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Jai Ganesh

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Registered: 2005-06-28

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Re: Miscellany

2476) Fractional Distillation

Gist

Fractional distillation is the most common form of separation technology used in petroleum refineries, petrochemical and chemical plants, natural gas processing and cryogenic air separation plants. In most cases, the distillation is operated at a continuous steady state.

Fractional distillation is a method to separate a liquid mixture into its parts (fractions) by heating it, relying on the components' different boiling points, especially when those boiling points are close (less than 25°C apart). It uses a fractionating column with obstacles to create multiple cycles of vaporization and condensation, allowing for a purer separation of components than simple distillation. 

Summary

The various components of crude oil have different sizes, weights and boiling temperatures; so, the first step is to separate these components. Because they have different boiling temperatures, they can be separated easily by a process called fractional distillation. The steps of fractional distillation are as follows:

* You heat the mixture of two or more substances (liquids) with different boiling points to a high temperature. Heating is usually done with high pressure steam to temperatures of about 1112 degrees Fahrenheit / 600 degrees Celsius.
* The mixture boils, forming vapor (gases); most substances go into the vapor phase.
* The vapor enters the bottom of a long column (fractional distillation column) that is filled with trays or plates. The trays have many holes or bubble caps (like a loosened cap on a soda bottle) in them to allow the vapor to pass through. They increase the contact time between the vapor and the liquids in the column and help to collect liquids that form at various heights in the column. There is a temperature difference across the column (hot at the bottom, cool at the top).
* The vapor rises in the column.
* As the vapor rises through the trays in the column, it cools.
* When a substance in the vapor reaches a height where the temperature of the column is equal to that substance's boiling point, it will condense to form a liquid. (The substance with the lowest boiling point will condense at the highest point in the column; substances with higher boiling points will condense lower in the column.).
* The trays collect the various liquid fractions.
* The collected liquid fractions may pass to condensers, which cool them further, and then go to storage tanks, or they may go to other areas for further chemical processing.

Fractional distillation is useful for separating a mixture of substances with narrow differences in boiling points, and is the most important step in the refining process.

Very few of the components come out of the fractional distillation column ready for market. Many of them must be chemically processed to make other fractions. For example, only 40% of distilled crude oil is gasoline; however, gasoline is one of the major products made by oil companies. Rather than continually distilling large quantities of crude oil, oil companies chemically process some other fractions from the distillation column to make gasoline; this processing increases the yield of gasoline from each barrel of crude oil.

Details

Fractional distillation is the most common form of separation technology used in petroleum refineries, petrochemical and chemical plants, natural gas processing and cryogenic air separation plants. In most cases, the distillation is operated at a continuous steady state. New feed is always being added to the distillation column and products are always being removed. Unless the process is disturbed due to changes in feed, heat, ambient temperature, or condensing, the amount of feed being added and the amount of product being removed are normally equal. This is known as continuous, steady-state fractional distillation.

Industrial distillation is typically performed in large, vertical cylindrical columns known as "distillation or fractionation towers" or "distillation columns" with diameters ranging from about 0.65 to 6 meters (2 to 20 ft) and heights ranging from about 6 to 60 meters (20 to 197 ft) or more. The distillation towers have liquid outlets at intervals up the column which allow for the withdrawal of different fractions or products having different boiling points or boiling ranges. By increasing the temperature of the product inside the columns, the different products are separated. The "lightest" products (those with the lowest boiling point) exit from the top of the columns and the "heaviest" products (those with the highest boiling point) exit from the bottom of the column.

For example, fractional distillation is used in oil refineries to separate crude oil into useful substances (or fractions) having different hydrocarbons of different boiling points. The crude oil fractions with higher boiling points:

* have more carbon atoms
* have higher molecular weights
* are less branched-chain alkanes
* are darker in color
* are more viscous
* are more difficult to ignite and to burn

Large-scale industrial towers use reflux to achieve a more complete separation of products. Reflux refers to the portion of the condensed overhead liquid product from a distillation or fractionation tower that is returned to the upper part of the tower as shown in the schematic diagram of a typical, large-scale industrial distillation tower. Inside the tower, the reflux liquid flowing downwards provides the cooling needed to condense the vapors flowing upwards, thereby increasing the effectiveness of the distillation tower. The more reflux is provided for a given number of theoretical plates, the better the tower's separation of lower boiling materials from higher boiling materials. Alternatively, the more reflux provided for a given desired separation, the fewer theoretical plates are required.

