Detailed Procedure of Distillation in our distillation column and distillation column internals
As former distillation and distillation column internals manufacturers and suppliers in Ethiopia, we have given below a key procedure about how the distillation process is done with smooth workflow:
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Feed Preparation:
The feed contains multiple amounts of unwanted compounds and mixtures that are heated, and partial vaporization occurs in the process. This is the first and most important process. The heated feed is sent towards the column and specific tray and differentiated as per their base composition. We have used advanced heat integration systems in our modern distillation column systems, which are designed with pinch analysis and consume heat from previous operations and reuse it for upcoming operations for energy savings.
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Entry into the Column:
The heated feed enters the column and is distributed across the trays according to the properties, design, and separation process. Based on the volume of each mixture, the heavier components move downward while the lighter ones vaporize. The trays and packing create a larger surface area, allowing for efficient mass transfer and smooth flow of the mixture. Our distillation columns are equipped with high-performance internals and low-pressure-drop structured packing to enhance efficiency. The feed process is carefully optimized within the internals to further improve separation efficiency.
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Vapor-Liquid Contact and Mass Transfer:
When the feed comes into the column, the vapor phase, which has a lower density and falls on the upper side, and the liquid phase, which has a higher gravity and falls on the lower side, come into contact with the trays and packing. The whole mass mixture gets in between these phases and forms a mass transfer. The trays and packings help with holding the liquid and throwing the vapor outside to form holes and create bubbles. The enhanced structure packing in the internal columns helps for mixing a liquid into pure form, reducing the friction and improving mass transfer.
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Condensation in the Overhead Condenser:
As vapor rises through the column and reaches the overhead condenser, it is cooled, causing the lighter components to condense into highly purified liquid. The condensed vapor is collected in attached reflux drums, while the remaining liquid is returned to the distillation process for further separation. Our advanced hybrid condensers offer both air-cooled and water-cooled functions, which help reduce water consumption and boost overall energy efficiency.
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Reboiling at the Bottom of the Column:
When the whole condensation process is down, the remaining liquid is collected in the column and reheated in the reboiler. The vapor generated is collected and sent back to the column to interact with the liquid descending from the trays. In the stripping section, the heavy component is left and stripped back from the liquid. We have attached a high-quality heat-integrated reboiler in our distillation column, which uses heat pump-assisted and vapor recompression to improve energy efficiency and reuse for reboiling.
Technical Specifications :
We have included below a technical table sheet which gives you detailed information about each procedure of our distillation trays & column internals:
| Process |
Description |
Key Components/Internals |
Temperature |
Pressure |
Flow Rate |
| Feed Preparation |
Preconditioning of the feed to ensure it enters the column at appropriate thermodynamic conditions. |
Heat Exchanger, Feed Preheater, Flash Drum |
Feed temperature: 100°C - 180°C |
Moderate (1-3 bar) |
Feed rate: 100 - 500 m³/h |
| Entry into the Column |
The feed enters at a specific tray or section based on its volatility. |
Feed Inlet Nozzle, Distributor Plate, Feed Pipes |
Slightly below feed temperature |
Entry pressure: 1.5 - 3 bar |
Entry flow: 100 - 500 m³/h |
| Vapor-Liquid Contact and Mass Transfer |
Separation occurs as vapor rises and liquid flows downward. |
Trays (Sieve, Bubble Cap, Valve Trays), Packing (Random or Structured), Downcomers, Liquid Distributors |
100°C to 250°C |
Pressure drop across column: 0.05 - 0.3 bar |
Vapor flow: 10 - 50 kg/s |
| Condensation in the Overhead Condenser |
Vapor from the top of the column is condensed and returned as reflux or distillate. |
Overhead Condenser (Air-cooled or Water-cooled), Reflux Drum, Reflux Pump |
Condenser Temp: 30°C - 60°C |
Top column pressure: 1 - 2 bar |
Reflux rate: 50 - 200 m³/h |
| Reboiling at the Bottom of the Column |
Heat is applied to reboil the bottom liquid, generating vapor that drives separation. |
Reboiler (Kettle, Thermosyphon, or Forced Circulation), Bottoms Pump, Reboiler Exchanger |
Reboiler Temp: 150°C - 300°C |
Bottom column pressure: 1.5 - 3 bar |
Bottoms flow rate: 30 - 100 m³/h |
| Control of Column Pressure |
The column operates under controlled pressure to maintain vapor-liquid equilibrium. |
Pressure Control Valve, Pressure Sensors, Overhead Accumulator |
Top Temp: 100°C - 120°C |
Pressure control range: 1 - 5 bar |
Flow adjusted as per required pressure |
Unique features and benefits of our distillation column and distillation column internals:
As a former distillation column systems suppliers and exporters in Ethiopia, these systems are built with precise engineering and equipped with new technological updates that give higher performance while working. Here we have listed down some list of features:
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Lower Pressure Drop:
Our distillation columns are designed to minimize pressure drops, which helps prevent operational issues like flooding and resistance to vapor flow. With features like low-pressure-drop packing and innovative tray designs such as high-capacity trays and caged valve trays, these columns improve overall workflow and increase capacity.
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Energy Optimization:
Known for their energy efficiency and cost-saving abilities, our distillation columns and internals can significantly cut energy consumption by 30–50%. Technologies such as heat-pump distillation and thermally coupled distillation columns allow them to reuse heat from previous operations to pre-heat the reboiler, reducing the need for additional energy.
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High Separation Efficiency:
Incorporating the latest advancements such as dividing wall columns (DWC), our distillation columns combine dual functions, saving both space and costs. Designed to prevent thermal loss and remixing, our distillation trays and internals are particularly efficient in applications like alcohol distillation, refining crude oil, and producing high-purity chemicals.
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Enhanced Durability:
Our distillation columns are constructed from corrosion-resistant materials, making them suitable for both standard and harsh environments. These durable materials ensure long-lasting performance, reducing the need for frequent maintenance or replacement.
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Process Flexibility:
Our distillation columns are highly adaptable and can handle a wide range of pressures, temperatures, and flow rates. With advanced features like smart sensors and control systems, they monitor operations in real-time, detect errors early, and help maintain smooth and efficient production across industries.
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Improved Safety Measures:
Safety is a top priority in our design. Our columns are equipped with safety features such as pressure relief valves and emergency shutoff systems, which ensure smooth operation and minimize the risk of accidents during the distillation process.
Applications of our distillation column and distillation column internals:
Being a best distillation column internals manufacturers and suppliers in Ethiopia, our columns and internals are applied into multiple industrial functional areas for improving their performance. We have mentioned below some list of applications such as:
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Biodiesel production and component separation
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Ethylene production through steam cracking
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Purification of high-purity industrial gases
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Desalination using multi-stage distillation
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Oxygen and nitrogen separation in air separation units
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Hydrogen production and carbon dioxide separation
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Pharmaceutical solvent recovery and recycling
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Ammonia production and gas separation
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Distillation in the production of alcoholic beverages
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Petrochemical feedstock refining and separation
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Water purification via evaporation processes
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Production of essential oils through fractional distillation
As a former distillation column and distillation column internals manufacturers, suppliers and exporters in Ethiopia, At Attaquant Enterprises, we offer top-quality distillation columns and internals with advanced features. Our systems are designed to effectively mix liquids and vapors, ensuring pure and efficient distillation. With the latest technology and innovative designs, our solutions help boost productivity across a wide range of applications. Get in touch with us today for more information!
