Absorption & Stripping: Senior Design CHE 396

NDSS
CONSULTING
Absorption
&
Stripping
Senior Design CHE 396
Nadim Dahdal
Deron Grzetich
Steven Jackson
Satinderpal Chadha
CHE-396 Senior Design
Absorption & Stripping
Table of Content
Introduction_____________________________________________________________3
Flowsheet_______________________________________________________________3
Process Operation________________________________________________________4
Limitations______________________________________________________________5
Applicability_____________________________________________________________5
Theory_________________________________________________________________6
Case
study_____________________________________________________________28
Properties______________________________________________________________42
Alternatives____________________________________________________________42
References_____________________________________________________________43
Comments_____________________________________________________________43
Introduction
Important Concepts
Solvent - Liquid applied to remove the solute from a gas stream.
Solute - Components to be removed from an entering stream.
Absorption - Unit operation where the solute of a gas are removed by being
placed in contact with a nonvolatile liquid solvent that removes the components
from the gas.
Stripping - Unit operation where one or more components of a liquid stream are
removed by being placed in contact with a gas stream that is insoluble in the
liquid stream.
Absorbers and strippers are often used in conjunction with each other. Absorbers
are often employed to remove trace components from gas streams. Strippers are often
applied to remove the trace components from the liquid in a more concentrated form.
Absorption and stripping operations are carried out in vertical, cylindrical columns or
towers containing plates or packing elements. The plates and packing provide a surface
area for the liquid and gas to come into contact facilitating mass transfer between the two
streams. The gas and liquid streams for both operations are commonly counter-current for
a more effective mass transfer. The columns are simpler than those for distillation are
because they commonly do not include a condenser or a reboiler.
There are two types of absorption. The two types are chemical and physical. In
chemical absorption, the liquid solvent reacts with the gas stream and remains in solution.
In physical absorption, the solute in the gas is more soluble in the liquid solvent and,
therefore, the solute is transferred to the liquid. Chemical is usually preferred over
physical because the equilibrium for chemical absorption is much more favorable for the
separation. However, physical absorption is important since it can be applied when
chemical absorption is not possible.
Flowsheet
A diagram of an absorber-stripper system is shown in figure 0. The gas
containing the solute to be removed enters at the bottom of the absorber column. In the
column, the gas is placed in contact with the solvent that removes the solute and the
purified gas exits the top of the column. Recycled solvent enters the top of the absorber
column and exits the bottom where it is boiled and sent to the top of the stripping column.
The solute in the solvent is removed in the stripping column by a stripping gas that enters
3
at the bottom of the column. The solvent now exits from the bottom of the column and is
condensed before it is recycled back to the absorption column. The gas exiting the
stripping column can now be stored or processed easier.
Treated
Gas
Conc. Gas
Recycle Solvent
A
B
S
O
R
B
E
R
Cooler
S
T
R
I
P
P
E
R
Stripping Gas
Gas to
be
Treated
Spent Solvent
Heater
Figure 0. flowsheet of absorption process
Process Operation
Changing the conditions of the absorption column can influence the effectiveness and
efficiency of absorption. Some important controllable conditions are as follows:
Pressure of the column.

Temperature of entering liquid and gas streams.
Humidity of the gas stream.
Ratio of the liquid and gas stream rates.
4
Raising the total pressure of the column may increase the efficiency of the separation
because increasing the pressure decreases the liquid flowrate and increases the
concentration of the gas. The temperature of entering liquid effect absorption in that it
effects the flowrate of liquid required for the separation with a given number of stages.
Increasing the temperature of the entering solvent increases the liquid flowrate required.
Inlet gases of the absorber with high humidity at a high tempreature effect the capability
of the gas to consume latent heat hindering the absorption process. Therefore,
dehumidification of the inlet gas should be considered for absorbers with large heat
effects. The ratio of the liquid to gas stream rates in that if the ratio is too low, the solute
bulids in the upper portion of the column causing a higher temperature profile in the top
of the column. As a result, internal cooling maybe necessary for lower liquid to gas ratios.
Limitations
- Absorption and air stripping:
For high VOC (volatile compounds) concentration above 1000 mg/l and different
VOC.
Solids <2%
- Absorption and steam stripping:

VOC highly soluble in water like alcohol and ketones ( acetone, ethanol, .).
Tb > 150C
Excess VOC (>10%).
Suspended solids higher than 2% tend to polymerize.
If phenols can not be treated, use extraction.
Applicability
Remove of VOC at low concentration (<200 mg/l) from contaminated ground water.

Remove of H2S and ammonia NH3 before biological treatment.
Best available technology for an array of organic compounds, Plasic and synthetic
fibers ( OCPSF ) category like benzene, ..
Higher VOC concentration as with air stripping (100 mg/l and more).
Pyridines, cresols, monomers and halogenated solvents.
Elimination of flow VOC concentration from high volume flow of waste stream.
Recovery of thermally unstable materials (low boiling pt.).
5

Xo, L'
Theory
Y1, G'
Design of the Gas Absorber
2
:
:
Figure 1 shows the streams entering and

exiting the absorption column.
N
YN+1, G'
XN,, L'
General Design Decisions

The designer is required to consider and determine:
1. Entering gas (liquid) flowrate, composition, temperature, and pressure
2. Desired degree of recovery of one or more solutes
3. Choice of absorbent
4. Operating pressure and temperature
5. Minimum absorbent (stripping agent) flow rate and actual absorbent
(stripping agent) flow rate as a multiple of the minimum rate needed to
make the separation.
6. Number of equilibrium stages
7. Heat effects and need for cooling
8. Type of absorber (stripper)
9. Height and diameter of absorber (stripper)
10. Cost of vapor recovery system
Entering gas/liquid flow rates and composition

