CHE 501:

SEPARATION PROCESSES

Lecture 6: Fenske-Underwood-Gilliland Method

(Application to Multicomponent Distillation)

Engr. Michael Allan Ramos, M.Sc. M.Eng.Sc.

Assistant Professor, Chemical Engineering Department
College of Engineering and Architecture
Technological Institute of the Philippines – Manila

1st Semester, A.Y. 2019 - 2020

PC /TC
Multicomponent Rectification
REFLUX DISTILLATE
• This is a distillation application to a
multicomponent system where a
fractionating column is used. Rectifying Section
V L
FEED
• A Reflux Rate from a Condenser
and a Boil-up Rate from a Reboiler Stripping Section
!
𝐕 𝐋̅
generate the liquid and vapor flows
through several contact plates. BOIL-UP

• The Feed is introduced in a proper

BOTTOMS
plate; the section above the feed is PR
called the Rectifying Section; below
is the Stripping Section.
Plate Analysis

• As contact between liquid and vapor

occurs in each plate, the vapor becomes 𝑛−1 MVC
𝑥*,-
richer in MVC; while MVC is removed from 𝑦*
the liquid.
𝑛 MVC
• This means that the MVC fraction in the
𝑦*.- 𝑥*
vapor (y) increases from bottom to top and
the MVC fraction in the liquid (x) decreases 𝑛+1 MVC
from top to bottom.

∴ 𝑇*,- < 𝑇* < 𝑇*.-

Reflux Ratio and Number of Stages

• Generally, the higher the reflux ratio, the less number of stages will be required
to achieve certain degree of separation of two components.

• A total reflux operation would require the minimum number of stages

• A minimum reflux operation would require an infinite number of stages

Fenske-Underwood-Gilliland Method
• multicomponent shortcut methods for design approximation of simple distillation

• combines Fenske’s total reflux equation and Underwood’s minimum reflux

equation with a graphical correlation by Gilliland that relates actual column
performance to total and minimum reflux conditions for a specified separation
between two key components.

Fenske à Nmin
Underwood à Rmin
Gilliland à Actual R & N
Fenske’s Equation
• Fenske’s equation is used to calculate Nmin, which is the number of plates
required to make a specified separation at total reflux.

Perry’s Chemical Engineers’ Handbook / M.F. Doherty, Z.T. Fidkowski, M.F. Malone, R. Taylor. – 8th Edition
Underwood Equations
• The Underwood minimum reflux equations that apply when some of the
components do not appear in either the distillate or the bottom products at
minimum reflux are:

Perry’s Chemical Engineers’ Handbook / M.F. Doherty, Z.T. Fidkowski, M.F. Malone, R. Taylor. – 8th Edition
Gilliland Correlation
• The empirical correlation of Gilliland as shown in the graph below is used to give
N for any specified R, or R for any specified N.

Perry’s Chemical Engineers’ Handbook / M.F. Doherty, Z.T. Fidkowski, M.F. Malone, R. Taylor. – 8th Edition
Algorithm for Multicomponent Distillation by FUG

• The FUG method is convenient for new column

design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)

Separation Process Principles : Chemical and Biochemical Operations / J. D. Seader, Ernest J. Henley, D. Keith Roper.—3rd ed.
Illustrative Problem
100 kgmol/h of feed containing 0.5% acetaldehyde, 19% acrolein, 76% water, and
4.5% acrylic acid (all by mole basis) is to be processed in a distillation column. The
product streams obtained must conform with the following specifications:
(1) Distillate with water content of not more than 5%
(2) Bottoms with acrolein content of not more than 2%
Assuming a saturated liquid feed at feed tray condition, 2 psi pressure drop in the
condenser, 5 psi pressure drop in the column, determine the following:
a) Column Pressure and Type of condenser
b) Minimum number of ideal stages
c) Minimum Reflux Ratio
d) Number of ideal stages if the R = 1.2 Rmin, R = 1.5 Rmin, and R = 1.1 Rmin
Algorithm for Multicomponent Distillation by FUG

• The FUG method is convenient for new column

design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)

Separation Process Principles : Chemical and Biochemical Operations / J. D. Seader, Ernest J. Henley, D. Keith Roper.—3rd ed.
PC /TC

REFLUX DISTILLATE

Distillate xDi
Acetaldehyde
Acrolein
Water 0.05 (SET)
FEED
Acrylic Acid
Feed kmol/h xFi
Acetaldehyde 0.5 0.005
Acrolein 19 0.19
Water 76 0.76
BOIL-UP Bottoms xBi
Acrylic Acid 4.5 0.045
Acetaldehyde
Acrolein 0.02 (SET)
BOTTOMS Water
PR Acrylic Acid
Initial Estimate of splits of components
Assume Split: kmol/h
Feed Distillate Bottoms
Acetaldehyde 0.5 0.4 0.1
LK Acrolein 19 18.5 0.5
HK Water 76 1 75
Acrylic Acid 4.5 1 3.5
Algorithm for Multicomponent Distillation by FUG

