Project Report On
Continuous Contact Equipment
Submitted by
Khant Dhruv D. (150305103022)
Savan Ladani (150305103025)
Vaghasiya Pratik (150305103072)
Guided by
Neha Kulshreshtha (Asst. Prof.)
Chemical Engineering Department
Parul Institute Of Technology
Limda Vadodara
Certificate
This is to certify that the project report, submitted along with project entitled
‘Continuous Contact Equipment’ has been carried out by Khant Dhruv, Savan
Ladani, Vaghasiya Pratik, under my guidance in partial fulfilment for
degree of Bachelor of Chemical Engineering, 6th semester during the academic
year 2017-2018. These students have successfully completed project activity
under my guidance.
Date:
Place:
Signature & Name of Guide Signature & Name of HOD
Mrs. Neha Kulshreshtha Mr. Parag Saxena
Acknowledgement
We have taken efforts in this project. However, it would not have been possible without the
kind support and help of many individuals and organizations. We would like to extend our
sincere thanks to all of them. We are highly indebted to Mrs. Neha Kulshreshtha for their
guidance and constant supervision as well as for providing necessary information regarding the
project & also for their support in completing the project. We would like to express our
gratitude to Mr. Parag Saxena Sir (HOD) for their kind cooperation and encouragement which
help us in completion of this project. Our thanks and appreciations also go to my colleague in
developing the project and people who have willingly helped me out with their abilities.
We all are very thankful to have such amazing Guidance and support.
Thanking you.
Khant Dhruv D. (150305103022)
Savan Ladani (150305103025)
Vaghasiya Pratik (150305103072)
Index
(1)Introduction…………………………………………………….5
(2)Packed tower………………………………………………...…5
2.1 Types of packing……………………………………...6
2.2 Packing support…………………………………….…7
2.3 Liquid distributor…………………………………..….8
2.4 Mist eliminator………………………………………..9
2.5 Application of packed tower……………………...…..9
(3)Tray tower……………………………………………………..11
3.1Types of tray…………………………………………..11
3.2Selection criteria for tray………..…………………….14
3.3Problems related to tray tower…………...……………15
(4)Choice between packed tower and tray tower………………...17
1) Continuous contact equipment
The continuous contact equipment are those equipment which are used to bring direct contact
between liquid and gas phase. Mainly there are two equipments which are used widely for this
operation one is packed tower and another is tray tower.
The liquid and gas compositions in a packed tower changes continuously throughout the height.
The composition of solute from entry to exit of the packed tower is represented by operating
line and every point indicates some location in the packed tower. On the other hand, in tray
tower, few points (number of trays) in the operating line represents the conditions in the trays.
2) Packed Tower
In chemical processing, a packed bed is a hollow tube, pipe, or other vessel that is filled with
a packing material. The packing can be randomly filled with small objects like Rasching
rings or else it can be a specifically designed structured packing. Packed beds may also contain
catalyst particles or adsorbents such as zeolite pellets, granular activated carbon, etc.
The purpose of a packed bed is typically to improve contact between two phases in a chemical
or similar process. Packed beds can be used in a chemical reactor, a distillation process, or
a scrubber, but packed beds have also been used to store heat in chemical plants. In this case,
hot gases are allowed to escape through a vessel that is packed with a refractory material until
the packing is hot. Air or other cool gas is then fed back to the plant through the hot bed, thereby
pre-heating the air or gas feed.
2.1) Types of packing
2.1.1) Random packing materials: Random packing materials are classified into two categories
as first generation (1907 to mid 1950); second generation (mid 1950 to mid 1970). The first
generation random packing materials are of three categories, such as, (a) Raschig rings; (b)
Lessing rings and modified Raschig rings and (c) Berl saddles.
Figure 1 Raschig Ring Figure 2 Lessing Ring
Figure 3 Berl Saddle Ring
The second generation random packing materials are mainly Pall ring and modification. Pall
rings are modified version of Raschig rings.
