ABSORBERS

Absorbers bring gas and liquid phases in contact, so that contaminants in the gas
phase absorb into the liquid phase as a result of their interaction.

ABOUT ABSORPTION

During absorption, soluble components of a gas mixture dissolve into a liquid. The
animation below demonstrates that as the two streams contact, mass transfer of
the soluble components takes place.

The entering gas stream, shown in yellow, contains solutes that are absorbed into
the entering liquid stream, shown in purple. The exiting gas stream shown in
orange leaves the column without the solute, while the exiting liquid stream,
shown in blue, leaves with the solute. Absorption is usually carried out in vertical
and cylindrical columns or towers. The gas and liquid phases can interact via co-
current flow, counter-flow, or cross-flow.

PACKED BEDS

Packed bed columns use absorption to remove contaminants such as corrosive

gaseous emissions, acidic fumes, and various odors. Distillation columns and
packed bed columns involve essentially the same equipment.
 (Copyright Tri-Mer Corporation, Owosso, MI)

GENERAL INFORMATION
Packed beds are used to clean gas streams. As the animation below shows, gases
flow up through the packed bed, shown by the arrows from orange to yellow, and
the scrubbing liquid flows down the bed, shown by the arrows from blue to violet.
Contaminants are transferred from the gas stream to the liquid stream. The
packing provides a large surface area for gas to liquid mass transfer to occur.

EQUIPMENT DESIGN
A packed bed column contains a support plate, a liquid distributor, and a mist
eliminator. The liquid stream flows through a liquid distributor and down the
column due to gravity, resulting in counter-flow, cross-flow, or co-current flow.
Contaminants are transferred from the vapor to the liquid, due to equilibrium or
kinetic mechanisms, with the packing providing contact between phases for
this transfer.
 (Copyright MikroPul, Inc., Charlotte, NC)

Mist eliminators are used to condense any vaporized scrubbing liquid. The picture
below to the left shows a mesh mist eliminator, and the picture below to the right
shows a vane mist eliminator. For more information, see the mist
eliminators section of this Encyclopedia.

(Copyright Amistco Separation Products Inc., Alvin, TX)

Support plates hold the packing in place within the column. The picture below
shows two types of support plates.
 (Copyright Sulzer Chemtech Ltd., Switzerland)

The liquid streams flow through distributors to avoid channeling, the uneven

distribution of liquid, which can reduce the transfer of the gas contaminant to the
liquid. A variety of distributors are shown below.

Spray-Nozzle Distributor Extraction Distributor Slotted Distributor

Tube Distributor Radial Distributor Bottom-Hole Distributor

(Copyright Sulzer Chemtech Ltd., Switzerland)

The picture below shows a packed tower. The outer shells can be made out of
fiberglass- reinforced plastic, stainless steel, high-nickel alloys, non-ferrous
metals, or thermoplastics. The inside packing can be made of metals, ceramics, or
plastics. Inert ceramics and plastics are commonly used when operating with
corrosive substances. The packing can be dumped(random) or structured.
 (Copyright Tri-Mer Corporation, Owosso, MI)

USAGE EXAMPLES
Packed beds are most commonly used in air pollution control, but they are also
used in the chemical, petrochemical, food, pharmaceutical, paper, and aerospace
industries. The beds shown below are used to absorb and eliminate ethylene gas
from a sterilization chamber. The water-soluble ethylene gas is hydrolyzed to
ethylene glycol.

(Copyright Croll Reynolds, Inc., Parsippany, NJ)

The packed bed absorption column shown below removes acidic fumes such as
H2SO4, HCl, HNO3, and HF from an inlet gas stream. Packed bed absorption is
commonly used when dealing with corrosive substances such as these.

(Copyright Tri-Mer Corporation, Owosso, MI)

ADVANTAGES
 Low pressure drop required.
 Small diameters possible.
 Can handle foaming systems.
 Low capital, operating, and
maintenance cost.
 Simple construction.
 Can handle corrosive materials due
to corrosion-resistant packing.
 Reduces backmixing in comparison
to spray columns.
 Better mass transfer than in spray
columns.
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DISADVANTAGES
 Fewer stages compared to other
columns.
 Channeling, which must be
controlled by redistributing liquid.
 Cannot handle extremely high or
low flow rates.
 Cannot handle liquids with high
viscosities.
 Need to be preferentially wetted
to avoid reduction of the
interfacial area to volume ratio.
SPRAY COLUMNS

GENERAL INFORMATION
Spray columns are differential contactors, and as such they use continuous contact
between the two phases, as opposed to the stages used in staged contactors.

EQUIPMENT DESIGN
As the animation below demonstrates, the liquid stream enters the column through
spray nozzles, shown by the movement of arrows from blue to violet. Nozzles can
be placed at different heights in the column. The droplets that form provide a
large surface area for exposure to the gas stream; smaller droplets result in a
greater exchange area. Gas flows counter-currently with respect to the liquid in
the animation below, as shown by the movement of arrows from orange to yellow.
The gas could also flow co-currently with the liquid. Low droplet velocities may
lead to low contact or turbulence, and high droplet velocities may cause flooding.
Therefore, an optimum droplet velocity is essential. A mist eliminator (not shown) is
used to separate any liquid that is entrained into the gaseous phase.

