Prepared by : Column Tag No.

:
Checked by : Job No. :
Date : Client :
Project :
Input Data Stream :
Packing type = Intallox Saddles
Packing size = 25 mm
Packing MOC = PP
Gas pr. Drop / m bed = 15 mmWC / m packing height =
Total packing height = 3.2 m (including all packed beds)
Gas / Vapour Properties
Gas / Air flow rate = 1000 kg/h OR 0
m
3
/h
= 0.2778 kg/s = 0
m
3
/s
Gas pressure at entry = 1.0000 atm
Gas temperature at entry = 30.00
o
C
= 303.00
o
K
Gas / Air mol weight = 29
Component to be scrubbed
Component Name = HCL Vap
Component flow rate = 70 Kg/h
% comp. in air/gas = 6 % (v/v) (presumed) / (given by client) / (by process cal.)
Molecular weight of comp. = 36.5
Liquid / Scrubbing media Properties
Scrubbing media = 20% NaOH
Liquid flow rate, L = 77 kg/h
= 0.0214 kg/s
Liquid Density,
L = 1100
kg/m
3
Conversion :
Liquid Viscosity,
L = 0.0035000
Ns/m
2
3.5
C
p
=
Packing factor, F
p
= 21
m
-1
Charac. Packing Factor,C
f
= 33 Ref. Table 6.3, Characterstics of Random packings
Conversion factor, J = 1.0 factor for adequate liquid distribution & irrigation across the bed
SCRUBBER DESIGN (PACKED COLUMN)
0.00350000
Sheet 1 of 16

Calculations
Since larger flow quantities are at the bottom for an absorber, the diameter will be chosen to
accommodate the bottom conditions.
To calculate Gas density
Avg. molecular weight = 29.45 Kg / Kmol
If gas flow rate is given in kg/h If gas flow rate is given in m3/h
Gas in = 0.009432183 Kmol/s Gas in
= (m
3
/s) x 273
x
kmol = mass / mol wt T in kelvin
=
(kmol/s) x T in kelvin x 1.0 atm x 22.4
273 pr. In atm 1 = 0 Kmol/s
= 0.234499
m
3
/s
= 0 Kg/s
mass = mol wt x kmol
Select vol. flow rate and mass flow rate from above,
Selected mass flow rate = 0.277778 Kg/s
Selected vol. Flow rate = 0.234499 m
3
/s
Selected molar flow rate = 0.009432 Kmol/s
Therefore, gas density = 1.1846
Kg/m
3
(mass flow rate / vol. Flow rate)
To find L', G' and Tower c/s area
Assuming essentially complete absorbtion,
Component removed = 0.0207 Kg/s (molar flow rate x % comp. x mol. Wt.)
Liquid leaving = 0.0420 Kg/s (Inlet liquid flow rate + comp. Removed)
L'
G
0.5
= 0.00497
G'
L
Using 0.00497 as ordinate, Refer fig.6.34 using a gas pressure drop of
G'
2
C
f

L
0.1
J = 0.04 (from graph)

G
(
L
--
G
) g
c
Therefore, G' = 0.04
G
(
L
--
G
) g
c
0.5
C
f

L
0.1
J
= 1.6665
Kg / m
2
.s
Tower c/s area = 0.1667
m
2
( c/s area = mass flow rate / G' )
Tower diameter = 0.4607 m = 460.7 mm
= 500 mm
Corresponding c/s area = 0.1963
m
2
TO CALCULATE COLUMN DIAMETER
Sheet 2 of 16

