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Problem 3.

Design of Sulfur Dioxide Absorber

You are a member of a group of design engineers designing equipment for the
recovery of SO2 from stack gases.

The group leader has asked you to determine the optimum size of the SO 2
absorption tower. Specifically, he has asked you to determine the height and cross-
sectional area of the optimum absorption tower and to present your
recommendations in the form of a formal report.

Your group has held several meetings to discuss the proposed overall design.
Following is a list of conditions, assumptions, and data on which the group has
decided to base the design:

100,000 ft3 of gas per minute at 300F and 1 atm are to be treated.
The entering gas contains 0.3 percent by volume SO 2 and 11.0 percent CO 2 with the
balance being N2, O2, and H2O.
The average molecular weight of the entering gas = 29.4
The mole percent SO2 in the exit gas is to be 0.01 percent.
The entering and exit pressures of the absorption column may be assumed to be 1
atm for purposes of calculating the SO2 pressures.

The zinc oxide process will be used for recovering the SO 2. In this process, a
solution of H2O, NaHSO3m and Na2SO3 is circulated through the absorption tower to
absorb the SO2. This mixture is then treated with ZnO, and the ZnSO 3 formed is
filtered off, dried, and calcined to yield practically pure SO 2. The ZnO from the
calciner is reused, and the sulfite-bisulfite liquor from the filter is recycled.

The absorption tower will contain non-staggered wood grids of the following
dimensions:

Clearance = 1.5 in.


Height = 4 in.
Thickness = in.
Free cross-sectional area = 85.8%
Active absorption area per cubic foot of volume = a = 13.7 ft 2/ft3

The average density of the gas at the tower entrance can be assumed to be
0.054 lb/ft3. The sulfite-bisulfite liquid has a density of 70 lb/ft 3 and can be considered
as having a zero equilibrium SO, vapor pressure at both the inlet and outlet of the
tower.

The sulfite-bisulfite liquid must be supplied at a rate of 675 lb/(h)(ft 2) of column


cross-sectional area).
The optimum design can be assumed to be that corresponding to a minimum
total power cost for circulating the liquid and forcing the gas through the tower. You
may assume that this optimum corresponds to the optimum that would be obtained
if fixed charges were also considered.

The following simplified equations are applicable for grids of the dimensions to
be used:

K g =0.00222 ( Go )0.8

hw 1.8
=0.23 x 107 ( Go )
L

where Kg = molar absorption coefficient, lb mole of component absorbed/ (h)(ft 2)


(atm)log mean
Go = superficial mass velocity of gas in tower, lb/(h)(ft 2)
hw = pressure drop through tower, in. of water
L = height of tower, ft

The liquid is put into the absorption tower by means of a nozzle at the top of the
tower. The pressure just before the nozzle is 35 psig. Assume the pump for the liquid
must supply power to lift the liquid to the top of the tower and compress the liquid to
35 psig. Use a 10 percent safety factor on the above pumping-power requirements to
take care of the friction in the lines and other minor losses.

The gas blower has an overall efficiency of 55 percent.

The pump has an overall efficiency of 65 percent.


DESIGN DESCRIPTION
A gas absorption tower is designed for the recovery of Sulfur Dioxide (SO2) from
stack gases.

DATA AND ASSUMPTIONS


1. The gas to be treated enters at 100,000 ft3 of gas per minute at 300F and 1
atm.
2. The entering gas contains 0.3 percent by volume SO 2 and 11.0 percent CO2
with the balance being N2, O2, and H2O.
3. The average molecular weight of the entering gas = 29.4
4. The mole percent SO2 in the exit gas is to be 0.01 percent.
5. The entering and exit pressures of the absorption column may be assumed to
be 1 atm for purposes of calculating the SO 2 pressures.
6. The average density of the gas at the tower entrance can be assumed to be
0.054 lb/ft3.
7. The sulfite-bisulfite liquid has a density of 70 lb/ft 3

DESIGN CONSIDERATIONS
1. The absorption tower will contain non-staggered wood grids of the following
dimensions:
Clearance = 1.5 in.
Height = 4 in.
Thickness = in.
Free cross-sectional area = 85.8%
Active absorption area per cubic foot of volume = a = 13.7 ft 2/ft3

