References

1. Wankat: 10.6  10.9 and 15.1  15.6

2. Coulson & Richardson (Vol 6): 11.14
3. Seader and Henley (Vol 2): Chapter 6

1
 Packed Columns
• Packed columns are used for distillation, gas absorption,
and liquid-liquid extraction.
• The gas liquid contact in a packed bed column is
continuous, not stage-wise, as in a plate column.
• The liquid flows down the column over the packing surface
and the gas or vapor, counter-currently, up the column.
Some gas-absorption columns are co-current
• The performance of a packed column is very dependent on
the maintenance of good liquid and gas distribution
throughout the packed bed.

2
Representation of a Packed Column

Packing material
Packing Height (Z)

3
Components of a Packed Column

4
 Advantages of Trayed Columns
1) Plate columns can handle a wider range of liquid and gas flow-rates
than packed columns.
2) Packed columns are not suitable for very low liquid rates.
3) The efficiency of a plate can be predicted with more certainty than the
equivalent term for packing (HETP or HTU).
4) Plate columns can be designed with more assurance than packed
columns. There is always some doubt that good liquid distribution can
be maintained throughout a packed column under all operating
conditions, particularly in large columns.
5) It is easier to make cooling in a plate column; coils can be installed on
the plates.
6) It is easier to have withdrawal of side-streams from plate columns.
7) If the liquid causes fouling, or contains solids, it is easier to provide
cleaning in a plate column; manways can be installed on the plates. With
small diameter columns it may be cheaper to use packing and replace
the packing when it becomes fouled.
5
 Advantages of Packed Columns
1. For corrosive liquids, a packed column will usually be cheaper
than the equivalent plate column.
2. The liquid hold-up is lower in a packed column than a plate
column. This can be important when the inventory of toxic or
flammable liquids needs to be kept as small as possible for
safety reasons.
3. Packed columns are more suitable for handling foaming
systems.
4. The pressure drop can be lower for packing than plates; and
packing should be considered for vacuum columns.
5. Packing should always be considered for small diameter
columns, say less than 0.6 m, where plates would be difficult
to install, and expensive.
6
 Design Procedure

Specify
Select type and Determine
separation
size of packing column height (Z)
requirements

Select column Determine

internals column diameter
(support and distributor)

7
 Packing Materials
1. Ceramic: superior wettability, corrosion
resistance at elevated temperature, bad
strength
2. Metal: superior strength & good wettability
3. Plastic: inexpensive, good strength but may
have poor wettability at low liquid rate

8
Reference:
Seader and Henley

9
Structured
packing materials

Reference:
Seader and Henley
10
 Characteristics of Packing

Reference:
Seader and Henley
11
Reference:
Seader and Henley 12
 Packing Height (Z)
Vout yout

Lin xin

Transfer Unit (TU)  TU

TU
Packing Height (Z)
Height of Transfer Unit (HTU) TU
TU
n

Vin yin

Lout xout

Packing Height (Z) = height of transfer unit (HTU)  number of transfer units (n)
13
 Methods for Packing Height (Z)
2 methods
More common

Equilibrium stage Mass Transfer

analysis analysis
HETP method HTU method

Z = HETP  N Z = HTU  NTU

N = number of theoretical stages obtained from HTU = Height of a Transfer unit
McCabe-Thiele method NTU = Number of Transfer Units (obtained by
HETP numerical integration)
• Height Equivalent to a Theoretical Plate y A out
V dy
• Represents the height of packing that gives
similar separation to as a theoretical stage.
Z
K y a Ac 
y A in
( yA  yA )
*
Z  H OG  NOG
• HETP values are provided for each type of
x A out
packing L d xA
Z
K x a Ac 
x A in
( x A  x*A )
Z  H OL  NOL

14
 Evaluating height based on HTU-NTU model
y A out
V dy
Z
K y a Ac 
y A in
( y *A  y A )
HOG
Substitute values to calculate HOG
Integration = NOG
• NOG is evaluated graphically by numerical integration using the equilibrium and
operating lines.
• Draw 1/(yA* -yA) (on y-axis) vs. yA (on x-axis). Area under the curve is the value
of integration.
1
( y *A  y A ) Evaluate area
y under the curve
by numerical
integration

