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Table 1.1 Inlet stream of quench tower...6
Table 1.2 Outlet 1 of quench tower.7
Table 1.3 Outlet 2 of quench tower.8
Table 1.4 Summary of chemical engineering design of quench tower.19
Table 1.5 Summary of mechanical engineering calculations27
Spray towers
Venturi scrubbers
Packed towers
Many nozzles are placed across the tower at different heights to spray all of the gas as it
moves up through the tower. The reason for using many nozzles is to maximize the heat
transfer. The liquid droplet must be large enough not to be carried out of the scrubber by the
scrubbed outlet gas.
Advantages of spray tower
many of the scale buildup and plugging problems associated with other scrubbers.
This is an inexpensive and control device primarily used for gas conditioning.
Very little space is required and only that amount of water that is needed to maintain
MASSS
MASS
FLOW,kg/hr
FRACTION
H2 + CH4
542
9%
Ethylene
1630
28%
Propylene
168
3%
Butadiene
39.6
1%
butenes
44.9
1%
C5+
109
2%
N2
83.1
1%
CO2
194
3%
Mixed
H2O
1780
31%
ethane
1060
18%
propane
70.9
1%
butane
9.11
0%
TOTAL
5730
100%
MASSS
MASS
FLOW,kg/hr
FRACTION
H2 + CH4
5.42E+02
14%
Ethylene
1.63E+03
41%
Propylene
1.68E+02
4%
Butadiene
3.96E+01
1%
butenes
4.49E+01
1%
C5+
1.09E+02
3%
N2
8.31E+01
2%
CO2
1.94E+02
5%
ethane
1.06E+03
27%
propane
7.09E+01
2%
butane
9.11E+00
0%
TOTAL
3.95E+03
100%
Mixed
MASSS
MASS
4
NT
FLOW
PERCENTA
kg/hr
GE
WATER
18400
100%
PM
R T
g =
2.3 68.26
0.08206 613
g = 3.73 kg/m3
QG =
Where,
G = gas density = 3.73 kg/m3
G = gas mass flowrate = 1.5 kg/s
QG =
1.5
3.73
= 0.402 m3/s
1.4.3 The ratio of the liquid mass flow rate to the gas mass flow rate is given by
L
G
5.11
1.5
= 3.41
X=
G
L
G ( L
3.73
X = 3.41 ( 1000
0.5
0.5
= 0.208
Flooding curve in quench tower can be accurately described by the polynomial regression
lnYflood = [3.50221+1.028lnX+ 0.11093(lnX)2]
6
(Leva,1954)
Yflood = 0.115
Csflood = (
F p
Y flood
)0.5
(Leva,1954)
Csflood = (
0.115
0.5
27 0.0010.1 ) = 0.092 m/s
VGF
G
0.5
L G
Csflood
(Leva, 1954)
VGF =
3.73
10003.73
0.092
= 1.5 m/s
4 0.402
D = ( 0.7 1.05
(Kister, 1992)
)0.5
= 0.83 m
D = 0.83 m
A=
D
4
A=
(0.83)2
4
= 0.541 m2
1.4.8 The wall factor can be important for columns with an inadequate ratio of effective
particle diameter to inside column diameter, and is given by:
1
=
KW
1+
2
1
(
3
1
dp
) D
1
a
dp = 6(
10.951
112.6
1
=
KW
1+
) = 0.0026110
2
1
(
3
10.951
0.0026110
0.83
1
KW
= 1.043
KW = 0.959
1.4.10 The Reynolds number of the gas can be calculated as
ReG =
v G d p G K W
(1)(G )
ReG =
10
( G)2
G
=
( )3 2 K w
Po
Z = 177.39 Pa/m
Gx =
L
2
(D)
4
Gx =
5.11
2
(0.83)
4
= 9.444 kg/m2.s
11
ReL =
ReL =
Gx
a L
Gx
a L
9.444
112.6 0.001
= 83.87
G x2 a
g
FrL =
G x 112.6
2
100 9.81
FrL = 0.1028
For ReL 5, the ratio of specific areas is given by :
R eL
ah
=0.85 Ch
a
Where, Ch = is a (packing constant) characteristic of the particular type and size of packing
= 0.784. (Wiley and Jaime,1987)
12
ah
=0.85 Ch
a
ah
= 1.606
a
=(
1
3
ah
a
2
3
(Billetand Schultes,1995)
hL
=(
12(1.028)
83.87
1
3
( 1.606 3
= 0.724
h L = 0.724
13
=
( hL ) exp(
PO
R eL
200 (Billet and Schultes)
1.5
P
PO
83.87
200
1.5
= 5.5
= 5.5
= 645.24 Pa/m
HETP =
0.19
0.21
[ ] [ ]
20
0.2
Where,
A = Size of packing
= 50 mm
D = 0.83 m
= Overall viscosity of feed stream = 0.0006 Pa s
3 69.8
HETP = 50 10
20
0.19
( ) (
0.0006
0.2
0.21
HETP 0.0116 m
1.4.17 Number of Transfer Units (NTU)
Number of transfer units is given by;
NTU =
x y
1
ln ( 1 ) 2 1 +
1
x 1 y 1
Where,
= L/HG
= 0.000381
= 1022.22 kmol/h
= 78.74 kmol/h
= 3410Pa/mol fraction
15
= 0.00
NTU = 4.3
NTU = 5
1.4.18 Height of Overall Gas Transfer Unit (HOG)
Height of overall gas transfer unit is given as;
Hog =
1
1
HETP
1
ln
( ( ))
(6)
Hog = 2.01 m
1.4.19 COLUMN HEIGHT
Packing height is calculated as;
Htotal = Hog x NTU
Htotal = 2.01 x 5
Htotal = 10.05 m
Giving 0.457 allowance for disengagement of vapors at top and at bottom for liquid,
Htotal = 10.51 m
Therefore, total height of tower = 10.51 m
16
value
1.05
0.83
117.4
0.724
645
2.01
10.51
Pi =
110
100 233.047 kPa = 256.352 kPa
17
Pi D i
,
2f i - Pi
e=
(Sinnott, 2005b)
Where,
Di is the internal diameter = 0.83 m = 830 mm
e is the minimum thickness required
f is the design stress of stainless steel at 340oC = 100 N/mm2 (Sinnott, 2005c)
Pi is the internal design pressure of the shell = 256.352 kPa = 0.256 N/mm2
0.256 830
(2 100) 0.256
e=
2 mm
C v m g D m H v 0.8D m t
Wv
(Sinnott, 2005e)
18
Where,
CV = factor to account for the weight of nozzles, man ways, internal supports etc, which
can be taken as 1.08 for vessels with few fittings.
