The scrubber design Excel template is not just a collection of formulas; it is a user-friendly, robust tool that: Allows quick iterations of packing types and sizes. Automatically checks for flooding.
High-quality, pre-built Excel templates can be found through professional engineering communities and regulatory agencies: Wet Scrubber Application Guide - Sly Inc.
: The U.S. EPA provides specialized spreadsheets for calculating both the design parameters and annualized costs for wet and dry scrubbers.
High pressure drops increase blower horsepower requirements, leading to high utility bills over the system's operational lifespan.
Before trusting your spreadsheet for live projects, validate its calculations against known cases. Input data from an existing scrubber and verify that the calculated diameter, pressure drop, and efficiency match actual performance data. scrubber design calculation excel best
y2=y1×(1−η)y sub 2 equals y sub 1 cross open paren 1 minus eta close paren 2. Determine Column Diameter (Flooding Approach)
, engineers look up the flooding line on an Eckert diagram. In Excel, you can convert the Eckert curve into a polynomial equation using regression analysis, allowing Excel to calculate the flooding point automatically using the TREND or LINEST functions.
) ratios, and estimating pressure drop. The "best" Excel-based approach involves a structured layout that separates input constants, intermediate physical property calculations, and final design outputs. Core Calculation Steps
Sizing the column diameter prevents , a failure state where gas velocity hinders the downward flow of liquid. Excel solves this using the Sherwood-Shipley-Holloway flooding correlation. Step A: Calculate the Flow Parameter ( Flvcap F sub l v end-sub The scrubber design Excel template is not just
Column Diameter (D)=4⋅AcπColumn Diameter open paren cap D close paren equals the square root of the fraction with numerator 4 center dot cap A sub c and denominator pi end-fraction end-root 4. Packing Properties Reference Table
If you want to tailor this further, let me know the you are scrubbing (e.g., SO2cap S cap O sub 2 NH3cap N cap H sub 3 HClcap H cap C l
Dedicate this area to raw process variables. Never hardcode numbers inside formulas; reference these input cells instead. Gas molecular weight Inlet/outlet concentrations Selected packing factor ( Fpcap F sub p Zone 2: Lookup Tables (Gray Reference Sheets)
) transfer units to find the overall height of a transfer unit ( HOGcap H sub cap O cap G end-sub Step 5: Pressure Drop Verification Calculate the pressure drop per foot of packing ( : The U
Include worksheets for capital cost estimation (vessel, packing, nozzles, mist eliminator) and operating cost estimation (fan power, liquid pumping, chemical consumption, maintenance). This transforms your spreadsheet from a sizing tool into a full decision-support system.
Uf=Y⋅g⋅ρlFp⋅ρg⋅μl0.1cap U sub f equals the square root of the fraction with numerator cap Y center dot g center dot rho sub l and denominator cap F sub p center dot rho sub g center dot mu sub l to the 0.1 power end-fraction end-root (acceleration due to gravity) Fpcap F sub p = Packing Factor ( m-1m to the negative 1 power ), specific to the packing type and size. μlmu sub l = Liquid viscosity ( Cross-Sectional Area and Sizing Industrial scrubbers typically operate between of the gas flooding velocity to prevent entrainment.
Y=exp(c0+c1⋅ln(Flv)+c2⋅(ln(Flv))2)cap Y equals exp open paren c sub 0 plus c sub 1 center dot l n open paren cap F sub l v end-sub close paren plus c sub 2 center dot open paren l n open paren cap F sub l v end-sub close paren close paren squared close paren The gas flooding velocity ( Ufcap U sub f ) is determined by: