Packed Tower / Scrubber Design

Complete design of a packed scrubber: gas density, tower diameter, pressure drop, fan power, hydraulic check and HETP.

1. Column Diameter

Packing (auto-fill Fp, Cf)

Packing type

Packing size

Packing MOC

Gas flow given as

Gas flow rate

kg/h

Gas inlet pressure

atm

Gas inlet temperature

°C

Gas molar mass

kg/kmol

Component name

Component flow rate

kg/h

Component in gas (% v/v)

Component molar mass

kg/kmol

Liquid flow rate L

kg/h

Liquid density

kg/m³

Liquid viscosity μL

Pa·s

Packing factor Fp

m⁻¹

Dry packing factor Cf

—

Correction factor J

—

Ordinance value (Fig. 6.34)

—

2. Pressure Drop & Power

Gas pressure drop / m bed

mmWC/m

Total packing height

Fan / blower efficiency

Gas velocity (for losses)

m/s

Dry packing coefficient CD

—

3. Hydraulic Check

K4 (from chart, 15 mm H₂O/m)

—

K4 at flooding

—

4. HETP Prediction

Liquid surface tension

dyne/cm

Liquid viscosity

Constant n (Table 6.2)

—

Number of theoretical stages

—

5. Neutralizer Consumption

Acid type

Acid molar mass MW

kg/kmol

Acid removed

kg/h

Alkali type

Commercial purity

Excess factor

Solution concentration

% w/w

Reactions: HCl + NaOH → NaCl + H₂O; H₂SO₄ + 2 NaOH → Na₂SO₄ + 2 H₂O; HNO₃ + NaOH → NaNO₃ + H₂O; 2 HCl + Ca(OH)₂ → CaCl₂ + 2 H₂O; H₂SO₄ + Ca(OH)₂ → CaSO₄ + 2 H₂O. Acid removed normally equals the component flow rate in section 1.