# Project: 3rd year design By: D.

Mody Date: Nov 25 2008

Engineering Calculations

Purpose: Vertical Separator Calculation This example shows a difficult to size separator due to the very high liquid flow rates

Method: The method follows that presented in "Applied Process Design, Vol 1" by Ernest Ludwig for impingment separators vallow = k⋅ ρL − ρv ρv

Assumptions: Per the method, droplet sizes of less than about 10 microns will be captured. There is a curve of droplet size vs efficiency in the book.

Unit Definition (for Mathcad use): none used

Page 1 of 8

286 m Calculate the Liquid holdup requirements holdup time := 10⋅ min m flowliquid := 237⋅ hr 3 Page 2 of 8 .064 m 2 Area = π ⋅     2  Vessel Diameter for adequate vapour/liquid separation dia := 2 Area π dia = 0.Project: 3rd year design By: D.156 × 10 hr vdesign := 0.12⋅ kg m Vapour Density 3 kg m 3 k for demister k := 1260 ⋅ m hr with a demister Vapour Flow Rate m volflow := 558⋅ hr 3 Liquid Flow Rate m flowliquid := 237⋅ hr 3 vallow := k⋅ ρL − ρv ρv 4m vallow = 1.75⋅ vallow m vdesign = 2. Mody Date: Nov 25 2008 Engineering Calculations Data: Liquid Density ρ L := 1033⋅ ρ v := 12.409 s Area := volflow vdesign dia  2 Area = 0.939 ft dia = 0.

We'll remove the demister and calculate the maximum diameter 10% of velocity allowable is a typcial minimum velocity (when using a demister) that ensures droplets impact the wire mesh.86 m . If our diameter were larger more the same amount of liquid could be held in a shorter vessel.1 ⋅ vallow m volflow := 558⋅ hr Area := volflow vdesign Area = 0. vdesign := 0.Project: 3rd year design By: D.572 ft dia  dia = 0.947 m This is not a feasible solution.483 m 2 2 3 m vdesign = 0.5 m 3 Calculate the vessel height for just the liquid holdup portion heightliquid_holdup := volholdup Area heightliquid_holdup = 613.321 s Area = π ⋅   dia := 2   2  Area π dia = 2.5 m 3 Calculate the vessel height for just the liquid holdup portion heightliquid_holdup := volholdup Area Page 3 of 8 heightliquid_holdup = 81. Mody Date: Nov 25 2008 Engineering Calculations volholdup := holdup time⋅ flowliquid volholdup = 39.784 m Now Calculate the Liquid holdup requirements holdup time := 10⋅ min m flowliquid = 237 hr 3 volholdup := holdup time⋅ flowliquid volholdup = 39.

555 ft This liquid height is to the normal liquid level. therefore total height for the liquid holdup is: heightliquid_holdup := 2 ⋅ heightliquid_holdup heightliquid_holdup = 14. should be split into two vessels. Mody Date: Nov 25 2008 Engineering Calculations Still not feasible.803 ft Now Calculate the Liquid holdup requirements holdup time := 2 ⋅ min flowliquid = 237 hr volholdup = 7. The maximum liquid height is usually twice the normal.9 m 3 m 3 volholdup := holdup time⋅ flowliquid Calculate the vessel height for just the liquid holdup portion heightliquid_holdup := volholdup Area heightliquid_holdup = 7. or we need to go below Vmin and we need to check our correlations (Stokes Law & Impingment separators) to see if separation is still going to work.11 ft Still extremely tall. For illustration purposes of the method.286 × 10 hr without a demister vallow := k⋅ m vdesign = 0. Add in the Vapour Liquid disengagement space Page 4 of 8 .159 m dia = 3.147 s volflow = 558 hr m 3 Area := volflow vdesign dia  2 2 Area = 1.969 m heightliquid_holdup = 49. we'll go with this design for now.Project: 3rd year design By: D.484 m heightliquid_holdup = 24.1 ⋅ vallow 3m vallow = 5. Remove the demister and use 10% of Vel allowable k := 576⋅ m hr ρL − ρv ρv vdesign := 0.056 m 2 Area = π ⋅      therefore dia := 2 Area π dia = 1.

