Flowrateofcrackedgas(ethylene)intothetower=G=11870Kg/hr

EnthalpyperKgofthecrackedgasat111C=hs+1=558.24Kj/Kg
Quenchliquidflowrateirrigatedtothetower=Ls=66760Kg/hr
SpecificHeatCapacityofwater=Cs=1Kcal/kg
Temperatureofquenchwaterbeforesection=ts1=53C
Temperatureofwaterafterthesection=ts=73C
Nowusingtherelation
G(hs+1hs)=LsCs(tsts1)
Where
G=Hourlyethyleneflowrate(Kg/hr)
hs+1=Crackedgasenthalpybeforeenteringthesection(Kcal/Kgofethylene)
hs=Crackedgasenthalpyafterthesection(Kcal/Kgofethylene)
Ls=Quenchliquidflowrate(Kg/hr)
Cs=Heatcapacityofquenchliquid(Kj/KgC)
ts=Temperatureofthequenchliquidbeforeenteringthesection(C)
ts1=Temperatureofthequenchliquidaftersection(C)

11870*(558.24hs)=67760(7353)
hs=444.22Kj/kg
Nowweknowtheenthalpyatwhichthegasisleavingthesection,andsowecanfind
thetemperatureatwhichthegasisleavingthesectionbyusingrelation
h=aT2
Where
h=Crackedfeedgasenthalpy,(Kcal/Kgofethylene)
T=Temperatureofthecrackedgas(C)
a=Aconstant,thevalueofwhichisdefinedfordifferentfeedstocks.For naphthafeed
stocksthevalueis,a=0.138.
444.22=0.138*T2
T2=444.22/0.138
T2=3218.98
Ts=57C

CalculationsforNumberofIdealStages
Thenumberofidealstagesforthissectioniethelowersectioncanbecalculatedby
usingtherelation,

ln{(Ts+1ts)/(Tsts1)}

Ns=_____________________________________

ln{(Ts+1Ts)/tsts1)}+ln{(Ts+Ts+1)/2(TsTs+1)0.5
Where
Ts+1=Temperatureofthecrackedgasbeforeenteringthesection(C)
Ts=Temperatureofthecrackedgasafterthesection(C)
ts=Temperatureofthequenchliquidbeforeenteringthesection(C)
ts1=Temperatureofthequenchliquidaftersection(C)
Now putting the values and solving the equation we get the Number of plates
theoreticallyrequired,
ln{(11173/5753)
Ns=___________________________________________
ln{(11157)/7353)}+ln{(111+57)/2(111*57)}

Ns=3.029
Nowtakingtheoverallthermalcoefficientoftheplateas0.45(As
reportedbyPicciotiandintheotherliteratureaswell),wefindtheactualNumberofPlates
byusingrelation
(Ns)Eff=Ns/Es

SotheactualNumberofPlatesforthelowersectionis

(Ns)eff=3.029/0.45

(Ns)

Eff

6.73

PlateCalculationsforSecondSection
Thesameabovedescribedprocedureisrepeatedforfindingthenumberofplatesinthe
uppersectionofthetower,wefindthetheoreticalnumberofplatesfortheuppersectionof
thequenchtowerandthesecametobe
Ns2=3.6
Actualnumberofplatesfortheuppersectionwerefoundtobe=8plates
Totalnumberofplatesrequired=8+7=15plates
TowerDesignCalculations
Estimatevaporandliquidflowrates
Vaporandliquidflowratesareestimatedbyapplyingmaterialandenergybalances
aroundwaterquenchtower.
Calculatevaporload(VLoad)
Thevaporloadisgivenbytherelation,
VLoad=Q{v/(Lv)}0.5
WhereQ=Volumetricflowofvapors(ft3/sec)
v=Densityofvapors(lb/ft3)
L=Densityofliquid(lb/ft3)
SubstitutingthevaluesVapourLoad=5.2ft3/sec
EstimationofthetowerDiameter
Fromthefigurethetowerdiametercomesouttobe4.25ftwhenasinglepasstrayis
usedwithatrayspacingof2ft.
Calculationsofactivearea(Aa)
Theactiveareaiscalculatedby,
Aa,min={VLoad+q*L/13000]C*F
Where
q=liquidflowrate(gal/min)
L=9Dt/N..(1)
Dt=Estimatedtowerdiameter(ft)
N=Numberoftraypasses

