Designing of Scrubber before Scaling
Number of Transfer Units
Since in packed columns, there are no clearly defined stages as in the distillation column. So, a
number of transfer units are calculated which helps in calculations of the height of the column.
Taking the fraction of CO2 present in the inlet air as 0.00399. (10% unreacted)
755.46
𝐶𝑂 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑎𝑡 𝑡ℎ𝑒 𝑒𝑥𝑖𝑡 = 𝑦1 = = 0.0399
18906.10
𝑦1 0.0399
= = 100
𝑦2 0.00399
Gm
Since the term m Lm have an optimal n value that lies between 0.7 and 0.8. So, using the Figure
1[1];
𝐺𝑚
𝐴𝑡 𝑚 = 0.7: 𝑁𝑂𝐺 = 11
𝐿𝑚
𝐺𝑚
𝐴𝑡 𝑚 = 0.8: 𝑁𝑂𝐺 = 14
𝐿𝑚
So, number of the transfer units are chosen in between the two values.
𝑁𝑂𝐺 = 13
Figure 1: No. of Transfer units NOG as a function of y1/y2 with mGm/Lm as parameter [1]
Diameter of Column
The pre-bundled not entirely set in column width is initially determined by selecting the packing.
The vapor-liquid factor is calculated using physical characteristics. The vapor loading is computed
for the required pressure drop, and then the area and hence the diameter are calculated. The actual
and flooding parameters are used to calculate the percent flooding.
From figure 1
Fp=52m-1
𝑚2
𝑎 = 85
𝑚3
𝑑𝑝 = 89 𝑚𝑚 = 0.089 𝑚
By using the properties of liquid streams (KOH)
Property Value
Phase Liquid
Density (kg/m3) 2044
Viscosity (Ns/m^2) 0.0010016
Molar Mass(g/mol) 56.10
Surface tension 56.43×10^-3
Now by using the stream condition before scaling
Stream Number Mass flow rate (kg/hr)
Stream 11 959.27
Stream 12 133.766
Stream 13 356.816
Stream 14 516.95
The following values from [2]
Density of the gas is determined as:
44 273 𝑘𝑔
𝜌𝑣 = × = 1.799 3
22.4 298 𝑚
𝑘𝑔
𝜌𝐿 = 2044
𝑚3
18906.10 × 56.10 𝑘𝑔
𝐿𝑊 = = 12.27
3600 × 24 𝑠
755.96 × 44 𝑘𝑔
𝑉𝑊 = = 0.385
3600 × 24 𝑠
Table 1: Random Packing’s design Data [1]
Vapor-Liquid factor is calculated using:
𝐿𝑊 𝜌𝑣 12.27 1.799
𝐹𝐿𝑉 = √ = √ = 0.938
𝑉𝑊 𝜌𝐿 0.385 2044
For a pressure drop of 45 mm H2O/m, packing would be designed from Figure 2 [1];
𝐾4 = 0.7
𝐴𝑡 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 𝐾4 = 1.2
0.7
% 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 = √ × 100 = 76.37
1.2
% flooding comes out to be satisfactory.
Vapor loading is obtained using:
1/2
1/2
∗
𝐾4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 0.7 × 1.799 × (2044 − 1.799) 𝑘𝑔
𝑉𝑊 =[ ] = 0.1 =4
13.1𝐹𝑃 (𝜇𝐿 ⁄𝜌𝐿 )0.1 1.016 × 10−3 𝑚2 𝑠
[13.1 × 52 × ( 2044 ) ]
Figure 2: Generalized Pressure Drop Correlations [1]
Area of the column: [1]
𝑉𝑊 0.385
𝐴= ∗ = = 0.09625 𝑚2
𝑉𝑊 4
Diameter: [1]
Diameter of the column is now calculated using:
4𝐴 4 × 0.092625
𝐷=√ =√ = 0.385 𝑚
𝜋 𝜋
Height of the column:[4]
𝑍 = 𝑁𝑂𝐺 × 𝐻𝑂𝐺 = 13 × 2.465 = 32.05 𝑚
Pressure drop
There will be an aggregate of four central issues
1. The strain diminishes inside the pinnacle:
2. Diminished strain because of dry pressing,
3. Diminished strain because of fluid showering over dry pressing, as well
4. Diminished strain because of mechanical disappointment.
5. Diminished interior tension (pressing help + conveyance plate)
6. Diminished inside strain because of loss of gas access.
(Gas stream rate − the section to be considered for sanding)
Outside gas stream rate = Column area
Outlet gas pressure = 1 x (6802.7 -516.95)/0.09625
= 655306.49N/m2
Density of the outlet gas stream = (100883.7 / 655306.49) x (36.5 / 22.414) x (273.15 / 303.15) =
2.26 Kg/m3
Calculations for Pressure drop:
∆𝑃 𝐺2
= Cd× ( )
𝑍 ⍴g
Table 2: Characteristics of Random Packing’s [1]
Installed Intalox saddles of 25NB, From Table No. 2 value of Cd is 96.7,
Pressure drop from packing:
By using stream 14 outlet flow
∆𝑃 1.542
= 96.7 x ( )
𝑍 2.26
∆𝑃
= 101.17 N/m2;
𝑍
Scrubber Design after Scaling
After the scaling design of the scrubber, the calculation change due to the flow rates of the stream
will change for input and output streams but some common things before and after scaling will
remain the same.
Number of Transfer Units
Since in packed columns, there are no clearly defined stages as in the distillation column. So, the
number of transfer units is calculated which helps in calculations of the height of the column.
