DESCRIPTION
AIChE manual updates and consolidates procedures for testing performance of distillation columns
From classic distillation operations to air stripping to other separations processes, selecting the correct column for appropriate efficient, safe, and environmentally-sound operations can be an important step. The newest updated volume in AIChE’s long-running Equipment Testing Procedures series, Trayed and Packed Columns: A Guide to Performance Evaluation, Third Editionprovides chemical engineers, plant managers, and other professionals with helpful advice to assess and measure performance of a variety of distillation columns, including those that utilize bubble cap, sieve, valve trays, or packing material.
The new book combines and updates into one user-friendly volume the best available field knowledge from previous publications on both types of distillation columns. Designed not as a single set of compulsory steps, but as a compilation of techniques, it will allow the user to select the procedure that best applies to its operating parameters. The testing steps presented can be used to assess reliable performance data on mass transfer efficiency, capacity, energy consumption, and pressure drop—information essential to effective troubleshooting of performance problems, identifying capacity bottlenecks, determining operating ranges, and a number of other routine maintenance and optimization processes.
Opening with an extensive definition section, organized by topical area, the book then goes on to address:
- Selection of instrumentation and identification of elements to be measured
- Pre-test planning procedures
- Strategies for data collection and evaluation, including sampling procedures
- Pre-test, in-test, and post-test considerations (equipment, safety, process, environmental)
- Computation and interpretation of results, including individual breakdowns for trayed and packed columns in terms of hydraulic and efficiency performance
- Test troubleshooting analysis in twelve key areas
The book concludes with appendices for relevant symbols and nomenclature, plus sample caculations generated from performance tests.
With its engineer-tested procedures and thorough explanations, Trayed and Packed Columns: A Guide to Performance Evaluation, Third Edition is an essential text for anyone engaged in implementing new technology in equipment design, identifying process problems, and optimizing equipment performance.
THE AMERICAN INSTITUTE OF CHEMICAL ENGINEERS (AIChE) is a distinguished professional association that strives to provide leadership in the advancing chemical engineering profession. The Equipment Testing Procedures Committee is composed of engineers with substantial experience in the design and operation of process plants, as well as in solving problems that can arise with the equipment used in these plants.
100.0 PURPOSE & SCOPE 1
101.0 Purpose 1
102.0 Scope 1
200.0 DEFINITION AND DESCRIPTION OF TERMS 2
201.0 Flow Quantities 2
202.0 Key Components 3
203.0 Mass Transfer Efficiency 4
203.1 Theoretical Trays or Plates or Stages 4
203.2 Overall Column Efficiency 4
203.3 Apparent Murphree Tray Efficiency 4
203.4 Ideal Murphree Tray Efficiency 4
203.5 Murphree Point Efficiency 4
203.6 HETP 4
203.7 HTU 4
203.8 NTU 4
204.0 Operating Lines 5
205.0 Pinch 5
206.0 Maximum Throughput 5
206.1 Maximum Hydraulic Throughput 5
206.2 Maximum Operational Capacity 5
206.3 Maximum Efficient Capacity 5
207.0 Minimum Operating Rate 5
208.0 Operating Section 5
209.0 Hardware 6
209.1 Components of a Trayed Column 6
209.2 Components of a Packed Column 7
300.0 TEST PLANNING 9
301.0 Preliminary Preparation 9
301.1 Safety 10
301.2 Environmental Considerations 10
301.3 Test Objectives 10
301.4 Organizational Resources 10
301.5 Schedule 10
301.6 Review of Historic Operating Data 10
302.0 Column Control and Instrumentation 11
303.0 Peripheral Equipment 11
304.0 Pre-test Calculations 11
304.1 Process Simulation 11
304.2 Dry Run 11
305.0 Types of Tests 12
305.1 Performance Tests 12
305.2 Acceptance Tests 12
306.0 Specific Areas of Interest 12
306.1 Packing Efficiencies 12
306.2 Tray Efficiencies 12
306.3 Overall Column Efficiency 13
306.4 Capacity Limitations 13
307.0 Energy Consumption 14
308.0 Pressure Drop Restrictions 15
309.0 Data Collection Requirements 15
309.1 Process Operating Data 15
