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1.Industrial fractionating columns
Fractional distillation is one of the unit operations of chemical engineering. Fractionating columns are widely used in the chemical process industries where large quantities of liquids have to be distilled. Such industries are petroleum processing, petrochemical production, natural gas processing, coal tar processing, brewing, liquified air separation, and hydrocarbon solvents production and similar industries but it finds its widest application in petroleum refineries. In such refineries, the crude oil feedstock is a complex, multi-component mixture that must be separated, and yields of pure chemical compounds are not expected, only groups of compounds within a relatively small range of boiling points, also called fractions. That is the origin of the name fractional distillation or fractionation. It is often not worthwhile separating the components in these fractions any further based on product requirements and economics.
Distillation is one of the most common and energy-intensive separation processes. The effectiveness of separation is dependent upon the height and diameter of the column, the ratio of the column's height to diameter, and the material that comprises the distillation column itself. In a typical chemical plant, it accounts for about 40% of the total energy consumption. Industrial distillation is typically performed in large, vertical cylindrical columns (as shown in Figure 2) known as "distillation towers" or "distillation columns" with diameters ranging from about 65 centimeters to 6 meters and heights ranging from about 6 meters to 60 meters or more.
Industrial distillation towers are usually operated at a continuous steady state. Unless disturbed by changes in feed, heat, ambient temperature, or condensing, the amount of feed being added normally equals the amount of product being removed.
The amount of heat entering the column from the reboiler and with the feed must equal the amount of heat removed by the overhead condenser and with the products. The heat entering a distillation column is a crucial operating parameter, the addition of excess or insufficient heat to the column can lead to foaming, weeping, entrainment, or flooding.
2.Applicable Industry:
All these products are widely used in the chemical process industries where large quantities of liquids have to be distilled. Such industries are petroleum processing, petrochemical production, natural gas processing, coal tar processing, brewing, liquified air separation, and hydrocarbon solvents production and similar industries but it finds its widest application in petroleum refineries.
The application of distillation can roughly be divided into four groups: laboratory scale, industrial distillation, a distillation of herbs for perfumery and medicinals (herbal distillate), and food processing. The latter two are distinctively different from the former two in that distillation is not used as a true purification method but more to transfer all volatiles from the source materials to the distillate in the processing of beverages and herbs.
The main difference between laboratory scale distillation and industrial distillation is that laboratory scale distillation is often performed on a batch basis, whereas industrial distillation often occurs continuously. In batch distillation, the composition of the source material, the vapors of the distilling compounds, and the distillate change during the distillation. In batch distillation, a still is charged (supplied) with a batch of feed mixture, which is then separated into its component fractions, which are collected sequentially from most volatile to less volatile, with the bottoms - remaining least or non-volatile fraction - removed at the end. The still can then be recharged and the process repeated.
In continuous distillation, the source materials, vapors, and distillate are kept at a constant composition by carefully replenishing the source material and removing fractions from both vapor and liquid in the system. This results in a more detailed control of the separation process.
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