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Revision as of 12:26, 4 December 2025

Title: Shortcut Column for Binary Mixture

Author: Priyam Nayak

Keywords: DWSIM, Material stream, shortcut distillation, compounds, thermodynamic package, heavy key, light key, recovery, feed stage, reflux ratio, video tutorial.


Visual Cue Narration
Slide Number 1

Title Slide

Welcome to this tutorial on simulating a Shortcut Column for Binary Mixture in DWSIM.
Slide Number 2

Learning Objectives

In this tutorial, we will learn to:
  • Design a Distillation Column for desired separation using Shortcut method
  • Calculate Minimum Number of Stages
  • Calculate Minimum Reflux Ratio
  • Calculate Optimal Feed Stage Location
  • Calculate Operating Reflux Ratio
Slide Number 3

System Requirements

This tutorial is recorded using
  • DWSIM version 9.0.2
  • Windows 11 OS

But, this process is identical in Linux, Mac OS X, or FOSSEE OS on ARM.

Slide Number 4

Pre-requisites

To practice this tutorial, you should know to
  • add components to a flowsheet.
  • select thermodynamic packages.
  • add material stream and specify the properties of a material stream
Slide Number 5

Problem Statement Hover the mouse on the flowsheet image.

Using the shortcut method, we will develop a flowsheet to design a distillation column.

Benzene and Toluene enter the column at this given flow rate, temperature, and pressure.

The condenser is operated at 1.2 bar pressure. 99% of the benzene fed is recovered as distillate.

The column is operated at a reflux ratio of 1.5 times the minimum.

The reboiler is operated at 1.5 bar pressure.

99.5% of the toluene fed is recovered as bottoms.

Switch to DWSIM. I have opened the DWSIM interface.
File >> New Chemical Process Model Click on File on the menu bar.

Select New Chemical Process Model.

Point to Simulation Configuration Wizard window

Click the Next button.

A Simulation Configuration Wizard window appears.

Click the Next button to continue.

Type Benzene in the search tab In the Compounds Search tab, type Benzene.
ChemSep database >> Benzene Select Benzene from ChemSep database.
Type Toluene in the Search tab Similarly, add Toluene.
Point to Added Compounds. All the compounds required for this simulation are added.

It can be seen in the Added Compounds.

click the Next button at the bottom. Click the Next button to continue.
Point to Property Packages

Property Packages >> Available Property Package

>> Peng- Robinson (PR)

Click on Add.

Added Property Package >> Peng- Robinson (PR)

Now comes Property Packages.

From the Available Property Packages,

select Peng-Robinson (PR).

Then click on Add.


Peng-Robinson has been added under Added Property Packages.

click the Next button at the bottom. Click the Next button to continue.
System of Units >>

select C5 from the drop down.

The next option is the System of Units.

We will select C5.

C5 has the desired system of units according to our problem statement.

click the Next button at the bottom. Click the Next button to continue.
Behavior >> Next Click the Next button at the bottom.
Undo/Redo Operation >> Finish Click the Finish button at the bottom.

This completes configuring the simulation.

Point to Object Palette

click the Columns section.

Click and drag Shortcut Column to the flowsheet

Now let us add a Shortcut Column.

Go to the Column section in the Object Palette.

Scroll down a little to see Shortcut Column.

Drag and drop Shortcut Column to the flowsheet.

Point to SCOL-1 added to the flowsheet. This is the Shortcut Column.

It has 3 material streams and 2 energy streams auto-connected to its connection ports.

Point to material Stream 1. Material Stream named 1 enters the Shortcut Column as feed.
Point to Material Stream 2. Material Stream named 2 leaves the Shortcut Column as Distillate.
Point to Material Stream 3. Material Stream named 3 leaves the Shortcut Column as a Bottoms.
Point to Energy Stream E1. Energy Stream E1 acts as Condenser Duty.
Point to Energy Stream E2. Energy Stream E2 acts as Reboiler Duty.
Point to Shortcut Column SCOL-1. Now, let us rename all the objects.
Click 1

Type SC-Feed to change the name of this stream.

Press Enter.

Click the Material Stream named 1 and rename it as SC-Feed.

Press Enter.

