This is the critical design constraint.
$$ \Delta P = \fracu_t^2 \times L \times \rho_l1000 \times C_d \quad \text(Simplified units) $$
A more robust Excel formula using the Hesketh Equation: $$ \Delta P \approx \fracu_t^2 \rho_g A_t^0.1331270 \times \left( L/G \right) $$ (Note: Ensure consistent units: Pa or in. w.c.)
Embed an XLOOKUP table:
| Max Temp (°C) | Material | Corrosion Allowance |
| :--- | :--- | :--- |
| 70 | PP (Polypropylene) | 3 mm |
| 150 | FRP (Vinyl Ester) | 5 mm |
| 400 | SS316L | 2 mm |
| 900 | Refractory lined CS | 0 mm |
If T_out_gas > 70°C, the Excel sheet should automatically highlight "Material Risk: Upgrade to SS316L."
This document outlines the methodology for designing a Venturi Scrubber system intended for hot gas cleaning. The design focuses on removing particulate matter (PM) from high-temperature flue gases using a liquid spray. The accompanying Excel calculation tool utilizes iterative algorithms to determine the throat dimensions, pressure drop, liquid-to-gas ratio (L/G), and overall collection efficiency.
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.
The search for "scrubber design calculation excel hot" is not about finding any spreadsheet—it is about finding the right thermodynamic engine. A standard isothermal calculator will overestimate efficiency and underestimate vessel size by a factor of 2 or more.
By building or purchasing an Excel tool that solves the adiabatic energy balance, corrects gas viscosity for temperature, and uses saturated gas volume for velocity calculations, you move from guessing to engineering.
Next Step: [Download the Pro-Tier "Hot Gas Venturi Scrubber Calculator" Excel Template (VBA Enabled)] – Includes psychrometric loop, material selector, and 3D output chart.
Author Bio: The author is a process engineer with 15 years of experience in cement kiln and incinerator scrubber retrofits.
Keywords: scrubber design calculation excel hot, venturi scrubber sizing spreadsheet, high temperature gas cleaning, adiabatic saturation Excel tool, packed bed scrubber thermal design.
Designing a wet scrubber for high-temperature ("hot") gas streams requires balancing pollutant removal efficiency with heat recovery and structural integrity
. Using Excel allows for iterative modeling of these complex thermal and chemical interactions. www.mchip.net Core Design Parameters scrubber design calculation excel hot
A proper design calculation must start with these foundational inputs: Gas Characteristics : Volumetric flow rate ( cap Q sub g ), inlet temperature ( cap T sub i n end-sub ), moisture content, and pollutant concentration (e.g., cap H sub 2 cap S cap S cap O sub 2 , or particulate matter). Removal Requirements : Desired outlet concentration ( cap C sub o u t end-sub ) and overall absorption efficiency ( Saturation State : For hot gases, calculating the saturation temperature ( cap T sub s a t end-sub
) and saturated volume is critical for sizing the shell diameter. www.mchip.net Step-by-Step Calculation Logic in Excel Gas Volume Correction
: Hot gas volume must be corrected to saturated conditions. For example, a 10,000 ACFM stream at 450°F may reduce to 7,500 ACFM upon saturation. Tower Sizing
: Determine based on the allowable gas velocity through the shell (typically 1–2 m/s or 500 ft/min).
: Calculated using the Height of a Transfer Unit (HETP) and the required Number of Transfer Units (NTU) based on absorption kinetics. Liquid-to-Gas (L/G) Ratio
: This ratio (typically 0.1 to 10) determines the volume of scrubbing liquid needed to handle the pollutant load and provide necessary cooling. Pressure Drop ( cap delta cap P : Use correlations like Norton’s Darcy-Weisbach
equation to ensure the system operates within fan/blower limits. : For hot gases, calculate the energy balance (
) to determine the cooling load or potential for heat recovery. www.mchip.net Excel Implementation Resources
For a professional starting point, utilize these established templates: EPA Cost & Design Spreadsheets US EPA Cost Calculation Spreadsheets
provide detailed tabs for Packed Bed and Wet Flue Gas Desulfurization (WFGD) parameters. Spray Tower Calculators : Marco Meloni offers a specialized Spray Tower Excel Sheet that covers removal efficiency and pressure losses. General Wet Scrubber Sheets
: Detailed sizing guides for diameter, plate thickness, and packing selection can be found on platforms like H2s Scrubber Design Calculation - MCHIP
The design of a wet scrubber—whether for particulate removal or gas absorption—requires a systematic calculation process to determine critical dimensions and operational parameters. Utilizing a structured Excel spreadsheet
allows engineers to quickly iterate through design variables like gas flow rates, temperature, and pressure drops to find an optimal configuration. 1. Define Design Inputs and Gas Conditions
The first step is establishing the "source" data. In an Excel sheet, these are typically grouped in a dedicated "Inputs" tab. Gas Stream Properties : Include the inlet volumetric flow rate (e.g., in ), inlet temperature, and pressure. Saturation Calculations
: For hot gases, the scrubber will saturate the stream. You must calculate the saturated gas flow rate cap Q sub s a t end-sub ) and temperature ( cap T sub s a t end-sub
) using a psychrometric chart or humidity ratios. The scrubber is sized based on this saturated outlet volume, not the hot inlet volume. Target Efficiency : Define the required collection efficiency (e.g., for particulates) based on regulatory standards. 2. Determine Column Diameter The column diameter ( ) is primarily a function of the gas velocity required to avoid flooding while maintaining contact time. Calculation This is the critical design constraint
