characteristics of a packed distillation column for on
TRANSCRIPT
Retrospective Theses and Dissertations Iowa State University Capstones, Theses andDissertations
1983
Characteristics of a packed distillation column foron-farm ethanol productionTimothy M. P. WallIowa State University
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Recommended CitationWall, Timothy M. P., "Characteristics of a packed distillation column for on-farm ethanol production" (1983). Retrospective Theses andDissertations. 16660.https://lib.dr.iastate.edu/rtd/16660
Characteristics of a packed distillation column
for on-farm ethanol production
by
Timothy M. P. Wall
A Thesis Submitted to the
Graduate Faculty in Partial Fulfillment of the
Requirements for the Degree of
MASTER OF SCIENCE
Major: Agricultural Engineering
Signatures have been redacted for privacy
Iowa State University Ame s, Iowa
1983
LIST OF SYMBOLS
INTRODUCTION
ii
TABLE OF CONTENTS
Page
iii
OBJECTIVES 5
DISTILLATION COLUMN DESIGN 6
DESCRIPTION OF COMPUTER AIDED DESIGN PROGRAM 27
DESIGN 35
DATA COLLECTION 43
COLUMN CONSTRUCTION 65
EXPERIMENTAL PROCEDURE 70
RESULTS 71
DISCUSSION AND RECOMMENDATIONS 75
CONCLUSIONS 79
REFERENCES 80
AKNOWLEDGEMENTS 82
APPENDIX A: DESIGN COMPUTER PROGRAM LISTING 83
APPENDIX B: DATA LOGGER COMPUTER CONTROL PROGRAM LISTING 92
APPENDIX C: DATA COLLECTED ON AUGUST 24, 1982 97
APPENDIX D: DATA COLLECTED ON AUGUST 21, 1982 101
APPENDIX E: COMPUTER DATA COLLECTED ON AUGUST 24, 1982 105
iii
LIST OF SYMBOLS
B bottoms molar flow rate
BM bottoms mass flow rate
cp specific heat
D distillate molar flow rate
DM distillate mass flow rate
d column diameter
F feed molar flow rate
FM feed mass flow rate
I D, 1 1 , 1 2 , 13 current
L molar flow rate at the bo~tom of the column
L molar reflux rate
liquid molar flow in rectifying and stripping
section respectively
MF , MB, MD mass fraction of ethanol in feed, bottoms, and
distillate respectively
. m mass flow rate of coolant
. m
steam mass flow rate of steam
N number of ideal stages
p proof
q moles added to the stripping section liquid due the
introduction of one mole of feed
R reflux ratio
iv
resistance
V, V molar vapour flow flow rate top and bottom of column
respectively
Vn+1' Vm+1 molar vapour flow rates in rectifying and
stripping section
V vapour velocity in column gas
Vo voltage out of op-amp circuit
XD , XB , XF mol fracti~n of ethanol in the distillate,
bottoms and feed respectively
mol fraction of ethanol in the liquid in the
rectifying and stripping section
mol fraction of ethanol in the vapour entering the
condenser and leaving the reboiler respectively
y y n+1' m+1
mole fraction of ethanol in the vapour in the
rectifying and stripping section
Pgas vapour density
P liquid density
latent heat of vapo~rization of distillate,
feed and bottoms respectively
INTRODUCTION
Wi&h an abundance of corn on farms in recen& years
&here has been increasing interest in &he feasib1li&y of
conver&ing corn to ethanol for use as fuel. For &his reason
a number of small scale ethanol plants (producing less than
300 m3/year) have been built on farms and for research
in the las& few years.
The production of ethanol from corn by fermenta&ion
usually consis&s of six steps (Bothast and Detroy 1981): (1)
milling, (2) COOking, (3) saccharification, (4)
fermentation, (5) distillation, and (6) feed recovery.
A kernel of corn consists of a fibre shell which
contains s&arch, prote1n, gluten and germ (Ensminger and
Olen&ine 1978). The shell needs to be brOken and the starch
disrupted to enhance enzymatic hydrolysis during COOking.
This can be accomplished using a hammer or roller mill &0
grind the corn in&o a fine meal which will pass through a 20
mesh (0.833 mm) screen.
make a slurry.
Water is then added to the meal to
In the COOking process, enzymes are used to break down
the starch &0 soluble dextrins. COOking can be ei&her
carried out continuously, in batches or by extrusion.
Saccharification 1S the conversion of dextrins to simple
sugars such as glucose.
temperature sensitive.
2
Eacn enzyme used is pH and
Fermentation converts the sugar into ethanol and carbon
dioxide (Williams 1980). It is a relatively simple process
to perform, provided care is taken to keep equipment clean.
Normally, the solution to be fermented has a sugar content
of about 15-20% to effect a compromise between microorganism
inhibition and distillation economics. Yeast is used for
the conversion and the whole process can take up to 3 days.
The result of fermentation is a mixture of ethanol,
water and any solids that could not be converted to ethanol.
Continuous distillation is commonly used to separate the
ethanol from the water.
The residual water and SOllds is called stillage. This
has a feed value for livestock. Large commercial producers
of ethanol usually produce dried distiller's solubles and
dried distiller's grains because these are more readily
stored and marketed.
The actual amount of ethanol obtained from a quantity
of corn depends on the efficiency of the above processes.
Typically 10 kg of corn (dry basis) contains about 8 kg of
starch (Ensminger and Olentine 1978). In practice only
about 6.3 kg out of 10 kg dry matter is converted to sugar.
Due to the molecular combination witn water, 7 kg of sugar
3
are actually obtained. This sugar is converted to 3.6 kg of
ethanol and 3.4 kg of carbon dioxide. The density of 200
proof (proof = 2 x actual percent by volume of ethanol in a
mixture) ethanol is 794 Kg/m 3 (table 3) so 10 kg (dry basis)
of corn can produce ij.5 L of ethanol at 200 proof.
Distillation is a new technology to the farm community
and to agribusiness. One of the functions of agricultural
extension is transferring technology from the university to
farmers. In recent years computer programs for
mlcrocomputers have been jointly produced by personnel in
extension and research to be used as a medium for technology
transfer. This report gives the theory of distillation
column design and a computer program which was written to
calculate column characteristics for deSigning the column
used in this project. The program also provides the
framework for de~eloping a program suitable for use by
extenSion. Chemical englneers probably have advanced
computer aided programs for designing large industrial
distillation columns, such as for petroleum refining but
these are not accessible to the farm audience.
The dis~illation column was part of a complete farm
size distillery. One of the concerns with farm-scale plants
has been/maintenance of distilla~e quality at levels that
allow optimum output to input energy ratios. It was
4
expected that some form of automatic control would be
essential if distillate quality were to remain constant as
feed quality and temperature varied.
Before automatic control can be applied to a system,
either theoretical or empirical Knowledge of the transfer
function of the plant is necessary. Distillation plant
transfer functions could be obtained from theoretical
calculations (Coughanowr and Koppel 1965) but it was thought
that a more satisfactory approach would be to calculate a
transfer function from measured characteristics. Determining
enough characteristics of the worKing column would require
measurements from several sensors. Because commercially
available data loggers were considered excessively
expensive, it was decided that a data logger based on a
commercial microcomputer would be constructed.
Each of the topics briefly discussed here is an area that
can be studied in detail individually, but in this report
only continuous distillation is examined. A method of
column design is discussed, followed by construction and
then performance evaluation using an electroniC data
collection system.
5
OBJECTIVES
1. Develop an interactlve design program that would run on
a microcomputer.
2. Design a distillation column that would produce 180
proof ethanol continuously at 100 L/day.
3. Construct the column using commercially and locally
available materials.
4. Evaluate the column performance with the aid of an
electronic data acquisition system designed to measure
temperatures and liquid flow rates.
6
DISTILLATION COLUMN DESIGN
When building a distlilation column, it is necessary to
know the number of ideal equilibrium stages required to
obtain the necessary separation (hence column height),
diameter of column, heat input at reboiler and heat out at
the condenser.
The McCabe-Thiele (McCabe and Smith 1976) graphical
method was used for this design which assumes constant molar
overflow and 100S efficiency. At low pressures ethanol
water mi~tures satisfy the constant molar overflow condltion
(Brown et al. 1950).
McCabe-Thiele method
Ethanol and water comprise a two component system.
Separation by distillation can be examined graphically based
on material balances. Figure 1 shows the layout for a
continuous fractionating column. The column is divided into
two parts, the upper being the rectifying section and the
lower the stripping section. The beer feed (liquid to be
separated) enters between them. Total material and
component balances for each section can be calculated. For
the rectifying section a material balance for the ethanol
I FY II~G RECT SEC TION
ED
STR SE
IPPING CTION
L n X n
L m Xm
t
I
v y o
REFLUX
"'n+1 PUMP
'(n+1
V m+1 Y m+1
-V YB
L
7
CONDENSER
COO LANT FLOW
L 0 DISTILLATE
XD v "D
I~EBOILER
STEAM F LOW
~ 0 X
BOTTOMS B
Figure 1. Material-balance for a continuous fractionating column
8
component can be wrltten:
(1)
which rearranged gives:
LnXn VY D - LX D Yn+1 = + ---------
Vn+1 Vn+1
( 2)
A material balance around the condenser yields:
D = V - L
and for the rectifying section (including condenser):
D = V 1 - L n+ n (4 )
Similarly a material balance for the ethanol component gives:
DX D = VY D - LX D = Vn+1Yn+1 - LnXn ( 5 )
Substituting Eqs. 4 and 5 into Eq. 2 and rearranging:
( 6 )
This can be plotted on a graph with X as the abscissa n
and Yn+1 as the ordinate and is ~nown as the rectifying
section operating line. A similar equation can be developed
for the stripping section where:
B = L - V m m+1
and
solving gives
L - B m L - B m
(7)
(8 )
( 9 )
9
which is the stripping section operating line. Note that
this line passes through the point (XB,XB).
For constant molar overflow the subscripts n, m, n+1
and m+1 can be dropped, which makes the material balance
equations linear and the operating lines straight.
Reflux ratio
Reflux ratio is defined as
R = L/O (10)
Eliminating V and L from Eq. (6) gives
Y = RX Xo
----- + -----R + 1 R + 1
This line can be plotted if Rand Xo are known.
the line passes through the po~nt (Xo,XO).
( 1 1 )
Note that
The number of ideal stages in cascade that are needed
to produce XB
and Xo at the ends of the column may be
determ~ned from ethanol-water equilibrium data (table 1).
The l~quid and vapour streams leaving a stage are in
equilibrium, thus for each stage (say stage n) the point
(X ,Y ) must lie on the equilibrium curve. n n
So by plotting
the operating lines and equilibrium curve on the same graph,
the stages can be located (figure 2).
10
Table 1. Equilibrium data for ethanol-water mixtures at atmospheric pressure expressed as mole fractions of liquid (X) and vapour (Y) for ethanol
. X Y X Y
0 0 0.3213 0.5826 0.0190 0.1100 0.3965 0.6122 0.0210 0.1990 0.4030 0.6190 0.0330 0.2120 0.4030 0.6250 0.0500 0.3530 0.5019 0.6564 0.0121 0-3891 0.5198 0.6599 0.0850 0.4110 0.5560 0.6150 0.0966 0.4315 0.5132 0.6841 0.1050 0.4580 0.6020 0.6950 o. 1238 0.4104 0.6430 0.1130 0.1250 0.4880 0.6163 0.1385 0.1350 0.4840 0.6890 0.1410 0.1661 0.5089 0.1412 0.1815 0.2331 0.5445 0.8050 .0.8140 0.2608 0.5580 0.8943 0.8943 0.3150 0.5110 0.9260 0.9110 0-3210 0.5120 0.9810 0.9850
Least squares fitted polynomials for ranges indicated:
0.0966 < X < 1
Y = 0.061063 + 4.935611 X - 16.186 X2 + 24.0~94 X3 11.5682 X
o < X < 0.0966
Y = -4.6318x10-5 + 10.0338 X - 20.0183 X2 - 1~64.5249 X3 + 9143.132 X
Linear approximation for 0 < X < 0.03
Y = 8.5382 X
------------------------------------------------------------Source: Hirata, M., S. Ohe, and K. Nagahama. Computer A~ded Data BOOk of Vapour-Liquid Equilibria. Kodansha Ltd. 12-21 Otowa 2-chome, BunKyo-ku, TOkyo, 1915. ------------------------------------------------------------
:z 0
I-u ~ 0:: LL..
UJ ...J 0 :::::: 0:: ::J 0 o. ~ >
0.5
VAPOUR-LIQUID EQUILIBRIUM LINE
11
RECTIFYING OPERATI NG
LIUE
FEED LINE (SATURATED LIQUID)
0.5
LIQUID MOLE FRACTION
Figure 2. Vapour-liquid equilibrium curve for ethanol-water mixture
12
Feed
The condition of the feed affects operation. The feed
may be superheated vapour, saturated vapour, a mixture of
liquid and vapour, saturated liquid at its bubble pOint, or
cold liquid. All five feed types can be correlated by the
use of one factor q, where q is the additional number"of
moles of liquid flow in the stripping section that results
from the introduction of one mole of feed.
