Chapter 5 Equipment Design

Absorber

EQUIPMENT DESIGN

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Chapter 5 Equipment Design
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DESIGN OF ABSORBER

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DESIGN OF ABSORBER

Absorber

The removal of one or more selected components from a mixture of gas by absorption into
a suitable solvent.

Selection of Solvent

The most commonly used solvents for the removal of hydrogen sulfide & CO 2 from the gaseous
streams are amines, especially alkanolamines. A number of different compounds belonging to
this category can be used for this purpose. Some of the most commonly used amines are
compared in the following lines.

Mono-Ethanol Amine:

• Preferred for low concentrations without contaminants COS & CS2.

• Easy regeneration.

• Very corrosive in nature.

• High heat of reaction with H2S.

• Relatively high vapor pressure.

• Relatively low cost.

Di-Ethanol Amine:

• Used for the purification of natural gas even with contaminants COS & CS2.

• Low vapor pressure.

• Very less corrosive than MEA.

• Gives excellent loading (0.7-1 mol of gas/mol of DEA) at high concentrated aqueous
solution from 25-50%.

• Easy recovery.

• Relatively low cost.

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Tri Ethanol Amine

• TEA is less reactive with acid gases.it has less acid gas carrying capacity.

• And also cannot reduce H2S content to general pipeline specifications.

• But the advantage of TEA is that it is selective for H2S.

Selection Criteria

Sufficient data and operating experience with several alkanolamines are on hand to
permit a judicious selection of the treating solution for a wide range of conditions.

An ideal absorbent should meet the following criteria:

• Have a high degree of solubility for the solute (minimizes absorbent required).

• Have low volatility (increases solute recovery and reduces absorbent loss)

• Be stable (reduces need to replace absorbent).

• Be non-corrosive (reduces need for corrosion resistant equipment).

• Be non-foaming when in gas contact (reduces size of equipment).

• Be nontoxic and non-flammable (safety).

Choice between Plate & Packed column

Vapor liquid mass transfer operation may be carried either in plate or packed
column. These two types of operation are quite different. The relative merits of plate over packed
column are as follows:

1-Plate column are designed to handle wide range of liquid flow rates without flooding.

2-If a system contains solid contents; it will be handled in plate column, because solid will
accumulate in the voids, coating the packing materials and making it ineffective.

3-Dispersion difficulties are handled in plate column when flow rate of liquid are low as
compared to gases.

4-For large column heights, weight of the packed column is more than plate column.

5-If periodic cleaning is required, man holes will be provided for cleaning. In packed columns
packing must be removed before cleaning.

6-For non-foaming systems the plate column is preferred.

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7-Design information for plate column is more readily available and more reliable than that for
packed column.

8-Inter stage cooling can be provided to remove heat of reaction or solution in plate column.

9-When temperature change is involved, packing may be damaged.

Choice of Plate Type

There are three main types, sieve tray, bubble cap, valve tray. I’ve selected sieve tray because:

1-They are lighter in weight and less expensive. It is easier and cheaper to install.

2-Pressure drop is low as compared to bubble cap trays.

3-Peak efficiency is generally high.

4-Maintenance cost is reduced due to the ease of cleaning. [2]

Sieve Trays

Sieve trays are simply metal plates with holes in them. Vapor passes straight upward through the
liquid on the plate. The arrangement, number and size of the holes are design parameters.

Because of their efficiency, wide operating range, ease of maintenance and cost factors, sieve
and valve trays have replaced the once highly thought of bubble cap trays in many applications.

Factors affecting the absorption Column

VAPOR FLOW CONDITIONS

Adverse vapor flow conditions can cause:

1. Foaming

2. entrainment

3. weeping/dumping

4. flooding

Foaming

Foaming refers to the expansion of liquid due to passage of vapor or gas. Although it
provides high interfacial liquid-vapor contact, excessive foaming often leads to liquid buildup on
trays. In some cases, foaming may be so bad that the foam mixes with liquid on the tray above.
Whether foaming will occur depends primarily on physical properties of the liquid mixtures, but

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is sometimes due to tray designs and condition. Whatever the cause, separation efficiency is
always reduced.

