Packed Bed Scrubber Sizing

Basis:-
Absorption of Formaldehyde from Formaldehyde + Air Mixture
Scrubbing Media is Sodium Sulphide, Na2S
Isothermal Absorption no temp. rise during absorption

Process Data
T Scrubber Operating Temp. 70
P Oeperating Pressure 1
760
HCHO ppm in inlet gas 3
HCHO Volume % in inlet gas (3 ppm) 0.0003
Pipe Diameter 450
Assuming Inlet Velocity 20
Inlet Vol. Flow Rate of Gas 11445.3
Molecular Wt. of Formaldehyde 30
Molecular Wt. of Air 29
R Universal Gas Constant 0.082
Absorption required 80
0.8
Tower Outlet H-CHO ppm (STEL = 1) will be 0.6
Nomenculture
Gs Molar Flow rate of Air
G1 Molar Flow of Inlet Gas Mixture
y1 Mole Fraction of HCHO in Inlet Gas
Y1 Kmol of HCHO/ Kmol Air in Inlet Gas
G2 Molar Flow of Outlet Gas Mixture
y2 Mole Fraction of HCHO in Outlet Gas
Y2 Kmol of HCHO/ Kmol Air in Outlet Gas
x2 Mole Fraction of HCHO in Inlet Water
X2 Kmol of HCHO/ Kmol Water in Inlet Liquid
L2=Ls Molar Flow Rate of Water at Inlet
L1 Molar Flow Rate of Water at Outlet
x1 Mole Fraction of HCHO in Outlet Water
X1 Kmol of HCHO/ Kmol Water in Outlet Liquid
Lsm Minimum Amount of Solvent Required
X1m Value of X1 corrospond to Minimum Amount of Solvent Req
Admin:
Calculation Fresh Solvent
ρA Assumed
Density of Air 1.031
Gs Molar Flow Rate of Air 406.93
x2 Mole Fraction of HCHO in Inlet Liquid 0
X2 Kmol of HCHO/ Kmol Water in Inlet Liquid 0.000
y1 Mole Fraction of HCHO in Inlet Gas 3E-06
Y1 Kmol of HCHO/ Kmol Air in Inlet Gas 0.00000
y2 Mole Fraction of HCHO in Outlet Gas 6E-07
 Y2 Kmol of HCHO/ Kmol Air in Outlet Gas 0.00000
Mole Fraction of Air in Outlet Gas 0.9999994
Minimum Amount of Solvent required for desired absorption
Antoine's co. A 7.1561
HCHO B 957.24
C 243.01
Pv Vapour Pressure of HCHO @ 70 °C 250.29
m Pv/ P 0.33

Ls=MWR= Minimum Wetting Rate required to form Liquid Film all over Packing.
MWR can be found out based on Tower Diameter which is yet not known
So this is required Trial & Error method for estimation of MWR
Minimum 1 M3/hr of Flow Rate is required for use of Centrifugal Pump for facilate absorption

ρL Density of Sol. @ atm. temp. 1800

Mw Molecular Wt. of Sol. 78
Ls Minimum Solvent Flow Rate 4
92.31
7200

Absorption Column Tower Diameter required at Top based on Inlet Condition

Lw Mass Velocity of Solvent/ Water entering Tower
Lw= (1000/3600)/(0.785*D2)
Lw=0.2778/(0.785*D2)
G2 Molar Flow of Outlet Gas Mixture 406.93
G2=Gs(1+Y2) 3.278045481993

Mav Avg. Molecular Wt. of Gas Mixture outlet 29.000

Mav= Mole fraction* Molecular Wt.

Gw Gw=(G2*Mav)/(0.785*D2)
Gw=0.462/(0.785* D2)

ρg Density of Outlet Gas Mixture 1.031

FLG Lw/Gw 0.0847

(ρg/ρL)^1/2 0.0239
FLG 0.0020
From Fig. 9.3 Find Kf Value

Kf From Chart of FLG vs K at max. flooding 0.2

Considering @ 66 % of Flooding

F Flooding Considering 66
K At 66% Flooding 0.08712
From Fig. 9.3 Find Pressure Drop at 66% Flooding
Pressure Drop 60

Ψ Density of Na2s 1.8

g Gravitational Accelration 9.81
µL Viscosity of Na2s @ 20 °C 1
0.001

Packing Detail
Select Packing Metal Pall Ring
Packing size 50
Fp Packing Factor 66

Gw Mass Velocity of Gas through Tower 3.654

At Tower Area required at Top 0.8971

Dt Tower Diameter required at Top 1.069028825738
1069.028825738
Say 1100
Tower Diameter/ Packing Size 22
Recommended > 10 so satisfactory
Wetting Liquid Rate 4.211
Recommended MWR required is 4 m3/m2*hr for random packing
If We keep 1 m3/hr Rate MWR will fall below Rocommended MWR Value
Let's increse Solvent Rate to get MWR 4 m3/m2*hr
Liquid mass flow Rate per m2 of tower 7580.1
Kister has also suggested keep MWR of circulation 5 M3/m2*Hr

Based on Morris & Jackson Minimum Solvent Required

Lmin. Minimum Solvent Required = MWR* at
MWR for Ring <75 mm is 0.08
at For 50 mm SS Pall Ring 115
Lmin. Minimum Solvent Required 9.2
14856
L2 190.46

Cross Checking of Liquid Rate based on this method

FLG 0.030
From Figure 9.3 FLG Vs. K at Flooding
Kf From Fig. 9.3 0.17
Let the Actual Velocity of Gas = 66 % of Flooding Velocity

