Kb method in distillation

The "Kb method" in distillation refers to the shortcut method of determining the number of
theoretical plates required for separation in a distillation column. It involves using the
difference in boiling points (ΔT) between the components being separated and the overall
separation factor (K) to calculate the number of theoretical plates needed for a desired
separation. The equation is:

Number of theoretical plates (N) = (ΔT / K)

This method is a simplified approach compared to rigorous distillation calculations but is

often used for initial design estimations.

Problem 1:A mixture of two components, A and B, with boiling points of 80°C and 100°C,
respectively. The separation factor (K) between the two components is 1.5. Determine the
number of theoretical plates needed to achieve 90% separation efficiency using the Kb
method.

Solution:

1. Calculate the difference in boiling points (ΔT): ΔT = Boiling point of B - Boiling

point of A = 100°C - 80°C = 20°C
2. Use the separation factor (K) and the formula N = (ΔT / K) to find the number of
theoretical plates: N = ΔT / K = 20°C / 1.5 ≈ 13.3
3. Since we can't have a fraction of a plate, we round up to the nearest whole number: N
≈ 14 theoretical plates

So, to achieve 90% separation efficiency, you would need approximately 14 theoretical plates
in your distillation column.
Problem 2:

Separating a binary mixture consisting of components C and D. The boiling points of C and
D are 60°C and 80°C, respectively. The separation factor (K) between the two components is
2. Calculate the number of theoretical plates required to achieve 80% separation efficiency
using the Kb method.

Solution:

1. Calculate the difference in boiling points (ΔT): ΔT = Boiling point of D - Boiling

point of C = 80°C - 60°C = 20°C
 2. Use the separation factor (K) and the formula N = (ΔT / K) to find the number of
theoretical plates: N = ΔT / K = 20°C / 2 = 10 theoretical plates
3. Since the desired separation efficiency is 80%, we need to account for this by
multiplying the number of theoretical plates by the efficiency factor: Efficiency factor
= Desired separation efficiency / Actual separation efficiency = 0.80 / 1.00 = 0.80
Number of theoretical plates needed = 10xEfficiency factor = 10 x0.80 = 8

So, to achieve 80% separation efficiency, you would need approximately 8 theoretical plates
in your distillation column.
The Lewis-Matheson method
The Lewis-Matheson method, also known as the Lewis method or the Modified Shortcut
Method, is a simplified technique used for the preliminary design of distillation columns. It
provides an estimation of the number of theoretical stages required for separation based on
the relative volatilities of the components in the mixture.

The method uses the relative volatilities (α-values) of the components, along with the desired
separation factor (K-value) and the reflux ratio (R), to calculate the number of theoretical
stages (N) needed for separation.

The Lewis-Matheson equation is:

N=log10((R+1)K)/ log10(α)

Where:

 R = Reflux ratio (ratio of reflux to distillate flow rates)

 K = Separation factor (ratio of compositions in the liquid and vapor phases)
 α = Relative volatility (ratio of vapor pressures at a given temperature)

Problem 1:Designing a distillation column to separate a binary mixture of components A and

B. The relative volatility (α) between A and B is 2.5, and the desired separation factor (K) is
1.8. Determine the number of theoretical stages required using the Lewis-Matheson method,
assuming a reflux ratio (R) of 2.

Solution: Lewis-Matheson equation:

N=log10((R+1)K)/log10(α)

Given:

 Relative volatility (α) = 2.5

 Separation factor (K) = 1.8
 Reflux ratio (R) = 2
 N=log10(3+1)×2)/ log101.5

N=log10(8)/log10(1.5)
Using logarithmic properties:
N≈5.13
N≈6

Approximately 6 theoretical stages in your distillation column to achieve the desired

separation efficiency using the Lewis-Matheson method with a reflux ratio of 3.
Different types or Methods of distillation

1. Simple Distillation:
 Uses: Separation of components with significantly different boiling points.
 Advantages: Simple setup, suitable for purifying liquids with a large
difference in boiling points.
 Disadvantages: Inefficient for separating components with close boiling
points, does not provide high purity.
 Limitations: Limited separation efficiency for mixtures with close boiling
points.
 Applications: Purification of water, purification of organic solvents,
production of alcoholic beverages.
Boiling Point Range: Large difference in boiling points between components.
Example:
 Component A: Boiling point = 60°C
 Component B: Boiling point = 100°C
 Boiling point range = 40°C

2. Fractional Distillation:
  Uses: Separation of components with closer boiling points by utilizing a
fractionating column.
 Advantages: Higher separation efficiency compared to simple distillation,
suitable for separating components with similar boiling points.
 Disadvantages: Requires more complex equipment, higher energy
consumption.
 Limitations: Limited effectiveness for mixtures with extremely close boiling
points.
 Applications: Petroleum refining, separation of crude oil into its fractions
(e.g., gasoline, diesel, kerosene).
Boiling Difference
Component Boiling Point Range (°C) (ΔT, °C)
A 80-90 10
B 100-110 10
C 150-160 10
D 200-205 5

3. Steam Distillation:

 Cooking: Extracts flavors from vegetables.

