝒕 = 𝟏𝟓𝟓. 𝟓𝟒 𝒎𝒎

(Equation 11.87 page 575 Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design Volume
6)

1.5
ℎ𝑡 = = 0.0015
1000

Head of Bottom

1.5
ℎ𝑡 = = 0.0015
1000

Since the values obtained in calculating the pressure drop of both top and bottom sections are lower
than the calculated head, the assumed pressure drop per tray is accepted.

DOWNCOMER BACKUP LIQUID AND RESIDENCE TIME

The height of the bottom edge of the apron above the plate is usually set at 5 to 10 mm below the
outlet weir height.

Height of Bottom Edge of Apron Above Plate (hap)

The clearance area under the downcomer is given by the equation:

ℎ𝑎𝑝 = 40 − (10 𝑚𝑚)

(Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design Volume 6, page 578)

𝒉𝒂𝒑 = 𝟑𝟎 𝒎𝒎
Clearance Area Under Downcomer (Aap)

The variable Am is the smaller clearance area under the downcomer apron (Aap) and downcomer area
(AD)

𝐴𝑎𝑝 = (30)(0.4011)

𝑨𝒂𝒑 = 𝟎. 𝟎𝟏𝟐𝟎𝟑𝟑 𝒎𝟐

(Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design Volume 6, page 578)

Head loss in downcomer (hdc)

The liquid level and froth in the downcomer should be well below the top of the outlet weir on the tray
above to avoid flooding.

𝑙𝑤𝑑 2
ℎ𝑑𝑐 = 166 [ ]
𝜌𝑙 𝐴𝑚
2
0.0927
ℎ𝑑𝑐 = 166 [ ]
(987.3)(0.012033)

𝒉𝒅𝒄 = 𝟎. 𝟎𝟏𝟎𝟏𝟎 𝒎𝒎

[Cicalese Equation 11.92 page 578 Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering
Design Volume 6]

Downcomer back (hbc)

ℎ𝑏𝑐 = ℎ𝑑𝑐 + (ℎ𝑤𝑐 + ℎ𝑤 ) + ℎ𝑡

ℎ𝑏𝑐 = 0.01010 + 42.19 + 61.49

𝒉𝒃𝒄 = 𝟏𝟎𝟑. 𝟔𝟗 𝒎𝒎

Downcomer residence time

Downcomer residence time is the time when the entrained vapor to disengage from the liquid stream,
this is to prevent the “aerated” liquid being carried down. The time should be at least three seconds is
recommended.

𝐴𝐷 ℎ𝑏𝑐 𝜌𝑙
𝑡𝑑𝑟𝑡 =
𝑙𝑤𝑑
 (0.1066)(0.1037)(987.3)
𝑡𝑑𝑟𝑡 =
0.0992

𝒕𝒅𝒓𝒕 = 𝟏𝟏𝟎. 𝟎𝟐 𝒔

[Equation 11.95 page 579 Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design
Volume 6]

Bottom Section

Head loss in downcomer (hdc)

The liquid level and froth in the downcomer should be well below the top of the outlet weir on the tray
above to avoid flooding.

𝑙𝑤𝑑 2
ℎ𝑑𝑐 = 166 [ ]
𝜌𝑙 𝐴𝑚
2
0.00327
ℎ𝑑𝑐 = 166 [ ]
(983.05)(0.0120)

𝒉𝒅𝒄 = 𝟎. 𝟎𝟎𝟎𝟎𝟏𝟐𝟕𝟔 𝒎𝒎

[Cicalese Equation 11.92 page 578 Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design
Volume 6]

Downcomer back (hbc)

ℎ𝑏𝑐 = ℎ𝑑𝑐 + (ℎ𝑤𝑐 + ℎ𝑤 ) + ℎ𝑡

ℎ𝑏𝑐 = 61.487 + 40.295 + 0.00001276

𝒉𝒃𝒄 = 𝟏𝟎𝟏. 𝟕𝟖𝟐 𝒎𝒎

Downcomer residence time

Downcomer residence time is the time when the entrained vapor to disengage from the liquid stream,
this is to prevent the “aerated” liquid being carried down. The time should be at least three seconds is
recommended.

𝐴𝐷 ℎ𝑏𝑐 𝜌𝑙
𝑡𝑑𝑟𝑡 =
𝑙𝑤𝑑
 (0.1066)(101.782)(983.7)
𝑡𝑑𝑟𝑡 =
0.00326

𝒕𝒅𝒓𝒕 = 𝟑𝟐𝟔𝟓. 𝟔𝟒 𝒔

[Equation 11.95 page 579 Sinnott, R. K. Coulson’s and Richardson’s Chemical Engineering Design
Volume 6]

Top Section

138.59 mm

Therefore, it is accepted.

Bottom Section

101.78 mm

Therefore, it is accepted.

Since both the residence time obtained in top and bottom sections are greater than 3, the design
criteria is met.

CALMING ZONES AND HOLE PITCH

Calming zones are unperforated strips of the tray at the inlet and outlet side of the tray. Inlet
calming zone helps in reducing excessive weeping in this area because of high vertical velocity of
the entering liquid in the downward direction. Outlet calming zone allows disengagement of vapor
before the liquid enters the downcomer area. 75 mm calming zones are used.

