I

A SEMINAR REPORT
ON
SIMULATION OF SCRUBBER
(PACKED BED ABSORPTION TOWER)
USING EXCEL

PRESENTED BY GUIDED BY
ARJUNKUMAR B. PATAT Dr. N.V. BHATE
EXAM NO. 801028
PRN NO. 2015033800102985

DEPARTMENT OF CHEMICAL ENGINEERING

FACULTY OF TECHNOLOGY AND ENGINEERING
THE MAHARAJA SAYAJIRAO UNIVERSITY OF BARODA
VADODARA 390001
YEAR- 2018-19
 II

CERTIFICATE

This is to certified that Mr. Arjunkumar B. Patat, student of B.E –IV Chemical
Engineering, Exam no. 801028 has satisfactorily completed his seminar report work on
“Simulation of Scrubber (Packed Bed Absorption Tower) using EXCEL” under my guidance
and here with submit his report in partial fulfillment of the degree of B.E – Chemical for the
year 2018-19.

Guide Head of Department

Dr. N.V. BHATE Dr. N.V. BHATE

 III

ACKNOWLEDGEMENT

It is my duty to acknowledge the kind of help and guidence received from the people
in completion of this seminar report. It would not have been possible to prepare this report
without their valuable guidance.

I would like to express my gratitude towards my guide and Head of Department Dr.
N.V. Bhate for his useful guidance and support in preparation of this seminar report. His
guidance enabled me to address the problems related to seminar report.

I would also like to thank all teaching and non-teaching staff of my department for their
indirect support.

Arjunkumar B. Patat
 IV

ABSTRACT

This seminar report includes, design of packed bed absorption tower for non-reactive
dilute system. Design includes, selection of type and size of packing, column diameter, packing
height, volume and mass of packing. All calculation is done using microsoft EXCEL. Packed
tower is design using different packings so we can compare the result. EXCEL is easy to use
in this case because we just need to build the mathematical models for a given problem. The
case study of SO2-Water system has taken to design packed bed scrubber.
 V

INDEX

CHAPTER- 1 INTRODUCTION…………………………………………………………....01
1.1 What is Scrubber?..................................................................................................01
1.1.1 Various type of scrubber and their Application……………………………01
1.2 What is Simulation?...............................................................................................02
1.2.1 Simulation in Excel………………………………………………………...02
CHAPTER-2 PACKED BED SCRUBBER…………………………………………………03
2.1 Introduction………………………………………………………………………03
2.2 Advantages and Disadvantages…………………………………………………..04
2.2.1 Advantages………………………………………………………………...04
2.2.2 Disadavntages……………………………………………………………..04
2.3 Construction……………………………………………………………………...04
2.3.1 Shell………………………………………………………………………..05
2.3.2 Packing…………………………………………………………………….05
2.3.3 Other column internals…………………………………………………….08
CHAPTER-3 DESIGN OF PACKED BED TOWER……………………………………….09
3.1 Selection of Type and Size of Packing…………………………………………..09
3.1.1 Type of Packing…………………………………………………………...09
3.1.2 Size of Packing……………………………………………………………10
3.2 Number of Stages………………………………………………………………..11
3.3 Column Diameter………………………………………………………………..13
3.4 Height of Packing………………………………………………………………..14
3.4.1 Estimation of HOG by Onda’s method…………………………………….15
3.5 Volume of Packing………………………………………………………………16
3.6 Mass of Packing…………………………………………………………………16
CHAPTER-4 CASE STUDY USING EXCEL………..........................................................17
4.1 Problem………………………………………………………………………….17
4.2 Inputs……………………………………………………………………………18
4.3 Model……………………………………………………………………………19
4.4 Protocol………………………………………………………………………….20
CHAPTER-5 SUMMARY………………………………………………………………….22
5.1 Result……………………………………………………………………………22
 VI

5.2 Conclusion………………………………………………………………………..22
References……………………………………………………………………………………23
 VII

LIST OF FIGURES

Figure No. Title Page No.

