Gravity Separation

Training Services
Gravity Separation
2003 ENGINEERING DESIGN SEMINAR – LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential EDS 2003/GS-1
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Surge Drums
Surge Volume
n Absorbs variations in the incoming flow,

providing a uniform feed rate to downstream
equipment
n Allows time for problem correction or shut

down in the event of large variations
n May be a dedicated vessel or provided as

part of another vessel
Residence Time
n Normal time a fluid remains within a vessel,

portion of a vessel, or other equipment
n May be defined to give the needed surge

capacity or to allow a desired reaction to
occur while minimizing undesired side effects
n Requirement set by process or operational

characteristics
Examples of Uses
n Smoothes liquid flow variations resulting from

large distance pumped (e.g. from tank farm)
or the type of pump (reciprocating, etc.)
n Allows operator reaction time in the event of
loss of liquid feed to the unit
n Protects pump suctions from loss of liquid
feed by allowing time for pump shutdown (e.g.
separator liquid pumps)
n Absorbs temporary increases or “slugs” of
liquid flow (e.g. short term steam injection
upstream)
Surge Drum Orientation
n Vertical
– Most economical orientation considering
vessel cost
– Level reacts more quickly to changes in flow
than in a horizontal vessel
n Horizontal
– Greater liquid surface area results in less
change in liquid level during flow variations
Surge/Storage Sizing Example
Size a feed surge drum for a Tatoray Unit. The

feed rate is 20.4 m3/h (QL).
– Select an L/D of 3
– Size vessel for 30 minutes of liquid residence
time (t) at 75 percent liquid full (F)
– Calculate the liquid holdup volume
VL = QLt = (20.4 m3/h)(0.5 h) = 10.2 m3
– Calculate the required volume of the vessel
VV = VL/F = 10.2 m3/0.75 = 13.6 m3
Surge/Storage Sizing Example
Set the volume of the vessel equal to the volume of

a cylinder whose L/D is 3 and solve for D (ignore
the head volume).
V Cyl = πD2L/4 = 3πD3/4 = 13.6 m3
1 1
4Vcyl  3 4 ×13.6  3
D=  3π   = 
   3π 
D = 1.79 m
so L = 3D = 5.38 m
Convert to millimeters and round to 1800
millimeters inside diameter and 5400 millimeters
tangent length
Separators
Separation
n The Act or Process of Separating
n The State of Being Separate
n To Isolate From a Mixture
n To Divide Into Constituent Parts
Reasons for Separation
n Remove unwanted fluids, such as water

n Divide a desired product (vapor or fluid) from
other components
n Divide phases for further processing (e.g. vapor
product and liquid reflux on a fractionator
overhead)
n Protect liquid handling equipment (e.g. pumps)
from vapor entry and damage
n Protect vapor handling equipment (e.g.
compressors) from liquid entry and damage
Separation Limitations
n For gravity separation to occur, fluids must

be immiscible and of different densities
n The closer the fluid densities, the more

difficult the separation
n No separation method is complete. The

degree of desired separation must be defined,
normally by defining the minimum particle
size to be separated.
Immiscible
Incapable of being mixed without the

phases or components separating under the
influence of gravity. Cannot attain
homogeneity (uniformity).
Separation Methods
n Momentum
n Gravity Settling
n Coalescing
Separation using a combination of these methods is

common.
Momentum Separation
n Denser fluid changes direction more slowly

than less dense fluid
n Often used for initial or “bulk” separation
Gravity Separation
n Denser fluids sink and lighter fluids “rise”

due to the influence of gravity
n Most common means of separation used in

refineries and petrochemical plants
Coalesce
n To unite into a whole

n To grow together
n Fuse
1.26 D
Coalescing Separation
n Droplets follow a torturous path through a

coalescing device
– Droplets collide with each other and with the
device, forming larger droplets
n Generally used for fine droplet removal,

fusing them into larger drops removed by
gravity settling
Separator Zones
n Usually four zones in a separator

– Primary separation -- “bulk” separation using
momentum and a change of direction at the
inlet
– Secondary separation -- uses gravity separation
with low velocity, no turbulence fluids
– Coalescing separation -- uses coalescing to
remove fine droplets with a mist extractor near
the outlet
– Sump/liquid collection -- “gravity” degassing
separation and surge volume
Horizontal and Vertical Separators
Gravity Settling Laws
Particle Moving in a Fluid
n For Vessel Design

– Calculate droplet terminal velocity
– To allow separation in vertical vessels, size the
vessel to keep the velocity of the continuous
phase less than the particle terminal velocity
– Size horizontal vessels to permit the particle
to escape from the continuous phase before
the continuous phase (or the particle phase) is
withdrawn from the vessel
Terminal Velocity
n Steady state velocity at which a dispersed

phase particle falls (or rises) relative to the
continuous fluid phase
n Reached when the forces acting on the

dispersed phase particle balance and the
particle no longer accelerates
Continuous Phase
n The predominant, or carrying fluid in the

region under consideration
Dispersed Phase
n Fluid scattered within and being carried by

the continuous phase in the region under
consideration
Particle Settling in a Fluid
Fd + Fb Fd = Drag
Fb = Buoyant Force
Fg = Gravitational Force
F = Resultant Force
a = Particle Acceleration
Fg u = Particle Velocity
du
F = Fg − Fd − Fb = ma = m
dt
n At Steady State:
du
=0
dt
and u = ut = terminal velocity
So Fg = Fd + Fb
mg
n Where: Fg =
gc
mρg
Fb =
ρp gc
CDu t2ρA p
Fd =
2gc
πDp2
Ap =
4
1
m = πρp Dp3
6
m = Mass of particle
g = Gravitational acceleration
gc = Gravitation constant
ρ = Density of continuous fluid
ρp = Density of particle
Ap = Projected area of particle
Dp = Diameter of particle
CD = Drag coefficient (based upon velocity
relative to continuous phase)
µ = Viscosity of continuous fluid
ut = Terminal velocity
Substitute and solve for ut:
4D p g(ρp − ρ)

