SCRUBBER DESIGN (PACKED COLUMN)

Prepared by :
Checked by :
Date :

### Input Data

Packing type
Packing size
Packing MOC
Gas pr. Drop / m bed
Total packing height
Gas / Vapour Properties
Gas / Air flow rate

Gas pressure at entry

Gas temperature at entry
Gas / Air mol weight

Column Tag No.

Job No.
Client
Project

:
:
:
:

HCL Scrubber
4506A
JOL
SR - Plant -4, 5

Stream

HCL Vap.

= Intallox Saddles
=
25 mm
=
PP
=
15 mmWC / m packing height
=
3.2 m (including all packed beds)

=
=

1000 kg/h
0.2778 kg/s

=
=
=

1.0000 atm
30.00 oC
29

Component to be scrubbed
Component Name
=
Component flow rate
=
% comp. in air/gas
=
Molecular weight of comp. =

HCL Vap
70 Kg/h
6 % (v/v)
36.5

OR

= 0.0035000 Ns/m2

Packing factor, Fp

Charac. Packing Factor,Cf =

Conversion factor, J
=

147.1 (N/m2)/m

0 m3/h
0 m3/s

303.00 oK

(presumed) / (given by client) / (by process cal.)

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
Liquid Viscosity, L

Conversion :
3.5 Cp

0.00350000

Ns/m2

21 m-1
33
Ref. Table 6.3, Characterstics of Random packings
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 =

Gas in

0.0094321826 Kmol/s
kmol = mass / mol wt
= (kmol/s) x T in kelvin x 1.0 atm x 22.4
273
pr. In atm
1
3
=
0.234499 m /s

= (m3/s) x

273
x pr. in atm x
T in kelvin
1.0 atm

=
=

1
22.4

0 Kmol/s
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
Liquid leaving
=
0.0420 Kg/s
L'

G'

0.5

Using

0.00497

G' 2 Cf L0.1 J
(
G

-L

(molar flow rate x % comp. x mol. Wt.)

(Inlet liquid flow rate + comp. Removed)

0.00497

as ordinate,

Refer fig.6.34 using a gas pressure drop of

0.04 (from graph)

0.04

) gc
G

Therefore, G'

--

) gc

0.5

Cf L0.1 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
500 mm

Corresponding c/s area

0.1963 m2

Sheet 2 of 11

460.7 mm

147.1

(N/m2)/m

TO ESTIMATE POWER REQUIREMENT

Efficiency of fan / blower

60 %

assumed / given

To calculate pressure drop

Pressure drop for irrigated =
packing

470.72 N/m2

(pressure drop per m packing x total ht. of packing)

For dry packing,

O/L Gas flow rate, G'
O/L Gas pressure
Gas density,
G

=
1.3095 Kg / m2.s (Gas inlet flow rate - Component removed) / c/s area
= 100854.28 N/m2
(subtracting pressure drop across packing)

CD

Delta P

= CD

gas mol wt. x

273
x
22.41m3/Kmol T in kelvin
=
1.1605 Kg/m3

96.7

gas o/l pr.

101330

Ref. Table 6.3, Characterstics of Random packings

G' 2
G

142.89 N/m2

Pressure drop for packing =

613.61 N/m2

(irrigated packing + dry packing)

Pressure drop for internals =

=

25 mmWC
245.17 N/m2

(packing supports and liquid distributors)

Gas velocity
Inlet expansion & outlet
contraction losses

=
7.5 m/s
= 1.5 x Velocity heads
=
42.19 N m / Kg
=
49.97 N/m2
908.75 N/m2

1.5 x (V2 / 2g)

(divide by density)

Total pressure drop

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
0.45 hp

(packing + internals + losses)

(fan power output / motor efficiency)

Sheet 3 of 11

COLUMN DIAMETER / HYDRAULIC CHECK

Liq.-Vap. Flow factor, FLV

= (L / V) x (
=
0.0025

Design for an initial pressure drop of

From K4 v/s FLV,

15

mm H2O /m packing

K4

0.85

K4 at flooding

6.50

Trial % flooding

= ( (K4 / K4 at flooding)
=
36.1620

Gas mass flow rate, Vm

K4 .

13.1 Fp (L /
=
Trial column c/s area
(Trial As)

Trial column dia., D

--

V
L

) x 100
(1/2)

)0.1

3.7763 kg/m2.s
V / Vm

0.0736 m2

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

% flooding

0.1963 m2

13.5472

As = (pi/4) x D2

% 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
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

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