Entrainment

Entrainment refers to the liquid carried by vapor up to the tray above and is again caused
by high vapor flow rates. It is detrimental because tray efficiency is reduced: lower volatile
material is carried to a plate holding liquid of higher volatility. It could also contaminate high
purity distillate. Excessive entrainment can lead to flooding.

Weeping / Dumping

This phenomenon is caused by low vapor flow. The pressure exerted by the vapor is
insufficient to hold up the liquid on the tray. Therefore, liquid starts to leak through perforations.
Excessive weeping will lead to dumping. That is the liquid on all trays will crash (dump) through
to the base of the column (via a domino effect) and the column will have to be re-started.
Weeping is indicated by a sharp pressure drop in the column and reduced separation efficiency.

Flooding

Flooding is brought about by excessive vapor flow, causing liquid to be entrained in the
vapor up the column. The increased pressure from excessive vapor also backs up the liquid in the
down comer, causing an increase in liquid holdup on the plate above. Depending on the degree
of flooding, the maximum capacity of the column may be severely reduced. Flooding is detected
by sharp increases in column differential pressure and significant decrease in separation
efficiency.

State of trays & packing

Remember that the actual number of trays required for a particular separation duty is
determined by the efficiency of the plate. Thus, any factors that cause a decrease in tray
efficiency will also change the performance of the column. Tray efficiencies are affected by
fouling, wear and tear and corrosion, and the rates at which these occur depends on the properties
of the liquids being processed. Thus appropriate materials should be specified for tray
construction.

Column Diameter

Vapor flow velocity is dependent on column diameter. Weeping determines the minimum
vapor flow required while flooding determines the maximum vapor flow allowed, hence column
capacity. Thus, if the column diameter is not sized properly, the column will not perform well.

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Material Balance across the Absorption Column

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Standard Design Steps

1. Calculation of theoretical number of stages.

2. Calculation of actual number of stages.

3. Calculation of diameter of the column.

4. Calculation of weeping point.

5. Calculation of pressure drop.

6. Down comer Design.

7. Residence Time and Entrainment Calculation.

8. Calculation of the height of the column.
1. Calculation of theoretical number of stages.
Now evaluating no of stages from the Kremser method

[3]

N=5

Efficiency of column;

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[4]

Efficiency of column=75 %

2. Calculation of actual number of stages.

Efficiency the column is;

Eo = 75%

So total number of stages = 7

3. Calculation of diameter of the column.

Flooding velocity is given by

[6]

Where,

= flooding vapor velocity, m/s, based on the net column cross-sectional area An

= a constant obtained from figure 11.27 vol. 6 Coulson & Richardson’s “Chemical Engineering”

Where

= liquid mass flow-rate, kg/sec

= vapor mass flow-rate, kg/sec

So,

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FLV = 0.376

So K1

K1 =0.05

Hence

Uf = 0.209 m/s

Max. Vapor Volumetric Flow rate is given by (Vm*M.W/Pv*3600)

Vmax =0.135mm3/sec

So net area required is

= 0.758 m2

Take down comer area as 12%

So the column cross-sectional area is

At = 0.862 m2

Hence the column diameter is given by

D = 1.05m

mol molecular yiPc,Psi

fraction wt Lb/mol Tc,₀R yiTc,₀R Pc,Psia a
305.193 598.385
Methane 0.889 16 14.23 343.3 7 673.1 9
ethane 0.0096 30 0.29 549.8 5.27808 708.3 6.79968
Propane 0.0022 44 0.097 666 1.4652 617.4 1.35828
I-butane 0.0006 58 0.0348 734.1 0.44046 529.1 0.31746
n-butane 0.0005 58 0.029 765.3 0.38265 550.7 0.27535

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I-pentane 0.0003 72 0.022 829.8 0.24894 483 0.1449

n-pentane 0.0003 72 0.022 845.6 0.25368 489.5 0.14685
n-hexane 0.0015 86 0.129 914.1 1.37115 439.7 0.65955
H2S 0.0001 34 0.0034 672.4 0.06724 1306 0.1306
29.1924
CO2 0.0533 44 2.3452 547.7 1 1073 57.1909
N2 0.0419 28 1.173 226.9 9.50711 492 20.6148
Pseudo
Pseudo critical 686.024
critical 353.400 pressur 3
temp 62 e

From fig. ρ=PM/ZR

Z =0.9 T 915 18.3756
1.62704
Tr 9 3.51 575 379
56.6Kg/m
3
3.5Lb/ft3 14.7 550
Pr 915 0.9

