Chapter 5 ABSORBER
DESIGN OF ABSORBER
5.1 ABSORPTIONS
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 is based on mass transfer.
In gas absorption, 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;
a) For Separation of component having the economic value.
b) As a stage in the preparation of some compound.
c) For removing of undesired component (pollution).
5.2 TYPES OF ABSORPTION
1) Physical absorption,
2) Chemical Absorption.
5.2.1 Physical Absorption
In physical absorption mass transfer take place purely by diffusion
and physical absorption is governed by the physical equilibria.
58
Chapter 5 ABSORBER
5.2.2 Chemical Absorption
In this type of absorption as soon as a 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.
5.3 TYPES OF ABSOR5SRS
There are two major types of absorbers which are mainly used for
absorption purposes:
Packed column
Plate column
5.4 COMPARISON BETWEEN PACKED AND PLATE
COLUMN
1) The packed column provides continuous contact between vapors 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 8 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
59
Chapter 5 ABSORBER
number 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 3 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 approximately
2 meters. 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.
5.5 PACKING
The packing is the most important component of the system. The
packing provides sufficient area for intimate contact between phases. The
efficiency of the packing with respect to both HTU and flow capacity
determines to a significance extent the overall size of the tower. The
economics of the installation is therefore tied up with packing choice.
The packings are divided into those types which are dumped at
random into the tower and these which must be stacked by hand. Dumped
packing consists of unit 1/4 lo 2 inches in major dimension and is used roost
in the smaller columns. The units in stacked packing are 2 to about 8 inches
in size; they are used only in the larger towers.
60
Chapter 5 ABSORBER
The Principal Requirement of a Tower packing are:
1) It must be chemically inert to the fluids in the tower.
2) It must be strong without excessive weight.
3) It must contain adequate passages for both streams without
excessive liquid hold up or pressure drop.
4) It must provide good contact between liquid and gas.
5) It must be reasonable in cost.
Thus most packing is made of cheap, inert, fairly light materials such as
clay, porcelain, or graphite. Thin-walled metal rings of steel or aluminum are
some limes used.
Common Packings are:
a) Berl Saddle.
b) Intalox Saddle.
c) Rasching rings.
d) Lessing rings.
e) Cross-partition rings.
f) Single spiral ring.
g) Double - Spiral ring.
h) Triple - Spiral ring.
5.6 DESIGNING STEPS FOR ABSORPTION COLUMN
Determining the approximate dia of the column
Selection of column.
Selection of packing and material
Calculating the size of packing
Calculating the actual dia of column
61
Chapter 5 ABSORBER
Calculating the flooding velocity
a) Finding loading velocity with the knowledge the flooding
velocity
b) Calculating actual dia of column
Finding the no. of transfer units (NoG)
Determining the height of packing
Determining the height of the column
Determining the pressure drop.
a 10bg 2F
by equation P = [in. water /ft of packing]
ρG
62
Chapter 5 ABSORBER
Design calculation of absorber
We want to scrub Acetonitrile, HCN and acrylonitrile in the absorption
tower using water stream .this is known as multi component absorption.
The solubility data of these components shows that Acetonitrile and HCN
Are infinitely soluble in water while acrylonitrile has limited solubility in
water. Acrylonitrile is least soluble among three components, therefore we
base our design of packed bed absorption tower on the solubility of
acrylonitrile in water. The solvent used for this purpose is water.
Basis: 1 hour operation
Input gaseous stream
Components Kg Kgmol Mol%
Acrylonitrile 9900 186.79 5.95
HCN 1687.4 62.50 1.99
Acetonitrile 996.46 24.30 0.77
CO 982 35.07 1.12
CO2 3394.8 77.16 2.46
Propane 1234.5 28.06 0.89
Propylene 736 17.54 0.56
Water 9847.8 547.10 17.43
Oxygen 2356.7 73.65 2.35
Nitrogen 58329 2083.19 66.37
Impurities 212.46 3.51 0.11
Total 89677.12 3138.87 100
Water entering in the absorber = 223607 Kg /hr
63
Chapter 5 ABSORBER
Output liquid stream
Components Kg Kgmol Mol%
Acrylonitrile 9702 183.05 1.54
HCN 1654 61.25 0.512
Acetonitrile 976.5 23.817 0.199
Water 210109.3 11672.73 97.72
Impurities 212.5 3.507 .0293
Total 223654.3 11944.35 100
Selection of Packing
We have selected ceramic Intalox saddle.
Intalox saddle and pall rings are most popular choices. We have selected
ceramic intalox saddle because they are most efficient. We have selected the
ceramic material of packing because in our system oxygen and water are
present and they can cause corrosion and ceramic material will prevent
corrosion.
Size of the Packing
Now we will find the maximum size of intalox saddle which would be used
for this particular dia of the column.
