-ABSTRACT

This project on packed absorption column was designed to remove 95

percent of ammonia from a gaseous mixture of 8% ammonia and 92% air by
volume. The flow rate of the gaseous mixture entering the tower at 293k and
1.013 x 105 N/m2 is 2.5kmol/hr. pure water, flowing at the rate of 30% above
the minimum, is used as solvent. While One inch ceramics Berl saddle was
used as the packing materials.

The aim is to determine the total height, the diameter, and costing of the
tower.

The design was successful using carbon molybdenum steel (SA – 135 Grade
B) as materials of construction with thickness and hemispherical head of
6.25mm

The tower height was estimated to be 1.922m, with diameter of 0.1405m

and the column operating at 293k and 1atm costs approximately N380000.
TABLE OF CONTENTS

APPROVAL/CERTIFICATION

DEDICATION

ACKNOWLEDGMENTS

ABSTRACT

TABLE OF CONTENTS

LIST OF TABLES

LIST OF FIGURES

CHAPTER ONE

INTRODUCTION

1.1 application of gas absorption work

1.2 Aims and objectives of the design

CHAPTER TWO

LITERATURE REVIEW

2.1 Packed absorption tower

2.2 System efficiencies and performance

2.3 Absorber system configuration

2.4 Process description

2.5 Types of absorber equipment

2.6 plate or Tray tower

2.7 Venturi scrubbers

2.8 Spray tower

2.9 Welted wall tower

2.10 Packed tower internals

2.11 A liquid distributor

2.12 Packing materials

2.13 Supporting plates

2.14 A packed restrainer

2.15 Tower shell

2.16 Packed tower

2.17 Random packing

2.18 Regular packings

2.19 Choice of solvent for absorption

2.20 Types of solvent for gas absorption

2.21 – 2.25 Ammonia; properties, uses an health effect

CHAPTER THREE

DESIGN PROCEDURES

3.1 Equilibrium data

3.2 Determination of gas and liquid stream property

3.3 Physical properties

3.4 Determination of absorption factor

3.5 Column (Tower) diameter

3.6 Determination of tower height

3.7 Mechanical design

3.8 Costing of the tower

CHAPTER FOUR

RESULTS ANALYSIS, DISCUSSION, CONCLUSION AND RECOMMENDATION

4.1 Results analysis

4.2 Discussion, concision and recommendation

REFERENCES

APPENDIX 1

APPENDIX 2

APPENDIX 3

APPENDIX 4

APPENDIX 5

Nomenclature

LIST OF TABLES

Table 1

Table 1.1, Equilibrium data

Table 1.1 Equilibrium solubility data for NH3 in air

Fig. 2.1 A schematic diagram of packed tower

Fig 2.6 A sketch of tray tower

Fig. 2.7 A sketch of venture scrubber

Fig. 2.9 A sketch of wetted wall tower

Fig. 2.11 A sketch of inadequate and adequate distributor

Fig. 2.17 various sketch of packing materials

Fig. (A-1) A Schematic diagram of packed absorber

Fig. (D -1) Single V Buff joint with 600C level and roof opening Of 1/16 inch

Fig. (D-2) A Sketch of packed absorption tower

Fig. (D-3) A sketch of the hemispherical Head.

CHAPTER ONE

INTRODUCTION

Packed column (tower) is an equipment used for gas absorption and

other operations. It is a cylindrical column with a gas inlet and distributing
space at the bottom, liquid inlet and distribution at the top. It consists of
liquid and gas exists at bottom and top respectively.

Packing tower is used for gas absorption operation in which a gaseous

mixture is allowed to contact with the liquid in a counter-current manner for
the intention of preferentially dissolving one or more component from the
gas to form a solution of them in the liquid. The liquid which consist of pure
solvent is pumped into the column at the top and flows downward.

The gaseous mixture is pumped into the tower at the bottom and flow
upward through the space in the packing. It flows counter currently to the
flow of the liquid. The arrangements of the packings provide a large surface
for contact between the liquid and the gas which help the contact between
the two phases. The solute in the gas mixture is absorbed by the two phases.
The solute in the gas mixture is absorbed by the fresh liquid flowing down
while the dilute gas or lean gas leaves at the top of the tower. The liquid is
enriched with the solute gas it flows down the tower and concentrated liquid
called strong liquid leaves at the bottom of the tower through the liquid exit.

The project is required to design a packed column which will remove

95% of ammonia from the gaseous mixture of 8% and 92% air by volume.
The flow at 293k and 1.013 x 105 N/m2 is 2.5kmol/hr and pure water flowing
at the rate of 30% above the minimum is required to be used as solvent
while 1 inch ceramic Berl Saddle would serve as the packing materials.

The design parameters will be solved for by applying liquid and gas
condition along with the associated physical properties to estimate the
diameter of the tower and height of the packing required. The tower
mechanical design would be based on the diameter while the overall costing
will be the function of the overall height and material of the constructions of
the tower.

APPLICATION OF GAS ABSORPTION

Gas absorption is applied for the separation and purification of dirty air.
Gas absorption is the removal of gases from the air by a liquid. The
undesirable gas dissolves in the scrubbing liquid while other gasses do not,
the pollutants gas can be scrubbed out. The most efficient gas scrubber is
the packed tower, which is also used for capturing particulates. The packings
material, supported by plates or screens, provides many channels for the air
and scrubbing liquid to come into close contact. The packing materials used
are ceramic or plastic pieces, wood slates, stones, marble ping pong ball.

Gas absorber is an instrument used widely in industry for separation

and cleanliness of gaseous mixture as product recovery device. It is used for
pollution abatement on gas streams which have a pollutant concentration
ranging from 250- 10,000ppmv. It can be apply for removal of water solution
of inorganic contaminant from air stream.

AIMS AND OBJECTIVES OF THE DESIGN

The objective of the design of the packed tower is to remove 95% of

ammonia from a gaseous mixture of 8% and 92% air by volume. This has a
flow rate at 293k and 1.013 x 105N/m2 as 2.5kmol/hr. The solvent is pure
water and 1inch ceramic Berl saddle is used while the liquid flow at 30
percent above the minimum. It is required to determine the following:

Equilibrium data

Diameter of the column

The material balance of the column

Height of the column

The mechanical design of the column

The cost of the tower

The design drawing of the column.

CHAPTER TWO

LITERATURE

2.1 PACKED ABSORPTION TOWER

Absorption is the act by which one or more components of a gaseous

mixture are dissolved in a liquid (that is, a solvent). The gas exits as by-
product of coke oven when washed with water to remove NH3, and also with
oil to remove benzene and toluene vapors. When mass transfer occurs from
the liquid to the gas, the operation is called “adsorption” or “stripping”. For
instance, benzene and toluene are removed from the absorption oil by
contacting the liquid solution with steam. If the gas steam enters the liquid in
the absorption tower, it is called “absorption”. The operations are used only
for solute recovery or solute removal. The absorption process can be
classified into two ways, such as physical and chemical absorption in the
solvent. Chemical absorption occurs when the components and the solvent
are chemically combined together. The fluid (liquid) commonly used as
solvent include water, mineral oil, and aqueous solution etc.

Gas absorbers is the apparatus used widely in industry for separation

and purification of gaseous mixtures as product recovery devices. This
chapter focuses on the use of absorption for pollution abatement on gas
streams which have a pollutant concentrations ranging from 250 to
10,000ppmv. Gas absorbers are commonly used to remove water solution of
inorganic contaminant from air stream.
Fig. 2.1 Packed Tower

2.2 SYSTEM EFFICIENCIES AND PERFORMANCE

The efficiency of gas absorber depends on the type of pollutant solvent

system and also based on the gas absorber used. Most absorbers have
removal efficiencies in excess of 90% while packed tower absorbers in some
solvent system achieve efficiencies as high as 99.9%.

The acceptable gas absorption for pollution abatement method is justified by

the following factors

- Desired removal efficiency

- Pollutant concentration in the inlet vapor

- Capacity required for controlling waste gas

- Recovery value of the solute.

Physical absorption is used on properties of the gas stream and

solvent, such as viscosity and density as well as specific characteristics of
the pollutant in the gas and the liquid stream (e.g. equilibrium solubility,
diffusivity). These parameters are based on temperature, and lower
temperature generally favor absorption of gases by the solvent.

Absorption is facilitated by larger contacting surface, higher liquid gas

ratios, and greater concentrations in the gas stream.