Figure 4 Pall Ring
2.1.2) Structured packing materials: These materials are used widely as packing materials in
packed tower due to low gas pressure drop and improved efficiency. Corrugated metal sheet
structured packing and Wire mesh structured packing materials are widely used in the
industries. These include Mellapak, Flexipak
Figure 5 Mellapak Figure 6 Flexipak
2.2) Packing support
Packing support plate, also called packing support grid, is an important tower internals in the
packing tower. As its name says, packing support plate is designed for supporting the tower
packing bed, including random packing and structured packing. It is also important to load the
liquid weight and ensure the normal and smooth mass transfer. The large open area and strict
design ensures high efficient gas and liquid distribution and prevent liquid blocking and liquid
flooding. Grating type and multi-beam type are designed for structured packing and random
packing in different environments, pressure and pressure
Figure 7 Packing Support
2.3) Liquid distributor
A liquid distributor is a device which is used to spread liquid when it enters a packed column.
Main purpose of distributor is to pass liquid uniformly to surface of packing.
It is placed above packing material.
Figure 8 Liquid Distributor
2.4) Mist Eliminator
When the gas velocity is very high it may carry some droplets of liquid. So mist eliminator is
used to trap remove trapped liquid droplets.
It is placed above liquid distributor.
Figure 9 Mist Elemenator
2.5) Applications
Packed bed reactors can be used in chemical reactions in chemical industries. These reactors
are tubular and are filled with solid catalyst particles, most often used to catalyze gas reactions.
The chemical reaction takes place on the surface of the catalyst. The advantage of using a
packed bed reactor is the higher conversion per weight of catalyst than other catalytic reactors.
The conversion is based on the amount of the solid catalyst rather than the volume of the
reactor.
Packed tower is also used for gas absorption operation like to separate NH3 from air and NH3
mixture. NH3 is more dissolve in water as compare to air so it will dissolve in water and after
that we can separate NH3 from water.
Absorption of acidic gases like SO2, SO3, NO2 can be separated from mixture by using basic
solution like NaOH, KOH etc.
Packed tower is also used for vacuum distillation.
Packed tower is also used as cooling tower in various industries.
3) Tray Tower
Tray tower is a chemical equipment used to carry out unit operations where it is necessary
to transfer mass between a liquid phase and a gas phase. In other words, it is a particular gas-
liquid contactor. The peculiarity of this gas-liquid contactor is that the gas comes in contact
with liquid through different stages. each stage is delimited by two plates. Tray tower is
applicable for both batch as well as continuous operation.
3.1) Types of tray
The tray tower consists of tray which are mainly made from metal ceramic, etc.
There are many types of tray but three trays are widely used.
1) Bubble cap tray
2) Sieve tray
3) Valve tray
3.1.1) Bubble cap tray
The bubble cap tray consists a slotted cap on a riser.
The gas flows up through the riser, reverse flow under the cap, passes downward through the
annulus between riser and cap, and finally passes into the liquid through a series if opening in
the lower side of the cap.
The device has a built-in liquid seal which prevents liquid drainage at low gas rates. This design
does not rely on the velocity of the upcoming vapor to hold the liquid on the tray.
Because of its high cost and complexity, most modern tower design favor the use of sieve or
valve trays over bubble-cap tray. Bubble-cap should only be used where very low vapor rates
have to be handled, or adequate resistance time is necessary for separation and chemical
reaction, or in applications where a positive liquid seal is essential at all flow rates.
Figure 10 Bubble Cap Tray
3.1.2) Sieve tray
In sieve tray the vapor passes through a large no. of holes known as perforations (sieve) and
emerges through the liquid in a vertical direction.
The sieve tray has the simplest design among the various tray types. There are no mechanical
moving parts. There is no liquid seal and it is the passage of vapour that effectively prevents
the loss of liquid through the sieve.
Typical layout for sieve tray follows either a square hole pitch or equilateral triangular hole
pitch. Hole pitch is the center to center hole spacing.
Typical sieve sizes used industrially range from as small as 1/16 inch to 1 inch. Small sieve are
not suitable for fouling or corrosive services as they may be susceptible to blockage, leading
to excessive pressure drop and premature flooding.
Small holes have better turndown characteristics because they reduce tray weeping and
therefore increase tray capacity. In terms of cost, larger holes are holes are cheaper as the holes
can be punched, and there are fewer holes to be punched. Smaller holes are more expensive as
drilling may be required.
Figure 11 Sieve Tray
3.1.3) Valve tray
A valve tray is a flat perforated plate, with each perforation fitted with a movable disk.
The perforation and disk may be circular or rectangular. The disk ate the movable component
of the tray.
