Scrubber Design (Packed Column)

SCRUBBER DESIGN (PACKED COLUMN)
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Checked by :
Date :
### Input Data

Packing type
Packing size
Packing MOC
= Intallox Saddles
=
25 mm
=
PP
Gas pr. Drop / m bed

Total packing height
=
=
Column Tag No.

Job No.
Client
Project
:
:
:
:
HCL Scrubber
4506A
JOL
SR - Plant -4, 5
Stream
HCL Vap.
15 mmWC / m packing height

3.2 m (including all packed beds)
147.1 (N/m2)/m
Gas / Vapour Properties

Gas / Air flow rate
1000 kg/h
0.2778 kg/s
Gas pressure at entry
1.0000 atm
Gas temperature at entry

Gas / Air mol weight
=
=
30.00 oC
29
Component to be scrubbed
Component Name
=
Component flow rate
=
% comp. in air/gas
=
Molecular weight of comp. =
OR
=
HCL Vap
70 Kg/h
6 % (v/v)
36.5
Liquid Viscosity, L
= 0.0035000 Ns/m2
Packing factor, Fp
0 m3/s
303.00 oK
(presumed) / (given by client) / (by process cal.)
Liquid / Scrubbing media Properties

Scrubbing media
= 20% NaOH
Liquid flow rate, L
=
77 kg/h
=
0.0214 kg/s
Liquid Density, L
=
1100 kg/m3
Charac. Packing Factor,Cf =

Conversion factor, J
=
0 m3/h
Conversion :
3.5 Cp
0.00350000
Ns/m2
21 m-1
33
Ref. Table 6.3, Characterstics of Random packings
1.0 factor for adequate liquid distribution & irrigation across the bed
Sheet 1 of 11
Calculations
TO CALCULATE COLUMN DIAMETER
Since larger flow quantities are at the bottom for an absorber, the diameter will be chosen to
accommodate the bottom conditions.
To calculate Gas density
Avg. molecular weight
=
29.45 Kg / Kmol
If gas flow rate is given in kg/h
If gas flow rate is given in m3/h
Gas in =
Gas in
0.0094321826 Kmol/s
kmol = mass / mol wt
= (kmol/s) x T in kelvin x 1.0 atm x 22.4
273
pr. In atm
1
0.234499 m /s
3
= (m3/s) x
273
x pr. in atm x
T in kelvin
1.0 atm
1
22.4
0 Kmol/s
0 Kg/s
mass = mol wt x kmol
Select vol. flow rate and mass flow rate from above,
Selected mass flow rate
= 0.2777778 Kg/s
Selected vol. Flow rate
Selected molar flow rate
= 0.234499 m3/s
= 0.0094322 Kmol/s
Therefore, gas density
1.1846 Kg/m3
(mass flow rate / vol. Flow rate)
To find L', G' and Tower c/s area

Assuming essentially complete absorbtion,
Component removed
=
0.0207 Kg/s
Liquid leaving
=
0.0420 Kg/s
L'
G'
0.5
Using
0.00497
G' 2 Cf L0.1 J
(
G
-L
(molar flow rate x % comp. x mol. Wt.)

(Inlet liquid flow rate + comp. Removed)
0.00497
as ordinate,
Refer fig.6.34 using a gas pressure drop of
0.04 (from graph)
0.04
) gc
G
Therefore, G'
Cf
--
0.1
L
) gc
0.5
1.6665 Kg / m2.s
Tower c/s area
0.1667 m2
( c/s area = mass flow rate / G' )
Tower diameter
=
=
0.4607 m
500 mm
Sheet 2 of 11
460.7 mm
147.1
(N/m2)/m
Corresponding c/s area
0.1963 m2
TO ESTIMATE POWER REQUIREMENT
Efficiency of fan / blower
60 %
assumed / given
To calculate pressure drop

Pressure drop for irrigated =
packing
470.72 N/m2
(pressure drop per m packing x total ht. of packing)
For dry packing,

O/L Gas flow rate, G'
O/L Gas pressure

Gas density,
G
= 100854.28 N/m2
=
1.3095 Kg / m2.s (Gas inlet flow rate - Component removed) / c/s area
gas mol wt. x
273
x
22.41m3/Kmol T in kelvin
=
CD
Delta P
= CD
(subtracting pressure drop across packing)

gas o/l pr.
101330
1.1605 Kg/m3
96.7
Ref. Table 6.3, Characterstics of Random packings
G' 2
G
142.89 N/m2
Pressure drop for packing =
613.61 N/m2
Pressure drop for internals =
25 mmWC
245.17 N/m
Gas velocity
7.5 m/s
Inlet expansion & outlet

contraction losses
= 1.5 x Velocity heads

=
42.19 N m / Kg
(irrigated packing + dry packing)