The considered solvent to remove the pollutant(s) should have a higher

solubility for the gas, must have low vapor pressure, low viscosity, and
should be relatively inexpensive.

The most common solvent is water, to remove inorganic contaminant,

and also used to absorb organic compounds having relatively high water
solubility. Some organic compound that have low water solubility, solvent
such as hydrocarbon oil are used, through only industries where large
quantities of these oil are available (e.g. petroleum refineries sand
petrochemical plants).

Solute removal can also be facilitated by forming the chemistry of the

absorbing solution to react with the pollutant (e.g. caustic solution for acid-
gas absorption versus pure water sued as solvent). Chemical absorption may
be limited by the range of reaction, although the rate limiting step is
typically the physical absorption rate then the chemical reaction rate.

2.3 ABSORBER SYSTEM CONFIGURATION

The flow of gas and liquid in the absorber may be counter current,
concurrent or cross-current. The most usefully installed designs are counter-
current, where the waste gas stream flow is at the bottom of absorber tower
and exit at the top. The solvent stream flows in, at the top and exit at the
bottom. Counter current design provide the highest theoretical removal
efficiency, due to the gas with the lowest pollutant concentration contact
liquid with the lowest pollutant concentration in the column. His increases
the average driving force for absorption through the column (Mc Innes et al
1990).

Sometime, counter current designs usually required lower liquid to gas

ratios than concurrent and very suitable when the pollutant loading is higher
(Josel, 1992).

For cross current, the waste gas flows horizontally across the column
while the solvent flows vertically down the column. Cross current design
have lower pressure drop and required lower liquid to gas ratios than
concurrent and counter current design. They are mainly used when gases
are highly suitable, since they offer less contact time for absorption (Mc
Innes et al, 1990).

For concurrent tower, the waste gas and the solvent flow sin at the
bottom. Concurrent design have lower pressure drops, are not subject to
flooding limitation and more efficient for the (that is submicron) mist
removal. Concurrent designs are efficient where large absorption driven
forces are available. The removal efficiency reduces since the gas-liquid
system approaches equilibrium at the bottom of the column (Mc Innes et al,
1990).

2.4 PROCESS DESCRIPTION

Gas absorption is a mass transfer operation in which one or more

component of the gaseous mixture are dissolved in a liquid that has lower
volatility under the process condition. The solute diffuses from the gaseous
phase into the liquid phase; when the liquid state is below the equilibrium
concentrations while the equilibrium. Concentration supply the driving force
fro absorption. A well designed a gas absorber will provide large contact
between the gas and the solvent in order to facilitate diffusion of the
pollutant(s). It performs much better than a poorly designed absorber
(Raymond, 1992).

The rate of mass transfer between two phases is largely based on the
surface are and period of contact. the factor guiding the absorption rate,
such as solubility of the gas in a particular solvent and the degree of the
chemical reaction are characteristics of the constituent involved and
relatively base don’t eh apparatus used.

2.5 TYPES OF ABSORBER EQUIPMENT

Absorbers are classified based on absorption principles which include

packed tower, spray lower, venture scrubbers, tray (plate) columns and
wetted wall tower.

This chapter focuses more on packed tower or column, which is the

given design and the most commonly used gas absorber for pollution
abatement. Packed absorption tower are column filled with packing material
which provide enough surface area to facilitate the contact between the
liquid and gas. Packed with higher liquid range, and water consumption is
low compared to other type of gas absorbers. Packed column may have high
system pressure drops, high clogging and fouling potential and extensive
maintenance cost, as a result of the presence of packing material.
Installation operation and waste water disposal cost are higher for packed
bed absorber that for other absorbers. In addition to pump and fan power
requirement and solvent cost, packed tower have operating cost associated
with replacing damage packing (Mc Innes et al, 1990).

2.6 PLATE OR TRAY TOWER

Tray tower are vertical cylinder in which the liquid and gas are
contacted in stage wise fashion on tray (plate). Liquid enter at the top of the
column and flow through a down spout (down corner) to plate, below. Gs
moves upwards though openings in the plate, bubbles into the liquid, and
passes to the plate above. They are easier to clean and tend to handle
substantial temperature fluctuation properly than packed lower do. However,
at high gas flow rate plate tower exhibit larger pressure drops and have
larger liquid holdup. Plate tower are generally made of materials such as
stainless steel. This make sit to withstand the force of liquid on the plate and
facilitate corrosion protection. Packed tower are considered better when acid
and other design can be of fiberglass, polyvinylchloride, or other less cost
corrosive resistant materials. Packed tower are preferred to column smaller
than two feet in diameter and when pressure drop in important consideration
(Perry, 1984).

Fig. 2.6: A socket of tray tower

2.7 VENTURI SCRUBBERS

Venture scrubbers are generally applied for controlling a particular

matter and sulfur dioxide. They are designs for application of submicron
particle of range 0.5 - 5.0 micrometers in diameter (Treybal 1980). Venturi
scrubber employs a gradually converging and then diverging section called
the throat as shown in the diagram below, to clean the inflow gas stream.
Liquid is introduced to the venture upstream of the throat. It can be infected
directly into the throat where it is atomized by the gaseous stream. If liquid
is atomized, it dissolves particles from the venture. The high pressure drop
through this system result in high energy used, and relatively short gas liquid
contact time restricts their application to highly soluble gases. Therefore,
they are frequently employed for control of volatile organic compound
emission in dilute concentration (Mc Innes et al, 1990).

Fig. 2.7: Venturi scrubber

2.8 SPRAY TOWER

Spray tower works by delivering a liquid droplet through a spray

distribution system. The droplet fall through a counter current gas stream
under influence of gravity and contact the pollutant(s) in the gas (Perry and
Chillon, 1984). Spray towers are simple to operate and maintain, it have
relatively low energy requirement. However, they have the least effective
mass transfer capacity of absorbers described and they are usually restricted
to particulate removal and control of highly soluble and ammonia. They need
high water recirculation rate and are inefficient at removing small particle
(Jack, 1992).

2.9 WETTED WALL TOWER

A thin film of liquid running down the inside of a vertical pipe, with gas
flowing either concurrently or counter currently, constitute a wetted wall
tower. A flow of liquids through soluble pipe, a volatile pure liquid is
permitted to flow down the inside surface of permitted to flow down the
inside surface of a circular pipe while a gas is blown upward or downward
through the central core. Industrially, they have been used as absorber for
hydrochloric acid, where absorption involves a large evolution of heat. The
wetted wall tower is surrounded by a rapidly flowing of cooling water. Gas
pressure drop is lower than any other gas liquid contacting design.
Fig. 2.9: A sketch of a wetted wall tower

2.10 PACKED TOWER INTERNALS

A packed absorption tower is made up of column shell, mist eliminator,

liquid distributor packing support. Corrosion resistant alloy or plastic material
such as polypropylene are required for column internals when highly
corrosive solvent or gases are used. The absorption tower packing is more
expensive than design of one section (Kack, 1992).

The tower shell may be made of plastic or steel or a combination of

these materials depending on the corrosiveness of the gas and liquid
streams, and the process operating considerations. The shell is sometimes
lined with a protective membrane often made from a corrosion resistant
polymer. For absorption involving acid gases, an interior layer of acid
resistant brick provide additional chemical and temperature resistance
(Crowe and Cooper, 1988).

At high gas velocities, the gas existing in the top of the column may
carry off droplets of liquid as a mist. To prevent this, eliminator in the form of
corrugated sheets or layer of mesh and be installed at the top of the column
to collect the liquid droplets which coalesce and fall back into the lower.
2.11 A LIQUID DISTRIBUTOR

A distributor is designed to distribute the liquid evenly at the surface of

the packings to facilitate the uniform contact of the liquid and the gaseous
mixture in the tower. The liquid distributor must spread the liquid uniformly,
resist plugging and fouling, provide free space for gas flow and permit
operational flexibility. A substantial lower have re-distributor which divert the
movement of liquid from the wall shell to the center of the tower for proper
spreading of the liquid and enhance contact in the lower section of the
packing. Redistributors are incorporated with tower of 8-20 feet of random
packing depth (Coker, 1991).

Fig. 2.11: (A) (B)

INADEQUATE ADEQAUTE

DISTRIBUTOR DISTRIBUTOR

2.12 PACKING MATERIALS

Packing materials provide a large wetted surface for the gas stream
maximizing the area available fro mass transfer operation. Packing materials
are available in variety of forms each having specific characteristics with
respect to surface area, pressure drop, weight, corrosion resistance, and
cost. Packing life varies, depending on the application. In ideal circumstance,
packing will last as long as the tower itself in adverse environments, parking
life may be as short as 1-5 years due to corrosion, fouling and brakeage (Roy
1992).

