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    Scrubber Design (Packed Column)

    Uploaded by

    Peddy Nesa
    1. The packed column scrubber is designed to remove HCL vapor from a gas stream at a rate of 70 kg/hr using 20% NaOH as the scrubbing liquid. 2. Key design parameters include a packing height of 3.2m, gas and liquid flow rates of 1000 kg/hr and 77 kg/hr respectively, and a predicted HETP of 0.7042211 m. 3. Hydraulic calculations show the column can be designed with a diameter of 500mm to avoid flooding above 85% at a pressure drop of 15mmWC/m packing height.

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    Scrubber Design (Packed Column)

    Uploaded by

    Peddy Nesa
    603 views11 pages
    1. The packed column scrubber is designed to remove HCL vapor from a gas stream at a rate of 70 kg/hr using 20% NaOH as the scrubbing liquid. 2. Key design parameters include a packing height of 3.2m, gas and liquid flow rates of 1000 kg/hr and 77 kg/hr respectively, and a predicted HETP of 0.7042211 m. 3. Hydraulic calculations show the column can be designed with a diameter of 500mm to avoid flooding above 85% at a pressure drop of 15mmWC/m packing height.

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    scrubber_design

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    1. The packed column scrubber is designed to remove HCL vapor from a gas stream at a rate of 70 kg/hr using 20% NaOH as the scrubbing liquid. 2. Key design parameters include a packing height of 3.2m, gas and liquid flow rates of 1000 kg/hr and 77 kg/hr respectively, and a predicted HETP of 0.7042211 m. 3. Hydraulic calculations show the column can be designed with a diameter of 500mm to avoid flooding above 85% at a pressure drop of 15mmWC/m packing height.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    603 views11 pages

    Scrubber Design (Packed Column)

    Uploaded by

    Peddy Nesa
    1. The packed column scrubber is designed to remove HCL vapor from a gas stream at a rate of 70 kg/hr using 20% NaOH as the scrubbing liquid. 2. Key design parameters include a packing height of 3.2m, gas and liquid flow rates of 1000 kg/hr and 77 kg/hr respectively, and a predicted HETP of 0.7042211 m. 3. Hydraulic calculations show the column can be designed with a diameter of 500mm to avoid flooding above 85% at a pressure drop of 15mmWC/m packing height.

    Copyright:

    © All Rights Reserved
    Download as XLS, PDF, TXT or read online from Scribd
    Download as xls, pdf, or txt
    of 11
    At a glance
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    The key takeaways are that the document discusses the design of a packed column scrubber including calculations for column diameter, pressure drop, power requirement and height of a transfer unit (HETP).

    The packed column scrubber is designed to remove HCl vapors from an air/gas stream using 20% NaOH as the scrubbing media.

    The steps involved in calculating the column diameter are: calculating gas density, finding L' and G', determining the tower cross-sectional area, and selecting the column diameter.

    SCRUBBER DESIGN (PACKED COLUMN)

    Prepared by : Column Tag No. :


    Checked by : Job No. :
    Date : Client :
    Project :

    ### Input Data Stream : HCL Vap.

    Packing type = Intallox Saddles


    Packing size = 25 mm
    Packing MOC = PP
    Gas pr. Drop / m bed = 15 mmWC / m packing height = 147.1 (N/m2)/m
    Total packing height = 3.2 m (including all packed beds)

    Gas / Vapour Properties


    Gas / Air flow rate = 1000 kg/h OR 0 m3/h
    = 0.2778 kg/s = 0 m3/s

    Gas pressure at entry = 1.0000 atm


    Gas temperature at entry = 30.00 oC = 303.00 oK
    Gas / Air mol weight = 29

    Component to be scrubbed
    Component Name = HCL Vap
    Component flow rate = 70 Kg/h
    % comp. in air/gas = 6 % (v/v) (presumed) / (given by client) / (by process cal.)
    Molecular weight of comp. = 36.5

