Mini Project Report

On

Study and Simulation of a Distillation Column Using DWSIM

Submitted in partial fulfilment of the requirements

For TE/Semester V

Chemical Engineering

by

POOJA BHOSALE – 23111021

SANCHITI GANGURDE - 23111036

RUPALI THAKARE - 23111044

Under Supervision of

[Link]

DEPARTMENT OF CHEMICAL ENGINEERING

BHARATI VIDYAPEETH COLLEGE OF ENGINEERING,

NAVI MUMBAI

2025-26
 Certificate

This project report ‘Study and Simulation of a Distillation Column Using DWSIM’ by Pooja
Bhosale, Sanchiti Gangurde, Rupali Thakare is approved for the Miniproject of T.E. –
Chemical Engineering.

[Link]

Project Guide

Dr. S. P. Shingare Dr. Sandhya. Jadhav

Head of Department Principal

Date:-

Place:-
 Synopsis Report Approval for T.E

This project report ‘Study and Simulation of a Distillation Column Using DWSIM’ by Pooja
Bhosale, Sanchiti Gangurde, Rupali Thakare is approved for the Miniproject of T.E. –
Chemical Engineering.

Examiners

1.

2.

Date:

Place:
 Declaration

We declare that this written submission represents our ideas in our own words and where others'
ideas or words have been included, we have adequately cited and referenced the original
sources. We also declare that we have adhered to all principles of academic honesty and
integrity and have not misrepresented or fabricated or falsified any idea/data/fact/source in our
submission. We understand that any violation of the above will be cause for disciplinary action
by the Institute and can also evoke penal action from the sources which have thus not been
properly cited or from whom proper permission has not been taken when needed.

Pooja Bhosale (3105)

Sanchiti Gangurde (3115)

Rupali Thakare (3159)

Date
 Abstract

This project report presents a comprehensive study of the distillation process using DWSIM,
an open-source chemical process simulator. The work focuses on the simulation and analysis
of simple, fractional, and azeotropic distillation methods, which are fundamental operations in
chemical engineering. The study systematically investigates the impact of key process
parameters on the efficiency and separation performance of these distillation techniques.
Through the development of process flow diagrams and detailed simulation results, the project
demonstrates the application of core chemical engineering principles in process analysis and
optimization. The outcomes provide valuable insights for the design and operation of
distillation systems in industrial settings.

i
 Table of Content
Chapter No. Content Page. No

Abstract i
Table of Content ii
List of Figures iii
List of Tables iv
1 Introduction 5

1.1 What is DWSIM 5

1.2 Why DWSIM is Used for Distillation 6

Column Simulation
1.3 Principle of Distillation Column 7

1.4 Types of Distillation 8

2 Literature Review 9

2.1 Fundamentals of Distillation 9

2.2 Process Simulation and DWSIM 10

2.3 Advances and Applications in Distillation 11

Simulation
3 3.1 Experimental Process 12

3.2 Problem Formulation 13

3.2.1 Simulation of Water and 14
Methanol Binary Component Mixture
3.2.2 Simulation of Benzene and Toulene 15
Binary Component Mixture
3.3.3 Case Study 16
4 Plan of Work 23

5 Summary 24
6 Future scope 25

References

ii
 List of Figures

Fig no. Name [Link].

3.2.1 Process flowsheet (SS From DWSIM) 14

3.2.2 Process Flow sheet for Rigourous distillation 15

Column for Benzene-Toluene System (SS
from DWSIM)
3.3.1 Process Flow sheet (SS from DWSIM) 18

3.3.2 Process Flow sheet (SS from DWSIM) 19

3.3.3 Process Flow sheet (SS from DWSIM) 20

3.3.4 Process Flow sheet (SS from DWSIM) 21

3.3.5 Process Flow sheet (SS from DWSIM) 22

iii
 List of Tables

Table No. Name Page. no

1.1 Types of Distillation 7
3.2.1 Results of Simulated Rigorous Distillation Column (SS From 16
DWSIM)
3.3.1 Results Table (from DWSIM) 17
4.1 Plan of Work 23

iv
 Chapter 1

Introduction

Process simulation is a vital tool in chemical engineering, enabling the design, optimization,
and control of chemical processes throughout their lifecycle. By using modeling techniques
and simulation software, engineers can evaluate plant performance, test different
configurations, and optimize operations without the need for costly or impractical full-scale
experiments. DWSIM, an open-source process simulator, provides a flexible platform for
simulating a wide range of chemical processes, including various types of distillation.

