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Activated Carbon Adsorption Calculator

GPSA Ch. 21

Activated Carbon Adsorption Calculator
Sizes activated carbon adsorption beds for removal of H₂S, mercury (Hg), BTEX, and VOCs from natural gas streams. Calculates vessel dimensions, carbon weight, breakthrough time, pressure drop, and operating costs. Supports design mode (new bed sizing) and rate mode (evaluate existing beds) per GPSA Ch. 21.
GPSA Ch. 21
Calculation Mode:
Design: Size new activated carbon beds from gas conditions and contaminant loading.

Gas Conditions

MMSCFD
psig
°F

Contaminant

ppmv
ppmv

Bed Design

months

Typical Carbon Capacities

Carbon Type H₂S Capacity Mercury BTEX Cost
Virgin 10% 5% 15% $0.80/lb
Impregnated 20% 12% 12% $1.50/lb
Catalytic 25% 8% 18% $2.00/lb

Engineering Basis

Adsorption Principle:

Activated carbon removes contaminants through physical adsorption (van der Waals forces) onto the carbon’s high surface area (800–1200 m²/g). Impregnated carbons add chemisorption via chemical reaction with the impregnant (KOH, NaOH, or metal oxides) for enhanced H₂S and mercury removal.

Mass Transfer Zone (MTZ):

LMTZ = v × ts

Where v = superficial velocity (ft/min), ts = stoichiometric time. The MTZ is the active adsorption zone moving through the bed. Lead-lag configurations ensure the lag bed captures breakthrough from the lead bed.

Breakthrough Curve:

Breakthrough occurs when the MTZ reaches the bed outlet and contaminant concentration rises above the outlet target. Design bed depth must exceed the MTZ length to ensure adequate contact time. Minimum contact time of 2–5 seconds is required for effective adsorption.

Design Guidelines

Superficial Velocity: 15–30 ft/min recommended. Higher velocities reduce contact time and may cause carbon attrition and channeling.
Contact Time: Minimum 2–5 seconds required for effective adsorption. Longer contact times improve removal efficiency, especially for mercury and BTEX.
Lead-Lag Configuration: Recommended for continuous operation. The lag bed captures breakthrough from the lead bed, allowing full utilization of carbon capacity before changeout.