604 CHEMICAL ENGINEERING

The term K4 on Figure 11.44 is the function:

 0.1
L
13.1
VŁw 2 Fp
L
K4 D
11.118
v
L
v 
where VŁw D gas mass flow-rate per unit column cross-sectional area, kg/m2 s
Fp D packing factor, characteristic of the size and type of packing,
see Table 11.3, m
1 .
L D liquid viscosity, Ns/m2
L , v D liquid and vapour densities, kg/m3
The values of the flow factor FLV given in Figure 11.44 covers the range that will
generally give satisfactory column performance.
The ratio of liquid to gas flow will be fixed by the reflux ratio in distillation; and in
gas absorption will be selected to give the required separation with the most economic
use of solvent.
A new generalised correlation for pressure drop in packed columns, similar to
Figure 11.44, has been published by Leva (1992), (1995). The new correlations gives
a better prediction for systems where the density of the irrigating fluid is appreciably
greater than that of water. It can also be used to predict the pressure drop over dry
packing.

Example 11.14
Sulphur dioxide produced by the combustion of sulphur in air is absorbed in water. Pure
SO2 is then recovered from the solution by steam stripping. Make a preliminary design
for the absorption column. The feed will be 5000 kg/h of gas containing 8 per cent v/v
SO2 . The gas will be cooled to 20Ž C. A 95 per cent recovery of the sulphur dioxide is
required.

Solution
As the solubility of SO2 in water is high, operation at atmospheric pressure should be
satisfactory. The feed-water temperature will be taken as 20Ž C, a reasonable design value.

Solubility data
From Chemical Engineers Handbook, 5th edn, McGraw-Hill, 1973.

per cent w/w 0.05 0.1 0.15 0.2 0.3 0.5 0.7 1.0 1.5
solution
SO2
Partial press.
gas mmHg 1.2 3.2 5.8 8.5 14.1 26 39 59 92

Partial pressure of SO2 in the feed D
8/100 ð 760 D 60.8 mm Hg

 SEPARATION COLUMNS (DISTILLATION, ABSORPTION AND EXTRACTION) 605

Figure (d). SO2 absorber design (Example 11.14)

These figures are plotted in Figure
d.

Number of stages
Partial pressure in the exit gas at 95 per cent recovery D 60.8 ð 0.05 D 3.04 mm Hg
Over this range of partial pressure the equilibrium line is essentially straight so
Figure 11.40 can be used to estimate the number of stages needed.
The use of Figure 11.40 will slightly overestimate the number of stages and a more
accurate estimate would be made by graphical integration of equation 11.104; but this is
not justified in view of the uncertainty in the prediction of the transfer unit height.
Molecular weights: SO2 D 64, H2 O D 18, air D 29

Slope of equilibrium line

From the data: partial pressure at 1.0% w/w SO2 D 59 mm Hg.
59
Mol. fraction in vapour D D 0.0776
760
1
Mol. fraction in liquid D 64 D 0.0028
1 99
C
64 18
0.0776
mD D 27.4
0.0028
606 CHEMICAL ENGINEERING

To decide the most economic water flow-rate, the stripper design should be considered
together with the absorption design, but for the purpose of this example the absorption
design will be considered alone. Using Figure 11.40 the number of stages required at
different water rates will be determined and the “optimum” rate chosen:
y1 p1 60.8
D D D 20
y2 p2 3.04

Gm
m 0.5 0.6 0.7 0.8 0.9 1.0
Lm
NOG 3.7 4.1 6.3 8 10.8 19.0

It can be seen that the “optimum” will be between mGm /Lm D 0.6 to 0.8, as would
be expected. 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.
Check the liquid outlet composition at 0.6 and 0.8:
Material balance Lm x1 D Gm
y1
y2 
Gm m Gm
so x1 D
0.08 ð 0.95 D
0.076
Lm 27.4 Lm
mGm
at D 0.6, x1 D 1.66 ð 10
3 mol fraction
Lm
mGm
at D 0.8, x1 D 2.22 ð 10
3 mol fraction
Lm
Use 0.8, as the higher concentration will favour the stripper design and operation,
without significantly increasing the number of stages needed in the absorber.
NOG D 8

Column diameter
The physical properties of the gas can be taken as those for air, as the concentration of
SO2 is low.
5000 1.39
Gas flow-rate D D 1.39 kg/s, D D 0.048 kmol/s
3600 29
27.4
Liquid flow-rate D ð 0.048 D 1.64 kmol/s
0.8
D 29.5 kg/s.
Select 38 mm
1 12 in. ceramic Intalox saddles.
From Table 11.3, Fp D 170 m
1
29 273
Gas density at 20Ž C D ð D 1.21 kg/m3
22.4 293
Liquid density ' 1000 kg/m3
 SEPARATION COLUMNS (DISTILLATION, ABSORPTION AND EXTRACTION) 607

