3-25

x = 0
in
x
out
y
out
y = 0.08
in
G = 5000 kg/hr
Chapter 3
Example 3.2-5.

----------------------------------------------------------------------------------
Sulfur dioxide produced by the combustion of sulfur in air is absorbed in water. Pure SO
2
is
then recovered from the solution by steam stripping. Make a preliminary design for the
absorption column. The feed will be 5000 kg/hr of gas containing 8 mole percent SO
2
. The
gas will be cooled to 20
o
C. A 95 percent recovery of the SO
2
is required
2
.

Solution -----------------------------------------------------------------------------------------
Operation is at atmospheric pressure as the solubility of SO
2
in water is high. The feed water
temperature will be taken as 20
o
C.

Table E-1. Equilibrium data for SO
2
at 1 atm and 20
o
C.
x 0 .000564 .000842 .001403 .001965 .00279 .00420
y 0 .0112 .01855 .0342 .0513 .0775 .121

At 95 percent recovery of SO
2


y
out
= (0.05)(0.08) = 0.004

Slope of equilibrium line: y* = mx

0.0775 = m(0.00279) m = 27.8

To decide the most economic water flow rate,
the stripper should be considered together with the
absorption design. For this example, the absorption
design will be considered alone.

The number of gas transfer unit may be estimated from

N
OG
=
L mG / 1
1

L mG
y y
y y
L mG
out out
out in
/ ) / 1 ( ln
*
*


Where G =
) 29 )( 3600 )( 454 . 0 (
5000
= 0.1055 lbmol/s

y
in
= 0.08, y
out
= 0.004, y*
out
= mx
in
= (27.8)(0) = 0


Evaluate as N
OG
a function of mG/L

mG/L 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0.99
N
OG
3.5 3.8 4.2 4.7 5.4 6.3 7.8 10.6 17.4
L,lbmol/s 14.66 9.78 7.33 5.87 4.89 4.19 3.67 3.26 2.96

3-26
The optimum will be between mG/L = 0.6 to 0.8. Below 0.6 there is only a small
decrease in the number of stages required with increasing liquid rate and above 0.8, the
number of stages increases rapidly with decreasing liquid rate (Figure E-1)

Figure E-1. Optimum liquid flow rate for Sulfur Dioxide absorption.

Check the liquid outlet composition at mG/L = 0.6 and at mG/L = 0.8. Assuming dilute
solution, the material balance is

L(x
out
x
in
) = G(y
in
y
out
) x
out
= G(y
in
y
out
)/L + x
in


x
out
= (0.08 0.004)
L
mG
8 . 27


At mG/L = 0.6, x
out
= 1.6410
-3


At mG/L = 0.8, x
out
= 2.1910
-3


Use mG/L = 0.8 as the higher concentration will favor the stripper design and operation
without significantly increasing the number of stages needed in the absorber. Therefore

N
OG
= 8

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
2
4
6
8
10
12
14
16
18
mG/L
L
(
l
b
m
o
l
/
s
)
,

N
O
G
L
NOG

Estimate column diameter: 2 methods.

First design method: chooses the pre
Figure 13.4
1
to evaluate G'(lb/s

Area =
lbmol
G

\
|

Check the percent of flooding (65 to 90%).


Figure E-2 Generalized flooding and pressure drop correlation.
Second design method:
determine G'
flood
and operate at some percentage of

G' = (.65 to .90) G'
flood

Once G' is known the column cross


10
Wankat, P. C., Equilibrium Staged Separations
3-27
: 2 methods.
chooses the pressure drop per unit length of packing then use
'(lb/sft
2
). Note: G in the ordinate of Figure E-2 is actually
2
'
. .
ft s
lb
G
lbmol
lb
vapor W M
s
lbmol

\
|
|

|

Check the percent of flooding (65 to 90%).
Generalized flooding and pressure drop correlation.

Second design method: Use the flooding curve of Figure E-2 or the Eq. (3.2
and operate at some percentage of G'
flood
.
flood

' is known the column cross-sectional area A can be determined.

Equilibrium Staged Separations, Elsevier, 1988, pg. 420
ssure drop per unit length of packing then use
is actually G'.

Generalized flooding and pressure drop correlation.
2 or the Eq. (3.2-21)
10
to

log
10
(

c L G
g
F G

2 . 0 2
'
=

where F
lv
=
'
'
G
L

L
G

G
m
are mass flow rates in this expression.

The first design method will be applied. The physical properties of the gas can be taken
as those for air as the concentration of SO

G =
3600 )( 454 . 0 (
5000

At mG/L = 0.8,

Packing: Choose 1.5" Ceramic Intalox saddle (picture below) with packing parameters
32, = 0.13, = 0.15. Intalox saddle is one type of dumped packings.