Entering gas composition and flow rates are generally set from the preceding unit
operation, the flash drum in our case. The pressure and temperature are also set from this
flash calculation.
Desired degree of recovery
The amount of solute recovery is generally set by the designer. It may be a

recovery to ensure product purity requirements or to satisfy a purity requirement if the
recovered solute is a feed stream to another unit.
Selection of Solvent
The ideal absorbent should:
1. have a high solubility for the solute(s)
2. have a low volatility to reduce loss of absorbent
3. be noncorrosive
4. have a low viscosity to provide a low pressure drop
5. be nontoxic
6. be available and not expensive
Determination of operating pressure and temperature

a) In general, operating pressure should be high and temperature low for
an absorber, to
minimize stage requirements and/or absorbent flow rate and to lower
the equipment
volume required to accommodate the gas flow.
b) Operating pressure should be low and temperature high for a stripper to
minimize
stage requirements or stripping agent flow rate.
Heat Effects and need for cooling
One of the most important considerations involved in designing a gas absorption tower is
to determine whether or not temperatures will vary along the length of the tower, since
the solubility of the solute gas depends strongly upon the temperature. Heat effects that
may cause temperature to vary from point to point in a gas absorber are :
1.
2.
3.
4.
the heat of solution of the solute

the heat of vaporization or condensation of the solvent
the change of the sensible heat between the gas and the liquid phases
the loss of sensible heat form the fluids to internal and external cooling coils
or to the atmosphere via the tower walls
Types of Absorbers
Absorption and stripping are conducted in trayed towers, packed columns, spray towers,
bubble columns, and centrifugal contactors. Absorption and stripping are frequently
conducted in packed columns, particularly when (1) the required column diameter is less
than 2 ft; (2) the pressure drop must be low, as for a vacuum service; (3) corrosion
considerations favor the use of ceramic or polymeric materials; and (4) low liquid holdup
is desirable. Each type has its own benefits such as greater contact surfaces, length of
residence time required, and available packing space.
For the additional design considerations, one needs to specify an isothermal or nonisothermal absorber. Each case will be dealt with separately, starting with the isothermal,
and followed by the non-isothermal with an example problem. The non-isothermal case
is of more importance as it more closely models current topics in our design of the
anhydride plant and is presented in more detail than the isothermal case.
Absorber Design for the isothermal case

Isothermal design will not be covered in great detail because it is of little
relevance to our process design problem. However, for some applications it maybe
necessary to use inter-stage cooling and force isothermal condition if the temperature
change in the absorption column is great enough to cause large solvent losses.
Determination of absorbent (stripping agent) flow rates

Xo, L'
Y1, G'
1
2
:
:
XN,, L'
where L'
G'
X
Y
m
YN+1, G'
molar flow rate of pure absorbent

molar flow rate of pure gas
mole ratio of solute to pure absorbent in liquid
mole ratio of solute to pure gas in the vapor
P/Ptot
Material Balances written around one end of the tower in figure 1 and an arbitrary
intermediate stage n, yield:
YN+1=Xn(L'/G')+Y1-Xo(L'/G')
(1)
Yn=Xn+1(L'/G')+Yo-X1(L'/G')
(2)
These equations are called operating line equations and when plotted represent the
conditions at the top and bottom of the towers. The slope of the line yields the liquid to
gas ratio (L'/G'). Given the gas flowrate, the minimum solvent flowrate can be calculated
from the relation:
L'min=G'm
(3)
Once the minimum solvent flow rate is found, the actual solvent can be found by
multiplying the minimum flow rate by a factor of 1.4.
To obtain the equilibrium line for the plot, one would use the following derivation. A
balance around a section of the tower will give:
L, To, Xin
G, Yout, To
L, X G, Y
L, TL, Xout
G, Yin, To
Yacet = (moles acetone/moles inerts) / (moles acetone + inerts / moles inerts)

Yacet = Y / 1 + Y
And similarly for the liquid component:
Xacet = X / 1 X
Applying the equilibrium constraint on the system:
Yacet = K (Xacet)
giving:
(Y / 1 + Y) = K( X / 1 X)
solving for Y:
Y = KX / 1 + X KX
(4)
10
Equation 4 is the equation that determines the equilibrium line in the plot of the McCabeThiele diagram. The McCabe-Thiele diagram will be discussed following, as a graphical
method of determining the theoretical number of stages or plates in the absorber. Also,
this equation can be used for the non-isothermal case due to the dependence of the K
values on the temperature of each stage.
Number of Equilibrium stages
The number of equilibrium stages can be calculated either graphically or algebraically.
When the graphical method is chosen, a McCabe-Thiele diagram is constructed by
plotting the equilibrium line and the equilibrium curve. The number of stages can be
found to reach a specified degree of purity by stepping off between the equilibrium curve
and the operating line. This method is illustrated in the figure 4.
operating line
Equilibrium
The algebraic method for determining the number of equilibrium stages is more precise
than the graphical method. The Colburn equation (Perry's 7th edition) for the number of
equilibrium stages is:
Nt=[ln[(1-A-1)(y1-y2)/(y2-y2)+A-1]] / ln(A)
where
A
y1
y2
y2
(5)
abosorbtion factor = L'/mG'

mole fraction of solute in entering gas
mole fraction of solute in exiting gas
mole fraction of solute in equilibrium with incoming solvent
Once the theoretical number of equilibrium stages has been determined, the actual
number of equilibrium stages can be calculated from the relation:
11