2.1 Packed bed scrubber 03
2.2 Various types of packing 06
3.1 Number of transfer units NOG as a function of y1/y2 with as 12
parameter
3.2 Generalized pressure drop correlation 13
4.1 Excel sheet work 21

LIST OF TABLES

Table No. Title Page No.

1.1 Various types of scrubbers and their Applications 01
2.1 Design data for various packings 07
4.1 Solubility data 17
5.1 Result Table 22
 VIII

NOMENCLATURE

Symbol Title First used on

Page No.
a Packing surface area per unit volume 07
Fp Packing factor 07
Lm Molar flow rate of liquid per unit area 11
Gm Molar flow rate of gas per unit area 11
NOG Number of overall gas phase transfer units 11
m Slope of equilibrium line 11
Yi Mole fraction of solute in gas 11
Xi Mole fraction of solute in liquid 11
FLV Liquid-vapour flow parameter 13
ρv Density of vapour 13
ρL Density of liquid 13
Vw Vapour mass flow rate per unit area 13
Lw Liquid mass flow rate per unit area 13
µL Viscosity of liquid 14
Z Height of packing 14
HTU Height of overall transfer unit 14
NTU Number of overall transfer unit 14
KG Overall gas phase mass transfer coefficient 14
Ye Equilibrium concentration of solute in vapour 14
P Total pressure 14
HOG Height of overall gas phase transfer unit 15
aw Effective interfacial area of packing per unit volume 15
dp Packing size 15
𝛔L Liquid surface tension 15
kG Gas film mass transfer coefficient 15
kL Liquid film mass transfer coefficient 15
𝛔c Critical surface tension for the particular material 16
HG Height of gas film transfer unit 16
HL Height of liquid film transfer unit 16
 1

CHAPTER 1
INTRODUCTION

1.1 What is Scrubber?

A scrubber is a system that is used to remove harmful materials from industrial exhaust gases
before they are released into the environment.

Scrubbers are devices that use liquid to remove particulate matter or gases from an industrial
exhaust or fuel gas stream.

1.1.1 Various types of scrubbers and their Applications

Two main types of scrubbers are Dry scrubbers and Wet scrubbers. Different types of scrubbers
and their applications are shown in the following table.

Table 1.1 Various types of scrubbers and their Applications

Spray Scrubbers Coarse particulate matter removal and moderate

Wet Cyclone Scrubbers
Horizontal Baffled Spray Scrubbers
Vertical Baffled Scrubbers
Packed Bed Scrubber
Venturi Scrubber
Ejector Scrubber
Cleanable High Efficiency Air Filter
removal efficiency for gaseous pollutants
Moderate/High particulate matter removal upto 5
microns
High efficiency for gaseous pollutants
Moderate to high removal for scrubbers coarse
particulate upto 3 microns and gas pollutants
High efficiency for gaseous pollutants
Very high efficiency for fine particulate with
partial removal of gaseous pollutants
Very high efficiency for coarse particulate and
gaseous pollutants
For removal of aerosol P205, SO3, etc.
 2

1.2 What is Simulation?

 A simulation is commonly defined as an approximate imitation of a situation or
process.
 This typically entails creating a mathematical model that represent characteristics and
other features of a system.
 This model can be used to simulate how the system will respond in certain scenarios.

1.2.1 Simulation using Excel

 Excel is the most commonly used means to create data model and run simulation.
 Excel uses the model and the input.
 The Model- A simulation in Excel must built around a model and that is defined by a
system of formulas and mathematical operations.
 The Inputs- Determining the inputs is just as important as building the calculation
model.
 Without correct inputs, a model cannot generate the correct results.
 3

CHAPTER 2

PACKED BED SCRUBBER

2.1 Introduction
Packed bed scrubber is a vertical assembly which uses a counter flow design with contaminated
gas flowing upwards and liquid downward into the packing media.

Absorption is based on difference in solubility level or by chemical reaction with reagent in

solvent.

