‘CONTINUOUS GRAVITY DECANTER. A gravity decanter of the type shown in Fig. 2.6 is used for the continuous szparation of two immiscible liquids of differing densities, The feed mixture enters af one end of the separator; the two liquids flow slowly through the vessel, separate into two layers, and discharge through overflow lines at the other end of the scparator. Provided the overflow lines are so large that frictional resistance to the flow of the liquids is negligible, and provided they discharge at the same pressure as that in the gas space above the liquid in the vessel, the performance of the decanter can be analyzed by the principles of fluid statics. For example, in the decanter shown in Fig. 2.6 let the density of the heavy liquid be g,, and that of the light liquid be p,. The depth of the layer of heavy liquid is Z4, and that of the light liquid is Zp. The total depth of liquid in the vessel Z; is fixed by the position of the overfiow line for the light liquid. Heavy liquid discharges through an overflow leg connected to the bottom of the vessel and rising to a height Z,, above the vessel floor. The overflow lines and the top ‘of the vessel are all vented to the atmosphere. Haney ~ liquid outtet Vent fed ‘Light - tiquid euttet Tor view Fond, ‘SIDE VIEW FIGURE 26 Continuous gravity decanter far immiscible fiquids,Since there is negligible frictional resistance to flow in the discharge lines, the column of heavy liquid in the heavy-liquid overfiow leg must balance the somewhat greater depth of the two liquids in the vessel. A hydrostatic balance leads to the equation Zon + Zapa= Zorba (2.12) Solving Eq, (2.12) for Zy, gives . Pi Zyi= Zia — Zp t= Za (2-2) (213) Pa Pa where the total depth of liquid in the vessel is Z; = Zy + Z4;. From this _Zar~ Erloniea) = peiba Equation (2.14) shows that the position of the liquid-liquid interface in the separator depends on the ratio of the densities of the two liquids and on the elevations of the overflow lines, It is independent of the rates of flow of the liquids. Equation (2.14) shows that as py approaches py, the position of the interlace becomes very sensitive to changes. in Z,,, the height of the heavy-liquid leg. With liquids that differ widely in density this height is not critical, but with liquids of nearly the same density it must be set with care, Often the top of the leg is made movable so that in service it can be adjusted to give the best separation, ‘The size of a decanter is established by the time required for separation, which in turn depends on the difference between the densities of the two liquids and on the viscosity of the continuous phase, Provided the liquids are clean and do not form emulsions, the separation time may be estimated from the empirical equation’ Zar (2.14) 00, t= OH 215) Pa Pa where f = separation time, h Par Py = densities of liquids A and B, kg/m? j= viscosity of the continuous phase, cP Equation (2.15) is not dimensionless, and the indicated units must be used. Example 2.2. A horizontal cylindrical continuous decanter is to separate 1500 bbl/d (day} (9.93 mh) of a liquid petroleum fraction from an equal volume of wash acid. ‘The oil is the continuous phase and at the operating temperature has a viscosity of LicP and a density of 54 Ib/ft” (865 kg/m), The density of the acid is 72 Ib/ht? (1153 kg/m}. Compute (a) the size of the vessel, and (b) the height of the acid overflow above the vessel floor. Solution {a) The vessel size is found from the separation time. Substitution in Eq. (2.15) gives 100 x Ll 1=————_ = 038h 1153 — 865or 23 min. Since | bbl = 42 gal, the rate of flow of cach stream ix 1300 % 42 Sa = 43-8 gal/min 24 60 The total liquid holdup is 2x 438 x 23 = 2014 gal ‘The versel should be about 95 percent full, uo its volume is 2014/95, or 2120, gal (8.03 m?}. The length of the tank should be about 5 times its diameter. A tank 4 ft (1.22 m) in diameter and 22 (6.10 m) long would be satisfactory; with standard dished heads ‘on the ends, its total volume would be 2124 gul, (6) The fraction of the tank volume occupied by the liquicl will be 95 percent, and for a horizontal cylinder this means that the liquid depth will be 90 percent of the tank diameter.“* Thus Z,=090 x 4=36h ‘Ifthe interface is halfway between the veusel floor and the liquid surface, Z4, = 1.801. Solving Eq. (2.14) for 2, the beight of the heavy-liquid overflow, gives: Zaz = 1.80-+ (3.60 — LB0)¥4 = 3.15 (096m) ‘Successful operation of a decanter depends on both the sedimentation and the coalescence of the dispersed phase. Equation (2.15) gives poor results if the liquids to be separated are not clean but contain particulates or polymeric films that reduce the rate of coalescence, Such contaminants may also lead to the formation of a dirty layer of uncoalesced droplets—called a “rag"—at the liquid-liquid interface. Coalescing devices such as beds of porous solids, mem- branes, or high-voltage fields are often necessary for a satisfactory separation.” With cleaner liquids the size of a decanter can often