The Mott Souders - George Granger Brown Equation is:

V
max
= (K) [ (r
L
- r
V
) / r
V
]
0.5
where,
V
max
=
the maximum allowable superficial vapor velocity through the vessel = 7.5 ft/sec
r
L
= the density of the liquid entering the vessel = 54.00
lb/ft
3
r
V
= the density of the vapor entering the vessel = 0.06
lb/ft
3
K = an empirical constant whose value depends on the type of vessel, the
use of internals, and the height of the disengaging space above any
mesh employed. = 0.25
Values of "K" are found in Ernest Ludwig's "Applied Process Design for Chemical and Petrochemical Plants",
Volume 1, chapter 4:
(Bottom of mesh shuld be at least 12 inches above the liquid surface)
Service Conditions K" Value
Clean fluids, moderate liquid load; fits 90% 0.36 Standard design
of process situations and applications. 0.35 High efficiency (?)
(the rating description is probably backwards) 0.25 Very high efficiency (?)
High viscosity; dirty, suspended solids 0.40 Low density or Herringbone, high
through-put
Vacuum operations:
2" Hg absolute 0.20 Standard design
16" Hg absolute 0.27 High Efficiency
Corrosive chemical 0.21 Plastic coated wire, or plastic strand
3
4
5
6
7
8
9
10
11
12
13
14
This table is from Otto H. York data.
Values based on 12 lb/ft
3
wire mesh. Design practice
normally does not exceed k of 0.4 even for higher
disengaging height.
Additionally, the GPSA Engineering Data Book (11th Edition, electronic) states that vertical separators
0.38
0.40
0.42
0.43
0.29
0.32
Calculation of a Gas-Liquid Separator or Flash Drum
K Values for Knitted Mesh
General type mesh
Variations of K with Disengaging Height
Disengaging height above mesh,
inches
0.35
Allowable "K" value
0.12
0.15
0.19
0.22
0.25
have a K factor (in ft/sec) value of 0.18 to 0.35. It recommends adjustment of the K factor due to system
pressure:
Pressure % of K
atm. 100
150 psi 90
300 psi 85
600 psi 80
1,150 psi 75
For Vertical Separator Design:
100 lb/hr = 0.463 ft
3
/sec
0.062 ft
2
0.28 ft = 3.37 inches
The GPSA states that separators without mist extractors are sized using the above equation with a K
that is typically 1/2 of that used for vessel with mist extractors.
John M. Campbell, in his book "Gas Conditioning and Processing", states: "(Separator sizing).. Is
a semi-empirical approach since one cannot measure things like droplet size and other variables.
Furthermore, many of the assumptions in the derivation of the Souders-Brown equation are not satisfied in
actual practice.
"The value of K depends on all factors that affect separation other than density - such as vortex action,
foaming, pulsating flow, liquid flowing in heads, presence of solids, degree of separation needed, separation
length, varying gas to liquid ratios, and the like. It is not surprising that K varies widely in different
applications. How does one predict it? From experience!
"Do not be nave. Most published capacity curves are for ideal conditions. Use them cautiously. Consider a
factor like pulsating flow from a well head or a two-phase line. The liquid enters in "heads". During this time
the gas rate is low. Between "heads" the gas rate is normal but little liquid enters. Using some average 24
hour gas and liquid rate to size the separator would be criminal, or at least unprofessional. There must be
sufficient capacity to handle properly the instantaneous rates expected.
"The value of K used in the Souders-Brown equation thus varies. The normal range of values is:
Separator cross-sectional area =
Separator inside diameter =
K = 0.06 to 0.35
Maximum vapor flow rate =
Art Montemayor September 30, 2005
Rev: 0
Project:
K Values
SG
liquid
0.464 0.289 ft/sec
SG
gas
0.6571 0.144 ft/sec
P 715 psig 0.231 ft/sec
T -76
o
F
Q 12,800 MScfd
Z 1.0000
r
liquid
= = 28.94 28.94 28.94 lb
f
/ ft
3
(P+14.7)(SG
gas
*28.9625) 3.37 3.37 3.37
Qr
gas
7.43 7.43 7.43
(379.49)(24)(3600)
M
rate
2.20 2.20 2.20
r
gas
K r
liquid
- r
gas
0.79 0.40 0.64
r
gas
V
rate
2.77 5.55 3.47
vel
max
12 4A 22.55 31.89 25.21
p
Vertical Separator Sizing Calculations
r
gas
=
M
rate
=
V
rate
=
vel
max
=
Vertical
Separator
(w/ mist pad)
Vertical
Separator
(w/o mist
pad)
Vertical
Separator
(Compressor)
=
= A =
=
SG
liquid
*62.371
lb
f
/ ft
3
lb
m
/ sec
inches
ft
3
/ sec
ft
2
f
ID
=
Separator (w/ mist pad)
Separator (w/o mist pad)
Compressor Separator
Inlet Conditions:
=
Units
ft / sec
=
=
Z(10.73)(T + 459.67)
Page 3 of 13
FileName: 228901629.xls.ms_office
WorkSheet: Vertical Nat. Gas Sep.