Fig. 2.1 Packed Bed Scrubber

 4

2.2 Advantages and Disadvantages

There are some Advantages and as well as Disadvantages of Absorption using packed bed
tower compare to tray tower are as below.

2.2.1 Advantages

 Low pressure drop

 Low capital investment
 Small space requirements
 Type of packing can be changed to improve mass transfer without purchasing new
equipment
 Provide smaller liquid hold up
 Suitable for foaming system and use for high corrosive liquid and vapor

2.2.2 Disadvantages

 Cleaning is not easy

 Large temperature fluctuation
 Side stream is difficult to take out
 Liquid cooling is not convenient in case of packed column

2.3 Construction
The basic unit consist of following components:

1. Shell
2. Packing
3. Packing supports
4. Liquid distributors
5. Intermediate supports and redistributors
6. Gas and Liquid entrance and exit nozzles
 5

2.3.1 Shell

The shell may be of metal (steel, alloy, or non-ferrous), plastic, wood or some combination
which may require the addition of liners or inner layers of rubber, plastic or brick.

Ceramic, plastic and other non-metal tower shells are used quite often.

It is important to consider in ceramic construction that the main inlet or outlet nozzles or any
other large connections should be oriented 90” to each other to reduce the possibility of
cracking the walls, as most cracks go one-half diameter.

Preferably there should only be one nozzle at any one horizontal plane. The nozzles should
never carry any piping or other stress load.

2.3.2 Packing

The principle requirements of Packing are that it should:

 Give large surface area. A high surface area is required to minimize the mass transfer
resistances.

 Not resist the flow, means it should have open structure. Closed structure will increase
the tower pressure drop.

 Provide uniform distribution of gas on packing surface.

 Promote uniform liquid distribution on the packing surface.

 It should be chemically inert to chemicals in operation.

 Consist proper structural strength for easy handling and installation.

 Most important, it should be economical.

Types of Packing

Many diverse types and shapes of packing have been developed to satisfy these requirements.
They can be divided into two broad classes 1) Stacked or Structural Packing 2) Random
Packing.
1. Stacked Packing
Such as grid, have an open structure, and are used for high gas rates, where low pressure
drop is essential. E.g. in cooling towers
 6

2. Random Packing
Random packings are most commonly used in the process industries. The principle
types of random packings are shown in figure.

Fig. 2.2 Various types of Packing

 7

Table 2.1 Design data for various packings

Packing Size Bulk Surface Packing

density area, a factor, Fp
in. mm (kg/m3) (m2/m3)
(1) Raschig rings 0.5 13 881 368 640
Ceramic
1.0 25 673 190 160
1.5 38 689 128 95
2.0 51 651 95 65
3.0 76 561 69 36
Metal 0.5 13 1201 417 300
(density for carbon steel)
1.0 25 625 207 115
1.5 38 785 141 83
2.0 51 593 102 57
3.0 76 400 72 32
(2) Pall rings 0.625 16 593 341 70
Metal
(density for carbon steel) 1.0 25 481 210 48
1.25 32 385 128 28
2.0 51 353 102 20
3.5 76 273 66 16
Plastics 0.625 16 112 341 97
(density for polypropylene)
1.0 25 88 207 52
1.5 38 76 128 40
2.0 51 68 102 25
3.5 89 64 85 16
(3) Intalox saddles 0.5 13 737 480 200
Ceramic
1.0 25 673 253 92
1.5 38 625 194 52
2.0 51 609 108 40
3.0 76 577 22
 8

2.3.3 Other column internals

 The packing support may be anything from cross grid bars spaced to prevent fall
through of packing to more refined speciality units design to direct the flow of gas and
liquid.
 Good tower performance is definitely linked to proper packing support.
 The weight to be carried by the support plate is the sum of the weight of the packing
plus the weight of the flooded liquid volume of the packing voids plus any pressure
surges that might be imposed on the system.
 Liquid distributor probably plays the most important part in efficient operation of a
packed tower.
 Poor distribution reduces the effective wetted packing area and promotes liquid
channelling.
 Pan distributor, Koch/Sulzer trough distributor, Orifice distributor, Multipan two stage
distributor, Spray nozzle distributor.
 The liquid coming down through the packing and on the wall of the tower should be
redistributed after a certain bed depth.
 The height of packing before redistribution is a function of the liquid flow pattern
through packing, and this is a function of the size and type of packing.
 Wall wipers or side wipers, Hold down grids, etc. are redistributors.
 9

