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EQUIPMENTS
Packed Bed Column
Packed Bed Column - Introduction
Packed bed columns use absorption to remove
contaminants such as corrosive gaseous
emissions, acidic fumes, and various odors.
Packed beds are used to clean gas streams. Here,
gases flow up through the packed bed and the
scrubbing liquid flows down the bed.
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.
Equipment Design
Mist eliminators are used to condense any vaporized scrubbing
liquid. Support plates hold the packing in place within the
column.
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.
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.
Applications
Packed beds are most commonly used in
Air pollution control
Chemical
Petrochemical
Food
Pharmaceutical
Paper
Aerospace industries.
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.
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
Spray columns – Introduction and
Application
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.
Usage Examples
One example of a spray column is in the
absorption of sulfur dioxide from coal-fired
boiler exhaust gases.
Equipment Design
Here, the liquid stream enters the column
through spray nozzles. 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. The gas could also flow co-
currently with the liquid.
Equipment Design
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 is used to separate any
liquid that is entrained into the gaseous
phase.
Advantages and Disadvantages
Advantages
Low pressure drop.
Only one stage.
Most effective for solutes with high liquid solubility
Disadvantages
High pumping cost.
Entrainment; gas carries liquid as mist.
Poor mass transfer.
Low residence times.
Backmixing.
Droplets may form improperly or coalesce.
Falling Film Absorber
Falling film absorbers – Introduction
and Equipment Design
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.
Here, the cooling medium falls through the
absorber and the vapor rises through the tubes
whereas the solvent falls through the tubes
Falling film absorbers – Introduction
and Equipment Design
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
Low pressure drop.
Minimal static head and residence time.
Ideal for heat-sensitive fluids.
Easy cleanup.
Continuous heat removal.
Disadvantages
Flooding.
Restricted by pressure drop.
Film breakup.
Need continuous heat removal.
Evaporation may deteriorate components.
Liquid must be uniformly supplied.
Bubble Column
Bubble Columns – Introduction and Equipment Design