Eo=Nt/Na
where
Eo
Na
Nt

(6)
stage efficiency
actual number of stages
theoretical number stages
The stage efficiency can be found to be a complex function of the flow rates of vapor and
liquid streams, the geometry and design of the contacting trays, and the properties of the
vapor and liquid streams. The stage efficiency can be found multiple ways such as from
performance data, semi-theoretical models, scaled up laboratory data, and the O'Connell
correlation for plate efficiency. The O'Connell correlation can be used given that the
operating conditions fall within those covered by the correlation. Once the efficiency has
been estimated, the number of actual stages can be determined.
12
Absorber Design for the non-isothermal case

Since non-isothermal operation is of more value given our current process design
considerations, a methodology will be given to find all needed values for the design. The
methodology is illustrated with an example problem. The equations for each step are in
bold, the answers to these equations for our example are presented below the equations in
normal faced text.
The example problem is: the total gas flow rate from the flash drum is 22.2 moles/hr
and acetone flow rate is 15.5 moles/hr. The gas enters at 1 atm and 100 F. We
assume that Xin is 0.00001 from the distillation(stripping column) and that we want
a 99.75% recovery of acetone. Design the absorber including annualized capital
cost.
Xo, L'
S2
Non condensibles
Acetone
S2
Desired purity of
non condensibles
S3
Acid feed
S4
Acid
Acetone
Y1, G'
S3
1
2
:
:
S1
S1
S4
YN+1, G'
XN,, L'
Figure 5
13
In general, the steps for design are:

1.
2.
3.
4.
5.
6.
7.
8.
9.
Calculate Yin, Yout, assume Xin

Calculate Xout
Determine the (G/L)min and (G/L) actual flow rates
Overall Heat Balance
Material and Enthalpy balance stage by stage
Stage Efficiency
Height
Diameter
Annualized Capital Cost
Methodology for non-isothermal absorber design

Step 1. Calculate Yin, Yout, Xin
This is a simple calculation, and the concentration of S1 is known since it comes from a
previous unit operation in the process. However, knowing the moles of solute, acetone in
our example and the inerts flow rate, the composition of the inlet gas stream may be
specified as follows:
Yin = moles of acetone / moles inerts
Yin = 15.5 / 22.2 = 0.698
(7)
Xin = 0.00001 (by assumption)

Yout is also a simple calculation using a specified recovery of the solute, and the flow
rates of the solute in and total gas flow rate:
Yout = moles acetone ( 1 recovery %) / moles inerts
Yout = 15.5 (1 0.9975) / 22.2 = 0.00175
(8)
14
Step 2. Determine Xout

Xout cannot be calculated now until the liquid flow rate has been set by the
procedure in step 3. The solvent is flow rate is obatined in step 3, but is guessed here to
illustrate the example. By using an material balance over the entire column, the equations
that result are:
L, To, Xin
L, TL, Xout
G, Yout, To
G, Yin, To
Figure 6. Mass balance around entire column
G ( Yin Yout ) = L (Xout Xin )

Xout = (G/L) ( Yin Yout ) + ( Xin)
Xout = 22.2 (0.698 0.00175) + 90 (0.00001) / 90 = 0.1717
(9)
From this result we can see that there is a significant change from Xin of 0.00001
to Xout of 0.192, so the heat effect of this absorber will need to be considered.
15
Step 3. Determine the (G/L)min ratio and actual (G/L)

Step 3 can be completed in two ways. The first way applies a modified version of
equation A1-27 from Douglas. We have been able to derive the same equation, however
all of the assumptions made were not presented, therefore at this point we are not
comfortable enough with this equation to use it in our design. The derivation of this
equation is included at the end of the report. More information on the derivation is
available from the sources referenced in Douglas. An alternate way is presented
following this equation. The modified equation to find L/Gmin is:
L/moG = F [1+Yin{1+2(A21-2A12) + Hvap2/RcpTo2]G/L}
(10)
where:
L
G
F
Yin
R
To
A21, A12
Cp
mo
liquid flow rate

gas flow rate
F factor
conc. of solute in gas entering
gas constant
temperature of gas in
Margules constants
Cp of liquid acetone
K = P/Pt
Derivation of equation 10 from Douglas
Y mX
relation between X and Y
Expand Taylor series around infinite dilution where;

Y 0
X 0
TL inletliquidtemp
mo
0 Po
Ptot
Expansion yields:
m m0
d
Y
m
dY
d
m
dX
d
TL
m
dT
16

d
m
dY
Finding
d
dT
d
m
dT
P 1
Ptot 1 X
d
m
dY
mo
Hv
mo
R T
2
L
P
1
d
m
dX
P ( 1 X)2
ln( )
Po
e
x A12
2
P (1
P (1
( A12 )
Hv 1
d x2
Y) d
d
x
X) d x d X
2 x2 ( A21
P d d
x
P dx dX
mo
A12 )
1
TL
2 x ( A21
2
A12 )
2 x A12
2
2 x1 ( A21
A12 )
2 ( A21
A12 )
for x1=0 and x2=1

