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CHAPTER No.7
DESIGN OF QUENCHER
7.1 QUENCHER:The word quencher means sudden cooling. It may be used for various purposes, e.g. for
hardening of solid surfaces, for stopping further reactions etc. In our case quenching of
the reactor product is needed for sudden cooling, for removing impurities and to avoid
side reactions. Cooling by liquid quenching is essentially accomplished by introducing
the hot gases into a liquid contacting device.
When the liquid evaporates the energy necessary to vaporize the liquid is obtained at the
expense of hot combustion gases, resulting in a reduction of gas temperature. The
temperature of the combustion gases discharge from the quencher is at the adiabatic
saturation temperature of the combustion gases if the operation is adiabatic and the gas
leaves the quencher saturated with water vapors.
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DESIGN OF QUENCHER
3. Packed towers
In venture scrubber contact area available for water and gases is less.
A precooler is to be used when venture scrubber is used for removing particulates.
There construction is not so simple.
Large amount of water is required for cooling.
7.7 SPRAY TOWERS:Spray towers or spray chambers consist of empty cylindrical vessels made of steel or
plastic and nozzles that spray liquid into the vessels. The inlet gas stream usually enters
the bottom of the tower and moves upward, while liquid is sprayed downward from one
or more levels. This flow of inlet gas and liquid in the opposite direction is called
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DESIGN OF QUENCHER
countercurrent flow. Countercurrent flow exposes the outlet gas with the lowest pollutant
concentration to the freshest scrubbing liquid.
Many nozzles are placed across the tower at
different heights to spray all of the gas as it
moves up through the tower. The reasons for
using many nozzles is to maximize the number
of fine droplets impacting the pollutant particles
and to provide a large surface area for absorbing
gas.
Theoretically, the smaller the droplets formed,
the higher the collection efficiency achieved for
both gaseous and particulate pollutants. However,
the liquid droplets must be large enough to not be
carried out of the scrubber by the scrubbed outlet
gas stream. Therefore, spray towers use nozzles
to produce droplets that are usually 500 to 1,000
m in diameter. Although small in size, these
droplets are large compared to those created in the
venturi scrubbers that are 10 to 50 m in size.
In a spray tower, absorption can be increased by
decreasing the size of the liquid droplets and/or
increasing the liquid-to-gas ratio (L/G). However, to
accomplish either of these, an increase in both power
consumed and operating cost is required. In addition,
the physical size of the spray tower will limit the amount of liquid and the size of droplets
that can be used. Cooling hot gases with the acidic quench is relatively simple and
required very little space. Only that amount of water is used that is needed to maintain the
desire temperature of the gases at the discharge. Their installation and operating costs are
generally considered to be less than that for other cooling methods.
7.8 SPRAY NOZZLE:A spray nozzle is a device that facilitates the formation of spray. When a liquid is
dispersed as a stream of droplets (atomization), it is called a spray. Spray nozzles are used
to achieve two primary functions: increase liquid surface area to enhance evaporation, or
distribute a liquid over an area. It is a device which makes use of the pressure energy of a
liquid to increase its velocity through an orifice and breaks it into drops. Each nozzle type
has a specific type of characteristics and capabilities and is designed for use under certain
application conditions.
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DESIGN OF QUENCHER
1. Hydraulic spray:
The hydraulic spray nozzle utilizes the liquid kinetic energy as the energy source to break
the liquid into droplets. This type of spray is less energy consuming than a gas atomized
or twin-fluid spray nozzle. As the fluid pressure increases the flow increases and the drop
size decreases. But this leads to problems in selecting a droplet size and to achieve a
certain flow rate at a given pressure. To overcome this situation a special hydraulic nozzle
(Lechler Spillback Nozzle) has been developed. This nozzle can vary the liquid flow rate
at a particular droplet size and pressure. This nozzle creates a better and optimum control
on the liquid spray and in certain applications can eliminate the need of expensive
compressed air.
Internal mixing
External mixing
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DESIGN OF QUENCHER
This type of spray nozzle may require more air, but the mixing and atomization of liquid
takes places outside the nozzle. If a liquid is atomized using any gas which may react
with the liquid, it is possible that the reaction may damage the inside of the nozzle. This
type of nozzle is most beneficial for a liquid which may evaporate inside the mixing
chamber of an internal mix nozzle or using steam to atomize the liquid. Also this nozzle
is suitable of spraying viscous fluid.
3. Rotary (spinning disc):
Rotary atomizers use a high speed rotating disk, cup or wheel to disperse the liquid into a
hollow cone spray. The rotational speed controls the drop size. Spray drying and spray
painting are the most common uses of this technology.
4. Ultrasonic:
Ultrasonic atomizers This type of spray nozzle utilizes high (20 kHz to 50 kHz)
frequency vibration to produce nearly narrow drop size distribution and low velocity
spray from a liquid. The vibration of a piezoelectric crystal causes capillary waves on the
nozzle surface liquid film.
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DESIGN OF QUENCHER
T1 - T2
ln ( T1/ T2)
T LMTD = 82.1 oC
Superficial Mass Velocities:
For Gas Stream,
G = mass flow
area
G = 6529.26 kg/m2 .hr
L = mass flow
Area
L=
19124
9.186
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DESIGN OF QUENCHER
Where
mo = molar flow rate of liquid stream = 4985.94 kmol /hr
q = heat rate required to vaporize the water to discharge temperature
Cp = 7.53 J /kmol .K
T = 82.1 oC
q = 3003929.131 J/hr
Heat Transfer Coefficient:
U = 0.43 G0.8 L0.4
Z0.5
.. equation 4
Where
Z= height of Quencher
U = Heat Transfer Coefficient
Volume of Quencher :
V = q / U x T LMTD
..equation 5
Calculation of Height of Quencher :
V = Ax Z
..equation 6
Combining equations 4, 5 and 6 we get the height of the Quencher
V = q x Z 0.5 / 0.43 G 0.8 x L 0.4 x T LMTD
A x Z = q x Z 0.5 / 0.43 G 0.8 x L 0.4 x T LMTD
Z 0.5 = q / 0.43 G 0.8 x L 0.4 x A
Putting all the values,
Z 0.5 = 3.5539
Z = 12.63 m
Volume of Quencher:
V =A x Z
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V = 116.019 m3
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DESIGN OF QUENCHER
Quencher
Item #
Q-101
Type
Spray Type
No. of item
1
Function
220 oC
85 oC
5 oC
65 oC
Operating Pressure
172 kPa
Design Temperature
350 oC
Design Pressure
200kPa
Diameter
3.419 m
Height
12.63 m
Material
Carbon Steel 81 B 45
Volume
116.01 m3
Quenching mechanism
Quenching media
H2SO4 (30 %)
Quenching Systems
Nozzles
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