(packing supports and liquid distributors)
1.5 x (V2 / 2g)
49.97 N/m2
Total pressure drop
908.75 N/m2
Fan power output
= pressure drop,N/m2 x (gas in - component removed) Kg/s

=
=
Power for fan motor
=
=
(divide by density)
(packing + internals + losses)
O/L gas density, Kg/m3

201.35 N .m / s
0.20 kW
0.34 kW
0.45 hp
(fan power output / motor efficiency)
Sheet 3 of 11
COLUMN DIAMETER / HYDRAULIC CHECK

Liq.-Vap. Flow factor, FLV
= (L / V) x (
=
0.0025
Design for an initial pressure drop of

From K4 v/s FLV,
15
mm H2O /m packing
K4
0.85
K4 at flooding
6.50
Trial % flooding
= ( (K4 / K4 at flooding)
=
36.1620
Gas mass flow rate, Vm
K4 .
13.1 Fp (L /
=
Trial column c/s area
(Trial As)
Trial column dia., D
--
V
L
) x 100
(1/2)
)0.1
3.7763 kg/m2.s
V / Vm
0.0736 m2
0.3060 m
D = (4/pi) x Trial As
Round off 'D' to nearest standard size

Therefore, D
=
0.500 m
Column C/S area, As
% flooding
0.1963 m2
13.5472
As = (pi/4) x D2
% flooding = Trial % flooding x (Trial As / As)
Conclusion
Generally packed towers are designed for 50% -- 85% flooding.
If flooding is to be reduced,
(i) Select larger packing size and repeat the above steps.
OR
(ii) Increase the column diameter and repeat the above steps.
Sheet 4 of 11
HETP PREDICTION
Norton's Correlation :
ln HETP = n - 0.187 ln
+ 0.213 ln
Applicable when,
liquid phase surface tension > 4 dyne/cm & < 36 dyne/cm
liquid viscosity > 0.08 cP & < 0.83 cP
Conversion :
Input Data
0.018 N/m = 18 dyne/cm
Liquid-phase
Surface Tension,
=
20 dyne/cm
Norton's Correlation Applicable
Liquid Viscosity
3.5 cP
Norton's Correlation NOT applicable
1.13080
Calculation
ln HETP
= 0.8374366
HETP
= 2.3104368 ft
= 0.7042211 m
For separations, less than 15 theoritical stages, a 20% design safety factor can be applied.
Considering 20% safety factor,
HETP
= 0.8450653 m
For separations, requiring 15 to 25 theoritical stages, a 15% design safety factor can be applied.
Considering 15% safety factor,
HETP
= 0.8098543 m
Sheet 5 of 11
Table 6.2
Constant for HETP Correlation
Ref.:: Random Packings and Packed Towers ---- Strigle
Ref. : : Chemical Engineering, Volume-6 , COULSON & RICHARDSON'S
Ref. : : Mass Transfer Operation : : Treybal

Scrubber Design (Packed Column)

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SCRUBBER DESIGN (PACKED COLUMN)

### Input Data

Gas pr. Drop / m bed

Column Tag No.

15 mmWC / m packing height

Gas / Vapour Properties

Gas pressure at entry

Gas temperature at entry

(presumed) / (given by client) / (by process cal.)

Liquid / Scrubbing media Properties

Charac. Packing Factor,Cf =

If gas flow rate is given in kg/h

If gas flow rate is given in m3/h

Therefore, gas density

(mass flow rate / vol. Flow rate)

To find L', G' and Tower c/s area

(molar flow rate x % comp. x mol. Wt.)

Refer fig.6.34 using a gas pressure drop of

0.04 (from graph)

Tower c/s area

( c/s area = mass flow rate / G' )

Corresponding c/s area

Efficiency of fan / blower

To calculate pressure drop

(pressure drop per m packing x total ht. of packing)

For dry packing,

O/L Gas pressure

(subtracting pressure drop across packing)

Ref. Table 6.3, Characterstics of Random packings

Pressure drop for packing =

Pressure drop for internals =

Inlet expansion & outlet

= 1.5 x Velocity heads

(irrigated packing + dry packing)

1.5 x (V2 / 2g)

Total pressure drop

Fan power output

= pressure drop,N/m2 x (gas in - component removed) Kg/s

Power for fan motor

O/L gas density, Kg/m3

(fan power output / motor efficiency)

COLUMN DIAMETER / HYDRAULIC CHECK

Design for an initial pressure drop of

Gas mass flow rate, Vm

Trial column dia., D

Round off 'D' to nearest standard size

Column C/S area, As

% flooding = Trial % flooding x (Trial As / As)

Norton's Correlation NOT applicable

Ref.:: Random Packings and Packed Towers ---- Strigle

Ref. : : Chemical Engineering, Volume-6 , COULSON & RICHARDSON'S

Ref. : : Mass Transfer Operation : : Treybal

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