d
d x2
d
d x2
d
m
dX
o ( 2 A12
2 A21
2 o ( 2 A12
A21 )
2 A12 )
2 mo ( 2 A12 A21 )
mo
Taking G*Yin=L*Xout
and G*Yin* Hv=Cp*L*(Tout-TL)
m
mo
Yin
L
m
F
F 1
mo G
mo
Yin
2 ( A21
2 A12 )
2 ( A21
Hv
R Cp T
2 A12)
2
L
G
L
Hv
R Cp T
2
L
G
L
17
An alternative way to find the minimum liquid absorbent flow rate is by use of the heat,
material, and enthaply balance equations, it uses these equations with a trail and error
method. The minimum liquid flow rate is one that will give the y composition equal to
that of Yin, the entering composition. The trial and error method works as follows. A
liquid flow rate, L, is assumed. Knowing the gas flow rate G, and the Yin, Yout, and Xin
from step 1, Xout can be calculated by step 2. Next the temperature of the liquid out, TL,
will be recalculated and the K values for acetone at this new outlet temperature will
depend on temperature, pressure, and liquid phase composition
A flow diagram explaining the trial and error procedure is on the proceeding page.
Known =
,Yin, Yout, in
Guess =L
18
Calculate Xout
from overall material balance
Calculate Tout
from overall heat balance
Calculate k
as a function of temperature
Guess new L value higher if

Yo Y out lower if Yo Yout
Solve for Yn
using values of Xout and K(T)
Does Yo Yout
No
Yes
minimum flow rate is n
Multiply L by 1.4
for operation flow rate
Figure 7. Flow sheet to determine L by the try and error method
19
.
K value will be calculated using the modified Raoult's law expression .
= (P/Pt)
(11)
Where:
Pt is the atmosphere pressure.
P assumed to be the vapor pressure of acetone as a function of temperature and
can be found in
"Perry's Chemical Engineers' Handbook" Seventh Edition, Table 2-6.
is the activity coefficient and can be determined by Margules equation.
ln(1) = ( A12+2(A21-A12)X1)(X2) 2
(12)
Where:
A12 & A21 are the Margules Constant.
X1 = Xout
X 2= ( 1- X1)
Once a value of gamma is obtained, it is then necessary to find the vapor pressure of
acetone at the desired outlet temperature of 165F. The vapor pressure found using
equation:
P= e(A+B/T+C*lm(T)+D*T^E)
Where:
A,B,C,D,E
T
are vapor constants from Perry's 7th edition

the outlet temperature specified in degrees Kelvin
For our example, K(165F) = 1.894
The value of K at this temperature will be used in the next step which is stage by stage
material and entropy balances.
20
Finally, using the K values and Xout values associated with the guessed liquid flow rate,
L, the composition of y may be found from step 5.1. If the value of the gas
composition y = Yin, then you have found the minimum liquid flow rate. If the value
of y is higher than Yin then re-guess the liquid flow rate, L, to be a higher value.
Alternatively, if y is lower than Yin, guess a value of L to be lower than the initial guess
and recalculate.
As an initial guess we will use a L, liquid flow rate, of 100 mols/hr.
Calculation of Xout:
Xout = (G/L) ( Yin Yout ) + ( Xin)
Xout = (22.2/100) (0.698 0.00175) + (0.00001) = 0.1545775
Next, calculate the temperature TL from the overall heat balance and the K values
at the temperature TL:
Tout =Tin + {G(Yin Yout) Hv }/ {Cplacid L + Cplacet(Xout Xin)L}
Tout = 100 + 22.2(0.698-0.00175)(207) / 0.55(100)
+ 0.55(0.1545775-0.00001)100 = 150.385 F
K(158 F) = 1.47
Finally, the gas composition leaving the first stage, y is:
Y = Kace(T) Xout / 1 + Xout Kace(T) Xout
y = 1.47 (0.1545775) / 1 + 0.1545775 1.47 (0.1545775) = 0.245
The value of y is 0.245 is much less than Yin, we must try again at a lower liquid flow
rate to see if y = Yin, if so, this is our minimum liquid flow rate.
Calculations again with L = 70 mols/hr
Xout = 0.2208, Tout = 168.07F, K = 1.994, Y= 0.564
This value is closer to our Yin, so lowering the flow rate again
and recalculating with L = 65
Xout = 0.2377, Tout = 172.31 F, K = 2.139, y = 0.698
21
From this point we will again stop with sample calculations, and with the minimum
liquid flow rate known from our initial guess and stepping method, we can multiply this
minimum value by 1.4 to obtain an actual flow rate that will be used in the absorber.
Lmin (1.4) = Lactual
(13)
Now the temperature of the liquid out can be calculated and the vapor composition
leaving the first plate can be found using the actual liquid flow rate.
Step 4. Overall Heat Balances
The overall heat balance, from figure x. is:
G (Yin Yout)Hv = {Cplacid + Cplacet(Xout Xin)L } (Tout Tin)
solving for Tout:
Tout = Tin + G(Yin Yout) Hv / {Cplacid L + Cplacet(Xout Xin)}
(14)
Tout = 100 F + 22.2(0.698 0.00175)(207 Btu/hr) /

{0.55 (90) + 0.55(0.1717 0.00001)} = 165 F
Tout is the temperature of the liquid exiting the absorber assuming that the liquid
entering, and the gas entering and leaving were all at 100 F. From this outlet
temperature we are able to calculate the new equilibrium relations ie. K values, from the
following derivation.
22
Step 5. Material and Enthalpy Balances