Hv = height of the cylindrical section, 10.51 m
g = gravitational acceleration = 9.81 m/s2
t = wall thickness of vessel = 4 mm = 0.004 m
m = density of vessel material (carbon steel) = 8000 kg/m3
Pw
19
(Sinnott, 2005h)
Hence,
0.256 x 830
13.28 N/mm 2
4x4
26.56
N/mm2
WT
D i t t
(Sinnott, 2005i)
20
9988.98
0.953 N / mm2
830 4 4
(Sinnott, 2005j)
11.33 N /mm2
The maximum allowable stress for the material of construction is 100 N/mm 2. Since this
stress is higher than the maximum stress intensity at any point in the material, the design is
not prone to failure under stress.
1.5.11 Vessel Support
The support system designed for a separator and all tall vessels depends on the size, shape,
and weight of the vessel; the design temperature and pressure; the vessel location and
arrangement; and the internal and external fittings and attachments.
A skirt support is used for vertical columns. Its thickness is designed to withstand the deadweight loads and bending moments imposed on it by the separator. (Sinnott, 2005k)
1.5.11.1 Skirt Support Thickness
Data
21
( max )
bs=
4 Ms
( Ds +t s ) t s
ws =
W
( D s +t s ) t s
Where,
bs = bending stress in the skirt
22
s ( compressive )= bs + ws
bs=
4 59241.96 Nm 1 0
( 830+20 ) 830 20
ws (test )=
55785.05 1 03
( 830+ 20 ) 20
ws (operational)=
= 5.35 N/mm2
=1.044 N/mm2
9988 1 03
( 830+ 20 ) 20
= 0.19 N/mm2
^
Maximum s (compressive)= 5.35 + 1.044 = 6.394 N/mm2
^
Maximum s ( tensile ) =5.350.19=5.16 N/mm2
s ( compressive ) <0.125 E
ts
sin s ( Sinnott , 2005 m)
Ds
( )
Where,
fs = maximum allowable design stress for the skirt material, normally taken at ambient
temperature, 20 0C
J = weld joint factor, if applicable = 0.85
s = base angle of a conical skirt, normally 800 to 900
E is the Youngs modulus of steel = 210 kN/mm2 at ambient temperature.
Testing for maximum tensile strength
fsJsins; 5.16 < 0.85 165 sin(90) = 114.75
5.16 < 140.25
Testing for maximum compressive strength
20
( 830
) sin ( 90)=246.
02
24
Parameter
Material
Design pressure, kPa
Design temperature, oC
Vessel thickness, mm
Longitudinal stress, N/mm2
Circumferential stress, N/mm2
Dead weight stress, N/mm2
Dead weight, N
Total longitudinal stresses, N/mm2
Skirt support thickness, mm
Wind Loading, N/m
Maximum stress intensity, N/mm2
Value
Stainless steel 304
256
340
4
13.28
26.56
0.953
9988
14.233
20
1072.64
11.33
25
Table
1.5
Summary of
mechanical
engineering
calculations
REFERENCES
Sinnott, R.K. (2005b) Chemical Engineering Design 4th ed., Laserwords private
limited, Chennai, p:832
Sinnott, R.K. (2005f) Chemical Engineering Design 4th ed., Laserwords private
limited, Chennai, p:853
Sinnott, R.K. (2005g) Chemical Engineering Design 4th ed., Laserwords private
limited, Chennai, p:856
Sinnott, R.K. (2005h) Chemical Engineering Design 4th ed., Laserwords private
limited, Chennai, p:848
Sinnott, R.K. (2005i) Chemical Engineering Design 4th ed., Laserwords private
limited, Chennai, p:849
Sinnott, R.K. (2005j) Chemical Engineering Design 4th ed., Laserwords private
26
Sinnott, R.K. (2005k) Chemical Engineering Design 4th ed., Laserwords private
limited, Chennai, p:861
Sinnott, R.K. (2005l) Chemical Engineering Design 4th ed., Laserwords private
limited, Chennai, p:866
27