Distillation Engineering Course

Lesson 1 • Thermodynamic Basis of Separation

Covers phase behaviour, Raoult's law, and activity coefficients governing vapour-liquid equilibrium. Establishes the thermodynamic framework used throughout the course.

Lesson 2 • Industrial Distillation Overview

Surveys distillation types—simple, flash, continuous, and batch—and their industrial roles. Frames the scope of applications students will encounter in practice.

Lesson 3 • Phase Diagrams and Equilibrium Curves

Teaches construction and interpretation of T-x-y and x-y diagrams. Connects equilibrium data to graphical design methods used in later chapters.

Lesson 1 • Feed Condition and q-Line Analysis

Analyses how feed thermal condition affects operating lines and stage requirements. Demonstrates sensitivity of design to feed quality changes.

Lesson 2 • Tray Efficiency and Real Stages

Converts theoretical stages to actual trays using Murphree and overall efficiency. Bridges ideal design to real column sizing.

Lesson 3 • McCabe-Thiele Method Foundations

Introduces the McCabe-Thiele graphical method using operating lines and equilibrium stages. Serves as the primary design tool for binary column analysis.

Lesson 4 • Reflux Ratio Selection and Optimisation

Examines the trade-off between reflux ratio, stage count, and operating cost. Guides students towards economically optimal reflux ratio selection.

Lesson 1 • Multicomponent Column Sequencing

Evaluates direct, indirect, and thermally coupled sequences for separating multicomponent mixtures. Develops cost-aware sequencing strategies.

Lesson 2 • Rigorous Stage-by-Stage Calculations

Introduces MESH equations and iterative solution strategies for rigorous column modelling. Connects shortcut estimates to simulation-grade accuracy.

Lesson 3 • Shortcut Design Methods

Applies Fenske-Underwood-Gilliland (FUG) shortcut procedure to multicomponent columns. Provides rapid estimates before rigorous simulation.

Lesson 4 • Key Component Selection

Defines light and heavy key components and their role in multicomponent design. Establishes the basis for shortcut calculation methods.

Lesson 1 • Packed Column Hydraulics

Applies loading and flooding correlations to size packed column diameter. Ensures safe and efficient operation within hydraulic constraints.

Lesson 2 • Tray Types and Mechanical Design

Compares sieve, valve, and bubble-cap trays on capacity, efficiency, and cost. Provides selection criteria for common industrial applications.

Lesson 3 • Column Diameter and Height Integration

Integrates hydraulic and stage calculations to finalise column dimensions. Produces a complete column sizing summary for engineering documents.

Lesson 4 • Structured and Random Packing

Covers packing types, HETP, and pressure drop correlations for packed columns. Enables comparison of packing versus tray internals for a given service.

Lesson 1 • Composition Measurement and Inferential Control

Examines online analysers and temperature-based inferential composition control. Reduces analyser cost and lag whilst maintaining product quality.

Lesson 2 • Advanced Regulatory and Feedforward Control

Applies cascade, ratio, and feedforward strategies to reject feed disturbances. Improves dynamic response beyond single-loop proportional-integral-derivative control.

Lesson 3 • Degrees of Freedom in Column Control

Identifies manipulated and controlled variables using degrees-of-freedom analysis. Establishes the control problem structure before loop design.

Lesson 4 • Model Predictive Control for Distillation

Introduces MPC principles applied to multivariable distillation control. Demonstrates performance gains over conventional single-loop strategies.

Lesson 1 • Dividing-Wall Column Design

Designs thermally equivalent dividing-wall columns for three-product separations. Quantifies energy savings versus conventional column sequences.

Lesson 2 • Reactive Distillation

Integrates chemical reaction and distillation in a single vessel to shift equilibrium and reduce capital cost. Covers feasibility criteria and design challenges.

Lesson 3 • Pressure-Swing Distillation

Exploits pressure sensitivity of azeotrope composition to achieve separation across two columns. Applies to binary azeotropes with strong pressure dependence.

Lesson 4 • Azeotropic Distillation

Analyses homogeneous and heterogeneous azeotropic distillation using residue curve maps. Enables design of entrainer-based separation sequences.

Lesson 1 • Heat Pump and Vapour Recompression

Evaluates mechanical vapour recompression and heat pump cycles for close-boiling separations. Quantifies coefficient of performance and payback period.

Lesson 2 • Pinch Analysis for Distillation

Applies pinch technology to identify minimum utility targets for distillation-dominated processes. Establishes the thermodynamic benchmark before retrofit or grassroots design.

Lesson 3 • Multiple-Effect Distillation

Applies multiple-effect and multi-pressure column configurations to recover latent heat. Reduces reboiler duty by cascading column condensers and reboilers.

Lesson 4 • Energy Performance Metrics and Benchmarking

Defines specific energy consumption, thermodynamic efficiency, and exergy loss metrics. Enables comparison of designs against best-practice benchmarks.

Lesson 1 • Column Performance Testing

Designs and executes plant performance tests to measure actual efficiency and capacity. Validates design assumptions and identifies improvement opportunities.

Lesson 2 • Common Column Operating Problems

Identifies flooding, weeping, foaming, and fouling symptoms and their root causes. Builds diagnostic skills applicable to any tray or packed column.

Lesson 3 • Debottlenecking and Capacity Improvement

Evaluates tray replacement, packing upgrades, and feed conditioning to increase throughput. Prioritises modifications by cost-effectiveness and implementation risk.

Lesson 4 • Field Diagnostic Techniques

Applies gamma scanning, tracer testing, and temperature profiling to locate internal problems. Connects field data to corrective action decisions.