Comparison of Hand Calculations and ChemSep Simulation for Ethanol-Water Distillation Column Design
Abstract
Muhammed Ameen O, Muhammed Sadik KM and Ansiya Abbas
This study presents the design and simulation of a distillation column aimed at separating a binary ethanol-water mixture, using both hand calculations and ChemSep simulation. The analysis follows principles illustrated in the distillation of benzene- toluene systems and applies them to ethanol-water separation under atmospheric pressure. The column setup includes a total condenser, kettle-type reboiler, and 15 theoretical stages, with the feed being partially vaporized. Key design parameters such as reflux ratio, theoretical stages, tray efficiency, column height, and diameter were estimated using mass balances and vapor- liquid equilibrium (VLE) data. These hand calculations were compared with detailed ChemSep simulations, which incorporated the Wilson thermodynamic model for improved accuracy. While the manual approach assumed constant relative volatility and simplified energy balances, the simulation provided refined results through dynamic VLE modeling and enthalpy data. The comparison highlighted variations in tray count, column sizing, and energy use, emphasizing the importance of simulation tools in process design. The study concludes with practical insights into industrial applications, material selection, and a cost estimate for constructing a lab-scale distillation unit.