CHAPTER 3

DESIGN OF PACKED BED TOWER

Design of packed bed tower includes,

 Selection of Type and Size of packing

 Number of stages
 Column Diameter
 Height of packing
 Volume of packing
 Mass of packing

3.1 Selection of Type and Size of packing

Principal requirements of packing, types of packing, size of packing are important factors to
be considered in the selection of packing.

3.1.1 Type of packing

Each type of packing has different efficiency of contact. Many diverse types and shapes of
packing have been developed to satisfy these requirements. They can be divided into two broad
classes 1) Stacked or Structural Packing 2) Random Packing.

1. Stacked Packing
Such as grid, have an open structure, and are used for high gas rates, where low pressure
drop is essential. E.g. in cooling towers
2. Random Packing
Random packings are most commonly used in the process industries. The principle
types of random packings are shown in figure 2.1.
 10

Problems concerned with structured packing are,

 The cost of unit volume of structured packing is significantly higher than that of random
packing but it is compensated by the increased value of efficiency and decreased value
of pressure drop.
 Another problem with this type of packing is easy plugging of packing by solid in
operation, which may be impurity or may be produced by reaction during operation.
 The efficiency decreases with slight increase in gas flow-rate, mass transfer limitation
exists.
 The pressure drop increases rapidly with slight increase in gas flow-rate, hydraulic flood
exists.

3.1.2 Size of packing

 The largest size of packing that is suitable for the size of column should be used, up to
50mm.
 Small sizes are appreciably more expensive than the larger sizes.
 Above 50mm the lower cost per cubic metre does not normally compensate for the
lower mas transfer efficiency.
 Use of too large size in a small column can cause poor liquid distribution.
 Certain things need to be optimized like, mass transfer is high for small sized packings,
but the pressure drop is higher for small packings, which results in increased diameter
for high capacity. On contrary, for comparatively bigger sized packings, the pressure
drop and capacity are high but results in decreased mass transfer, hence, lower value of
efficiency.
 Recommended size ranges are,

Column Diameter Use packing size

< 0.3 m < 25 mm
0.3 to 0.9 m 25 to 38 mm
>0.9 m 50 o 75 mm
 11

3.2 Number of stages

It can be found out by numerical or graphical approach.

1. Numerical approach
 Convert the %w/w vs partial pressure data in to mole fraction data.
 Plot vapour mole fraction vs liquid mole fraction graph.
 Find out slope and intercept of the graph.
 Find out the value of Xe* at inlet.
 Find out the Lmin by following equation.
( )
 𝐿 = 𝐺 ∗ ( )

 Find out value of mGm/Lm and y1/y2.

 Using following equation find out the NOG

 𝑁 = ln 1− +
( )

2. Graphical approach
 Take different values of the and estimate the NOG for a given value of y1/y2.

 Choose the optimum value of .

 Respected value of NOG is selected based on higher outlet concentration of liquid.

 12

Fig. 3.1 Number of transfer units NOG as a function of y1/y2 with as parameter
 13

3.3 Column diameter

 Fix the value of pressure drop per meter of packing height.

 Generally, for absorber, recommended values of pressure drop lies between 15 to 50mm
water per m of packing.
 Find out liquid-vapour flow parameter FLV using following formula.

 𝐹 =

Where, Vw = vapour flow rate in kg/s

Lw = Liquid flow rate in kg/s
 From following graph find out the value of K4 at given pressure drop line and at flooding
line.

Fig. 3.2 Generalized pressure drop correlation

 60 to 80 % flooding can be tolerated.

 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 = ∗ 100

 14

 Find out the vapour velocity in kg/m2s using following formula.

