Short-cut methods for the optimal design of simple and complex distillation columns

New short-cut methods providing optimal design parameters for distillation columns with simple and complex configurations including two-feed and one-feed-one-side-stream columns are presented. The methods assume constant relative volatilities and constant molar flow rates within each distillation section. The design equations are based on the Underwood equations for the calculation of minimum reflux (reboil) ratio, the analytical formulations of the distillation line, the Eigenfunction and the number of theoretical stages for each mass transfer section of the column. Furthermore, the geometrical properties of a given separation are considered. Optimization algorithms based on the minimization of the total number of theoretical stages of the column with taking into account the mass balance at each feed section have been elaborated. In comparison to the boundary value method the new short-cut methods require a minimum number of specifications; they do not need any graphical support, and provide a lower total number of theoretical stages particularly for complex configurations. The new short-cut methods have been extended to the design of columns separating azeotropic mixtures by approximating the latter by appropriate pseudo-ideal mixtures. Several separation examples for azeotropic mixtures, including different types of splits as well as columns with simple and complex configurations were tested and show a very good agreement with the simulation results obtained with Radfrac (Aspenplus).

► The new design methods allow the optimal design of complex distillation columns.
► They are based on the design tools for ideal mixtures and the separation geometry.
► A minimum number of specifications are required for the design algorithms.
► The new short-cut methods are completely numerical.
► The new design methods are well suited for the screening of distillation sequences.