Hence,
q > 1, Cold feed
q = 1 , Saturated liquid
0 < q < 1 , Feed partially vapour
q = 0, Saturated vapour
q < 0, Superheated vapour
Only cold and saturated liquid feed are considered in this
design. For purely liquid feed, q is given by:
The contribution of feed to the column liquid is qF, so:
L = L + qF (13)
and for vapour the contribution is (q-1)F so:
13
v = V + (1-q)F
With constant molar overflow (from Eqs. 5 and 8):
VY = LX + OXO
VY = LX - BX B
By substitution and rearranging Eqs. 13, 14,
15, 16 and noting FX F = OXO + BX B (complete material
balance for one component), the feed llne is:
Y = -qX XF
----- + -----1 - q 1 - q
( 1 4 )
( 1 5 )
( 16)
( 17)
Note that the feed line passes through point (X X) F' F •
It may be shown that the recti~ying and stripping
operating lines and feed line all intersect at the same
point. This enables all three to be drawn when XF
' XB
' XO
'
q and R are ~nown.
Example
Find the number of ldeal stages for an ethanol-water
feed of 24 proof supplied at the bubble point. The
distillate is required at 180 proof and the bottoms product
should be less than 1 proof. Assume R = 4.
14
Solution
Feed
The proofs need to be changed to mole fractions.
24 proof = 12% by volume
From table 2 the density of the mixture = 984.3 kg/m 3
Pure ethanol has a density = 793.7 kg/m 3 (table 3)
The mass of ethanol in 1 m3 of 24 proof feed
= 793.7 x 0.12 = 95.2 kg
and the mass of water = 984.3 - 95.2 = 889.1 kg
Molecular weights:
= 18
Therefore, number of moles of ethanol = 95.2/46 = 2.070
number of moles of water = 889.1/18 = 49.394
total moles = 51.464
mole fraction of feed XF = 2.07/51.464 = 0.0402
Similarly,
XD = 0.7009
and XB = 1.558X10- 3
Since R=4, the rectifying operating line (from Eq. 11) will be:
Y = 0.8 X + 0.1402 (18)
15
Table 2. Density of ethanol-water mixtures at 15 C and 1 atm for proofs less than 30
Proof
1 2 3 4 5 6 7 8 9
10 1 1 12 13 14 15
DenSi§Y kg/m
999.25 998.5 997.76 997.03 996.30 995.59 994.87 994.18 993.49 992.81 992.14 991.49 990.84 990.21 989.59
Polynomial function:
Proof
16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
p = 999.991 - 0.7603 p + 4.4518x10- 3 p2
DenSi§Y kg/m
988.98 988.37 987.78 987.19 986.60 986.01 985.43 984.85 984.28 983·72 983. 17 982.62 982.08 981. 55 981.02
Source: Department of the Treasury. Bureau of Alcohol, Tobacco and Firearms. Gauging Manual. ATF-P5110.6 (11/78). u.S. Government Printing Office, Washington D.C., 1978
16
Table 3. Density of e~hanol-wa~er mixtures at 15 C and 1 atm for proofs greater than 160
------------------------------------------------------------Proof
161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180
Densi§Y kg/m
862.25 860.84 859.43 858.01 856.58 855.15 853.69 852.23 850.76 849.27 847.77 846.25 844.71 843.17 841.62 840.06 838.48 836.88 835.26 833.62
Polynomial function:
Proof
181 182 183 184 185 186 187 188 189 190 19 1 192 193 194 195 196 197 198 199 200
DenSi§Y l<g/m
831.96 830.29 828.59 826.85 825.09 823.30 821.49 819.63 817.75 815.82 813.85 811.84 809.79 807.70 805.55 803.33 801.04 798.66 796.20 793.65
p = 1305.51 - 4.155 p - 1'~17Xao-3 p2 + 1.3118X10-4 p3 -4.135x10 p
Source: Department of the Treasury. Bureau of Alcohol, Tobacco and Firearms. Gauging Manual. ATF-P5110.6 (11/78). U.S. Government Printing Office, Washing~on, D.C., 1978.
17
The feed is, at the bubble point, so q= 1 and the feed
line is X = XF = 0.0402. The operating line for the
stripping section passes through (XB,XB
) and intersects the
feed line at the same point as the rectifying operating line.
Knowing XF = 0.0402 and using Eq. 18, this common
intersection point is (0.0402,0.1724). The rectifying,
stripping and feed lines can be drawn on a graph (see figure
2 for graphical solution).
Data points for the equilibrium curve are given in table 1.
See figure 2 for graphical solution.
Number of plates in rectifying section = 4
Number of plates in stripping section = 2
The feed plate will be the fourth plate down from the top.
Stripping section plates
The example shows that using graphical construction is
difficult when determining the stripping section stages when
At these small values of XB , however, Henry's
law indicates that it is reasonable to assume the
equilibrium curve is straight.
18
Then Che number of places is given by:
N = In (XA1-XB1)/(XA-XB)
(McCabe and SmiCh 1976; see figure 3)
OpCimum reflux raCio
( 19)
The to Cal number of plates is parcly dependenC on the
reflux raCio. AC to Cal reflux, Che places will be a
minimum. The column diameCer, however, is proporCional Co
Che square root of Che vapour veloclty which will increase
with reflux. The cosC of Che column is roughly proporCional
Co Che column area so there will be an optimum reflux raCio
aC which a column has a leasc cost. IC also musC be noted
Chac che heat required aC the reboiler and quancity of
coolant needed at the condenser (figure 1) increase with
reflux. Calculations co find Che optimum reflux ratio can
be made based on the above, buC normally it is Caken as 1.2
to 2.0 Cimes the minimum reflux (McCabe and SmiCh 1976).
Minimum reflux occurs when the number of plates becomes
infinice, and is determined by passing the reccifying
operating line though the point where the feed line and
equilibrium curve intersect or, in Che case of an azeotropic
mixture (ethanol and water falls into this category), by
:z o Iu <x: 0::: lJ..
lJJ ..J o ~
0::: :::> o c.. <x: :>
19
STR I PP I riG I
OPERAT r tJG LINE
XA
LIMIT OF STRAIGHT-LINE PORTION OF THE
EQUILIBRIUM CURVE
EQUILIBRIUM LINE
y = x NUMBER OF IDEAL
STAGES
LIQUID MOLE FRACTION
Figure 3. Vapour-liquid equilibrium curve for ethanol-water mixture at low concentration of ethanol
20
allowing the rectifying operating line to be tangent to the
equilibrium curve. The larger reflux ratio found by the two
methods is used as the minimum reflux.
Flow rates
For a total material balance:
(20)
and for a component balance:
( 2 1 )
Usually, the feed rate and feed proof are Known and the
distillate proof and bottoms proof are design goals. From
these, the mole feed rate and the mole fractions of the
feed, distillate and bottoms can be determined. Sy solving
E q s. 20 and 2 1, the dis till ate and bot tom s mol a r f1 ox x_a t_e s
can be found:
D XF - Xs = ------- (22)
F XD - Xs
S XD - XF
= ------- (23) F X
D - Xs
Similarly, if mass balances are used:
DM MF - MS = ------- (24)
FM MD - MS
21
BM MD - MF = ------- (25)
FM MD - MB
By using the densities (tables 2 and 3) of the various
components, volumetriC flow rates can be determined and
flows within the column can be calculated. Using Eq. 10:
L = D R (26)
since R is established from the minimum reflux rate.
The material balance around the condenser (Eq. 13) gives
(27)
Equations 13 and 14 can be used to find V and L, the vapour
and liquid flow rates, ·in the stripping section.
Heat flows
For design purposes, it is necessary to know the amount
of heat flowing into and out of the reboiler and condenser,
in order to estimate the heat and coolant requirements.
In this design, steam is used in the reboiler. If it
is considered that the energy lost with the bottoms product
is small compared with the latent heat of steam and
stripping section vapour, then the energy balance around the
reboiler becomes:
(28)
Using steam tables to find the latent heat of the steam at
22
the pressure being used, the mass flow rate of steam can be
found.
For the condenser using water as a coolant:
m C p ( T 2 - T 1) = V M AD
The inlet and outlet temperature (T1
,T2
) are set design
parameters which usually give a ~T of about 10 C.
It is assumed that the radiant heat loss from the
column itself is small and the system is essentially
adiabatic. The values of AF' AD and AB will vary wi th
proo f • Table 4 gives latent heats for different mass
fractions.
Column diameter
The vapour velocity up the column must not be greater
than the settling velocity of the liquid droplets down the
column or entrainment will occur. The settling velocity is
con si d er ed to be,,_.in.-t-he-Ne-wton-i-an. reg ime (Den n 1980) so:
(v g~:-= 0.055 ( pi Pgas - 1)) (30)
'- ..."....,-- ~ The rna x i m-u-ril"V-a p'O'ur-- v e loc it Y is in the stripping section for
cold and bubble point feed, so:
If at the bottom of the column the vapour is assumed to be
steam at atmospheric pressure, then from steam tables:
23
Table 4. Latent heats of vapourization for ethanol-water mixtures expressed as mass fraction of ethanol
Mass fraction ethanol
0.00 0.05 0.10 0.20 0.30 0.40 0.50 0.60 0.10 0.80 0.90 1 .00
Polynomial function:
Latent heat kJ/Kg
2255.8 2199.5 2144.9 2019.3 1819.2 1132-3 1584.1 1433.9 • 1285.9 1144.8 998.1 851.1
A = 2254 - 941.05 X - 1215.2 *2 + 1315.31 X3 - 151.56 X
Source: Brown, G. G., D. Katz, A. S. Foust, and R. Schneidewind. Unit Operations. John Wiley & Sons, Inc., New YorK, 1950.
24
Pgas = 0.598 Kg/m 3
and P = 998 Kg/m 3
which substituting in Eq. 30 and solving with Eq. 31 gives:
d (32)
Packed columns and plate columns
Plate columns have a number of horizontal plates or
trays equally spaced. Tray designs vary greatly (Brown et
ale 1950), but essentially provide a volume to ensure
intimate contact of the counter flowing streams of liquid and
vapour.
In a packed column, the plates are replaced with loose
pieces of material pacKed at random. The length of the
column is proportional to the number of theoretical plates
For each required and varies according to the packing used.
packing, there is a different height equivalent per
theoretical plate (H.E.T.P.) (Perry 1941) I which is listed
by the manufacturer. The maximum dimension for pacKing is
about 10$ of the column diameter.
Computer aided design
This brief review of distillation column design
suggests that the repeated applications of the graphical
construction needed for each change in input conditions
25
would soon become tedious. It was felt that a computer
program developed to run on a desk top computer would not
only allow the column for this project to be designed more
flexibly, but would also serve as the skeleton of a program
that could be further developed by Agricultural Engineering
Extension.
The program was written for Apple II with 48k of memory
and a printer.
The required program input are:
Feed proof
Feed rate (L/min)
Feed temperature (C)
Distillate proof
Bottoms proof
Minimum reflux ratio multiplier.
The program prints out:
Total plates
Rectifying plates
Stripping plates
Reflux ratio
Distillate rate (L/min)
Bottoms rate (L/min)
Coolant rate (L/min)
Steam rate (kg/h)
Condensate rate (L/min)
Column diameter (em).
26
The complete program listing is contained in Appendix A.
27
DISTILLATION COLUMN DESIGN BY MICROCOMPUTER
Line numbers Program description
10-120
130-150
160
170
180
190
200
210-550
560-590
Print format statements for use with Apple print
using program.
Defining of the fourth order polynomial and its
first and second derivatives, which are used to
represent the equilibrium curve. The coefficients
are changed depending on the section of curve
being used (table 1).
Polynomial for latent heat of vapourlzation of the
ethanol-water"mlxture as a function of mass
fraction (table 4).
Polynomial for mixture density as a function of
proof with proofs less than 30 (table 2).
Polynomial for mixture density as a function of
proof with proofs greater than 160 (table 3).
Polynomial for bubble point temperature as a
function of mass fraction for proofs less then 30
(table 5).
Densities of pure ethanol and water, respectively.
Input statements for all variables used in the
design.
Dimensionalizing arrays used.
600-970
980-990
1000
1010
1020
28
Initializing arrays with design parameters so that
they will be printed in table form with the
results.
Sets variables VE and MASS equal to the distillate
proof and distillate density.
Calculates the mass and mole fraction for the
distillate using subroutine 2010. which bases its
calculations on the variables VE and MASS.
Stores the variables mole fraction (XD). mass
fraction (MD) and mixture density (PD).
Sets coefficients of the equilibrium curve
polynomial for 0.0966 < mole fraction < 1 (table
1). Coefficients are stored in subroutine 1830.
1030-1100 Finds the minimum reflux ratio based on the
tangent to the equilibrium curve by equating the
slope of the rectifying section operating line
(Y-YD)/(X-XD) to the first differential (gradient
of the tangent (Fl(X))) of the equilibrium curve
polynomial. Newton's approximation (Selby and
Girling 1965) is used to solve the equations
iteratively. Variable R2DMIN stores this value to
compare with the minimum reflux value found from
the intersection of the feed line with the
equilibrium curve.
29
1110-1140 Calculates mole fraction (XB), mass fraction (MB)
and density (PS) of the bottoms product.
1150-1180 Calculates mole fraction (XF), mass fraction (MF)
and density (PF) of the feed.
1190
1200
1210
1220
1230
1240
1250
Determines latent heat of vapourization of feed
(LFAN).
Calculates q-value (Q) for feed line based on the
bubble point temperature (TP(MF», feed
temperature (FT) and latent heat (LFAN).
Sets equilibrium curve coefficients for 0.0966 < X
< 1.
If Q = 1 then feed line is X = XF.
Uses Newton's approximation in subroutine 1950 to
flnd the point of intersection of the feed line
with the equilibrium curve.
If the point of intersection is out of the range
the of polynomial then coefficients for 0.03 < X <
0.0966, stored in subroutine 1890, are used and
the point of intersection is recalculated.