0 .5
For Heavy Droplet -
ut =   Light Continuous Phase

 3CDρ 
 For Light Droplet -
Heavy Continuous Phase,
use ρ − ρp
n Limitations
– Spherical particle
– Stagnant fluid
– No interaction with other particles
– No wall effects
n Terminal velocity for a particle can now be

calculated if CD can be quantified
Drag Coefficient vs. Reynolds Number
100,000
10,000
1,000
100
Spheres
10
Disks
Cylinders
1.0
0.1
0.0001 0.001 0.01 0.1 1.0 10 100 1,000 10,000 100,000 1,000,000
Particle Reynolds Number, NRe = Dpρut

µ
EDS-R02-3446
Newton’s Equation
n For: 500 < N Re < 200 , 000
n Where: Particle Reynolds Number D p ρu t

N Re =
µ
n Then: C D = 0.44
gDp (ρp − ρ)

0.5
n And: u t = 1.75 
 ρ 
Newton’s Equation
(continued)
100,000
10,000
1,000
100
SPHERES
10
DISKS
CYLINDERS
1.0
0.1
0.0001 0.001 0.01 0.1 1.0 10 100 1,000 10,000 100,000 1,000,000
Particle Reynolds Number, NRe = µ Newton CD = 0.44

500<NRe<200,000
SD-R03-01a
Newton’s Equation
(continued)
n In range of Newton’s Equation, Nre > 500, liquid
droplets falling in vapor will deform
Then: C D ≠ 0.44
Let: ρp = ρL
ρ = ρV
For: Dp = 1750 micron
And: CD = 1
4Dp g(ρL − ρV ) 4(1.75)(32.2)

0.5 0.5 0.5
ρL − ρV 
ut =   =  
 ρ 

 3 C ρ
D V   3(1)(304.8)   V 
0.5
ρ − ρV 
= 0.496 L 
 ρ V 
Stokes’Equation
n For: N Re < 2
D Pρµ t
n Where: N Re =
µ
24
n Then: CD =
NRe
n And: (
ut = P
ρ − ρ) P
gD 2
18µ
Stokes’Equation
(continued)
24
Stokes NRe< 2 CD =
NRe
100,000
10,000
1,000
100
SPHERES
10
DISKS
CYLINDERS
1.0
0.1
0.0001 0.001 0.01 0.1 1.0 10 100 1,000 10,000 100,000 1,000,000
Dpρut
500<NRe<200,000
SD-R05-03
Intermediate Equation
n For: 2 < N Re < 500
D p ρu t
n Where: N Re =
µ
18.5
n Then: CD =
N 0Re.6
( − ρ)
0 . 71
0.153g 0 . 71
D 1p.14 ρp
n And: ut =
ρ µ
0 . 29 0 . 43
Intermediate Equation
24
Stokes NRe< 2 CD =
NRe 18.5
Intermediate CD =
NRe 0.6
2<NRe<500
100,000
10,000
1,000
100
SPHERES
10
DISKS
CYLINDERS
1.0
0.1
0.0001 0.001 0.01 0.1 1.0 10 100 1,000 10,000 100,000 1,000,000

500<NRe<200,000
SD-R05-02
Close Fluid Densities
n The closer the fluid densities are, the more

difficult they are to separate
– Example: Find the terminal velocity for
separating water from two fluids, air and a
hydrocarbon liquid and apply Stokes’Equation
CASE A CASE B
Droplet diameter 175 175 microns
Water density 62 62 lb/ft3
Continuous density 0.5 45 lb/ft3
Viscosity 0.5 0.5 Cp
g 32.2 32.2 ft/s2
ut 0.108 0.030 ft/s
Gravity Setting
Laws and
Particle
Characteristics
SD-R01-09
Separators and Receivers Use --
n Stokes Law
– Vapor separation from a continuous liquid
phase
– Dispersed liquid separation from a continuous
liquid phase
n Intermediate Law
– Liquid separation from a continuous vapor
phase
Selection of the Dispersed
Particle Size to be Separated
n Consider effect upon downstream equipment,

effluent quality, overall economics
n Consider difficulty and cost of separating
small(er) particles
n Dispersed particles vary in size but generally
follow a bell, or normal curve
– Use of an “average” size works well
n Optimal particle size is difficult to determine
Dispersed Particle Sizes for Separation
n Default particle sizes used for gravity

separation are:
– Liquid from vapor separation: 250 microns
(0.00082 feet)
– Vapor from liquid separation: 175 microns
(0.00057 feet)
– Dispersed liquid from continuous liquid: 125
microns (0.00041 feet)
Horizontal Separator Sizing Example
Problem
Design a Reactor Product Separator for
a Naphtha Hydrotreating Process Unit.
The relevant portion of the heat and material

balance is reproduced on the next slide.
Horizontal Separator Sizing Example
(continued)
n Tabulate data and calculate volumetric flows
HYDROCARBON WATER TOTAL

VAPOR LIQUID LIQUID LIQUID
Flow, lb/h 693 58586 2250 60836
, ft3/s 1.54 0.35 0.01 0.36
, gal/min – 158 5 163
Density, lb/ft3 0.125 46.34 61.55
Viscosity, cp 0.01 0.42 0.51
, lb/ft sec (x 10–4) 0.06 2.82 3.42
Flow Schematic
SD-R01-10
Horizontal Vessel Sizing Example
Sizing Steps
n Select L/D
n Determine Liquid Residence Time
n Determine Normal Liquid Level
n Calculate Diameter to Satisfy Residence Time
Sizing Steps (continued)
n Calculate the diameter required for each

phase separation
– Liquid from vapor
– Vapor from liquid
– Liquid from liquid
n If a liquid coalescing blanket is used, calculate
diameter for 3 ft/m liquid velocity
n Select governing (largest) diameter
n Round up to nearest multiple of 6" or 100mm
Liquid Coalescing Blanket
n Coalescing blankets are often used to

accelerate separation of two liquid phases
– Because of the often close densities,
dependence upon gravity separation only may
require a large vessel
n When removing water, UOP always uses
coalescing blankets
n Liquid velocities over 3 feet per minute may
re-entrain droplets from the blanket
Vessel Configuration
SD-R02-12
Liquid Levels
NLL = Normal Liquid Level

