Distillation Column

Company Profile

PIONEER GROUP was founded in 2006, covered an area of 50,000㎡and has more than 200 employees. The headquarters of PIONEER GROUP which located in Zibo city, Shandong province - a famous manufacture base of chemical equipment in RR.China, also build two new manufacturing bases in Weifang city, Shandong province and Zhangye city, Gansu province.
Glass lined and stainless steel reactor, storage tank/receiver, distillation tank , film evaporator, vacuum dryer, filter, separator, heat exchanger, condenser, column systems and various accessories. Also can specializes in GMP standard products and customized operating unit of chemical process.

Why Choose Us

Our Factory
PIONEER GROUP is a professional design & manufacture in chemical equipment especially in glass lined equipment with advanced technology, completed production equipment, perfect quality control system and intimate sale and after-sale service.

Our Certificate
Certification of ISO 9001:2015, Design & manufacture License of pressure vessel, 10 Certificate of Patent

Production Equipment
CNC plasma cutting machine, CNC rolling machine, Automatic submerged arc welding machine, Swagging machine, Grinding machine, PLC control underground electric furnace, Coating room, Painting room, Spark tester, Thickness indicator, RT/MT tester, Hydraulic test machine and etc.

Our Service
The R&D department welcome customization with many years experience,we can design and order all kinds of glass lined and stainless steel products and non-standard products according to the requirements of customers.

Glass Lined Distillation Column

Glass lined column is usually assembled by several glass lined section.

Add to Inquiry

What is Distillation Column？

A distillation column is an essential item used in the distillation of liquid mixtures to separate the mixture into its component parts, or fractions, based on the differences in volatilities. Fractionating columns are used in small scale laboratory distillations as well as large scale industrial distillations.
A distillation column, or tower, is used to separate liquid mixtures into individual constituents based on their boiling points. The liquid is heated to produce vapours which are then condensed, by cooling, back into liquid form. The liquids are then collected in trays or plates positioned at different heights inside the column, their position based on the boiling point of each separate component.

Benefits of Distillation Column

High efficiency

Distillation columns are highly efficient at separating mixtures into their individual components, making them ideal for purifying and separating complex mixtures.

Versatility

Distillation columns can be designed and operated to separate a wide variety of mixtures, including liquids, gases, and multi-component mixtures.

High purity

The distillation process results in highly purified individual components, making it ideal for applications in the chemical and pharmaceutical industries.

Scalability

Distillation columns can be designed for small-scale or large-scale operations, making them suitable for a wide range of applications.

Safe

When designed and operated properly, distillation columns are a safe method for separating mixtures.

Type of Distillation Column

Batch distillation columns: These columns are used to separate a mixture in a single batch. They are commonly used for small-scale applications, such as the production of alcoholic beverages.

Continuous distillation columns: These columns are used to separate a mixture continuously, with the mixture being continuously fed into the column and the separated components being continuously withdrawn. They are commonly used in the petrochemical industry for the separation of crude oil into its various components.

Packed distillation columns: In this type of column, a packing material, such as ceramic or metal rings, is placed within the column to increase the surface area for vapor-liquid contact. This allows for more efficient mass transfer and improved separation.

Trayed distillation columns: In this type of column, trays or plates are placed at various heights within the column to allow for the separation of the mixture. The liquid components are collected on the trays, and the vapors are drawn off and condensed.

Short-path distillation columns: These columns use a shorter distillation path and are commonly used for the separation of high-boiling and high-molecular weight components, such as waxes, oils, and resins.

Fractionating columns: These are specialized columns used in the fractional distillation of mixtures. They are commonly used in the chemical and pharmaceutical industries for the separation of complex mixtures into their individual components.

What are the Essential Properties of Materials Used in Distillation Columns?

Thermal properties
One of the most important properties of materials used in distillation columns is their thermal conductivity, which determines how well they can transfer heat between the vapour and liquid phases. High thermal conductivity can reduce the temperature gradient and improve the mass transfer efficiency in the column.