The equilibrium curve is approximated to a
straight line for mole fractions less than 0.03.
The feed line is then solved simultaneously with
the equilibrium line Y = 8.5382333*X (table 1) if
necessary.
1260
30
Res~ores coefficien~s for equilibrium curve 0.966
< X < 1-
1270-1280 Poin~ of intersection for feed line and
1290
1300
1310
equilibrium line (X1F,Y1F).
Calculates minimum reflux ratio (R2DMIN) based on
the point (X1F,Y1F).
Compares R2DMIN with the previously calculated
reflux ratio (R1DMIN) and selects the larger
value.
Reflux ratio = minimum reflux * const (1.2 < const
< 2).
1320-1350 Prin~s to the screen the q-value (Q) and reflux
ra~io for given feed proof and feed temperature.
1360-1370 Rectifying operating line is of ~he form
Y=MR*X+CR. Constants MR and CR are calculated
from the distillate mole frac~ion and reflux
ratio.
1380-1390 Feed line and rectifying operating line are solved
simultaneously to find the point of intersec~ion
(X2F,Y2F).
1400-1410 Stripping operating line is Y=MS*X+CS, where
MS=(YB-Y2F)/(XB-X2F) and CS=Y2F-MS*X2F (Note YB =
XB) •
1420-1530 Determines the number of ideal s~ages (N?). The
31
sequence starts at the point (XD,YD) and uses
Newton's approximation in subroutine 1760 to find
the point of intersection for each ideal stage
down the curve. Each X value obtained from the
subroutine is substituted into the appropriate
operating line to find a new Y value, which is
used for the next stage and returned to the
subroutine. Lines 1420 and 1450 are needed to
initialize the Newton's approXimation, which can
be unstable When not started near the root. Each
equilibrium point (X,Y) is printed to the screen.
When the equilibrium points are being calculated
for the stripping section and X < 0.03, the number
6f plates is calculated by the logarithmic method
using Eq. 19.
1540-1590 Uses the logarithmic method of finding the number
of ideal stages between two straight lines.
S=LOG(XA1-XB1)/(XA-XB). Variable NP is the total
number of ideal stages and variable NS is the
number of ideal stages in the stripping section.
1600-1690 Total stages, stripping stages and rectifying
stages are stored in arrays as integers.
1700 Subroutine calculates the flow rates.
1710-1730 Next increment for the feed temperature.
1740
1750
32
Subroutine for printing results.
End.
Subroutines
1760-1820 Newton's approximation used to find the
intersection of the ideal stages with the
equilibrium curve. Total stages advance by one
each time.
1830-1800 Equilibrium polynomial coefficients for 0.0966 < X
< 1-
1890-1940 Equilibrium polynomial coefficients for 0.03 < X <
0.0966.
1950-2000 Newton's approximation used to find the point of
intersection of the feed line with the equilibrium
curve.
2010-2050 Calculates the mass fraction and mole fraction
based on the values of variables VE and MASS.
2060-2070 Latent heat of vapourization for the distillate
and bottoms, respectively.
2080-2130 For each feed rate, the mass flow rates of the
distillate, bottoms, liquid reflux, rectifying
section vapour and stripping section vapour are
calculated (kg/min).
2140-2150 Array storage of the distillate and bottoms flow
33
rates (L/min).
2160-2170 Array storage of the heat out at the condenser and
heat in at the reboiler (KW).
2180-2210 Maximum and minimum heat requirements of the
condenser and reboiler are stored to use in
calculating the coolant and steam requi~ements.
2220-2230 Maximum and minimum vapour flow rate in the
stripping section are stored to be used in
calculating the column diameter.
2240-2270 Increment of feed rate.
2280-3400 Prints the results.
2930-2940 Maximum and minimum flow rates of coolant water
based on a 10 C temperature rise across the
condenser (L/min).
2950-2960 Maximum and minimum steam requi~ement based on the
enthalpy of vapourization of steam supplied at 5.5
x 105 Pa (2095 KJ/Kg). Steam rate in Kg/h.
2970-2980 Condensate flow rate (L/min).
3050-3060 Maximum and minimum column diameters (em) from Eq.
31.
34
Table 5. Bubble point temperature of ethanol-water mixture expressed as mass fraction of ethanol for proofs less than 30
Mass fraction ethanol
0.00 0.01 0.02 0.03 0.04 0.05 0.10
Polynomial function:
Bubble point C
100.00 98.94 98.06 91.11 96.00 95·.22 91 .18
T = 99.91 - 103.015 X + 199.5292 X2
Source: Brown, G. G., D. Katz, A. S. Foust, and R. Schneidewind. Unit Operations. John Wiley & Sons, Inc., New York, 1950. ----
35
DESIGN
Distillation column
For the distillation column used. the design program
was run with the following conditions.
Feed proof: Maximum = 24. Minimum = 8. Increments = 4
Feed temperature (C): Maximum = 90. Minimum = 10.
Increments = 20
Feed rate (L/min): Maximum = 2.5. Minimum = 0.5.
Increments = 1
Distillate proof: 180
Bottoms proof: 0.1
Minimum reflux ratio multiplier: 1.5
Tables 6. 7. 8. 9 and 10 show the computir program
results. Table 6 indicates that the number of stages in the
rectifying section varies little with changes in t'eed
temperature and feed proof. The stages in the stripping
section vary by a greater amount. Since the building used
to house the column was limited in height (11 m). it was
decided to fix the length of the rectifying section and use
the remaining space for the stripping section.
The flow rates (table 9) indicate that the column
should have a diameter between 4.60 and 14.13 cm. Copper
drainage pipe. with a diameter of 10.00 cm. was available
36
Table 6. Number of pla~es predic~ed when ~he dis~illate and the bottoms were fixed at 180 and 0.1 proof, respectively
Total Plates
Feed Proof
8 12 16 20 24
Rectifying Plates
Stripping Plates
8 12 16 20 24
8 12 16 20 24
10
15 14 14 13 14
6 6 6 6 6
9 8 8 7 8
Feed Temperature C 30 50 70
17 15 14 1 3 13
5 6 6 6 6
12 9 8 7 7
19 16 14 14 13
6 6 5 6 6
13 10
9 8 7
17 16 15 14 1 3
5 6 6 6 5
12 10
9 8 8
90
18 14 14 13 13
5 5 6 6 6
13 9 8 7 7
37
Table 7. Reboiler heat demand (kW) predicted when the distillate and bottom were fixed at 180 and 0.1 proof, respectively
Feed rate = 0.5 L/min
Feed rate = 1.5 L/min
Feed rate = 2.5 L/min
Feed Proof
8 12 16 20 24
8 12 16 20 24
8 12 16 20 24
10
5.35 6.23 7.00 7.66 8.20
16.05 18.68 20.99 22.99 24.60
26.75 31 .13 34.98 38.32 41 .00
Feed 30
5.06 6.00 6.81 7.53 8.16
15.17 17.99 20.44 22.59 24.48
25.28 29.98 34.07 37.66 40.80
Temperature C 50 70
5.13 6.09 6.90 7.61 8.23
15.40 18.27 20.71 22.83 24.70
25.66 30.44 34.51 38.06 41.17
5.78 6.65 7.43 8.09 8.65
17 -33 19.94 22 -30 24.27 25.96
28.88 33.24 37.17 40.46 43.27
90
6. 15 7 .41 8.29 8.97 9.50
18.44 22.23 24.88 26·91 28.51
30.73 37.05 41 .47 44.85 47.52
------------------------------------------------------------
38
Table 8. Condenser heat rejection (kW) predicted when the distillate and bottoms were fixed at 180 and 0.1 proof, respectively
Feed rate = 0.5
Feed Proof
L/min 8
Feed rate = 1.5
12 16 20 24
L/min 8
Feed rate = 2.5
12 16 20 24
L/min 8 12 16 20 24
10
1 .05 1 .48 1. 86 2. 18 2.44
3. 15 4.44 5.57 6.55 7-32
5.25 7.40 9.28
10.91 1 2 .21
Feed Temperature C 30 50 70
1. 25 1. 71 2. 11 2.46 2.77
3.75 5.13 6.33 7.39 8.31
6.25 8.55
10.55 12.31 13·85
1. 62 2.09 2.49 2.84 3. 15
4.87 6.28 7.48 8.53 9.45
8 • 11 10.46 12.46 14.21 15.75
2.26 2.69 3.08 3.41 3.69
6.79 8.08 9.25
10.23 11 .08
11 .32 13.47 15.42 17.05 18.46
90
2.78 3·39 3.83 4. 17 4.44
8.33 10. 18 11 .49 1 2 .51 13·32
13·88 16.97 19 . 16 20.85 22.20
39
Table 9. Selected flow rates predicted when the distillate and bottoms were fixed at 180 and 0.1 proof, respectively
Feed Proof
Feed rate = 0.5 L/min 8
12 16 20 24
Steam, l<g/h 8.69 Condensate, L/min 0.145 Coolant, L/min 1. 50 Diameter, cm 4.61
Feed rate = 1 .5 L/min 8
12 16 20 24
Steam, l<g/h 26.05 Condensate, L/min 0.434 Coolant, L/min 4.51 Diameter, cm 7.98
Feed rate = 2.5 L/min 8
12 16 20 24
Steam, l<g/h 43.41 Condensate, L/min 0.724 Coolent, L/min 7.52 Diameter, cm 10.31
-
-
-
Distillate L/min
0.022 0.033 0.044 0.055 0.066
16·33 0.272 6 -36 6 -32
0.066 0.099 o. 133 0.166 0.199
48.96 0.816
19.08 10.94
O. 110 0.165 0.221 0.277 0.332
81 .60 1 .361
31 .81 14. 13
Bottoms L/min
0.479 0.468 0.458 0.447 0.437
1 .437 1 .405 1 .373 1 -342 1. 31 0
2.394 2 -341 2.288 2.236 2. 184
------------------------------------------------------------
40
Table 10. Reflux ratio (1.5 x mlnlmum ratio) predicted when the distillate and bottoms were fixed at 180 and 0.1 proof, respectively
Feed Proof
8 /'2
~C6-
20 24
10
2.2 -2.0 1.9 1.7 1.5
Feed 30
2.9 2.5 2.2 2.0 1.8
Temperature C 50 70 90
4.0 6.0 7.6 3 ~3-- 4.5 6.0 2.8 3.7 4.9 2.5 3.2 4 • 1 2.2 2.8 3.5
41
locally and therefore was used for construction.
limited the feed rate to about 1.5 L/min.
This
The packing for the column was plastic Flexirings (Koch
Engineering Company. Wichita. Kansas). The smallest
diameter available was 1.5 cm. which was greater than 10% of
the column diameter. but these were used in the rectifying
section because they were inexpensive compared with other
packings. The manufacturer's recommendation of 2.5 cm
packing was used in the stripping section. The H.E.T.P. of
the Flexirings was 25 to 40 cm. The rectifying section was
built 3 m long. which was longer than necessary to enable
higher than 180 proof distlilate to be produced.
Me'ters and pumps
The sizes of pumps and meters were based on the results
in table 9. The following flow meters were used:
Feed: Kent Metron meter (361 pulses/L). 1% accuracy
for flow rates of 1.13 to 15 L/min.
Coolant and condensate: Kent positive displacement
water meter (C-100-FE) (52 pulses/L). 1.5% accuracy for
flow rates of 0.95 to 16 L/min.
Reflux and distillate: FloScan 300-1 (10433 pulses/L).
2% accuracy for flow rates of 0.13 to 1.8 L/min.
The following pumps were used:
42
Reflux pump: ViKing C32 gear pump driven by a manually
controlled variable speed D.C. motor.
Feed pump: Jabsco 7030 flexible-rotor pump driven by a
manually controlled variable speed D.C. motor.
Bottoms: The bottoms product flow was by gravity
through a solenoid valve controlled by a float switch in the
reboiler.
The steam entering the reboiler was at 33 KPa gauge.
This pressure was controlled by throttling the steam supply
through a Spence type ED series pressure regulator. Note
that for energy calculations the enthalpy of the supply
steam is used. The steam flow rate was controlled by a
pneumat..ic valve (Johnson controls series 9001) wi th 1 t.s
temperature sensor placed in the reboiler.
The water coolant flow rate was manually controlled
with a Kates automatic flow rate controller, which maintains
a constant flow rate regardless of the water pressure on
either side of the controller.
Data were collected electronically when possible with a
data logging device.
43
DATA COLLECTION
Introduction
Tne operating characteristics of the distillation
column were determined experimentally. The flow meters
selected produce electric pulses having a frequency
proportional to the flow rate and these pulses can be
recorded electronically. Temperatures were also recorded
electronically using current sourcing temperature sensors.
These give a current proportional to the absolute
temperature. The data logging device used in this
experiment was a CBM (Commodore Business Machines)
microcomputer (CBM User Manual 1979) provided wlth locally
constructed interface circuits.
cassette tape.
CBM microcomputer
The data were stored on
The microprocessor used by the CBM is a 6502. which is
an 8-bit device (R6500 Hardware Manual 1978). At the slde
of the CBM case there is a memory expansion port Which can
be used to access the 6502 address and data lines for
interfacing external devices.
44
Versatile Interface Adapter (VIA)
The 6522 VIA (R6500 Hardware Manual 1978) is a device
which acts as an interface between the microprocessor and
external circuits. It consists primarily of two
bi-directional ports, labeled PAO-PA7 and PBO-PB7, and two
16-bit counters. The VIA is programmable and has to be
initialized by software after every power up.
