Chapater 5 Process Equipment Sizing

5.1 Absorber Sizing

The removal of one or more component from the mixture of gases by using a suitable
solvent is second major operation of Chemical Engineering that based on mass transfer. In gas
absorption a soluble vapors are more or less absorbed in the solvent from its mixture with inert
gas. The purpose of such gas scrubbing operations may be any of the following that is for
separation of component having the economic value, as a stage in the preparation of some

compound and for removing of undesired component. There are two type of absorption
which are physical absorption and chemical absorption. Physical absorption is mass
transfer take place purely by diffusion and physical absorption is governed by the
physical equilibria. While for chemical absorption are particular component comes in
contact with the absorbing liquid a chemical reaction take place. Then by reducing the
concentration of component in the liquid phase, which enhances the rate of diffusion.

5.2 TYPES OF ABSORBER

There are two major types of absorbers which are used for absorption purposes:
Packed column
Plate column
5.3 COMPARISON BETWEEN PACKED AND PLATE COLUMN
1)

The packed column provides continuous contact between vapor and liquid phases
while the plate column brings the two phases into contact on stage wise basis.

2)

SCALE: For column diameter of less than approximately 6 ft. It is more usual to
employ packed towers because of high fabrication cost of small trays. But if the
column is very large then the liquid distribution is problem and large volume of
packing and its weight is problem.

3)

PRESSURE DROP: Pressure drop in packed column is less than the plate column.
In plate column there is additional friction generated as the vapor passes through
the liquid on each tray. If there are large No. of Plates in the tower, this pressure
drop may be quite high and the use of packed column could effect considerable
saving.

4)

LIQUID HOLD UP: Because of the liquid on each plate there may be a Urge
quantity of the liquid in plate column, whereas in a packed tower the liquid flows
as a thin film over the packing.

5)

SIZE AND COST: For diameters of less than 6 ft, packed tower require lower
fabrication and material costs than plate tower with regard to height, a packed
column is usually shorter than the equivalent plate column.

From the above consideration packed column is selected as the absorber, because in our
case the diameter of the column is less than 6 ft. As the solubility is infinity so the liquid
will absorb as much gases as it remain in contact with gases so packed tower provide
more contact. It is easy to operate.

Calculation Of Diameter Of Column:

Flow rate of entering gases =G =94035 Kg/hr
Flow rate of entering solvent=L= 90195 Kg/hr
Temperature of entering gas=Tg=44 oC =317K
Temperature of entering Solvent=TL=5 oC =278K
Pressure of entering gases=P= 1.7 atm
Average molecular weight of entering gases=28.4 Kg
Density of gas mixture= g = PM /RTg
= (1.728.4) /(0.08205317)
=1.86Kg/m3
Density of liquid solvent at 5oC= L=1022Kg/m3
Viscosity of liquid solvent at 5 oC = L =1.4 cp(From Appendix-9 MCcab & Smith 5 thEd)
Viscosity of Gaseous mixture at 44 oC = g = 0.103 cp
Now
Abscissa of fig 11.44

L
G

g
L

= 0.04

For pressure drop 42 mm of H2O /m of packing

K4 = 1.5
Also from table 22.1 MCcab & Smith 5th-Ed,
Packing factor for 3-inch ceramic intalox - saddles =Fp=22
From Coulson & Richardson volume-6

G* = [k4 g (L-g) / 13.1Fp (L /L) 0.1]

G*= [1.51.86 (1022-1.86) /13.122 (1.410-3 /1022)0.1]1/2

G*=11.1Kg/m2-sec.
Flow rate of gas entering =G =94035 /3600
=26.12 Kg/sec.
As
Area =A= G / G* =2.35 m2
Diameter of column=D= 4[A]
[3.14]
So

Diameter of column= 1.73 m

Calculation Of Height Of Transfer Units:

From coulson & Richardson volume-6
Equation for calculation of effective interfacial area is given as.



aw
1 exp 1.45 c
a

0.75

Lw

a L

0.1

0.05

Lw 2 a

2g
L

Lw

a
L L
2

0.2

Where
aw = effective interfacial area of packing per unit volume m2/m3
Lw = liquid mass velocity kg/m2s
a = actual area of packing per unit volume m2/m3
c = critical surface tension for particular packing material
L = liquid surface tension N/m
a = 92 m2/m3
Lw = 1.85 kg/m2s
c = 61 x 10-3 N/m
L = 70 x 10-3 N/m
L=1.4 CP
L =1022Kg /m3

aw
61
1 exp 1.45

92
70

0.75

10.66

3
92 1.4 10

aw
Calculation
K L

L g

1
3

Of

Lw
0.0051
aw L

0.1

10.66 2 92

2
1022 9.8

0.05

10.66 2

3
1022 70 10 92

0.2

= 53.5 m2/m3

Liquid
2

Film

L

L DL

1
2

ad
p

0.4

Mass

Transfer

Coefficient:

KL = liquid film coefficient m/s

dp = packing size =50 x 10-3 m (From table 11.4 Coulson & Richardson)
DL = diffusivity of liquid = 1.7 x 10-9 m2/sec (From Coulson & Richardson)

Then, by substituting the values,

KL = 7.87 x 10-4 m/s
Calculation Of Gas Film Mass Transfer Coefficient:
K G RT g
aD g

