Sumitomo Chemical India Ltd., Bhavnagar 18.02.

2020

Costing for New Installation of Packed Bed type Scrubbing Tower for SFD in GT Plant

Sr. No. Activity/Item Cost (Lakh)

1 Equipment

Packed Column Shell with Nozzles & Accesorries in SS-316 L 3.00

Random Packing-SS-316 L Pall Ring 50 mm + internals i.e. Distributor, Supporting Plate etc

Strctured Packing-SS-316 5.0 L + internals i.e. Distributor, Supporting Plate etc 2.50

2 Structural

Structrual related work for Scrubbing Tower & Blower Installation 1.00

3 Piping

Piping Modification (18") for installation of Tower 0.50

4 Utility

N/A 0.00

5 Electrical

N/A 0.00

6 Instruments

N/A 0.00

7 Others

Equipment Installation, Piping related khalasi work 0.50

Total Budgatory Cost 5.00

With 10% contingency, Say 5.50

Basis for Costing :-

1. Calculation for Sizing of Proposed Equipments are attached in seperate sheet

2. Proper Size Packed Tower is consider against Existing Installed Plate Tower due to inefficient scrubbing operation

3. Structred Packing 5.0 L in SS-316 is consider to installed in tower based on allowable pressure drop to use existing blower

4. Existing Installed 01+01 Centrifugal Pump for Scrubbing Solution circulation will be used
 ID Blower Detail FD Blower Detail

Type Centrifugal Type Centrifugal

Capacity 12000 CMH Capacity 9000
Speed 1850 RPM Speed 1670
SP 355 mmwc @ 70°C SP 200 mmwc
Drive Type V- Belt Drive Type V- Belt
Motor 20 HP Motor 15
Motor RPM 1440 RPM Motor RPM 1440
MOC MOC
Casing MS Casing MS
Impeller SS-304 Impeller SS-304
Shaft SS-304 Shaft SS-304
Pully Size Pully Size
Fan 8.5" Fan 9"
Motor 11" Motor 7"

Entrainement Sep. Tower Detail

MOC SS-316
Diameter 1300
Height 3600
Internal Baffle
wer Detail Scrubber Pump-1 Detail

Type Centrifugal
CMH Model 35CT
RPM Capacity 10 CMH
Head 10 Mtr
Motor 3 HP
HP Motor RPM 1440 RPM
RPM MOC PVDF

Scrubber Pump-2 Detail

Type Centrifugal
Model 40*160 Sulzer
Capacity 25 CMH
Head 25 Mtr
Motor 5 HP
Motor RPM 1440 RPM
MOC SS-316
F.D Fan I.D Fan Static Pr. Readings
RPM RPM SFD Vapour Column Blower Suction Tower O/L
0 1400 -140 mmwc -250 mmwc
1400 1400 -10 mmwc -170 mmwc +15 mmwc

Allowable Pr. Drop for Scrubbing Tower Sizing 155 mmWc

Tower Exit VOC 0.6-2.8 ppm

 Admin:
Select Max.
Velocity @ Throat
Existing Ventury Scrubber Pressure drop to get max. pr.
drop
Inlet Pipe Size 450 mm
Gas Velocity 20 m/s
Gas Volumatric Flow Rate 11445 m3/hr
Tower I.D. 1300 mm
Gas Flow 11445.3 m3/hr
Liquid Flow 25000 Kg/hr
6.944 Kg/sec
13888.889 L/hr
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, L 1.21

Ventury Scrubber Pressure drop 4.854 Cm

0.0485 m
Ventury Scrubber Pressure drop 49 mmWc
 Proposed Demister Mesh Pad Type - Pressure drop
Liquid Density 1800 kg/m3
Gas Density 1.06 Kg/m3
K factor for Vertical Flow 0.107
Actual Vapour Velocity, Vs 4.4 m/s
Admin:
Approximate Pressure Drop through Demister Incase Liquid spray
for absorption
C- For Mesh Pad Type 0.200
facility
t- Pad Thickness (normally 100-150 mm) 0.150
downstream to m
Mist Eliminator
provided
Wet Pressure Drop 0.6 Kpa
61.8 mmWc

Dry Pressure Drop 30.89 mmWc

 Proposed Demister Vane Type - Pressure drop
Liquid Density 1800
Gas Density 1.06
K factor for Vertical Flow 0.175
Admin:
Actual Vapour Velocity, Vs 7.2 Liquid spray
Incase
for absorption
facility
Approximate Pressure Drop through Demister downstream to
Mist Eliminator
C- For Mesh Pad Type 8.000
provided
Wet Pressure Drop 0.4
44.1

Dry Pressure Drop 22.04

ure drop
kg/m3
Kg/m3
Admin:
m/s
Incase Liquid spray
for absorption
facility
downstream to
Mist Eliminator
provided
Kpa
mmWc

mmWc
 Packed Bed Scrubber Sizing
Basis:-
Absorption of Formaldehyde from Formaldehyde + Air Mixture
Scrubbing Media is Sodium Sulphite, Na2SO3
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 Solution
X2 Kmol of HCHO/ Kmol Water in Inlet Solution
L2=Ls Molar Flow Rate of Solution at Inlet
L1 Molar Flow Rate of Solution at Outlet
x1 Mole Fraction of HCHO in Outlet Solution
X1 Kmol of HCHO/ Kmol Water in Outlet Solution
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 Na2SO3 @ 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 0.8
H1 Height req. for Random Packing 2.11

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 84

∆P1 Overall Pressure Drop for Random Packing 51

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