Figures 4 and 5 show how the two VIAs used for this
data logger are connected to the memory expansion connectors
of the CBM. All communication between the CBM and the VIAs
is digital in the form of TTL (transistor-transistor logic)
slgnals. The VIAs are controlled by the register select
lines (RSO-RS3), .which are connected to the CBM address
lines BAO-BA3. Before the VIA can accept any commands it has
to be enabled by the chip select lines CS1 and CS2, which
need high and low Signals, respectively, for chip selection.
The data bus lines (DO-D7) of the VIAs are directly
connected to the 6502 data bus in the CBM.
The control program for the data logger is written in
BASIC and is shown in Appendix B. To send data (write) to a
VIA the command POKE(address, data) is used; the read data
command is PEEK(address). Address is a decimal number which
1s translated internally by the CBM into the binary code for
chip selection and VIA control. For example, to select
GN
O
BA
li
BA
I
BA
2
BA
3
BA
,
BA
8
RES
Boa
BOI
B0
2
803
B0
4
B0
5
BD
6
B01
8!i2
~I
."'-.
J9
·3
J9
·4
J9
-5
...I
ti-
~
J4
-??
.-. J4
·3
J4
·4
J4
-S
J4
-6
J4
·7
J4
-8
J4
·9
J9-2
1
; .IQ
-17
SE
L E
fll
IRQ
o J
9·2
2
J9·1
9
vssW
PA
&
2 3
8
RS
O
PAl
3
'7
RS
I P
A2
4
36
R
SZ
PA
3 5
35
RS
3 P
A4
6
PA
5 7
PAG
8
34
R
ES
P
Al
9
33
00
pa
o 10
32
01
<t
PBI
II
31
02
>
P
B2
12
30
0
3
C\J
P
B3
13
C\J
2
9
D.
lf)
pa
4
14
<D
28
0
5
PB
5
15
27
06
P
B6
~Ne
.~
07
P
B1
~
25
1/
2 N
C
18 N
C
24
eS
I e
B2
19
I 2
3
eS
2
ve
e rl.
22
R
/Vi
21
.5V
IR
Q
} to
fi
g
5
+5
v
~~1615
14
1'3t:
1\ IO~
PI}
~V
~LF'
3332
17
1Li>
I 'I
4:>
I
2 3 ~~~
7 8
L
INQ
12
3
INI f¥
----
-~
1--
---1
IN
2
21
IN3
I
1 37
01
1 IN
4
2
36
01
rfTT
IN5
3
35
0
2
IN6
• 2
Z0
n
Olp
F
3.
03
IN
7 5
33
D.
INB
6
I I
I r-
----
-' 32
0
5
IN9
7 r-
I· 31
0
6
INIO
S
f.-
30
0
1
INII
9
.---
-2
5
AO
A
INI2
10
1
2tl
l .---
"-2
6
AO
B
CO
14
13
10
9 8
f---
-IN
I3
\I
~LM32~
27
A
De
0 IN
14
12
U
2B
AD
O
0 E
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l "
1
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0K
n
<t
29
A
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INI5
14
~ ~
40
OU
TPU
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8 E
NA
BLE
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UT
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RT
ve
e
I 2
3 4
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6 1
f.-
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QM
P
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IN
39
f!
L!5
V
CLO
CK
R
EF t
L-t
-,----f-
--
GN
O n-
IT f 11
2
F
56
n
1
: 11
5KO
~
'---
--1
-t-
----
---
l--
r t----- ~-
Ii
11
---
t5V
3OK
O
30
KO
13
0K
fl
30
Kn
r 2
Kn
2K
n12K
n 2K
nl T
RIM
P
OT
S
TR
IM
PO
TS
Fig
ure
4
. A
nalo
g
to d
igit
al
co
nv
ert
er
an
d
tem
pera
ture
sen
so
r cir
cu
its
} TO
SE
NS
OR
S
A0
59
0
~
\Jl
GN
D
aA~
BA
I I[J
~9~-~3
~-----
------
------
-~~
BA
2
J~9~-~
4~----
------
------
--~
aA
3
J9
-5
~
BA
4
J9
-S
o
BA
a
9~-~1 ~ _
_ _
~
RE
S
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BD~
~
BD
I
J4
-22
J4
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AD
3
5
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3
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O
PA
S
7
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P
AS
I 0
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7 9
DA
TA
LIN
ES
FR
OM
C
OU
NT
ER
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(fIQ
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I.
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z
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30
03
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:: P
BO
1
0
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4
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29
9
04
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2
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05
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S
PB
3
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7
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D7
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-9
~ ",,,,,
~I SIT
91 J4
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BR
/W
J9
-22
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r 23
m
2
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rna
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5 14
a
tt 6
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7 12
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40
4
Fig
ure
5
. M
ult
iple
xin
g
and
co
ntr
ol
cir
cu
it
CO
NTR
OL
RE
LAY
S
(no
l u
se
d)
AN
ALO
G
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ITC
HE
S
(IIQ
.4)
CO
UN
TE
R
CLE
AR
S
(fiQ
. 7
a 8
)
CO
NTR
OL
LIN
ES
fO
R
TR
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TA
TE
B
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ER
S
(lig
. a
)
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AR
B
-B
IT
CO
UN
TER
TIM
ING
S
IGN
AL
(f
iQ.
7)
"" 0\
47
the VIA in figure 4, in which CS2 is connected to SEL9 and
CS1 is connected to BA4, the address 36880 is used (SEL9 +
BA4 = 36864 decimal (9000 Hex) + 16 (24) (CBM User Manual
1979». To select the VIA in figure 5, address 37120 is used
(SEL9 + BA8 = 36864 + 256 (28». These two addresses are
stored as constants P and 0 in lines 230 and 240 of the
control program.
Initializing the VIAs
The VIA's bi-directional ports (PAO-PA7, PBO-PB7) can
be individually programmed so that each pin can either act
as an input or an output under the control of the Data
Direction Registers (DDRA, DDRB) which are set during
initializatlon. To make a pin an input, a "0" corresponding
to that pin must be put in the Data Direction Register;
similarly a "1" corresponds to an output.
The VIA in figure 4 is used to control and read datd
from an analog to digital converter. Port A is used to
recelve data and consists entirely of input lines, while
Port B is used for control (except for PB7 which is a data
line) and is configured mainly for output lines. To dchleve
this condition, it is necessary to determine the deCimal
number that the software must store in DDRA and DDRB. The
pins and their corresponding decimal numbers are given by (0
input, 1 output).
Pi n Ii Port A Port B
Therefore DDRA = 0
48
DORB = 1 + 2 + 4 + 8 + 16 + 32 + 64 + 0 = 127
Table 11 gives the control settings for the RSO-RS3
pins used to select various registers in the VIA. To put 0
in DORA and 127 in DORB for ~he VIA in figure 4 ~he software
commands POKE(P + 3, 0) and POKE(P + 2, 127) are used (lines
250-260 of the program). The VIA is now initialized. Note
that PB6 has no connec~ion, so i~ does not matter whether it
is set as an input or an output. The command POKE(P + 2,
63) would also satisfy the system. Similarly, the second VIA
~s initialized wi~h Port A as inputs and Port B as outputs
(except PB7).
Table 11. Control addresses for the VIA registers
------------------------------------------------------------Register RS3 RS2 RS1 RSO Decimal Address
------------------------------------------------------------ODRA 0 0 1 1 3 + chip select DDRB 0 0 1 0 2 + Chip select ORA/IRA 0 0 0 1 + chip selec~ ORB/IRB 0 0 0 0 0 + chip select ARC 1 0 1 1 11 + chip select T1R-L 0 0 0 4 + Chip select T1R-H 0 0 1 5 + chip select
------------------------------------------------------------
49
Once initialized, the VIAs are ready to receive and
send data. The output of Port B is accessed by the Output
Register (ORB), in which a "0" would cause the corresponding
pin to have a low output and "1" a high output. For
instance, to make pins PBO and PB6 high, the following
decimal value needs to be written to the ORB.
Pin H Port B
ORB = 1 + 64 = 65
6 1 1x26 (input)
Using Table 11 for the ORB address, the software
command required to obtain the above output configuration on
Port B of the VIA in figure 4 would be POKE(O + 0, 65) or
just POKE(O, 65). Once the Output Register is written to,
the pin outputs will remain unchanged (latched) until a
different data value is: stored. Pin PB1 was designated as
an input pin by the DDRB and its state will remain unaltered
whether it is written to by the ORB or not, i.e. POKE(O,
193) will accomplish the same result as above.
The data on Port A are received by reading the Input
Register (IRA). The commands PEEK(O + 1) and PEEK(P + 1)
will give a decimal value which can be interpreted to find
the state of each pin.
50
Analog ~ digital converter
The ADC0817 chip (figure 4) is an analog to digital
converter (National Semiconductor 1980). An analog Signal
is an electric signal which can vary in amplitude to any
value within the range that a particular device can produce
(e.g. 0-5 V). A digital signal is one which changes
abruptly between two levels (i.e. high or low).
The temperature sensors are analog devices. An analog
to digital (A to D) converter is used to convert the analog
voltage derived from the sensor into a digital Signal that
can be read by the microcomputer.
The ADC0817 is a 16-channel 8-bit A to D converter that
can multiplex up to 16 different analog signals. An 8-bit A
to D converter can respond to an input change of 1 part in
256 of the working range; in this instance the range is 0-5
V. The conversion is linear such that 1 V input would give
a (255/5) = 51 decimal output.
The data lines of the A to D converter are connected
directly to port A of the VIA (figure 4). Each channel of
the ADC0817 is selected by the address pins A, B, C and D,
which are connected to pins PBO-PB3. Pin PB4 is
simultaneously connected to the "start" pin and "ALE" pin.
When a digital pulse 1S sent to these pins, the channel
selected by the address line will begin converting. When
5 1
the conversion is stable an end of conversion signal (low to
high) will be given at pin "EOC" that can be read by the
microcomputer via pin PB7. In practice, control software
written in BASIC is so slow that by the time the
microcomputer can read PB7, after sending the start pulse
the conversion will be complete. In this case, the data can
be read immediately by sending a signal" (high) to the
tri-state control through PB5, which enables the data lines
so Port A can read the data.
For example, to read in the digital equivalent of the
analog signal on channel 10 the following sequence would be
used. First channel 10 is addressed by supplying the
command POKE(P, 10). The start conversion Signal, POKE(P,
10 + 16) is sent, next POKE(P, 10) is sent to give a
starting pulse (low-high-low), then the tri-state control 1S
enabled by POKE(P, 10 + 32) and finally the data value is
read with PEEK(P + 1). Note that a decimal value is read
into the microcomputer that is directly proportional to the
voltage on the channel being read.
Temperature transducer and circuit
The temperature transducer is an AD590 (Intersil
DataboOK 1981), which is a two terminal integrated circuit.
Calibration is at 298.2 K (25 C) when the transducer has an
52
output of 298.2 pA that changes at the rate of 1 pA/K. The
direct current produced is unaffected by changes in voltage
supply (+4 to +30 V).
The analog current output needs to be converted to an
analog voltage with a 0 to 5 V range for the A to D
converter. This is achieved with an operational amplifier
connected as a summing circuit (Maloney 1979); figure 6
shows the circuit. The output voltage V , var1es from 0 to o
5 V. Calibration of V for rate change and absolute value o
is accomplished by adjusting the variable resistors R2 and R4
•
If the temperature range is selected as 0 to 100 C the
current 12 will vary from 273.2 to 373.2 pA. For Vo = 0 at
o C the current 13 must equal zero. An ideal operational
amplifier has ID = 0, so that at this state I, = 12 which
gives:
5 10-6
12 = ------- = 273·2 x A (33)
Rl + R3
Hence Rl + R2 = 18.3 Kohm, the values chosen were R, = '7
Kohm and R2 = 2 Kohm trim pot.
For the upper limit of Vo = 5 V at 100 C, Kirchoff's
law at the summing junction gives:
(34)
I3
+ 5V
... --,
II
I2
-1
5V
·e----f
+
AD
59
0
10 K
.n.
Flg
ure
6
. T
em
pera
ture
sen
so
r clr
cu
it
22
0tl
. '.
eVO
O.lp
F
I U
1
W
54
so 13 = -100 x 10-6 A.
For summing amplifier circuits (Maloney 1979)
-v o 13 = -------
R3 + R4
which gives R3 + R4 = 50 Kohm.
Values R3 = 39 Kohm and R4 = 20 Kohm trim pot.
From equations 33. 34 and 35 it can be found that
5 -------:0 T, x '0
5
R3 + R4 = (~~=~~)-~-~~:6
where T, is lower and T2 the upper temperature in K.
(36)
In this experiment the following temperature ranges and
resistors were used.
T 1 ( C) T2
(C) R 1 (K) R2
(K) R3
(K) R4 (K)
50 100 15 2 56 30 55 105 13 2 56 30 60 110 13 2 56 30 20 95 17 2 39 20
The LM324 (National Semiconductor 1980) was the
operational amplifier used because it has a single positive
supply voltage (figure 6). which insures that V does not o
become negative if the temperature being measured is below
the lower end of the temperature range. Negative voltages
can cause serious damage to A to D converters.
55
Calibration of the temperature sensing circuit is done
by placing the transducer in a controlled temperature bath.
It is important that the lower end of the temperature range
is obtained to adjust R2 since the operational amplifier
offset (ID
~ 0) is also corrected for by this resistor. At
this condition I3 = 0 so the values of R3 and R4 are
unimportant. Once R2 is set R4 can be adjusted using a
higher temperature bath.