 Tea making: Draws out flavors from tea leaves.
 Essential oil extraction: Separates oils from plants.
 Alcohol distillation: Separates alcohol from water.
 Laboratory purification: Separates components based on boiling points.
  Uses: Extraction of volatile compounds from organic substances, especially
when they are sensitive to heat.
 Advantages: Gentle extraction process, suitable for heat-sensitive
compounds.
 Disadvantages: Limited to volatile and heat-sensitive compounds, may not be
suitable for non-volatile compounds.
 Limitations: In effective for separating non-volatile components.
 Applications: Extraction of essential oils from plants, purification of natural
compounds.
 Examples:
Steam Distillation Boiling Point Difference:

 Example:
 Compound A: 90°C
 Compound B: 130°C
 Boiling Point Difference: 40°C


4. Vacuum Distillation:
 Uses: Distillation at reduced pressure to lower the boiling points of
components, suitable for heat-sensitive materials.
 Advantages: Lower operating temperatures, reduced risk of thermal
degradation.
 Disadvantages: Requires specialized equipment, higher initial investment.
 Limitations: Limited to substances stable under vacuum conditions.
 Applications: Refining of heat-sensitive compounds, separation of high-
boiling point mixtures.

5. Azeotropic Distillation:

Original Azeotrope Boiling Azeotropic Distillation Boiling Point

Components Point Difference
A+B 80°C 70°C (with entrainer)

This table demonstrates how azeotropic distillation, with the addition of an entrainer,
can lower the boiling point from the original azeotrope.

 Breaks azeotropes by adding a third component.

 Forms a new azeotrope, separating components.
 Widely used in industries like petrochemicals and pharmaceuticals.
 Enables high-purity separation of close-boiling mixtures.

 Uses: Breaks azeotropic mixtures by adding a third component or using

different pressures or temperatures.
 Advantages: Effective for separating azeotropic mixtures, high purity
achievable.
 Disadvantages: Requires additional components or complex process
conditions.
  Limitations: Dependent on the availability of suitable entrainers or
conditions.
 Applications: Production of high-purity chemicals, separation of azeotropic
mixtures in chemical manufacturing.

6. Extractive Distillation:

Uses:

 Separating close-boiling or azeotropic mixtures.

 Extracting high-purity products from complex mixtures.

Applications:

 Petrochemical industry: separating ethanol-water mixtures.

 Pharmaceutical industry: purifying isopropanol from water.
 Chemical processing: separating acetic acid from methyl acetate.
 Advantages:
 Enhances separation efficiency.
 Selectively interacts with one component, altering its volatility.
 Enables extraction of high-purity products.

Disadvantages:

 Requires additional solvent.

 Potential for solvent recycling challenges.
 Sensitivity to solvent composition and impurities.

Limitations:

 Limited to systems where an appropriate solvent is available.

 Increased operational complexity compared to simple distillation methods.

Boiling Point Range with

Mixture Original Boiling Point Range Extractive Distillation
~78.4°C (ethanol) - ~100°C
Ethanol-Water (water) ~70-90°C (with solvent)
~82.3°C (isopropanol) - ~100°C
Isopropanol-Water (water) ~75-90°C (with solvent)
Acetic Acid-Methyl ~118.1°C (acetic acid) - ~57.8°C
Acetate (methyl acetate) Varies based on solvent used

7. Reactive Distillation:
 Integrates reaction and separation.
 Conducts reaction within distillation column.
 Allows continuous product removal.
 Enhances yield and purity.
  Reduces energy consumption and capital costs.
 Widely used in industries like petrochemicals and pharmaceuticals.

Disadvantages and Limitations:

 Complex design and operation.

 Difficult control due to coupled reaction and separation.
 Limited to reactions suitable for continuous operation.
 Sensitivity to impurities and catalyst deactivation.
 Potential for higher maintenance requirements.

Applications:

 Petrochemical industry: for the production of fuels, plastics, and chemicals.

 Pharmaceutical industry: for the synthesis of active pharmaceutical ingredients.
 Fine chemicals industry: for specialty chemical production.
 Environmental applications: for waste treatment and pollutant removal.