309.2 Gamma Scan Data 15
310.0 Conditions of External Streams 18
310.1 Overall and Component Material Balances 18
310.2 Overall Enthalpy Balances 18
311.0 Internal Temperatures 18
311.1 Heat Balances 18
311.2 Internal Profiles 18
312.0 Internal Samples 20
312.1 Internal Samples for Efficiency Checks 20
312.2 Internal Samples for Overall Performance 20
313.0 Pressure Profiles 20
314.0 Data Requirements-Physical Properties 20
314.1 Test Mixtures 20
314.2 Essential Data 21
315.0 Auxiliary Data 21
316.0 Test Procedure Documentation 21
400.0 METHODS OF MEASUREMENT AND SAMPLING 22
401.0 System Controls and Operating Stability 22
402.0 Measurement of Temperatures 22
402.1 Accuracy 22
402.2 Errors 22
403.0 Measurement of Flow Rates 24
403.1 Orifice Meters 24
403.2 Rotameters 25
403.3 Vortex Flow Meters 25
403.4 Coriolis Flow Meters 25
403.5 Magnetic Flow Meters 25
403.6 Pitot Tube (or Annubar) 25
403.7 Direct Volume or Weight Measurement 26
404.0 Measurement of Column Pressure Drop 26
404.1 Instrument 26
404.2 Pressure Taps 26
404.3 Seal Pots 33
404.4 Leakage Check 33
404.5 Accuracy 33
405.0 Sampling Procedure 34
405.1 General 34
405.2 Selection of Sampling Points 34
405.3 Sample Connections 35
405.4 Containers 35
405.5 Sampling of High Boiling Materials 36
405.6 Sampling of Intermediate Boiling Materials 37
405.7 Sampling of Materials Having Boiling Points Below -50°F (-46°C) 40
405.8 Leakage Check 41
405.9 Labeling and Handling the Samples 41
500.0 TEST PROCEDURE 43
501.0 Preliminary 43
502.0 Test Procedure for Maximum Hydraulic Throughput 43
502.1 Flood Symptoms 44
502.2 Performing Capacity Tests 45
502.3 Optional Test Technique – Gamma Scanning 48
503.0 Considerations Affecting Efficiency Test Procedure 48
503.1 Rigorous Versus Shortcut Efficiency Tests 48
503.2 Strategy of Efficiency Testing 49
503.3 Early Preparation for Efficiency Tests 50
503.4 Last-minute Preparations for Efficiency Tests 53
503.5 Establishment of Steady State Conditions 55
503.6 The Test Day 56
503.7 Concluding Test 56
600.0 COMPUTATION OF RESULTS
601.0 Verification of Test Data and Simulation Models 58
602.0 Material Balance 59
602.1 End Effects 59
603.0 Enthalpy Balance 59
603.1 Overall Balance 59
603.2 Internal Flow Rates 60
604.0 Hydraulic Performance 60
604.1 Trayed Column 60
604.2 Packed Column 61
605.0 Efficiency Performance 61
605.1 Trayed Column 62
605.2 Packed Column 69
700.0 INTERPRETATION OF RESULTS 76
701.0 Sources of Experimental Error 76
701.1 Material and Enthalpy Balances 77
702.0 Effects of Experimental Error 78
703.0 Design versus Performance 78
703.1 Mechanical/Tower Equipment 78
703.2 Process Conditions 78
704.0 Hydraulic Performance 79
704.1 Mechanical/Tower Equipment 79
704.2 Tray 79
704.3 Packing 80
704.4 Process Conditions 80
705.0 Mass Transfer Performance 81
705.1 Mechanical/Tower Equipment 81
705.2 Tray 81
705.3 Packing 82
705.4 Maldistribution 82
705.5 Process 84
706.0 Test Troubleshooting 85
706.1 Analysis Procedure 85
706.2 Sampling 85
706.3 Equilibrium Data 85
706.4 Temperature Measurements 85
706.5 Heat and Material Balances 86
706.6 Fluctuation of Process Conditions 86
706.7 Pressure Drop Measurements 86
706.8 Incorrect Prediction of Pressure Drop 86
706.9 Errors in Assumptions in Modeling Mass Transfer 86
706.10 Multicomponent Systems Deviate from Binary Data 87
706.11 High Purity Separation 87
706.12 Test and Design Conditions 87
800.0 APPENDIX 88
801.0 Notation 88
801.1 Greek Symbols 90
802.0 Sample Calculations 90
802.1 General Analysis of Test Data 90
802.2 Packed Column 91
802.3 Trayed Column 107
803.0 References 126
101.0 Purpose 1
102.0 Scope 1
200.0 DEFINITION AND DESCRIPTION OF TERMS 2
201.0 Flow Quantities 2
202.0 Key Components 3
203.0 Mass Transfer Efficiency 4
203.1 Theoretical Trays or Plates or Stages 4
203.2 Overall Column Efficiency 4
203.3 Apparent Murphree Tray Efficiency 4
203.4 Ideal Murphree Tray Efficiency 4
203.5 Murphree Point Efficiency 4
203.6 HETP 4
203.7 HTU 4
203.8 NTU 4
204.0 Operating Lines 5
205.0 Pinch 5
206.0 Maximum Throughput 5
206.1 Maximum Hydraulic Throughput 5
206.2 Maximum Operational Capacity 5
206.3 Maximum Efficient Capacity 5
207.0 Minimum Operating Rate 5
208.0 Operating Section 5
209.0 Hardware 6
209.1 Components of a Trayed Column 6
209.2 Components of a Packed Column 7
300.0 TEST PLANNING 9
301.0 Preliminary Preparation 9