The sensitivity of the temperature measurements depends
largely on the temperature range chosen. A 0 to 100 C
temperature range is represented by 0 to 5 V Which, after
going to the A to D converter, is represented by an integer
between 0 and 255. Therefore on this temperature range the
microcomputer can only measure to within ~ 0.39 C. By
reducing the temperature range a more precise reading can be
made.
A total of 30 temperature sensors were used in the
experiment with 22 equally spaced down the column. The
approximate temperature distribution along the column is
known from the ethanol-water equilibrium data, thus the
temperature range of some sensors can be reduced to improve
precision. The top of column operates at about 78 C and the
bottom at 100 C. Therefore the first 8 sensors from the top
had. a temperature range of 50-100 C, the next 8 a range of
56
55-105 C. and the final 6 (2 sensors unused) a range of
60-110 C. The remaining six sensors had a 20-95 C range and
were used to measure beer feed when cold. beer feed heated.
condenser coolant in and out. reflux temperature and the
temperature of ethanol leaving the condenser.
The A to 0 converter had only 16 channels. so analog
switches were used to double the use of each channel. The
LF13332N (National Semiconductor 1980) analog switches
(figure 4) switch from one set of 15 temperature ~ensors to
the other under the control of the multiplexing system shown
in figure 5. Lines 550-610 of the control software
(Appendix B) poll 15 temperature sensors and line 620
switches to the second 15 sensors. which are then polled by
lines 630-690. The 16th channel on the A to 0 converter was
reserved for measuring pressure. but the system was not
completed.
The arrays A (I) and B (I). in the software now store
numbers which are directly propor~ional to the temperatures
being measured. The program converts these numbers to
temperature readings (lines 740-1000 of the program).
Each equation depends on the temperature range being
used. For example. suppose that a sensor at the top of the
column produces a 1 V signal from the operational amplifier
which after A to 0 convertion is represented by the integer
57
51. Then
temperature = 51x50/255 + 50 = 60 C.
The software shows a slightly different conversion
equation, because the A to D converter at the lower end of
the temperature range could not be completely zeroed. By
maKing a software correction the lower end of the range
could be obtained.
Counters
All the flow meters used in this experiment have
pulsing outputs proportional to the rate of flow of liquid.
To measure the flows it is necessary to Know the number of
pulses in a given time. To achieve this, the output of each
meter was connected to a 16-bit counter. The pulse train to
the counters was started and stopped by hardware controlled
by the CBM's internal clocK.
The hardware control primarily consists of dual pulse
synchronizers/drivers (SN74120) (TTL DatabooK 1981) and
divide by N counters used to step down the 1 MHz
microprocesser clocK. The SN74120 chips are used to start
and stop the pulse train. A signal to the SN74120 allows the
pulse train from the meters to pass through to the counters.
Another signal to the SN74120 then inhibits the pulse train,
after a started meter pulse has been completed. This insures
58
no glitching of the counters.
The time period between the start and finish of the
pulse train was determined by the calculated flow rates, the
number of pulses from each meter, and the size of the
counters. For accuracy it is necessary to count as many
pulses as possible without the counter overflowing. Each
16-bit counter will count up to 65535 pulses. The time
period chosen had to insure that the pulse train from the
meter with the maximum pulse rate did not overflow the
counters and that the pulse train from the meter with the
minimum pulse rate registered sufficient pulses to allow an
accurate measurement. For this equipment a time period of
10 s was chosen.
The 10 s time period was accomplished by stepping down
the system's internal 1 MHz clock with a 16-bit counter in
the VIA, and two 4-bit counters. Two 4-bit counters
(SN14161) were used instead of decade counters (SN74160)
because the SN74161 direct clear feature is independent of
the state (high or low) of the clock input. This prevents
glitching when control software enables the clears to reset
the counters. The 4-bit counters are connected as ripple
look ahead counters (TTL Databook 1981) that will count up
to 255 before resetting to zero. For a 10 s time period
output these counters require a (10/256) = 0.039062 s input
59
clock period. This comes from pin PB7 of the VIA.
The VIA internal counters can be used in several
different ways (R6500 Hardware Manual 1978). For this
application the VIA counter is initialized so that it counts
down from a set value to zero at a rate equal to the
system's clock (1 MHz). At zero the output of pin PB7 is
inverted (i.e. high to low or low to high) and the counter
is returned to its preset value to begin the sequence again.
The preset value is determined by the rate at which pin PB7
is required to oscillate. The 4-bit counters need a 0.039062
s clock input, but the SN74161s are positive edge triggered
counters meaning that pin PB7 would have to invert twice
every 0.039062 s. For this to happen the internal VIA
counter must reach zero at (0.039062/2) = 0.019531 s
intervals. A preset value of 19531 declining at the system
ClOCK rate of 1 MHz would accomplish this.
Conditioning pin PB7 to toggle is done during tne
initialization of the VIAs. When the respective bits ACR6
and ACR7 of the Auxiliary Control Register (ACR) in the VIA
are set to "1" pin PB7 will generate a continuous square
wave. The Auxiliary Control Register is accessed using the
address in Table 11 and the decimal value (2 6 + 27) = 192
is written to it (line 270 of software in appendix B).
During initialization the 16-bit counter also has to be
60a
set to the value of 19531. Since the CBM is an 8-bit
machine that can only transfer numbers up to 255 at one time,
the 16-bit counter is loaded in two halves. The least
significant 8-bits are first loaded into Timer One
Register-Lower (T1R-L) then the most significant 8-bits are
loaded into Timer One Register-Higher (T1R-H), such that the
net effect is the number 19531 in the 16-bit counter. The
two 8-bit numbers are determined by:
Most significant
2 15
32768 19531= 0
214 2 13
16384 8192 1 0
212
4096 o
Binary 01001100 = 76 decimal.
211
2048 1
2 10
1024 1
+ 75 remainder
The most significant 8-bits = 76 and the least
significant = 75. Lines 280 and 290 initialize the VIA with
these values. Once initialized the VIA will continuously
toggle pin PB7 with a period of 0.039062 s until the power
is shut off or the CBM clock signal stops.
Figure 7 gives the complete 10 s timing c~rcuit
including the SN74120s. The SN74109 chip is a dual positive
edge triggered flip-flop (TTL databook 1981) that is needed
to synchronize the 256th pulse from the VIA with the stop
TIM
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61
counting pulse that activates the SN74120s. This is because
the 4-bit counters are wired as ripple loOk ahead counters.
The SN74109 also synchronizes the first pulse after the
counter clear signal with the start counting pulse. The
SN744120 chips are activated by a pulse (low-high-low),
which is achieved using the monostable SN74123 (TTL Databook
1981).
Pulse trains from the beer, reflux, distillate and
coolant meters passed through a SN74120 before going to the
16-bit counters which consist of four 4-bit (SN74161)
counters wired as ripple lOOk ahead counters (figure 8).
After a 10 s time period the counters stop counting and
are ready to be read by the microcomputer. Again the 16-bit
count has to be handled as two 8-bit counts. The 4-bit
counters are taken in pairs and the data lines connected to
a tri-state buffer (SN74244) (TTL Databook 1981), which in
turn is connected to port A of the VIA in figure 5. A
tri-state buffer acts as an open circuit for each data line
except when it is activated. This enables the CBM to read
each pair of 4-bit counters in turn through the same VIA by
signalling the SN74244s. If the least significant 8-bits
(LSB) of say the reflux counter are first read into the CBM,
followed by the most significant 8-bits (MSB), the total
62
COUNTER CLEARS (f i g 5) PULSES (fig 7)----------------------------------------------------------~
DATA LINES { ____ ~ ( fig 5)
1"5V ..JQ. ENT L GND ful' ENP~t5V
r---------------------~I~I 0 --12 A * A 3
t
15V r---------------------...:1=-i3 O. ~ B 4 NC
r------------------~::!..I Oc __ C 5 20 Iq, r-----------------~14:!..1 0 0 rt D 6
VCCGNC11' ~ RC CK:4-_...--2 ---
CONTROL LINES lfig 5)
~ 2Y4 __ 2A4 ~ r6 VCC CLR °1------......
~ 2Y3 * 2A31L-1-..5. 2Y2 <;t 2A2~ .......... ~~V"""<""::":-:--:: ___ ~ ~++_3~ 2YI <;t 2A1 17 T5V 69
H+f-+--,1.=j2 IY4 ~ IA4 8 L GND ~" 14 IY3 IA3 b ~ ENT N 7
1
'--________________ ---LI Wi OA "k. ENP~ H+-jf-.+.+-+--,1l£l6IY2 1A2 ~4 ~
l '--__________________ ---L12~ a -- A 3
H+f-+-+--I-l--.2:18>!jIYI 13 • ~ B 4 NC IAI L--------------------~ac ~ C 5
rl9 2<; IG l 14 00 I'- D 6
,.--li. R t. CK'<l--=-2--+------<i 16 CLR P----!-~ (VCC I
t5v t 5V
t5V -l9 l20 I Of' L GNDIilI"
L..-b.L ENT r<) ENP~ VCC 10 r-----------!..WII a :ft:
GND811' 12 aA
__ A 3 e-2 2Y4 2A4/lL-J I 13 a 1O 8 4 ~ 2Y3 N 2A31!L-JW3 OC <j= C 5 NC ~ 2Y2 fl:: 2A21 14 aD I'- 0 6
~ RC CK;t-,.2~+--3 2YI <;t 2AI 171 r6 CLR
'--____ -"12"'1IY4 <;t IA48 VCC I
'--____ ---'1.:!l4 1Y3 ~ IA3 ~ ..... t5V t5V L-______ ...!12.j6 IY2 I'- IA2 ~ -.-
'--_______ -"18"'lIYI IAI ~ )$ L GND lm
J ~ 2(; I/; ~ ---1Q. ENT ENP~ 1 . , L-------------------~II!..jaA <;t A 3
L-_________________ ~12::..J Qa '=" B 4
L-___________________ ....!1~3 Oc ~ C 5 NC
'--____________________ !2.I14 a ~ 0 6
NC~ R~ I'- C K:~2--...J t5V ~ VCC CLR I
Figure 8. counters and tri-state buffers
63
count is given by:
total count = LSB + 256 x MSB
Multiplexing
Port B of the VIA in figure 5 is used control all the
SN74244s, the analog switches, and four lines to operate
relays for proposed automatic control of the column. The
total number of control lines needed is greater than the
seven lines of port B available (since PB7 is providing the
square-wave timing cycle). In order to multiplex these
lines, the BCD to decimal decoder (SN74145) and the 3 to 8
line decoder (SN74138) are used (TTL DataboOK 1981); figure
5 shows the wiring. SN74145 has open-collector outputs that
can sink up to 80 rnA of current. Pullup resistors of 1 0
Kohm are used to tie the outputs high when not switched on
(except pin 6 whiCh has a 2 kohm pullup resistor and drives
all the counter clears).
Table 12 gives the address ar.d function of all the
decoder outputs.
64
Table 12. Multiplexing address used with the command POKE(O, Address) . ------------------------------------------------------------
Address
o 1 2 3 4 5 6 7 8 9
1 1 26 42 58 74 90
106 122
Function
Control relay (not used) Control relay (not used) Control relay (not used) Control relay (not used) Analog switches Clear counters and 10 s timing LSB Feed meter MSB Feed meter LSB Coolant meter MSB Coolant meter No state (All outputs off) LSB Reflux meter MSB Reflux meter LSB Distillate meter MSB Distillate meter Condensate meter, 8-bits only Unused 8-bit counter Clear 8-bit counters
------------------------------------------------------------
65
COLUMN CONSTRUCTION
The dis~illation plant was constructed in an unused
grain eleva~or. Figure 9 shows the column ascending through
the building. Locally available pipes and fit~ings were
used for column construction and piping. Insulation was
used to decrease heat loss from the column surface. The
~emperature sensors were placed in copper sheaths and
screwed into holes in the column. These copper sheaths may
have caused a temperature gradient between ~he vapour and
column wall ~emperatures.
The column and reboiler (figure 10) were built in an
enclosure with elec~rical equipment outside to reduce
explosion hazard due to e~hanol vapour. Figure 11 shows
the datalogger outside the enclosure. The CBM screen
(figure 12) continuously indicates the temperature of each
sensor with T1 at the top of the column (T23 and T24 not
connected and T14 and T17 were faulty). The counters C1-C6
indicate the number of pulses received from each flow meter
in 10 s. The time is shown at the top of the screen.
66
Figure 9. View up the distillation column
61
Figure 10. Reboiler and column in explosion proof enclosure
68
Flgure 11. Dat.alogger
69
l31617 2335 2 3 : ~~:~ fi~ : ~a:1 = 77.5 T15 = 96.9 T 4 = 77.7 T 16 = 98.3 T S = 77.9 T17 = 62.2
, auto
T 6 = 78.5 T18 = 98.9 T 7 = 88 T19 = 99.1 T 8 = 84 T28 = 99. 3 T 9 = 91. 6 T21 = 99. 5 T 18 = 93.3 T22 'i. 97 • 4 T 11. = 94. 3 T23 .. 64 • 9 T 12 = 9S. 3 T24 = 64.7
distillate out = 18.5 accumulator = 38.9 cond in = 28.9 cond out = 41.3 cold beer = 35.2 hot b~~r = 85.9
c1 = 6S c2 = 3S c3 = 1282 g~ : is 06 • 2
...
