CHAPTER NO.

9 Absorber Design

ABSORBER DESIGN
9.1 Objective:
The objective of using absorption column here in our process is to absorb maleic
anhydride from reaction residues and to produce 40% maleic acid solution in scrubbed
liquid (liquid leaving the absorber).

9.2 Absorption:
Unit operation where the solute of a gas are removed by being placed in contact
with a nonvolatile liquid solvent that removes the components from the gas.

In gas absorption a soluble vapors are more or less absorbed in the solvent from its
mixture with inert gas. The 'purpose of such gas scrubbing operations may be any of the
following;

 For Separation of component having the economic value.

 As a stage in the preparation of some compound.
 For removing of undesired component (pollution).
Solvent:
Liquid applied to remove the solute from a gas stream.

Solute:
Components to be removed from an entering stream.

9.3 Absorber System Configuration:

Gas and liquid flow through an absorber may be countercurrent, crosscurrent, or co-
current. The most commonly installed designs are countercurrent, in which the waste gas
stream enters at the bottom of the absorber column and exits at the top. Conversely, the
solvent stream enters at the top and exits at the bottom. Moreover, countercurrent
designs usually require lower liquid to gas ratios than co-current and are more suitable
when the loading is higher.

In a crosscurrent tower, the waste gas flows horizontally across the column while the
solvent flows vertically down the column. As a rule, crosscurrent designs have lower
pressure drops and require lower liquid-to-gas ratios than both co-current and

146
CHAPTER NO. 9 Absorber Design

countercurrent designs. They are applicable when gases are highly soluble, since they
offer less contact time for absorption.

In co-current towers, both the gas and solvent enter the column at the top of the tower and
exit at the bottom. Co-current designs have lower pressure drops, are not subject to
flooding limitations and are more efficient for fine (i.e., submicron) mist removal. Co-
current designs are only efficient where large absorption driving forces are available.
Removal efficiency is limited since the gas-liquid system approaches equilibrium at the
bottom of the tower.

9.4 Types of Absorption:

 Physical Absorption
 Chemical Absorption

9.4.1 Physical absorption:

In physical absorption mass transfer take place purely by diffusion and physical
absorption is governed by the physical equilibrium.

9.4.2 Chemical Absorption:

In this type of absorption as soon as a particular component comes in contact with

the absorbing liquid a chemical reaction take place. Then by reducing the concentration
of component in the liquid phase, which enhances the rate of diffusion.
The case under consideration is a chemisorption where maleic anhydride is reacted with
that of water to produce maleic acid solution.
Reaction:
C4H2O3 + H2O C4H4O4
Heat of reaction = 3.6 x 104 Kj/kgmol

9.5 Types of Absorption Equipment

 Packed Column
 Tray column
 Venturi Scrubber
 Spray Column

147
CHAPTER NO. 9 Absorber Design

9.5.1 COMPARISON BETWEEN PACKED AND PLATE COLUMN

 Plate columns can be designed to handle a wider range of liquid and gas flow-
rates than packed columns.
 Packed columns are not suitable for very low liquid rates.
 The efficiency of a plate can be predicted with more certainty than the
equivalent term for packing (HETP or HTU).
 Plate columns can be designed with more assurance than packed columns.
There is always some doubt that good liquid distribution can be maintained
throughout a packed column under all operating conditions, particularly in
large columns.
 It is easier to make provision for cooling in a plate column; coils can be
installed on the plates.
 It is easier to make provision for the withdrawal of side-streams from plate
columns.
 If the liquid causes fouling, or contains solids, it is easier to make provision
for cleaning in a plate column; manways can be installed on the plates. With
small diameter columns it may be cheaper to use packing and replace the
packing when it becomes fouled.
 For corrosive liquids a packed column will usually be cheaper than the
equivalent plate column.
 The liquid hold-up is appreciably lower in a packed column than a plate
column. This can be important when the inventory of toxic or flammable
liquids needs to be kept as small as possible for safety reasons.
 Packed columns are more suitable for handling foaming systems.
 The pressure drop per equilibrium stage (HETP) can be lower for packing
than plates; and packing should be considered for vacuum columns.
 Packing should always be considered for small diameter columns, say less
than 0.6 m, where plates would be difficult to install, and expensive.

From the above consideration plate column is selected as the absorber, because in
our case the diameter of the column is approximately 2.97 meter which is greater than 3
ft.

148
CHAPTER NO. 9 Absorber Design

9.6 SELECTION OF PLATE TYPE:

Type Sieve tray Valve tray Bubble cap tray

Capacity High High to very high Moderate to high
Efficiency High High Moderate to high
Turn down About 2:1 , not About 4-5:1 Excellent,better than
suitable to operate valve trays good at
under variable load extremly low liquid
rate
Entrainment Moderate Moderate High,about three
times higher than
that of sieve trays
Pressure drop Moderate Moderate High
Cost Low About 20% higher High, about 2-3
than that of sieve times higher than
trays that of sieve trays
Maintanance Low Low to moderate Relatevly high
Fouling tendency Low Low to moderate High , tends to
collect solids.
Effect of Low Low to moderate High
corrosion
Availability of Well known Rarely available Well known
design
information

From above informtion I have selected sieve trays for desired degree of
absorption.

