Ministry of Higher Education

& Scientific Research

Basrah University for Oil & Gas
College of Oil & Gas Engineering

Process Equipment Design II

Design of Packed Bed Column II

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Outlines

❑ Column Diameter
❑ Column Internals: Packing Support
❑ Liquid Distributors
❑ Liquid Redistributors
❑ Hold-down Plates
❑ Liquid hold-up
❑ Wetting Rates
❑ References

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 Column Diameter
The capacity of a packed column is determined by its cross-sectional area.

Normally, the column will operate at the highest economical pressure drop, ensuring good liquid and gas distribution.

For random packings, the pressure drop will not normally exceed 80 mm of water per meter of packing height.

At this value, the gas velocity will be about 80 percent of the flooding velocity.

Recommended design values, mm water per m packing, are:

➢ Absorbers and strippers 15 to 50

➢ Distillation, atmospheric and moderate pressure 40 to 80

When the liquid is likely to foam, these values should be halved.

For vacuum distillations the maximum allowable pressure drop will be determined by the process requirements, but for

satisfactory liquid distribution the pressure drop should not be less than 8 mm water per m

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Column Diameter
The term K4, is the function:

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 Column Internals: Packing Support
The internal fittings in a packed column are simpler than those in a plate column but must be carefully designed for good performance. As a

general rule, the standard fittings developed by the packing manufacturers should be specified.

➢ The function of the support plate is to carry the weight of the wet packing, whilst allowing free passage of the gas and liquid. These

requirements conflict; A poorly designed support will give a high pressure drop and can cause local flooding.

➢ Simple grid and perforated plate supports are used, but in these designs the liquid and gas have to vie for the same openings. Wide-spaced

grids are used to increase the flow area; With layers of larger size packing stacked on the grid to support the small size random packing.

➢ The best design of packing support is one in which gas inlets are provided above the level where the liquid flows from the bed; Such as

the gas-injection type

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Packing Support
➢ Packing Support these designs have a low-pressure drop and no tendency to flooding. They are available in a wide range of sizes and
materials: metals, ceramics, and plastics.

➢ Gas is distributed directly into the packed bed-no hydrostatic head-gas and liquid flows through separate openings in the plate

➢ Stacked packing used to support random packing Gas-injection support plate.

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 Liquid Distributors

For small-diameter columns a central open feed pipe, or one fitted with a spray nozzle, may well be adequate.

➢ In the orifice type the liquid flows through holes in the plate and the gas through short standpipes. The gas pipes should be sized to give

sufficient area for gas flow without creating a significant pressure drop.

➢ In the weir type, the liquid flows over notched weirs in the gas stand-pipes. This type can be designed to cope with a wider range of liquid

flow rates than the simpler orifice type.

➢ Liquid Distributors For large-diameter columns, the trough-type distributor can be used, and will give good liquid distribution with a large

free area for gas flow.

➢ A pipe manifold distributor can be used when the liquid is fed to the column under pressure and the flow-rate is reasonably constant.

The distribution pipes and orifices should be sized to give an even flow from each element

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Liquid Distributors

Orifice-type distributor Weir-type distributor Weir-trough distributors Pipe distributor

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 Liquid Redistributors
Redistributors are used to collect liquid that has migrated to the column walls and redistribute it evenly over the packing.

A full redistributors combines the functions of a packing support and a liquid distributor.

Full redistributor “Wall wiper” redistributor

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Hold-down Plates
At high gas rates, the top layers of packing can be fluidized under these conditions ceramic packing can break up and the pieces filter down

the column and plug the packing; Metal and plastic packing can be blown out of the column.

➢ Hold-down plates are used with ceramic packing to weigh down the top layers and prevent fluidization.

➢ Bed-limiters are sometimes used with plastics and metal packings to prevent expansion of the bed when operating at a high-pressure drop.

They are similar to hold-down plates but are of lighter construction and are fixed to the column walls.

➢ The openings in hold-down plates and bed limiters should be small enough to retain the packing,

but should not restrict the gas and liquid flow.

Hold-down plate design

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 Liquid hold-up

An estimate of the amount of liquid held up in the packing under operating conditions is needed to calculate the total load carried by the packing

support.

➢ The liquid hold-up will depend on the liquid rate and, to some extent, on the gas flow-rate.

➢ The packing manufacturers' design literature should be consulted to obtain accurate estimates.

➢ As a rough guide, a value of about 25 per cent of the packing weight can be taken for ceramic packings.

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Wetting Rates
For very low liquid rates have to be used, packing wetting rate should be checked to make sure it is above the minimum recommended by the

packing manufacturer.

➢ Wetting rates are frequently expressed in terms of mass or volume flow-rate per unit column cross-sectional area.

➢ If the design liquor rate is too low, the diameter of the column should be reduced. For some processes, liquid can be recycled to increase

the flow over the packing.

➢ A substantial factor of safety should be applied to the calculated bed height for the process where the wetting rate is likely to be low.

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References
• Sinnott, R. K. "Chemical Engineering Design: Coulson and Richardson’s
Chemical Engineering, Volume 6, 6, 1056." (2005).

• Peters, Max Stone, Klaus D. Timmerhaus, and Ronald Emmett

West. Plant design and economics for chemical engineers. Vol. 4. New
York: McGraw-Hill, 2003.