Design and Parametric Analysis of a Binary Distillaion Column Using McCabe-Thiele Method

Distillation remains one of the most widely employed separation processes in chemical and petrochemical industries due to its reliability and effectiveness in separating liquid mixtures based on volatility differences. Despite the availability of advanced simulation and optimization tools, classical design methodologies continue to play a crucial role in building fundamental understanding and supporting preliminary design decisions. This paper presents the theoretical design and parametric analysis of a binary distillation column for the separation of a benzene–toluene mixture using the McCabe–Thiele graphical method. Vapor– liquid equilibrium data are utilized to construct equilibrium and operating lines, enabling the estimation of minimum reflux ratio, number of theoretical stages, and feed tray location. A detailed parametric study is conducted to evaluate the influence of reflux ratio and feed condition on column performance, separation efficiency, and energy considerations. The results demonstrate that while higher reflux ratios reduce the required number of stages, they lead to increased energy consumption. The study further discusses the relevance of classical design techniques in modern engineering practice, particularly in the context of energy optimization and sustainable process design. This work is intended for undergraduate academic study and serves as a foundation for further simulation-based analysis.