2.13 SUPPORTING PLATES

To ensure the waste is properly distributed, an open space between

the bottom of the tower and the packing is necessary. The support plates
hold the parking above the open space. The support plate must be strong
enough to carry the weight of the ceramic Berl Saddle (packings) to allow the
gas and solvent flow with minimum restriction (Trey Bal 1980).

2.14 PACKED RESTRAINER

The packings are fluidized at high velocities son top of a bed. The
packings may be emitted to the distributor, become unevenly, or be damage
(Harrison and John, 1989). A parked restrainer may be installed at the
packing. To avoid the restrainer from being dislocated, it should be secured
at the wall and also not to “float”, unattached weight plate may be placed on
top of the packings so that it can settle with the bed. The later is often used
for fragile ceramic packings.

2.15 TOWER SHELL

The tower shell may be metal, wood, chemical stone ware, acid, proof
brick, glass, plastic or glass linked metal or other material depending on the
corrosion condition. They are usually circular in cross section for ease of
construction and strength.

2.16 PACKED TOWER

Packed tower, which is applied continuous contact of liquid and gas in

both concurrent and counter current flow, are vertical, column that have
been filed with packing of large surfaces. Packings are of two major types
such as random and regular packing.

2.17 RANDOM PACKINGS

This is a packing dumped into the tower during the time of installation
and deposited at random. Sometimes ago materials as broken stone, gravel
or lumps of coke were used and are not expensive. They are not needed for
small surface and poor fluid flow. The random packing is produced and
effective. The common types are Rashing ring, which have the hollow
cylinders with diameter ranging from 6 – 100mm (1/4 to 4 inch0 or more. It
can be made of chemical stone ware or porcelain for contacting of most
liquid except alkaline and hydrofluoric acid, of carbon which is useful except
in strongly oxidizing atmosphere; of metals; or plastics. Plastics should be
chosen, since they may deteriorate rapidly with certain organic solvents. The
plastic offers the advantage of lightness in weight. The Lessing rings and
others with internal partition are frequently used. Berl and intalox saddles
and variant of them are available in size from 6-75mm (1/4 to 3 inch) made
of chemical stone were or plastic. Pall rings which are called “Flexi ring”,
cascade rings, hy-pack is available in metal and plastic. They offer large
specific surface (and large gas pressure drop) in the small size and cost less
per unit volume in larger sizes. To avid breakage during pouring, water is
first filled in the tower before releasing the packing.
(A) Rashing Ring (b) Lessing Ring

(c) Partition Ring (d) Metal

(e) Ceramics

2.18 REGULAR PACKINGS

The regular packing have the advantages of lower pressure drop for
gas and greater possible fluid flow rates, usually at the expense of more
costly installation than random packing. Stacked Rashing rings are
economically practical only in very large sizes. A lot of medication of the
expanded metal packings. Wood grids, or hurdles re inexpensive and
frequently adopted where large void volume are required as in thecae of far-
bearing gases from coke oven or liquid that carry solid particles.

2.19 CHOICE OF SOLVENT FOR ABSORPTION

The choice of solvent for absorption is very significant in the process

industries. The solvent is specified by the nature of the product. If the
principal purpose is to remove some constituent from the gas, some choices
are considered. They are:

GAS SOLUBILITY: The gas solubility should be high, thus increasing the rate
of absorption and decreasing the quantity of solvent required. Generally,
solvent of a chemical nature similar to that of the solute to be absorbed will
provide good solubility. Thus, hydrocarbon oils are used to remove benzene
from coke oven gas. For some cases, where the solution formed is ideal, the
solubility of the gas is the same in terms of model fraction for all solvent. A
chemical reaction of solvent with the solute will frequently result in very high
gas solubility but if the solvent is to be recovered for reuse, the reaction
must be reversible.

VOLATILITY: The solvent should have a low vapor pressure, since the gas
leaving an absorption operation is ordinarily saturated with the solvent and
much may be lost. If necessary, a second less volatile liquid can be use to
recover the evaporated portion of the first,

CORROSIVENESS: the solvent chosen must not corrode the absorption lower
or introduce any act of pollutant to the mixture to be separated.

COST: The solvent should be inexpensive, so that losses are not costly and
should be readily available.

VISCOSITY: low viscosity is preferred for reason of raid absorption rates,

improved flooding characteristics in absorption towers. Low pressure drops
on pumping and good heat transfer characteristics.

Miscellaneous: The solvent should not be toxic, flammable and chemical

unstable and have a low freezing point.

2.20 TYPES OF SOLVENT FOR GAS ABSORPTION

WATER: Is often used to absorb ammonia.

CAUSTIC SODA: Is often employed to absorb hydrogen sulphide

ETHANOLAMINE SOLUTION: Is some time employed to remove hydrogen

sulphide also

HYDROCARBON OILS: Is also used to remove benzene from the coke-oven

gas.

2.21 AMMONIA-PROPERTIES, SUES AND HEALTH EFFECTS

Ammonia is largely produced for commercially by the use of Haber-

Bosech process, which is also sometime referred to as the Harber-Ammonia
process or synthetic ammonia process. First Haber, the German physical
chemist, created the process in 1909, and it was further developed by Carl
Bosch to make it economically viable.

The production of ammonia is achieved by the direct combination of

hydrogen and nitrogen over an iron or aluminum catalyst. Hydrogen is
obtained from the decomposition of methane by heating. Nitrogen is
obtained from the distillation of liquefied air. It was the first chemical process
to use high pressure conditions. The reaction is shown below.

N2 (g) + 3H2 (g) > 2NH3 (g)

The process is highly exothermic with a ΔH value of 92.2kgt per mol. The
solubility of ammonia at 200C and 1alm is given by Henry’s law. That is

P = HX

Where, P is the partial pressure

H is the Henry’s constant

X is the mass function

The solubility has been found experimentally to be 33.1% (w.w)

2.22 PROPERTIES OF AMMONIA

The physical properties of ammonia include;

Ammonia is the most soluble gas. That is why it cannot be collected over
water. The solubility can be demonstrated with the fountain experiment.

Anhydrous ammonia gas is considerably lighter than air and will rise in dry
air.

Liquid and gas ammonia expand and contract with change sin pressure and
temperature

Anhydrous ammonia is a clear liquid boils at a temperature of 280f.

Ammonia is a colorless gas with a choking smell.

2.23 CHEMICAL PROPERTIES OF AMMONIA

Anhydrous ammonia is an alkali.

Anhydrous ammonia is easily absorbed by water.

Anhydrous ammonia is non flammable

Anhydrous ammonia in the presence of moisture reacts and corrodes copper,

zinc, and many other alloys.

2.24 USES OF AMMONIA

Ammonia is used as a fertilizer, which improves the growth and

productiveness of plant by enhancing the fertility of the soil.

Ammonia is also found in household detergent and cleaner sand for pH

control.

In the solvent process: it is one of the most important compounds for

manufacture of washing soda.

Ammonia is used as a refrigerant, since it is easily liquefied by compression

and when heated back into its gas page, absorbers much heat.

Ammonia is also used in the manufacture of nylon; the dying of cotton wool
and silk,

Ammonia is used for the production of paint.

2.25 HEALTH EFFECT

Ammonia has some detrimental effect to some part of human body.

Small concentration of ammonia in the air causes initiating to the eyes,
throat, and breathing passages. The anhydrous ammonia primary affects the
lungs, skin and eyes.
CHAPTER THREE

DESIGN PROCEDURES

The design of packed tower absorber for purification of gaseous

mixture pollutant and air depend son knowledge of the following
characteristics:

Required removal efficiency

Waste gas flow rate

Waste gas composition and concentration of gas streams.

Equilibrium relationship between the pollutant and solvent, and

Properties of the pollutant(s) waste gas and solvent, diffusivity, viscosity,

density and molecular weight.

Packed absorption tower (column) is design to determine the parameters

below:

To find the equilibrium data

The material balance

The diameter of the lower

To calculate the height of packing

The mechanical design calculation

To find the costing of the packed absorption tower.

