What is a Flare KOD | Working, Functions, Sizing,

and Design of a Knock Out Drum (PDF)

Written by Anup Kumar Deyin Mechanical,Process

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A Knock out drum is a specific type of pressure vessel in the flare header system used to
remove & accumulate any condensed & entrained liquids or liquid droplets from the relief/flare
gases. This process equipment is also known as the flash drum, knockout pot, KO drum, knock-
out vessel, or flare KO drum. A knock-out drum is one of the primary components in a
pressure-relief arrangement system in process industries. Flare knockout drums are available
in vertical or horizontal configurations.

Knockout drums are classified as “two-phase” when they separate gas from the total liquid
stream. Again, they are known as “three-phase” when they separate gas, water, and oil phase
means separating crude oil and water from the liquid stream.

Function of a Knockout Drum

The main function of a knockout drum is to provide residence time for liquid discharges and to
limit the size of droplets directed to the liquid seal drum or the flare burner. They are used to
remove any liquid droplets of oil or water from the industry relieved/flare gases. The liquid in
the vent system is not desirable due to the following reasons:

the liquid causes irregular combustion and smoking. Join us on Telegram

the liquid can extinguish the flame.
liquid flaring can generate a burning chemical spray that could reach ground level and cause
a safety hazard.
It is therefore the main function of a knock-out drum to remove the liquid that may be
condensed out in the transfer lines and collection headers. Also, as the liquid product is
recovered from the relieving gas, the efficiency of product recovery increases.

Flare KO Drum Design Configurations

A flare drum is designed in either a horizontal or vertical configuration. The KO drum
configuration is decided by operating parameters and space availability. When a large liquid
storage capacity is required and vapor flow is high, a horizontal flare KO drum is preferred.
Horizontal knockout drums have a low-pressure drop. They are economical and can handle
large relief loads. In general, three types of horizontal KOD configuration are found. They are

Horizontal drum with the vapor entering at one end of the vessel and exiting at the top of
the opposite end without internal baffling.
Horizontal drum with the vapor entering at each end on the horizontal axis and a central
outlet.
Horizontal drum with the vapor entering in the center and exiting at each end on the
horizontal axis.

Vertical knockout drums are only used when the liquid load is low and there is a scarcity of plot
space. Vertical flash drums are well suited for incorporating into the base of the flare stack.
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Basic vertical KOD configurations are:
 Vertical KO drum with radial inlet nozzle and top outlet nozzle.
Vertical vessel with a tangential nozzle.

Sometimes, a combination of a vertical drum in the base of the flare stack and a horizontal
drum upstream to remove the bulk of the liquid entrained in the vapor is also found in process
plants.

Designing and Sizing of Flare Knockout Drum

The sizing of flare KOD is basically a trial and error method with widespread table lookups. The
sizing process is constrained by a set of fluid dynamic and mechanical relationships and is
based on the gravity-settling theory. The principle of settling theory is that the liquid droplets
will settle due to gravitational force. The size of the knock-out vessel is decided by the
anticipated liquid and vapor flow. The KOD diameter is estimated using the maximum allowable
vapor velocity.

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The knockout drums are designed and sized following a specific length-to-diameter ratio in the
range of 2 to 4. This maintains a low vapor velocity such that the liquids settle out. The KO
drum design requires the expert application of many thumb rules. Because of multivariable
manual trial-and-error procedures, the knockout drum design is usually done by experienced
process engineers.

A liquid level indicator is always installed as these knockout vessels shall remain drained and
free of excess liquid.

The KO drum sizing is done following the bellow-mentioned two

steps as per API 521:
Step-1: The starting step of Flare knock-out drum sizing is to determine the drum size required
for liquid entrainment separation. Liquid particles separate: If the residence time of the vapor
or gas is equal to or greater than the time required to travel the available vertical height at the
dropout velocity of the liquid particles, and if the gas velocity is sufficiently low to permit the
liquid dropout to fall.

This vertical height is considered from the maximum liquid level. To prevent large slugs of
liquid from entering the flare, the vertical velocity of the vapor and gas should be low enough.
The dropout velocity (uc), in m/s, of a particle in a stream, is estimated using the
Joinfollowing
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equation:
 Fig. 1: Equation for drop out velocity

Step-2: The next step in sizing a flare knockout drum is to take care of the effect that any
liquid present in the drum can produce on reducing the volume available for vapor/liquid
disengagement. This liquid may result from:

condensate that separates during a vapor release, or

liquid streams that accompany a vapor release.

The capacity of the liquid holdup of a flare KO drum is decided based on the consideration of
the amount of liquid that can be released during an emergency situation without exceeding the
maximum level for the intended degree of liquid disengagement. Different applications require
different holdup times. However, the primary requirement is to provide sufficient volume for a
20 min to 30 min emergency release. When it takes longer to stop the flow, longer holdup
times may be required.
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Locating the Knockout Drum

Flare knockout drums should be located considering the following:
 liquid droplet agglomeration and vapor condensation when there is a long line between the
flare stack and flare knockout drum.
knockout drum maintenance access during normal and emergency situations.
thermal radiation effects on flare knockout drum instrumentation and necessity for thermal
shielding.

In general, knockout drums are located on the main flare line upstream of the flare stack or any
liquid seal. However, if any equipment releases a large amount of liquid to the flare header,
additional KO vessels inside the battery limit are installed to collect these liquids. This not only
reduces the sizing load of the main flare KOD but also increases product recovery. Knockout
drums are also installed ahead of compressor suction to eliminate liquid from entering into the
compressor.

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Maintenance Requirement of Knockout Drums
Knockout drums are considered as dirty service and routine maintenance cleaning of the
gauge glasses, checking level instruments, pump shut down instruments, etc must be planned
as per vendor recommendations.

What are the types of Knock-out Drums?

Depending on configurations there are two types of knockout drums; vertical and horizontal
knockout drums. Again, based on separation capability they are classified as; two-phase
knock-out drum and three-phase knockout drum.

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What is the burning rain phenomenon?

when a liquid hydrocarbon droplet does not burn completely within the flare flame envelope
and the rate of burning is lower than the rate of settling of the liquid droplet, a phenomenon
known as burning rain occurs. When burning rain occurs, slugs of liquid are carried over from
the flare knockout drum, liquid seal drum, or re-entrainment of liquid accumulated within the
flare piping or the flare gas riser.

What is the difference between a Knockout Drum and a

Separator?
Knockout drum and separator are used interchangeably. The basic function of both knockout
drums and separators are the same. However, from the application point of view, there is a
slight difference. Knock-out drums are used in the flare systems or just before compressors
for safety concerns and product recovery. Separators have broad applications. They are
extensively used in processing plants to separate oil, water, and gas streams for sending for
further processing.

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