Continuous Distillation - Principle

Principle

The principle for continuous distillation is the same as for normal distillation: when a liquid mixture is heated so that it boils, the composition of the vapor above the liquid differs from the liquid composition. If this vapor is then separated and condensed into a liquid, it becomes richer in the lower boiling component(s) of the original mixture.

This is what happens in a continuous distillation column. A mixture is heated up, and routed into the distillation column. On entering the column, the feed starts flowing down but part of it, the component(s) with lower boiling point(s), vaporizes and rises. However, as it rises, it cools and while part of it continues up as vapor, some of it (enriched in the less volatile component) begins to descend again.

Image 3 depicts a simple continuous fractional distillation tower for separating a feed stream into two fractions, an overhead distillate product and a bottoms product. The "lightest" products (those with the lowest boiling point or highest volatility) exit from the top of the columns and the "heaviest" products (the bottoms, those with the highest boiling point) exit from the bottom of the column. The overhead stream may be cooled and condensed using a water-cooled or air-cooled condenser. The bottoms reboiler may be a steam-heated or hot oil-heated heat exchanger, or even a gas or oil-fired furnace.

In a continuous distillation, the system is kept in a steady state or approximate steady state. Steady state means that quantities related to the process do not change as time passes during operation. Such constant quantities include feed input rate, output stream rates, heating and cooling rates, reflux ratio, and temperatures, pressures, and compositions at every point (location). Unless the process is disturbed due to changes in feed, heating, ambient temperature, or condensing, steady state is normally maintained. This is also the main attraction of continuous distillation, apart from the minimum amount of (easily instrumentable) surveillance; if the feed rate and feed composition are kept constant, product rate and quality are also constant. Even when a variation in conditions occurs, modern process control methods are commonly able to gradually return the continuous process to another steady state again.

Since a continuous distillation unit is fed constantly with a feed mixture and not filled all at once like a batch distillation, a continuous distillation unit does not need a sizable distillation pot, vessel, or reservoir for a batch fill. Instead, the mixture can be fed directly into the column, where the actual separation occurs. The height of the feed point along the column can vary on the situation and is designed so as to provide optimal results. See McCabe-Thiele method.

A continuous distillation is often a fractional distillation and can be a vacuum distillation or a steam distillation.