3.1 EQUILIBRIUM DATA

Table 1: Equilibrium data

S/N Mass of NH3/mass NH3 partial pressure (NH3)

of H20 mmHg

1 100.0 -

2 90.0 -

3 80.0 1450

4 70.0 1170

5 60.0 945.0

6 50.0 686.0

7 40.0 470.0

8 30.0 298.0

9 25.0 227.0

10 20.0 166.0

11 15.0 114.0

12 10.0 69.6
13 7.5 50.0

14 5.0 31.7

15 4 24.9

16 3 18.2

17 2 12.0

1 -

3.2 DETERMINATIONS OF GAS AND LIQUID STREAM PROPERTY

Gas absorption column is designed on the ratio of liquid togas entering

the column (Ls /Gs) which is the slope of the equilibrium curve (M). All these
parameters are calculated from the inlet and outlet gas and liquid streams
variables.

Wastes gas flow rate, actual meter cube per minute (m3/min) entering and
exiting column (G1 and G2 respectively).

Pollutant concentration (1kg mole pollutant/kg mol of pollutant free gas)

entering and exiting the column in the waste (Y1 and Y2 respectively).

Solvent flow rate entering and exiting the column (L1 and L2) respectively
and

Pollutant concentration entering and exiting the column in the solvent (X1
and X2).

Then the exit pollutant concentration

Y2 = Y1 (1- ŋ/100) ……………………………………………………… (3.2.1)

The liquid flow rate entering the absorber, 1, is then calculated using a
graphical method. The equilibrium curve indicates that relationship between
the concentration of pollutant in the waste gas and the concentration of
pollutant in the solvent at a specified temperature and pressure. The slope of
the operating line intersecting the equilibrium curve is the minimum L/G ratio
on moles of pollutant free gas basis Gs.

The slope is calculated using

Slope (m) = Ls /Gs= ΔY/ ΔX = (Y2 –Y1)/ (X2 – X1)………………………..(3.2)

The value of X2 is taken from the equilibrium curve.

To calculate the actual L/G ratio

Ls /Gs= Ls/Gs x (adjustment factor)

To estimate Gs

Gs = G1 (1-Y1) ………………………………………………………… (3.2.3)

Where G1 = Gas flow rate

The variables Ls

Ls (min) = Gs (Y1 – Y2) ……………………………………………….(3.2.4)

X1(min) – X2

Ls (actual) = 1.3 Ls (min) ………………………………………………… (3.2.5)

The total molar flow rate of the gas and liquid entering the absorber (G2 and
L2) are evaluated using the following equation.

Gs = Gs or G2 = Gs (1+Y2) ………………………………………… (3.2.6)

1-Y2

L2 = Ls or L2 = Ls (1 + X2) ………………………………………… (3.2.7)

1-x2
3.3 PHYSICAL PROPERTIES

The physical properties are gas density, surface tension, of the mature

Gas density (ρG)

ρG = P.M (axg) ………………………………………………………….(3.3.1)

RT

Surface tension (σ)

σ= Pch (ρ1 - ρv) 4 x 10-12 ………………………………………………..(3.3.2)

3.4 MATERIAL BALANCE

G1 + L2 = G2 + L1 ………………………………………………………(3.4.1)

3.5 DETERMINATION OF ABSORPTION FACTOR

The absorption factor (AF) value is frequently used to describe the

relationship between the equilibrium lien and liquid t gas ratio.

AF = L. mol, i …………………………………………………………………. (3.5.1)

M. Gmol, i

M = ΔY = Y2 – Y1 ………………………………………………………….(3.5.2)

ΔX = X2 – X1
 Where Y2 and Y1 are the mole fractions of the pollutants in the vapor
phase in equilibrium with mole fraction of the absorber in the liquid X1 and X2
respectively.

X1 = X1 …………………………………………………… (3.5.3)

1+X1

X2 = X2 …………………………………………………….. (3.5.4)

1 + X2

Y1 = Y1 ……………………………………………………... (3.5.5)

1+Y1

Y2 = Y2 ……………………………………………….. (3.5.6)

1+Y2

The absorption factor is used to evaluate the theoretical number or

transfer unit and the theoretical height of a transfer unit.

3.6 COLUMN (TOWER) DIAMETER

From Eckert’s modification to the generalized correlation for randomly

packed lower, the abscissa value (X-axis) in the graph is

Abscissa = L’ (ρG) 1/2 ………………………………………………. (3.6.1)

G’ (ρL-ρG)
The ordinate value (Y-axis) in the graph is expressed as

Ordinate = G2sfr, 1CFµl0.1J ……………………………………… (3.6.2)

ρG (ρL - ρG) gc

Where Cf = correlation factor

µL = Ratio of the density of the scrubbing liquid.

But

G2sfr, I = Ordinate ρG (ρL - ρG) ……………………………… (3.6.3)

Cfµi 0.1J

The cross sectional area of the tower

A = Gmi …………………………………………….. (3.6.4)

Gsfr, i

Then, the diameter of the column

D = 4A …………………………………………………………. (3.6.5)

3.7 DETERMINATION OF TOWER HEIGHT

The tower height is primarily a function of packing depth. The required depth
of packing (H pack) is determined from the theoretical number of overall
transfer unit (N10G) needed to achieve a height of the overall transfer unit
(HtoG)

H pack = NtoG HtoG

For NtoG
NtoG = in ………………… (3.7.1)

For HtoG

HtoG = HtG = Htl ………………………………………………….. (3.7.2)

AF

To estimate HtG and HtL

HtoG = G ………………………………………………………….. (3.7.3)

FGα

HIL = L ……………………………………………………………… (3.7.4)

FLα

α = α Aw QLO …………………………………………… (3.7.5)

QLow

Overall total height of the column

Htower = 1.40 Hpack + 1.02 (D) + 2.81 …………………….. (3.7.6)

3.7 Mechanical design

Estimation of wall thickness(tm)

tm = PR+ CA …………………………………… (3.8.1)

SE – 0.6P

Where tm = wall thickness of the tower

P = design pressure

S = stress value
 R = radius of the tower

E = welded joint factor

CA = Corrosion allowance

Hemispherical head (t)

t= PR + CA …………………………………………(3.8.2)

2SE – 0.2p

3.9 COSTING OF THE TOWER

Installed equipment cost = installed equipment cost x overall height in feet

For molybdenum steel, the relative cost is

Cost of carbon molybdenum steel = 1.065

Cost of carbon steel

Installed cost for carbon molybdenum = 1.065 x Cost of carbon steel..(3.9.2

Using cost index method. Installed cost for 2010 = Cost index for 2010 /cost
index for 2000………………… (3.9.2)
CHAPTER FOUR

RESULT ANALYSIS, DISCUSSION, CONCLUSION AND RECOMMENDATION

4.1 RESULT ANALYSIS

The successful design drawing has been sketched, based on the value
obtained from the parameters calculated and attached at the back cover of
this report. The qualitative and quantities material flow is illustrated in
chapter two (literature review) of this report. The flowing of material in and
out, tower diameter, the packing height, the total height of the tower, the
mechanical design and the installed equipment cost, are calculated in the
appendices and the following values were obtained:

A. Material flow in and out

Gas in (G1) = 0.000694kmol/sec

Gas out (G2) = 0.000641kmol/sec

Air in (Gs) = 0.0006385kmol/sec

Liquid in (L2) = 0.001306097kmol/sec

Liquid out (L1) = 0.001359kmol/sec

 NH3 removed = 0.000897kg/sec

B. Diameter of the tower (D) =0.1405m

D. Height of the packing =0.6589m

D. overall Height (Htower) =1.9223m

E. The construction material used is carbon molybdenum steel

(SA – 135) Grad B

ii. Corrosion allowance (C) = 4mm

iii. Wall thickness (lm) = 6.25mm

IV Hemispherical head (f) = 6.25mm

F. installed equipment cost = N, 380,000

4.2 DISCUSSION, CONCLUSION AND RECOMMENDATION

The required design of a packed absorption tower to remove 95% of

ammonia (NH3) from a gaseous mixture of 8% NH3 and 92% air by volume
has been completed. The rate of the solvent (water) required was found to
be 0.001306097kmol/sec. While the diameter of the tower or column was
calculated to be 0.1405m and the height of the towers packings is 1.9223m.
Their values in ft are 0.460958ft and 6.3067585ft respectively.

The material used for the construction from American society of

mechanical engineering (ASME) is carbon molybdenum steel (SA – 135 Grade
B); has been recommended as the material of construction. Comparing the
cost and high corrosion allowance of 4mm is recommended. According to the
recommendation, the joints of the equipment should be totally radio
graphed.