Distillation remains one of the most widely used separation techniques in the chemical and
petrochemical industries, essential for purifying products and recovering solvents. Both
continuous and batch distillation methods are employed, with batch distillation playing an
important role in specialty, pharmaceutical, and biochemical applications. The ability to
simulate different types of distillation processes allows engineers to analyze the impact of key
parameters—such as reflux ratio, number of stages, and feed composition—on separation
efficiency and energy consumption.

Through simulation, engineers can identify process bottlenecks, enhance safety, and optimize
system performance before implementing changes in real plants. This approach not only
reduces operational risks and costs but also supports the development of more sustainable and
efficient chemical manufacturing processes. (Pauls et al, 1977.)

1.1 What is DWSIM (Bandyopadhyay, S. 2015)

DWSIM is an open-source chemical process simulator widely used in academic and industrial
settings for modeling, simulating, and analyzing chemical processes. Developed in .NET and
Mono, DWSIM offers a user-friendly graphical interface and supports a variety of unit
operations, thermodynamic models, and chemical components. It enables users to build process
flow diagrams, perform material and energy balances, and simulate complex chemical
engineering systems without the need for expensive proprietary software.

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1.2 Why DWSIM is Used for Distillation Column Simulation (Bandyopadhyay,
S. 2015).

DWSIM is particularly useful for distillation studies because it allows engineers and students
to simulate different types of distillation processes, such as continuous and batch operations.
The software provides tools to model distillation columns, set key parameters (like reflux ratio,
number of stages, and feed composition), and analyze separation efficiency. By using DWSIM,
users can visualize process behavior, optimize operating conditions, and evaluate the impact of
changes before implementing them in real-world systems. This makes DWSIM an effective
platform for learning, research, and process optimization in distillation and other chemical
engineering applications.

1.3 Principle of Distillation Column (Kister, H. Z. 1992)

A distillation column separates the components of a liquid mixture by exploiting differences in

their volatilities. As the mixture is heated, the more volatile components vaporize and rise
through the column, while the less volatile components remain in the liquid phase. The column
is designed with multiple stages or trays to maximize vapor-liquid contact, enabling repeated
enrichment of the vapor in the more volatile component and the liquid in the less volatile
component. This counter-current flow results in efficient separation, allowing for the collection
of purified products at different points in the column.

The performance of a distillation column is influenced by several key operating parameters.

The reflux ratio, which is the proportion of condensed vapor returned to the column, directly
affects both product purity and energy consumption—higher reflux ratios generally improve
separation but increase energy use. The number of stages or trays determines the extent of
separation achievable, with more stages typically leading to higher purity but also greater
capital and operational costs. Feed composition and feed location within the column play
crucial roles in determining the ease and efficiency of separation. Operating pressure influences
boiling points and can be adjusted to optimize separation for specific mixtures. Additionally,
parameters such as column diameter, heat input (reboiler duty), and condenser cooling rate also
impact the efficiency and energy requirements of the process. By systematically analyzing
these parameters using simulation tools like DWSIM, it is possible to gain valuable insights
into how each factor affects product purity, separation efficiency, and overall energy
consumption, supporting both educational understanding and process optimization efforts.
6
1.4 TYPES OF DISTILLATION

Table 1.1 (McCabe and Smith1993)

Type of Description Applications Advantages Limitations

Distillation
Simple Single Purification of Simple and Inefficient for
Distillation vaporization- liquids with inexpensive. close boiling
condensation step; widely different points.
for components boiling points.
with large boiling
point difference
(>25°C).
Fractional Uses fractionating Separation of High separation More complex
Distillation column to provide mixtures with efficiency. and costly than
multiple close boiling simple
equilibrium stages points (e.g., distillation.
for better petroleum
separation. refining).
Steam Uses steam to Extraction of Operates at lower Requires steam
Distillation lower boiling essential oils, temperatures; supply; limited
points for heat- natural products. protects sensitive to immiscible
sensitive compounds. mixtures.
compounds.
Vacuum Distillation under High boiling or Prevents thermal Requires
Distillation reduced pressure heat-sensitive decomposition. vacuum
to lower boiling substances (e.g., system; higher
points. heavy oils). capital cost.
Azeotropic Adds entrainer to Separation of Enables Additional
Distillation break azeotropes azeotropic separation of solvent
by altering relative mixtures (e.g., difficult mixtures. recovery
volatility. ethanol-water). required.

