Bubble-caps

Nonisothermal Gas Absorption. The computation of nonisothermal gas absorption processes is difficult because of all the interactions involved as described for packed columns. A computer is normally required for the enormous number of plate calculations necessary to estabUsh the correct concentration and temperature profiles through the tower. Suitable algorithms have been developed (46,105) and nonisothermal gas absorption in plate columns has been studied experimentally and the measured profiles compared to the calculated results (47,106). Figure 27 shows a typical Hquid temperature profile observed in an adiabatic bubble plate absorber (107). The close agreement between the calculated and observed profiles was obtained without adjusting parameters. The plate efficiencies required for the calculations were measured independendy on a single exact copy of the bubble cap plates installed in the five-tray absorber. 

Fig. 27. Computed and experimental Hquid temperature profiles in an ammonia absorber with 5 bubble cap trays (107). Water was used as a solvent.

Recovery of Ammonia. The filter Hquor contains unreacted sodium chloride and substantially all the ammonia with which the brine was originally saturated. The ammonia may be fixed or free. Fixed ammonia (ammonium chloride [12125-02-97]) corresponds stoichiometrically to the precipitated sodium bicarbonate. Free ammonia includes salts such as ammonium hydroxide, bicarbonate, and carbonate, and the several possible carbon—ammonia compounds that decompose at moderate temperatures. A sulfide solution may be added to the filter Hquor for corrosion protection. The sulfide is distilled for eventual absorption by the brine in the absorber. As the filter Hquor enters the distiller, it is preheated by indirect contact with departing gases. The warmed Hquor enters the main coke, tile, or bubble cap-fiUed sections of the distiller where heat decomposes the free ammonium compounds and steam strips the ammonia and carbon dioxide from the solution. 

Several descriptions have been pubUshed of the continuous tar stills used in the CIS (9—11). These appear to be of the single-pass, atmospheric-pressure type, but are noteworthy in three respects the stills do not employ heat exchange and they incorporate a column having a bubble-cap fractionating section and a baffled enrichment section instead of the simple baffled-pitch flash chamber used in other designs. Both this column and the fractionation column, from which light oil and water overhead distillates, carboHc and naphthalene oil side streams, and a wash oil-base product are taken, are equipped with reboilers. 

The rectifying section contains three or four bubble cap (wine) plates in the top section of the stiU to produce distillates up to 160° proof. Whiskey stills are usually made of copper, especially in the rectifying section, which often yields a superior product. Additional copper surface in the upper section of the column may be provided by a demister, a flat disk of copper mesh. Stainless steel is also used in some stills. 

Steam is introduced at the base of the whiskey column through a sparger. Where economy is an important factor, as in a fuel alcohol plant, a calandtia is employed as the source of indirect heat. The diameter of the stiU, number of perforated and bubble cap plates, capacity of the doubler, and proof of distiUation are the critical factors that largely determine the characteristics of a whiskey. 

Bourbon Distillation. The basic distiUation system for the production of bourbon and other straight whiskeys consists of a beer stiU and a beer heater, thumper, or doubler (Fig. 4). The whiskey stiU consists of between 14 and 21 stripping trays. The upper portion of the stiU is fitted with either a bubble cap section or a section packed with copper rings to enhance the removal of unwanted flavors and ethyl carbamate precursors. The reduction of carbamate precursors requites strict adherence to a cleaning protocol with a 5% caustic solution as often as twice a week. 

The lye boHer is usuaHy steam heated but may be direct-fired. Separation efficiency may be iacreased by adding a tower section with bubble-cap trays. To permit the bicarbonate content of the solution to buHd up, many plants are designed to recirculate the lye over the absorber tower with only 20—25% of the solution flowing over this tower passiag through the boHer. Several absorbers may also be used ia series to iacrease absorptioa efficieacies. 