Part 1. Material Balances
From the isothermal absorber material balance, which also holds in the non-isothermal
cases assuming that the K values have been adjusted for their temperature dependence.
From figure 8, the balance around the bottom stage and using the equilibrium relation, the
value for Yo, the vapor composition leaving stage is:
To Yout
To Xin
L
n
Y1
X2
1
Yo
X1,T1
Yin, To
G
TL Xout
L
Figure 8. Material balances around bottom tray
Y = Kace(T) Xout / (1 + Xout Kace(T) Xout)
(14)
Part 2. Enthalpy Balances

Enthalpy balances around each stage are necessary to fix the temperature of next stage in
question so the K values, and finally the gas composition leaving the next stage may be
calculated.
23
Using a balance from the top of the absorber to the stage where the temperature needs to
be determined is depicted in figure 9.
To, G, Yout
Yo, TL
To, G, Yin
To, L, Xin
X1, T1
TL, L, Xout
Figure 9. Enthalpy balance to find T1
The heat balance includes terms for the heating of the gas, heating of the liquid,
evaporation of the acetone, heating of the acetone gas stream, and heating of the acetone
liquid stream. The balance is:
G Cp(g)acid (To TL) + L Cp(l)acid (Tn+1 To) + G (Yn Yout) (-Hv) +
G Yout Cp(g)ace (To TL) + G (Yn Yout) Cp(l)ace (Tn+1 To) = 0
(15)
Where Tn+1 is the temperature of the liquid leaving the next stage that we will be solving
for, and Yn is the gas composition at stage n. For our example we will be considering the
gas composition, Yo, and the temperature of the liquid leaving the next stage, T1. Recall
that To is set by the problem as 100 F.
For our example, the equation becomes:
G Cp(g)acid (To-TL) + L Cp(l)acid (T1-To) + G (Yo-Yout) (-Hv) +
G Yout Cp(g)ace (To TL) + G (Yo Yout) Cp(l)ace (T1 To) = 0
24
The number of trays or stages is determined by Yn, where n is the stage where the vapor
concentration leaving was equal or less than that of the specified Yout.
Step 6. Stage Efficiency
Stage efficiency is used to determine the actual number of trays or stages needed to reach
the specified recovery. The number of trays or stages determined in the previous step
considered trays that were 100% efficient, however, real-world applications show that
efficiencies for absorbers are generally below 25% (Douglas) and can be computed by the
correlation given by Douglas in Appendix A.1 as:
The actual number of trays is now:

Nactual = Ntheoretical / Eo
(16)
Step 7. Height of the Column

Height of the column is based on the number of trays, tray spacing, and the end lengths to
allow the vapor and liquid to disengage. End length of about 10 feet for our application
should be adequate, however, one could use the height + 15% extra. The equation we use
to find height is:
H (ft) = S N + end length
(17)
where:
S
tray spacing
N
actual number of trays
Length 10 ft or 15% extra height
Step 8. Column Diameter

Column diameter should be specified as to avoid flooding in the column. At a high
enough vapor flow rates the force exerted on the liquid as it falls due to gravity will be
overcome by the force of the vapor, effectively holding all of the liquid in the column.
The derivation of the following is unclear due to not having the source of the derivation
and the all assumptions made were not listed. However, it follows that to find the
flooding velocity we can use:
25

v
= F = constant
(19)
where the density can be obtained from:

g = ni i / ni
We have now determined the vapor velocity where the column will flood. However, we
want to design our column where we will have 60% of the flooding velocity. The
methodology in Douglas suggest that we use 60-80% of this value.
The correlation for flooding velocity, for turbulent flow, which is derived from the
balance of forces on a small droplet of liquid is:
v=
8gR / 1.32 *
(L g ) / g
where:
g
R
v
gravational acceleration
radius of the droplet
flooding velocity
This allows one to find the velocity where droplets of radius R will fall back onto the
tray. Assuming that g is much less than L, and that Ls are generally the same, the
equation becomes:
v
= F = constant
(19)
The F factor is determined by the Fair* correlation. We feel it is beyond the scope of this
report to include the derivation, it can be found in Douglas, A.3, pages 455-456. The
main thing to note is that the Fair correlation gives a graph of L/G ratio versus flooding
velocities at different tray spacing. It is a function of the liquid and vapor densities and
surface tension of the liquid. Based on chosen plate spacing and the liquid used for the
solvent, it is possible to obtain the value for F, and finally the flooding velocity.
The diameter of the column may now be determined by using the value of 60% of the
flooding velocity by:
Dt = (4At / )1/2
(20)
where:
Dt
column diameter
At
cross-sectional area
26

At = (V
Mg / m
) / F (3600) 0.88
(21)
where:
V
Mg
m
3600
0.88
molar flow rate of vapor

molecular weight of gas
density of gas
unit conversion of hr. to sec.
extra 12% area added to allow for downcomer area
The diameter is importanat because it will allow one to choose a plate or packed column.
If the Dt is less than 4.5 ft. use a packed column, and if Dt is greater than 4.5 ft. us a plate
column. Plate column are not chosen when the Dt is less than 4.5 ft. because of the
absence of room for manways to be installed. The plates will need to be check, cleaned,
and fixed during their operational lifetime.
Step 9. Costing of the Absorber