DESIGN REQUIREMENTS
1. Gas Mass Velocity
2. Inner Diameter of the Column
3. Packing Height
4. Column Height
5. Power Requirement
6. Total Cost
7. Design of Parts of Column

Design Calculations:

1. Determination of gas mass velocity


Flooding pressure is estimated to be 0.5 in H 2O/ft of packing. The gas mass velocity at
flooding can be obtained using the relation given in the problem:

hw
=0.23 x 107 G1.8
o
L
1/ 1.8
0.5 lb
(
Go , flooding=
0.23107 ) =11,919.1600
h . ft 2

2. Solving for the inner diameter of the column


Absorbers used in the industry typically operate in the range of 60-75% of the flooding
velocity. The gas mass velocity of the optimum design lies within this range, therefore,
the diameter of the column that falls within it must be determined. For the calculations,
increments of 2.5% will be used.

For 65% of flooding velocity,

lb lb
Go=0.65 x 11,919.1600 2
=7,747.4540 2
h . ft h . ft

100,000 ft 3
( )( 0.54ft lb )( 60hmin ) =41.8202 ft
3
v , g min 2
A= =
Go lb
7,747.4540
h . ft 2

The diameter is then

D=

4 ( 41.8202 ft 2 )

=7.2971 ft

Table 3. Inner Diameter of column at different gas mass velocities

% of Go,flooding (lb/ft2.h) Go(lb/ft2.h) Area(ft2) Diameter(ft)


60 7151.4960 45.3052 7.5950
62.5 7449.4750 43.4930 7.4416
65 7747.4540 41.8202 7.2971
67.5 8045.4330 40.2713 7.1606
70 8343.4120 38.8330 7.0316
72.5 8641.3910 37.4940 6.9093
75 8939.3700 36.2442 6.7932
It can be seen in Table 3 that the least diameter can be obtained at 75% of the flooding
velocity.
The minimum diameter gives the least volumetric flow rate of the liquid to be
pumped into the tower. Therefore, this gives the minimum cost for power for
pumping.

3. Determination of Packing Height

3.1 Establishing the operating lines


Before the operating lines can be established, the molality of the solution must first be
calculated. At 60% of flooding velocity,

Assume lbmol/h of NaHSO3 = 65lbmol/h

Solving for the molality of the solution,

It was calculated from the overall mass balance that the total amount of SO 2 absorbed is
31.96lbmol/h. The reaction stoichiometry between the sodium sulphite, SO 2, and water
system is

Therefore,
Table 4. Molalities of the inlet and outlet liquid streams

Na2SO3 IN NaHSO3 IN (mHSO3-)2/ (mSO3-) IN (mHSO3- )2


(lbmol/h) (lbmol/h) /mSO3-) OUT
60.00 55 65 1 44.24
62.50 55 64 1 46.77
65.00 55 63 1 49.37
67.50 60 62 1 44.91
70.00 60 61 1 47.47
72.50 55 60 1 50.13
75.00 55 59 1 52.91

4. Determination of Column Height

After evaluating the integral, the column height can now be determined.

At 60% of flooding velocity and x1 = 44 mol/kg,


The relation between the mass transfer coefficient Kg, and the gas mass velocity, G o
was given in the problem through the equation:
The surface area per unit volume of packing for non-staggered grids was also given
as and the total system pressure, P, is at 1 atm.

Finally,

Table 6. Possible heights at operating at 60-75% of flooding gas mass velocity

% of flooding 60% 62.50% 65% 67.50% 70% 75%


x1(mol/kg) 45 47 49 50 47 53
I 9.6231 11.2439 18.1712 6.5422 11.2439 5.2280
2
Gm(lbmol/h.ft ) 243.2482 253.3835 263.5188 273.6542 283.7895 293.9249
3
Kga(lbmol/h.ft .atm) 36.8630 38.0868 39.3007 40.5054 41.7012 42.8885
Z(ft) 63.4997 74.8033 121.8416 44.1992 76.5181 35.8286

