Scrubber Design Calculation Excel Hot 【90% PREMIUM】

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| Parameter | Value | Unit | |-----------|-------|------| | Gas flow rate (actual @ T,in) | 25,000 | m³/h | | Inlet gas temperature | 850 | °C | | Outlet gas temperature | 72 | °C | | Evaporation rate | 2.8 | L/s | | Scrubber type | Venturi | - | | Pressure drop | 12.4 | kPa | | Overall efficiency (2 µm) | 96.3 | % | | d50 cut diameter | 0.85 | µm | | Vessel diameter | 1.8 | m | | Total installed cost (est.) | $187,000 | USD | | Annual operating cost | $34,200 | USD/year |

The throat velocity must typically range between 60 m/s to 120 m/s (200–400 ft/s) for effective atomization.

When a hot gas enters, water evaporates. If you don't account for this, you'll run dry.

Heat to remove: $$Q_sensible = m_g \times C_p,g \times (T_in - T_out)$$

Water evaporated: $$m_evap (kg/h) = \fracQ_sensible2257 , kJ/kg$$

Excel check: Add a cell that calculates Evaporation % of recirc flow. If > 3-5%, you need blowdown or a bigger pump.

Create these mandatory input cells:

The gas will cool to the adiabatic saturation temperature (typically 40°C to 70°C depending on water temperature). Equation: m_gas * Cp_gas * (T_in - T_out) = m_water * λ Where λ is the latent heat of vaporization of water.

If you want, I can also provide the Excel formulas (e.g., for adiabatic saturation, pressure drop, or d50) so you can implement them directly into cells. Just let me know which module you'd like to start with.

Scrubber Design Calculation using Excel

A scrubber is a type of air pollution control device that uses a liquid to remove contaminants and pollutants from gas streams. Designing a scrubber requires careful calculation of various parameters to ensure effective performance. Here's a step-by-step guide on how to perform scrubber design calculations using Excel:

Step 1: Define Design Parameters

Step 2: Calculate Scrubber Diameter

The scrubber diameter (D) can be calculated using the following formula:

D = √(4 * Qg / (π * Vg))

where Vg is the gas velocity (m/s or ft/s)

Assuming a typical gas velocity of 3-5 m/s, let's use 4 m/s for this example.

| | | | --- | --- | | Qg (m³/s) | 1 | | Vg (m/s) | 4 | | D (m) | =SQRT(4*1/(PI()*4)) | =0.89 m |

Step 3: Calculate Scrubber Height

The scrubber height (H) can be calculated using the following formula:

H = (L/D) * D

where L/D is the aspect ratio (typically 3-5)

Assuming an aspect ratio of 4, let's use L/D = 4 for this example.

| | | | --- | --- | | L/D | 4 | | D (m) | 0.89 | | H (m) | =4*0.89 | =3.56 m |

Step 4: Calculate Liquid-to-Gas Ratio (L/G)

The liquid-to-gas ratio (L/G) is a critical parameter in scrubber design. A higher L/G ratio typically results in better contaminant removal, but also increases the energy consumption.

L/G = Ql / Qg

| | | | --- | --- | | Ql (m³/s) | 0.01 | | Qg (m³/s) | 1 | | L/G | =0.01/1 | =0.01 |

Step 5: Calculate Contaminant Removal Efficiency

The contaminant removal efficiency (η) can be calculated using the following formula:

η = (C_in - C_out) / C_in

where C_in is the inlet contaminant concentration and C_out is the outlet contaminant concentration.

Assuming a target removal efficiency of 90%, let's use η = 0.9 for this example.

| | | | --- | --- | | C_in (ppm) | 100 | | η | 0.9 | | C_out (ppm) | =(1-0.9)*100 | =10 ppm |

Excel Template

Here's an example Excel template that you can use to perform scrubber design calculations:

| Parameter | Value | Unit | | --- | --- | --- | | Gas flow rate (Qg) | | m³/s | | Gas temperature (Tg) | | °C | | Gas pressure (Pg) | | Pa | | Liquid flow rate (Ql) | | m³/s | | Liquid temperature (Tl) | | °C | | Contaminant concentration (C) | | ppm | | Scrubber diameter (D) | | m | | Scrubber height (H) | | m | | Liquid-to-gas ratio (L/G) | | - | | Contaminant removal efficiency (η) | | - |

You can download a sample Excel template from [insert link].