301.1 Safety 10
301.2 Environmental Considerations 10
301.3 Test Objectives 10
301.4 Organizational Resources 10
301.5 Schedule 10
301.6 Review of Historic Operating Data 10
302.0 Column Control and Instrumentation 11
303.0 Peripheral Equipment 11
304.0 Pre-test Calculations 11
304.1 Process Simulation 11
304.2 Dry Run 11
305.0 Types of Tests 12
305.1 Performance Tests 12
305.2 Acceptance Tests 12
306.0 Specific Areas of Interest 12
306.1 Packing Efficiencies 12
306.2 Tray Efficiencies 12
306.3 Overall Column Efficiency 13
306.4 Capacity Limitations 13
307.0 Energy Consumption 14
308.0 Pressure Drop Restrictions 15
309.0 Data Collection Requirements 15
309.1 Process Operating Data 15
309.2 Gamma Scan Data 15
310.0 Conditions of External Streams 18
310.1 Overall and Component Material Balances 18
310.2 Overall Enthalpy Balances 18
311.0 Internal Temperatures 18
311.1 Heat Balances 18
311.2 Internal Profiles 18
312.0 Internal Samples 20
312.1 Internal Samples for Efficiency Checks 20
312.2 Internal Samples for Overall Performance 20
313.0 Pressure Profiles 20
314.0 Data Requirements-Physical Properties 20
314.1 Test Mixtures 20
314.2 Essential Data 21
315.0 Auxiliary Data 21
316.0 Test Procedure Documentation 21
400.0 METHODS OF MEASUREMENT AND SAMPLING 22
401.0 System Controls and Operating Stability 22
402.0 Measurement of Temperatures 22
402.1 Accuracy 22
402.2 Errors 22
403.0 Measurement of Flow Rates 24
403.1 Orifice Meters 24
403.2 Rotameters 25
403.3 Vortex Flow Meters 25
403.4 Coriolis Flow Meters 25
403.5 Magnetic Flow Meters 25
403.6 Pitot Tube (or Annubar) 25
403.7 Direct Volume or Weight Measurement 26
404.0 Measurement of Column Pressure Drop 26
404.1 Instrument 26
404.2 Pressure Taps 26
404.3 Seal Pots 33
404.4 Leakage Check 33
404.5 Accuracy 33
405.0 Sampling Procedure 34
405.1 General 34
405.2 Selection of Sampling Points 34
405.3 Sample Connections 35
405.4 Containers 35
405.5 Sampling of High Boiling Materials 36
405.6 Sampling of Intermediate Boiling Materials 37
405.7 Sampling of Materials Having Boiling Points Below -50°F (-46°C) 40
405.8 Leakage Check 41
405.9 Labeling and Handling the Samples 41
500.0 TEST PROCEDURE 43
501.0 Preliminary 43
502.0 Test Procedure for Maximum Hydraulic Throughput 43
502.1 Flood Symptoms 44
502.2 Performing Capacity Tests 45
502.3 Optional Test Technique – Gamma Scanning 48
503.0 Considerations Affecting Efficiency Test Procedure 48
503.1 Rigorous Versus Shortcut Efficiency Tests 48
503.2 Strategy of Efficiency Testing 49
503.3 Early Preparation for Efficiency Tests 50
503.4 Last-minute Preparations for Efficiency Tests 53
503.5 Establishment of Steady State Conditions 55
503.6 The Test Day 56
503.7 Concluding Test 56
600.0 COMPUTATION OF RESULTS
601.0 Verification of Test Data and Simulation Models 58
602.0 Material Balance 59
602.1 End Effects 59
603.0 Enthalpy Balance 59
603.1 Overall Balance 59
603.2 Internal Flow Rates 60
604.0 Hydraulic Performance 60
604.1 Trayed Column 60
604.2 Packed Column 61
605.0 Efficiency Performance 61
605.1 Trayed Column 62
605.2 Packed Column 69
700.0 INTERPRETATION OF RESULTS 76
701.0 Sources of Experimental Error 76
701.1 Material and Enthalpy Balances 77
702.0 Effects of Experimental Error 78
703.0 Design versus Performance 78
703.1 Mechanical/Tower Equipment 78
703.2 Process Conditions 78
704.0 Hydraulic Performance 79
704.1 Mechanical/Tower Equipment 79
704.2 Tray 79
704.3 Packing 80
704.4 Process Conditions 80
705.0 Mass Transfer Performance 81
705.1 Mechanical/Tower Equipment 81
705.2 Tray 81
705.3 Packing 82
705.4 Maldistribution 82
705.5 Process 84
706.0 Test Troubleshooting 85
706.1 Analysis Procedure 85
706.2 Sampling 85
706.3 Equilibrium Data 85
706.4 Temperature Measurements 85
706.5 Heat and Material Balances 86
706.6 Fluctuation of Process Conditions 86
706.7 Pressure Drop Measurements 86
706.8 Incorrect Prediction of Pressure Drop 86
706.9 Errors in Assumptions in Modeling Mass Transfer 86
706.10 Multicomponent Systems Deviate from Binary Data 87
706.11 High Purity Separation 87
706.12 Test and Design Conditions 87
800.0 APPENDIX 88
801.0 Notation 88
801.1 Greek Symbols 90
802.0 Sample Calculations 90
802.1 General Analysis of Test Data 90
802.2 Packed Column 91
802.3 Trayed Column 107
803.0 References 126
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