Figure 12. Screen of the CBM snowing temperatures and flow rates
70
EXPERIMENTAL PROCEDURE
Before collecting data it was necessary for the column
to reach steady state. After a cold start the temperatures
were monitored on the screen of the CBM. To have a
distillate of 180 proof, it was necessary to maintain the
top of the column at about 78 C (Hirata ~ ale 1975). Once
some ethanol had been collected in the accumulator at the
top of column, the reflux rate was adjusted until the
desired temperature was obtained. The reflux rate and the
distillate rate could both be monitored on the CBM screen.
Some problems were encountered with the float switch in
the reboiler. Vapour loc~s in the float housing caused
flooding during the warm up and venting to the atmosphere
was necessary. Vapour in the distillate line caused erratic
flow measurements. A continuous flow of liquid was obtained
by restricting the flow outlet, causing a head of llquid in
the distillate line.
The time ta~en for the column to become stable was
approximately 20 min. On each run, however, the column was
operated for several hours.
71
RESULTS
The CBM recorded data on cassette tape once every
minute. These data were averages of all the temperature and
flow readings taken during that minute. Appendix E gives a
printed sample of data collected over a two hour period.
The column had been running for 2 h before the sample was
taken. Each page of Appendix E shows 5 min of collected
data with the mean and standard deviation for that perlod.
At the end of the table an overall average and standard
deviation are given.
As expected, the temperatures increase on moving down
the column (T1-T22) as water becomes the dominant component.
A large standard deviation indicates that the temperature
changed during operation. Sensors T3 and T9 were located
directly below the reflux return point and feed pOint,
respectively. The reflux from the accumulator maintained a
consistent temperature (ACCUMUL) during the 2 h period as
did the feed temperature (HOT BEER). These incoming liquid
streams seem to have stabilized T3 and T9, proving that many
of the column temperatures were varying while running and
that the large standard deviations were not due to the
erratic performance of the data logging system. Sensors T1
and T2 were above the packing and measured vapour
t.emperat.ures.
reflux rat.e.
72
These t.emperat.ures were used t.o set. the
All t.he t.ables in Appendix C refer t.o dat.a collect.ed on
August. 24, 1982.
August 21, 1982.
Appendix D gives the data collect.ed on
In each case, measurements of dat.a for the
feed, condensate, and distillate flow rates were t.aken
manually. These results could be used t.o check the
measurement.s made by the data logger.
Flow rates
For the August. 24 results, t.able C1 gives a mean feed
rate (FEEDRATE) of 1.338 Llmin recorded by the data logger;
this rate compares well wit.h the mean flow rate of 1.335
Llmin from table C2, which was based on readings taken
manually from t.he meter dial. A third measure of flow rate,
calculated from the change in feed tank dept.h, indicated a
much higher flow of 1.52 L/min. The same result. occurred
for August 21, as shown in tables D1 and D2. After the
tests were completed, the reason for this discrepancy was
det.ermined t.o be solids accumulat.ed in t.he meter.
rate was at the low end of the meter's range.
The flow
Tables C3 and D3 give the dist.illate flow rates, which
compare well with average flow rates recorded and shown in
t.ables C1 and D1 (DISTILL).
73
The reflux flow meter used was the same type as the
dlstillate meter. By dividing the reflux flow rate (REFLUX)
by the distillate flow rate (DISTILL), the reflux ratio is
obtained (RF RATIO). The reflux ratio has a standard
deviation greater than that of either the distillate or
reflux, caused largely by the reflux ratiO being defined as
reflux divided by distillate. During operation the reflux
rate remained reasonably constant whereas the distillate
flow rate could, at times, almost approach zero causing a
large reflux ratio.
The condensate flow rate measurements from the reboiler
shown in tables C4 and D4 indicated that condensate flow
meter measurements (CONDENSATE) were low. This could be
expected because the flow meter was operating below its
minimum recommended capacity.
Energy
From the condensate flow rate, it is possible to
calculate the energy being used by the column. For both
August 21 and 24 the main steam pressure was 290 kPa
absolute. If the condensate is considered saturated, then
energy given to the system is 2167 kJ/L of condensate.
Using the measured data from tables C4 and D4, the rate
of heat input required on August 21 was:
74
ra~e of hea~ input = 14.4 kW.
and on the August 24 was:
rate of heat input = 16.0 kW.
Energy used ~o produce a litre of distillate on Augus~ 21
was:
Energy/litre = 11014 kJ/L
and on Augus~ 24 was:
Energy/li~re = 6093 KJ/L.
75
DISCUSSION AND RECOMMENDATIONS
The data logger seemed to work well. Further work needs
to be done on the calibrations of both flow and temperature
sensors.
The energy requirement of a conventional distillation
column is about 4900 kJ/L to convert 20 proof beer to 190
proof distillate (Eakin ~ ale "1981). On August 24 about
185 proof distillate was produced from 18 proof beer using
6093 kJ/L. Note that the energy requirement increases when
the feed proof decreases, as in the case of August 21.
If the feed is preheated, the design program indicates
more energy is needed for distillation. Table 7 shows that
for feed temperatures above 30 C the energy requirement of
the column increases rapidly. This seems to be due partly
to the increase of reflux with feed temperature (table 10).
With a higher reflux rate, more heat is removed by the
condenser (table 8) and so the energy required at the
reboiler increases. The design program also indicates that
the heat energy rate supplied to the column decreases with
proof (table 7). This seems to have been confirmed by the .
energy rate of 14.4 kW used on August 21 when the feed was
10 proof compared with 16.0 kW used on August 24 when the
feed was 18 proof.
76
The actual performance of the column and the design
program prediction can be compared by using input data equal
to the measured values in Appendix C. The data in Appendix C
for the August 24 are used because the distillate flow rate
and reflux ratio recorded by the data logger had smaller
standard deviations than the data recorded on August 21.
The following results were obtained:
Input:
Feed proof: 18.07
Feed rate (L/min): 1.515
Feed temperature (C): 65.602
Distillate proof: 183.5
Bottoms proof: 0.1
Minimum reflux ratio multiplier: 1.5
Condenser fiT (C): 25.1
Output:
Total plates:
Rectifying plates:
Stripping plates:
Reflux ratio:
Distillate rate (L/min):
Coolant rate (L/min):
Condensate rate (L/min):
15
7
8
3.5
o. 127
7.87
0.64
77
Column diameter (cm): 9.95
These results compare reasonably well with those
Appendix C, except that the condensate and coolant rate
measured were lower than predicted. Better positioning of
the sensor measuring the coolant temperature from the
condenser may have given a larger ~T, which would decrease
the predicted coolant flow rate. The measured dlstillate
flow rate and reflux ratio compared well with thos~
predicted by the computer model.
The rectifying section was 3 m long, which, according
to the computer program, is equivaient to 7 plates. This
gives:
H.E.T.P. = 300/7
= 42 cm
and for the stripping section,
H.E.T.P. = 800/8
= 100 cm
These results are high compared with the manufacturer's
figures (25 to 40 cm), but it must be noted that the paCKing
diameter is greater than 10% of the column diameter. Better
results for the stripping section might have been obtained
if 1.5 cm paCKing had been used.
The flow meters in the data logging system produced
78
consistent results, but better calibration is necessary.
For further operations, it would be desirable to run the
column with the same feed and distillate proofs but vary the
feed temperature to see how this affects the steam
requirements.
to be devised.
An improved method measuring steam flow needs
Little attention was given to the bottoms product and
bottoms flow rate because of difficulties 1n measuring flows
from the solenoid valve. Using a continuously overflowing
weir from the reboiler would simplify flow measurement.
Running the bottoms product into a tanK would also be a
feasible method of data collection. All the flow rates could
be accurately measured electronically with tanKS on load
cells.
79
CONCLUSIONS
The distillation column worked in a way that was
expected from the design. Alcohol of over 180 proof was
produced with an energy requirement that agreed wi~h
available literature.
The da~a logger proved reliable enough ~o record da~a
~ha~ could be used for fur~her study.
The design program and the limited data available
indicate ~hat no energy saving advantage is obtained by
preheating the feed to a conventional frac~ionating
dis~illation column that is separating an e~hanol-water
mixture. In fac~ preheating feed seems to be de~rimental.
80
REFERENCES
Bothast, R. J., and R. W. Detroy. "What is alcohol? How is it made?" Proceedings of regional worKshop, Alcohol and Vegetable oil as Alternative Fuels, Raleigh, NC, April 7-9, 19&1; Sacramento, CA, April 21-23 1981; Peoria, IL, April 28-30, 1981.
Brown, G. G., D. Katz, A. S. Foust, and R. Schneidewind. Unit Operations. John Wiley & Sons, Inc., New York, 1950.
Commodore Business Machlnes, Inc. CBM User Manual, Model 2001-16, 16N 32, 32N. Professional Computer. 1st ed. CBM, Santa Clara, CA, 1979.
Coughanowr, D. R., and L. K. Koppel. Process Systems Analysis and Control. McGraw-Hill, New York, 1965.
Denn, N. M. Process Fluid Mechanics. Prentice-Hall International Series, Englewood Cliffs, NJ, 1980.
Department of the Treasury. Bureau of Alcohol, Tobacco and Firearms. Gauging Manual. Embracing instructions and tables for determining the quantity of distilled spirits by proof and weight. ATF-P5110.6 (11/78). U.S. Government Printing Office, WaShington D.C., 1978.
Eakin, D. E., J. M. Donvan, G. R. Cysewskl, S. E. Petty, and J. V. Maxham. "Evaluation of Ethanol/Water Separation Process." Fuel Alcohol and Gasohol U.S.A. 3, N0.9: 13-18, September 1981.
Ensminger, H. E., and C. G. Olentine, Jr. Feeds and Nutrition Complete. The Ensminger PUblishing-Gompany, Clovis, CA, 1978.
Hirata, M., S. Ohe, and K. Nagahama, Computer Aided Data BOOK of Vapor-Liquid Equilibria. Kodansha Scientific BOOKS, Kodansha Ltd., 12-21 Otowa 2-chome, BunKyo-Ku, TOkyo, 1975.
Intersil, Inc. 1981.
Data Book. Intersil, Inc., Cupertino, CA,
81
Maloney, T. J. Industrial Solid-State Electronics, Devices and Systems. prentice-Hall, Englewood Cliffs, NJ, 1979.
McCabe, W. L., and J. C. Smith. Unit Operations ~ Chemical Engineering. 3rd ed. McGraw-Hill, New York, 1976.
National Semiconductor. Linear Databook, National Semiconductor Corporation, Santa Clara, CA, 1980.
Perry, J. H. Chemical Engineers Handbook. 2nd. ed. McGraw-Hill, New York, 1941.
Rockwell International. R6500 microcomputer system hardware manual. ROCkwell International, Document No. 29650 N31, August 1978.
Selby, S. M., and B. Girling. Standard Mathematical Tables. 14th ed. The Chemical Rubber Co., Cleveland OH, 1965.
Texas Instruments, Inc. Engineers. 2nd ed. TX, 1981.
The TTL Data Book for DeSign Texas Instruments, Inc., Dallas
Williams, L. A. "The Production of Alcohol for Fuel." proceedings, Biomass Alcohol for California: A potential for the 1980's. University of California, Davis, CA, January 18, 1980.
82
ACKNOWLEDGEMENTS
I would like to express my appreciation to Dr. Richard
Smith for all his help on this project. I would also liKe
to thanK Dr. Harold SKanK, Jonathan Chaplin, James Andrew
and Don Schultz for their help with the experimental worK
and Gillian Smith, Kevin CmeliK, Dennis Jones and Carol
Hansen for their help in producing this thesis.
