Scrubber Design Calculation Excel Hot Page

The Excel sheet should be organized into distinct modules to handle the physics of the scrubber.

Scrubbers require a minimum liquid flow to keep the packing wetted.

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.

Designing a scrubber, specifically for "hot" or high-temperature gas streams, requires accounting for gas humidification and volume changes before sizing the vessel. You can find pre-built templates on platforms like Scribd or Cheresources that handle these calculations. Core Calculation Steps for Hot Gas Scrubbers

For high-temperature applications, the "hot" gas must be cooled to its adiabatic saturation temperature before or during the scrubbing process. Gas Inlet Properties: Define your inlet gas temperature ( Tincap T sub i n end-sub

), flow rate, and pressure. Hot gases have lower density, which significantly increases the required tower diameter.

Saturation & Humidity: Calculate the saturated gas flow rate. For example, a gas at 400°F may have a saturation temperature around 127°F, which changes the volumetric flow rate ( Qsatcap Q sub s a t end-sub ) used for sizing.

Liquid-to-Gas (L/G) Ratio: This is the most critical design parameter. For venturi scrubbers, typical ratios are 7–20 gallons per 1,000 cubic feet of gas. scrubber design calculation excel hot

Tower Diameter: Use the gas velocity and pressure drop to find the cross-sectional area. The diameter ( ) is typically calculated as Pressure Drop ( ΔPcap delta cap P

): For venturi types, use the Hesketh or Calvert equations to ensure the fan can handle the resistance. Recommended Excel Templates

Excel calculation sheet for rating of a spray tower scrubber

The hum of the plant was usually a comfort to Elias, but today, the caustic scrubber

was screaming. Not literally, of course—though the high-pressure alarm on the control panel was doing a fine job of that.

The inlet gas temperature from the kiln had spiked, and the old design parameters were failing. If the liquid-to-gas ratio stayed this off-balance, the stack would start "yellow-smoking," and the EPA would be at the gates by noon.

Elias ducked into the site office, his boots clacking on the linoleum. He pulled up his master file: Scrubber_Design_Final_v4_HOT.xlsx The Excel sheet should be organized into distinct

"Talk to me," he muttered, fingers flying across the mechanical keyboard. He didn't just need a fix; he needed a recalculation for adiabatic saturation

. As the hot gas hit the recirculating liquor, it would evaporate water instantly, cooling the gas but shrinking its volume and changing the density. The Inputs:

He punched in the new 450°F inlet temp and the soaring flow rate. The Magic:

The spreadsheet’s hidden VLOOKUPs pulled the physical properties of the gas. The NTU (Number of Transfer Units) cells turned a cautionary orange. The Solve:

He adjusted the packing depth from 10 feet to 14. The pressure drop calculation—the heart of the sheet—recalculated.

With a final tweak to the pump frequency on the screen, he watched the "Flood Point %" drop from a dangerous 92% to a stable 70%. He hit 'Save,' exported the setpoints, and ran back to the floor.

Ten minutes later, the alarm fell silent. The plume at the top of the stack turned from a ghost of a haze to invisible, clean air. Elias leaned against the steel railing, the heat of the tower radiating against his back, and smiled. If you want, I can also provide the Excel formulas (e

The math held. The Excel sheet, messy as it was, had saved the day. pressure drop across the packing for your own design?

User inputs are marked in Bold.

  • Calculation (Hot Gas Conversion): Convert actual flow to standard flow if input is volumetric, or calculate actual density using the Ideal Gas Law: $$ \rho_g = \fracP \times MWR \times T_abs $$

    • The diameter of a vertical packed scrubber is determined by the gas velocity relative to the flooding point.

  • Operating Velocity: Typically, scrubbers operate at 50–75% of the flooding velocity.
  • Diameter Result: $Area = Q_gas / Velocity$; $Diameter = \sqrt(4 \times Area) / \pi$.

    • By: Chemical Engineering Hub

    In the world of industrial air pollution control, the wet scrubber remains a non-negotiable workhorse. Whether you are dealing with kiln exhaust, furnace flue gas, or high-temperature reactor off-gases, the challenge is always the same: How do we cool and clean the gas efficiently?

    If you have searched for "scrubber design calculation excel hot," you are likely an engineer or plant operator tired of manual spreadsheets that crumble under high thermal loads. You need a robust, dynamic tool.

    This article explores the core calculations for designing a venturi or packed bed scrubber for hot gas streams and how to build (or source) an Excel template that won't freeze or fail you.

    Automatically populated, ready to print or share:

    | 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 |