Art Montemayor September 30, 2005
Rev: 0
The Specific Gravity of a liquid fluid is defined as the density of the given liquid (at a defined temperature) divided
by the density of water at the reference temperature of 60
o
F ( 62.371 lb/ft
3
)
The Specific Gravity of a gas is defined as the density of the given gas (at a defined temperature and pressure) divided
by the density of dry air at the reference temperature and pressure of 60
o
F and 14.696 psia ( 0.076322 lb/ft
3
). Usually
the Specific Gravity is given for a gas also at 60
o
F.
The Molecular Weight of Dry Air is given as 28.9625 (GPSA Engineering Data Book; 1983)
One lb-mole of an Ideal gas yields a volume of 379.49 ft
3
at 14.696 psia and 60
o
F (GPSA Engineering Data Book.
Specific Gravity of a gas at 60
o
F and 14.696 psia = (gas Molecular Weight) / (28.9625)
The equation used to calculate Natural Gas density is:
where,
r
V
=
Natural Gas density at temperature T, lb/ft
3
MW = Natural Gas Molecular Weight, lbs/lb-mol
P = Natural Gas pressure, psia
T =
Natural Gas temperature,
o
R
Z = Natural Gas Compressibility Factor
r
V
= (MW) (P) / (10.73) (T) (Z)
Page 4 of 13
FileName: 228901629.xls.ms_office
WorkSheet: Vertical Nat. Gas Sep.
Vertical liquid-vapor separators are used primarily to disengage a liquid from a vapor when the volume of liquid is
small compared with the vapor volume. The maximum allowable vapor velocity in a vertical separator, to reduce
liquid carryover, is a function of liquid and vapor density and a constant, K, based on surface tension, droplet size,
and physical characteristics of the system. Usually these K values for vertical vessels vary between 0.1 to 0.35,
if mist eliminators are used to enhance disentrainment. Watkins
(1)
developed a correlation between separation factor
(S Fac) and K value which has proved useful in sizing process liquid-vapor separators. Watkins' data have been fitted
to an equation, and this correlation is used in this program for calculation of K values for a range of separation factors
between 0.006 and 5.0. However, other K values can be entered if desired.
Once the K value and maximum vapor velocity are determined, the cross-sectional area of the separator is calculated
using the equation for Av. Vessel diameter is calculated from cross-sectional area by the equation for D, and
maximum liquid level is calculated from liquid flow rate and surge time using the equations for QL and LL.
It is normally recommended that 36 inches plus one-half the feed nozzle OD (48 inches minimum) be left above the
feed nozzle for vapor disengagement. Below the feed nozzle, leave 12 inches plus one-half the feed nozzle OD for
clearance between the maximum liquid level and the feed nozzle (minimum of 18 inches). At some value between
L/D ratios of 3 and 5 a minimum vessel weight will occur, resulting in minimum cost for the separator's steel material
of construction.
Equations employed:
L
V
V
L
W
W
Fac S
r
r
=
) ( exp
4 3 2
GX FX EX DX B K
V
=
V
V L
Max
K V
r
r r
=
) 3600 (
V
V
V
W
Q
r
=
Max
V
V
V
Q
A =
p
V
A
D
4
=
4
2
D
A
p
=
) 60 (
L
L
L
W
Q
r
=
A
T Q
LL
L
) (
=
Nomenclature:
S Fac = Separation Factor
K
V
= Vapor velocity factor for vertical separators
V
Max
= Maximum allowable vapor velocity, ft/sec
W
L
= Liquid mass flow rate, lb/hr
W
V
= Vapor mass flow rate, lb/hr
r
V
=
Vapor density, lb/ft
3
r
L
=
Liquid density, lb/ft
3
Q
V
=
Vapor volumetric flow rate, ft
3
/sec
D = Separator's internal diameter, ft
A = Separator's cross-sectional flow area, ft
2
A
V
=
Separator's minimum cross-sectional flow area, ft
2
References:
1. Watkins, R.N.: "Sizing Separators and accumulators", Hydrocarbon Processing; November, 1967;
pp. 253-256.
A. Kayode Coker, in his book "Fortran Programs for Chemical Process Design", gives the Watkins Curve which
relates K
V
to (W
L
/W
V
) (r
V
/r
L
)
0.5
. He qualifies the data as based on five percent of the liquid being entrained with
the vapor and at 85 % of flooding.
The data on the curve are as follows:
K
V
0.006 0.23
0.008 0.25
0.01 0.27
0.02 0.41
0.04 0.45
0.06 0.44
0.08 0.43
0.1 0.42
0.2 0.35
0.4 0.28
0.6 0.2
0.8 0.17
1.0 0.14
2.0 0.07
4.0 0.033
I regressed this data using the Datafit program and got a much better equation in:
y = x/(a+b*x-c*x
2
)
a = 0.01746538478
b = 1.620701278
c = -5.47525025
(W
L
/W
V
) (r
V
/r
L
)
0.5
Vertical liquid-vapor separators are used primarily to disengage a liquid from a vapor when the volume of liquid is
small compared with the vapor volume. The maximum allowable vapor velocity in a vertical separator, to reduce
liquid carryover, is a function of liquid and vapor density and a constant, K, based on surface tension, droplet size,
and physical characteristics of the system. Usually these K values for vertical vessels vary between 0.1 to 0.35,
if mist eliminators are used to enhance disentrainment. Watkins
(1)
developed a correlation between separation factor
(S Fac) and K value which has proved useful in sizing process liquid-vapor separators. Watkins' data have been fitted
to an equation, and this correlation is used in this program for calculation of K values for a range of separation factors
Once the K value and maximum vapor velocity are determined, the cross-sectional area of the separator is calculated
using the equation for Av. Vessel diameter is calculated from cross-sectional area by the equation for D, and
maximum liquid level is calculated from liquid flow rate and surge time using the equations for QL and LL.
It is normally recommended that 36 inches plus one-half the feed nozzle OD (48 inches minimum) be left above the
feed nozzle for vapor disengagement. Below the feed nozzle, leave 12 inches plus one-half the feed nozzle OD for
clearance between the maximum liquid level and the feed nozzle (minimum of 18 inches). At some value between
L/D ratios of 3 and 5 a minimum vessel weight will occur, resulting in minimum cost for the separator's steel material
Watkins, R.N.: "Sizing Separators and accumulators", Hydrocarbon Processing; November, 1967;
A. Kayode Coker, in his book "Fortran Programs for Chemical Process Design", gives the Watkins Curve which
relates K
V
to (W
L
/W
V
) (r
V
/r
L
)
0.5
. He qualifies the data as based on five percent of the liquid being entrained with
Art Montemayor
September 30, 2005
Rev: 0
Project:
K Values
SG
liquid
0.550 Separator (w/ mist pad) 0.310 ft/sec
SG
gas
0.7000 Separator (w/o mist pad) 0.155 ft/sec
P 500 psig Filter Separator * 1.300 ft/sec
T 80
o
F
Q 50,000 M Scfd
L 30.0 Feet
r
liquid
= = 34.30 34.30 34.30 lb
m
/ ft
3
(P+14.7)(SG
gas
*28.9625) 1.75 1.75 1.75
Z(10.73)(T+460)
Qr
gas
30.92 30.92 30.92
(379.49)(24)(3600)
M
rate
17.67 17.67 17.67
r
gas
K r
liquid
- r
gas
2.47 1.24 5.61
r
gas
V
rate
7.14 14.29 3.15
vel
max
12 4A 36.19 51.18 24.04 inches
p
Horizontal Separator Sizing Calculations
f
ID
=
A =
vel
max
=
V
rate
=
M
rate
=
r
gas
=
=
=
=
LONE CAMP FILTER SEPARATOR-AT PLANT-HP TURBINES
Inlet Conditions:
* Filter Seps are Proprietary Designs. This is estimate only
SG
liquid
*62.367
Horizontal
Separator
(w/ mist pad)
Horizontal
Separator
(w/o mist pad)
Filter
Separator *
Units
ft
2
ft / sec (L/10)
0.56
lb
m
/ft
3
=
lb
m
/sec
ft
3
/ sec
=
=
Wet Gas in
Gas out
Liquid out
Page 9 of 13
FileName: 228901629.xls.ms_office
WorkSheet: Horizontal Sep
Art Montemayor August 21, 2005
Rev: 0
ANALYTICAL STUDY OF 'LIQUID/VAPOR SEPARATION EFFICIENCY
BY
Dr. W.D. Monnery Dr. W.Y. Svrcek
Chem-Pet Process Technology Ltd. Department of Chemical & Petroleum Engineering
335 Ranchridge Bay NW University of Calgary
Calgary, AB Calgary, AB T2N 1N4
5-Sep-00
SUMMARY
The purpose of this work was to establish the separation efficiency of flare knock-out drums and determine the
expected entrained liquid droplet diameter that is carried over to the flare. This was accomplished by using a
field pilot plant skid at the Prime West East Crossfield gas plant. The skid consisted of gas and liquid inlets test
separators and entrained liquid collection in a filter/coalescer. The raw test data was entrained liquid carryover
amount as a function of gas velocity data.