F is the parameter in the ordinate of Figure E
parameters to determine the pressure drop

p = (10
L'
)

\
|

Air (gas) density at 20
o
C:

Liquid density:
L
= 62.3 lb/ft

The column will be designed for a pressure drop of 0.5 in of water/ft of packing. Table
E-2 shows the recommended design values.
3-28
1.6678 1.085 log
10
(F
lv
) 0.29655[log
10
(F
lv
)]
2
2 / 1
(

(
=
m
m
G
L
2 / 1
(

L
G

= the abscissa of Figure E-

are mass flow rates in this expression.
The first design method will be applied. The physical properties of the gas can be taken
as those for air as the concentration of SO
2
is low.
) 29 )( 3600
5000
= 0.1055 lbmol/s
= 0.8, L = mG/0.8 = (27.8)(0.1055)/0.8 = 3.666 lbmol/s
Packing: Choose 1.5" Ceramic Intalox saddle (picture below) with packing parameters
= 0.15. Intalox saddle is one type of dumped packings.


r in the ordinate of Figure E-2
(

c L G
g
F G

2 . 0 2
'
.
parameters to determine the pressure drop p in inches of water per foot of packing given by
|
|

\
|
G
G

2
'

C:
G
=
) 293 )( 359 (
) 273 )( 29 (
= 0.0753 lb/ft
3

= 62.3 lb/ft
3
, liquid viscosity = 1 cp.
The column will be designed for a pressure drop of 0.5 in of water/ft of packing. Table
2 shows the recommended design values.
2
(3.2-11)
-2. Note: L
m
and
The first design method will be applied. The physical properties of the gas can be taken
0.8 = (27.8)(0.1055)/0.8 = 3.666 lbmol/s
Packing: Choose 1.5" Ceramic Intalox saddle (picture below) with packing parameters F =
and are the
in inches of water per foot of packing given by
(3.2-22)
The column will be designed for a pressure drop of 0.5 in of water/ft of packing. Table
3-29
Table E-2. Recommended design value for p (inches of water per foot of packing)

Application p (inches of water per foot of packing)
Absorber and stripper 0.2 0.6
Distillation (atmospheric & moderate
pressure)
0.5 1.0
Vacuum columns 0.1 0.4

If very low bottom pressures are required, structured packings or special low pressure drop
dumped packings should be considered (Hyperfil, Multifil, or Dixon rings).

The column area may be estimated from the pressure drop p using either Eq. (3.2-22)
or Figure E-2. The procedure for using Figure E-2 will be discussed

=
liquid of Density
water of Density
= 1

F
lv
=
'
'
G
L
2 / 1
(

L
G

=
m
m
G
L
2 / 1
(

L
G

=
) 29 )( 1055 . 0 (
) 18 )( 67 . 3 (
2 / 1
3 . 62
0753 . 0
|

\
|
= 0.75

From Figure E-2 at F
lv
= 0.75 and p = 0.5 in water/ft of packing


(

c L G
g
F G

2 . 0 2
'
= 0.018

At flooding using the flooding line or Eq. 3.2-21:
(
(

c L G
f
g
F G

2 . 0 2
'
= 0.0294


2
'
'
|
|

\
|
f
G
G
=
0294 . 0
018 . 0
= 0.612
f
G
G
'
'
= 0.78 (O.K., between 65 and 90 %)

G' =
2 / 1
2 . 0
018 . 0
(

F
g
c L G
=
2 / 1
) 1 )( 52 (
) 2 . 32 )( 3 . 62 )( 0753 . 0 )( 018 . 0 (
(

= 0.229 lb/sft
2


Note: in the above expression is the liquid viscosity in centipoises.

Gas mass flow rate G
m
= (0.1055)(29) = 3.06 lb/s = A
c
G'

A
c
=
229 . 0
06 . 3
= 13.38 ft
2
D
c
=
2 / 1
) 38 . 13 )( 4 (
|

\
|

= 4.13 ft

3-30
Check packing size: Recommend size ranges are

Column diameter Use packing size
< 1 ft
1 to 3 ft
> 3 ft
1 in.
1 to 1.5 in.
2 to 3 in.

In general, the largest size of packing that is suitable for the size of column should be used,
up to 2 in. Small sizes are appreciably more expensive than the larger sizes. Above 2 in., the
lower cost does not normally compensate for the lower mass transfer efficiency. Use of too
large a size in a small column can cause poor liquid distribution. Since 1.5 in. ceramic
Intalox saddle is used in this example, a larger size could be considered.

The height of packing may be determined from the following formula

h
p
= N
OG
H
OG


The height of overall gas transfer unit, H
OG
, may be evaluated from the height of gas transfer
unit, H
G
, and the height of liquid transfer unit, H
L


H
OG
= H
G
+
L
mG
H
L

The correlation for H
G
is

H
G
=
2 8 . 0 25 . 1
2 / 1 3 / 1 1
] ) / ( ) / ( ' ) 3600 [(
) ( ) 10 / ( ) ' (
b
V L V L
v p
b
col
L
Sc h D

Where b1 = 1.11 for saddles, b2 = 0.50 for saddles
D'
col
= lesser of column diameter in ft or 2
h
p
= height of packed bed in ft
Sc
v
= Schmidt number for vapor =
v
/
v
D
v

L' = mass flux of liquid, lb/sft
2

= surface tension of liquid (L) or water (W)
= packing parameter given by Figure E-3.