( )
𝑉 = µ
. ∗ ∗( ) .

Where, Fp = packing factor

 From this gas mass velocity find out the area of column.

4 ∗ 𝐴𝑟𝑒𝑎
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =
𝑝𝑖

3.4 Height of packing

Height of packing can be found out by transfer unit method by following equation.

Z = HTU*NTU

HTU = height of overall transfer unit

NTU = number of overall transfer unit

In terms of overall gas phase mass transfer coefficient KG,

𝐺𝑚 𝑑𝑦
𝑍=
𝐾 𝑎𝑃 𝑦−𝑦

Where, HOG =

NOG = ∫

Gm = molar gas flow rate per unit cross sectional area

a = interfacial surface area per unit volume

P = total pressure

y1 and y2 = the mole fraction of the solute in the gas at the bottom and top of the column

ye = the concentration in the gas that would be in equilibrium with the liquid concentration at
any point
 15

So, Z = HOG* NOG

We already calculated NOG.

To find out the HOG two methods are used, Cornell’s method and Onda’s method.

3.4.1 Estimation of HOG by Onda’s method

 Onda published useful correlation for the film mass transfer coefficient kG and kL and the
effective wetted area of packing aw, which is used to calculate HG and HL.
 Their correlations were based on a large amount of data on gas absorption and distillation.
 The equation for the effective area is,
. . .
𝑎 𝜎 . 𝐿 𝐿 𝑎 𝐿
= 1 − exp −1.45
𝑎 𝜎 𝑎µ 𝜌 𝑔 𝜌 𝜎𝑎

 For the mass transfer coefficient

. . .
𝜌 𝐿 µ .
𝑘 = 0.0051 𝑎𝑑
µ 𝑔 𝑎 µ 𝜌 𝐷

. .
𝑘 𝑅𝑇 𝑉 µ .
= 𝐾 𝑎𝑑
𝑎𝐷 𝑎µ 𝜌 𝐷

Where,

K5 = 5.23 for packing sizes above 15 mm, and 2 for sizes below 15 mm

Lw = liquid mass flow rate per unit cross sectional area

Vw = gas mass flow rate per unit cross sectional area

aw = effective interfacial area of packing per unit volume, m2/m3

a = actual interfacial area of packing per unit volume

dp = packing size, mm

𝛔L = liquid surface tension, N/m

kG = gas film mass transfer coefficient, kmol/m2s atm

kL = liquid film mass transfer coefficient, m/s

 16

𝛔c = critical surface tension for the particular packing material given below in mN/m

Ceramic – 61
Metal(steel) – 75
Plastic – 33
Carbon - 56

 The film transfer unit heights are given by following equations,

𝐻 =

𝐿
𝐻 =
𝑘 𝑎 𝐶

Where,

P = column operating pressure, atm

Ct = total concentration, kmol/m3

HOG can be calculated by following equation,

𝐺
𝐻 =𝐻 +𝑚 𝐻
𝐿

So, height of packing Z = HOG* NOG

3.5 Volume of packing

Volume of packing = Height of packing * column area

3.6 Mass of packing

Mass of packing = Volume of packing * Bulk density of packing
 17

CHAPTER 4

CASE STUDY USING EXCEL

4.1 Problem
A packed bed tower is to be built to treat 800 m3/hr of an entering gas. The SO2 content
of the entering gas is 7% and 93% Air by mole. 95% of the SO2 is to be absorbed using a
water rate which is 1.85 times the minimum. The absorber will operate at 300C and 1.2
atm. Design a suitable packed bed tower for this operation.

