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distillation-designer skill

/plugins/babysitter/skills/babysit/process/specializations/domains/science/chemical-engineering/skills/distillation-designer

This skill helps you design distillation columns by selecting trays or packing, performing hydraulic analyses, and optimizing performance.

npx playbooks add skill a5c-ai/babysitter --skill distillation-designer

Review the files below or copy the command above to add this skill to your agents.

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SKILL.md
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---
name: distillation-designer
description: Distillation column design skill for tray/packing selection, hydraulic analysis, and column optimization
allowed-tools:
  - Read
  - Write
  - Glob
  - Grep
  - Edit
  - Bash
metadata:
  specialization: chemical-engineering
  domain: science
  category: Separation Processes
  skill-id: CE-SK-010
---

# Distillation Designer Skill

## Purpose

The Distillation Designer Skill performs distillation column design including tray and packing selection, hydraulic calculations, and column optimization for vapor-liquid separations.

## Capabilities

- McCabe-Thiele and Ponchon-Savarit methods
- Shortcut design calculations (Fenske, Underwood, Gilliland)
- Tray hydraulics (flooding, weeping, entrainment)
- Packing selection and sizing (HETP, pressure drop)
- Feed location optimization
- Reflux ratio optimization
- Side draw design
- Azeotropic and extractive distillation

## Usage Guidelines

### When to Use
- Designing new distillation columns
- Rating existing columns
- Optimizing column performance
- Evaluating tray vs. packing

### Prerequisites
- VLE data available
- Feed composition defined
- Product specifications set
- Thermodynamic model validated

### Best Practices
- Validate VLE predictions
- Consider turndown requirements
- Allow for design margins
- Evaluate energy integration

## Process Integration

This skill integrates with:
- Distillation Column Design and Optimization
- Separation Sequence Synthesis
- Heat Integration Analysis

## Configuration

```yaml
distillation-designer:
  internals:
    - sieve-trays
    - valve-trays
    - structured-packing
    - random-packing
  design-methods:
    - rigorous
    - shortcut
```

## Output Artifacts

- Column specifications
- Tray/packing datasheets
- Hydraulic analysis
- Operating envelopes
- Optimization recommendations

Overview

This skill performs distillation column design, selecting trays or packing, performing hydraulic analysis, and producing optimization recommendations for vapor–liquid separations. It produces column specs, tray/packing datasheets, operating envelopes, and practical guidance for implementation. Use it to move from VLE data and process specs to a buildable column design.

How this skill works

The skill accepts feed composition, product targets, VLE data, and a thermodynamic model, then runs shortcut and rigorous calculations (Fenske, Underwood, Gilliland, McCabe–Thiele, Ponchon–Savarit) to size the column. It evaluates hydraulics (flooding, weeping, entrainment), selects tray or packing types, computes HETP and pressure drop for packing, and optimizes feed location, reflux ratio, and side draws. Outputs include datasheets, operating envelopes, and optimization recommendations for energy and capacity.

When to use it

  • Designing a new distillation column from process specs and VLE data
  • Rating or troubleshooting an existing column (identify flooding, weeping, inefficiency)
  • Comparing tray versus packing alternatives for cost and performance
  • Optimizing reflux ratio, feed stage, or side-draw strategy
  • Sizing columns for turndown and start-up constraints

Best practices

  • Validate VLE and thermodynamic models before detailed design
  • Provide full feed composition and impurity limits to define specifications
  • Allow conservative design margins for hydraulics and operability
  • Evaluate energy integration and reflux trade-offs early
  • Cross-check shortcut results with at least one rigorous method

Example use cases

  • Generate tray count and column diameter for multicomponent separations using Fenske and Gilliland shortcuts
  • Select structured packing and estimate HETP and pressure drop for low-pressure systems
  • Perform hydraulic checks to determine maximum vapor load and flooding margin
  • Optimize feed stage and reflux ratio to minimize reboiler duty while meeting product purities
  • Design side-draws and evaluate their impact on stage requirements and capacity

FAQ

What inputs are required to run a reliable design?

Provide validated VLE data or a thermodynamic model, full feed composition, flowrates, pressures, and product purity specs.

When should I prefer packing over trays?

Choose packing for low-pressure or corrosive services, where lower pressure drop and higher turndown are needed; trays are often preferred for fouling streams or when easier mechanical access is required.