Gutheries correlations are used to cost the absorber. It may be modeled as a vessel, and
the addition of the cost for the trays, all added together and divided by payback period to
get the annualized capital cost.
Estimate Cost:
Use Guthrie's Correlation (D,H)
M&S Index for price
Trays Cost:
Installed Capital Cost, $ = (M&S/280)* 4.7* D1.55 * H * FC
Where:
D = diameter
H = tray stack height
FC = 1
Annual Capital Cost, $ = Installed Capital Cost / Payback period
27
Vessel Cost:
Installed Capital Cost, $ = (M&S/280)* 101.9*D1.066*H.002*(2.18+FC)
Where:
D = diameter
H = tray stack height
FC = 1
Annual Capital Cost, $ = Installed Capital Cost / Payback period
Total Cost of the Absorber:
Total Cost of the Absorber, $ = ACC(trays) + ACC(vessel)
Case study
The case study presented is one taken from our design problem, the production of
acetic anhydride by acetone cracking. The problem statement is as follows: We need to
design a non-isothermal absorber to remove acetone from a vapor stream. The acetone
vapor along with methane, ehtylene, and carbon monoxide leave in the vapor purge
stream from a condenser/flash drum at 2 atm. The amount of acetone contained in the
vapor stream is high enough that it is economically feasible to design an absorption
system. Acetic Acid is used as a solvent, as it is present in our recycle stream and acetone
has fair solubility in the acid. The flow rate of acetone vapor is 44.73 lbmols/hr and the
28
inerts flow rate is 181.69 lbmols/hr. The entering temperature of the vapor stream is 37
C, and the acid solvent also enters at 37 C. The objective is to design and cost an
absorber that will recover 99.5% of the acetone and return it to a liquid recovery system
to be stripped from the acid solvent. Following our design methodology of a nonisothermal we obtain:
In general the steps are:

1.) Determine vapor composition of inlet gas
2.) Set recovery, outlet gas composition, and assume an inlet liquid composition
3.) Solve for the outlet liquid composition
4.) Find the Lmin by trail and error, includes liquid temperature out and K values
5.) Find Lactual, find real Xout value
6.) Stage by stage energy and material balances to determine number of stages
7.) Use efficiency to determine actual number of stages
8.) Find flooding velocity, and diameter
9.) Costing of absorber by height and diameter, and number of trays
Step 1.
The vapor streams coming from the flash drum to the absorber give the inlet gas
composition, Yin. By the equation:
Yin = moles of acetone / moles of inerts
Yin = 44.73 lbmols/hr / 181.69 lbmols/hr
Yin = 0.246
29
Step 2.
Next the composition of the entering liquid from distillation, Xin, is assumed to
be:
Xin = 0.0001
Recovery is assumed to be 99.5% of the acetone, so the outlet composition, Yout,
of the gas is:
Yout = moles acetone ( 1 recovery% ) / moles of inerts

Yout = 44.73 lbmols/hr ( 1 0.995) / 181.69 lbmols/hr
Yout = 1.23e-3
Step 3.
The liquid composition cannot be solved for until the actual liquid flow rate L has been
solved for in step 4. The equation is presented here because it is used in the trial and error method and
when the minimum liquid flow rate has been solved for, multiplying the minimum liquid flow rate by 1.4
gives the actual liquid floe rate to be used, and finally the actual liquid composition leaving the absorber
can be solved for.
Xout = G (Yin Yout) + L(Xin) / L
30
Step 4.
The trial and error method works as follows:
To Yout
To Xin
L
n
Y1
X2
1
Yo
X1,T1
Yin, To
G
TL Xout
L
The minimum liquid flow rate is one that will give the y composition equal to
that of Yin, the entering composition. The trial and error method works as follows. A
liquid flow rate, L, is assumed. Knowing the gas flow rate G, and the Yin, Yout, and Xin
from steps 1 and 2, Xout can be calculated by step 3. Next the temperature of the liquid
out, TL, will be recalculated and the K values for acetone at this new outlet temperature
will depend on temperature, pressure, and liquid phase composition
Assume L = 279.55 lbmol/hr*
31
*this is the actual minimum liquid flow rate chosen here for simplicity
Now using step 3 a value for Xout can be calculated by:

Xout = {181.59 lbmols/hr / 279.55 lbmols/hr} * (0.264 1.23e-3) + 0.00001
Xout = 0.159
Next, the overall heat balance gives the temperature on the y stage, then K
values can be computed and used to solve for Y1, the gas composition leaving stage y.
The overall heat balance is, with Tin of 100 F from the flash drum:
Tout = Tin + [G (Yin Yout) Hvap / {Cp(l)acid L + Cp(l)acetone (Xout Xin)L}
Tout = 100 F + [181.69 lbmols/hr (0.264 1.23e-3) (12006
Btu/lbmol) /
{33 Btu/lbmol F * 279.55 lbmol/hr + 33 Btu/lbmol F(0.159
0.0001)
279.55 lbmols/hr}
Tout = 149.9 F, (338.656 K)
Now that we have the temperature on the y stage we can compute the
values of activity and vapor pressure, and finally K values to use in the equilibrium
material balance to determine if the composition Yin is equal to y, proving that we have
the minimum flow rate where none of the acetone is transferred.
Activity is determined by the temperature at the y stage and the
Margules constants as follows:
1 = exp (A12 + 2(A21-A12) Xout ) (1 Xout)2
Using Margules constants, A12 = -0.0508 and A21 = 0.3481, solving for 1
1 = exp (-0.0508 + 2(0.3481+0.0508) 0.159 ) (1 0.159)2
1 = 1.055
32
Vapor Pressure is found by:

