Mathematical Modeling of Heat and Mass Processes in a Scrubber: The Box–Wilson Optimization Method

Optimal performance parameters must be found in order to organize efficient heat and mass transfer and effective flue gas cooling using a wet scrubber. Mathematical models are widely used for system optimization. However, a significant number of the available models have application limitations. This study presents a universal model for heat and mass transfer simulation in a scrubber called a fog unit, which has been developed and validated. Validation was performed by comparing the experimental and calculated results. Good agreement was achieved among the data, with differences between results not exceeding 10%. The model facilitates an investigation of the effects of gas flow, droplet size, and sprayed water on heat recovery from flue gas. An experimental matrix for fog unit capacity which included five main variables was designed and analyzed. The boundaries of the parameters are set considering the results of the experiments. The optimization method used is the path of the steepest ascent. The obtained results show the parameter change steps to achieve higher capacity of the condenser. In the studied unit, the maximum condenser capacity is limited by a flue gas flow value of 0.01 Nm 3 /s. The condenser optimization study that was conducted is viewed as a basis for further studies.