Crude oil is separated into fractions by fractional distillation. The fractions at the top of the fractionating column have lower boiling points than the fractions at the bottom. All of the fractions are processed further in other refining units.

Fractional distillation is also used in air separation, producing liquid oxygen, liquid nitrogen, and highly concentrated argon. Distillation of chlorosilanes also enable the production of high-purity silicon for use as a semiconductor.

In industrial uses, sometimes a packing material is used in the column instead of trays, especially when low-pressure drops across the column are required, as when operating under vacuum. This packing material can either be random dumped packing (1–3 in (25–76 mm) wide) such as Raschig rings or structured sheet metal. Typical manufacturers are Koch, Sulzer, and other companies. Liquids tend to wet the surface of the packing and the vapors pass across this wetted surface, where mass transfer takes place. Unlike conventional tray distillation in which every tray represents a separate point of vapor liquid equilibrium the vapor-liquid equilibrium curve in a packed column is continuous. However, when modeling packed columns it is useful to compute several "theoretical plates" to denote the separation efficiency of the packed column concerning more traditional trays. Differently shaped packings have different surface areas and porosity. Both of these factors affect packing performance.

Design and operation of a distillation column depends on the feed and desired products. Given a simple, binary component feed, analytical methods such as the McCabe–Thiele method or the Fenske equation can be used. For a multi-component feed, simulation models are used both for design and operation.

Moreover, the efficiencies of the vapor-liquid contact devices (referred to as plates or trays) used in distillation columns are typically lower than that of a theoretical 100% efficient equilibrium stage. Hence, a distillation column needs more plates than the number of theoretical vapor-liquid equilibrium stages.

Reflux refers to the portion of the condensed overhead product that is returned to the tower. The reflux flowing downwards provides the cooling required for condensing the vapors flowing upwards. The reflux ratio, which is the ratio of the (internal) reflux to the overhead product, is conversely related to the theoretical number of stages required for efficient separation of the distillation products. Fractional distillation towers or columns are designed to achieve the required separation efficiently. The design of fractionation columns is normally made in two steps; a process design, followed by a mechanical design. The purpose of the process design is to calculate the number of required theoretical stages and stream flows including the reflux ratio, heat reflux, and other heat duties. The purpose of the mechanical design, on the other hand, is to select the tower internals, column diameter, and height. In most cases, the mechanical design of fractionation towers is not straightforward. For the efficient selection of tower internals and the accurate calculation of column height and diameter, many factors must be taken into account. Some of the factors involved in design calculations include feed load size and properties and the type of distillation column used.

The two major types of distillation columns used are tray and packing columns. Packing columns are normally used for smaller towers and loads that are corrosive or temperature-sensitive or for vacuum service where pressure drop is important. Tray columns, on the other hand, are used for larger columns with high liquid loads. They first appeared on the scene in the 1820s. In most oil refinery operations, tray columns are mainly used for the separation of petroleum fractions at different stages of oil refining.

In the oil refining industry, the design and operation of fractionation towers is still largely accomplished on an empirical basis. The calculations involved in the design of petroleum fractionation columns require in the usual practice the use of numerable charts, tables, and complex empirical equations. In recent years, however, a considerable amount of work has been done to develop efficient and reliable computer-aided design procedures for fractional distillation.

Additional Information

The inside of a fractional distilling column has sets of perforated trays. Each perforation is fitted with a bubble cap. Very hot, vaporized crude oil is pumped into the bottom of the column and rises up through the perforations. The bubble cap forces the oil vapor to bubble through liquid on the tray. This causes the vapor to cool as it flows upward and to condense into liquids. Excess liquid overflows through a pipe called a downcomer to the tray below. At various levels in the column, liquid is drawn off. The heavier products, such as straight-run heavy gas oil, are taken from the bottom part of the column and the lighter products, such as straight-run gasoline, are taken from the top. Straight-run natural gas comes out the top, and straight-run residuum comes out the bottom.

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