V
K5 w
a
g

0.7

D
g g

1
3

ad

Where KG = Gas film coefficient, kmol/m2s.bar

VW= Gas mass velocity = 94035/(3600x2.35)=11.1 Kg m2/sec
K5= 5.23 (For packing size above 15mm,Coulson & Richardson)
Dg =Diffusivity of gas = 1.81 x 10-5 m2/sec (MCcab & Smith 5th-Ed)
Then, by substituting the values,
KG =1.07 x 10-2 kmol/m2s.bar

G
m
H
G K a P
G w
Now,

Where,
HG = Gas-film transfer unit height
Gm = 11.1/28.4 = 0.39 Kmol/m2.sec
Then,

HG = 0.39/(1.07 x 10-2 53.5 2.5)

= 0.40 m (From Coulson & Richardson,table 11.2,for ceramic
randon packing,it is almost 0.48 m)

L
m
H
L K a C
L w t

And
HL= Liquid-film transfer unit height
Lm= 10.66/18 = 0.59 Kmol/m2.sec
Ct = Concentration of solvent = 1022/18 = 56.7 Kmol/m3
Then,
HL = 0.59/(6.94 10-4 53.5 56.7)
= 0.28 m
Calculation Of Height Of Transfer Units:
H oG H G

mGm
HL
Lm

As,

HG = 0.40 m
HL =

0.28 m

So,
Height of transfer units=HOG = 0.4 + 0.75 0.28
HOG = 0.61 m (From Coulson & Richardson, range is 0.6 to
1m, topic 11.14.3)

Calculation Of Height Of Tower:

Total height of packing =Z= NOG HOG
Z = 15 0.61 = 9 m
Allowances for liquid distribution = 1m
Allowances for liquid Re-distribution =1m
Total height of tower = 9 + 1 + 1
Zt = 11 m
Total height of tower = 11 m

Calculations Of Operating Velocity:

The abscissa of fig 11.44

L g
G L
= 0.04

Operating velocity of gas

(From Ludwig, pg-159)

G2 FpL0.1 / g (L - g)gc = 0.046

G =2.76 m/sec
Calculation Of Flooding Velocity:

g
L
G
L g
= 0.04

Operating velocity at flooding for dumped packing,

G2 FpL0.1 / g (L - g)gc

0 .13 (From Ludwig, 2nd vol)

G = 4.6 m/sec

Operating velocity as

= (2.76/4.6) 100

% of flooding velocity
= 60% (Operating velocity must be 50-90% of flooding
velocity,MCcab & Smith)

Calculation of wetting rate:

If very low liquid rates have to be used the packing wetting rate should be checked to
make it sure it is above the minimum recommended by packing manufacturer Wetting
rate is defined by following relation.

Wetting rate = Liquid volumetric flow rate per unit cross-sectional area
Specific area of packing per unit volume

Liquid volumetric flow rate/Unit cross-sectional area = 90195/(360010222.35)

=1.0410 -2 m3/m2-sec

Specific area of packing = 92 m2/m3

Wetting rate =1.1310 -4 m3sec-1/m2
.
Calculation Of Pressure Drop At Flooding:

From McCabe & smith 5th edition,Eq.22.1,

Pressure drop at flooding is given by relation.
Pflooding =0.115Fp 0.7
Where
Pflooding =pressure drop at flooding.
Fp =packing factor for 3-inch ceramic intalox saddles = 22
Pflooding =0.115(22)0.7
= 1 in.H2O/ft of packing (For 3-in packing size,it should be 0.7 to
1.5 in.H2O/ft of packing, MCcab & Smith)
Pflooding=0.8kPa/m of packing

Calculation Of Total Pressure Drop:

From figure 22.6, MCcab & Smith(5th Ed.)

Gx
Gy

y
x y
= 0.04

Here,

Gx = L

(lb/sec.ft2)

Gy = G

(lb/sec.ft2)

x L
=

(lb/ft3)
(lb/ft3)

Also,
G2 FpL0.1 / g (L - g)gc = 0.069
Then,
P = 0.6 in.H2O/ft of packing
P =1.9 in.H2O/m of packing
P = 47.5 mmH2O/m of packing (Recommended pressure drop for
absorber is 15 to 50 mmH2O/m of packing, topic 11.14.4, Coulson & Richardson)
Total Pressure Drop = 47.5 x 9= 427.5 mmH2O/m of packing
Total Pressure Drop = 4 kPa/m of packing

Calculation of number of streams for liquid distribution at top of the packing:

Number of liquid distribution streams at the top of the packing
Ns= (D/6) 2
D = Diameter of the absorption column in inches = 68 inch
Putting values in above equations, we get, Ns = 128

8.8 SPECIFICATION SHEET:

Identification:

Function:

Item:

Packed Absorption Column

Item No:

A-101

No. required:

01

To absorb H2O and CO2 in a mixture of gases.

Operation: Continuous
Entering gas

Exit gas

Kg/hr

Kg/hr

Liquid
entering

Liquid leaving
Kg/hr

Kg/hr
94035

79465

90195

104765

Design Data:
No. of transfer units = 15
Height of transfer units = 0.61 m
Height of packing section = 9 m
Total height of column = 11 m
Diameter = 1.73 m
Pressure drop = 4kPa/m of packing
Internals:
Size and type = 66 mm
Material of packing:
Packing arrangement:
Type of packing support:

Intalox saddles
Ceramic
Dumped
Simple grid & perforated support

Reference
http://encyclopedia.che.engin.umich.edu/Pages/SeparationsChemical/Absorbers/Absorbers.html
http://che.uri.edu/course/che349/absorption
http://www.slideshare.net/alsyourih/design-of-packed-columns
https://independent.academia.edu/MohamadFarid18