1 D 1 1
Packing size = = 0.0666 m = 66 mm
15 15
Although the efficiency of higher for small packing, it is generally
accept that it is economical to use these small sizes in an attempt to improve
the performance of a column. It is preferable to use the largest recommended
size of a particular type of packing and to increase the packed height to
compensate for small loss of efficiency.
Number of Transfer Units (NOG)
64
Chapter 5 ABSORBER
In an absorption tower mol. fraction of acrylonitrile is X, Y in liquid
gas respectively. Then by acrylonitrile mass balance we have:
Gm (Y – Y2) = Lm (X – X2)
3138.87( Y - .001) = 11944.35(X – 0)
Y = 3.805X + .001→ (1)
X = .26Y - .00026
X = .26( Y - .001)→(2)
The equation no. 1 and 2 represents the operating line of absorption of
acrylonitrile.
65
Chapter 5 ABSORBER
As the concentration of acrylonitrile is very small in stream, the
equilibrium curve for the system will b straight line with a slop of [Link]
the equation of equilibrium curve for the acrylonitrile water system is
Y* = 1.7 X → (3)
Now we assumed different values of Y and calculated their
corresponding value of X & Y* using equation (2 and 3) the graph is shown
below:
Number of transfer unit after drawing graph between X Vs Y and X Vs
Y*we get using Mecab Theile method:
NOG = 10
66
Chapter 5 ABSORBER
Calculation of column dia:
Most methods for determining the size of
randomly packed towers are derived from the Sherwood correlations which
are used here to fine out diameter of absorber. The physical property of a gas
can be taken as that of air at 45 0C and 170 KN/m2 because concentration of
acrylonitrile is very small in a gas mixture and average molecular weight of
gas mixture is 28.56 Kg/Kgmol
Thus for abscisox = L/G. × rv/rl
L = Flow rate of water = 223607 Kg/hr
G = Flow rate of a gas mixture = 89677.12 Kg/hr
rv = density of gas at 45 0C and 170 KN/m2
rl = density of water at 45 0C and 170 KN/m2
rv = PM/RT (where, R = 0.08205)
1.7 28.56
rv = 0.08205 318
= 1.862 g/L = 1.862 Kg/m3
rl = 990 Kg/m3
Therefore
L/G. × rv/rl = 0.108
For our absorber we will design for 42mm water in packing.
Thus for 42mm of water / m of packing height
K4 = 1.4, Fp = 22.3
μL = viscosity of water at 45 0C = .63 Cp
G* = [K4 rv (rl - rv ) / 13.1 Fp (μL / rl ) ] 1/2
G* = 6.06 Kg m2/sec.
Thus
A = area of cross section = G / G*
A = 4.11 m2
67
Chapter 5 ABSORBER
Diameter = D = [4×A/π] ½
D = 2.3 m.
Height of Packing(Z)
For ceramic intalox saddle:
Gm 0.316
HOG = 1.14
Lm 0.315
Where
Gm = gas flow rate, lb moles/hr. ft2
Lm = liquid flow rate, lbmol/hr.ft2
We have,
Gm = 763.71 Kgmol/hr m2
Since cross-section area = A = 4.11 m2
Gm = 113.3/0.502 Kg mol/m2hr = 0.212 Kgmol/m2sec
Similarly,
Lm = 11944.35/4.11 Kgmol/m2hr = .807 Kgmol/sec. m2
1.14
0.212 0.316
HOG =
0.807 0.315
HOG = 0.752 m
Where
HOG = height of a transfer unit
Z = HOG NOG
Z = 0.752 10 = 7.52 m
68
Chapter 5 ABSORBER
Z = 7.52 m
Where Z is the height of packing.
Allowance for liquid distribution = 1.00 m
Allowance for liquid redistribution = 1.00 m
Total height of column = 1.00+1.00+7.52
Total height of column = 9.5 m ≈ 10 m
Degree of wetting
Liquid rate
LP = Specific are of packing
Liquid flow rate = 62.11 Kg/sec
And
Specific area of packing = 11 m2/m3
LP = 62.11/4.11×11×990 = 1.39 × 10-3 m3/msec
Calculation of pressure drop at flooding region:
Pressure drop at flooding point = 3 in of water / ft of packing.
Therefore,
∆Pflood = 3 in of water / ft of packing × height of packing
∆Pflood = 24.67 × 3
= 74.01 in of water
∆Pflood = 18.43 KN/m2
Calculation of liquid hold up :
25% of packing weight can be taken as the liquid hold up for ceramic
packing as the bulk density of 2 inch intallox saddles packing is
69
Chapter 5 ABSORBER
= 609 Kg/m3
Volume of packing = π/4 D2 × Hp
= π/4 ( 2.3)2 × 7.52
= 31.24 m3
thus liquid hold up is = 0.25 × 31.24 × 609
= 4756.29 kg of water.
70