USAGE EXAMPLES
One example of a spray column is in the absorption of sulfur dioxide from coal-
fired boiler exhaust gases.

ADVANTAGES DISADVANTAGES
 Low pressure drop.  High pumping cost.
 Only one stage.  Entrainment; gas carries liquid as
 Most effective for solutes with high mist.
liquid solubility  Poor mass transfer.
 Low residence times.
 Backmixing.
 Droplets may form improperly or
coalesce.
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FALLING FILM

GENERAL INFORMATION/EQUIPMENT DESIGN

The animation below shows the operation of a falling film absorber. Falling film
absorbers are differential contactors, and are mainly used when a large amount of
heat is removed during absorption. Falling film absorbers are also vertical shell and
tube heat exchangers. As the animation below demonstrates, the cooling medium
falls through the absorber according to the movement of arrows from teal to
green. The vapor rises through the tubes, shown by the movement of bubbles from
orange to yellow, and the solvent falls through the tubes, shown by the movement
of arrows from blue to violet.

The solvent enters at the top and falls down the tube as a film. Gas enters at the
bottom or top to produce counter-current or co-current flow. The absorption of
contaminants from the gas to the solvent depends on gas velocity, liquid-gas
distribution, and the tube surface condition.

ADVANTAGES DISADVANTAGES
 Low pressure drop.  Flooding.
 Minimal static head and residence  Restricted by pressure drop.
time.  Film breakup.
 Ideal for heat-sensitive fluids.  Need continuous heat removal.
 Easy cleanup.  Evaporation may deteriorate
 Continuous heat removal. components.
 Liquid must be uniformly supplied.
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BUBBLE COLUMNS

GENERAL INFORMATION/EQUIPMENT DESIGN

Bubble columns are a type of sparged tank. In a sparged tank, the gas stream is
introduced in the form of small bubbles and acts as the agitator. As shown in the
animation, gas enters at the bottom through a gas distributor or sparger, shown by
the movement of arrows from orange to yellow, and is dispersed in the form of
bubbles through the liquid stream, shown by the movement of arrows from blue to
violet. The liquid can be introduced at the top or the bottom, resulting in either
counter-flow or co-current flow, respectively. The bubbles rise at a velocity
determined by the bubble size: the larger the bubbles, the faster they rise.
Spargers are designed to produce consistent bubble sizes, so that all the bubbles
rise at the same velocity. The bubbles may contain entrained liquid, which may
result in more hold up at high velocities.

USAGE EXAMPLES
Bubble columns can be used to purify nitroglycerin with water; in the chemical
industry for hydrogenation, oxidation, chlorination, and alkylation; and in the
biotechnology field for effluent treatment, single-cell protein production, animal
cell culture, and antibiotic fermentation. Bubble columns can be used for
radioactive elements because there are no moving parts.
ADVANTAGES DISADVANTAGES
 High thermal stability.  Low contact efficiency.
 Uniform distribution because of  Backmixing.
high liquid circulation.  Short gas residence time.
 Low energy input requirements.  High gas pressure drop.
 Two gases that form an explosive
mixture may be used.
 Long liquid residence time.
 Low investment cost.
 Large mass transfer area.
 Can handle radioactive materials
because there are no moving parts.
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TRAY COLUMNS

The number of trays, or stages, in a tray column are specific to a given

application.
 (Copyright Sulzer Chemtech Ltd., Switzerland)

GENERAL INFORMATION
The animation below shows a tray column absorber in action. The vapor stream
flows up through the trays, as shown by the movement of arrows from orange to
yellow, and contacts the down-flowing liquid stream, shown by the movement of
arrows from blue to violet, which causes the absorption of the red contaminant.
The equipment used is similar to that used in distillation columns.

EQUIPMENT DESIGN
The geometry of the trays within the column affects the extent and type of
contact between the vapor and liquid streams. The different tray types include
sieve, valve, and bubble cap. Sieve trays contain holes for vapor to flow through.
Valve trays are similar, containing holes with opening and closing valves. Bubble
cap trays contain caps that allow vapor to flow through tiny openings through the
liquid. The three ypes of trays are shown below: sieve, valve, and bubble cap (left
to right).
 (Copyright Vendome Copper & Brass Works Louisville, KY)

(Copyright Clean Gas Systems, Inc.,

Hauppauge, NY)

After the feed mixture enters the column, it flows down the column and across the
trays in either cross flow or counter-flow. In cross flow columns, downcomers
channel the liquid flowing from one tray down to the tray below.