Area = N 15
x
 Two-Film Theory of Mass Transfer
Local Local
At a specific gas phase liq phase
location in
the column

Overall
gas phase or Liquid phase

Gas phase Boundary layer Liq phase Boundary layer

(Ref.: Seader and Henley) 16

 Alternative Mass Transfer Grouping
Phase LOCAL coefficient OVERALL coefficient
Gas Phase Z = HG  NG Z = HOG  NOG

M. Transfer Coeff.: ky a M. Transfer Coeff.: Ky a

Driving force: (y – yi) Driving force: (y – y*)

Liquid Z = H L  NL Z = HOL  NOL

Phase
M. Transfer Coeff.: kx a M. Transfer Coeff.: Kx a
Driving force: (x – xi) Driving force: (x – x*)

Note: Driving force could be ( y – yi) or (yi – y) is decided based on direction of flow. This
applies to gas and liquid phases, overall and local. 17
 Graphical evaluation of N (integral)
y A out y A out
dy A 1
Assume we are evaluating
N OG   *  y ( y*A  y A ) dy A
y A in
( yA  yA ) A in
yout

yA yA* (yA*-yA) 1/(yA*-yA)

yA in   
   
yin yA out   
• Use Equilibrium data related to process (e.g., x-y for absorption
and stripping) and the operating line (from mass balance).
• Obtain data of the integral in the given range and fill in the table
• Draw yA vs. 1/(yA *- yA)
• Then find area under the curve graphically or numerically 18
 Distillation random case

Equilibrium line

operating lines

19
 Simpson’s Rule for approximating the integral
7 point Simpson’s rule:
X6

 f ( X ) dX 
h
 f ( X 0 )  4 f ( X 1 )  2 f ( X 2 )  4 f ( X 3 )  2 f ( X 4 )  4 f ( X 5 )  f ( X 6 )
X0
3

h 6
X  X 0 
6

5 points Simpson’s rule:

X 4  X 0 
X4

 f ( X ) dX 
h
 f ( X 0 )  4 f ( X 1 )  2 f ( X 2 )  4 f ( X 3 )  f ( X 4 ) h
X0
3 4

3 points Simpson’s rule:

X2

 f ( X ) dX 
h
 f ( X 0 )  4 f ( X 1 )  f ( X 2 ) h
X 2  X 0 
X0
3 2
20
ABSORPTION/STRIPPING IN PACKED COLUMNS

Ref.: Seader and Henley

L' L'
Yn1  X n  (Y1  X o )
V' V' 21
22
23
 Counter-current Absorption (local gas phase)
Y
Y out X in
Y in Y1

Y2

Y3
Y3 i
Y4

Y out Y5 Y in X out

X in X out X
 kxa
slope 
kya
24
 Counter-current Absorption (overall gas phase)
Y
Y out X in
Y in Y1

Y2

Y3
vertical
Y4
Y3 *
Y out Y5 Y in X out

X in X out X

25
Counter-current Absorption (local liquid phase)
 kxa
Y
slope 
kya
Y out X in
Y in

Y out Y in X out

X1 X2 X3 X3 i X 4 X
X in X out
26
Counter-current Absorption (overall liquid phase)
Y
Y out X in
Y in

horizontal

Y out Y in X out
X3 *
X1 X2 X3 X4 X
X in X out
27
Note: This exercise (from Seader and Henley) was solved using an equation
based on a certain approximation. You need to re-solve it graphically using
Simspon’s rule and compare the results.
28
29
30
 Stripping Exercise
Wankat 15D8
We wish to strip SO2 from water using air at 20C.
The inlet air is pure. The outlet water contains
0.0001 mole fraction SO2, while the inlet water
contains 0.0011 mole fraction SO2. Operation is
at 855 mmHg and L/V = 0.9×(L/V)max. Assume
HOL = 2.76 feet and that the Henry’s law
constant is 22,500 mmHg/mole frac SO2.