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Extractive Adds solvent to Separation of Effective for very Requires
Distillation change relative close-boiling or difficult solvent
volatility without azeotropic separations. management
forming mixtures. and recovery.
azeotropes.
Molecular Vacuum Purification of Low thermal Specialized
(Thin Film) distillation with vitamins, degradation. equipment;
Distillation very short polymers, and limited
residence time for oils. throughput.
sensitive, high
molecular weight
compounds.

8
 Chapter 2

Literature Review

2.1 Fundamentals of Distillation

Coulson and Richardson (2002) discuss the basic principles and operation of distillation in their
book . This text provides a comprehensive overview of vapor-liquid equilibrium, tray and
packed columns, and the design considerations essential for effective separation. The authors
also explain the influence of operational variables on column efficiency and present practical
examples relevant to industrial practice.

Seader, Henley, and Roper (2011) in Separation Process Principles offer detailed explanations
of distillation theory, including the McCabe-Thiele method and the impact of key parameters
such as reflux ratio and number of stages on separation efficiency. The book further explores
the application of these principles in both binary and multicomponent systems, making it a
valuable resource for process simulation studies.

Kister (1992) reviews practical aspects of distillation operation in Distillation Operation,

highlighting common challenges in column design, control, and troubleshooting. This
reference provides real-world case studies and discusses troubleshooting strategies for common
operational issues, offering insights that are directly applicable to simulation and optimization
tasks.

2.2 Process Simulation and DWSIM

Costa and Pessoa (2014) present DWSIM as an open-source process simulator in their article
"DWSIM: An Open Source Process Simulator for Chemical Engineering Education". The
authors demonstrate how DWSIM can be used to model distillation columns, perform material
and energy balances, and visualize process flow diagrams. Their work emphasizes the
accessibility and flexibility of DWSIM for both educational and research purposes.

Mota and Pessoa (2016) explore the educational applications of DWSIM in "Using DWSIM
for Teaching and Learning Chemical Engineering Principles". This paper highlights the
simulator's role in helping users understand the impact of operational parameters on distillation

9
performance. The study also shows how DWSIM facilitates hands-on learning and enhances
conceptual understanding through interactive simulations.

Smith (2005) in Chemical Process: Design and Integration discusses the integration of
simulation tools in process design, emphasizing how software like DWSIM supports
optimization and evaluation of separation processes. The book also covers the economic and
environmental aspects of process design, providing a holistic view of simulation-driven
decision-making.

2.3 Advances and Applications in Distillation Simulation

Sinnott and Towler (2020) in Chemical Engineering Design: Principles, Practice and
Economics of Plant and Process Design provide insights into modern simulation practices,
including the use of DWSIM for flowsheet development and process safety analysis. The
authors discuss recent advancements in simulation technology and their impact on process
reliability and efficiency.

Bandyopadhyay (2015) reviews the application of process simulation software for distillation
column design and optimization in "Process Simulation Tools for Chemical Engineering",
comparing features and benefits of DWSIM with other simulators. The article also addresses
the importance of user interface and computational accuracy in selecting appropriate simulation
tools for academic and industrial projects.

Perry and Green (2008) in Perry's Chemical Engineers' Handbook offer practical guidelines for
distillation column design and simulation, including case studies and best practices for
industrial applications. The handbook serves as a comprehensive reference for both
fundamental principles and advanced simulation techniques, making it indispensable for
process engineers.

Henley and Seader (1981) in Equilibrium-Stage Separation Operations in Chemical

Engineering provide foundational knowledge on equilibrium-stage modeling, which underpins
simulation approaches in DWSIM and other platforms. Their work details the mathematical
methods used to analyze and design separation processes, supporting accurate and reliable
simulation outcomes.