• The FUG method is convenient for new column

design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)

Separation Process Principles : Chemical and Biochemical Operations / J. D. Seader, Ernest J. Henley, D. Keith Roper.—3rd ed.
Distillation-column Pressure and Condenser Type

Separation Process Principles : Chemical and Biochemical Operations / J. D. Seader, Ernest J. Henley, D. Keith Roper.—3rd ed.
Distillation-column Pressure and Condenser Type
Condenser Pressure Set condenser temp 49 deg C 322.15K
Trial condenser pressure 84566.87147Pa

Distillate kmol/h xi Pisat Ki yi

Acetaldehyde 0.4 0.01914 252516.95942 2.98600 0.05715
LK Acrolein 18.5 0.88517 89341.83135 1.05646 0.93515
HK Water 1 0.04785 11752.08013 0.13897 0.00665
Acrylic Acid 1 0.04785 2325.62871 0.02750 0.00132
TOTAL 20.9 1.00026
Distillation-column Pressure and Condenser Type
Condenser Pressure Trial condenser temp 54.41 degC 327.559659K
Set condenser pressure 101325Pa

Distillate kmol/h xi Pisat Ki yi

Acetaldehyde 0.4 0.40000 0.01914 295440.84278 2.91577
LK Acrolein 18.5 18.50000 0.88517 107088.37425 1.05688
HK Water 1 1.00000 0.04785 15319.61528 0.15119
Acrylic Acid 1 1.00000 0.04785 3095.28258 0.03055
TOTAL 20.9 20.90000 1.00002
Distillation-column Pressure and Condenser Type
Top Temperature Trial top temp 75.35 degC 355.280473K
Set pressure (2psi drop) 115110.714Pa

Distillate kmol/h yi Pisat Ki xi

Acetaldehyde 0.4 0.01914 612131.53888 5.31776 0.00360
LK Acrolein 18.5 0.88517 246678.21501 2.14296 0.41306
HK Water 1 0.04785 51601.89754 0.44828 0.10673
Acrylic Acid 1 0.04785 11555.67926 0.10039 0.47662
TOTAL 20.9 1.00001
Distillation-column Pressure and Condenser Type

Bubble
Bottoms Temp Set pressure: Allowing 5 psi pressure drop: 149575Pa Temperature 384.73951K

Bottoms kmol/h xi Pisat Ki yi

Acetaldehyde 0.1 0.00126 1194641.35538 7.98691 0.01010
Acrolein 0.5 0.00632 522123.50656 3.49071 0.02207
Water 75 0.94817 150930.50746 1.00906 0.95676
Acrylic Acid 3.5 0.04425 37398.52314 0.25003 0.01106
79.1 0.99999
Algorithm for Multicomponent Distillation by FUG

• The FUG method is convenient for new column

design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)

Separation Process Principles : Chemical and Biochemical Operations / J. D. Seader, Ernest J. Henley, D. Keith Roper.—3rd ed.
Minimum No. of Ideal Stages
𝟎. 𝟖𝟖𝟓𝟏𝟕 𝟎. 𝟗𝟒𝟖𝟏𝟕
𝐥𝐨𝐠
𝑵𝒎𝒊𝒏 = 𝟎. 𝟎𝟒𝟕𝟖𝟓 𝟎. 𝟎𝟎𝟔𝟑𝟐 = 𝟓. 𝟔𝟓𝟏𝟗 𝒔𝒕𝒂𝒈𝒆𝒔
𝐥𝐨𝐠(𝟒. 𝟎𝟔𝟔𝟓𝟗)

Nmin Top Section Tdew 355.280473K

Component, i xi Ki alpha i/w
Acetaldehyde 0.01914 5.31776 11.86258 Component, i alpha mean
LK Acrolein 0.88517 2.14296 4.78041 Acetaldehyde 9.68991
HK Water 0.04785 0.44828 1.00000 Acrolein 4.06659
Acrylic Acid 0.04785 0.10039 0.22394 Water 1.00000
Acrylic Acid 0.23556

Bottom Section Tbubble 384.7395126K

Component, i xi Ki alpha i/w
Acetaldehyde 0.00126 7.98691 7.91517
LK Acrolein 0.00632 3.49071 3.45936
HK Water 0.94817 1.00906 1.00000
Acrylic Acid 0.04425 0.25003 0.24779
Algorithm for Multicomponent Distillation by FUG