Click 2

Type SC-Distillate to change the name of this stream.

Press Enter.

Next, click the Material Stream named 2 and rename it as SC-Distillate.

Press Enter.

Click 3

Type SC-Bottoms to change the name of this stream.

Press Enter.

Next, click the Material Stream named 3 and rename it as SC-Bottoms.

Press Enter.

Click E1

Type SC-C-Duty.

Press Enter.

Next, click the Energy Stream named E1 and rename it as SC-C-Duty.
Click E2

Type SC-R-Duty.

Press Enter.

Next, click the Energy Stream named E2 and rename it as SC-R-Duty.

Press Enter.

Click SCOL-1

Type SColumn.

Press Enter.

Click the Shortcut Column named SCOL-1 and rename it as Scolumn.


Press Enter.

Point to all the streams. All our streams and the unit operation have been named.
Hover Mouse at Feed. Now, we will specify the Feed stream properties.
Click on Feed.


Property editor window opens.

Now click the Feed.


Here, the property editor window opens.

Input Data>> Stream Condition >>

Flash Spec>> Temperature and Pressure(TP).

Under Input Data, in Stream Conditions section, select Flash Spec as Temperature and Pressure (TP).

By default, Temperature and Pressure are already selected as Flash Spec.

So let’s not change it.

Input Data >> Stream Condition

>> Temperature >> 92.5 C


Press Enter

Change Temperature to 92.5 degree C and press Enter.
Input Data >> Stream Condition

>> Pressure >> 1.2 bar


Press Enter

Change Pressure to 1.2 bar and press Enter.
Point to Molar Flow Rate Instead of the Overall Flow Rate, we have the individual flow rate of components.


So, we will not specify anything here.

Now, we will specify the component flow rates.
Input Data >> Compound Amounts


Basis >> Mole Flows

To do this, click on Compound Amounts.

Choose the Basis as Mole Flows.

Point to the Amount Table.

Benzene >> 800

Toluene >> 1200

Now, we will enter the Mole Flows for each compound.

Click the first cell below Amount against Benzene and enter 800. Press Enter.

Similarly, for Toluene, enter it as 1200 and press Enter.

We have entered all the values.

Click the Accept Changes button On the right, click the Accept Changes button.
Click on SColumn (Shortcut Column).

Property Editor Window opens.

Now, we will configure the Shortcut Column.

To do this, click on SColumn.

Point to the Property Editor Window on the left. On the left, we see a tab displaying properties related to the SColumn.
Hover Mouse on Connections. Under Connections, we can see that all the necessary material streams and energy streams are connected to the column.
Hover mouse on Calculation Parameters Now, go to the section Calculation Parameters by scrolling down.
Click on drop-down arrow against Light Key Compound (LK)

Select Benzene.

Click the drop-down against Light Key Compound (LK) and select Benzene.
Click the drop-down against Heavy Key Compound (HK).

Select Toluene.

Click the drop-down against Heavy Key Compound (HK) and select Toluene.
Point to LK Mole Fraction in Bottom and

HK Mole Fraction in Distillate.

Next, we have to specify the LK mole fractions in the bottoms and the HK mole fractions in the distillate.
Switch to slides


Slide Number 5

Problem Statement

Point to given Recovery %

Let me go back to the slides.

These mole fractions are not given directly in this problem statement.

Instead, percentage recovery of the components are given.

So, we will calculate mole fractions from the given recovery.

Slide Number 6

Material Balance

The material balance calculation is demonstrated in this slide.

You can pause the video here for a minute and check the calculation.

Switch to DWSIM


For LK Mole Fraction in Bottoms >> 0.0067

Press Enter.

Let us go back to DWSIM.

Click the field against LK Mole Fraction in Bottoms and enter the value as 0.0067.

We have got this value from the material balance calculation shown earlier.

Press Enter.

For HK Mole Fraction in Distillate >> 0.0075


Press Enter.

Click the field against HK Mole Fraction in Distillate and enter the value as 0.0075.

We have got this value from the material balance calculation shown earlier.

Press Enter.

Hover Mouse at Reflux Ratio. Next is Reflux Ratio.

As per the problem statement, the Reflux Ratio should be 1.5 times the minimum.