9.7 Process Operation

149
CHAPTER NO. 9 Absorber Design

 Changing the conditions of the absorption column can influence the effectiveness
and efficiency of absorption. Some important controllable conditions are as
follows:
 Pressure of the column.
 Temperature of entering liquid and gas streams.
 Humidity of the gas stream.
 Ratio of the liquid and gas stream rates.

Raising the total pressure of the column may increase the efficiency of the separation
because increasing the pressure decreases the liquid flow rate and increases the
concentration of the gas. The temperature of entering liquid effect absorption in that it
effects the flow rate of liquid required for the separation with a given number of
stages.Increasing the temperature of the entering solvent increases the liquid flow rate
required.

Inlet gases of the absorber with high humidity at a high temperature effect the capability
of the gas to consume latent heat hindering the absorption process. Therefore,
dehumidification of the inlet gas should be considered for absorbers with large heat
effects. The ratio of the liquid to gas stream rates in that if the ratio is too low, the solute
builds in the upper portion of the column causing a higher temperature profile in the top
of the column. As a result, internal cooling maybe necessary for lower liquid to gas
ratios.

9.7.1 Desired degree of recovery

The amount of solute recovery is generally set by the designer. It may be a
recovery to ensure product purity requirements or to satisfy a purity requirement if the
recovered solute is a feed stream to another unit.

9.8 Selection of Solvent

The ideal absorbent should:

 have a high solubility for the solute(s)

 have a low volatility to reduce loss of absorbent
 have a low viscosity to provide a low pressure drop
 be nontoxic
 Easily available and not expensive.
We have selected 40% maleic acid solution as a solvent to absorb maleic anhydride from
mixture of gases.

150
CHAPTER NO. 9 Absorber Design

9.9 Determination of operating pressure and temperature

Operating pressure should be high and temperature low for an absorber, to
minimize stage requirements and/or absorbent flow rate and to lower the equipment
volume required accommodating the gas flow. But in case of stripper operating pressure
should be low and temperature high for a stripper to minimize stage requirements or
stripping agent flow rate.

9.10 Heat Effects and need for cooling

One of the most important considerations involved in designing a gas absorption
tower is to determine whether or not temperatures will vary along the length of the tower,
since the solubility of the solute gas depends strongly upon the temperature. Heat effects
that may cause temperature to vary from point to point in a gas absorber are:

 the heat of solution

 the heat of vaporization or condensation of the solvent
 the change of the sensible heat between the gas and the liquid phases
 the loss of sensible heat form the fluids to internal and external cooling coils or to
the atmosphere via the tower walls

9.11 DESIGN CALCULATIONS

 DESIGN STEPS:

151
CHAPTER NO. 9 Absorber Design

 Find out minimum flow rate of liquid

 Number of theoretical stages
 Efficiency of the column
 Number of actual stages required for seperation
 Height of the column
 Cross sectional area and diameter of column

 TRAY DESIGN:
 Entrainment
 Active area of the plate
 Hole area
 Hole size/diameter
 Plate thickness
 Weir height
 Weir length
 Hole pitch
 Number of holes
 Check weeping
 Plate pressure drop
 Downcomer liquid backup
 Residence time in downcomer

 MINIMUM LIQUID FLOW RATE:

It is the flow rate of liquid at which seperation can not occure.
It is found by
mLm y 2 k− y 1 k
=
mv y 2k
−x 1 k
Kk

and
y 1 k=(1−є ) y 2 k

where
mLm = minimum liquid flow rate
mv’’ = vapor flow rate = 2380kgmol/hr
Kk= equilibrium value of key compnent (k value) = 0.93
y1k= vapor fraction of key component in top of column = 1*10-4

152
CHAPTER NO. 9 Absorber Design

y2k= vapor fraction of key component at bottom of column = 6*10-3

x1k= fraction of key component in yhe top liquid = 0
є = solute fraction absorbed = 0.983
Substituting values in above
Minimum liquid flow rate = mLm = 2175.7 kgmol/hr
Actual liquid flow rate = mL = 1.5 * mLm = 3263.5 kgmol /hr

 NUMBER OF THEORETICAL STAGES:

Absorption factor
L
Ai=
KV
=1.47 ≈ 1.5

Using Kresmer Equation For Calculation Of No.Of Stages

( Ai¿¿ N +1− Ai)/( Ai ¿¿ N +1−1)=solute fraction absorbed ¿ ¿

simplifying above equation

( Ai−∈)
N +1 log ( Ai )=log
(1−∈)

