Distillation Column Systems
Column process design, internals — trays, packings and distributors — auxiliaries, turnkey supply and commissioning, engineered as one system.
Design that starts with the separation
A column is only as good as its design basis. We begin with the chemistry — relative volatility, azeotropes, heat sensitivity — and build up to stages, reflux, hydraulics and mechanical design.
- Process simulation and vapour–liquid equilibrium modelling
- Theoretical stage and reflux ratio optimisation
- Tray and packing hydraulic rating
- Column diameter and height sizing
- Pressure drop and flooding analysis
- Energy integration and heat recovery
- Atmospheric, pressure and vacuum distillation
- Batch and continuous distillation
Internals selected for the duty, not the catalogue
Trays, packings and distributors are chosen and specified on hydraulic and efficiency calculations for each section of the column.
Trays
- Sieve trays
- Valve trays (fixed and moving)
- Bubble cap trays
- Multi-downcomer and high-capacity trays
- Chimney trays and draw-off trays
Packings
- Structured packing (sheet and gauze)
- Random packing (metal, plastic, ceramic)
- Grid packing for fouling services
- Demister pads and mist eliminators
Distributors & supports
- Liquid distributors (trough, pipe, orifice pan)
- Liquid collectors and redistributors
- Vapour distributors and feed devices
- Support grids and bed limiters
The complete column system
- Reboilers — thermosiphon, kettle and forced circulation
- Overhead condensers and vent condensers
- Reflux drums and reflux pumps
- Feed preheaters and product coolers
- Vacuum systems — ejectors and vacuum pumps
- Instrumentation, control and safety systems
Delivered, installed and proven
- Column shell design and fabrication
- Internals supply and installation
- Skid-mounted and modular column systems
- Erection, piping and E&I
- Commissioning and performance testing
- Revamps, debottlenecking and troubleshooting
Explore how a column works
- Vapour leaving the top of the column is condensed. Part of the liquid returns as reflux to keep the separation sharp; the rest is drawn off as distillate (top product).
- Above the feed, rising vapour is enriched in the lighter component as it contacts the descending reflux on each tray or through each bed of packing.
- Spreads liquid evenly over the packing. Poor distribution is one of the most common causes of lost efficiency in packed columns.
- Feed enters where its composition best matches the column profile. Feed devices and flash zones slow the incoming flow and separate vapour from liquid.
- Below the feed, the lighter component is stripped out of the descending liquid so the bottom product meets its purity specification.
- Heat at the base generates the vapour that drives the whole column. Reboiler duty and reflux ratio together set energy use and product quality.
Select a section of the column or a heading to see what happens there.
Distillation questions
Which separation services do you design columns for?
Distillation, fractionation, absorption, stripping and solvent recovery columns in atmospheric, pressure and vacuum service — for chemicals, petrochemicals, refining, pharma, ethanol and oil re-refining applications.
Should my column use trays or packing?
It depends on capacity, pressure drop, fouling tendency, liquid load and turndown. Packing suits vacuum and low pressure-drop duties; trays suit high liquid loads and fouling services. We evaluate both before recommending one.
Can you improve an existing column?
Yes. We rate existing columns against current operating data, identify bottlenecks such as flooding or maldistribution, and propose internals replacement or revamp schemes.
Distillation Systems Brochure 2026
Design approach, internals and turnkey scope in a downloadable PDF.
Planning a new column or a revamp?
Share your process, capacity and site details — our engineers will respond with a clear scope and the right team.