Three principal vapor—Hquid contacting devices are used in current crossflow plate design the sieve plate, the valve plate, and the bubble cap plate. These devices provide the needed intimate contacting of vapor and Hquid, requisite to maximizing transfer of mass across the interfacial boundary. 

Fig. 18. Flooding correlation for crossflow trays (sieve, valve, bubble-cap) where the numbers represent tray spacing in mm. Also shown are approximate...

Research. Much of the research on commercial-size distiUation equipment is being done by Fractionation Research, Inc. (FRI), a nonprofit, industry-sponsored, research corporation. The industrial sponsors are fabricators, designers, and constmctors, or users of distiUation equipment. PubHcations include Hquid mixing on sieve plates (91), bubble cap plate efficiency (92), and sieve plate efficiency (93,94). A motion picture of downcomer performance is also avaUable (95). References 96 and 97 cover the Hterature from 1967 to 1990. 

It should be noted that the fraction of column cross-sectional area available for gas dispersers (perforations, bubble caps) decreases when more than one downcomer is used. Thus, optimum design of the plate involves a balance between hquid-flow accommodation and effective use of cross section for gas flow. 

Historically the most common gas disperser for cross-flow plates has been the bubble cap. This device has a built-in seal which prevents liquid drainage at low gas-flow rates. Typical bubble caps are shown in Fig. 14-20. Gas flows up through a center riser, reverses flow under the cap, passes downward through the annulus between riser and cap, and finally passes into the liquid through a series of openings, or slots, in the lower side of the cap. 

Bubble caps were used almost exclusively as cross-flow-plate dispersers until about 1950, when they were largely displaced by simple or valve-type perforations. Many varieties of bubble-cap design were used (and therefore are extant in many operating columns), but in most cases bell caps of 75- to 150-mm (3- to 6-in) diameter were utilized. 

Figure 14-25 or Eq. (14-92) may be used for sieve plates, valve plates, or bubble-cap plates. The value of the flooding vapor velocity must be considered as approximate, and prudent designs call for approaches to flooding of 75 to 85 percent. The value of the capacity parameter (ordinate term in Fig. 14-25) may be used to calculate the maximum allowable vapor velocity through the net area of the plate ... 

FIG. 14-25 Flooding correlation for columns with crossflow plates (sieve, valve, bubble-cap). [Fair, Pet/Chem Eng 33(10), 45 (September 1961),]... 

Ratio of slot (bubble cap), perforation (sieve), or full valve opening (valve plate) area A/, to active area A is 0.1 or greater. Otherwise the value of U j obtained from Fig. 14-25 should be corrected ... 

Plate Layouts Cross-flow plates, whether bubble-cap, sieve, or valve, are similar in layout (Fig. 14-28). Possible zones on each plate are Active vapor-dispersion Peripheral stiffening and support Disengaging Distributing Downcomer... 

The peripheral stiffening zone (tray ring) is generally 25 to 50 mm (1 to 2 in) wide and occupies 2 to 5 percent of the cross section, the fraction decreasing with increase in plate diameter. Peripheiy waste (Fig. 14-28) occurs primarily with bubble-cap trays and results from the inabihty to fit the cap layout to the circular form of the plate. Valves and perforations can be located close to the wall and little dead area results. Typical values of the fraction of the total cross-sectional area available for vapor dispersion and contact with the liquid for cross-flow plates with a chord weir equal to 75 percent of the column diameter are given in Table 14-6. 

The plate thickness of bubble-cap and sieve plates is generally estabhshed by mechanical design factors and has little effect on pressure drop. For a sieve plate, however, the plate is an integral component of the vapor-dispersion system, and its thickness is important. 

The open area for these plates ranges from 15 to 30 percent of the total cross section compared with 5 to 15 percent for sieve plates and 8 to 15 percent for bubble-cap plates. Hole sizes range from 6 to 25 mm (1/4 to 1 in), and slot widths from 6 to 12 mm (14 to V2 in). The Turbogrid and Ripple plates are proprietary devices. 

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