Where
Ai = absorption factor
Є = solute fraction absorbed
Putting values
N = 7.70 ≈ 8 stages

 EFFICIENCY OF THE COLUMN:

Using Graph (fig 9.1) For The Efficiency Of The Column For Gas Absorption
Efficiency of the column = E⁰ = 51%

 NO. OF ACTUAL TRAYS:

153
CHAPTER NO. 9 Absorber Design

N
Na=
E°
Actual trays =15.71 ≈ 16 tarys

 HEIGHT OF THE COLUMN:

Height of column is determined by
Hc=(Na−1)Hs+ ∆ H

Where
Hs = tray spacing = 0.45m
∆H = disengagement region = 3.056m
Na = no. of actual trays = 21 trays
So
Hc = 9.18 m

 CROSS SECTIONAL AREA OF COLUMN:

Liquid – vapor flow factor
Lw
Flv= √ ρv / ρL
Vw

where

Lw = liquid mass flow-rate= 24.31 kg/s,

Vw = vapour mass flow-rate =19.17 kg/s.
рv = density of vapors =1.744kg/m3
рL = density of liquid = 846 kg/m3
subsituting values
FLV = 0.05
From graph (fig 9.2) using tray spacing of 0.45 m
K1 = 0.08
As this graph is limited to liquid of surface tension less than or equal to 0.02 N/m
Surface tension of liquid = 0.05 N/m

154
CHAPTER NO. 9 Absorber Design

Corrected K1 = 0.08{0.05/0.02}0.2
= 0.09
Flooding Velocity

Uf =K 1 √( ρL−ρV )/ ρV

subsituting values
Uf = 2.11 m/s
Actual flooding velocity is 80- 85% of this so
Un = 0.8*2.11
= 1.69 m/s

Net column area

mv
An=
Un
where
mv = volumetric flow rate of vapor in m3/sec = 10.5 m3/sec
Un = actual flooding velocity = 1.69 m/sec
Putting values in above equation
An = 6.20 m2
Assuming downcomer occupies 12% of cross sectional area so
Ac = An + Ad
Ac = An + 0.12Ac
Ac = An/0.88
Cross Sectional Area Of Column=Ac = 6.20/0.88 = 7.05 m2

 DIAMETER OF COLUMN:

155
CHAPTER NO. 9 Absorber Design

4 Ac
Dc=
π
Subsituting values
Dc = 2.99 m ≈ 3.0 m

TRAY DESIGN

 LIQUID FLOW ARRANGEMENT:

Liquid flow rate in m3/sec = 4*10-2

From graph (fig 9.3) liquid flow arrangement is selected as double pass.

 ENTRAINMENT:
Using graph (fig 9.4)
% flooding = Un/Uf
= 80%
Then
Ψ = 0.06 (acceptable below 0.1)

 ACTIVE AREA OF PLATE:

Aa = Ac-2Ad

Putting values we get

Active area of plate = Aa = 6.20 m2

 HOLES AREA:
It is rule of thumb that hole area is 10% of that of active area of column.
So
Ah = 6.20 * .10

156
CHAPTER NO. 9 Absorber Design

= 0.620 m2

 HOLE SIZE OR DIAMETER:

typically 5 mm hole size is used
so
Dh = 5mm

 PLATE THICKNESS:
Plate thickness for carbon steel material is 5 mm

 WEIR HEIGHT:

Weir height = hw = 50 mm
 WEIR LENGTH:
Weir height normally used is 77% of column diameter.
So
Weir length = 0.77* 3.0
= 2.30

 PERFORATED AREA:
LW/DC = 0.8
Then From Graph (fig 9.5 )
ѲC = 108
Angle subtended by plate edge strip = 180 – 108
= 72
mean length of un perforated strip = (3.68 * 0.05 ) π *72/180
= 3.75 m
Area of unperforated edge strip = 0.05 * 3.75 =0.01 m2
Mean length of calming zone =(3.68 – 0.05)sin (54) = 2.37 m
Area of calming zone = 2* 2.24* 0.05 = 0.23 m2
Total area of perforations =

157
CHAPTER NO. 9 Absorber Design

(active area-area of unperforated strip –area of calming zone)

=5.96 m2
Ah/Ap = 0.1
Then from graph (fig 9.6)
Lp/Dh = 2.9 (acceptable b/w 2.5 & 4.0)

 NO. OF HOLES:
Area of one hole = π/4 (Dh2)
= 1.96 * 10-5 m2
No. of holes = area of holes / area of one hole
= 1509 holes

 CHECK WEEPING:
maximun liquid rate = 24.31 kg/sec
maximum liquid rate at 70% turn down ratio = 0.7 * 24.31
= 17.017 kg/sec