Londhe Shubham and Prof. Nitin B Chavan (2023) presents a detailed study on process simulation
as a tool for the design, optimization, and control of chemical processes. The paper highlights
how simulation software enables evaluation of plant characteristics and performance without
10
constructing or operating full-scale plants. It discusses the application of modeling techniques
in understanding distillation processes, including the impact of key parameters on separation
efficiency and energy consumption. This work supports the use of simulation platforms like
DWSIM for educational and industrial process analysis, emphasizing the benefits of simulation
in reducing risks and optimizing system performance.

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 Chapter 3

3.1 Experimental Process (Londhe Shubham and Chavan 2023).

1. Start a new DWSIM Simulation. Click on “New steady-state Simulation” as a template for
a new simulation.
2. The simulation configuration window will be opened. Add the two components required
for simulation. Ensure that all the components are added from the same property package.
Click the “Next” button.
3. Select and add the property package and click “Next”. Add the default flash algorithm for
the simulation. Click “Next”.
4. The flow sheeting section of simulation window will be opened. Drag and drop the Material
stream from the object palette. Rename it as “Feed”. This serves as input stream.
5. On clicking the “Feed” stream, general information about the block will be displayed on
the left of the screen. Specify the feed compositions, flow rate, temperature and pressure
for the inlet streams. Once composition and flow rate are specified for the inlet streams, the
color of stream turns blue. •
6. Add two more Material streams i.e., Drag and drop them into the flow sheet. Rename them
as “Distillate” and “Bottoms”. These serves as output streams.
7. Add two energy streams, one is for condenser duty (C-Duty) and the other is for re-boiler
duty (R-Duty).
8. Below the Unit Operation tab, locate the “Shortcut Column” block. Drag and drop into the
flow sheet. Rename it as “DC”.
9. Click on “DC” block, the general information about the block is displayed on the left of the
screen. Provide calculation parameters as shown in the screenshot given below.
10. Under Column configuration select “connections” tab. Click the dropdown button and give
appropriate connections. If all the connections are given correctly, the blocks will turn blue.
11. Run the simulation by pressing “Solve flow sheet” button on the top corner of the screen.
12. To analyze/display the results, select on “Master property table” icon on the tool bar. A box
will appear which is double clicked to modify it further. Select the streams which have to
be shown in output and click “OK”. The property table will be opened showing all the
results as shown in the figure below.

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3.2 Problem Formulation (Shubham and Chavan 2023).

3.2.1. Simulation of Water and Methanol Binary Components Mixture

Problem Statement: A mixture of water and methanol is fed to a distillation column at a rate of
100 kmol/hr, with the feed containing 60% water and 40% methanol by mole. The column
operates at a condenser pressure of 1 atm. The reflux ratio is set at 1.5 times the minimum
reflux ratio. Methanol is designated as the light key (LK) component and water as the heavy
key (HK) component. The distillate is required to contain 99% methanol, while the bottoms
product should contain 99% water on a mole basis. Calculate the following:

1. Minimum reflux ratio

2. Minimum number of stages
3. Actual number of stages
4. Optimal feed stage location
5. Condenser and reboiler duty

Fig 3.2.1 : Process flowsheet (SS From DWSIM)

Results :

 Distillate composition: 0.989 Methanol, 0.01 Water

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 Bottom composition: 0.99 Water, 0.01 Methanol
 Temperature (Distillate): 63.7 °C
 Condenser Duty: –111.92 kW
 Reboiler Duty: +115.10 kW
 Minimum Reflux Ratio: 0.935
 Minimum Number of Stages: 12
 Actual Number of Stages: 20 (including reboiler)
 Optimal Feed Stage: 9
 Table shows the actual feed condition used for the simulation Shortcut column were
[Link] on the shortcut distillation column simulation, the following parameters were
obtained:
Optimal Feed Stage = 09
Actual Feed Stage = 20 (Including Reboiler = 21)
Reflux Ratio = 2.317
Feed Flow Rate = 100 kg/h (≈ 4.232 kmol/h)

