Mass Transfer 2 2015

CHEMCAD Seminar
Mass Transfer 2
John Edwards, P&I Design Ltd

January, 2015
www.chemstations.com
MASS TRANSFER ABSORPTION
SESSION OBJECTIVES
Basic Theory
Thermodynamics CO2 Amine System
Carbon capture simulation
Design considerations
SIMULATION
CHEMCAD SUITE
SOFTWARE
www.chemstations.com www.chemcad.co.uk
MASS TRANSFER - ABSORPTION
BASIC THEORY ENHANCEMENT FACTOR
* H x
Henrys Law y m x where m is slope of equilibrium line
PT H=2950 bar for CO2
m G
Stripping Factor CHEMCAD AMINE HG only
L
Transfer Unit relationships HO G HG HL HO L HO G NO L NO G
H
Enhancement Factor E mE reduces influence of liquid film
PT E
SIMULATION
CHEMCAD SUITE
increasing
SOFTWARE E same as increasing P T
mE G
Stripping Factor E
L
1 1 mE 1 1 1

Mass Transfer Coefficients KG k G k L K L m Ek G k L
CASE 8.01 CO2 ABSORPTION IN MEA
Case 8.01 page 291 - 294
SIMULATION
CHEMCAD SUITE
SOFTWARE
CASE 8.01 COLUMN OPERATION
Case 8.01 page 291 - 294
SIMULATION
CHEMCAD SUITE
SOFTWARE
CASE 8.01 PACKED COLUMN SIZING
Case 8.01 page 291 - 294
HTU OV
SIMULATION
CHEMCAD SUITE
SOFTWARE
POST COMBUSTION CO2 / MEA SYSTEM
Case 14.05 page 500 - 502
Cooled flue gas at 100C is fed to an absorber re-circulating 30% MEA solution to absorb CO2
CO2 rich bottoms is fed via a cross heat exchanger for heat integration to a steam stripper
SIMULATION
CHEMCAD SUITE
SOFTWARE
POST COMBUSTION CO2/MEA PARAMETERS
Case 14.05 page 500 - 502
SIMULATION
CHEMCAD SUITE
SOFTWARE
PROCESS REVIEW
Classification
Physical - exploits differences in physical properties
vapor pressure, solubility, molecular geometry, surface activity
Chemical - based on reaction kinetics and interfacial model
Mixture Classification
Homogeneous (V/L/S) - single phase gas or liquids
Air
Miscible Solvents
Heterogeneous (V/L/L/S) - immiscible phases
Liquid + Liquid
Liquid + Gas
Select Separation Process
Physical Absorption Thermal Stripping
SIMULATION
CHEMCAD
Reactive Absorption SUITE
SOFTWARE
Select Separating Agent
Solvent for Absorption
Stripping Method
Design Phases
Conceptual
Detailed
Final validation and release for construction
DESIGN PRINCIPLES
Extent of separation
Number of equilibrium stages, predictable with reasonable confidence
Concept methods - Kremser equation, independent calculation
Rigorous methods - computer simulation, manufacturers software
Time of phase contact
Rate = (Driving Force) / Resistance
Driving Force = Departure from Equilibrium (Post combustion CC small)
Resistance (difficult to predict)
operating conditions: T, P, composition
physical properties of both phases
interfacial reaction mechanism
velocity, flow regime

SIMULATION
Permissible pressure drop
CHEMCAD SUITE
SOFTWARE
Sets column diameter
Energy requirements
Heat
Heating and cooling
Heat of solution effects
Mechanical/Electrical
Prime movers for gas & liquids
DESIGN PROCEDURE
SIMULATION
CHEMCAD SUITE
SOFTWARE
COLUMN DESIGN INTERNALS EFFICIENCY
Tray Column Murphree

Apply efficiency factor to theoretical plate
Obtain actual column profile for desired recovery
Apply safety factor for final number of trays
Nt
Na
Em
Packed Column Height Equivalent of Theoretical Plate (HETP)
Determine theoretical stages for desired separation
Obtain column profile
Multiply by HETP to get total height of packed section
SIMULATION SUITE
H N HETP SOFTWARE
CHEMCAD t
Difficult to predict Murphree or HETP from theory