• The FUG method is convenient for new column

design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)
Calculating splits of non-key components
Assumed Split: kmol/h
𝐷𝑥Q 𝐵𝑥S
Feed Distillate Bottoms αNOM*
M =
𝐵𝑥S 𝐷𝑥Q
Acetaldehyde 0.5 0.4 0.1 M T
LK Acrolein 19 18.5 0.5 𝐷𝑥Q 1
HK Water 76 1 75 αU.VU-W
M =
𝐹𝑥Y − 𝐷𝑥Q 0.013333
Acrylic Acid 4.5 1 3.5 M
TOTAL 100 20.9 79.1
𝐷𝑥Q 1 (0.013333) (𝛼MU.VU-W)
= = 0.013333 (Dx^)M = U.VU-W 𝐹𝑥Y M
𝐵𝑥S `abcT 75 1 + (0.013333) (𝛼M )

355.28047 384.73951
Component, i FxFi alpha top alpha bottom alpha i DxDi BxBi xDi xBi
Acetaldehyde 0.5 11.86258 7.91517 9.68991 0.49990 0.00010 0.02500 0.00000
LK Acrolein 19 4.78041 3.45936 4.06659 18.50004 0.49996 0.92501 0.00625
HK Water 76 1.00000 1.00000 1.00000 0.99998 75.00002 0.05000 0.93750
Acrylic Acid 4.5 0.22394 0.24779 0.23556 0.00002 4.49998 0.00000 0.05625
19.99993 80.00007 1.00000 1.00000
Algorithm for Multicomponent Distillation by FUG
Trial 2
• The FUG method is convenient for new column
design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)
Distillation-column Pressure and Condenser Type
Condenser Pressure Set condenser temp 49 deg C 322.15K
Trial condenser pressure 89530.24258Pa

Distillate kmol/h xi Pisat Ki yi

Acetaldehyde 0.49990 0.02500 252516.95942 2.82047 0.07050
LK Acrolein 18.50004 0.92501 89341.83135 0.99790 0.92306
HK Water 0.99998 0.05000 11752.08013 0.13126 0.00656
Acrylic Acid 0.00002 0.00000 2325.62871 0.02598 0.00000
TOTAL 19.99993 1.00012
Distillation-column Pressure and Condenser Type
Condenser Pressure Trial condenser temp 325.8437148K
Set condenser pressure 101325Pa

Distillate kmol/h xi Pisat Ki yi

Acetaldehyde 0.49990 0.02500 281256.92348 2.77579 0.06938
LK Acrolein 18.50004 0.92501 101180.60095 0.99857 0.92369
HK Water 0.99998 0.05000 14099.44934 0.13915 0.00696
Acrylic Acid 0.00002 0.00000 2830.09319 0.02793 0.00000
TOTAL 19.99993 1.00003
Distillation-column Pressure and Condenser Type
Top Temperature Trial top temp 336.5994049K
Set pressure (2psi drop) 115110.714Pa

Distillate kmol/h yi Pisat Ki xi

Acetaldehyde 0.49990 0.02500 379585.85040 3.29757 0.00758
LK Acrolein 18.50004 0.92501 142892.99336 1.24135 0.74516
HK Water 0.99998 0.05000 23345.38158 0.20281 0.24653
Acrylic Acid 0.00002 0.00000 4881.25026 0.04240 0.00002
TOTAL 19.99993 0.99929
Distillation-column Pressure and Condenser Type
Set pressure Bubble
Bottoms Temp Allowing 5 psi pressure drop: 135789.2857Pa Temperature 382.361156K

Bottoms kmol/h xi Pisat Ki yi

Acetaldehyde 0.00010 0.00000 1135385.48410 8.36138 0.00001
Acrolein 0.49996 0.00625 493549.34868 3.63467 0.02271
Water 75.00002 0.93750 139374.50851 1.02640 0.96225
Acrylic Acid 4.49998 0.05625 34266.02869 0.25235 0.01419
80.00007 0.99917
Minimum No. of Ideal Stages
𝟎. 𝟗𝟐𝟓𝟎𝟏 𝟎. 𝟗𝟑𝟕𝟓𝟎
𝐥𝐨𝐠
𝑵𝒎𝒊𝒏 = 𝟎. 𝟎𝟓𝟎𝟎𝟎 𝟎. 𝟎𝟎𝟔𝟐𝟓 = 𝟓. 𝟏𝟓𝟒𝟖 𝒔𝒕𝒂𝒈𝒆𝒔
𝐥𝐨𝐠(𝟒. 𝟔𝟓𝟓𝟔𝟑)