    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 Conversion :
    Liquid Viscosity, µL = 0.0035000 Ns/m2 3.5 Cp = 0.00350000 Ns/m2

    Packing factor, Fp = 21 m-1


    Charac. Packing Factor,Cf = 33 Ref. Table 6.3, Characterstics of Random packings
    Conversion factor, J = 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 = 0.0094321826 Kmol/s Gas in = (m3/s) x 273 x pr. in atm x 1


    kmol = mass / mol wt T in kelvin 1.0 atm 22.4
    = (kmol/s) x T in kelvin x 1.0 atm x 22.4
    273 pr. In atm 1 = 0 Kmol/s
    = 0.234499 m /s 3
    = 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 = 0.234499 m3/s
    Selected molar flow rate = 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 (molar flow rate x % comp. x mol. Wt.)
    Liquid leaving = 0.0420 Kg/s (Inlet liquid flow rate + comp. Removed)

    L' G 0.5 = 0.00497


    G' L

    Using 0.00497 as ordinate, Refer fig.6.34 using a gas pressure drop of 147.1 (N/m2)/m

    G' 2 Cf µL0.1 J = 0.04 (from graph)


    G
    ( L
    -- G
    ) gc

    Therefore, G' = 0.04 G


    ( L
    -- ) gc
    G 0.5
    Cf µ L
    0.1
    J

    = 1.6665 Kg / m2.s

    Tower c/s area = 0.1667 m2 ( c/s area = mass flow rate / G' )

    Tower diameter = 0.4607 m = 460.7 mm


    = 500 mm

    Corresponding c/s area = 0.1963 m2

    Sheet 2 of 11
    TO ESTIMATE POWER REQUIREMENT

    Efficiency of fan / blower = 60 % assumed / given

    To calculate pressure drop

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

    For dry packing,


    O/L Gas flow rate, G' = 1.3095 Kg / m2.s (Gas inlet flow rate - Component removed) / c/s area
    O/L Gas pressure = 100854.28 N/m2 (subtracting pressure drop across packing)
    Gas density, G = gas mol wt. x 273 x gas o/l pr.
    22.41m3/Kmol T in kelvin 101330
    = 1.1605 Kg/m3

    CD = 96.7 Ref. Table 6.3, Characterstics of Random packings

    Delta P = CD G' 2
    Z G

    = 142.89 N/m2

    Pressure drop for packing = 613.61 N/m2 (irrigated packing + dry packing)

    Pressure drop for internals = 25 mmWC (packing supports and liquid distributors)
    = 245.17 N/m 2

    Gas velocity = 7.5 m/s


    Inlet expansion & outlet = 1.5 x Velocity heads = 1.5 x (V2 / 2g)
    contraction losses = 42.19 N m / Kg
    = 49.97 N/m2 (divide by density)

    Total pressure drop = 908.75 N/m2 (packing + internals + losses)

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


    O/L gas density, Kg/m3
    = 201.35 N .m / s
    = 0.20 kW

    Power for fan motor = 0.34 kW (fan power output / motor efficiency)
    = 0.45 hp

    Sheet 3 of 11
    COLUMN DIAMETER / HYDRAULIC CHECK

    Liq.-Vap. Flow factor, FLV = (L / V) x ( V


    / L
    )
    = 0.0025

    Design for an initial pressure drop of 15 mm H2O /m packing


    From K4 v/s FLV,
    K4 = 0.85

    K4 at flooding = 6.50

    Trial % flooding = ( (K4 / K4 at flooding) ) x 100


    = 36.1620

    (1/2)
    Gas mass flow rate, Vm = K4 . V
    ( L
    -- V
    )
    13.1 Fp (µL / )0.1
    L

    = 3.7763 kg/m2.s

    Trial column c/s area = V / Vm


    (Trial As)
    = 0.0736 m2

    Trial column dia., D = 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 = 0.1963 m2 As = (pi/4) x D2

    % flooding = 13.5472 % 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 µ


    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

    n = 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

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