It is shown in Table 6 that the minimum height at any gas mass velocity is obtained
when the sulphite-bisulphite liquor concentration is at 53 mol/kg. Therefore, the
operating point at x1, y1 should be (53, 0.003). It was stated previously that the
optimum design would be the one that has the minimum diameter and minimum
height. In this design, the optimum diameter, which is the minimum diameter, is
obtained when the gas mass velocity is 75% of that of flooding and has a value of

Dopt =6.7932 ft

The minimum height is also obtained at 75% of flooding velocity and is equal to

H min =35.8286 ft

5. Calculating the power requirements for the pump and the compressor and
power costs
5.1 Pump Power Requirements and Power Costs

The power requirement of the pump is dependent upon the cross-sectional area of the
column. Minimum pumping cost is obtained when the diameter is the smallest possible
diameter. At 75% of flooding velocity,

Applying 10% safety factor

For the power cost

Basis of 1 hour:

Pump Power Cost = Php 11.1884

5.2 Compressor Power Requirement and Power Cost

For the compressor power:


hp=1.57 x 104 Qp

where:
hp = ideal power, hp
QG = volumetric flowrate of the gas, ft3/min
p = inlet pressure, in.H2O = 407.55

Basis of 1 hour:

5.3 Total Costs (Power Costs and Fixed Charges)

Fixed charges, which include depreciation, local taxes, and insurance (Timmerhaus,
1991) is assumed to be 15% of the total power cost. The total cost per hour of operation
is then,

6. Determination of other important parts of the absorber

The following are other important factors that need to be considered in designing an
absorption column:

6.1 Packing Support

The function of the support plate is to carry the weight of the wet packing, whilst
allowing free passage of the gas and liquid. The best design of packing support is one in
which gas inlets are provided above the level where the liquid flows from the bed like
the gas-injection packing support. It has a low pressure drop and no tendency of
flooding. (Sinnott, 1999)
6.2 Liquid distributors

The satisfactory performance of a column is dependent on maintaining a uniform flow of


liquid throughout the column, and good initial liquid distribution is essential. 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.

6.3 Liquid redistributors

Redistributors are used to collect the liquid that has migrated to the column walls and
redistributes it evenly over the packing. They will also even out any maldistribution that
has occurred within the packing. According to Walas(2002), liquid distributors are
needed at least every 20ft of packing. For the design, the total packing height is 45.19ft.

45.19 ft
N packed beds= =2.2595 packed beds 3
20 ft

The height of each of three equally sized packed beds is,


45.19
H pb= =15.06 ft each
3

It was stated in the design problem that non-staggered grids are to be used with the
following specifications:

Clearance = 1.5 in
Height = 4 in
Thickness = 0.25 in

The number of grids per packed bed is calculated by dividing the total height of the
packed bed by the height plus the clearance of (n-1) grids plus the height of the
topmost grid.

6.4 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.

6.5 Liquid Level at the bottom and Vapor disengagement

Walas (2002) suggests that 6 feet should be added to the bottom for liquid level and 4
feet above the tower for vapor disengagement.

6.6 Distance of top of liquid level(bottom) to gas inlet


The distance of the top of the liquid level at the bottom of the tower to the gas inlet
should be half of the column diameter, and should not be less than 0.6m. (Sinnott,
1999)

6.7 Distance of gas inlet to the bottom of the last packing support

The distance between the gas inlet to the bottom of the first packing support (bottom to
top) should be at least 1m or one column diameter.

6.8 Distance between packed beds

An allowance of 1.5 feet is allotted for the liquid redistributor and the space between the
packings.

6.9 Wetting rates

The packing wetting rate should be checked to make sure it is above the minimum
recommended by the packing manufacturer. For structured packing, the minimum
wetting rate is from 0.07x10-5 to 0.14 x 10-3 m3s-1/m2. To check if the liquid flow rate in
the problem is above the minimum wetting rate, the following equation is used:

Therefore, the system is well irrigated.

7.10 Maximum Allowable Vapor Velocity

The maximum allowable vapor velocity is usually the velocity at flooding


(Timmerhaus,1991).
For the problem, the gas mass velocity at flooding is at 11, 919.160 lb/h.ft2.

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