Now Plate design is given by

Column Diameter = Dc = 0.69 m

Column Area = Ac = 0.86 m2

Down Comer Area = Ad = 0.103 m2

Net Area = An = 0.758 m2

Active Area = Aa = 0.655m2

Hole Area = Ah = 0.033 m2

Take,

Weir height = 50 mm

Hole diameter = 5 mm

Plate thickness = 5 mm

Total number of holes is given by = Area of holes / area of one hole

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So,

Total number of holes is =1680

4. Calculation of weeping point.

For the calculation of weeping hole diameter must be selected so that at lowest operating rate the
vapor flow velocity is still above the weep point.

[7]

Where

= minimum vapor velocity through the holes, m/s

= hole diameter, mm

a constant, dependent on the depth of clear liquid on the plate, obtained from figure 11.30 vol. 6 Coulson &
Richardson’s “Chemical Engineering”

Where

= weir length, m

= weir crest, mm liquid

= liquid flow-rate, kg/s

At 70% of maximum liquid rate.

So Min how = 36.16 mm liq.

K2 from graph 11.30 is

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K2 = 30.9

So

Uhmin = 1.6 m/sec

Actual minimum vapor velocity is = 2.1 m/sec

So the column is operating above weep point

5. Calculation of pressure drop.

It is convenient to express the pressure drop in terms of millimeters of liquid. But in pressure
units it is given by

Where

= total pressure drop, Pa (N/m2)

= total pressure drop, mm liquid

Dry pressure drop is given by

Where

= dry plate pressure drop

= orifice coefficient

= vapor velocity

So

hd = 71.12 mm liq.

Residual head is given by

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Where

= residual head

hr = 11.87 mm liq.

Total pressure drop is given by

Where,

= total plate pressure drop

= dry plate pressure drop

= height of the weir

= weir crest, mm liquid

ht = 169.15 mm liq.

In pressure units

1747 Pa (N/m2)

6. Down comer Design.

The down comer area and the plate spacing must be such that the level of the liquid and froth in
the down comer is well below the top of the outlet weir on the plate above. If the level rises
above the outlet weir the column will flood.

Where

= down comer back-up, measured from plate surface, mm

= head loss in the down comer, mm

Where

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= head loss in the down comer, mm

= liquid flow-rate in the down comer, kg/s

= either down comer area Ad or the clearance area under the down comer Aap which is smaller

Where,

= clearance area under the down comer

= height of the bottom edge of the apron above the plate

= length of the weir

40 mm

So

23.73 mm

And

= 0.24 m

As

Where

= down comer back-up, measured from plate surface, mm

= plate spacing

So

The tray spacing is acceptable.

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7. Residence Time and Entrainment Calculation.

Residence time in the down comer is given by

Where

= residence time, s

= down comer area

= clear liquid back-up, m

= liquid flow-rate in the down comer, kg/s

So

tr = 5.3 sec

As it is well above 3 sec so design is acceptable.

For the check of entrainment evaluate

Uv =

Uv = 0.18 m/sec

So % flooding = 84.90%

FLV we know so using graph 11.29

Ψ = 0.004

It is well below 0.1 so there is no chance of entrainment.

& the Process is satisfactory.

8. Calculation of the height of the column

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No. of plates = 7

Tray Spacing = 0.5 m

Tray Thickness = 0.005 m

Total Thickness of Trays = 0.035 m

Top Clearance = 1 m

Bottom Clearance = 1 m

Total Height = 5 m

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Specification Sheet

Equipment : Absorption Column

Operation: Continuous
Function: Removal of Acid gases

Design Data:

No. of trays 7
Efficiency 75%
Diameter 1.05 m

Height 5m
No. of holes 1680
Flooding 84.9%
No weeping
Fractional entrainment 0.004
Pressure 6300 kPa
Design Pressure 7560 kPa
Tray Thickness 0.005 m
Weir Height 0.05 m
Weir Length 0.78 m
Tray Spacing 0.457 m
Hole Diameter 0.005 m
Area of one Hole 0.00002 m2
Total Hole Area 0.033 m2
Down Comer Area 0.103 m2
Net Area 0.758 m2
Material of construction Stainless steel 316
Head type Ellipsoidal

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