N min Top Tdew 336.59940 K

Component, i xi Ki alpha i/w
Acetaldehyde 0.02500 3.29757 16.25957
LK Acrolein 0.92501 1.24135 6.12082
Component, i alpha mean
HK Water 0.05000 0.20281 1.00000
Acetaldehyde 11.50892
Acrylic Acid 0.00000 0.04240 0.20909
Acrolein 4.65563
Water 1.00000
Acrylic Acid 0.22673
Bottom Tbubble 382.36116 K
Component, i xi Ki alpha i/w
Acetaldehyde 1.2482E-06 8.3614E+00 8.1463E+00
LK Acrolein 6.2495E-03 3.6347E+00 3.5412E+00
HK Water 9.3750E-01 1.0264E+00 1.0000E+00
Acrylic Acid 5.6250E-02 2.5235E-01 2.4586E-01
Calculating splits of non-key components
Assumed Split: kmol/h
𝐷𝑥Q 𝐵𝑥S
Feed Distillate Bottoms αNOM*
M =
𝐵𝑥S 𝐷𝑥Q
Acetaldehyde 0.5 0.49990 0.00010 M T
LK Acrolein 19 18.50004 0.49996 𝐷𝑥Q 1
HK Water 76 0.99998 75.00002 αU.-UfW
M =
𝐹𝑥Y − 𝐷𝑥Q 0.013333
Acrylic Acid 4.5 0.00002 4.49998 M
TOTAL 100 19.99993 80.00007
𝐷𝑥Q 0.99998 (0.013333) (𝛼MU.-UfW)
= = 0.013333 (Dx^)M = U.-UfW 𝐹𝑥Y M
𝐵𝑥S `abcT 75.00002 1 + (0.013333) (𝛼M )

336.59940 382.36115
Component, i FxFi alpha top alpha bottom alpha i DxDi BxBi xDi xBi
Acetaldehyde 0.5 16.25957 8.14629 11.50892 0.49987 0.00013 0.02499 0.00000
LK Acrolein 19 6.12082 3.54117 4.65563 18.50010 0.49990 0.92501 0.00625
HK Water 76 1.00000 1.00000 1.00000 0.99998 75.00002 0.05000 0.93750
Acrylic Acid 4.5 0.20909 0.24586 0.22673 0.00003 4.49997 0.00000 0.05625
19.99998 80.00002 1.00000 1.00000
Algorithm for Multicomponent Distillation by FUG

• The FUG method is convenient for new column

design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)

Separation Process Principles : Chemical and Biochemical Operations / J. D. Seader, Ernest J. Henley, D. Keith Roper.—3rd ed.
Calculating minimum reflux ratio
alpha i -
Component, i xFi alpha i alpha i * xFi xDi alpha i * xDi theta alpha i*xDi / alpha i - theta
Acetaldehyde 0.00500 11.50892 0.05754 0.02499 0.28765 8.82432 0.03260
LK Acrolein 0.19000 4.65563 0.88457 0.92501 4.30649 1.97103 2.18489
HK Water 0.76000 1.00000 0.76000 0.05000 0.05000 -1.68460 -0.02968
Acrylic Acid 0.04500 0.22673 0.01020 0.00000 0.00000 -2.45787 0.00000
2.18781

0.05754 0.88457 0.76 0.01020

+ + + =1−1
11.50892 − 𝜃 4.65563 − 𝜃 1 − 𝜃 0.22673 − 𝜃

∴ 𝜃 = 2.6846

2.1878 = 𝑅OM* + 1 ∴ 𝑅OM* = 1.1878

Algorithm for Multicomponent Distillation by FUG

• The FUG method is convenient for new column

design with the following specifications:
1. A value for R/Rmin
2. Desired split on the reference component
(usually chosen as the heavy key)
3. Desired split on one other component
(usually the light key)

Separation Process Principles : Chemical and Biochemical Operations / J. D. Seader, Ernest J. Henley, D. Keith Roper.—3rd ed.
Calculating no. of ideal stages

𝑅OM* = 1.1878 𝑁OM* = 5.1548 𝑠𝑡𝑎𝑔𝑒𝑠

@ 𝑅 = 1.2 𝑅OM* Ψ = _____________ N = _____________

@ 𝑅 = 1.5 𝑅OM* Ψ = _____________ N = _____________

@ 𝑅 = 1.1 𝑅OM* Ψ = _____________ N = _____________

Perry’s Chemical Engineers’ Handbook / M.F. Doherty, Z.T. Fidkowski, M.F. Malone, R. Taylor. – 8th Edition
END.