0
Figure E-3. Packing parameter
Ceramic Berl saddles are used to make conservative estimate of packing parameter for
Intalox saddles since mass transfer efficiency of Intalox saddles is higher than that of the
equivalent size Berl saddles.


W
L

= 1 ;
W
L

10
2
10
3

Figure E-4. Packing parameter


The correlation for H
L
is

H
L
= C
fL
(h
p
/10)

where = packing parameter given in Figure
C
fL
= vapor load
Sc
L
= Schmidt number for liquid =

Estimate h
p
by assuming a value for so
2.2 ft, then


11
Wankat, P. C., Equilibrium Staged Separations
12
Wankat, P. C., Equilibrium Staged Separations
3-31

20 40 60 80 90
. Packing parameter (ft) as a function of percent flood

saddles are used to make conservative estimate of packing parameter for
Intalox saddles since mass transfer efficiency of Intalox saddles is higher than that of the

= 1 ;
W
L

= 1

10
4
10
5

. Packing parameter (ft) as a function of L' Figure E-5. Vapor load coefficient
is
/10)
0.15
(Sc
L
)
1/2

= packing parameter given in Figure E-4
12

= vapor load coefficient given in Figure E-5
12
= Schmidt number for liquid =
L
/
L
D
L

by assuming a value for so H
OG
that H
G
and H
L
can be evaluated. Let

Equilibrium Staged Separations, Elsevier, 1988, pg. 652
Equilibrium Staged Separations, Elsevier, 1988, pg. 654

90
as a function of percent flood
11

saddles are used to make conservative estimate of packing parameter for
Intalox saddles since mass transfer efficiency of Intalox saddles is higher than that of the

. Vapor load coefficient
can be evaluated. Let H
OG
=
3-32
h
p
= N
OG
H
OG
= (8)(2.2) 18 ft

At 78% flooding and p = 1.5 in, Figure E-3 gives a packing value = 65 ft. From the
PROP program (T.K. Nguyen Website)

Diffusivity of SO
2
in water at 20
o
C: D
L
= 7.510
-6
cm
2
/s = 8.0710
-9
ft
2
/s
Diffusivity of SO
2
in air at 20
o
C and 1 atm: D
v
= 0.122 cm
2
/s = 1.3110
-4
ft
2
/s
Viscosity of gas (air) at 20
o
C:
v
= 1.8210
-5
kg/ms = 1.2210
-5
lb/fts

Sc
v
=
v
/
v
D
v
= (1.2210
-5
)/[(7.5310
-2
)(1.3110
-4
)] = 1.237

Sc
L
=
L
/
L
D
L
= (6.7210
-4
)/[(62.3)(8.0710
-9
)] = 1337

L' = (3.666)(18)/(13.38) = 4.93 lb/sft
2
= 1.7810
4
lb/hrft
2


Flooding ratio = 0.78 C
fL
0.70 (Figure 19-8)

H
G
=
2 8 . 0 25 . 1
2 / 1 3 / 1 1
] ) / ( ) / ( ' ) 3600 [(
) ( ) 10 / ( ) ' (
b
V L V L
v p
b
col
L
Sc h D

=
2 / 1
2 / 1 3 / 1 11 . 1
)] 93 . 4 )( 3600 [(
) 237 . 1 ( ) 10 / 18 ( ) 2 )( 65 (
= 1.42 ft


L' = 1.7810
4
lb/hrft
2
0.1 (Figure E-4)

H
L
= C
fL
(h
p
/10)
0.15
(Sc
L
)
1/2
= (0.1)(0.7)(1.8)
0.15
(1337)
1/2
= 2.80 ft

H
OG
= H
G
+
L
mG
H
L
= 1.42 + (0.8)(2.80) = 3.66 ft

h
p
= N
OG
H
OG
= (8)(3.66) = 29.3 ft

Repeat the calculation with h
p
= 30 ft

H
G
=
2 / 1
2 / 1 3 / 1 11 . 1
)] 93 . 4 )( 3600 [(
) 237 . 1 ( ) 10 / 30 ( ) 2 )( 65 (
=
3 / 1
8 . 1
3
|

\
|
(1.42) = 1.69 ft

H
L
= (0.1)(0.7)(3.0)
0.15
(1337)
1/2
=
15 . 0
8 . 1
3
|

\
|
(2.80) = 3.02 ft

H
OG
= H
G
+
L
mG
H
L
= 1.69 + (0.8)(3.02) = 4.1 ft

h
p
= N
OG
H
OG
= (8)(4.1 = 32.8 ft