C=0.44(asforhydrocarbonsS=1SoC*S=C=C*)
F=Floodfactor=0.8
Fromequation(1)L=38.25inches.
Puttingthevaluesthevaluecomestobe
Aa,min=14.7ft2
Calculationsofdowncomerarea(Ad)
ThedowncomerareaAd,min=q/U*F
Where
U=Idealdowncomerdesignvelocity(gal/minft2)
U=U*S
TheidealdowncomerdesignvelocityU* isfoundasthesmallestvalueofthefollowing
equations
U*=41[Lv]0.5
U*=7.5[Ts(Lv)]0.5
Substitutingthevaluesthesmallestdowncomervelocityis
U*250gal/minft2
Sotheactualdowncomervalueis
U=U**S
WhereS=1(forhydrocarbons)
U=250gal/minft2
ThedowncomerareaAd,min=2.55ft2
Sincethedowncomerareaisgreaterthan11%oftheactiveareahenceitisallright.
Calculationsoftowerarea(AT)
Thetowerareaisobtainedasequations
AT=Ad,min+Aa,min
Thecalculatedtowerareais17.25ft2
Calculationsoftowerdiameter
Thediameterofthetowerisgivenbytherelation
Dt=(4*AT/)0.5
=(4*17.25/3.1416)0.5
=4.7ft
Thetowerdiametercomesouttobe4.7ft.

Calculationsofvalveunits
Thenumberofvalveunitsistakentobe14/ft2oftheactivearea.
Sothenumberofvalveunitsare=14*14.7
=206
WeirSizing
TheratioAd/AT=2.55/17.25
=0.14
Sofromthegraphweirlength/towerdia=0.78
Soweirlengthis0.78*4.7=3.66ft
Pressuredropcalculations
Thedrypressuredropisgivenby
PDry=K2V2h(v/L)
WhereVh=Velocityofgasthroughvalves=
K2 =Aconstant=1.05(forlighterhydrocarbon)
PDry=3.9inwater/tray
ThewettrayPressuredropisgivenby
PT=PDry+0.4[q/Lw]0.67+0.4hw
WhereLw=Weirlength,hw=Weirheight,q=Liquidflowrate
Puttingthevaluesandgettingtheanswer,thetotaltraypressuredropcomestobe6.6inches
water
DesignoftheUpperSection
Thedesignoftheuppersectionofwaterquenchtowerisparalleltothelowersectiondesign
Estimatevapourandliquidflowrates
Massflowrateofcrackedgas(ethylene)=26114lb/hr
Volumetricflowrateofcrackedgas=75.6ft3/sec
Massflowrateofwaterin=106480lb/hr
Volumetricflowrateofwater(q)=212.4gal/min
Calculatevapourload
VLoad=2.96ft3/sec
Estimationoftowerdiameter

Fromthegraphthetowerdiametercomesouttobe3.25ftandasinglepasstrayisusedwith
atrayspacingof2ft.
Calculationofactivearea
Aa,min=6.6ft2

Calculationsofdowncomerarea
TheidealdowncomerdesignvelocitycomestobeU=250gal/minft2
ThedowncomerareaAd,min=q/U*F=1.062ft2
Thedowncomerareaisgreaterthanthe11%oftheactiveareahenceitisallright.
Calculationsoftowerarea
AT=8.724ft2
CalculationoftowerDiameter
Thediameterofthetowerisgivenbytherelation
Dt=(4*AT/)0.5
=3.3ft
Calculationsofnumberofvalveunits
Thenumbersofvalveunitsaretakentobe14/ft2oftheactivesurface
Sothenumberofvalveunits=16*6.6=105
Weirsizing
WeirLength/Towerdia=0.72
Sothatweirlength=0.72*3.3=2.37ft
Alsodowncomerwidth/towerdia=0.15
Sothedowncomerwidth=0.15*3.3=0.695ft
Pressuredropcalculations
PDry=5.3inwater/tray
PT=7.6inwater/plate