Liquid viscosity D 10
3 Ns/m2


Ł 
LW v 29.5 1.21
D D 0.74
VŁW L 1.39 103
Design for a pressure drop of 20 mm H2 O/m packing
From Figure 11.44,
K4 D 0.35
At flooding K4 D 0.8

0.35
Percentage flooding D ð 100 D 66 per cent, satisfactory.
0.8
From equation 11.118
 
K4 V
L
v  1/2
VŁW D
13.1Fp
L /L 0.1
 
0.35 ð 1.21
1000
1.21 1/2
D D 0.87 kg/m2 s
13.1 ð 170
10
3 /103 0.1
1.39
Column area required D D 1.6 m2
0.87

4
Diameter D ð 1.6 D 1.43 m

Round off to 1.50 m

Column area D ð 1.52 D 1.77 m2

4
1.5
Packing size to column diameter ratio D D 39,
38 ð 10
3
A larger packing size could be considered.
Percentage flooding at selected diameter
1.6
D 66 ð D 60 per cent,
1.77
Could consider reducing column diameter.

Estimation of HOG
Cornell’s method
DL D 1.7 ð 10
9 m2 /s
Dv D 1.45 ð 10
5 m2 /s
v D 0.018 ð 10
3 Ns/m2
0.018 ð 10
3

Scv D D 1.04
1.21 ð 1.45 ð 10
5
608 CHEMICAL ENGINEERING

10
3

ScL D D 588
1000 ð 1.7 ð 10
9
29.5
Ł
LW D D 16.7 kg/s m2
1.77
From Figure 11.41, at 60 per cent flooding, K3 D 0.85.
From Figure 11.42, at 60 per cent flooding, h D 80.
Ł
From Figure 11.43, at LW D 16.7, h D 0.1.
HOG can be expected to be around 1 m, so as a first estimate Z can be taken as
8 m. The column diameter is greater than 0.6 m so the diameter correction term will be
taken as 2.3.
 
0.5 8 0.15
HL D 0.305 ð 0.1
588 ð 0.85 D 0.7 m
11.111
3.05
As the liquid temperature has been taken as 20Ž C, and the liquid is water,
f1 D f2 D f3 D 1
  
8 0.33
HG D 0.011 ð 80
1.040.5
2.3
16.70.5 D 0.7 m
11.110
3.05
HOG D 0.7 C 0.8 ð 0.7 D 1.3 m
11.105
Z D 8 ð 1.3 D 10.4 m, close enough to the estimated value.

Onda’s method
R D 0.08314 bar m3 /kmol K.
Surface tension of liquid, taken as water at 20Ž C D 70 ð 10
3 N/m
g D 9.81 m/s2
dp D 38 ð 10
3 m
From Table 11.3, for 38 mm Intalox saddles
a D 194 m2 /m3
c for ceramics D 61 ð 10
3 N/m
  0.75  0.1  
0.05
aW 61 ð 10
3 17.6 17.62 ð 194
D 1
exp
1.45
a 70 ð 10
3 194 ð 10
3 10002 ð 9.81
 0.2 
17.62
ð D 0.71
11.113
1000 ð 70 ð 10
3 ð 194

aW D 0.71 ð 194 D 138 m2 /m3

 1/3  2/3  
1/2
103 17.6 10
3
kL D 0.0051
10
3 ð 9.81 138 ð 10
3 103 ð 1.7 ð 10
9
ð
194 ð 38 ð 10
3 0.4
11.114
kL D 2.5 ð 10
4 m/s
 SEPARATION COLUMNS (DISTILLATION, ABSORPTION AND EXTRACTION) 609
1.39
VŁW on actual column diameter D D 0.79 kg/m2 s
1.77
 0.7
0.08314 ð 293 0.79
kG D 5.23
11.115
194 ð 1.45 ð 10
5 194 ð 0.018 ð 10
3
 1/3
0.018 ð 10
3
ð
194 ð 38 ð 10
3 
2.0
1.21 ð 1.45 ð 10
5
kG D 5.0 ð 10
4 kmol/sm2 bar
0.79
Gm D D 0.027 kmol/m2 s
29
16.7
Lm D D 0.93 kmol/m2 s
18
0.027
HG D D 0.39 m
11.116
5.0 ð 10
4ð 138 ð 1.013
CT D total concentration, as water,
1000
D D 55.6 kmol/m3
18
0.93
HL D D 0.49 m
11.117
2.5 ð 10
4 ð 138 ð 55.6
HOG D 0.39 C 0.8 ð 0.49 D 0.78 m
11.105

Use higher value, estimated using Cornell’s method, and round up packed bed height
to 11 m.

11.14.5. Column internals

The internal fittings in a packed column are simpler than those in a plate column but must
be carefully designed to ensure good performance. As a general rule, the standard fittings
developed by the packing manufacturers should be specified. Some typical designs are
shown in Figures 11.45 to 11.54; and their use is discussed in the following paragraphs.

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. These requirements conflict; a poorly designed support
will give a high pressure drop and can cause local flooding. Simple grid and perfo-
rated 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,
Figure 11.45.
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 shown in Figure 11.46