HLL = High Liquid Level
LLL = Low Liquid Level
n Calculate diameter based on residence time

– Select L/D = 3 (most common, economical
value)
– For settling a water phase from a light
hydrocarbon phase, use a 10 minute residence
time
– Set the normal liquid level (NLL) at the
centerline
– Calculate liquid volume
0.36 ft 3 60 s 
VL = Q L t = 
 s

min (10 min )= 216 ft 3
 
– If the vessel is 1/2 full, then the full vessel

volume is:
VL 216 ft 3
VV = = = 432 ft 3
F 0.50
n V V is a cylinder with L/D = 3. Ignoring the

head volume:
πD2L 3πD3
VV = =
4 4
( ) 3
1 1
4VV  3 4 432 ft
3
D=  =
 3π   3π
 

D = 5.7 feet
Phase Separation in Horizontal Vessels
Horizontal Vessels D Inside diameter, ft
DDL O.D. of drop leg, in
Vessel dimensions based on vapor/liquid/liquid separation with drop leg. A DL Area of drop leg, ft2
L L Tangent length, ft
LDL Length of drop leg, ft
0.5D L-D 0.5D
VCV Velocity of continuous vaper phase, ft/s
Max. Minimum Max. VDV Velocity of dispersed vaper phase, ft/s
VTL Velocity of total liquid phase, ft/s
VCV VDL Velocity of dispersed liquid phase, ft/s
VDL
VDLL Velocity of dispersed light liquid phase, ft/s
VDV D
VDHL Velocity of dispersed heavy liquid phase, ft/s
VTL VHL Velocity of continuous heavy liquid phase, ft/s
VDHL X Diameter fraction of the continuous phase under study
L
VDLL Y - 1 (inlet and outlet 0.5D from ends)
D
coalescing V
LDL HL 0.5D
mesh blanket
Z Fraction of cross-section area corresponding to X
DDL Max.
(optional) T Time, minutes
0.5D ρL Liquid density, lb/ft3
ρV Vapor density, lb/ft3
Q CV Vapor flow rate, ft3/sec
Diameter for gravity setting liquid from vapor phase
µV Vapor viscosity, lb/ft•sec
µ Liquid viscosity, lb•ft/s
L
D Vapor particle diameter, ft (in the absence of
PV
specific process data ,use 0.00057 ft.)
DPL Liquid in thevapor particle diameter (feet) (0.00082 ft.)
DPH Heavy liquid particle diameter (feet) (0.00041 ft.)
QL Total liquid flow rate, gpm
Q CHL Heavy liquid flow rate, gpm
SD-R03-13
Horizontal Separator Liquid Levels
n Normal liquid level (NLL) is usually set at the

centerline to maximize amount of fluctuation
permitted
n With low vapor/high liquid rates, set NLL above
the centerline to maximize liquid residence
times
n With high vapor/low liquid rates, set NLL below
the centerline to minimize vapor velocity
Horizontal Separator Liquid Levels
(continued)
n High and low liquid levels (HLL and LLL)

are set the same distance from NLL
n Minimum vapor space is 20% of the cross
sectional area
– Corresponds to 25% of the diameter
– Excessive vapor velocity over liquid surface
is avoided
n Minimum liquid level is 25% of the diameter
(20% of the cross sectional area) to allow
for separation
n Calculate the diameter based on vapor from

liquid separation
– The terminal velocity of the bubble rising in
the liquid, VDV, is calculated with Stokes’Law
Continuous (Liquid)
VDV =
2
gD PV ( ρL − ρ V )
18µ L
Dispersed (Vapor)
(continued)
– If X is the distance from the bottom of the vessel

to the minimum liquid (continuous phase) level,
expressed as a fraction of the diameter D, then
the time, T, for the bubble to rise a distance XD
is:
XD
T=
VDV
(continued)
– The horizontal velocity of the liquid phase is the

volumetric flow of liquid divided by the flow area
QL QL
VTL =
(
Z 0.785D 2
)(7.48)(60) =
352.3ZD 2
Where: - QL is the liquid flow rate, gpm
- Z is the fraction of cross-sectional area
corresponding to X
- 0.785D2 is the total cross-sectional area
- (7.48)(60) converts from ft3/s to gpm
(continued)
– If Y = L/D - 1, then the time for the liquid

to flow from the inlet to the outlet is:
YD
T=
VTL
(continued)
– In the worst case, the time for bubble to rise

XD is equal to time for liquid to flow YD, and:
XD YD
T= =
VDV VTL
XDVTL = YDVDV
– Substitute:
XDQL gYDD2PV (ρL − ρV )

=
352.3ZD 2 18µL
(continued)
– Solve for D
0.5  0.5
 18X   Q L µL
D=  2 
352.3ZY 
 gDPV (ρL − ρV )
 
– For X = 0.25, then Z = 0.20

– For L/D = 3, then Y = 2
(continued)
n Use the minimum liquid level for any

separation occurring in continuous liquid
– Although the separation distance (liquid depth)
is short, the liquid velocity is maximized, giving
the minimum separation time
n Deep liquid increases the flowing area,
decreasing the horizontal velocity faster than
depth increases
– Does not govern vessel size
(continued)
– Then:
0.5
 Q L µL 
D = 0.18 
gDPV (ρL − ρV )
2
 
0.5

D = 0.18
(163)(0.000282) 

(32.2)(0.00057 ) (46.34 − 0.125)
2
 
D=1.75 feet
for vapor from liquid separation
(continued)
n Calculate diameter based on liquid/liquid

separation
– The method uses Stokes’Law to calculate the
terminal velocity of the heavy liquid droplet
and is very similar to the vapor from liquid
case
– Use subscripts HL and LL for heavy liquid
and light liquid
(continued)
– From Stokes Equation:
gD2PH (ρHL − ρLL )

VHL =
18µLL
– and:
XD YD
T= =
VHL VTL
(continued)
– Substitute and Solve for D:
0.5  0.5
 18X  Q L µLL 
D=  2 
352.3YZ 
 gDPH (ρHL − ρLL )
 