Where

Lw= weir length, m,

how = weir crest, mm liquid
Lw = liquid flow-rate kg/s

Maximum how = 750 [ 24.31/(846∗2.30) ]

= 39.706 mm of liquid

Minimum how = 750 [ 17.01/(846∗2.30) ]

=31.266 mm of liquid

At minimum rate = hw+how = 81.266 mm liquid

158
CHAPTER NO. 9 Absorber Design

Then from graph (fig 9.7)

K2 = 30.7

minmim design vapor velocity= Uh = 9.34 m/s

actual minimum vapor velocity = 11.8394 m/s

(minimum operating velocity is well above the

weep point)

 PLATE PRESSURE DROP:

Where
∆Pt = total plate pressure drop, Pa(N/m2),
ht = total plate pressure drop, mm liquid

 DRY PLATE DROP:

C0 = 0.84 from fig 9.8 at (Ah/Ap)*100 = 11 & unit plate thickness over hole diameter)

Minimum vapor velocity through holes Uh = volumetric flow rate of vapor/ hole area

= 16.94 m/s

then

hd = 42.62

 RESIDUAL HEAD:
159
CHAPTER NO. 9 Absorber Design

hr = 14.77541 mm of liquid
 TOTAL DROP:

The total plate drop is given by

=147.10 mm liquid

PLATE PRESSURE DROP

∆Pt = 1220.1 N./m2

 DOWNCOMER DESIGN [BACK-UP]:

Hap = hw -10

= 40 mm

Area under apron = Aap= Hap * weir length

Aap = 0.092m2

This is less than Ad so use it as in below equation

where

Lwd = liquid flow rate in downcomer = 24.31kg/s,

Am = Aap =clearance area under the downcomer= 0.092m2

Putting values

hdc = 16.08mm

then backup in downcomer will be

160
CHAPTER NO. 9 Absorber Design

hb = 252.88 mm

= 0.26m

[this is less than 0.5(plate spacing + weir height) so plate spacing is acceptable]

 DOWNCOMER RESIDENCE TIME:

The down comer residence time is given by

Where

tr= residence time (sec)

hbc = clear liquid back-up = 0.26 m

so

residence time in down comer = 7.65 seconds

9.12 COST ESTIMATION

From figure 15-11 and 15-13, given in “Plant Design and Economics for Chemical
Engineers” 5th edition, by Max S. Peters, Klaus D Timmerhaus, following are the cost
estimated for absorption column.

Purchased cost of vertical column without trays = $ 33000

Pressure adjustment factor = 1.6

Material adjustment factor = 1.0

So;

Cost of column without trays = $ 33000*1.6*1

= $ 52800

(See fig 9.9 in appendix)

Purchased cost/ tray = $ 420

161
CHAPTER NO. 9 Absorber Design

Quantity factor = 1.15

No. of trays = 16

So;

Purchased cost of trays = $ 420*17*1.15

= $ 8211

(See figure 9.10 in appendix)

Total purchased cost of distillation column = cost of column + cost of trays

= $ 52800 + $ 8211

= $ 61011

9.13 Specification sheet

162
CHAPTER NO. 9 Absorber Design

Item: gas absorber

Item number: T-100
Type: sieve tray
Operation: continous

Function: absorption of maleicanhydride by 40% maleic acid solution.

Column sppecifications Tray specifications

Liquid flow rate 24.31 kg/s Active area 6.20m2

Vapor flow rate 19.17 kg/s Hole area .620m2

Efficiency 51% Hole size .005m

No. Of actual 16 Plate thickness .005m

stages
Diameter 2.98m Weir height .05m

No. Of holes 1506 Weir length 2.30m

Pressure of 134KPa Calming zone 0.24m2

column area
Height of column 9.75 m Perforated area 5.94m2

Plate spacing 0.45m Pressure drop per 1.2 KPa

plate
Residence time 7 sec

REFERENCES

1. Coulson & Richardson, “Chemical Engineering “ Vol 6, R.K.Sinnott.

163
CHAPTER NO. 9 Absorber Design

2. Max S.Peter Hous D. Timmerhous Ronald. West, “Plant Design & Economics for

Chemical Engineers”, Ed # 5th.

3. Stanley M.Walas, “Chemical Process Equipment, Selection & Design”, Butterworth-

Heiaemamm Series in Chemical Engineer.

4.Carl Branan, “Rule of thumb for Chemical Engineer”, Edition 3rd.

5. Warren L. McCabe, Julian C. Smith, Peter Harriott, “ Unit Operation of Chemical

Engineering”, Edition 5th, McGraw-Hill, Inc.

6- Harry Silla, Chemical Process Engineering Design & Economics, Marcel Dekker,Inc.
2003, United States of America.

7- Ernest Ludwig, Applied Process Design For Chemical And Petrochemical Plants (3rd
Ed),Vol 2.

164