F Flooding Considering 66
K At 66% Flooding 0.074
From Fig. 9.3 Find Pressure Drop at 66% Flooding
Pressure Drop 40

Gw Mass Velocity of Gas through Tower 3.369

At Tower Area required at Top 0.9731
Dt Tower Diameter required at Top 1.11
1113.36
Say 1150

Lm Liquid Rate 15267.6

8.5
Hence it is satisfied the condition based on morries & Jackson calculation

Absorption Column Tower Diameter required at Bottom based on Outlet Condition

Mav Avg. Molecular Wt. of Gas- Vapour Mixture 29.000003

Mav= y1*m.w of HCHO+ (1-ye) m.w of air

ρg Density of Outlet Gas Mixture 1.031

HCHO Balance
Gs(Y1-Y2)=Ls(X1-X2)
X1 Kmol of HCHO/ Kmol Water in Outlet Liquid 0.000005
x1 Mole Fraction of HCHO in Outlet Water 0.000005
ρL Density of Solution leaving Tower 1800.0
L1 Molar Flow Rate of Water at Outlet 190.46555438197
L1=Ls(1+X1)

Mav Avg. Molecular Wt. of Solution leaving Tower 78.00

L1w Mass Velocity of Solvent/ Water leaving Tower
L1w= (L1*Mav/3600)/(0.785*D2)
L1w=4.25/(0.785*D2)

G1 G1=Gs(1+Y1) 406.93
3.28
G1w Mass Velocity of Gas leaving Tower
G1w= (G1*Mav gas/3600)/(0.785*D2)
G1w=3.42/(0.785*D2)

FLG Lw/Gw 1.2427

(ρg/ρL)^1/2 0.0239
FLG 0.0297
From Figure 9.3 FLG Vs. K at Flooding
Kf From Fig. 9.3 0.175
Let the Actual Velocity of Gas = 66 % of Flooding Velocity
 F Flooding Considering 66
K At 66% Flooding 0.076
From Fig. 9.3 Find Pressure Drop at 66% Flooding
Pressure Drop 40

Gw Mass Velocity of Gas through Tower 4.586

4.4
At Tower Area required at Top 0.7148
Dt Tower Diameter required at Top 0.95
954.27
Say, Tower Diameter required 1000

Packing Height req.

m Gm/Lm Avg. Gas Mass Velocity 0.704

NoG Nos. of Gas Phase Transfer Unit 2.64

HETP Assume for Random Packing 0.6
H1 Height req. for Random Packing 1.58

HETP Assume for Structred Packing 0.2

H2 Height req. for Structred packing 0.53

Packed Tower Overall Pressure Drop

∆P1 Overall Pressure Drop for Random Packing 63

∆P1 Overall Pressure Drop for Random Packing 38

New Blower Required SP Capacity

FAD Capacity 12000
 °C
Atm
mmhg
ppm
%
mm
m/s
m3/hr
g/mol
g/mol
m3 atm/ kmol k
%

Kmol/hr
Kmol/hr

Kmol/hr

Kmol/hr
Kmol/hr

Kmol/hr
Kmol/hr

Kg/m3
Kmol/hr
 mmhg

absorption

Kg/m3
g/mol
m3/hr
Kmol/hr
Kg/hr

Kg/ m2 sec
Kmol/hr
Kg/sec

Kg/ Kmol

Kg/ m2 sec

Kg/m3

%
 mmwc/m packing

m/s2
Cp
Kg/ m sec

SS-316
mm
m-1

Kg/ m2 sec

m2
m/s2
mm
mm

m3/m2 hr
g
WR Value

Kg/ hr m2

m2/ hr
m2/m3
m3/ m2 hr
Kg/hr 15 m3/hr
Kmol/hr

%
 mmwc/m packing

Kg/ m2 sec
m2
m/s2
mm
mm

Kg/ m2 hr
M3/ m2 hr

Kg/ Kmol

Kg/m3

Kg/m3
Kmol/hr

Kg/ kmol

Kg/ m2 sec

Kmol/hr
Kg/sec

Kg/ m2 sec
 %

mmwc/m packing

Kg/ m2 sec
m/s
m2
m
mm
mm

Nos.

mmwc

mmwc

mmwc
m3/hr
 Scrubbing Tower Sizing based on allowable pr. drop
Inlet Pipe Size 450 mm
Inlet Pipe Velocity 20 m/s
Gas Volumatric Flow Rate 11445 m3/hr
Tower I.D. 1300 mm
Velocity Inside Scrubber 2.4 m/s
Packing Height 3 m
Allowable Pr. Drop for Tower sizing 150 mmWc
Select Packing Type SS Pall Ring
Size 50 mm
Gas Flow 11445.3 m3/hr
Liquid Flow 25000 Kg/hr
6.944 Kg/sec
Liquid Density 1800.000 kg/m3
Gas Density 1.1 Kg/m3
Gas Mass Flow 12175.6 Kg/hr
3.382 Kg/sec
Liquid/Gas Ratio 2.05
0.024
FLG 0.050
Kf from chart of FLG Vs K at maximum Flooding
Kf 0.15
Kf at 66% Flooding 0.06534
∆P/ meter 40 mmwc
Overall Tower Pr. Drop for SS 2" Pall Ring 120 mmwc
Overall Tower Pr. Drop for Structred packing 72 mmwc

Pall Ring Qty, required

Apprx. Kg/m3 385
Volume of Tower 3.97995
Pall Ring Qty, required, Kgs 1532