– For X = 0.25, then Z = 0.20

– For L/D = 3, Y = 2
(continued)
0.5
 Q L µLL 
D = 0.18 
gDPH (ρHL − ρLL )
2
 
0.5

D = 0.18
(163)(0.000282) 

(32.2)(0.00041) (61.55 − 46.34)
2
 
D = 4.2 ft
for liquid/liquid separation
(continued)
n Calculate the diameter based upon liquid

from vapor separation
n Vapor is the continuous phase
– Use a vapor space depth of 0.25D, i.e. X=0.25
n If there is more than one liquid phase, use the
least dense phase because it will separate
from the vapor more slowly
n Use the intermediate law and logic similar
to that used in previous checks
(continued)
XD YD
T= =
VDL VCV
XDVCV = YDVDL
Q CV
VCV =
(
Z 0.785D2 )
VDL =
0.153g 0.71D1PL
.14
(ρL − ρV )0.71 (Intermediate Law )
ρ0V.29µ0V.43
(continued)
YD 0.153g 0 . 71D1PL.14 (ρL − ρV )

0 . 71
XDQ CV
=
(
Z 0.785D 2 ) ρ0V. 29 µ 0V.43
0 .5
 
0 .5
 X  Q CV ρ µ 0 . 29 0 . 43
D=   0 .71 1.14 0 . 71 
V V
0 .785( 0 .153) 
YZ g D PL (ρL − ρV ) 
 
For X = 0.25, then Z = 0.20

For L/D = 3, then Y = 2
(continued)
0.5
 0. 29
Q CV ρV µ V 0. 43 
D = 2.28
0.71 

g DPL (ρL − ρV ) 
0.71 1.14

Q CV = 1.54 ft 3 s
ρV = 0.125 lb ft 3 ρL = 46.34 lb ft 3
µ V = 0.06 x 10- 4 lb ft ⋅sec g = 32.2 ft s 2

0.5

D = 2.28
(1.54)(0.125) (0.000006)  0.29 0.43
0.71 
(32.2) (0.00082) (46.34 − 0.125) 
0.71 1.14
 
(continued)
D=0.68 feet
For liquid from vapor separation

(without coalescing blanket)
(continued)
n Diameter Requirements
– Residence time 5.7 feet
– Vapor from liquid 1.75 feet
– Liquid from liquid 4.2 feet
– Liquid from vapor 0.68 feet
(continued)
n The governing diameter, 5.7 feet, was that

determined by the liquid residence time
criteria. Round to:
D = 6 feet
L = 3D = 18 feet
(continued)
Check liquid velocity for a coalescing blanket.

QL
VTL =
352.3ZD 2
163
=
352.3( 0. 2)( 6)
2
= 0.065fps = 3.9 fpm > 3.0 fpm
(Maximum velocity through coalescing blanket)
(continued)
n Increase the vessel diameter to accommodate

maximum the permissible velocity through
coalescing blanket
Set VTL = 3 fpm = 0.05 fps
163
0.05 =
352.3(0.2)D 2 ( )
1
 163  2
 = (46.3) 2
1
D=
(352.3)(0.2)(0.05)
= 6.8, use 7 feet

(continued)
Drop Leg (Boot) Sizing Steps
n Determine residence time

n Calculate diameter based on phase separation
n Calculate diameter based on process velocity
limits (if any)
n Calculate diameter based on residence time
n Use UOP’s standard drop leg (boot) length
of 3.5 feet
(continued)
Drop Leg (Boot) Sizing Steps
n Select the governing (largest) diameter
n If DDL is greater than half of the vessel

diameter, then set DDL = 1/2 vessel diameter
and recalculate LDL
n Round up to the next pipe size
(continued)
SD-R01-14
(continued)
Vessel Drop Leg (Boot)
n Size the drop leg for 10 minute residence time

for the water phase
n Size the drop leg for separation of the

dispersed hydrocarbon liquid phase
from a continuous water phase
(continued)
n Use Stokes’Law to determine the terminal

velocity of the dispersed liquid droplet
VDLL =
2
gD PL ( ρHL − ρLL )
18µ HL
n Velocity of the continuous heavy liquid phase
(water) is the volumetric flow rate divided
by the cross-sectional area of the drop leg
Q CHL Q CHL
VCHL = = 2
A DL 0.785D DL
(continued)
n To insure that the light liquid rises, set the
velocity of continuous water phase, VCHL, equal to
the terminal velocity of the hydrocarbon droplet,
VDLL, and solve for diameter of the drop leg, DDL
gD2PL (ρHL − ρLL ) Q CHL

VCHL = VDLL = =
0.785DDL (7.48)(60)
2 18µHL
0.5  0.5
 18  Q CHLµ HL 
DDL = 12 ×   2 
.785(7.48)(60) gDPL (ρHL − ρLL )
 
(continued)
0.5
 Q CHLµ HL 
DDL = 2.71 
gDPL (ρHL − ρLL )
2
 
0.5

DDL = 2.71
(5)(0.000342) 

(32.2)(0.00041) (61.55 − 46.34)
2
 
DDL = 12.4 inches
(continued)
n Calculate the drop leg diameter based upon a
10 minute residence time and a drop leg length
of 3.5 feet
πD2DL L
VDL = Q CHL t =
4
5 gal   ft 3  3.5πD2DL
 (10 min ) =
7.48 gal 
 min    4
D2DL = 2.43
DDL = 1.56 ft = 18.7 inches