515⋅ 10 ⋅ Inlet_massdensity := 316⋅ kg 3 velnozzle = 3.064 m 2 dianozzle := 2 Nozzlearea π dianozzle = 0.Project: 3rd year design By: D.257 Inlet_massflow := 2. Mody Date: Nov 25 2008 Engineering Calculations Size the Nozzle at 50% of errosional velocity: velnozzle := 50⋅ %⋅ ⋅ ρ 2phase sec 100 ft ρ 2phase := 316⋅ kg m 3  lb   3  ft  ft sec m s velnozzle = 11.221 s Nozzlearea = 0.431 5 kg hr this is the density of the 2phase flow stream 3 Inlet_volflow := Inlet_massdensity Nozzlearea := Inlet_volflow velnozzle m Inlet_massflow m Inlet_volflow = 0.94 ft say 12 inch nozzle dianozzle := 12⋅ in Page 5 of 8 .

5 m Heightoverall = 54.11 ft heightLL_to_nozzle = 0. we would have a small separator that discharges liquid into a holding tank that we'll assume has an L/D of about 3 Page 6 of 8 .226 If we examine splitting this into two vessels.457 m heightnozzle_to_top = 1.067 m L / D ratio is: Heightoverall dia = 14.Project: 3rd year design By: D. Mody Date: Nov 25 2008 Engineering Calculations Distance from nozzle to high liquid level 1 heightLL_to_nozzle := 12in + ⋅ dianozzle 2 Distance from nozzle to top of separator 1 heightnozzle_to_top := 36in + ⋅ dianozzle 2 Overall height Heightoverall := heightnozzle_to_top + heightLL_to_nozzle + heightliquid_holdup Heightoverall = 16.

Project: 3rd year design By: D.457 m heightnozzle_to_top = 1.939 ft dia = 0.156 × 10 hr vdesign := 0.286 m Separator height 1 heightLL_to_nozzle := 12in + ⋅ dianozzle 2 Distance from nozzle to top of separator 1 heightnozzle_to_top := 36in + ⋅ dianozzle 2 Page 7 of 8 heightLL_to_nozzle = 0.067 m .064 m 2 Area = π ⋅     2  Vessel Diameter for adequate vapour/liquid separation dia := 2 Area π dia = 0.409 s Area := volflow vdesign dia  2 Area = 0.75⋅ vallow m vdesign = 2. Mody Date: Nov 25 2008 Engineering Calculations Two Vessels: Separator Dimensions will be per the first iteration of calculations Separator Liquid Holdup k for demister vallow := k⋅ ρL − ρv ρv k := 1260 ⋅ m hr with a demister 4m vallow = 1.

19. Separator dimensions 1ft dia x 5 ft high Page 8 of 8 .5 m Heightoverall = 5 ft Should check this against industrially available units .Project: 3rd year design By: D. Mody Date: Nov 25 2008 Engineering Calculations Heightoverall := heightnozzle_to_top + heightLL_to_nozzle Separator dimensions: Heightoverall = 1.89 m dia (rounded up to nearest 6") = 6.9 m 3 this is to the normal liquid level volholdup_full = 15.see spirax sarco Dimensions for liquid holdup volholdup = 7.5 ft long.5 ft.886 m vessel_length := 3 ⋅ dia dia = 6. The holdup vessel should be 1.8 m vessel_length = 3 ⋅ dia 1 3 3 volholdup_full := volholdup ⋅ 2 vol = vessel_length⋅ π ⋅   2 this is full   2  dia  2 dia  vol = 3 ⋅ dia⋅ π ⋅   2     volholdup  dia := 2 ⋅    π⋅3  dia = 1.8 m All okay! Summary.187 ft check the volume calculation dia  volumecalc := vessel_length⋅ π ⋅   2    3 2 volumecalc = 15. The vessel should be 3x that length.