83
APPENDIX A:
DESIGN COMPUTER PROGRAM LISTING
10 HOME 20 A$ : "/11111 " 30 B$ : "1111 .1111 " 40 C2$ :" ":C$:" " 50 E$ : " 11.111111" 60 D$: CHR$ (4)
84
70 F$ : "11/1 /1.11/1/1 /1.11/111" 80 G$ : " MIN: /1/1#.## MAX: ###.#11" 90 H$ : " MIN: ###.## MAX: ##11.#/1" 100 IS : "MIN: ##.#/1# MAX: #/1./1##" 110 PRINT D$;"BRUN PRINT USE" 120 PR$: CHR$ (9) 130 DEF FN F(X) : E + X * (A + B * X + C * X * X + D * X * X * X) 140 DEF FN F1(X) : * X)
A + X * (2 * B + 3 * C * X + 4 * D * X
150 DEF FN F2(X) : 160 DEF FN LA(X) : 1315.369 * X * X * X 170 DEF FN P1(X) :
2 * B + X * (6 * C + 2254 - 974.047 * X
12 * D * X) 1275.2 * X *
X * X - 463.03 * X * X * 999.991 - 0.7603 * X + 4.4518E
X +
3 * X * X 180 X + 190 X 200 210 220 230 240 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410
DEF FN P2(X) : 1305.51 - 4.155 * X - 1.697E - 3 * X * 1.3118E - 4 * X * X * X - 4.135E - 7 * X A 4
DEF FN TB(X) : 99.97286 - 103.015 * X + 199.5292 * X *
PE : 793.7:PW : 1000 PRINT "FEED PROOF" INPUT" MAX: ";FM INPUT" MIN= ";FP INPUT "# OF ITERATIONS (MAX 10) ";J2
F5P = FP FV = (FM - FP) / (J2 - 1)
PRINT "" PRINT "FEED INPUT " INPUT " INPUT "# OF
FIT = FT
TEMP" MAX= ";FH MIN= ";FT ITERATIONS (MAX 12) ";L2
FC = (FM - FT) / (L2 - 1) T = (40 - 6 * (L2 + 1) / 2)
PRINT "" PRINT "FEED RATE" INPUT" MAX= ";FM INPUT" MIN= ";FR INPUT "II OF ITERATIONS (N.B. PAGE EACH) ";02
SFS = FR FS = (FM - FR) / (02 - 1)
85
420 PRINT "" 430 INPUT "DISTILLATE PROOF <194 : ";DP 440 INPUT "BOTTOMS PROOF : ";BP 450 INPUT "REFLUX PRODUCT (CONS*RMIN) CONS: ";U 460 PRINT "" 470 PRINT" CORRECT DATA (YIN) "; 480 GET X$ 490 IF X$ : "N" THEN HOME: GOTO 210 500 IF X$ : "Y" THEN GOTO 520 510 GOTO 480 520 PRINT 530 PRINT 540 PRINT "CALCULATING" 550 PRINT 560 DIM NP(J2,L2) ,NS(J2,L2) ,NR(J2,L2) ,R(J2,L2) 570 DIM Q1(02,J2) ,Q2(02.J2) ,Q3(02,J2,L2) ,Q4(02,J2,L2) 580 DIM UMIN3(02) ,U1MAX3(02) ,U2MIN4(02) ,U3MAX3(02) 590 DIM DI(02),D2(02) 600 FOR J : 1 TO J2 610 NP(J,O) : FP 620 NS(J,O) : FP 630 NR(J,O) : FP 640 R(J,O) : FP 650 FP : FP + FV 660 NEXT 670 FOR J : 1 TO L2 680 NP(O,J) : FT 690 NS(O,J) : FT 700 NR(O,J) : FT 710 R(O,J) : FT 720 FT : FT + FC 730 NEXT 740 FOR ° : 1 TO 02 750 FP : F5P 760 FOR J : 1 TO J2 770 Q3(0,J,0) : FP 780 Q4(O,J,0) : FP 790 FP : FP + FV 800 NEXT J 810 NEXT 0 820 FR = SFS 830 FOR 0: TO 02 840 FT = FIT 850 UMIN3(0) : 1E6 860 U2MIN4(0) : 1E6 870 DICO) = 1E6 880 Q(O) = FR
890 FOR L = 1 TO L2 900 Q3(O,O,L) = FT 910 Q4(O,O,L) = FT 920 FT = FT + Fe 930 NEXT L 940 FR = FR + FS 950 NEXT 0 960 L = 1: J = 1 970 FP = F5P:FT = FIT:FR = SFS 980 VE = DP 990 MASS = FN P2(DP) 1000 GOSUB 2010
86
1010 XD = X:PD = FN P2(DP) / 1000:MD = M1 1020 GOSUB 1830 1030 X = .4 1040 YD = XD 1050 FOR I = 1 TO 15 1060 K = FN F(X) - YD + (XD - X) * FN F1(X) 1070 DK = (XD - X) * FN F2(X) 1080 x = X - K / DK 1090 NEXT 1100 R1DMIN = (XD - FN F(X» / ( FN F(X) - X) 1110 VE = BP 1120 MASS = FN P1(BP) 1130 GOSUB 2010 1140 XB = X:PB = FN P1(BP) / 1000:MB = M1
·1150 VE = FP 1160 MASS = FN P1(FP) 1170 GOSUB 2010 1180 XF = X:MF = M1:PF = FN P1(FP) / 1000 1190 LFAN = FN LA(MF) 1200 Q = 1 + 4.2705 * ( FN TB(MF) - FT) / LFAN 1210 GOSUB 1830 1220 IF Q = 1 THEN X = XF: GOTO 1260 1230 GOSUB 1950 1240 IF X < 0.0966 THEN GOSUB 1890: GOSUB 1950 1250 IF X < .03 THEN X = XF / (1 - Q) / (8.538233 + Q / (1 - Q» 1260 GOSUB 1830 1270 X1F = X 1280 Y1F = FN F(X) 1290 R2DMIN = (XD - Y1F) / (Y1F - X1F) 1300 IF R2 < R1 THEN R2 = R1 1310 R = U * R2DMIN 1320 PRINT "FEED PROOF = ";FP 1330 PRINT "FEED TEMP = ";FT 1340 PRINT "Q-VALUE = ";Q
87
1350 PRINT "REFLUX RATIO = ";R 1360 MR = R / (R + 1) 1370 CR = XD / (R + 1) 1380 X2F = (XF * (R + 1) - XD * (1 - Q» / (R + Q) 1390 Y2F = MR * X2F + CR 1400 MS = (XB - Y2F) / (XB - X2F) 1410 CS = Y2F - MS * X2F 1420 X = 0.7 1430 Y = XD:M = MR:CO = CR:NP = O:NS = 1440 GOSUB 1760 1450 IF X < 0 THEN X = .02: GOTO 1440 1460 IF X < X2F THEN M = MS:CO = CS:NS = NS + 1 1470 IF X < XB THEN GOTO 1430 1480 Y = M * X + co 1490 PRINT "X= ";X;" Y= ";Y 1500 IF X < .030 AND X < X2F THEN GOTO 1540 1510 IF X < .03 THEN X = Y / 8.5382333:NP = NP + 1: GOTO 1460 1520 IF X < 0.0966 THEN GOSUB 1890 1530 GOTO 1440 1540 XA = X 1550 XSA = Y / 8.5382333 1560 SXB = (MS * XB + CS) / 8.5382333 1570 S = LOG ((XSA - SXS) / (XA - XB» 1580 NP = NP + ( LOG ((XS - SXB) / (XA - XSA») / S 1590 NS = NS + ( LOG ((XS - SXS) / (XA - XSA») / S 1600 NS = INT (NS + 0.5) 1610 NP = INT (NP + 0.5) 1620 PRINT "TOTAL PLATES= ";NP 1630 PRINT 1640 PRINT 1650 NR = NP - NS 1660 NP(J,L) = NP 1670 NR(J,L) = NR 1680 NS(J,L) = NS 1690 R(J,L) = ( INT (R * 10 + .5» / 10 1700 GOSUB 2060 1710 IF J < J2 THEN J = J + 1:FP = FP + FV: GOTO 1150 1720 J = l:FP = F5P 1730 IF L < L2 THEN L = L + l:FT = FT + FC: GOTO 1150 1740 GOSUB 2280 1750 END 1760 FOR I = 1 TO 10 1770 K = FN F(X) - Y 1780 DK = FN Fl(X) 1790 X = X - K / DK 1800 NEXT
1810 1820 1830 1840 1850 1860 1870 1880 1890 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050 2060 2070 2080 2090 2100 2110 2120 2130 2140 2150 2160 2170 2180 2190 2200 2210 2220 2230 2240 2250 2260 2270
NP = NP + 1 RETURN
A = 4.93561743 B = - 16.78600i63 c = 24.08939704 D = - 11.56818878 E = 0.06106287
RETURN A = 10.0338264 B = - 20.078264 C = - 1264.52485 D = 9143.73197 E = - 4.63182E - 5
RETURN FOR I = 1 TO 15
88
K = FN F(X) + (Q * X - XF) I (1 - Q) DK = FN Fl(X) + Q I (1 - Q) X = X - K I DK
NEXT RETURN
ME = VE / 200 * PE MW = (MASS - ME) I 18 M1 = ME / MASS X = ME I 46 I (MW + (ME I 46»
RETURN LDAN = FN LA(MD) LBAN = FN LA(MB)
FOR 0 = 1 TO 02 DR = F R * (MF - M B) I (M D - M B) * P F BR = FR * (MD - MF) I (MD - MB) * PF LR = R * DR VR = LR + DR BARV = VR - (1 - Q) * FR * PF Ql(O,J) = DR I PD Q2(O,J) = BR / PB Q3(O,J,L) = LDAN * VR I 60 Q4(O,J,L) = LBAN * BARV I 60
IF Q3(O,J,L) < UMIN3(0) THEN UMIN3(0) = IF Q3(O,J,L) > U1MAX3(0) THEN U1MAX3(0) IF Q4(O,J,L) < U2MIN4(0) THEN U2MIN4(0) IF Q4(O,J,L) > U3MAX3(0) THEN U3MAX4(0) IF BARV < DI(O) THEN DI(O) = BARV IF BARV > D2(0) THEN D2(0) = BARV
FR = FR + FS NEXT
FR = SFS RETURN
Q3(O,J,L) = Q3(O,J,L) = Q4(O,J,L) = Q4(O,J,L)
2280 2290 2300 2310 2320 2330 2340 2350 2360 2370 2380 2390 2400 2410 2420 2430 2440 2450 2460 2470 2480 2490 2500 2510 2520 2530 2540 2550 2560 2570 2580 2590 2600 2610 2620 2630 2640 2650 2660 2670 2680 2690 2700 2710 2720 2730 2740
89
P RII 1 PRINT D$;PR$;"80N" PRINT "DISTILLATE PROOF= ";DP PRINT "BOTTOMS PROOF = ";BP PRINT "TOTAL NUMBER OF PLATES"
S = T - 1 HTAB S: PRINT "FP"; CHR$ (92);"FT";C$; FOR L = 1 TO L2 & PRINT USEA$;NP(O,L); NEXT : PRINT FOR J = 1 TO J2 HTAB T FOR L = ° TO L2 & PRINT USEA$;NP(J,L); NEXT : PRINT NEXT PRINT "" PRINT "" PRINT "RECTIFYING PLATES" HTAB S: PRINT "FP"; CHR$ (92);"FT";C$; FOR L = 1 TO L2 & PRINT USEA$;NR(O,L); NEXT : PRINT FOR J = 1 TO J2 HTAB T FOR L = ° TO L2 & PRINT USEA$;NR(J,L); NEXT : PRINT-NEXT PRINT "" PRINT "" PRINT "STRIPPING PLATES" HTAB S: PRINT "FP"; CHR$ (92);"FT";C$; FOR L = 1 TO L2 & PRINT USEA$;NS(O,L); NEXT : PRINT FOR J = 1 TO J2 HTAB T FOR L = 0 TO L2 & PRINT USEA$;NS(J,L); NEXT: PRINT NEXT PRINT "" PRINT '"' PRINT "REFLUX RATIO" HTAB S: PRINT "FP"; CHR$ (92);"FT";C2$; FOR L = 1 TO L2
2750 2760 2770 2780 2790 2800 2810 2820 2830 2840 2850 2860 2870 2880 2890 2900 2910 2920 2930 2940 2950 2960 2970 2980 2990 3000 3010 3020 3030 3040 3050 3060 3070 3080 3090 3100 3110 3120 3130 3140 3150 3160 3170 3180 3190 3200 3210
& PRINT USEA$;R(O,L); NEXT : PRINT FOR J = 1 TO J2
90
HTAB T: & PRINT USEA$;R(J,O); FOR L = 1 TO L2 & PRINT USEB$;R(J,L); NEXT : PRINT NEXT PRINT "" PRINT "" FOR 0 = 1 TO 02 PRINT "FEED RATE (L/MIN)= ";Q(O) HTAB S: PRINT" FP DIST.RATE BOTT.RATE" FOR J = 1 TO J2 HTAB S: & PRINT USEF$;Q3(0,J,0) ,Q1(O,J) ,Q2(0,J) NEXT PRINT PRINT
C1(1) = UMIN3(0) I 4.1878 * 60 I 10 C1(2) = U1MAX3(0) I 4.1878 * 60 I 10 C2(1) = U2MIN4(0) I 2095.726 * 3600 C2(2) = U3MAX4(0) I 2095.726 * 3600 C3(1) = C2(1) 160 C3(2) = C2(2) I 60
HTAB S I 2: PRINT "COOLANT(L/MIN):& PRINT USEG$;C1(1),C1(2) HTAB S I 2: PRINT "STEAM(KG/KR):& PRINT USEH$;C2(1),C2(2)
" . , " . ,
HTAB S I 2: PRINT "CONDESATE(L/MIN):- "; & PRINT USEI$;C3( 1) ,C3(2)
D1(1) = 97.32 * SQR (DI(O) I 60) D1(2) = 97.32 * SQR (D2(0) I 60)
HTAB S I 2: PRINT "DIAMETER(CM):& PRINT USEG$;D1(1),D1(2) PRINT PRINT PRINT "" PRINT "" PRINT "HEAT OUT (KWATTS)" HTAB S: PRINT "FP"; CHR$ (92);"FT";C$; FOR L = 1 TO L2 & PRINT USEA$;Q3(0,0,L); NEXT : PRINT FOR J = 1 TO J2 HTAB T: & PRINT USEA$;Q3(0,J,0); FOR L = 1 TO L2 & PRINT USEB$;Q3(0,J,L);
" . ,
3220 NEXT: PRINT 3230 NEXT 3 2 4 0 P R I N T 1111
3250 PRINT 1111
3260 PRINT "HEAT IN (KWATTS)"
91
3270 HTAB S: PRINT "FP"; CHR$ (92);IFT";C$; 3280 FOR L = 1 TO L2 3290 & PRINT USEA$;Q4(O,0,L); 3300 NEXT: PRINT 3310 FOR J = 1 TO J2 3320 HTAB T: & PRINT USEA$;Q4(O,J,0); 3330 FOR L = 1 TO L2 3340 & PRINT USEB$;Q4(O,J,L); 3350 NEXT: PRINT 3360 NEXT 3370 PRINT 1111
3380 PRINT 1111
3390 NEXT 3400 RETURN
92
APPENDIX B:
DATA LOGGER COMPUTER CONTROL PROGRAM LISTING
93