Conclusion

Scrubber design calculations involve several steps, including defining design parameters, calculating scrubber diameter and height, determining liquid-to-gas ratio, and estimating contaminant removal efficiency. By using Excel templates, you can simplify these calculations and optimize your scrubber design. Remember to validate your results with experimental data or simulation models to ensure accurate performance.

To get a highly accurate wet scrubber design calculation Excel sheet, you must account for thermal effects, evaporation, and gas expansion when handling hot gas streams. 

Below is the complete step-by-step framework to build your own robust design spreadsheet in Excel.  📊 Core Spreadsheet Input Parameters  scrubber design calculation excel hot

To begin your calculations, set up an Inputs Section in your Excel sheet with the following variables:  Gas Properties: Inlet Gas Flow Rate ( Qg,incap Q sub g comma i n end-sub ) in or CFMcap C cap F cap M . Inlet Gas Temperature ( Tincap T sub i n end-sub ) in ∘Craised to the composed with power cap C . Gas Molecular Weight ( MWgcap M cap W sub g ). Liquid Properties: Scrubbing Liquid (usually water) Inlet Temperature ( TL,incap T sub cap L comma i n end-sub ). Liquid Density ( ρLrho sub cap L ). Pollutant Data: Inlet Concentration ( Cincap C sub i n end-sub ). Desired Outlet Concentration ( Coutcap C sub o u t end-sub ) or target efficiency.  ⚙️ Step-by-Step Design Calculations 

Use these sequential formulas to build out the active calculating cells in your Excel grid.  1. Hot Gas Quenching & Saturation 

Hot gases will immediately evaporate a portion of the scrubbing liquid upon contact, cooling the gas to its adiabatic saturation temperature.  Excel Goal: Calculate the saturated gas flow rate ( Qg,satcap Q sub g comma s a t end-sub ).

Concept: Use the ideal gas law to account for volume shrinkage due to cooling, balanced against volume increase from added water vapor. Formula Clue:   2. Tower Diameter (Flooding Velocity Method) 

To prevent the liquid from being blown out of the top of the scrubber, you must calculate the tower's cross-sectional area based on the gas velocity.  Action: Calculate the Flooding Gas Velocity ( Ufcap U sub f ) using the Sherwood-Lobo Correlation. Excel Formula:Set your operating velocity ( Uopcap U sub o p end-sub ) at 60% to 70% of the flooding velocity.

Tower Area (A)=Qg,satUopTower Area open paren cap A close paren equals the fraction with numerator cap Q sub g comma s a t end-sub and denominator cap U sub o p end-sub end-fraction

Diameter (D)=4×AπDiameter open paren cap D close paren equals the square root of the fraction with numerator 4 cross cap A and denominator pi end-fraction end-root   3. Packing Height (Mass Transfer) 

This determines how tall your packed bed needs to be to achieve your removal efficiency.  Formula:

HTU (Height of a Transfer Unit): Characterizes the mass transfer efficiency of your chosen packing material. NTU (Number of Transfer Units): for lean systems.  4. Liquid-to-Gas (L/G) Ratio 

For effective particulate and acid gas removal, typical L/G ratios range from 1 to 3 liters of liquid per cubic meter of gas.

Ensure your pump sizing in Excel accounts for this total volume.  ⚠️ Critical Checks for "Hot" Gas Scrubbers  If your incoming gas is over 150∘C150 raised to the composed with power cap C ( 300∘F300 raised to the composed with power cap F

), you must build these safety checks into your Excel sheet: 

Materials of Construction (MOC): Standard fiberglass (FRP) or plastics like PVC will melt. Your spreadsheet should flag temperatures and recommend High-Temperature FRP, Hastelloy, or a brick-lined quench section.

Make-up Water Rate: Account for massive water loss due to evaporation. Your Excel sheet must calculate: . 

To help me tailor a specific set of formulas or a ready-to-copy tabular layout for your sheet, could you tell me:  What is the inlet temperature of your hot gas? What specific pollutant are you trying to scrub (e.g., SO2cap S cap O sub 2 , HClcap H cap C l , or just fly ash/dust)? Do you prefer your calculations in SI units (Celsius, ) or Imperial units (Fahrenheit, CFMcap C cap F cap M )? 