(continued)
n Select the largest calculated drop leg inside

diameter, 18.7 inches, and round to next larger
standard pipe size, 20 inch outside diameter
n Drop leg diameter is less than half of the 7 foot

vessel diameter
– Length of the drop leg is 3 feet, 6 inches
– Since the drop leg is less than 30 inches outside
diameter and vessel is internally lined, the drop
leg will be flanged to vessel
n Minimum drop leg diameter is 14" OD
n If drop leg diameter is <30" OD and vessel

is lined, flange the drop leg to the vessel
– Drop leg is not lined because it is too small
to enter and apply an overlay
– Provide extra corrosion allowance
and replace when corroded
(continued)
n If drop leg diameter is >30" and vessel is

lined, weld the drop leg to the vessel and line
the drop leg
n If the vessel is not lined, weld the drop leg
to the vessel
n Side outlets may be used to create a “trap”
for solids
– Effective boot length is measured
from the top of outlet nozzle
Reactor Products Separator
Inlet Vapor Outlet
21"-0"
Tangent Tangent
Line Line
1'-1" 2'-4" MR MR 1'-8" 1'-5" 8"
AI AH AU BL BK BB BO
Inlet Distributor
C Vortex Breaker C
2'-4"
20” OD
BO
3'-6" 6"
6" BN
12" Thick Mesh Blanket 9"
Tangent Line
Vortex Breaker
Hydrocarbon
BW Outlet
4'-4" 4'-4"
15'-7"
Water
PROVIDE 1/8" THICK E 316L WELD OVERLAY ON THE Outlet
BOTTOM HALF OF THE VESSEL. 316L OVERLAY IS CORROSION ALLOWANCE
NOZZLES IN LINED SECTION
SHALL BE LINED AND FACED.
SD-R03-15
Horizontal Vessel Level Relationships
SD-R01-15a
Horizontal Vessel Level Ranges
Percent of Allowable Time from Low Level to High Level of

Normal Liquid Vessel Level Allowable Level Range Based on Following
Level Elevations Liquid Full Range Vessel Design Residence Times, Minutes
5 10 15 20 25 30 35
0.125D below C
L 34 0.25D 4.4 8.8 13.2 17.6 22.1 26.5 30.9
0.0625D below CL 42 0.375D 5.5 10.9 16.4 21.9 27.4 32.9 38.3
At C
L 50 0.5D 6.0 12.0 18.0 24.0 30.0 36.0 42.0
0.0625D above C
L 58 0.375D 4.0 7.9 11.9 15.9 19.8 23.8 27.8
0.125D above CL 66 0.25D 2.3 4.5 6.8 9.1 11.4 13.6 15.9
Residence Time
n In addition to phase separation, separators

provide surge volume (i.e. residence time)
n A major factor affecting cost and size of the

vessel is residence time of liquid phase
Residence Time
(continued)
n Factors which determine residence time are:

– Experience with the same services
– Experience with actual operating conditions
and methods
– Difficulty of phase separation
– Effects of loss of level or high level on
downstream equipment
– Settling of two liquid phases
– Properties causing foaming or emulsions
– Source/destination of liquid phase
– Presence of suspended solids
Residence Time Guidelines
PROCESS SERVICE RESIDENCE TIME

Vapor/Liquid Separation 5 Minutes on Liquid
Horizontal Vessel
NLL at Centerline
Vapor/Liquid/Liquid Separation 10 Minutes on Liquid
Horizontal Vessel
NLL at Centerline
Liquid Surge for Control 2-4 Minutes
High to Low Level HLL to LLL
Critical Separator 2 Minutes from HLL to
Vertical Vessel Bottom of Inlet Nozzle
Residence Time Guidelines
(continued)
PROCESS SERVICE RESIDENCE TIME

Drop Leg (Boot) 5-10 Minutes
Controlled Level
Drop Leg (Boot) 600 Minutes
Manually Drained
Feed Surge Drum 15-30 Minutes
Reflux Drums 2-5 Minutes (50% Full)
Product Receiver 5-20 Minutes (50% Full)
Residence Time
Two Liquid Phases
n ρH -ρL > 14 lb/ft3 5 Min
n ρH -ρL < 7 lb/ft3 30 Min
n Viscosity of lighter phase > 1 Cp 30 Min
Horizontal Separator Nozzle Locations
0.25D + 4" + 0.5 Dia. of Manway + 6" (Minimum)
3'-6" Max. (For Tangent Length 10'-0" through 14'-6")
4'-0" Max. (For Tangent Length 14'-6" through 24'-6")
5'-0" Max. (For Tangent Length over 24'-6")
0.5 Dia. of Ventilation Flange +
0.5 Dia. of Process Outlet
0.5 D (1' min Flange + 3" 6" + 0.5 Dia. of Process Outlet
5' max) Flange (min), 0.5D (max)
L=3D
Ventilation
6” + 0.5Dia of inlet flange (min) Nozzle Process Outlet Nozzle
0.5D (max)
Manway
Saddle
D/4 Max. Coalescing Blanket 0.5D (max)

0.5D
Basis: 1. 24" Manway with a 6" Reinforcing Pad.
2. L/D Ratio of the Vessel is 3 to 1.
3. Inlet is at the Top or on the Side.
4. Saddle Width of 8".
SD-R03-16
UOP Manways and Auxiliary Nozzles
n Manways (18” min ID)

– Vertical Vessels
Provide on top head
•
• Flange top head if vessel diameter ≤30"
– Horizontal Vessels
• Provide on the side at or below centerline
• Place above the centerline if the bottom
half of the vessel is lined
• Flange vessel head if diameter ≤ 30"
• Locate near one end
(continued)
n Ventilation
– Required for safety on horizontal vessels > 10'
diameter
– Locate on top, at the end opposite the manway
– Minimum sizes
≥ 10' diameter 4" nozzle
> 15' diameter 6" nozzle
(continued)
n Vents and Drains

– Generally required on the vessel or on piping
near vessel
– Locate to completely vent and drain the vessel
(no pockets)
– Minimum sizes
≤15' diameter 2" nozzle
15' - 20' diameter 3" nozzle
Vertical Separator Sizing
Without a Disentraining Device
n Calculate the diameter based on phase

separation in the vapor phase
n Calculate the diameter based on phase

separation in the liquid phase
n Select the governing (largest) diameter
Without a Disentraining Device (continued)
n Determine the liquid depth

– Distance between HLL and LLL is determined
from the required residence time (surge
volume)
– Provide 6" from vessel TL to LLL
– Set NLL— and center of float (COF) on the level
glass — at the NLL
Without a Disentraining Device (continued)
n Determine the required tangent length