Provisional Plate Design

𝑙𝑤
= 0.85
𝐷𝑐

Using fig.11.32, Coulson & Richardson Chemical Engineering Vol 6, 4th Ed., p. 574]
 Figure:

Relation between angle subtended by chord, chord height and chord length

𝜭𝒄 = 𝟏𝟏𝟓°

Angle subtended by the chord (edge plate), 𝛼 = 180° − 100° = 80°

Weir chord length (Lh)

Using fig.11.32, Coulson & Richardson Chemical Engineering Vol 6, 4th Ed., p. 574]

𝐿ℎ
= 0.24
𝐷𝑐

𝐿ℎ = 0.24 𝐷𝑐

Unperforated edge strip

The length of the unperforated area is taken by this equation:

80𝜋
𝑙𝐸𝑆 = (𝐷𝑐 − 50𝑥10−3 ) ( )
180
80𝜋
𝑙𝐸𝑆 = (0.1066 − 50𝑥10−3 ) ( )
180

𝒍𝑬𝑺 = 𝟎. 𝟎𝟕𝟗𝟎 𝒎

[NPTEL Chemical Engineering Design II Module 7, page 27]

𝐴𝐸𝑆 = 50𝑥10−3 𝑙𝐸𝑆

 𝐴𝐸𝑆 = 50𝑥10−3 (0.0790)

𝑨𝑬𝑺 = 𝟎. 𝟎𝟎𝟑𝟗𝟓 𝒎𝟐

[NPTEL Chemical Engineering Design II Module 7, page 27]

Length of Zone (lcz)

According to Coulson et al. if the column diameter is below 1.5 m, use 75mm as width of each zone.

𝑙𝑐𝑧 = 𝑙𝑤 + 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑢𝑛𝑝𝑒𝑟𝑓𝑜𝑟𝑡𝑒𝑑 𝑒𝑑𝑔𝑒 𝑠𝑡𝑟𝑖𝑝

𝒍𝒄𝒛 = 𝟎. 𝟒𝟕𝟔𝟐 𝒎

[NPTEL Chemical Engineering Design II Module 7, page 27]

Area of Zone (Acz)

𝐴𝑐𝑧 = 2(50𝑥10−3 𝑙𝑐𝑧 )

𝐴𝑐𝑧 = 2(50𝑥10−3 (0.04762))

𝑨𝒄𝒛 = 𝟎. 𝟎𝟒𝟕𝟔𝟐

[NPTEL Chemical Engineering Design II Module 7, page 27]

Perforated area (Ap)

𝐴𝑝 = 𝐴𝐴 − 𝐴𝐶𝑍 − 𝐴𝐸𝑆

𝐴𝑝 = 0.3198 + 0.04762 + 0.00395

𝑨𝒑 = 𝟎. 𝟐𝟒𝟒𝟒 𝒎𝟐

[NPTEL Chemical Engineering Design II Module 7, page 27]

Total Hole Area (AH)

𝑨𝑯 = 𝟎. 𝟎𝟒𝟕𝟗𝟖 𝒎𝟐

Number of Holes (nH)

𝜋
𝑛𝐻 = (𝑑 2 )(𝐴𝐻 )
4 ℎ
 𝜋
𝑛𝐻 = 4 (32 )(0.04798)

𝑛𝐻 = 6790

[NPTEL Chemical Engineering Design II Module 7, page 27]

Hole pitch (lp)

𝑙𝑝
= 2.4495
𝑑ℎ

𝑙𝑝 = 2.4495𝑑ℎ

𝑙𝑝 = 2.4495(3)

𝒍𝒑 = 𝟕. 𝟑𝟒𝟖𝟓 𝒎𝒎

ENTRAINMENT CHECKING

Entrainment is the phenomena in which liquid droplets are carried by vapor to the tray above. Thus, the
less volatile liquid components from bottom tray are mixed with liquid having relatively more volatile
materials on the overhead tray. Entrainment increases with vapor velocity.

Top Section

Actual Vapor Velocity based on Area (Uv)

The actual vapor velocity based on the net area

0.4130
𝑈𝑉 =
0.4264

𝑼𝑽 = 𝟎. 𝟗𝟔𝟖𝟔 𝒎/𝒔
𝟎.𝟗𝟔𝟖𝟔
%Flooding= 𝟐.𝟖𝟑𝟕
𝒙 𝟏𝟎𝟎 = 𝟑𝟒. 𝟏𝟒 %

Using Fig. 11.29 (Fair Correlation) page 570 Sinnott, R. K. Coulson’s and Richardson’s Chemical
Engineering Design Volume 6,

𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝑬𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕,𝜳 = 𝟎.𝟎𝟏𝟓

 Figure: Entrainment correlation for sieve plates (Fair, 1961)

Bottom Section

3.5717
𝑈𝑉 =
0.4264

𝑼𝑽 = 𝟖. 𝟑𝟕𝟔 𝒎/𝒔
𝟏.𝟑𝟗𝟗𝟒−𝟖.𝟑𝟕𝟔
% Flooding = 𝟏.𝟑𝟗𝟗𝟒
𝒙𝟏𝟎𝟎 = 𝟒𝟗𝟖%

Using Fig. 11.29 (Fair Correlation) page 570 Sinnott, R. K. Coulson’s and Richardson’s Chemical
Engineering Design Volume 6,

𝑭𝒓𝒂𝒄𝒕𝒊𝒐𝒏𝒂𝒍 𝑬𝒏𝒕𝒓𝒂𝒊𝒏𝒎𝒆𝒏𝒕,𝜳 = 𝟎.𝟎𝟎𝟎𝟔

Height of Column (H)

𝐻 = 𝑇𝑡 + (𝑇𝑡 )(𝑁 − 1) + (𝑡𝑡 )(𝑁) + 𝑇𝑜𝑝 𝐷𝑖𝑠𝑒𝑛𝑔𝑎𝑔 𝑆𝑝𝑎𝑐𝑒 + 𝐵𝑜𝑡𝑡𝑜𝑚 𝑆𝑒𝑝𝑎𝑟𝑎𝑡𝑜𝑟 𝑆𝑝𝑎𝑐𝑒