The designed equipment will meet up the required specification, if all

the condition recommended are put into consideration and adhered to
properly during design and operation of the tower.

REFERENCES

1. Coullson and Richardson (1973) “Chemical Engineering Design:

Vol. 6, Perganon Press Oxford, page 294.

2. Control technologies for hazardous air pollution, office of Research

And Development, Us Environmental protection

Agency, Research Triangle per, North carling

Publication N. EPN 625/6-91014.

3. Churse, R. (`977). Pressure vessel the ASME code. Simplified 6th

Edition (McGraw-hill).

4. Coker A.K (1991) “Understanding the basics of Packed Column

 Design”, Chemical Engineering progress. Pp. 93-94.

5. Robert E. Treybal. (1970) “mass transfer operation” 3rd edition, Mc

Graw-hill international book company (Pp. 301–310)

6. Charles R, and cooper, D. (1988). “Brick/membrane linings pass

the Acid test”, chemical engineering. (Pg 83–86).

7. Fouls et al. principles of unit operation 2nd edition

8. Danwerks P.V (1970) “gas– liquid reaction” MC Graw-Hill book

company, New York.

9. Holland C.D (175) “fundamental of modeling of separation

process”. Principle– hall Englewood Chiffs, New Jersey.

10. Harrison, Mark E, and john France J. (1989) “distillation column

troubles– shooting, part 2. Packed column”. Chemical
Engineering. (Pg. 121– 128)

11. Letter from jack. D Broby of Anderson 2000, Inc; to Willian M.

Vatavuk, U.S environment protection agency, June 9, 1992.

12. Letter from Jose L. Bravo of Jaeger product, inc., to Willian M.

Vatavuk, U.S environmental protection agency, June, 8,
1992.

13. Mc Inness. R. Jameson K. and Austin D. (1990) “Scrubbing toxic

inorganic: chemical engineering. (Pp. 116 – 121).
14. Letter from S. Raymond will of air product, inc. to Willian M. vatavuk,
June 25, 1992,

15. Moss D.F (1987): pressure Vessel Design Manual (Hemisphere).

16. Jerry R. H and Clinton C.H (1984): “Chemical engineering Hand Book”.
6th Edition, Mc Graw–Hill Book Company. (Pg. 3–252)

17. Peter M.S and timmerhous K.D (1970) “Plant design and economists
for chemical engineering. 3rd edition. Mc Graw hill Siky Aliyu. Book
Company, New York. Pg. 671, 723, and 770.

18. (1987): Separation processes vol. 1, Warri Refinery, Nigeria.

19. Telephone conversation between Roy Commem, Radian Corporation

and Geraldnealon, Norton processes equipment, April 4, 1992.

20. Sherwood, T. K; and Holloway F.A.L (1940): Trans AICHE, 36, 39.

21. Ronald V. Gills (1976). “Fluid Mechanics and Hydraulics” 2nd Edition.
Mc Graw hill book company, New York. (Pg 294).
APPENDIX 1

STEADY STATE MATERIAL BALANCE

Temperature of the gaseous mixtures in 293k

293 – 273 = 200C

According to cousin and Richardson (1973) “Chemical Engineering Design

vol. 6. Page 294, chemical engineering design in based on K mole.

The pressure of the gaseous mixture in 1atm which is equivalent to 1.013 X

105N/M2 = 760 mmHg.

Percentage of ammonia (NH3) in the gas mixture is 8% = 0.08 mole fraction

of NH3 and also equivalent to y

:. Y1 = 0.08 kmole

The liquid is pure H20 with respect to NH3, which is equal to zero for X2.

Gas flow rate (G1) = 2.5 kmole/hr.

BASIS: 1 sec

G1=2.5 Kmol=0.000694kmol/sec

(60 X60) sec

GENERAL SOLUTION

From mass transfer operation by Robert E treybal (page 283):

X2 = X2 …………………………………………….1

1–X
Where X2 =0

:. X2 = 0 = 0 kmol of NH3 /Kmol of H2O

1–0

For y1

Y 1 = y1 ……………………… 2

1-y1

Where y1 = 0.08 K mole of NH3

Y1 = 0.08 =0.08696 Kmol of NH3

1- 0.08 k mol of Air

Since 95% removal of NH3 is desired, this is equal to 0.95

The removal efficiency η = 0.95

From Robert E treybal

Y2 = y1 (1– η) …………………………3

Y2 = 0.8696 (1 – 0.95)

Y2 = 0.00435 Kmol of NH3/Kmol of air

For gas (gs)

Gs = G1 (1-Y1) ……………………….. 4

: .Gs = 0.002695 (1 – 0.08)

Gs = 6.385 X 10-4 Kmol dry Air /sec

EQUILIBRIUM DATA

From reference table 2-123 Robert it Perry (chemical engineering

handbook), the equilibrium data is given below:

S/N Mass of NH3/ 100 weight Partial pressure of

of H2O NH3 in mmHg

1. 100 –––––

2. 90 –––––

3. 80 1450

4. 70 1170

5. 60 945

6. 50 686

7. 40 470

8. 30 298

9. 25 227

10. 15 166

11. 20 114

12. 7.5 69.6

13. 5 50.0

14. 4 31.7

15. 3 24.9

16. 2 18.2

17. 1 12.0

The table above is used to plot the graph of mole fraction of solute in
gaseous phase Y against mole fraction of solute in liquid phase X.

Recall:
 From mass transfer operation by Robert E Treybal (page 279):

XA = PA ……………………………….. 5a

Pt

YB = PB ………………………………….. 5b

Pt

But Y = YA = PA = PA

YB PB pt – PA

Y = PA ……………………………. 6

Pt – PA

Where: PA = partial pressure of NH3 at 200C

Pt = standard pressure of 760 mmHg

Y = mole ratio

By applying equation (6) we have:

Y1 = 0 = 0

760 – 0

Y2 = 0 = 0

760 –0

Y3 = 1450 = -2.101

760 – 1450
Y4 = 1170 = -2.854

760 – 1170

Y5 = 945 = -5.108

760 – 945

Y6 = 686 = 9.270

760 – 686

Y7= 470 = 1.620

760 – 470

Y8 = 298 = 0.645

760 – 298

Y9 = 227 = 0.425

760 – 227

Y10= 166 = 0.280

760 – 166

Y11 = 114 = 0.176

760 – 114
Y12 = 69.6 = 0.101

760 – 69.6

Y13 = 50 = 0.070

760 – 50

Y14 = 31.7 = 0.044

760 – 31.7

Y15 = 24.9 = 0.034

760 – 24.9

Y16= 18.2 = 0.024

760 – 18.2

Y17 = 12 = 0.016

760 – 12

Calculating the value of X from the equilibrium data, we have:

Mole (n) = Mass (m) ……………………. 7

Molar mass (M)

Thus M = nm
mA =nA mA …………………………….. 8

mB nB mB

Therefore,

X = nA = mA/MA = mA X MB …………….. 9

nB mB/MB MA mB

Molar mass of H2O, MA=18kg mol-1

Molar mass of gaseous mixture (NH3) MB=17Kg/mol-1

X1 = 100 X 17 = 0.944

18 100

X2 = 90 X 17 = 0.850

18 100

X3 = 80 X 17 = 0.756

18 100

X4 = 70 X 17 = 0.661
 18 100

X5 = 60 X 17 = 0.561

18 100

X6 = 50 X 17 = 0.472

18 100

X7 = 40 X 17 = 0.378

18 100

X8 = 30 X 17 = 0.283

18 100

X9 = 25 X 17 = 0.236

18 100

X10 = 15 X 17 = 0.142

18 100

X11 = 10 X 17 = 0.094

18 100
X12 = 7.5 X 17 = 0.071

18 100

X13 = 5 X 17 = 0.047

18 100

X14 = 4 X 17 = 0.038

18 100

X15 = 3 X 17 = 0.028

18 100

X16 = 2 X 17 = 0.019

18 100

X17 = 1 X 17 = 0.009

18 100

TABLE FOR THE GRAPH OF Y AGAINST X

S/N Mass of NH3/100 Partial Pressure Y X

mass of H2O NH3 mmHg

1 100 –––– 0 0.944

2. 90 –––– 0 0.850

3. 80 1450 -2.101 0.756

4. 70 1170 -2.854 0.661

5. 60 945 -5.108 0.561

6. 50 686 9.270 0.472

7. 40 470 1.620 0.378

8. 30 298 0.645 0.283

9. 25 227 0.425 0.236

10. 15 166 0.280 0.142

11. 10 114 0.176 0.094

12. 7.5 69.6 0.101 0.071

13. 5 50.0 0.070 0.047

14. 4 31.7 0.044 0.038

15. 3 24.9 0.034 0.028

16. 2 18.2 0.024 0.019

17. 1 12.0 0.016 0.009

For Graph
Plotting of Y against X

X1 = 0.0525 Kmol NH3

K mol H2O

X2 = 0 Kmol NH3

K mol H2O

Y1 = 0.8696 Kmol NH3

K mol H2O

Y2 = 0.00435 Kmol NH3

K mol H2O

The X1 value shows that the amount of NH3 that is per amount of H2O

To get the corresponding LS (min), we apply:

Ls (min) (X1 – X2) = Gs (Y1 – Y2)

Thus:

Ls (min) = Gs (Y1 – Y2)

X1 – X2

= 6.385 X 10-4 (0.08696 – 0.00435)

0.0525 – 0

= 5.27464850 X10-5
 0.0525

Ls (min) = 1.00469 X 10-3 kmol H2O

Minimum liquid flow rate for actual liquid flow rate is above 30%

Therefore,

Ls (actual) = 1.3 X Ls (min)

= 1.3 X (1.00469 X 10-3)

= 1.306097 X 10-3 kmol

For X1 (actual) = Gs (Y1 – Y2) + X2

Ls (actual)

= 6.385 X 10 -4 (0.08696 – 000435) + 0

1.30697 x 10-3

= 5.27464850 X 10-5

1.306097 X 10-3

X1 (actual) = 0.0404 Kmol NH3

K mol H2O

Thus,

L2 = Ls (1+X2)

Where Ls = Ls (actual)

L2 = 1.306097 X 10-3 (1+0)

L2 = 1.306097 X 10-3 kmol/sec

For, L1

L1= L2 (1 + X1 (actual))

L1 = 1.306097 X 10-3 (1 + 0.0404)

L1 = 0.001359 Kmol/sec

Therefore,

G2 = Gs (1 + Y2)

G2 = 6.385 X 10-4 (1+0.00435)

G2 = 0.000641 Kmol/ sec

Overall material balance

Input = output

G1 + L2 = G2 + L1

0.000694 + 1.306097 X 10-3 = 0.000641 + 0.001359

0.00200 = 0.00200
DIAGRAM OF COUNTER CURRENT PACKED BED OPERATION
For Y2

Y2 = Y2

1–Y2

0.00435 = Y2

1–Y2

Y2 = 0.00435 (1-Y2)

Y2 = 0.00435 – 0.00435 Y2

Y2 + 0.00435y2=0.00435

1.00435y2=0.00435

:. Y2 = 0.00435

1.00435

Y2 = 0.00433 Kmol

For X1

X1 = X1

1–X1

0.0525 = x1

1-x1

X1 = 0.0525 (1–X1)

X1 = 0.0525 – 0.0525 X1

X1 + 0.0525 X1 = 0.0525
:. X1 = 0.0525

1.0525

X1 = 0.04988 Kmol

TOWER DIAMETER ESTIMATION

Area can be calculated by the formula given below:

A = π D2

D2 = 4A

Thus,

D =√ 4A

To Estimate for Area

Average molecular weight of the gas M (avg) :

M avg = ∑ Y1 M1 + Y2 M2

M avg = (mole of fraction of NH3) in the gas X molecular weight of NH3) +

(mole fraction of air by volume X molecular weight of air).

Using Bottom Conditions

M avg = (0.08 X 17) + (0.92 X 29)

 = 1.36 + 26.68

= 28.04 kg/Kmol

Gas flow rate (Gm1) at the bottom

Gm1 = molar flow rate of gas (G1) X M avg

= 0.00694 X 28.04

Gm1 = 0.01946 Kg/sec

Density of gas mixture, ρ a

ρ a= P1 M avg

RT

P1 = 1.013 X 105 N/M2

Mavg = 28.04 Kg/kmol

R = 8314 Nm/mol k

T =293 K

Therefore,

ρ G = 1.013 X105 X 28.04

8314 X 293

ρ G = 1.6603 kg/m3

From reference (1), density of H20 at 200C and 1atm is equal to 100 kg/m3
and viscosity at the same condition is 1.0076 X10-3 kg/m.s the liquid mass
flow rate at top (LM2):

Lm2 = liquid flow rate at top (L2) X molecular Weight of the liquid

Thus,

Lm2 = 1.306097 X10-3 X 18

=0.023510 Kg/sec
NH3 removed from the gas mixture = Gas mixture flow rate X % NH3 in the
mixture X removal efficiency (η ) X molecular weight of NH3.

= 0.000694 X 0.08 X 0.95 X 17

= 0.00897 Kg/sec

Liquid mass flow rate, Lm, at the Bottom,

Lm1 = liquid flow rate at the top, (Lm2) + amount of NH3 removed.

= 0.023510 + 0.000897

= 0.032480 Kg/sec.

Pressure drop at the depth of the packed tower is taken to be 400 KN/M2 per
meter of packed height for 1 inch of ceramic Berl saddle packing.

For Abscissa, using the Eckert modification for generalized correlation for
random packed tower. From reference (1);

Abscissa = Ll (ρ G) 1/2

Gl ( ρ L –ρ G)

Where Ll = Lml = 0.032480 Kg/ sec

Gl = Gmi = 0.01946 kg/sec

Thus,

Abscissa = 0.032480 (1.16603)1/2

0.01946 (1000-1.16603)

= 1.669065 (0.001167) ½

1.669065 X 0.034167

= 0.0570

From figure 6.34 in references (1), the ordinates corresponding to 0.0570 =

0.075
Ordinate = (G1)2 CFµ L 0.1

ρ G (ρ L – ρ G) gc

From table 6.3 in references (1). CF for 1inch ceramic berl saddle = 110

:. (Gl)2 = ordinate ρ G (ρ L –ρ G) gc

CF µ L 0.1 j

(Gl)2 = 0.075 X 16603 (1000 – 1.16603)

110 X (1.0076 X 10-3)0.1 X 1.0

Gl =/ 0.075 X 1.16603 (1000 – 1.16603)1/2

110 X (1.0076 X 10 -3) 0.1 X 1.0

Gl = / 0.0875 X 998.83

110 X 0.5016 X 1.0

Gl = / 1.584

Gl = 1.259 Kg/ M2 sec

Therefore, area will be:

A = Gml

Gl
= 0.01946
1.259

A = 0.0155 M2
Diameter

D = 4A/π

Where π = 3.142

D = / 4X 0.0155

3.142

D = / 0.0620

3.142

D = / 0.01973

D = 0.1405 m

Therefore,

Area (A) = πD2

= 3.142 X (0.1405)2

= 0.0620

A = 0.0155m2

THE HEIGHT OF TOWER

From references (1)

Height of packing = HtoG NtoG ……………….1

Where

HtoG = overall height of transfer unit

NtoG = overall number of the transfer unit

But

HtoG = HtG + MG HTL + HTG + HTL ……………. 2

L AF

Where

AF = absorption factor

M = slope of the equilibrium curve

HtG = G …………………………………………. 3

FG aA

From reference (1):

FG SCG 2/3 = 1.195 (ds Gl) ………………….. 4

G µ G (1–∑L0)

Then

ScG = µ G …………………………….. 5

ρ G DG

Where
The subscript G denotes gas

Density of Gas mixture ρ a = 1.16603 Kg/M3

Viscosity of gas, µ G = 1X 10-5 Kg /Ms

Diffusivity of the gas = DNH3 – Air or DG

Pressure (Pt) = 1.013 X105 N/M2

MA = 17kg/ Kmol

MB = 29 Kg /Kmol
rΑ Β = rA + rB …………………. 6

From reference (1), table 2.2 pages 33, the molecular separation at

Collision (r AB ) for air and NH3 is 0.3711 and 0.29 respectively

r AB = 0.3711 + 0.29

= 0.33

The normal boiling point Tb, A = 351.4 K

∑ = 1.21 Tb ………………………………..7

For air
∑A = 1.21 x 351.4

= 425.2

∑AB =/ 425.2 x 78.6

Where ∑B = 78.6

Thus:

∑AB = 182.8

:. KT = 293 = 1.60

Σ AB 182.8

F (KT) = F (1.60) = 0.58

(∑AB)

Therefore,

DAB = 10-4 1.084 – 0.249 /1/mA + 1/mB) T3/2 / 1/mA + 1/mB

Pt (rAB) 2 F (KT / ∑AB)