 Types of distillation columns


 Batch Distillation Column: Processes finite feed amounts until desired separation.
 Continuous Distillation Column: Feed continuously added, products continuously
withdrawn.
 Fractionating Column: Separates mixtures into fractions based on boiling points.
 Packed Column: Contains packing material for increased vapor-liquid contact.
 Tray Column: Uses perforated trays or plates for vapor-liquid contact.
 Reactive Distillation Column: Integrates distillation and chemical reactions.
 Azeotropic Distillation Column: Breaks azeotropes through special techniques.
 Extractive Distillation Column: Uses third component to alter volatility for
separation.

Tray Column
Seive plate
 Seive plate

 Utilized for general distillation operations.

 Suitable for handling foaming systems.
 Offers good vapor-liquid contact.

Bubble Cap Tray:
 Effective for high vapor rates and deep vacuum conditions.
 Provides better liquid distribution and resistance to fouling.
 Commonly used in vacuum distillation and high-pressure processes.

Valve Tray:
 Offers flexibility in operation and efficient liquid-vapor distribution.
 Suitable for systems with high liquid rates.
 Allows for better control of weeping and entrainment.

 


Fixed Valve Tray:

Provides stable operation and ease of maintenance.
Suitable for applications with moderate to high liquid rates and fouling tendencies.
Offers improved resistance to pressure drop fluctuations.

Floating Valve Tray:
 Offers improved flexibility and efficiency compared to fixed valve trays.
 Suitable for systems with variable operating conditions.
 Provides better control of liquid level and weeping.

 Packed Distillation Columns:
 Filled with packing material for increased surface area.
 Common types: random packing, structured packing.
 Suitable for high liquid loads, low pressure drop.
 Widely used in petrochemicals, pharmaceuticals.
 Advantages: lower pressure drop, higher efficiency.
 Disadvantages: limited to certain conditions, potential fouling.
common types of packing materials used in distillation columns:

he types of packing that exist include Raschig rings, Pall rings, Berl saddle ceramic rings,
Intalox saddle ceramic rings, metal hypac and super Intalox ceramic rings. Three different
types of plates exist: sieve plate (perforated plate), bubble-cup plates and valve plates
(floating cap plates).
 Raschig Rings: Traditional cylindrical rings made of ceramic, metal, or plastic.
 Pall Rings: Open cylindrical rings with several internal and external structural
features.
 Berl Saddles: Large, hollow cylindrical structures with smooth surfaces.
 Intalox Saddles: Resembles a series of inverted funnels stacked on top of each other.
 Structured Packing: Consists of specially designed geometric shapes such as
corrugated sheets or wire mesh.
 Metal Pall Rings: Similar to traditional pall rings, but made entirely of metal.
 Ceramic Intalox Saddles: Structured ceramic packing with the shape of a saddle.
 Metal Grid Packing: Consists of metal grids or mesh arranged in a structured
manner.
 Plastic Intalox Saddles: Plastic version of the structured saddle packing.
 Cascade Mini Rings: Small cylindrical rings with internal and external structural
features.


 Packing Materials:
Random Packing:

When Used: Suitable for general distillation operations, especially in systems with
low to moderate liquid loads.
Advantages: Offers high void space, low pressure drop, and ease of handling.
Disadvantages: May experience channeling at high liquid rates, limited efficiency
compared to structured packing.
Application: Commonly used in applications where cost-effectiveness and simplicity
are prioritized.

 Structured Packing:
 When Used: Preferred for high-efficiency separation processes, especially in systems
with high liquid loads and strict separation requirements.
Advantages: Provides uniform flow distribution, high mass transfer rates, and
superior separation efficiency.
Disadvantages: Higher initial cost, potential for fouling in some applications.
Application: Widely used in industries such as petrochemicals, where high efficiency
and capacity are critical.

Ceramic Packing:
When Used: Suitable for corrosive environments and high-temperature applications.
Advantages: Offers excellent chemical resistance and thermal stability.
Disadvantages: Higher initial cost, brittle material may break under mechanical
stress.
Application: Used in processes involving acidic or alkaline solutions, as well as high-
temperature distillation operations.

Metal Packing:
When Used: Preferred for high-pressure and high-temperature applications.
Advantages: Provides excellent mechanical strength and durability.
Disadvantages: Higher cost compared to other packing materials.
Application: Commonly used in industries such as oil refining and chemical
processing, where extreme conditions are encountered.

Plastic Packing:
When Used: Suitable for applications requiring resistance to corrosion and low
pressure drop.
Advantages: Lightweight, corrosion-resistant, and cost-effective.
Disadvantages: May deform at high temperatures, limited compatibility with certain
solvents.
Application: Used in environmental engineering, wastewater treatment, and air
pollution control processes.