Calculate the packing height required.

31
Solution  Ptot = 855 mmHg
 H = 22,500 mmHg SO2 /mole frac SO2
Water
T = 20C
P = 855 mmHg
L  pSO2 = H xSO2
xin = 0.0011
= 11104  ySO2 Ptot = H xSO2
 ySO2 = (H/ Ptot) x SO2
or ySO2 = m x SO2
where m = (H/ Ptot) = 22,500/855
= 26.3 (used to draw equilibrium
data)
Draw over the range of interest,
i.e., from x=0 to x= 11104
Air (solvent)
at x= 0  y = 0
V xout = 0.0001 at x= 11104  y = 26.3 * 11104
yin = 0 = 1104 = 0.02893 = 28.93 104
32
 40

35

30

25
y SO2 103

20

15

10

0
0 2 4 6 8 10 12 14 16
xout xin
1104 11104
x SO2 104 33
 V(yout – yout) = L( xin-xout)  V(yout – 0) = L( 11x10-4-1x10-4)
yout= 10x10-4 (L/V)

(L/V) = 0.9 (L/V)max

From pinch point and darwing, (L/V)max = slope= 29.29
 (L/V) = 0.9  29.29 = 26.36

yout= 10x10-4 (L/V) = 10x10-4  26.36

 yout = 0.02636 = 26.36103

Draw actual operating line

34
 40

35

30

25
y SO2 103

20

15

10

0
0 2 4 6 8 10 12 14 16
xout xin
1104 11104
x SO2 104 35
 30

25

20
y SO2  103

15

10

0
0 2 4 6 8 10 12
x SO2  104
36
 30

25

20
y SO2 103

15

10

0
0 2 4 6 8 10 12
x SO2 104
37
 x x* 1/(x-x*) Apply a graphical
1.0E-4 0 10,000 or numerical
3.0E-04 2.0E-04 10,000 method for
5.0E-04 4.0E-04 10,000 evaluating NOL
7.0E-04 6.0E-04 10,000 x A in0.0011
dx
9.0E-04
1.1E-03
8.0E-04
1.0E-03
10,000
10,000

x A out 0.0001
( x A  x *
A)

For example, we can use Simpson’s rule. The 7 point

Simpson’s rule defined as follows:
X6

 f ( X ) dX 
h
 f ( X 0 )  4 f ( X 1 )  2 f ( X 2 )  4 f ( X 3 )  2 f ( X 4 )  4 f ( X 5 )  f ( X 6 )
X0
3

h
X 6  X 0 
6
X6
X 6  X 0   f ( X )  4 f ( X 1 )  2 f ( X 2 )  4 f ( X 3 )  2 f ( X 4 )  4 f ( X 5 )  f ( X 6 )

X0
f ( X ) dX 
63
0

38
X6
X 6  X 0   f ( X )  4 f ( X 1 )  2 f ( X 2 )  4 f ( X 3 )  2 f ( X 4 )  4 f ( X 5 )  f ( X 6 )

X0
f ( X ) dX 
63
0

x A in0.0011
dx

1
f (X ) 
x A out 0.0001
( x A  x *
A)
( x  x* )

Substituting values from Table gives NOL= 9.5.

Z = HOL(given)  NOL(calculated) = 2.76  9.5

 Z = 26.22 ft

39
 5-point method
X4

 f ( X ) dX 
h
 f ( X 0 )  4 f ( X 1 )  2 f ( X 2 )  4 f ( X 3 )  f ( X 4 )
X0
3

h
 X4  X0 
4

Pay attention to accuracy

of drawing and obtaining
data.
Grades will be subtracted
in case of hand drawing!