DAB = 10-4 (1.084 – 0.249 / 1/17 + 1/29) 2931.5 / 1/17 + 1/29

 1.013 x 105 (0.33)2 x 0.58

= 0.0001 (1.008) 5015.4 x 0.304

6398.3

= 0.154

6398.3

DAB = 0.000024m2/s = DG

From equation (5)

ScG = µ G

ρ G D G

= 0.00001

1.16603 x 0.000024

= 0.357

From the material balance,

Gl = molar gas flow rate

Gl = GMl

A
= 0.01946

0.0155

= 1.255 kg 1m2s

Converting to kmol /m2s

Gl = 1.255 kg x kmol

m2s 28.04kg

= 0.0448 kmol1m2s

From reference (1), table 6.3/6.5

∑ω - ∑ -φ LT

∑ = 0.69 for ceramic berl saddle.

j = 0.0320

φ LT = φ ω + φ Ls ……………………….11

φ Ls = 4.23 x10-3 µ L 0.04 σ 0.55 ………………12

ds 1.56 ρ L 0.37

Where

µ L = 0.002kg/ms
σ = 0.07475

ρ L = 1000kg/m3

Thus

φ = 4.23x10-3 x 0.002
Ls
0.04 x 0.07475 0.55

0.0320 1.56 x 1000 0.37

= 0.00 423 x 0.7799 x 0.2402

0.0047 x 12.88

= 0.000796

0.061

φ Ls = 0.01305

For φ low

φ low = φ Ltw -φ Lsw ………………………………13

From reference (1) table 6.5

φ Lsw = 5.014 x 10-5

ds 1.56

Where ds = 0.0472m

:. φ lsw = 5.014 x10-5

0.047

= 0.107m3/m3

For φ LtW

φ Ltw = (2.32 x 10-6) (73 7.5Ll) β

ds2

Where
β = 1.508 ds0.376

= 1508 x (0.0320)0.376

= 1.508 x 0.2741

= 0.413

Ll = 0.03248 kg/sec

φ Ltw = (2.32 x 10-6) (737.5 x 0.03248)0.413

(0.0320)2

= 2.32 x 10-6 x 3.7126

(0.0320)2

= 8.6133 x 10-6

0.001024

φ Ltw = 0.00841 m3/m3

Therefore

φ Low = φ Ltw - φ Lsw

= 0.00841 – 0.0107

= 0.00229 m3/m3

But:

φ Lo =φ Low H ……………………. 14

Calculating for Hs we have

H= 1404L 0.57 µ L (σ ) 0.2187-0.262logi

ρ L 0.84 (3.24L 0.413 -1) (0.073)

Where H =correlation factor (holding packed tower)

 σ = surface tension

From reference (2) table 3.317, page 294;

σ = (Pch (ρ L -ρ L) 4 x 10-12)

Where

Pch = sagolin’s parachor

M = molecular weight

Grant contribution

H 17 x 2 34.2

0 20.0 X1 20.0

54.20

Considering the surface tension of the liquid ammonia to be zero (0) for pure
water:

Let:

Density of pure water at 200c = 1000

Density of water vapor at 20oc = 1.16603

molecular weight of pure water = 18.0kmol/secs

σ L = 54-20 (1000 – 1.16603)4 x10-12

18.0
= 0.08125.N/M

But:

∑m = σ NH3 x NH3 σ H20 x H20

Since y1 + y2 = 1.0

y2 = 1 – y1

y2 = 1 – 0.08

= 0.92

:. σ = 0 (0.08) + 0.08125 (0.92)

= 0.07485 N/M

Then:

H = 1404 x (0.032480) 0.57 x 0.002 0.13 (0.07485) A

1000 0.84 (3.24 x 0.032480 0.413 -1) (0.073)

Where A = 0. 2187 – 0.262 log (0.032480)

H = (88. 74055467) 1.01535

(70.61030734)

H = (1.25676)1.01535

H = 1.2612

Therefore,

φ Lo = φ low H

= 0.00229 x 1.2612
 = 0.0029

Thus, from the equation,

φ Lt = φ Lo + φ Ls

= 0.0029 + 0.01305

φ Lt = 0.01595

But

∑ω = ∑ - φ Lt …………………………16

= 0.69 – 0.01595

= 0.67405

Estimating for FG

FG (SCG) ⅔ = 1.195 (ds Gl)- 0.36

Gl µ G (1-∑ω ) ……………17

FG (0.357) ⅔ = 1.195(0.0320 x 0.0448) -036

0.0448 0.00001 (1-0.67405)

FG (0.5032) = 1.195(0.00143) -036

0.0448 0.0000033

FG (0.5032) = 1.195 (433.333)-0.36

0.0448
FG (0.5032) = 1.195 (0.11239)

0.0448

FG (0.5032) = 0.006017

:. FG = 0.006017

0.5032

FG = 0.01196

Estimating for a

a= aAW φ Lo

φ Low

Where:

a = specific interfacial surface for adsorption area/vol (1.2/1.3)

From reference [1] table 6.4s the interfacial area in given by:

aAw = Μ ( 808Gl) n x Llρ ………………….18

(ρ G0.5)

Where M = 52.14

n = 0.0506Ll – 0.1029

p=0

Ll = 0.032480

:. n = 0.0506 x 0.32480 – 0.1029

 = - 0.10126

aAw = (52.14 808 x 0.0448) x1

-0.10126

(1.16603)0.5

= 52.14 (36.1984)-0.10126

(1.07983)

= 52.14 (33.5223) -0.10126

aAw = 36.536

Therefore

a = 36.536 (0.0029)

(0.00229)

= 36.536 x 1.26638

= 46.2683

:. FG a = 0.01196 x 46.2683

= 0.5534

For

HtG = Gl

FGa

= 0.0448

0.5534

HtG = 0.08095m

For
HtL = Ll/ FLa

Where FL = KL x c

To estimate for KL (liquid phase mass transfer coefficient).

KL ds = 25.1 (dsLl )-0.45 x SCL0.5 ……………………19

∆L ( µ L)

Where:

ds = 0.0320

µ L = 0.002

And

DL = (117.3 x 10-8) (φ MB) 0.5T ............................20

µ VA0.6

Where VA = molar volume of NH3 = 0.0267 m3/kmol

φ = Association factor for solvent (for water as solvent = 2.26)

µ L = viscosity of liquid = 1.055 x 10-3 kg/m.s

MB = molar mass of H20 = 18.02 kg/kmol

DL = Diffusivity of the liquid = DNH3O – H20

Thus

DNH3 – H20 = (117.3x10)-18 (2.26 x 18.02)0.5 x 293

1.055 x 10-3 x (0.0267)0.6

= 2.19 x 10-13
 0.000114

DL = 1.92 x 10-9 m2

Therefore

SCL = µ L

ρ L x DL

SCL = 1.055 x 10-3

1000 x 1.92 x 10-9

SCL=527.5

From the material balance

Ll = 0.032480 kg/m2s

Then using equation (19)

KL x 0.0320 = 25.1 (0.0320 x 0.032480) -0.45 x 527.5

1-92 x 10-9 0.002

KL x 0.0320 = 25.1 (0.03936 x 10-3) -0.45 x 527.5

1-92 x 10-9 0.002

kL 0.0320/1.92 x 10-9 = 25.1 (0.51968 -0.45 ) 52.75

kL x 0.0320 = 25.1 x 1.3425 x 527.5

1-92 x 10-9

KL x 0.0.320 = 3.4128 x 10-5

kL = 3.4128 x 10-5

0.00320

kL = 0.001067

Recall, that

FL = KL x C

Where: FL = liquid mass transfer coefficient

C = molar density of the solvent liquid

Where

C = density of liquid

AV. mol wt

ρ L = 1000kg/m2 (density of the liquid)

Average molecular wt. for liquid = 18.02

C= 1000 = 55.49

8.02
FL = 0.001067 x 55.49

= 0.05921

Therefore

HtL = Ll

FLa

HtL = 0.032480

0.05921 X 46.2683

HtL = 0.01186

DETERMINING THE ABSORPTION FACTOR (Af)