: Divide the saturated volumetric flow rate by the allowable shell velocity (typically around for spray towers). Cross-Sectional Area ( cap A sub s
cap A sub s equals the fraction with numerator cap Q sub s a t end-sub and denominator v end-fraction Diameter (
cap D equals the square root of the fraction with numerator 4 cross cap A sub s and denominator pi end-fraction end-root Hydraulic Check : For packed towers, the Excel sheet should check the % Flooding (typically designed for
) using correlations like Norton’s to ensure the gas can move through the packing without pushing the liquid back up. 3. Calculate Tower Height and Packing
The height ensures sufficient contact time between the gas and the scrubbing liquid. Wet scrubber design calculation xls
🔥 Master Your Scrubber Design: Hot Gas Stream Excel Guide
Designing a scrubber for "hot" gas streams requires more than just standard absorption formulas. You must account for gas cooling, adiabatic saturation, and volume expansion. Use this structure to build a robust Excel calculator. 1. Core Inputs (The Essentials) Gas Stream Data: Inlet temperature ( Tincap T sub i n end-sub ), mass flow rate ( ṁgasm dot sub g a s end-sub ), and initial pollutant concentration ( Cincap C sub i n end-sub Target Efficiency: Desired removal percentage (e.g., 99%). Liquid-to-Gas (L/G) Ratio: Typically for wet systems. 2. Key Design Formulas for your Excel Cells Saturation Temperature ( Tsatcap T sub s a t end-sub
): The gas must be cooled before effective scrubbing. Calculate the adiabatic saturation temperature to determine the final volume. Scrubber Capacity:
Blower Capacity (per hour) = Total Air Flow Rate (m³) / Time. Removal Efficiency ( ): Excel Formula: =(Entry_Conc - Exit_Conc) / Entry_Conc. L/G Ratio: Use the Torch-Air standard of gallons per ft3f t cubed of air for high-performance units. 3. Pro-Tips for "Hot" Scrubber Sizing
Material Selection: Hot gas often requires exotic alloys or specialized FRP (Fiber Reinforced Plastic). Ensure your Excel includes a "Material Factor" lookup table.
Volume Expansion: Remember that hot gas occupies more volume (
). Your blower CFM must be sized for the actual temperature, not just standard conditions.
Water Evaporation: Calculate the water lost to evaporation to ensure your pump and hydro-tanks are sized correctly.
Looking for a pre-built template? Check out engineering resources like the Microsoft Support Guide for help with complex cell logic or Torch-Air's Engineering Blog for the full physics breakdown.
Wet Scrubber Design: Steps, Parameters, Calculation, Equations
Need the template? Reply below with your gas composition and temperature—I'll share a link to the .xlsx file with macros for the flooding chart. The search for "scrubber design calculation excel hot"
Tag your design team. 🔥 Spreadsheets save lives (and budgets).
Designing a scrubber—specifically for hot gas streams—requires accounting for gas cooling (humidification) before sizing the physical vessel. Most Excel-based guides follow a specific sequence to determine the required tower diameter and height based on mass transfer or particulate removal needs. 1. Pre-Design Step: Humidification (Hot Gas Adjustment)
Before sizing the tower, you must calculate the saturated gas flow rate. Hot inlet gas will evaporate scrubbing liquid, increasing the gas volume and cooling it to its adiabatic saturation temperature.
Identify Inlet Conditions: Inlet gas temperature, pressure, and moisture content (lb water/lb dry gas).
Calculate Saturation: Use psychrometric data to find the saturation temperature and the resulting Saturated Gas Flow Rate (ACFM). This saturated volume is the basis for all subsequent diameter calculations. 2. Sizing the Scrubber Diameter
The diameter is typically limited by gas velocity to prevent "flooding" or excessive pressure drop.
Set Design Velocity: For common spray towers, a typical velocity is approximately Calculate Area ( ): Calculate Diameter ( ):
Check Flooding (Packed Towers): If using packing, aim for a "flooding" percentage between . If it exceeds this, increase the diameter. 3. Calculating Scrubber Height
Height depends on the required efficiency for gas absorption (mass transfer) or particulate removal.
Height of a Transfer Unit (HTU): A measure of the mass transfer efficiency of the packing material or spray.
Number of Transfer Units (NTU): Based on the log-mean concentration difference between the inlet and outlet pollutants. Total Height ( ): Safety Factor: For standard designs, adding a
design safety factor to the calculated height is common practice. 4. Pressure Drop and Power
Total system pressure drop dictates the fan size needed to pull or push gas through the scrubber. Calculate ΔPcap delta cap P
: Use correlations (like the Hesketh Equation for Venturis) to find the pressure drop based on liquid-to-gas ( ) ratios and gas velocity.
Fan Power: Calculate the required blower capacity based on the total pressure drop and the polluted air flow rate. Recommended Excel Resources
You can find pre-built templates and detailed manuals at these authoritative sites: Scrubber Design and Calculation Report | PDF - Scribd
This goes far beyond a simple pressure drop sheet. It is structured as a multi-module thermodynamic & hydraulic design tool.