Mechanical properties
Another key property of materials used in distillation columns is their mechanical strength, which affects their ability to withstand the pressure, weight, and vibration in the column. High mechanical strength can prevent the deformation, buckling, or failure of the column, the trays, or the packing, which can compromise the separation quality and safety.

Chemical properties
A third essential property of materials used in distillation columns is their chemical resistance, which determines how well they can resist corrosion, erosion, or fouling by the feed, the products, or the impurities in the column. High chemical resistance can increase the durability and reliability of the column, the trays, or the packing, which can reduce the maintenance and replacement costs.

Surface properties
A fourth important property of materials used in distillation columns is their surface area, which influences the contact area and the interfacial tension between the vapour and liquid phases. High surface area can enhance the mass transfer and the separation efficiency in the column, especially for packed columns that use random or structured packing. However, high surface area also means higher pressure drop and lower flow rate in the column, which can reduce the productivity and increase the energy consumption.

Catalytic properties
A fifth relevant property of materials used in distillation columns is their catalytic activity, which affects the rate and selectivity of the chemical reactions that occur in the column. High catalytic activity can increase the conversion and yield of the desired products in the column, especially for reactive distillation columns that combine reaction and separation in one unit.

Applications of Distillation Column

Petroleum Refining

In crude oil refining, distillation columns separate crude oil into fractions based on different boiling points, yielding valuable products like gasoline, diesel, and jet fuel.

Chemical Production

Distillation is vital in the production of chemicals, pharmaceuticals, and specialty chemicals, enabling the separation and purification of complex mixtures.

Beverage Industry

Distillation columns are integral to producing alcoholic beverages like whiskey, vodka, and gin. They separate alcohol from fermented mixtures to create high-proof spirits.

Environmental Applications

Distillation columns play a role in environmental processes such as water purification and wastewater treatment, removing impurities through separation.

Distillation Column Mode Of Operation

The distillation column working principle involves the separation of mixture components with varying boiling point. This way, vapor from a boiling mixture will mainly comprise of the element with a lower boiling point. Once this vapor is cooled, it condenses and the liquid formed will contain more of the volatile component; thus the original mixture will be left with more of the less volatile component.

Ideally, the mixture element with the lowest boiling point will vaporize first and the temperature remains constant until all substances are entirely evaporated.

Batch columns – in this operation, there is the introduction of a batch-wise feed to the column. This means that the column will be charged with a batch as the distillation process takes place. Once the desired results are achieved, the next batch is introduced, and the, cycle continues.

Continuous column – in this case, the distillation process is carried out in a continuous feed. This means that once the process is started, there are no interruptions until all the mixture is separated unless a problem occurs with the columns or other surrounding units. The continuous columns are designed to handle even high throughputs and happen to be the most commonly used in commercial industries.

Components of a Distillation Column

Reboiler:
Located at the bottom of the column, the reboiler is responsible for heating the liquid mixture to initiate vaporization. As heat is applied, the component with the lowest boiling point vaporizes and rises through the column.

Distillation Trays or Packing Materials:
These are situated within the column at specific intervals. They provide a surface area for vapor-liquid interaction, promoting equilibrium between the vapor and liquid phases. Trays consist of perforated plates placed horizontally across the column while packing materials (such as rings, saddles, or structured packing) increase surface area for better separation efficiency.

Column Shell:
The cylindrical body of the distillation column provides structural support and houses the trays or packing materials. It is designed to withstand the internal pressure and temperature conditions.

Condenser:
Positioned at the top of the column, the condenser cools down the vaporized components, causing them to condense back into liquid form. This condensed liquid is then collected and referred to as the distillate.

Distillate Receiver:
This is a vessel or container that collects the condensed distillate from the condenser. It is designed to separate the condensed liquid from any remaining vapor.

Reflux Drum:
The reflux drum is a vessel that collects and temporarily stores the returning reflux liquid before it is reintroduced into the column. It helps regulate the flow of reflux and prevents sudden disturbances in the column operation.

Bottoms Outlet:
Located at the bottom of the column, the bottom outlet allows the heavier components of the mixture to be withdrawn as a liquid stream. This stream may contain the least volatile components.