Af = L mol, i or Ls

M.G mol, I MGS

Where,

M = slope of the equilibrium curve

Ls = 1.306097 x 10-3kg/sec

Gs = 6.385 x 10-4 kg/sec

But

M = ∆ y = Y2 – Y1

∆x X2 – X1
:. M = 0.08696 – 0.00435

0.0525 - 0

M = 1.574

Then

Af = 1.306097 x 10-3

1.574 x 6.385 x 10-4

Af = 1.2996

To get HtG, we use the formula

HtoG= HtG + HtL

Af

HtoG= 0.08095+ 0.01186

1.2996

HtoG = 0.08095 + 0.009126

HtoG = 0.90076

From reference [1], page 309:

NtoG = ln (Y1 – mx2/Y2-mX2 (1 – 1/Af) + 1/Af)

1 – 1/Af

Where Af = 1.2996

Y1 = 0.08696
 m = 1.574

Y2 = 0.00435

1 + 0.00435

Y2 = 0.00433

X2 = 0

Thus

NtoG = In (0.08696 – 1.574 (0)) (1 – 1) + (1)

(0.00433 – 1.5740 (0)) (1.2996) (1.2996)

1–1

1.2996

NtoG = ln (20.0831) (0.2305) + 0.76947)

0.2305

= ln (5.398625)

0.2305

NtoG = 1.686144

0.2305

= 7.3152

Therefore,
Hpack = HtoG NtoG

= 7.3152 x 0.090076

Hpack = 0.6589m

TO ESTIMATE THE TOTAL HEIGHT OF THE TOWER

The total height is calculated from the equation below:

Htower = 1.40Hpack + 1.02 (D) + 2.81 ……………….. 23

Converting 0.6589m packing to Ft

1 inch = ½ Ft = 25.4mm

1ft = 12 x 254mm

= 304.8mm

= 0.3048m

:. 1ft = 0.3048m

Now:

0.304m = 1ft

0.6589m =x

:. x = 1ft x 0.6589m

0.3048m

x = 2.16175Ft.
For diameter, D = 0.1405m

0.3048m = 1ft

0.1405m = x

:. x = 0.1405m x 1ft

0.3048m

x = 0.46095Ft

Therefore,

Htower = 1.40 (2.16175) + 1.02 (0.46095) + 2.81

= 3.02645 + 0.470169 + 2.81

= 6.30662 Ft

Converting to Ft

1Ft = 0.3048m

6.30062ft = x

:. x = 0.3048m x 6.30662 ft

1ft

x = 1.9223m

MECHANICAL DESIGN CALCULATION

The material desired for the construction was made using the
American society of mechanical engineering (ASME) specification code for
boiler and pressure vessel. A low alloy steel given SA – 202 (Grade B), for the
construction. We considered the following factors while making the choice.

1) Physical and mechanical properties of construction material to

withstand the operating condition.
2) Resistant to corrosion with respect to ammonia air system.

3) The material should be relatively cheep in terms of cost

DESIGN CONDITION

From reference [2], table 13.2, page 812:

Maximum allowable temperature = O0c to 50oc

Maximum operating pressure = 15psig

Corrosion allowable = 4mm

= 0.004m

= 0.16inch

Design stress for SA 202 (Grade B) construction material is 135 N/mm2

Welding method is used for the joining of the construction material. A

single wedded buff/groove joint should be fully radio graphed.

Fig 4.1 single V buff joint 60oc level and roof opening of 1/16 inch. In the
welded buff joint where, the stress tending to share the join apart is given by
T= F/hl

Where h = weld threat = wall thickness

L = length of weld

from reference [2] , table 13.3 page/813, the welding efficiency for a
completely radiography of single buff wielded joint with backing strip in
shown in fig A is ∑ = 0.90
The wall thickness, according to ASME, the formula of wall thickness.

tm = PR + CA ……………….. 1

Sε - 0.6ρ

Where:

Tm = thickness of the tower

P = design pressure

S = stress value

R = Radius of the tower

∑ = wedded joint factor or joined sufficiency

CA = corrosion allowance

According to ASME recommendation, the design pressure in between 5 to

10% above the normal working pressure.

Design pressure = 1 atm + 10% of atm

=1 + 0.1 = 1.1 atm

But

1 atm =m 15 Psig

1.1 atm = x

:. x = 15 psig x 1.1 atm

1atm

= 16.5 psig

Design stress value for grade B material is

= 135 N/mm2

= 135 x 102 N/mm2 x (100)2 mm2 /m2

= 1.35 x 108 N/mm2

= 1.35 x 108 Pa
But:

10atm = 1.013 x 105 psig

x = atm = 1.35 x 108 psig

x = 1.35 x 10-8 psig x 1atm

1.013 x 105 psig

x = 1332.7 atm

Recall that: 1atm = 15psig

1332.7 atm = x

:. x = 15psig x 1332.7 atm

1 atm

x = 19990.5 psig

But,

D = 0.1405m

R = D = 0.1405m

2 2

R = 0.07025m

Then, 1 inch = 25.4mm = 0.0254m

0.0254m = 1 inch

0.07025m = x
:. x = 1 inch x 0.07025m

0.0254m

x = 2.7657 inch

Therefore,

c = 4mm = 0.004m

0.0254m =1inch

0.004m = x

:. X =1inch x 0.004m

0.0254

x = 0.1575 inch

Where

ε = 0.90

Using equation 1

tm = PR + CA

Sε - 0.6ρ

tm = 16.5 psig x 2.7657 inch + 0.1575

 19990. S psig x 0.90 -0.6x16.5psig

tm = 4.63405 + 0.1575

17981.55

tm = 0.002538 + 0.1575

= 0.1600038 inch

¼ inch = 0.25 inch

For 1 inch = 25.4mm

0.16038 inch = x

x = 25.4mm x 0.160038 inch

1 inch

x = 4.06496mm use 6.25mm

HEMISPHERICAL HEAD

The head is hemispherical head which is given according to ASME

recommendation

t= PR +CA ……………. 2

2Sε - 0.2ρ

Where t= the head

t= 16.5 x 2.7657 +0.1575

2 x 1990. 5 x 0 .9 – 0.2 (16.5)

 = 45.63405 + 0.1575

35979.60

= 0.001268 + 0.1575

t = 0.158768 inch. Using ¼ inch

Recall: ¼ inch = 0.25inch

Converting to mm

1 inch = 25mm

0.158768 inch = x

:. x = 25.4mm x 0.158768

1 inch

x = 4.032716mm. Using 6.25mm

a = 2b ……………………. 3

Where:

a = radius of the diameter

b = hemispherical height

D = diameter.
D = 2R

R=D

R= 0.1405

R = 0.07025

But

a = 2b

b=a

b = 0.07025

b = 0.03513m

COSTING OF THE TOWER

The costing of the purchasing and installation of equipment depend on the

total height of the equipment. The cost of eternal packings, plate support
and distribution cost of hemispherical head nuzzle and mandible and cost of
ladder etc. With reference to figure 16.28 peter and timmernans fourth
edition, the cost of tower including the installation and auxiliary can be
estimated directly for 23 to 27 inches material diameter tower, the January
2000 cost data in given by installed equipment per height as $640

For diameter
D = 0.1405m

Converting to inch

1 inch = 25.5 = 0.0254m

x = 0.1405m

x = 0.1405m

0.0254

Thus,

x = 5.53150 inch

The hemispherical head is 0.03513 deep. Since there is equal hemispherical

height at bottom, them we have the total hemispherical height as

(2 x 0.03513) m

= 0.070260m

The packed height is equal to 0.6589m converting to ft, we multiply by 3.290

That is; 0.6589 x 3.290

= 2.16778 ft

The total height = Hpack + Hemispherical head height + top and bottom
space height.

= 0.6589 + 0.070260 + 12 inch

= 0.6589 + 0.070260 + 0.3048

= 1.03396m

Converting to Ft, we multiply by 3.290

= 1.03396 x 3.290

= 3.401728 ft

Installed equipment cost

= $ 640 x 3.401728
= $ 2177.106

For carbon molybdenum steel, the relative cost is given by 1.065

The installation cost, using carbon molybdenum steel is:

1.065 x $ 2177.106

= $ 2318.61789

Using cost index method,

Installed cost for 2008 = installed cost for installed cost for 2000 x cost index
for 2008 / cost index for 2000.

That is; installed for 2008 = installation costs for 2000 X cost index for 2008

Cost index for 2000

From SYSSEX university England

2008 cost index = 987

2000 cost index = 904

Installed cost for 2008 = $ 2318.61789 X 987

904

= $ 2531. 4998

The current exchange rate as at 23rd march 2010

$ 1.00 was equivalent to N150

:. N150 X 2531.4998

= N379, 724.976 say N380, 000