The valve will move up or down in response to changing vapor flow rates. At normal flow
rates, the valve is roughly in the middle position. At low vapor rates, the disk settles over the
perforation and covers it to avoid liquid weeping. The valve should be heavy enough to prevent
excessive opening at low vapor flowrates. As the vapor rates is increased, the disk rises
vertically. The upward movement of the disk is restricted either by retaing legs or a cage.
Weeping may result if excessive valve opening occurs prematurely. This will reduce the tray
turndown.
Figure 12 Valve Tray
3.2) Selection criteria for Trays
3.2.1) Capacity: If tower diameter required for given flow rate is more it means capacity of
tray is less . Ranking for capacity is in order of sieve tray , valve tray ,bubble cap tray .
3.2.2) Operating range: Operating range of tray means range of liquid and vapour. Flow rate
at which tray work satisfactory. In bubble cap tray provide maximum operating range while
sieve tray provide minimum operating range. Generally for higher turndown ratio bubble cap
tray are prefers. Valve tray also offers more flexible than sieve tray.
3.2.3) Pressure drop: To vacuum distillation packed tower is first choice but for low vacuum
tray tower is selected. Among the tray sieve tray provides lowest pressure drop and bubble cap
provides higher pressure drop.
3.2.4) Efficiency: Efficiencies of trays are almost same if they are operated at designed flow
rate.
3.2.5) Cost: Bubble cap trays is costly as compare to other two trays.
3.3) Problems related to Tray Tower
3.3.1) Entrainment:
At high gas velocities, when the gas is disengaged from the froth, small droplets of liquid will
be carried by the gas to tray above.
Reduces the concentration change brought about by the mass transfer.
Adversely affects the tray efficiency.
Tray efficiency is reduced.
Lower volatile material is carried to a plate holding liquid of higher volatility.
Contaminate high purity distillate.
Excessive entrainment can lead to flooding.
3.3.2) Higher pressure drop:
Results due to great liquid depths and high velocity of gas.
Results in high fan power to blow or draw the gas through the tower.
High operating cost.
In case of distillation, results in high boiling temperatures.
May lead to heating difficulties.
Possibly damage to heat-sensitive compounds.
3.3.3) Flooding:
High pressure drop between tray spacing may led to condition of flooding.
It is brought about by excessive vapor flow.
Causes liquid to be entrained in the vapor up the column.
Depending on the degree of flooding, the maximum capacity of the column may be severely
reduced.
Flooding is detected by sharp increases in column differential pressure.
Decrease in separation efficiency. Further increase in either flow rate then aggravates the
condition rapidly.
Liquid will fill the entire space between the trays.
3.3.4) Weeping:
This phenomenon is caused by low vapor flow.
If the gas rate is too low, much of the liquid may rain down through the openings of the trays
which is called weeping.
The pressure exerted by the vapor is insufficient to hold up the liquid on the tray.
Therefore, liquid starts to leak through perforations.
Excessive weeping will lead to dumping.
That is the liquid on all trays will crash (dump) through to the base of the column and the
column will have to be re-started.
Weeping is indicated by a sharp pressure drop in the column and reduced separation efficiency.
3.3.5) Foaming:
Foaming refers to the expansion of liquid due to passage of vapor or gas.
Although it provides high interfacial liquid-vapor contact, excessive foaming often leads to
liquid buildup on trays.
In some cases, foaming may be so bad that the foam mixes with liquid on the tray above.
Whether foaming will occur depends primarily on physical properties of the liquid mixtures,
but is sometimes due to tray designs and condition.
Whatever the cause, separation efficiency is always reduced.
3.3.6) Coning:
If liquid rates are too low, the gas rising through the openings of tray may push the liquid away,
which is called coning.
4)Choice between packed tower and tray tower:
For very high liquid to vapour flow rate ratio packed tower are generally preferred but for small
ratio tray tower are first choice.
For larger tower diameter tray are more suitable and for smaller tower diameter packed tower
are preferred.
For corrosive liquid packed tower are generally used but for non-corrosive liquid tray tower
are used.
Packed tower are generally provide large pressure drop where as tray tower provide lower
pressure drop.
For vacuum distillation packed tower are most suitable but for low vacuum distillation tray
tower are also selected.
Packed tower are less expensive compare to tray tower when tower diameter is less than 0.6
meters.