Pvap = exp ( A + B/Tout + C ln(Tout) + D ToutE)
Pvap = exp (69.006 - 5599.6/338.656 K + -7.0985 ln(338.656 K) +
6.2237e-6 (338.656 K)2
Pvap = 1.363 atm
Finally K, with a Ptotal of 2 atm, can be calculated by:
K = 1 Pvap/Ptotal
K = 1.055 1.363/2
K = 0.719
The final step to make sure the liquid flow rate L is the minimum is to solve the
material balance around the first stage of the absorber, so the value of y can be found
by the equilibrium relation:
y = K(Tout) Xout / (1 + Xout K(Tout) Xout)
y = 0.719* 1.59 / (1 + 1.59 0.719 * 1.59)
y = 0.264
This proves that the liquid flow rate chosen as 279.55 lbmol/hr is the minimum
flow rate where none of the acetone will be transferred to the acid solvent. Now this
minimum value must be multiplied by 1.2 to 1.5 so a pinch point does not occur and an
infinite number of stages is required to affect the separation. We have chosen 1.4 as the
factor to multiply the Lmin by to obtain Lactual.
Step 5.
Lactual = 1.4 * Lmin
Lactual = 1.4 * 279.55 lbmols/hr
Lactual = 391.37
33
The value of Xout must now be calculated by using the Lactual flow rate:
Xout = {181.59 lbmols/hr / 391.37 lbmols/hr} * (0.264 1.23e-3) +
0.00001
Xout = 0.1135
Step 6.
Stage by stage energy and material balances will give the temperature of each
stage and the gas and liquid compositions leaving each stage. This is performed because
we want to find the stage where the gas composition leaving that particular stage is lower
than the gas composition out set by the recovery of Yout = 1.23e-3. From the following
diagram, the energy and material balances were found.
To, G, Yout
Yo, TL
To, G, Yin
To, L, Xin
X1, T1
TL, L, Xout
Diagram 2. energy balances stage by stage
34
The material balance as found for the first stage holds for each stage in the stage
by stage balances, and the energy balance is found by a combination of the condensation
of the acetone into the liquid acid solvent, the heating of the liquid, and heating of the gas
flows. The equation is:
G Cp(g)acid (To TL) + L Cp(l)acid (Tn+1 To) + G (Yn Yout) (-Hv) +
G Yout Cp(g)ace (To TL) + G (Yn Yout) Cp(l)ace (Tn+1 To) = 0
Solving this equation for Tn+1 will give the values of the stage in question, and
finally the Xout can be found, K values, and the gas composition leaving that stage. This
will not be done here as it was written in MathCad and repeated until the gas composition
leaving the stage was lower than Yout determined by the percent recovery. A copy of the
program for 0.13 conversion is attached in the appendix. It was found that the
temperature of stage 1 is 57C with Xo of 0.11350 and Yo of 0.0589, stage 2 is at
44.74C with Xo of 0.027 and Yo of 8.55e-3, stage 3 is at 38.62C with Xo of 0.00304
and Yo of 8.6e-4 . Presented in the following table:
Stage by Stage Energy Balance Solutions

Stage
Temp
(C )
1
2
3
Yo - Gas Composition
Leaving Stage
57.68
44.74
38.62
Yin - Gas Composition

Entering Stage
Xo - Liquid Comosition
Leaving Stage
(moles acetone/moles inerts)

(moles acetone/moles inerts)
0.0589
0.246
8.55E-03
0.0589
8.60E-04
8.55E-03
0.11350
0.02700
0.00304
Gas and Liquid Flow Rates in Absorber

G - Gas Flow Rate
Lmin, Liquid Flow Rate
Lactual, Liquid Flow Rate L/G Ratio
(lbmols/hr)
(lbmol/hr)
(lbmol/hr)
35

181.69

279.55
391.37
2.15
Step 6.
The efficiency of 25% was used to determine the actual number of stages. This is
not from the efficiency suggested by Douglas but by calculation. The average
temperature in the column is 47.5 C. According to the CRC Chemical Handbook, the
viscosity, L, of acid liquid at 50 C is 0.786 cP. By the Drickamer and Brandford
correlation for efficiency in absorbers with a liquid viscosity of 0.19 to 1.58 cP.
(Seperation Process Principles, J.D Seder, page 295) is:
Eo = 19.2 57.8 * log (L)

Eo = 19.2 57.8 * log (0.786)
Eo = 25.24 % = 0.25
Our use of 25% stage efficiency is justified by the correlation, so we will use 25%
in all our absorber design equations.
Step 7.
With the efficiency in hand, and theoretical number of stages, we can find the
height required for the column by:
H = S * Ntheoretical / Eo + 10 feet
36
H = 2 feet * 3 / .25 + 10 feet

H = 34 feet
Step 8.
The final value needed for the absorber design and costing is the diameter. This
can be found by the Fair Correlation (Douglas, page 455-456). The following graph
shows a plot of flooding velocity vs. L/G ratios. By using the values of acetone gas
densities and acid liquid densities we can obtain a value for Ff, the flooding velocity
factor.
Density was found by the ideal gas law, solving for the molar volume in terms of
ft3/lbmol and taking the inverse to get density in lbmols/ft3. Molecular weight was found
by the mole fractions of each component in the gas multiplied by the component's
molecular weight, and adding all of the components.
Graph. A plot of flooding velocity vs. L/G ratios
37
The simplified flooding velocity can be found by:

Vf * g1/2 = F = Constant
F is the Fair factor which can be found by the graph using our 24 inch plate spacing. The
density of acetone in the gas is 0.0046 g/ml and acid liquid density is 1.043 g/ml (65
lb/ft^3).
Solving for the x-axis equation:

L/G (g / L) 1/2
181.59 / 391.37 (0.0046 / 1.043)
= 1.40
Now, following the point 1.4 on the x-axis up to the 24 inch plate spacing and
across to the y-axis gives a value of 0.32. Solving for the equation for the y-axis:
Vf (g/L)1/2 = Ff
Ff / L1/2 = Vf g1/2
0.32 * (65 lb/ft^3)1/2 = Vf g1/2
= 2.58
38
Ff is the fair factor at flooding velocity, so if we run our column at 58.5% of the
flooding velocity we obtain an F factor of 1.51. The F factor will be used in the diameter
calculation, as it represents Vf *g1/2 .
The diameter can be calculated with the following assumptions: 12% extra area for
downcomers and 58.5% of the flooding velocity. The equation becomes:
Dt = 0.0164 * V1/2 (Mg / m) 1/2

where:
V = molar flow rate of the vapor
Mg = molar mass of the gas
m = molar density of the gas
Dt = 0.0164 * (226.42 lbmols/hr)1/2 (25.8852 lb/lbmol / 4.91E-3 lbmols/ft^3)1/2
Dt = 2.1 feet
Step 9.
We have enough information to cost the absorber according to Guthries cost
correlations. However, we will use a 4.5 foot diameter instead of 2.1 feet. Our
justification for this is that we have done all calculations for a trayed tower, and a trayed
tower is recommended for a 4.5 foot diameter and larger. So to allow room for manways
we increased the diameter from 2.1 feet to 4.5 feet. Another advantage is that the column
may be used in the future, since we built it out of solid stainless steel, if the production
rate is increased, or in another process.
39
The cost has an installed vessel cost and the tray costs. According to Guthrie the cost
correlations are:
Installed Vessel Cost = M&S / 280 * 101.9 * D1.066 * H0.802 (2.18 + Fc)
where:
M&S Marshall and Swift index
D column diameter (ft), 2.1 feet
H column height (ft), 34 feet
Fc factor for construction, Fm + Fp, 4.67
Fm material, solid stainless steel = 3.67
Fp pressure, up to 50psi = 1.00
For our vessel:
Installed Vessel Cost = 1061.9/280 * 101.9 * 2.11.066 * 340.802 (2.18 + 4.67)
Installed Vessel Cost = $97240
Now the tray costs are determined by the type of tray and spacing and diameter:
Installed Tray Cost =(M&S / 280 * 4.7 * D1.55 Hs * Fc) Ntrays
where:
D column diameter, 2.1 feet
Hs tray stacking height, 2 feet
Fc construction factors, Fs + Ft + Fm, 6.47
Fs spacing of trays, 2 feet
Ft type of tray, bubble cap trays = 1.8
Fm material, solid stainless steel = 3.67
40
Ntrays number of actual trays, 12

Installed tray cost = (1061.9/280 * 4.7 * 2.11.55 * 2 * 6.47) * 12
Installed tray cost = $8549
The total costs of the trays and vessel are added and factored over a 6-year pay
back period to give:
Installed Vessel Cost + Installed Tray Cost / Payback Period = Total Annualized
Cap. Cost
$97240 + $8549 / 6 years = $17,632
This completes the case study design of our absorber, which will have 12 bubblecap trays, 34 feet high, constructed of solid stainless and cost $17,632 per year.
41
Properties
All Properties that are needed to for the calculations are described in full in the theory
section
Alternatives
Pretreatment: remove solids through filtration and sedimemation to avoid fouling,
remove oil.
Post-treatment: carbon absorption, condensation, direct fume incineration of the offgas.

Air stripping for lower VOC concentrates.
Distillation for higher VOC.
Extraction for Phenols.
-Reactive Absorption
-Adsorption
-Extraction or Crystallization
-Membrane Separations and Ultrafiltration
42
References
1.
Douglas, J.M., Conceptual Design of Chemical Engineering, McGraw-Hill, New

York, 1988.
2. King, C.J., Separation Processes, McGraw-Hill, New York, 1971.

3. Perry, R.H and Green, Perrys Chemical Engineers Handbook, New York, 1997.
4. Reid, R.C., Prausnitz, J.M and B.E. Poling, Properties of gases and liquids,
McGraw-Hill, New York, 1987.
5. Seader, J.D., And Henley, E.J., Separation Processes Principles, John Wily & Sons,
New York , 1998
6. Strigle, R. F., Packed Tower Design and Applications, Gulf Publishing, Houston,
1994
7. Wankat, P.C. Equilibrium Staged Separations, Prentice Hall, Englewood Cliffs,
New Jersey, 1988.
Comments
Many of the equations presented in the theory section may easily be solved by setting the
equations up in MathCad. This works well because many of the parameters, temperature
of the liquid out for instance, has an effect on K values and the material and enthalphy
43
balances. Making a MathCad sheet that links the temperature to all equations it depends
on will cut down on calculation time.
44

Absorption & Stripping: Senior Design CHE 396

Transféré par

Informations du document

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Absorption & Stripping: Senior Design CHE 396

Transféré par

Droits d'auteur :

Formats disponibles

NDSS

Senior Design CHE 396

CHE-396 Senior Design