Experimental results provide incipient entrained liquid carryover velocities. The data show that carryover rises
sharply after the incipient carryover velocity and separation efficiency drops below 99.9%. Experimental results
indicate that entrained liquid carryover average droplet diameters are 200 to 600 microns for flare knock-out
drums at 10 to 100 psig. Calculations show that the maximum stable droplet size can be very large at low
velocities and the calculated liquid droplet size distribution indicates that there can be substantial variance in the
droplet size and that the latter may not be very uniform. In order to verify the estimated droplet sizes and
distributions, further experimental work must include the addition of online droplet size and distribution
measurement equipment.
Experimental results provide quantitative data for the relationship between horizontal and vertical K factors and
allowable velocities, which has to date been empirical and subjective. These results show that the factor between
horizontal and vertical K factors and allowable velocities vary from about 1.33 to 1.67 as L/D varies from
3.5 to 6.5.
Modeling results based on using the experimental data give entrained liquid average droplet diameters that are
consistent with API 521 for flare knock-out drums (300-600 microns) as well as other open literature. To
avoid carryover, flare knock-out drums should be designed using a droplet size of 300 microns.
1.0 INTRODUCTION/BACKGROUND
This study is part of the Alternative Flaring Technologies program sponsored by Environment Canada, CAPP
and PTAC. This study focuses on the efficiency of gravity separation as it relates to flare knockout drum
design and operation.
One of the critical issues in facilities process design and operation is vapor/liquid separation. This is also an
important issue for the improvement of existing flaring systems. The problem for flaring systems is that with the
uncertainty of design and operating conditions, liquid carryover droplets may be of such a size and composition
that they are incompletely combusted. This results in the emission of many undesirable compounds to the
atmosphere, as has been outlined in previous studies and of the current Government and Industry study
Page 1010 of 13
FileName: 228901629.xls.ms_office
WorkSheet: V-L Separator Analysis
Art Montemayor August 21, 2005
Rev: 0
aimed at mitigating emissions in flares.
There is an abundance of literature available on vapor/liquid separation and equipment design, yet there has never
been a systematic, comprehensive study to verify the accepted design methodology. Liquid vapor separator
design is described in several engineering and operating company guidelines, the GPSA Engineering Data Book
and recent publications such as Svrcek and Monnery (1993) and Monnery and Svrcek (1994). Other
publications of note are Watkins (1967) and Talavera (1990).
The present design philosophy is to simply attempt to be conservative enough so that separation equipment will
work. Unfortunately, the definition of how conservative these designs are remains in question. Furthermore,
equipment that does function properly at design rates may need to be re-rated for increased rates or at off-design
operating conditions and the above mentioned problem appears again (how conservative?). Although general
design methodology is well accepted, it is the subjectivity of some of the separation parameters used in the
models that are in question.
As such, the purpose of the research is to determine the efficiency of gravity separation. Specifically, it is to
determine the velocity at which carryover occurs and to estimate the liquid particle size going to flare. This data
can also be used to check current design criteria and estimate liquid carryover at operating conditions.
1.0 THEORY OF GRAVITY SEPARATION AND SIMPLIFIED COALESCENCE MODELLING
In a liquid-vapor separation vessel, there are typically three stages of separation. The first stage, primary
separation, uses an inlet diverter to cause the largest droplets to impinge by momentum and then drop by gravity.
The next stage is gravity separation of smaller droplets as the gas flows through the vapor disengagement section
of the separator. The final stage is mist elimination, where the smallest droplets are coalesced on an impingement
device, such as a mist pad or vane pack, followed by gravity settling of the larger formed droplets. In vessels
like flare knockout drums, we are primarily concerned with gravity separation since they typically have no
coalescing internals, such as mist pads.