Taking the fraction of CO2 present in the inlet air as 0.00399. (10% unreacted)
755.46
𝐶𝑂 𝑓𝑟𝑎𝑐𝑡𝑖𝑜𝑛 𝑎𝑡 𝑡ℎ𝑒 𝑒𝑥𝑖𝑡 = 𝑦1 = = 0.0399
18906.10
𝑦1 0.0399
= = 100
𝑦2 0.00399
Gm
Since the term m Lm an optimal n value that lies between 0.7 and 0.8. By using the Figure 1 [1];
𝐺𝑚
𝐴𝑡 𝑚 = 0.7: 𝑁𝑂𝐺 = 11
𝐿𝑚
𝐺𝑚
𝐴𝑡 𝑚 = 0.8: 𝑁𝑂𝐺 = 14
𝐿𝑚
So, the number of transfer units is chosen between the two values.
𝑁𝑂𝐺 = 13
Diameter of Column
The pre-bundled not entirely set in column width is initially determined by selecting the packing.
The vapor-liquid factor is calculated using physical characteristics. The vapor loading is computed
for the required pressure drop, and then the area and hence the diameter are calculated. The actual
and flooding parameters are used to calculate the percent flooding.
From Figure 1
Fp=52m-1
𝑚2
𝑎 = 85
𝑚3
𝑑𝑝 = 89 𝑚𝑚 = 0.089 𝑚
By using the properties of liquid streams (KOH)
Property Value
Property Liquid
Density(kg/m3) 2044
Viscosity (Ns/m^2) 0.0010016
Molar Mass(g/mol) 56.10
Surface tension 56.43×10^-3
Now by using the stream condition before scaling
Stream Number Mass flow rate (kg/hr)
Stream 11 155401.74
Stream 12 21670.092
Stream 13 57804.192
Stream 14 83745.9
The following values from [2]
Density of the gas is determined as:
44 273 𝑘𝑔
𝜌𝑣 = × = 1.799 3
22.4 298 𝑚
𝑘𝑔
𝜌𝐿 = 2044
𝑚3
18906.10 × 56.10 𝑘𝑔
𝐿𝑊 = = 12.27
3600 × 24 𝑠
755.96 × 44 𝑘𝑔
𝑉𝑊 = = 0.385
3600 × 24 𝑠
Vapor-Liquid factor is calculated using:
𝐿𝑊 𝜌𝑣 12.27 1.799
𝐹𝐿𝑉 = √ = √ = 0.938
𝑉𝑊 𝜌𝐿 0.385 2044
For a pressure drop of 45 mm H2O/m, packing would be designed from Figure 2 [1];
𝐾4 = 0.7
𝐴𝑡 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 𝐾4 = 1.2
0.7
% 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 = √ × 100 = 76.37 %
1.2
% flooding comes out to be satisfactory.
Vapor loading is obtained using:
1/2
1/2
∗
𝐾4 𝜌𝑉 (𝜌𝐿 − 𝜌𝑉 ) 0.7 × 2.26 × (2044 − 1.799) 𝑘𝑔
𝑉𝑊 =[ ] = 0.1 = 4.5
13.1𝐹𝑃 (𝜇𝐿 ⁄𝜌𝐿 )0.1 1.016 ×10−3 𝑚2 𝑠
[13.1 × 52 × ( 2044 ) ]
Area of the column: [1]
𝑉𝑊 0.385
𝐴= ∗ = = 0.0825 𝑚2
𝑉𝑊 4.5
Diameter: [1]
Diameter of the column is now calculated using:
4𝐴 4 × 0.0825
𝐷=√ =√ = 0.10 𝑚
𝜋 𝜋
Height of the column: [4]
𝑍 = 𝑁𝑂𝐺 × 𝐻𝑂𝐺 = 13 × 2.465 = 32.05 𝑚
Radius (r)= D/2= 0.10/2
=0.05m
Volume of Scrubber = V= 3.14 r2 h=
= 0.252 m3
Pressure drop
1) There will be an aggregate of four central issues
2) The strain diminishes inside the pinnacle:
3) Diminished strain because of dry pressing,
4) Diminished strain because of fluid showering over dry pressing, as well
5) Diminished strain because of mechanical disappointment.
6) Diminished interior tension (pressing help + conveyance plate)
7) Diminished inside strain because of loss of gas access.
(Gas stream rate − the section to be considered for sanding)
Outside gas stream rate = Column area
Outlet gas pressure = 1 x (31153.48 -16324.04)/0.09625
= 154061.71N/m2,
Outlet gas density= (100883.7 / 154061.71) x (36.5 / 22.414) x (273.15 / 303.15) = 0.96 Kg/m3
Calculations for Pressure drop:
∆𝑃 𝐺2
= Cd× ( )
𝑍 ⍴g
Installed Intalox saddles of 25NB, From Table No. 2 value of Cd is 96.7,
Pressure drop from packing:
By using stream 14 outlet flow
∆𝑃 1.542
= 96.7 x ( )
𝑍 0.96
∆𝑃
= 238.88 N/m2;
𝑍
References:
[1] R. K. Sinnott, Chemical Engineering Design, 4th ed., vol. 6. Oxford: Elsevier Butterworth
Heinemann, 2005.
[2] O. Sids, P. Chloride, and U. Publications, “Introduction Potassium Chloride,” Assessment,
pp. 1–96, 2001.
[3] ` Turton, R. (2014). Analysis, Synthesis, and Design of Chemical Process.
[4] BRANAN, C. (n.d.). Rules of Thumb for Chemical Engineers (3RD ed.). (C.
R. Branan, Ed.)