Column Internals:
These include various accessories and devices used to optimize column performance, such as distributors for even liquid distribution on trays, collectors for vapor distribution, and demisters to prevent the entrainment of liquid droplets in the vapor stream.

Pressure Relief System:
Distillation columns are operated under specific pressure conditions. A pressure relief system, such as safety valves or rupture discs, is incorporated to ensure the column’s integrity in case of pressure buildup.

What Causes Foaming in the Distillation Column?

During distillation, you may notice some foaming which can be a bit scary especially if you do not know its causes and effects. First of all, what does foaming in distillation means? This is the expansion of liquid which offers high constant between liquid and vapor. Although it is not common, the issue cannot be overlooked. Its major cause is the malfunction of the distillation equipment and could increase until the liquid in one tray mixes with the liquid on the tray above during the entrainment process. This is a process which decreases vapor-liquid equilibrium thus slowing down the process.

Trays
The design, placement, and condition of the trays can have a huge impact on the whole process and could result to foaming if not appropriately done take an example of a situation where the overhead disengaging area is not placed high enough. This can only mean that the trays will be closely placed above each other and therefore, in a case of liquid expansion, the liquid in the two trays, bottom and top will foam.

Vapor conditions
Foaming could result from passage of gas or vapor. This could happen due to a very high rate of gas velocity or a high rate of evaporation.

Liquid drop
This happens if liquid from the feeder hose falls on the sump and the higher the liquid drop, the lesser the created foam. This issue is more common in tray column sumps than in pack columns.

The liquid physical properties
The liquid's physical property can contribute to the creation of foam. The zero points of change far from PH will mean that the liquid has a bad acidity level. There are naturally occurring surfactants and ring polymers, both which reduce the fluid's surface tension. Any corrosion particles and any other solid articles could result in unwanted foam.

Wrong anti-foam agents
Use of ineffective antifoam agents is also a common cause of foam. The problem could be as a result of the wrong amount of the compound or using the wrong kind that does not go well with the fluid that intends to be distilled.

Troubleshooting and Maintenance of Distillation Columns

Performance Monitoring: Regular monitoring of key performance indicators (KPIs) such as product purity, reflux ratio, pressure drop, and temperature profiles can help identify potential issues early on.

Visual Inspection: Conducting visual inspections of the column internals, including trays or packing, to detect any signs of fouling, corrosion, or mechanical damage.

Pressure and Temperature Profiles: Analyzing pressure and temperature profiles along the column height to identify potential anomalies, such as hot spots, which could indicate tray or packing problems.

Liquid and Vapor Distribution: Ensuring proper liquid and vapor distribution across trays or packing by checking for uneven flow patterns, which can lead to reduced efficiency and poor separation performance.

Condenser and Reboiler Maintenance: Inspecting and cleaning condenser and reboiler tubes to prevent fouling and optimize heat transfer efficiency.

Safety Systems: Ensuring that safety systems, such as relief valves and pressure control devices, are in proper working condition to prevent overpressure incidents.

Cleaning Procedures: Developing and implementing regular cleaning procedures for removing fouling, deposits, or contaminants from trays, packing, and other column internals.

Our Certificate

Certification of ISO 9001:2015, Design & manufacture License of pressure vessel, 10 Certificate of Patent

20220427083423efc981ab9d014b0bad1369b38d15b7cb.jpg (900×524)

FAQ

Q: What is the distillation column?

A: A distillation column is a critical piece of equipment used primarily in the chemical processing industry to separate mixtures into their parts or fractions. This separation process is fundamental in the production of pure components from various mixtures.

Q: What is the basic principle of distillation column?

A: The basic principle behind the distillation of process is that different liquids boil at different temperatures. So when a mixture is heated, the substance with lower boiling point starts to boil first and convert into vapours which can be then collected separately.

Q: What is a distillation column in a refinery?

A: A distillation column is a critical piece of equipment in the refining of crude oil. It acts very much like a still, separating product into its different chemical components based on differences in volatility.

Q: What is the difference between a condenser and a distillation column?

