DESIGN OF ABSORBER

CHAPTER No.8
DESIGN OF ABSORBER
8.1 ABSORPTION
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;
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).

8.2 TYPES OF ABSORPTION

1) Physical absorption,
2) Chemical Absorption.

Physical Absorption:
In physical absorption mass transfer take place purely by diffusion and physical
absorption is governed by the physical equilibria.

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.

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8.3 TYPES OF ABSORBER

There are two major types of absorbers which are used for absorption purposes:

 Packed column
 Plate column

8.4 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.

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.

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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
3 inches in major dimension and are 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.
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.

8.5 DESIGNING STEPS FOR ABSORPTION

COLUMN

 Selection of column.
 Selection of packing and material
 Calculating the size of packing
 Calculating the diameter of column
 Determining the no. of transfer units (NOG)
 Determining the height of packing
 Determining the height of the column
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 Calculating the operating velocity

 Calculating the flooding velocity
 Determining the pressure drop.
 Select and design the column internal features: packing support, liquid
distributer and redistributer.

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8.6 SELECTION OF COLUMN:

 Components are corrosive.
 The liquid holdup is lower in packed columns.
 Pressure drop is lower in packing as compared to plates.
 Low cost of packing compared to plates.
Type of packing:
 Intalox saddles have been selected because;
 It provides a larger contact area per unit volume.
 It has an open structure and high bed porosity.
 Also provides high flooding limits and low pressure drop.
 Material of packing is ceramic because it resist corrosion.
Size of packing:
 For column diameter of greater than 0.9m,recommended packing size is 2in. to
3in.

8.7 Design of Absorber

Material Balance:
Gm(y1 – y2) = Lm(x1 – x2)

Gm=flow rate of gas entering (Kgmoles/hr)

Lm = flow rate of solvent entering (Kgmoles/ hr)
Y1=Mole fraction of AN in entering streams
Y2= Mole fraction of AN in leaving streams
X1= Mole fraction of AN in leaving solvent stream
X2== Mole fraction of AN in leaving solvent stream

3311.2(Y-0.0002) =5010.8(X-0)

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X=0.661(Y-0.0002)……………… (1)
Y=1.513X +0.0002 ……………… (2)

Equations (1) and (2) are the operating line equations.

Equation For Equilibrium Curve:
LET
Y1=Mole fraction of AN in entering gas stream=0.041
Y2= Mole fraction of AN in leaving gas stream=0.0002
Y1/Y2 = 0.041/0.0002 = 205
AS
Gm (y1 – y2) = Lm(x1 – x2)
y1 – y2 = (Lm/Gm)( x1 – x2)
The above equation is in the form y = mX + 0
From figure 11.40,we can find out the NOG using Y1/Y2 & mGm/Lm. Where ‘m ‘ is slope
of equilibrium line.
Colburn has suggested that the economic range for mGm/Lm lies from 0.7 to 0.8.For our
system,
m=0.72
Gm/Lm = 94035/90195 = 1.04
m Gm/Lm = 0.74
FROM GRAPH
Area Under the curve= NOG=15

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

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Average molecular weight of entering gases=28.4 Kg(HYSYS)

Density of gas mixture= ρg = PM /RTg
= (1.7×28.4) /(0.08205×317)
=1.86Kg/m3
Density of liquid solvent at 5oC= ρL=1022Kg/m3(HYSYS)
Viscosity of liquid solvent at 5oC = µL =1.4 cp(From Appendix-9 MCcab & Smith 5th-
Ed)
Viscosity of Gaseous mixture at 44 oC = µg = 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

From fig 11.44 (Coulson& Richardson volume-6)

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× ρg × (ρL-ρg) / 13.1×Fp× (µL /ρL) 0.1] ½

G*= [1.5×1.86× (1022-1.86) /13.1×22× (1.4×10-3 /1022)0.1]1/2

G*=11.1Kg/m2-sec.
Flow rate of gas entering =G =94035 /3600
=26.12 Kg/sec.
As
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Area =A= G / G* =2.35 m2

Diameter of column=D= 4[A] ½
[3.14] ½
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    c   L w   L w 2 a   Lw 2  
0.75 0.1 0.05 0.2

 1  exp 1.45     2    
a   a  g   a 
  l  L  L   L L  
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
σc = critical surface tension for particular packing material
σL = liquid surface tension N/m
a = 92 m2/m3
Lw = 1.85 kg/m2s
σc = 61 x 10-3 N/m
σL = 70 x 10-3 N/m
µL=1.4 CP
ρL =1022Kg /m3

aw  0.75
 61   10.66
0.1
  10.66  92 
2 0.05
 10.66 2  
0.2

 1  exp  1.45   3 

 
  
 1022  70  10 3  92  
 70   92  1.4  10   1022  9.8 
2
92    

aw = 53.5 m2/m3
Calculation Of Liquid Film Mass Transfer Coefficient:
1 2 1

  3  L  3  L 
 ad 
2
K L  L   0.0051 w    0 .4

 L g   aw  L    L DL
p


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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:

1
0 .7
K G RTg  V   g 3
 K5  w     ad p   2
aDg  a   D 
 g   g g 

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
Now, G
H  m
Where,
G K a P
G w
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
And H  m
L Ktransfer
H = Liquid-film a C
L
L wunittheight
Lm= 10.66/18 = 0.59 Kmol/m2.sec

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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:
As,
mGm
H oG  H G   HL
Lm

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
109
G
Production of Acrylonitrile L
 DESIGN OF ABSORBER

= 0.04

Operating velocity of gas (From Ludwig, pg-159)

G2 ×Fp×µL0.1 / ρg (ρL - ρg)gc = 0.046

G =2.76 m/sec
Calculation Of Flooding Velocity:

g
L
G      = 0.04
 L g

Operating velocity at flooding for dumped packing,

G2 ×Fp×µL0.1 / ρg (ρL - ρg)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
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Liquid volumetric flow rate/Unit cross-sectional area = 90195/(3600×1022×2.35)

=1.04×10 -2 m3/m2-sec
Specific area of packing = 92 m2/m3
Wetting rate =1.13×10-4 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.
ΔPflooding =0.115Fp 0.7
Where
ΔPflooding =pressure drop at flooding.
Fp =packing factor for 3-inch ceramic intalox saddles = 22
ΔPflooding =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)
ΔPflooding=0.8kPa/m of packing

Calculation Of Total Pressure Drop:

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

Gx y
Gy x  y  = 0.04

Here, Gx = L (lb/sec.ft2)
Gy = G (lb/sec.ft2)

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 = (lb/ft3)
y g

x L
 = (lb/ft3)

Also,
G2 ×Fp×µL0.1 / ρg (ρL - ρg)gc = 0.069
Then,
ΔP = 0.6 in.H2O/ft of packing
ΔP =1.9 in.H2O/m of packing
ΔP = 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

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8.8 SPECIFICATION SHEET:

Identification:
Item: Packed Absorption Column
Item No: A-104
No. required: 01

Function: To absorb acrylonitrile in a mixture of gases.

Operation: Continuous
Entering gas Exit gas Liquid Liquid leaving
Kg/hr Kg/hr entering 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 Intalox saddles
Material of packing: Ceramic
Packing arrangement: Dumped
Type of packing support: Simple grid & perforated support

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