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Designing Entrainment Separation Vessels
Designing Entrainment Separation Vessels
A Knockout drum with a mist eliminator is common whenever a process requires entrained droplets to be separated from a vapor stream. A simple knockout drum (no mist eliminator) will remove droplets larger than about 380 microns by gravity settling M. generally gravity settling removes more than 90% of the liquid entering the vessel .However the remaining droplets smaller than 380 microns can be a significant problem for a downstream unit. A mist eliminator in the top of the knockout drum will remove the remaining droplets down to a diameter of 6 microns or less, depending on the type of mist eliminator. A knockout drum with mist eliminator can achieve an overall efficiency of 99.99% liquid removal.
By expressing vapor loading in terms of the Souders-Brown transformation, a design variable is created which is largely independent of the system variable (molecular weight, density, pressure, temperature, viscosity, surface tension etc). this combined variable vapor load factor correlates buoyancy and differential inertial effects for a wide range of liquid/vapor systems. A similar design variable, designated Fs is also used for Liquid/Vapor systems. Fs accounts for vapor inertial effects but not buoyancy effects or differential inertial effects. Fs is defined as : Fs = Vv * (V)^0.5 In hydrocarbon liquid/vapor systems at a pressures higher than approximately 120 Psia, system load factors less than 0.35 ft/sec should be used as the design basis. Droplet terminal velocity departs significantly from Stokes Law as the system approaches the critical point. The main reason is that the interfacial tension decreases (approaches zero at the critical point ). Another reason is that the density difference (liquid-vapor) approaches zero.
However, because of liquid holdup, the cross sectional area for vapor flow causes an operating vapor load factor of 0.4 to 0.5 ft/sec for vertically installed mist eliminators. This vapor load corresponds to the optimum load for wire mesh pads in the horizontal flow. The design basis for the horizontal mist eliminator in a horizontal vessel should be K = 0.5 ft/sec (or less). The height of a vertical knockout drum is constrained by a number of factors. The following design guidelines are typical: 1. The top of a horizontal mist eliminator should be at least one-half vessel diameter from the exit nozzle (top or side mounted). This reduces the nonuniform flow through the pad caused by a radial pressure gradient. 2. The bottom of a mist eliminator should be at least one vessel diameter from the centerline of the inlet nozzle (side mounted). One-half vessel diameter is used in some cases (for light liquid loading) to satisfy space constraints. However, if the inlet fluid is a flashing liquid, one vessel diameter is essential for vapor/liquid disengaging. 3. The liquid level should be at least one-half vessel diameter below the side inlet nozzle centerline in order to avoid inducing. 4. If the vessel is to provide a liquid surge volume, the appropriate height increment will be required. For preliminary designs and cost estimates, the vessel aspect ratio (height/diameter) may be estimated at 2.5 (for zero liquid holdup) or 3.0 (to allow for liquid holdup).
The vessel manway may allow vessel entry below or above the mist eliminator. A manway location below the mist eliminator is typical. It should be located at 90 degrees from the inlet jet. A vortex breaker in the bottom of the vessel prevents potential pump suction problems if a pump is used to remove collected liquids. Tangential entry nozzles have been used on knockout vessels, but the swirling action of the gas can interfere with the operation of the mist eliminator. The insertion type unit may be used with a tangential inlet.
In general, vane mist pads should be selected when high liquid rates or high particulate loading are expected. TEX-MESH Technical bulletin 104 discusses design and selection guidelines for vane mist eliminators.
Operating Problems
If specified properly, a mist pad generally operates effectively and is essentially an inconspicuous component in a process. However, problems are generally a result of fouling (plugging of the mist pad by solid particles). At start-up, if the process equipment upstream of the mist pad is not flushed adequately, the mist pad is likely to collect dirt, scale, and other debris.
Furthermore, after the plant has operated for some time, solids can eventually plug the mist eliminator. Mist pads are efficient collectors of solids as well as liquids. If the solids are likely to reach the mist eliminator, a continuous or intermittent wash system above the pad establishes counter-current wash flow throughout the pad. Spraying from under the pad establishes heavy liquid loading at the bottom and a dry condition at the top of the pad. It is critical to limit the total liquid loading (wash liquid plus entrainment) to about 1.0 gpm/ft2. If higher liquid loading is unavoidable, then a corresponding decrease in vapor loading is required to avoid flooding. Vane mist pads seldom fail because of fouling. Solids either pass through or are washed off by the coalesced liquid. Relief Panels have been installed in the mist pads, but they often cause problems. When a mist pad becomes plugged, either the excess pressure drop indicates the problem, or tie wires or other mechanical supports fail, causing an upset in the process. A fouled pad is difficult to clean, but it is sometimes done. Non-Uniform flow in a mist pad can cause a local re-entrainment or local inefficiency. If fouling is not present, non-uniform flow is caused by improper placements of nozzles, baffles or blanking plates. Since wire mesh mist eliminators typically are constructed from stainless steel wire 0.006 to 0.011 inch in diameter, if corrosion failure is a problem, it will become obvious immediately. Correct material selection is essential.
Conclusion
The purpose of an entrainment separator is to maximize the detrimental effect of entrained liquid in a vapor stream. Very often, a knockout drum with a mist eliminator is the most cost effective method for entrainment control. Properly designed, the unit will provide trouble-free performance for many years.