A: A condenser cools the vapors that go up the column as it leaves the top of the unit. The condensed liquid is collected in a “reflux drum.” Some fluid is recirculated to the column top, referred to as “reflux.” The “distillate,” or top product, is the condensed liquid that comes out from the column.

Q: Do you need a condenser for distillation?

A: During distillation, vapors are formed in the heated distillation flask. The condenser cools these vapors condensing them back to liquid droplets that flow down the condenser into the receiver flask.

Q: How is a distillation column different from a separation column?

A: The distillation column is equipped with trays or plates that allow the vapor to rise and condense, thereby separating the different components. On the other hand, a separator is a device that separates two or more substances by exploiting differences in their physical properties such as density, size, and velocity.

Q: What is the other name for the distillation column?

A: It describes plate columns and packed columns as the two most widely used for distillation, gas absorption, and stripping. Plate columns are also known as tray columns, where the column is divided into stages by trays. The main types of trays are sieve, bubble-cap, and valve trays.

Q: What comes out of the bottom of a distillation column?

A: The vapour raised in the reboiler is re-introduced into the unit at the bottom of the column. The liquid removed from the reboiler is known as the bottoms product or simply, bottoms. The vapour moves up the column, and as it exits the top of the unit, it is cooled by a condenser.

Q: What are the principles of distillation column?

A: Distillation column mode of operation. As discussed earlier, the distillation column working principle involves the separation of mixture components with varying boiling point. This way, vapor from a boiling mixture will mainly comprise of the element with a lower boiling point.

Q: How to control a distillation column?

A: Reboiler and condenser heat duty: The primary means of controlling temperature in a distillation column is by adjusting the heat input (reboiler duty) and heat removal (condenser duty). Reflux ratio: Increasing the reflux ratio can lower the top section temperature, while decreasing it can raise the temperature.

Q: What is a simple explanation of distillation column?

A: A distillation column is a tube that provides surfaces on which condensations and vaporizations can occur before the gas enters the condenser in order to concentrate the more volatile liquid in the first fractions and the less volatile components in the later fractions.

Q: What is the difference between extraction column and distillation column?

A: While they are both separation techniques they differ in the following way: distillation separates on the basis of differences in boiling points of the components, while extraction separates on the basis of differences in solubility in the extracting solvent. Boiling point and solubility are not unrelated, however.

Q: What is the main part of distillation column?

A: These four main components are: Column (incorporating the enriching and stripping sections), where the liquid/gas phase separation takes place. Reboiler (heat exchanger), which provides the heat energy to partially vaporise the columns input feed (liquid) for the separation (distillation) process to take place.

Q: What is the liquid that leaves the condenser called?

A: Inside the condenser, the refrigerant vapor condenses into a liquid and is subcooled. This liquid refrigerant (D) then flows from the condenser to the expansion device. This device creates a pressure drop that reduces the pressure of the refrigerant to that of the evaporator.

Q: How to troubleshoot a distillation column?

A: Troubleshooting distillation columns begins with identifying the symptoms that indicate a problem. These can be determined from the column's operating conditions, such as pressure, temperature, flow rates, and compositions, or from the physical appearance of the column, like vapor plumes, noise, or vibration.

Q: How do you control a distillation column level?

A: It is generally better to control the level with the larger flow and control the composition with the smaller flow. However, the reflux flow has an immediate impact on composition while the distillate flow dynamics is slower as it must propagate back through the level and reflux flows to affect the composition.

Q: Why do distillation columns need reflux?

A: The purpose of reflux is to provide down-flowing liquid throughout the rectification section to contact with the up-flowing vapor in order to achieve stage-by-stage equilibrium heat and mass transfer and, hence, purification of the top product.

Q: What are the major problems in distillation column?

A: Distillation columns are known for their propensity to consume large amounts of energy, among other challenges. The main bottlenecks that hinder the separation process are: Fouling – Multiple factors, either independently or together can cause fouling tendencies in columns.

We're well-known as one of the leading distillation column manufacturers and suppliers in China. Please feel free to buy or wholesale high quality distillation column at competitive price from our factory. For more information, contact us now.