3.2.2 Simulation of Benzene and Toluene Binary Components Mixture

Problem Statement : Mixture of components feed at rate of 100 kmol/hr. to the distillation
column containing 40 % benzene and 60 % Toluene. Pressure at the condenser (T.P.) is 1 atm
and the Reflux ratio is 1.4 times of min. R. R. Light Key component (LK) Benzene and heavy
key (HK) component as toluene. Distillate contains 99% benzene and B.P. contains 99% of
Toluene on a mole basis. Calculate

1. Min. R.R.

2. Min. number of stages.

3. Actual no. of stages.

4. Optimal feed stage location.

5. Condenser and Reboiler duty

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Process Flow Sheet of simulated distillation Column for the above problem

Fig 3.2.2 Process Flow sheet for Rigourous distillation Column for Benzene-Toluene System
(SS From DWSIM)

Simulation Results for Benzene and Toluene Binary Mixture:

Table 3.2.1 : Results of Simulated Rigorous Distillation Column (SS From DWSIM)

15
Table shows the actual feed condition for simulation of Rigorous distillation column. With
help of above results, we simulating the Short Cut-Distillation column obtaining following
results. Putting the data on Rigorous distillation obtained from the Shortcut distillation
column

Optimal Feed Stage = 09

Actual Feed Stage = 20 (Including Reboiler = 21)

Reflux Ratio = 2.317 and Flow Rate = 100 kmol/hr.

3.3 Case study

In this study, multiple cases are considered by varying the feed mole fraction of benzene and
toluene, as well as other key operating parameters, to analyze their effects on product purity,
separation efficiency, and energy consumption in a rigorous distillation simulation using
DWSIM.

Table 3.3.1 Result Table (from DWSIM)

Case Min. Min. Actual Optimal Condenser Reboiler Distillate Bottoms Notes
R.R. Stages Stages Feed Duty (kW) Duty Purity Purity
Stage (kW) (benzene) (toluene)
1 1.7 12 21 9 1129 -1150 0.99 0.99 100
kmol/hr
feed, 1 atm
[1]

2 1.5 10 18 8 ~1000 ~-1100 0.99 0.99 Higher

toluene
reduces
stages [1]
3 2.2 14 25 10 ~1200 ~-1300 0.99 0.99 Higher
benzene
needs
more
stages [1]

Aligning the reflux ratio and number of stages to the specific feed composition optimizes both
energy usage and product purity. Higher benzene concentrations require increased reflux ratio
and more stages for effective separation, while lower benzene reduce these requirements.

16
Adjusting the feed stage location according to the feed mixture improves efficiency, especially
when energy integration like reboiler heat recycling is applied. These targeted adjustments in
DWSIM provide consistent product purities above 0.99 for benzene and toluene even as feed
composition varies, ensuring operational flexibility and sustainability

Fig 3.3.1 Process Flow sheet (SS from DWSIM)

17
Fig 3.3.2 Process Flow sheet (SS from DWSIM)

18
Fig 3.3.3 Process Flow sheet (SS from DWSIM)

19
Fig 3.3.4Process Flow sheet (SS from DWSIM)

20
Fig 3.3.5Process Flow sheet (SS from DWSIM)

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 Chapter 4

Plan of Work
Topic finalisation is done in the month of July, while literature review is done in month of July
and August in which paper reading and collection of data form research paper and perform on
Dwsim and process description is done in month of August-september.

Table 4.1 Plan of work

Sr no. Activities Month

1 Topic finalization July

2 Literature review July-August

3 Basic design on paper August

4 Perform on DWSIM Software September

5 Storing data in the form of ppt and report September-October

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 Chapter 5

Summary

The study and simulation of a distillation column using DWSIM, an open-source process
simulator widely used in chemical engineering education and process design. The main
objective was to understand the working principles of a continuous distillation column, model
its operation, and evaluate separation performance based on simulation outputs.

Distillation is a fundamental separation process in the chemical industry, used to separate

components in liquid mixtures based on differences in their boiling points. A distillation
column consists of a series of trays or stages where vapor and liquid phases interact, allowing
for mass and energy transfer, and ultimately component separation.