Wet Scrubber: Efficiency Сalculation, L/G Ratio, and Pressure Drop

The first step is to establish the properties of the incoming hot gas. Because the gas is "hot," you must account for its actual volume at operating temperature rather than standard conditions. Gas Flow Rate ( Vincap V sub i n end-sub ): Define in ACFM (Actual Cubic Feet per Minute) or Inlet Temperature ( Tincap T sub i n end-sub ): Note the temperature (e.g., 400∘F400 raised to the composed with power cap F 590∘C590 raised to the composed with power cap C

Contaminant Data: Identify the molecular weight and concentration (ppm or ) of the component to be removed (e.g., HCl, H2Scap H sub 2 cap S Gas Properties: Calculate gas density ( ρgrho sub g

) at inlet temperature and pressure using the Ideal Gas Law. 2. Perform Humidification and Saturation Calculations

Hot gases will evaporate the scrubbing liquid until they reach the adiabatic saturation temperature ( Tsatcap T sub s a t end-sub

). The scrubber must be sized for the saturated gas volume, not the inlet volume. Determine Saturation Temperature ( Tsatcap T sub s a t end-sub Automatically populated, ready to print or share: |

): Use a psychrometric chart or humidity balance to find the temperature at which the gas becomes saturated with moisture. Calculate Saturated Gas Flow ( Qsatcap Q sub s a t end-sub ):

Qsat=Qin×Volume Correction Factorcap Q sub s a t end-sub equals cap Q sub i n end-sub cross Volume Correction Factor For example, a gas at 450∘F450 raised to the composed with power cap F might have a correction factor of 3. Determine Column Diameter

The tower diameter is typically calculated to avoid "flooding," where upward gas velocity prevents downward liquid flow.

Select Packing Material: Choose a packing type (e.g., Intalox Saddles, Rosette) and its specific Packing Factor ( Fpcap F sub p ).

Calculate Flooding Velocity: Use the Generalized Pressure Drop Correlation (GPDC). Aim for an operating velocity between of the flooding velocity. Find Cross-Sectional Area ( Ascap A sub s ):

As=Qsatvgascap A sub s equals the fraction with numerator cap Q sub s a t end-sub and denominator v sub g a s end-sub end-fraction vgasv sub g a s end-sub is the selected design gas velocity (e.g., Final Diameter ( ):

D=4×Asπcap D equals the square root of the fraction with numerator 4 cross cap A sub s and denominator pi end-fraction end-root 4. Determine Packing Height

The required height depends on the mass transfer efficiency needed to meet outlet concentration targets.

HCL Packed Column Scrubber Design | PDF | Mole (Unit) - Scribd

Here’s a ready-to-post LinkedIn or forum-style post about scrubber design calculations using Excel, optimized for the keyword “scrubber design calculation excel hot”:

🔥 Scrubber Design Calculation Excel Hot – Master Wet Scrubbers with This Spreadsheet Tool 🧹💨

Struggling with manual venturi or packed bed scrubber sizing?
Want a fast, repeatable, and hot-off-the-press Excel tool for air pollution control design?

I’ve just updated my Scrubber Design Calculator – and it’s packed with features:

✅ Packed column scrubber – Diameter, pressure drop (Norton / Eckert), HETP, and packing height
✅ Venturi scrubber – Throat velocity, pressure drop, liquid-to-gas ratio, and particulate removal efficiency (Johnstone eqn.)
✅ Gas absorption – NOx, SO₂, or HCl removal with mass transfer coefficients
✅ Duct & fan sizing with static pressure loss
✅ Water balance & blowdown calculation
✅ Built-in unit converter and chemical properties table

🔥 Why “Excel Hot”?
Because it’s fully editable – no black-box VBA, just transparent formulas and lookup tables. Change packing type, gas flow, or removal efficiency – results update instantly.

📥 Perfect for:

👉 Comment “SCRUBBER” below, and I’ll DM you the download link (free limited version + paid full version).

Let’s design cleaner air – smarter and faster. 💨📊

#ScrubberDesign #ExcelHot #AirPollutionControl #WetScrubber #ChemicalEngineering #ExcelForEngineers #EnvironmentalEngineering

Title: Scrubber Design Calculation in Excel: The Hot, Handy Template You Need

Meta Description: Stop guessing the L/G ratio. Here is a step-by-step guide to building a hot (high-temperature) packed bed scrubber design sheet in Excel, including flooding velocity, pressure drop, and makeup water. The throat velocity must typically range between 60