Depends on contacting device, phase equilibrium, hydraulics
Experimental data and correlations
Vendor information
COLUMN DESIGN CONSIDERATIONS
Column diameter is chosen to provide flexible operation between flooding and weeping.
Typical operating range 60 to 70% of the flooding velocity.
The flooding velocity is determined by correlations.
Approach to flooding is used to get actual superficial velocity based on column diameter.
Minimum velocity to prevent plate weeping and wetting rate for packing
Plate column down-comers take up about 5-20% of column area
Packed columns require height allowance for liquid distribution and redistributors
Weeping Flooding
SIMULATION
CHEMCAD SUITE
SOFTWARE
Liquid weeps at low gas velocity Liquid flow reverses at high velocity
DESIGN TRAY COLUMNS
CHARACTERISTICS
Predictable hydraulic and mass transfer behaviour
Moderate to high pressure drop per tray
Can be scaled to large diameters
Suitable for fouling service
Feed point flexibility is easy
SPECIFICATION
Number of actual stages by applying Murphree plate efficiency
Feed tray location
Type of trays, tray spacing, tray layout
Column diameter
Column height
SIMULATION
CHEMCAD SUITE
SOFTWARE
Feed / Side take-off arrangements / Nozzle sizes
Reboiler / Condenser sizing
COLUMN HEIGHT
Number actual stages x tray spacing + space allowance for feed/draws + sump + top volume
Tray spacing for most applications is 18-24 inches
Rule of thumb could be to add 1- 2 nozzle diameters to the total height for feeds and draws
Sumps sized on liquid residence time. Two to five minutes is reasonable.
DESIGN PACKED COLUMNS
CHARACTERISTICS
Low pressure drop / smaller diameter / Feed point fixed
Random packing scale-up for HETP is difficult; structured packing scale-up is
predictable
HETP prediction less well developed than for trays
Low to moderate cost for random packing; high cost for structured packing
Not suitable for fouling service
SPECIFICATION
Type of packing
Random packing
Structured packing
SIMULATION
Trade-off pressure drop vs. HETP vs. cost
CHEMCAD SOFTWARE SUITE
Column diameter height of packing feeds and off-takes
PACKED HEIGHT
HETP Replaces Tray Efficiency
Bed Height = No of Theoretical Stages x HETP
HETP is difficult to generalize and is a function of the type of packing, the system
being separated and the hydraulics of the column. Experimental or vendor-supplied
values are used.
MASS TRANSFER SOLVENT EXTRACTION
COLUMN STAGE SENSITIVITY
Case Extraction Column
SIMULATION
CHEMCAD SUITE
SOFTWARE
Controller used to keep solvent feed at number of stages
MASS TRANSFER SOLVENT EXTRACTION
SENSITIVITY STUDY
Case Extraction Column
SIMULATION
CHEMCAD SUITE
SOFTWARE
DESIGN HEURISTICS
Air / Gas Movers Pressure Rises

Fans 12 in wg, blowers < 40 psig compressors > 40 psig
Compressors:
Reciprocating compressors:
Efficiencies 65% at compression ratio of 1.5, 75% at 2.0 and 80-85% at 3-6
SIMULATION
CHEMCAD SUITE
SOFTWARE
Efficiencies of large centrifugal compressors 76-78% and rotary compressors 70%.
Centrifugal pumps:
Single stage for 15-5000 gpm, 500 ft max head;
Multistage for 20 11,000 gpm, 5500 ft max head.
Efficiencies 45% at 100 gpm, 70% at 100 gpm and 80% at 10,000 gpm.

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CHEMCAD Seminar

John Edwards, P&I Design Ltd

Transfer Unit relationships HO G HG HL HO L HO G NO L NO G

Tray Column Murphree

Difficult to predict Murphree or HETP from theory

Controller used to keep solvent feed at number of stages

Air / Gas Movers Pressure Rises

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