USAGE EXAMPLES
A tray scrubber column is pictured below. Common applications include removal of
micron-sized particles and volatile organic compounds.
 (Copyright Clean Gas Systems, Inc.,
Hauppauge, NY)

ADVANTAGES DISADVANTAGES
 The liquid/vapor contact in the  Higher pressure drops than packed
cross flow of plate columns is more columns.
effective than the countercurrent  Slow reaction rate processes.
flow in packed columns.  Plugging and fouling may occur.
 Can handle high or low liquid flow
rates cost effectively.
 Can handle solids.
 Easily customized to specific
requirements such as operations
requiring much heat.
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VENTURI SRUBBERS

Venturi scrubbers are used in the removal of gas stream contaminants by liquid
droplets.
 (Copyright Sly Inc., Strongsville, OH)

GENERAL INFORMATION
In a venturi scrubber, contact between a high velocity gas and a free-flowing liquid
causes the gas contaminants to be trapped in liquid droplets. The liquid in venturi
scrubbers may contain solids, which would plug other types of absorbers. Venturi
scrubbers are able to remove solid sub-micron particles.

(Copyright Sly Inc., (Copyright Advanced Air 

Strongsville, OH) Technologies, Inc., Corunna, MI)

EQUIPMENT DESIGN
In venturi scrubbers, the gas and liquid streams enter from the top. The liquid jet
enters through a nozzle to a wet-approach or flooded wall entry designed to avoid
buildup. Below the entry is a throat where droplets are formed by shearing. Gas
contaminants are absorbed into these droplets in a single stage.

Below the venturi is a flooded elbow, or entrainment, that prevents wear. The
flow is circulated in the entrainment by a pump. The gas stream and the droplets
are further separated in a cyclone separator or demister. The lighter gas flows out
the top, and the heavier droplets fall to the bottom, where they exit with the
entrained liquid.

(Copyright MikroPul, Inc., Charlotte, NC)

USAGE EXAMPLES
Venturi scrubbers are used to recover valuable components from hot gases, and to
separate fine particles or liquid mists. The four venturi scrubbers pictured below
are used in copper mining applications, and operate at very high pressures.

(Copyright MikroPul, Inc., Charlotte, NC)

ADVANTAGES DISADVANTAGES
 Efficient atomization.  Pump is needed to circulate flow
 Good contact between the gas and through the entrainment.
 liquid.  Large gas pressure drop.
 Good for removal of sub-micron  Large power consumption.
particulate matter as well as  Limited to co-current flow.
soluble vapor.
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WET SCRUBBERS

Wet scrubbers combine a liquid spray and cyclonic action to purify gas streams of
gas compounds and dust particles.

(Copyright Sly Inc., Strongsville, OH)

GENERAL INFORMATION
The liquid spray in a wet scrubber removes fine particles, typically sulfur or acidic
compounds, or liquid mists entrained in a gas stream.

(Copyright Sly Inc., Strongsville, OH)

EQUIPMENT DESIGN
In a wet scrubber, contaminated gas enters through an inlet at the bottom of the
column. Liquid enters through a nozzle or pipe, flowing in a counter-flow, cross
flow, or co-current manner. The gas flows in a circular path within the cyclone
portion of the scrubber, forcing heavier dust particles against the wall. Any liquid
entrained within the remaining vapor is removed by the demister. Lighter particles
hit the vane stages, where much of the vapor-liquid contact takes place. Acidic
gases are converted to neutral salts and other solids so that the pH of the gas is 7
or 8. Gas exits at the top, while liquid and dust particles exit at the bottom.

(Copyright CMI-Schneible, Holly, MI) (Copyright MikroPul, Inc., Charlotte, NC)

A mist eliminator, installed near the top of the spray tower, removes droplets of
alkaline reactant that are transported by the flue gas stream. Mist eliminators can
be made from polypropylene, fiber-reinforced plastic, polysulfone, or stainless
steel. These mist eliminators can accumulate solids which can cause corrosion,
fouling, and heat related damage, so regular maintenance is critical.

USAGE EXAMPLES
Wet scrubbers are used by the food industry, such as in cheese processing, for dust
and ambient moisture removal. They also capture airborne dust in the processing
of a number of cereals.
 (Copyright Wisconsin Milk Marketing 
Board, Inc., Madison, Wisconsin)

ADVANTAGES DISADVANTAGES
 Can also recover waste heat  Complex design
 Can handle flammable feeds and  High maintenance costs
dust  Corrosion problems with interior
 Can neutralize corrosive gas metal
 Can be used in a multi-staged
configuration
 No secondary dust sources
 Relatively small space
requirements
 Can handle high-temperature,
high-humidity gas streams
 Low capital cost
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STIRRED TANK

GENERAL INFORMATION/EQUIPMENT DESIGN

Stirred tanks, also called agitated tanks or CSTRs, are used when the absorption
process includes a slow liquid-phase chemical reaction, or when close control of
the process is needed. In a stirred tank, the gas is introduced directly into the
liquid and mixed by the stirrer. The solids are suspended.

A cylindrical tank is typically used, with a liquid depth of one or two diameters.
There are no stages in a tank. Impellers, described in the Mixers section of this
Encyclopedia, are the most commonly used agitator. Propellers and turbines are
also used.
 (Copyright DCI, Inc., St. Cloud, MN)

USAGE EXAMPLES
Agitated tanks can be used in lime slurry carbonation, paper stock chlorination,
regular oil hydrogenation, fermentation broth aeration, penicillin production,
citric acid production, and aeration of activated sludge.

ADVANTAGES DISADVANTAGES
 Effective for reacting systems  Some types of agitators may cause
vortices
 High pressure drop