Efficiency of fan / blower = 60 % assumed / given
To calculate pressure drop
Pressure drop for irrigated = 470.72
N/m
2
(pressure drop per m packing x total ht. of packing)
packing
For dry packing,
O/L Gas flow rate, G' = 1.3095
Kg / m
2
.s
(Gas inlet flow rate - Component removed) / c/s area
O/L Gas pressure = 100854.3
N/m
2
(subtracting pressure drop across packing)
Gas density,
G
= gas mol wt. x 273 x gas o/l pr.
22.41m3/Kmol T in kelvin 101330
= 1.1605
Kg/m
3
C
D
= 96.7 Ref. Table 6.3, Characterstics of Random packings
Delta P = C
D
G'
2
Z
G
= 142.89
N/m
2
Pressure drop for packing = 613.61
N/m
2
(irrigated packing + dry packing)
Pressure drop for internals = 25 mmWC (packing supports and liquid distributors)
= 245.17
N/m
2
Gas velocity = 7.5 m/s
Inlet expansion & outlet = 1.5 x Velocity heads =
1.5 x (V
2
/ 2g)
contraction losses = 42.19 N m / Kg
= 49.97
N/m
2
(divide by density)
Total pressure drop = 908.75
N/m
2
(packing + internals + losses)
Fan power output = pressure drop,N/m
2
x (gas in - component removed) Kg/s
O/L gas density, Kg/m
3
= 201.35 N .m / s
= 0.20 kW
Power for fan motor = 0.34 kW (fan power output / motor efficiency)
= 0.45 hp
TO ESTIMATE POWER REQUIREMENT
Sheet 3 of 16

Liq.-Vap. Flow factor, F
LV =
(L / V) x (
V
/
L
)
= 0.0025
Design for an initial pressure drop of 15 mm H2O /m packing
From K
4
v/s F
LV
,
K
4
= 0.85
K
4
at flooding = 6.50
Trial % flooding =
( (K
4
/ K
4
at flooding) ) x 100
= 36.1620
Gas mass flow rate, V
m
= K
4
.
V
(
L
--
V
)
13.1 F
p
(
L
/
L
)
0.1
= 3.7763
kg/m
2
.s
Trial column c/s area = V / V
m
(Trial A
s
)
= 0.0736
m
2
Trial column dia., D = 0.3060 m D =
(4/pi) x Trial A
s
Round off 'D' to nearest standard size
Therefore, D = 0.500 m
Column C/S area, A
s = 0.1963
m
2
A
s
=
(pi/4) x D
2
% flooding = 13.5472
% flooding = Trial % flooding x (Trial A
s
/ A
s
)
Conclusion
Generally packed towers are designed for 50% -- 85% flooding.
If flooding is to be reduced,
(i) Select larger packing size and repeat the above steps.
OR
(ii) Increase the column diameter and repeat the above steps.
COLUMN DIAMETER / HYDRAULIC CHECK
(1/2)
Sheet 4 of 16

Norton's Correlation : ln HETP = n - 0.187 ln + 0.213 ln
Applicable when,
liquid phase surface tension > 4 dyne/cm & < 36 dyne/cm
liquid viscosity > 0.08 cP & < 0.83 cP
Conversion :
Input Data 0.018 N/m =
Liquid-phase
Surface Tension, = 20 dyne/cm
Liquid Viscosity = 3.5 cP
n = 1.13080
Calculation
ln HETP = 0.837437
HETP = 2.310437 ft
= 0.704221 m
For separations, less than 15 theoritical stages, a 20% design safety factor can be applied.
Considering 20% safety factor,
HETP = 0.845065 m
For separations, requiring 15 to 25 theoritical stages, a 15% design safety factor can be applied.
Considering 15% safety factor,
HETP = 0.809854 m
HETP PREDICTION
Norton's Correlation Applicable
Norton's Correlation NOT applicable
18
Sheet 5 of 16

HCL Scrubber
4506A
JOL
SR - Plant -4, 5
HCL Vap.
147.1
(N/m
2
)/m
Ns/m
2
factor for adequate liquid distribution & irrigation across the bed
SCRUBBER DESIGN (PACKED COLUMN)
0.00350000
Sheet 6 of 16

pr. in atm x 1
1.0 atm 22.4
147.1 (N/m
2
)/m
TO CALCULATE COLUMN DIAMETER
Sheet 7 of 16

(pressure drop per m packing x total ht. of packing)
(Gas inlet flow rate - Component removed) / c/s area
TO ESTIMATE POWER REQUIREMENT
Sheet 8 of 16

COLUMN DIAMETER / HYDRAULIC CHECK
Sheet 9 of 16

dyne/cm
HETP PREDICTION
Norton's Correlation Applicable
Norton's Correlation NOT applicable
Sheet 10 of 16

Constant for HETP Correlation
Ref.:: Random Packings and Packed Towers ---- Strigle
Table 6.2
Ref. : : Chemical Engineering, Volume-6 , COULSON & RICHARDSON'S
Ref. : : Mass Transfer Operation : : Treybal