40
Distillation in a Packed Column
Read Section 15.2 Wankat 2nd Ed.
Or Section 16.1 Wankat 3rd Ed.

41
1. Feed
2. Distillate
3. Bottom
4. Reflux
5. Boilup

6. Rectifying section
7. Striping section
8. Condenser
9. Re-boiler

10. Tray (plate or stage)

11. Number of Trays
12. Feed tray

42
𝑉 𝐿 Rectifying

𝑉 𝐿 Stripping

43
 Equilibrium and Operating Lines
Graphical
Design
Method

Binary
mixtures

44
 Rectifying section Stripping section

HTU NTU HTU NTU

𝑉 𝑦 𝑜𝑢𝑡
𝑉 𝑦 𝑜𝑢𝑡
𝐻𝐺 = 𝑑𝑦𝐴 𝑑𝑦𝐴
𝑘 𝑦 𝑎 𝐴𝑐 𝑁𝐺 = 𝐻𝐺 = 𝑁𝐺 =
𝑦𝐴𝑖 − 𝑦𝐴 𝑘𝑦 𝑎 𝐴𝑐 𝑦𝐴𝑖 − 𝑦𝐴
𝑦 𝑖𝑛 𝑦 𝑖𝑛
𝐿 𝑥 𝑖𝑛
𝐻𝐿 = 𝑑𝑥𝐴 𝐿 𝑥 𝑖𝑛
𝑘 𝑥 𝑎 𝐴𝑐 𝑁𝐿 = 𝐻𝐿 = 𝑑𝑥𝐴
𝑥𝐴 − 𝑥𝐴𝑖 𝑘𝑋 𝑎 𝐴𝑐 𝑁𝐿 =
𝑥 𝑜𝑢𝑡 𝑥𝐴 − 𝑥𝐴𝑖
𝑥 𝑜𝑢𝑡
𝑉 𝑦 𝑜𝑢𝑡
𝐻𝑂𝐺 = 𝑑𝑦𝐴 𝑉 𝑦 𝑜𝑢𝑡
𝐾𝑦 𝑎 𝐴𝑐 𝑁𝑂𝐺 = 𝐻𝑂𝐺 = 𝑑𝑦𝐴
𝑦𝐴∗ − 𝑦𝐴 𝐾𝑦 𝑎 𝐴𝑐 𝑁𝑂𝐺 =
𝑦 𝑖𝑛 𝑦𝐴∗ − 𝑦𝐴
𝑦 𝑖𝑛
𝐿 𝑥 𝑜𝑢𝑡
𝐻𝑂𝐿 = 𝑑𝑥𝐴 𝑥 𝑜𝑢𝑡
𝐾𝑥 𝑎 𝐴𝑐 𝑁𝑂𝐿 = 𝐿 𝑑𝑥𝐴
𝑥𝐴 − 𝑥𝐴∗ 𝐻𝑂𝐿 = 𝑁𝑂𝐿 =
𝑥 𝑖𝑛 𝐾𝑥 𝑎 𝐴𝑐 𝑥𝐴 − 𝑥𝐴∗
𝑦𝐴𝑖 −𝑦𝐴 −𝑘𝑥 𝑎 −𝐿 𝐻𝐺 𝑥 𝑖𝑛
Slope of tie line = =
𝑥𝐴𝑖 −𝑥𝐴 𝑘𝑦 𝑎 𝑉 𝐻𝐿 𝑦𝐴𝑖 −𝑦𝐴 −𝑘𝑥 𝑎 −𝐿 𝐻𝐺
Slope of tie line = =
𝑥𝐴𝑖 −𝑥𝐴 𝑘𝑦 𝑎 𝑉 𝐻𝐿
45
 xA
y Ai  y A  k x a L H G
xA i  
yA i x Ai  x A kya V HL
yA

46
Example 15-1 Wankat (pages 109 and 509)

47
Distillation Exercise 15D4 (Wankat)

48
49
50
 ya yai (yai-ya) 1/(yai-ya)

0.04 0.13 0.09 11.11

0.3225 0.455 0.1325 7.55
0.605 0.63 0.025 40.00
0.605 0.62 0.015 66.67
0.7625 0.8 0.0375 26.67
0.92 0.95 0.03 33.33

51
Diameter calculation of Packed Columns
• Read sections 10.7 to 10.9 Wankat (2nd or 3rd
Ed.)

52