In this study, a binary mixture was simulated using DWSIM. The key steps included:

 Selection of components and thermodynamic model

 Defining feed stream conditions (flowrate, temperature, pressure, composition)
 Configuring the column (number of stages, feed stage, condenser/reboiler type)
 Running the simulation and analyzing results: product purity, temperature profile,
energy duties, and mass balance.

The simulation outputs provided valuable insights:

 The more volatile component was successfully recovered as the top product (distillate),
while the less volatile component was concentrated in the bottoms stream.
 The temperature gradient increased from the top to the bottom of the column, consistent
with theoretical expectations.
 The condenser and reboiler duties quantified the energy requirements for separation.
 The mass balance was satisfied, verifying the accuracy of the simulation.

Through this project, students gained practical experience in using DWSIM for process
simulation and learned how to apply theoretical knowledge of vapor-liquid equilibrium, reflux
ratio, and column design to simulate real-world chemical processes. The simulation also helped
visualize how changes in parameters like feed stage location, reflux ratio, or number of stages
affect product purity and energy consumption.

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 Chapter 6

Future Scope
The study can be further extended by performing a more comprehensive and detailed design
and optimization of distillation columns in DWSIM for both binary and multicomponent
mixtures. Future work may involve a systematic analysis of the influence of feed composition,
feed temperature, and operating pressure on the separation efficiency, product purity, and
energy consumption. Advanced sensitivity analysis can be conducted to understand the impact
of varying reflux ratios, number of stages, and feed locations on column performance.
Additionally, design parameters such as column diameter, tray spacing, tray efficiency, and
packing type can be optimized to achieve higher separation efficiency while minimizing
operational costs.

Beyond conventional design, the simulation study can incorporate advanced process
intensification strategies, including the use of hybrid distillation techniques, heat integration
networks, and energy recovery systems. These modifications can significantly improve energy
efficiency and reduce the environmental footprint of the process. Process control strategies can
also be simulated to ensure stable operation under varying feed conditions and to enhance
operational safety.

Furthermore, the study can be expanded to include comparison between different

thermodynamic models and activity coefficient methods available in DWSIM to evaluate their
effect on simulation accuracy. Experimental validation of the simulation results can be
conducted through lab-scale or pilot-scale distillation setups to compare theoretical predictions
with practical outcomes. This would provide a more reliable understanding of column behavior
and help bridge the gap between simulation and real-world operation. Such studies would not
only enhance process optimization but also contribute to the development of sustainable and
cost-effective separation processes in chemical industries.

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 References.

Bandyopadhyay, S. (2015). Process Simulation Tools for Chemical Engineering. Chemical

Engineering World, Vol. 50(5), 24–30.

Costa, M., & Pessoa, C. (2014). DWSIM: An Open Source Process Simulator for Chemical
Engineering Education. Education for Chemical Engineers, Vol. 9, 32–41.

Henley, E. J., & Seader, J. D. (1981). Equilibrium-Stage Separation Operations in Chemical

Engineering, Vol. 1. John Wiley & Sons.

Mhase Omkar, shaikh Aftab, Londhe Shubham and Prof. Nitin B Chavan (2023). Process
Simulation as a Tool for Design, Optimization, and Control of Chemical Processes. Journal of
Emerging Technologies and Innovative Research, Vol. 10(5), 112–123.

Kister, H. Z. (1992). Distillation Operation, Vol. 1. McGraw-Hill.

Coulson, J. M., & Richardson, J. F. (2002). Chemical Engineering, Volume 2: Particle

Technology and Separation Processes, Vol. 2. Butterworth-Heinemann.

Mota, R., & Pessoa, C. (2016). Using DWSIM for Teaching and Learning Chemical
Engineering Principles. Computer Applications in Engineering Education, Vol. 24(4), 536–
546.

Perry, R. H., & Green, D. W. (2008). Perry’s Chemical Engineers’ Handbook, Vol. 8. McGraw-
Hill.

Seader, J. D., Henley, E. J., & Roper, D. K. (2011). Separation Process Principles, Vol. 3. John
Wiley & Sons.

Sinnott, R. K., & Towler, G. (2020). Chemical Engineering Design: Principles, Practice and
Economics of Plant and Process Design, Vol. 1. Elsevier.

Smith, R. (2005). Chemical Process: Design and Integration, Vol. 2. John Wiley & Sons.

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