100 print chr$(147);"Enter time of day as HHMMSS" 110 input "ti$";ti$ 120 print "Enter date as DDMMYYYY" 130 input "Date";d$ 140 print "Rewind programme tape and replace by empty data tape" 150 print "Ready?" 160 input "y or n";q$ 170 if q$="y" then goto 190 180 print chr$( 147) :goto 140 190 open 1,1,2,"distdat" 200 printIJ1,d$ 210 t=ti 220 print"" 230 p=36880 :rem via chipselect 240 0=37120 :rem via chipselect 250 poKe p+2,127 :rem port b output 260 poKe p+3,0 :rem port a input 270 poKe 0+11,192 :rem pin pb7 toggle 280 poKe 0+4,75 :rem load tlr-l 290 poKe 0+5,76 :rem load tlr-h 300 poKe 0+2,127 :rem port b output 310 poKe 0+3,0 :rem port a input 320 poKe 0,5 :rem clear counter 330 poKe 0,122 :rem 8bit counter 340 poke 0,11 :rem nostate 350 dim a$( 12) ,b$( 12) ,a( 15) ,be 15) ,a2( 16 ) ,b2( 16) ,ternp(30), tm$(21) 360 a$(1)=" 1":a$(2)=" 2":a$(3)=" 3":a$(4)=" 4":a$(5)=" 5" :a$(6)=" 6" 370 a$(7)=" 7":a$(8)=" 8":a$(9)=" 9":a$(10)="10":a$(11)="11" :a$( 12)="12" 380 b$(1)="13":b$(2)="14":b$(3)="15":b$(4)="16":b$(5)="17" :b$(6)="18" 390 b$(7)="19":b$(8)="20":b$(9)="21":b$(10)="22":b$(11)="23" :b$(12)="24" 410 for i=1 to 12 420 print"T";a$(i) ;tab(20) ;"T";b$(i) 430 next 440 print tab(4);"distillate out" 450 print tab(4);"accumulator " 460 print tab(4);"cond in" 470 print tab(4);"cond out 480 print tab(4);"cold beer 490 print tab(4);"hot beer 500 print"cl" 510 print"c2"
" " "
94
520 print"c3";tab(20);"pressure" 530 print"c4" 540 print"c5";tab(10);"c6 550 for i=O to 15 :rem aid addresses 560 poke p,i :rem channal 570 pOKe p,i+16 :rem start conversion 5S0 poke p,i 590 poke p,i+32 :rem enable tristate 600 a(i)=peek(p+1) :rem read channal 610 next 620 pOKe 0,4 :rem analog switch 630 for i=O to 15 640 poke p,i 650 poke p,i+16 660 poke p,i 670 poke p,i+32 6S0 b(i)=peeK(p+1) 690 next 700 b2(12)=(a(3)-2)*S/253+75 710 poke 0,11 720 rem convert a to d readings to temperatures 730 for i= St011 740 a2(i-7)=(b(i)-2)*50/253+50 750 a2(i-3)=(a(i)-2)*50/253+50 760 next 770 for i=4 to 7 780 a2(i+5)=(b(i)-2)*50/253+55 790 b2(i-3)=(a(i)-2)*50/253+55 800 next 810 for 1=0 to 3 820 b2(i+5)=(b(i)-2)*50/253+60 830 b2(i+9)=(a(i)-2)*50/253+60 840 next 850 for i=12 to 14 860 a2(i+1)=(a(i)-9)*75/246+20 870 b2(i+1)=(b(i)-9)*75/246+20 880 next 890 for i=1t015 900 a2(i)=int(a2(i)*15)/10 910 b2(i)=int(b2(i)*15)/10 920 next 930 for i=1to 12 940 temp(i)=temp(i)+a2(i) 950 temp(i+12)=temp(i+12)+b2(i) 960 next 970 for i=13 to 15 9S0 temp(i+12)=temp(i+12)+b2(i)
95
990 temp(i+15)=temp(i+15)+a2(i) 1000 next 1010 n=n+1 1020 for i=1 to 12 1030 print tab(4);z$;a2(i);tab(24);z$;b2(i) 1040 next i 1050 print tab(19);Z$;b2(13) 1060 print tab(19);z$;b2(14) 1070 print tab(19);z$;b2(15) 1080 print tab(19);z$;a2(13) 1090 print tab(19);z$;a2(14) 1100 print tab(19);z$;a2(15) 1110 tm=val(right$(ti$,2» 1120 if tm>54 goto 1500 :rem cheCK for 1 minute 1130 if ti-t<630 then goto 550 :rem checK for 10 1135 rem read counters 1140 poke 0,6 1150 c=peek(0+1) 1160 pOKe 0,7 1170 ca=peeK(0+1) 1180 c1=c+ca*256 1190 pOKe 0,8 1200 c=peek(0+1)
·1210 poke 0,9 1220 ca=peeK(0+1) 1230 c2=c+ca*256 1240 poke 0,26 1250 c=peeK(o+1) 1260 poke 0,42 1270 ca=peek(0+1) 1280 c3=c+ca*256 1290 pOke 0,58 1300 c=peeK(o+1) 1310 poke 0,74 1320 ca=peeK(0+1) 1330 c4=c+ca*256 1340 pOke 0,90 1350 c5=peeK(0+1) 1360 poke 0,106 1370 c6=peek(0+1) 1380 print tab(3);z$;c1 1390 print tab(3);z$;c2 1400 print tab(3);z$;c3;tab(28);z$;a(15) 1410 print tab(3);z$;c4 1420 print tab(3);z$;c5;tab(13);Z$;c6 1430 pOke 0,5:rem clear counters 1440 poke 0,11
96
1450 s1=s1+c1:s2=s2+c2:S3=s3+c3:s4=s4+c4:nn=nn+1:t=ti 1490 goto 550 1495 rem write averages to cassette 1500 s1=int«s1/ nn 5):s2=int«s2/nn5):s3=int«s3/nn5) 1510 s4=int«s4/nn5) 1520 a$=left$(ti$,4) 1530 print/11,a$ 1540 for i=1 to 30 1550 temp(i)=int«temp(i)/n*105)/10 1560 printIl1,temp(i) 1570 temp(i)=O 1580 next 1590 print/11,n 1600 printll1 ,s1 :print/11,s2:printil1,s3:printil1,s4:prlntil1,c5 :printil1,c6 1610 printll1,nn 1620 s1=0:s2=0:s3=0:s4=0:s5=0:n=0:nn=0
97
APPENDIX C:
DATA COLLECTED ON AUGUST 24, 1982
98
Table Cl. Mean values of computer collected data
Sensor Mean S.D.
Temperature C T1 76.48 0·38359 T2 77.480 0.33523 T3 77.095 0.29159 T4 79.403 3.85890 T5 82.152 5.38040 T6 83.595 5.47800 T7 85.599 4.81210 T8 88.089 3.80770 T9 90.187 0.65957 T10 93.524 2.12630 T 1 1 95.177 2.71420 T12 96.705 2.57190 T13 98.255 2.02280 T15 96.745 1.22490 T16 98.401 0.53685 T18 98.330 0.40164 T19 98.677 0·35931 T20 97.539 0.95206 T21 98.370 0.49780 T22 96.367 0.40438 CONDo IN 37.855 0.78865 COND.OUT 62.955 1.89530 COLDBEER 36.116 0.53708 HOT BEER 65.602 0.99843 ACCUMUL. 51.610 0.73990
Flow rates L/min FEEDRATE 1. 3379 0.03698 COOLANT 3.4109 0.05737 REFLUX 0.57310 0.13620 DISTILL. 0.16029 0.02370 CONDSATE 0.41416 0.01564 RF RATIO 3.66110 0.59935
------------------------------------------------------------
99
Table C2. Feed data August 24 1982
Time Meter Calculated Time Tank Calculated Proof Reading L/min Depth L/min
------------------------------------------------------------130127 2239.1 130215 9.3125 132931 2249.0 1.3668 133016 7.4375 1.6002 18 . 1 134326 2253.1 1.3416 134410 6.6250 1.5330 1 8 . 1
1.3081 1.3916 140250 2260.3 1·3383 140311 5.3750 1.5451
1.3143 1.4982 1.3183 1.5716
142145 2266.9 1.3415 142230 4.1815 1.5210 18.02 1 .3219 1. 4811 1.3349 1.5204 1 .3520 1.4699
Mean 1.3350 1.5151 lB.07 S.D. 0.0181 0.0565 0.046
------------------------------------------------------------
100
Table C3. Distillate data August 24, 1982 ------------------------------------------------------------
Time Collection Time min/L
Calculated L/min
Corrected Proof
Lab Proof (samples)
------------------------------------------------------------1259 5.83 0.172 179.8 1316 6.23 o. 161 185.6 1330 6.27 0.159 186.8 1349 6.33 0.158 189.2 1410 6.83 o . 146 191 .2 1427 6.80 0.147 191 .4
Mean 0.1572 187.3 S.D. 0.0094 4.36
Table C4. Condensate data August 24, 1982
Time
1305 1319 1333 1350 1410
Mean S.D.
Amount Collected L
1. 30 1. 74 1. 49 1 .30 1. 24
Collection Time min
3.0 4.0 3.0 3.0 3.0
178.9
184.8
186.8
183·5 4. 12
Flow rate L/min
0.433 0.435 0.497 0.433 0.413
0.442 0.032
-----------------------------------------------------------
101
APPENDIX D:
DATA COLLECTED ON AUGUST 21, 1982
102
Table D1. Mean values of computer collec~ed data
Sensor Mean S.D.
Temperature C T1 77.194 1.2644 T2 77.859 1 .2230 T3 76.963 0.5852 T4 86.946 5.5831 T5 92.453 2.1148 T6 93.065 0.9377 T7 93.988 0.7243 T8 94.106 0.6851 T9 93.835 0.4323 T10 95.533 1.1197 Tl1 96.134 1.4123 T12 96.651 1.5371 T13 97.870 1.4801 T15 97.604 1.2115 T16 98.568 0.8631 T18 98.946 0.4554 T19 99.160 0.3356 T20 99.057 0.3607 T21 99.283 0.3330 T22 97.502 0.2874 CONDo IN 42.261 1. 2969 COND.OUT 64.840 4.1421 COLDBEER 37.393 0.5954 HOT BEER 85.363 1.0594 ACCUMUL. 53.205 3.0707
Flow rates L/min FEED RATE 1.3141 0.0288 COOLANT 2.5310 0.0766 REFLUX 0-3722 0.0192 DISTILL. 0.0876 0.0571 CONDSATE 0.3017 0.0158 RF RATIO 14.8560 57.8240
------------------------------------------------------------
103
Table 02. Feed data August 21, 1982
------------------------------------------------------------Time Meter Calculated Time Tank Calculated Proof
Reading L/min Depth L/min _____ J ________________________________________________ ______
104000 2013.4 105225 2017.1 1.3419 112042 2027.1 1.3615
1·3101 123752 2054.0 1·3348 123752 13.0000 10 . 1
1·3339 1·3201
132954 2071.1 1.3291 133500 9.5000 1.4641 1·3281 1-3191 1.3181
134800 2017.85 1.3284 1 .3275 1.3193 1.3178 1.3166
142630 2090.0 1.3105 145500 4.4315 1.4929 9.2 1 .3081 1.2993 1.2841 1.2529 1 .2229
Mean 1.3165 1.4902 9.65 S.D. 0.0324 0.0243 0.64
------------------------------------------------------------
104
Table D3. Distillate data August 21, 1982
Time Collection Calculated Corrected Lab Proof Time min/L L/min Proof (samples)
------------------------------------------------------------1035 12.6 0.0794 167 1 110 13.92 0.0718 180 1200 12. 1 0.0826 181 1239 12.28 0.0814 184.4 1316 13·00 0.0769 182.4 1412 12.50 0.0800 180.4 1445 12.62 0.0792 178.9
l"1ean 0.0787 179.2 S.D. 0.0035 5.65
Table D4. Condensate data August 21, 1982.
Time
1115 11 31 1149 1156 1240 1334 1350
Mean S. D.
Amount Collected L
1. 19 1 .44 1. 10 1. 08 2.48 2.40 2.30
Collection Time min
3.0 3.0 3.0 3.0 6.0 6.0 6.0
176.6
178.2
177.4 1 • 1 3
Flow rate L/min
0.397 0.480 0·367 0.360 0.413 0.400 0.383
0.400 0.040
-----------------------------------------------------------
105
APPENDIX E:
COMPUTER DATA COLLECTED ON AUGUST 24. 1982
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107
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97.6 97.52
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T10 Tl1 T12 T13 TIS ~1~ 1.0 T18 T19 T20 T21 T22 CONDo IN COND.OUT COLDBEER HOT BEER ACCUMUL. ~EEDRATE COOLANT REFLUX DISTILL. CONDSATE RF RATIO
MEAN S.D. 76.48 .38359 77.48 .33523 77.095 .29159 79.403 3.8589 82.152 5.3804 83.595 5.4780 85.599 4.8121 88.089 3.8077 90.187 .65957 93.524 2.1263 95.177 2.7142 96.705 2.5719 98.255 2.0228 96.745 1.2249 98.401 .53685 98.330 98.677 97.539 98.370 96.367 ~7 o~~ ~J .v~~ ~~ Q~~ O~'J~~
36.116
.40164
.35931
.95206
.49780
.40438
.78865 1.8953 .53708
65.602 .99843 51.61 .73990 1.3379 .03698 3.4109 .05737 .57310 .01362 .16029 .02370 .41416 .01564 3.6611 .59935
130