Table 4.1 Solubility Data

% w/w of Partial pressure

A in of A in gas (mm-
solution Hg)

0.05 1.2

0.1 3.2
0.15 5.8
0.2 8.5
0.3 14.1
0.5 26
0.7 39
1 59
1.5 92

vapor mole fraction liquid mole fraction

(y) (x)
0.00132 0.00014
0.00351 0.00028
0.00636 0.00042
0.00932 0.00056
0.01546 0.00085
0.02851 0.00141
0.04276 0.00198
0.10088 0.00426
 18

4.2 Inputs
Column operating pressure (atm)

Operating temperature (K)

Molecular weight of solute (kg/kmol)

Molecular weight of solvent (kg/kmol)

Molecular weight of Air (kg/kmol)

Physical Data:

Density of solvent (kg/m3)

Viscosity of solvent (pa-s)

Density of Gas (kg/m3)

Viscosity of Gas (pa-s)

Surface tension of liquid (N/m)

Critical surface tension for the particular packing material (N/m)

Diffusivity in liquid (m2/s)

Diffusivity in gas (m2/s)

Packing data:

Type of packing

Size of packing

Bulk density of packing (kg/m3)

Surface area (m2/m3)

Packing factor
 19

Data Given in Problem:

Entering gas flow rate (m3/hr)

% recovery

Concentration of solute in feed gas (y1)

Concentration of solute in solvent (y2)

Design pressure drop (mmH2O per m of packing)

Data from graph: (Fig. 3.2)

Value of K4 at given pressure drop line

Value of K4 at flooding line

4.3 Model
Model includes following mathematical equations,

( )
1. 𝐿 = 𝐺 ∗ ( )

2. 𝑁 = ln 1− +
( )

3. 𝐹 =

4. 𝑝𝑒𝑟𝑐𝑒𝑛𝑡𝑎𝑔𝑒 𝑓𝑙𝑜𝑜𝑑𝑖𝑛𝑔 = ∗ 100

( )
5. 𝑉 = µ
. ∗ ∗( ) .

∗
6. 𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 =

7. Z = HOG* NOG
. . . .
8. = 1 − exp −1.45 µ
 20

. . µ . .
9. 𝑘 µ
= 0.0051 µ
𝑎𝑑
. µ . .
10. = 𝐾 µ
𝑎𝑑

11. 𝐻 =

12. 𝐻 =

13. 𝐻 =𝐻 +𝑚 𝐻

14. Volume of packing = Height of packing * column area

15. Mass of packing = Volume of packing * Bulk density of packing

4.4 Protocol

 First convert the solubility data in to mole fraction.

 Enter the all inputs; physical data; data given in the problem; data from graph and constants.
 Model work on this data and calculate all required outputs.
 Given problem performed in excel sheet by entering all the required inputs.
 All the results and data entry can be seen by following pictures.
 That includes, Type and size of packing
Number of stages
Column diameter
Height of packing
Volume and mass of packing
 By only changing in type and size of packing we can compare the result with each other.
 21

Fig. 4.1 Excel sheet work

 22

CHAPTER 5

SUMMARY

5.1 Result
Table 5.1 Result table

1 inch 1 inch
berl Raschig
saddle ring
ceramic ceramic
Number of overall gas phase transfer units NOG = 6 6
Column diameter (m) = 0.85 0.9
Packed bed hight (m) = 3 3
3 1.70149 1.90755
Volume of column (m ) =
Mass of packing (kg) = 1225.07 1283.78
Packing size to diameter ratio = 0.02965 0.02787

5.2 Conclusion

 The scrubber is simulated by taking two different types of packing which shows that the 1
inch Berl saddle is more suitable for this case.
 It can also be concluded that EXCEL is easy to use in this case because we just need to
build the mathematical models for a given problem.
 23

References:
1. Robert E. Treybal Mass Transfer Operations, McGrew Hill International Edition 1981,
Third edition;210-211
2. Ray Sinnott & Gavin Towler, Coulson & Richardson’s Chemical Engineering Design,
Volume-6 Fifth edition, 763-787
3. Ernest E. Ludwig, Applied Process Design For Chemical And Petrochemical Plants,
Volume-2, second edition, 129-170
4. Perry R.H. & Green D.W. 1997, Perry’s Chemical Engineering Handbook, 7th edition,
McGraw Hill Book Company, USA
5. http://paramountlimited.com/air_pollution_control_scrubber_filters.htm