Since, we don’t have the minimum reflux ratio, we will leave it with the default value for now.

Hover Mouse at Condenser Type. Now go to Condenser Type.

By default, it is Total Condenser.

If a partial condenser is required, we can change it here.

Condenser Pressure >> 1.2 bar

Press Enter


Click the field against Condenser Pressure and enter it as 1.2 bar.

And press Enter.

Reboiler Pressure >> 1.5 bar

Press Enter

Click the field against Reboiler Pressure and enter it as 1.5 bar.

Then press Enter.

Click Solve This completes the problem specifications.

Click the Solve button in the toolbar area.

Point to Messages at the bottom Once the calculations are complete, we see an error message at the bottom.


In the error message, we see that the minimum Reflux ratio is 1.6834.

Point to Messages at the bottom Therefore the reflux ratio should be more than 1.6834.

However, as per the problem statement, the operating reflux should be 1.5 times the minimum.

Click Reflux Ratio


Reflux Ratio >> 1.5 * 1.6834


Press Enter

Click the field against Reflux Ratio.

Enter the value 1.5 multiply sign 1.6834 and press Enter.


We can see that Reflux Ratio is calculated as 2.5251.

Click Solve This completes the problem specification.


Click the Solve button in the toolbar area.

Click the SColumn When calculations are completed, click the SColumn.
Hover mouse at Results From the Property Editor Window, locate Results section.

This shows all the required results like:

Minimum Reflux Ratio

Minimum Number of Stages

Actual Number of Stages

Optimal Feed Stage

Condenser Duty, Reboiler Duty

Slide Number 7

Results

I have tabulated these results in a slide.
Go to DWSIM


Insert >> Master Property Table

Now we will check the stream results.

For this, go back to DWSIM.

Go to the Insert menu and select Master Property Table.

Double click on Master Property Table to edit it. Double-click the Master Property Table to edit it.
Point to Configure Master Property Table Configure Master Property Table window opens.
Type Streamwise Results Enter Name as Streamwise Results.
Object >> SC-Feed, SC-Distillate and SC-Bottoms. Under Properties to display, select Object as SC-Feed, SC-Distillate and SC-Bottoms.
Configure Property Table>> Property Under Property, which is right beside the Object.

Now select the properties as:

Temperature

Pressure

Mass Flow

Molar Flow

Molar Fraction (Vapor)

Molar Fraction (Mixture) / Benzene

Molar Flow (Mixture) / Benzene

Molar Fraction (Mixture) / Toluene

Molar Flow (Mixture) / Toluene

Close this window. Close this window.


Move the Master Property Table for better visibility.

Now we can see the corresponding stream results for Shortcut Column.

Click File and Save As >> File name = binary-shortcut Let me save the file.

I will save it as binary-shortcut.

Slide Number 8


Important Points to Note

Let me make some important observations here.
  • This Shortcut Column is based on Fenske-Underwood-Gilliland method.
  • This column can be used for design of conventional distillation only.
  • It cannot be used for design of non-conventional distillation like
    • azeotropic distillation
    • extractive distillation
    • reactive distillation
This brings us to the end of this tutorial.
Slide Number 9

Summary


In this tutorial, we have learnt to:

  • Design a Distillation Column for desired separation using Shorcut method
  • Calculate Minimum Number of Stages
  • Calculate Minimum Reflux Ratio
  • Calculate Optimal Feed Stage Location
  • Calculate Operating Reflux Ratio
Let us summarize.
Slide Number 10

Assignment

Redo the material balance calculation for a different recovery.

Based on the mole fractions obtained from recovery, simulate the shortcut column.

Use reflux ratio equals to 1.3 times the minimum reflux.

As an assignment, please do the following:
Slide Number 11

DWSIM Flowsheeting Project

We invite you to participate in DWSIM Flowsheeting Project.
Slide Number 12

Lab Migration Project

We invite you to migrate commercial simulator labs to DWSIM.
Slide Number 13

Acknowledgements

The FOSSEE project is funded by NMEICT, Ministry of Education(MoE), Government of India.
Slide Number 14

Thanks

We thank the DWSIM team for making it as an open source software.

Thank you for joining.

Contributors and Content Editors

Madhurig

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