– Determine distance from HLL to inlet nozzle
• Use 1' 6" (minimum)
– For critical services, where moisture carryover is a
major concern, provide 2 minutes of surge volume, with
a 1' 6" minimum
– Determine the distance from the inlet nozzle to the top
TL
• Use 3' 0" (minimum)
– Add the maximum liquid depth + HLL to inlet + inlet to
TL + inlet nozzle size to determine the overall TL
– If TL is too long, consider a larger vessel diameter
Vapor/Liquid Separation
With Mesh Blanket
1′
0″ Minimum
6″ 1′
0″ Minimum
EDS-R01-3422
Vapor/Liquid Separation
A Cross-sectional area, ft 2
D Vessel I.D., ft.
DB Diameter of mesh blanket, ft.
DPI Nominal pipe diameter of inlet, in.
DPO Nominal pipe diameter of outlet, in.
DPL Liquid particle diameter, ft. * (0.00082 ft.)
4 DPHL Heavy liquid particle diameter, ft. *(0.00041 ft.)
DPLL Light liquid particle diameter, ft. *(0.00041 ft.)
4 DPI DPV Vapor particle diameter, ft. *(0.00057 ft.)
D F Percent liquid full
g 32.2 ft/s2
DPI L Tangent length, ft.
QL Flow rate of total liquid phase, gpm
6 QV Flow rate of vapor phase, ft 3/s
t Liquid residence time, minutes
L Maximum Level ρL Liquid density, lb/ft 3
ρHL Heavy liquid density, lb/ft 3
ρLL Light liquid density, lb/ft3
2 minute residence time ρV Vapor density, lb/ft3
µL Liquid viscosity, lb/ft sec
D for critical service µHL Heavy liquid viscosity, lb/ft sec
µLL Light liquid viscosity, lb/ft sec
µV Vapor viscosity, lb/ft sec
* Use in the absence of specific process data
Minimum Level ƒ 0.4DB (Min.)
„ 0.5DPI + 3'-0"
6" … 0.5D + 0.5DPI
>0.5DPI + 2'-0"
<0.5 DPI + 4'-0"
† 0.5DPI + 1'-6" (Min.)
Note: flowing data are at operating conditions.
SD-R01-04
Criteria for Vertical Vessel Sizing
n The following equations are derived by setting

the vapor velocity equal to particle terminal
velocity and solving for D
n For gravity settling of liquid from the vapor
phase (terminal velocity based upon
intermediate equation)
0.5
 Q V ρ0V.29µ0V.43 
D = 2.9
0.71 

g DPL (ρL − ρV ) 
0.71 1.14

Criteria for Vertical Vessel Sizing
(continued)
n For disentraining vapor from the liquid phase

(terminal velocity based upon Stokes’
Equation)
0 .5
 Q LµL 
D = 0. 23 2 
 PV ( L
gD ρ − ρ V )
Level Instrument Nozzles
Vessel
Nozzle Vessel
Nozzle
Displacer Displacer
Float Float
Instrument Instrument
Gauge Gauge
Glass Glass
Pipe
Column
Pipe Column Bridle

Installation Installation
SD-R00-17
Level Instruments
Span and Nozzle Size
Arrangements and Nozzles for Displacer Float Instruments and Gauge Glasses
Displacer Float Gauge
Instruments Glasses
Max. Span
Between Max.
Vessel Min. Vessel Max. Float Min. Vessel Nominal
Nozzles Nozzle Size Length Nozzle Size Length
Separate 15' 0" 1½" 10' 0" 1" 5' 6"
Connections (4600) (3048) (1650)
Bridle 9' 0" 1½" 5' 0" 1½" 5' 6"
Installation (2700) (1524) (1650)
Pipe Column 15' 0" 2" 10' 0" 2" 5' 6"
Installation (4600) (3048) (1650)
Level Float Dimensions
Note: Dimensions given for flanged connections are suitable for

ASME Class 150, 300, and 600 raised face and ring type joints
SD-R01-18
Level Float Dimensions
(continued)
SD-R01-18
Level Gauge Dimensions
SD-R01-19
Level Gauge Dimensions
SD-R01-19
Vortex Breakers
n Provide vortex breakers on liquid outlets

to eliminate possible vapor entrainment
(especially objectionable on a pump suction)
n When two liquid phases are present, raise the

light phase vortex breaker to prevent possible
inflow of heavy phase liquid
– For water, it is typically raised 6 inches
Vortex Breakers
Four Way
3 - 3/4" x 1/4" Bars Baffle
Spaced at 120º 2D
8" Dia.
for 3" 2D
6" Dia.
under 3"
D
D
4"
2" 3"
D D
3" and Under 4" Through 8" 10" and Over
2D 2D
8" Four Way
Baffle
D
D Pipe D D Pipe
4"
4" Pipe 2" 2" 3"
H H H
D D
3" and Under 4" Through 8" 10" and Over
H = as specified
Raised Vortex Breaker Required for Two Liquid Phases

SD-R01-20
Vortex Breakers
(continued)
Vortex Breakers
(continued)
Vortex Breakers
(continued)
Vortex Breakers
(continued)
Inlet Distributors
n Inlet distributors change the liquid direction

to provide momentum separation
n Horizontal Vessels
– Subcooled liquids use an open ended pipe
from the top or bottom of the vessel
• Distributor exit located to always remain
beneath the liquid
– Bubble point liquids (e.g. small amount
of vapor) use a vertical slotted pipe
the same size as the inlet
Inlet Distributors
(continued)
n Horizontal Vessels (continued)

– Two liquids of approximately equal volume --
use a horizontal slotted inlet pipe near the
normal liquid interface (i.e., vessel centerline)
• Pipe is the same size as the inlet
– Mixed Phases -- use a vertical slotted inlet one
pipe size larger than the inlet pipe
• Slot area is 2 to 3 times the pipe area
• If there are two approximately equal liquid
phases, locate the inlet near the center of
vessel and use two slots facing the shell
Inlet Distributors
(continued)
n Horizontal Vessels (continued)