be greatly reduced by putting in horizontal or slightly inclined pipes or flat plates, so that the heavy-phase droplets need to fall only a short distance before reaching a layer of the heavy liquid. ‘CENTRIFUGAL DECANTER. When the difference between the densities of the two liquids is small, the force of gravity may be too weak to separate the liquids in a reasonable time. The separation may then be accomplished in a liquid-liquid centrifuge, shown diagrammatically in Fig. 2.7. It conaiats of a cylindrical metal bowl, usually mounted vertically, that rotates about its axis at high speed, In Fig. 2.24 the bow! is at rest and contains a quantity of two immiscible liquids of differing densities. The heavy liquid forms a layer on the floor of the bow! beneath a layer of light tiquid. If the bow! is now rotated, as in Fig. 2.7), the heavy liquid forms a layer, denoted as zone A in the figure, next to the inside wall of the bowl. A layer of light liquid, denoted as zone 8, forms inside the layer of heavy liquid. A cylindrical interface of radius r, separates the two layers. Since the force of gravity can be neglected in comparison with the much greater centrifugal force, this interface is vertical, It is called the neutral zone,Centrifugal separation of immiscible liquids: (a) bow! at rest; (b) bow! rotating. Zone 4, separation. of light liquid from heavy; zone B, separation of heavy liquid from light (1) Heavy-liquidt drawofl, (2) Ligh-tiquid drawelt. In operation of the maching the feed is admitted continuously near the bottom of the bowl. Light liquid discharges at point 2 through ports near the axis of the bowl; heavy liquid passes under a ring, inward toward the axis of rotation, and discharges over a dam at point 1. If there ix negligible frictional resistance to the flow of the liquids as they leave the bowl, the position of the liquid-liquid interface is established by a hydrostatic balance and the relative “heights” (radial distances from the axis) of the overflow ports at | and 2 Assume that the heavy liquid, of density p,, overflows the dam at radius ry, and the light liquid, of density py, leaves through ports at radius ry. Then if both liquids rotate with the bow! and friction is negligible, the pressure difference in the light liquid between ry and r, must equal that in the heavy liquid between ry and 7;. The principle is exactly the same as in a continuous gravity decanter. Thos Pi Po = Pi Pa (2.16) where p, = pressure at liquid-liquid interface Po = pressure at free surface of light liquid at ry Pa = pressure at free surface of heavy liquid a1 ry From Eq. (2.9) be 5 pt yh ae ‘pul? —r3) ‘ nm pa eae a) ‘Equating these pressure drops and simplifying leads to eat? — 8) = pal? — 3)Solving for r, gives ne fA = (os/paira ay I= palPa Equation (2.17) is analogous to Eq. (2.14) for a gravity settling tank. It shows. that r,, the radius of the neutral zone, is sensitive to the density ratio, especially when the ratio is nearly unity. If the densities of the fluids are too nearly alike, the neutral zone may be unstable even if the speed of rotation is sufficient to separate the liquids quickly. The difference between p, and py should not be less than approximately 3 percent for stable operation. Equation (2.17) also shows that if ry is held constant and r,, the radius of the discharge lip for the heavier liquid, increased, the neutral zone is shifted toward the wall of the bowl If r, is decreased, the zone is shifted toward the axis. An increase in rg, at constant ry, also shifts the neutral zone toward the axis, and a decrease in ry causes a shift toward the wall. The position of the neutral zone is important practically. In zone A, the lighter liquid is being removed from a mass of heavier liquid, and in zone B, heavy liquid is being stripped from a mass of light liquid. If one of the processes is more difficult than the other, more time should be provided for the more difficult step. For example, if the separation in zone 2 is more difficult than that in zone A, zone B should be large and zone A small, ‘This is accomplished by moving the neutral zone toward the wall by increasing ry or decreasing ry. To obtain a larger time factor in zone A, the opposite adjustments would be made. Many centrifugal separators are so constructed that cither t, or rg-can be varied to control the position of the neutral zone. FLOW THROUGH CONTINUOUS DECANTERS. Equations (2.14) and (2.17) for the interfacial position in continuous decanters are based entirely on hydrostatic balances. As long as there is negligible resistance to flow in the outlet pipes, the position of the interface is the same regardless of the rates of flow of the liquids and of the relative quantities of the two liquids in the feed, The rate of separation is the most important variable, for as mentioned before, it fixes the size of a gravity decanter and determines whether or not a high centrifugal force is needed. The rales of motion of a dispersed phase through a continuous phase are discussed in Chap. 7.