For gravity separation, the allowable velocity is determined so that the required disengagement area can be
determined. For a vertical vessel, performing a force balance on the liquid droplet settling out provides the
necessary relationship. When the net gravity force, given by Eq.1,
.(1)
balances the drag force, given by Eq. 2,
.(2)
the liquid droplets will settle at a constant terminal velocity, U
T
. Equating Eqs. 1 and 2 results in:
c L
V L P
G
g
g M
F
r
r r ) (
=
c
V V P D
D
g
U D C
F
r p
2 2
) 8 / (
=
c
V V P D
D
g
U D C
F
r p
2 2
) 8 / (
=
Page 1111 of 13
FileName: 228901629.xls.ms_office
WorkSheet: V-L Separator Analysis
Art Montemayor August 21, 2005
Rev: 0
The purpose of this work was to establish the separation efficiency of flare knock-out drums and determine the
expected entrained liquid droplet diameter that is carried over to the flare. This was accomplished by using a
field pilot plant skid at the Prime West East Crossfield gas plant. The skid consisted of gas and liquid inlets test
separators and entrained liquid collection in a filter/coalescer. The raw test data was entrained liquid carryover
Experimental results provide incipient entrained liquid carryover velocities. The data show that carryover rises
sharply after the incipient carryover velocity and separation efficiency drops below 99.9%. Experimental results
indicate that entrained liquid carryover average droplet diameters are 200 to 600 microns for flare knock-out
drums at 10 to 100 psig. Calculations show that the maximum stable droplet size can be very large at low
velocities and the calculated liquid droplet size distribution indicates that there can be substantial variance in the
droplet size and that the latter may not be very uniform. In order to verify the estimated droplet sizes and
distributions, further experimental work must include the addition of online droplet size and distribution
Experimental results provide quantitative data for the relationship between horizontal and vertical K factors and
allowable velocities, which has to date been empirical and subjective. These results show that the factor between
horizontal and vertical K factors and allowable velocities vary from about 1.33 to 1.67 as L/D varies from
Modeling results based on using the experimental data give entrained liquid average droplet diameters that are
consistent with API 521 for flare knock-out drums (300-600 microns) as well as other open literature. To
This study is part of the Alternative Flaring Technologies program sponsored by Environment Canada, CAPP
and PTAC. This study focuses on the efficiency of gravity separation as it relates to flare knockout drum
One of the critical issues in facilities process design and operation is vapor/liquid separation. This is also an
important issue for the improvement of existing flaring systems. The problem for flaring systems is that with the
uncertainty of design and operating conditions, liquid carryover droplets may be of such a size and composition
that they are incompletely combusted. This results in the emission of many undesirable compounds to the
Page 1212 of 13
FileName: 228901629.xls.ms_office
WorkSheet: V-L Separator Analysis
Art Montemayor August 21, 2005
Rev: 0
There is an abundance of literature available on vapor/liquid separation and equipment design, yet there has never
been a systematic, comprehensive study to verify the accepted design methodology. Liquid vapor separator
design is described in several engineering and operating company guidelines, the GPSA Engineering Data Book
The present design philosophy is to simply attempt to be conservative enough so that separation equipment will
work. Unfortunately, the definition of how conservative these designs are remains in question. Furthermore,
equipment that does function properly at design rates may need to be re-rated for increased rates or at off-design
operating conditions and the above mentioned problem appears again (how conservative?). Although general
design methodology is well accepted, it is the subjectivity of some of the separation parameters used in the
As such, the purpose of the research is to determine the efficiency of gravity separation. Specifically, it is to
determine the velocity at which carryover occurs and to estimate the liquid particle size going to flare. This data
In a liquid-vapor separation vessel, there are typically three stages of separation. The first stage, primary
separation, uses an inlet diverter to cause the largest droplets to impinge by momentum and then drop by gravity.
The next stage is gravity separation of smaller droplets as the gas flows through the vapor disengagement section
of the separator. The final stage is mist elimination, where the smallest droplets are coalesced on an impingement
device, such as a mist pad or vane pack, followed by gravity settling of the larger formed droplets. In vessels
like flare knockout drums, we are primarily concerned with gravity separation since they typically have no
For gravity separation, the allowable velocity is determined so that the required disengagement area can be
determined. For a vertical vessel, performing a force balance on the liquid droplet settling out provides the
Page 1313 of 13
FileName: 228901629.xls.ms_office
WorkSheet: V-L Separator Analysis