– Unless otherwise noted:
• Slots begin 6" from the inlet nozzle
• Slots end at the end of the distributor
• Distributor ends 6" from the vessel bottom
• Slot area is twice the distributor area
• Use one slot
• Use intermittent rather than very narrow
(<3/16" (5mm)) slots
• Slots face the nearest head (to maximize vessel
gravity separation length and residence time,
and provide additional momentum separation)
Inlet Distributors
(continued)
n Vertical vessels use a tee style distributor,

except on small vessels with flanged heads
n Orient the “Tee” in the horizontal plane, so

the discharge directions are tangential
Subcooled Liquid Distributors
Bottom Entry
Subcooled Liquid Distributors
Bottom Entry (continued)
Alloy Lined Vessels Vessels

SD-R00-43
Vertical Distributors
for Horizontal Vessels
SD-R00-55
Horizontal Pipe Distributor
Liquid/Liquid Distributor
(approximately. equal volume liquids)
Tee Distributor for Vertical Vessels
Tee Distributor for Vertical Vessels
(continued)
Separation Phase Examples
PHASES EXAMPLE
Vapor/Liquid Separator
Flash Drum
Liquid/Liquid Caustic Settler
Desalter
Vapor/Liquid/Liquid Hydrotreater Separator
Wet Overhead Receiver
Vapor/Solid FCC Regenerator
Liquid/Solid Slurry Separator
Separators - Vertical
n Efficient use of vapor cross section- it does not

change
n Limited liquid-vapor interface for disengagement
n Liquid level is subject to variation
– Reacts rapidly to flow changes
n Efficient use of plot space
n Easy to support (skirt or legs to foundation)
n Continuous phase motion is opposite the direction
of the terminal velocity and can counteract the
tendency of the phases to separate
Separators - Horizontal
n Large liquid-vapor interface, optimal for

disengagement
n Liquid level responds more slowly to variations
in flow
n Handles two liquid phases well
n Vapor space subject to variation
n Uses more plot space
n Requires support structure
n Continuous phase motion is perpendicular
to the direction of the terminal velocity
– Do not influence each other
Separators - Spherical
n Minimum shell steel and weight

n Compact
n Cross sectional area changes rapidly
– Dimensions change in two directions
at the same time with elevation
n Low liquid flow volumes
n Rarely used (occasionally on high pressure
systems to reduce shell thickness and cost)
Separators
PROCESS VESSEL
CONDITIONS CONFIGURATION
High Vapor Rate Vertical Vessel
Low Liquid Rate (makes efficient use of the vessel
One Liquid Phase cross section)
Low Vapor Rate Horizontal Vessel
High Liquid Rate (vertical vessel may be considered)
One Liquid Phase
No Vapor Phase Horizontal Vessel
Two Liquid Phases
Separators
(continued)
PROCESS VESSEL
CONDITIONS CONFIGURATION
Vapor Phase Present Horizontal Vessel with
Two Liquid Phases Drop Leg (Boot)
Low Heavy Liquid Phase Rate
Vapor Phase Present Horizontal with Baffled
Two Liquid Phases Outlet for the Heavy
Low Light Liquid Phase Rate Liquid
Vapor Phase Present Horizontal with 2 Baffled
Two Liquid Phases Outlets
Liquid Phases Equal Rates
Types of Vessels
Tangent Length
M.R. M.R.
Vapor Out
A B F C
Min. Min.
Inlet Distributor
CL
I.D.
150
Min.
D
Example:Overhead Receiver Liquid Out
SD-R03-05
Types of Vessels
Liquid/Liquid Separator
Note: Use side inlet and horizontal distributor if liquid volume

flows are approximately equal.
SD-R03-06
Types of Vessels
Vapor/Liquid/Liquid Separator
Low Heavy Liquid Rate
Tangent Length
M.R. M.R.
Vapor Out
Feed
A B D E
Min.
Inlet Distributor
I.D.
CL
6"
Min.
F
Light Liquid Out
Example: HP Separator G
Heavy Liquid Out
SD-R02-07
Types of Vessels
Equivalent Light and Heavy Liquid Rates
SD-R00-44
Types of Vessels
Low Light Liquid Rate
SD-R00-45
A
I.D.
E B
Vortex Breaker
C
Access Opening
Example: Separator, Flash Drum

EDS-R01-3443
Small Vertical Separators
Mesh Blanket A
B 3" Min.
Inlet Distributor
E C
O.D.
Vortex Breaker
D
ID of 30 inch or less
Elevation of 5 feet or less
Example: Reciprocating Compressor Suction Drum
SD-R02-08
Mist Eliminators
Mist Eliminators
n Purpose
n Types
n Theory and Typical Installations
n Size Criteria
Mist Eliminators
(continued)
n Efficiency
n Pressure Drop
n Fabrication and Installation
n Material of Construction
n Sample Problem
Purpose of Mist Eliminators
n Enhance the separation of entrained:

– Small liquid droplets from vapor
– Liquid from liquid
– Small solid particles from vapor
Benefits of Mist Eliminators
n Reduce loss of valuable product (for

evaporators, absorbers, etc.)
n Increase throughput capacity (anywhere
gases and liquids come into contact)
n Improve product purity or yield
n Eliminate contamination (evaporator
overheads) or catalyst poisoning
Benefits of Mist Eliminators
(continued)
n Stop downstream corrosion

n Prevent equipment damage (compressor
knockout drums)
n Prevent air or water pollution (reduce
emissions from FCC regenerators and acid
plants)
n Permit the use of smaller separation vessels
How Does Entrainment Occur?
n Entrainment of liquid droplets of varying size

and quantity in a gas occurs:
– Whenever gas contacts a liquid
– When liquid condenses from a gas
– When gas is generated from a liquid
How Does Entrainment Occur?
(continued)
FROM FRACTIONATAR
OVERHEAD
AIR COOLER
Liquid may
M
be swept
along with
Liquid
the vapor.
condenses from
the vapor WATER CONDENSER
NET GAS
OVERHEAD
RECEIVER
LIQUID
WATER
SD-R00-28
Mechanisms That Cause Entrainment
Mechanical
sprays
evaporation
surface
trays and
column packings
Condensation
on surface
from saturated
vapor
chemical
reaction
0.1 1.0 10 100 1000

Particle Size (µ)
SD-R00-25
Droplet Size
n Droplet sizes are controlled by:

– Viscosity
– Surface tension
– Density
– Velocity
n Actual sizes are unknown and likely to follow
a normal distribution
n Design based upon average, estimated, sizes
works well
Advantages of Mist Eliminators
n Given enough time and low enough velocity, most

liquid can be separated by gravity settling; however,
the required equipment size may be impractical
n Mist eliminators accelerate the separation process
– Remove smaller droplets than would be practical, or
possible, to remove by gravity
– Enhance separation of fluids with smaller density
differences
– Allow higher vapor velocities and, therefore, smaller
equipment size by forming large droplets that can
more easily gravity settle
Disadvantages of Mist Eliminators
n Purchase and installation cost

n Require maintenance
n Increase pressure drop, potentially affecting
operating cost
n May plug
Decide if Mist Eliminator is Required
n Determine smallest size of particle/droplet

to be removed
– Smaller particles require larger vessels
and lower velocities for gravity settling
– Consider effect of particle/droplet carryover
n Determine required equipment size for
gravity settling
– Is it excessive?
Decide if Mist Eliminator is Required
n Evaluate costs of larger particle/droplet

carryover vs. cost of removal
n Is particle/droplet removal critical, considering
economics and safety?
– Liquid entrance into a compressor may damage
or destroy the expensive equipment and shut
down the unit
– In these cases, removal equipment is often sized
for gravity removal
• Mist eliminator added for additional
thoroughness of particle/droplet removal
Types of Mist Eliminators
n Vanes
n Centrifugal Elements
n Filters
n Mesh Blankets
n Perforated Plates
n Electrostatic Precipitators
Characteristics of Vanes
n Inertial impaction devices (continuous phase

forced to quickly change direction; however,
entrained particles and heavy droplets do not
turn quickly, collide with vanes, and drain)
n Reduced distance of drop (or settlement)
before extraction
n Do not drain liquid into rising gas stream
where it can be reentrained
n Liquid can be routed to downcomer
n Depend on inertia performance - turndown
is a problem
Characteristics of Vanes
(continued)
n Do not readily plug or foul

n Can be put into smaller vessels
n Same separation performance as wire mesh
n Suitable for high vapor velocities, high liquid
loadings, viscous fluids, and solids
n Sturdy construction
n Designs are proprietary
n Purchase and installation cost can be high
n Maintenance cost is higher
Vertical Separator
With Vane Mist Extractor
Vane Element Mist Extractor
Cross Section
Vane Mist Eliminators
Characteristics of Centrifugal Elements
n Use inertial separation

– Flow is spun rapidly, high density materials
go to the outside
n Separate solids, as well as liquids, from gas
n Design(s) are proprietary
n Less maintenance than a filter
n Efficiency is lower than other types
n Can handle high “loadings” of dense,
dispersed phase materials
Characteristics of Centrifugal Elements
(continued)
n Pressure drop higher than vane or mesh

n Narrow operating flow range
n Subject to wear and tear
n May plug
n May not handle sudden increases in flow (“slugs”)
Centrifugal Elements
SD-R00-46
Characteristics of Filters
n Continuous phase passes through a porous

media with very small openings to trap larger
particles/droplets
n High efficiency
n Can remove small particles
n Filter elements need replacement or a back-
wash system
n Handle higher solids load
n Design is proprietary
Characteristics of Filters
(continued)
n Filter-separators can remove solids and large

drops; small liquid droplets are coalesced for
easier separation by a downstream mesh
n Velocity out of filter-separator tubes must be
low to prevent shearing drops back into a fine
mist that will pass through a mesh
n High pressure drop, 1-2 psi when clean and 10
psi or more prior to cleaning
– May collapse at 25 psi
n Higher operating costs
n Higher purchase and installation costs
Horizontal Filter Separator
Inlet Vapor Out

Filter-Coalescing Baffle
Elements
Mist Eliminator
Flanged
Head
Liquid Out
SD-R02-47
Perforated Plates or Staggered Baffles
n Large openings are less likely, or take longer,

to plug
Electrostatic Precipitators
n Removes very small solid particles (< 3 microns)

n Uses attraction/repulsion from static electrical
charges
n Equipment is large and costly
n Electrical usage, hence utility costs, during operation
Characteristics of Mesh Blankets
n Used for coalescing of liquid

n High efficiency through wide velocity range
n Applicable to wide range of process operations,
fluids, and droplet sizes
n Used for very small droplets and high overall
removal percentage (up to 99.9% or more)
(continued)
n Efficient for a wide range of gas velocities

without liquid reentrainment
n Low pressure drop - approximately 1" H2O
n Low installed cost
– For 6" thick mesh blanket
• Stainless Steel 30 $/ft2
• Monel 60 $/ft2
n Easy to install
(continued)
n Low operation and maintenance costs
n Can be used for new and existing vessels
n Blankets installed vertically are less efficient
n Cannot be used where fouling or hydrate

formation is possible because it plugs easily
Mesh Blanket Installation Sites
n Knockout Drums
n Separators
n Absorbers
n Scrubbers
n Distillation Columns or Towers
n Steam Systems
Typical Mesh Blanket Installations
Suction Drum
Secondary Separator
SD-R00-29
(continued)
SD-R01-30
(continued)
Horizontal
Mesh Blanket
Products Separator
SD-R01-48
Types of Impingement Separators
SD-R01-24
Separation Steps
SD-R01-23
Separation Steps
1. Liquid - vapor disengaging

from liquid forms fine
droplets.
2. Gas rising from liquid carries
entrained droplets.
3. Mist - vapor impinges on
blanket, drops coalesce into
larger drops.
4. Liquid droplets falling free.
5. Dry gas leaving blanket.
SD-R01-42
Coalescing Separation Theory
n Mesh blankets operate by forcing the fluid to follow

a torturous path and coalescing, or combining,
small liquid droplets into larger droplets that may
then be removed by gravity settling
n For given fluids, the rate of gravity settling (rising)
is a function of particle/droplet/bubble size
– Larger particles/droplets/bubbles will separate
faster, requiring a smaller vessel
(continued)
n Droplets contact, but do not stick to, the

curved wire surfaces
– Surface tension causes droplets to remain
in contact with the wire
n Droplets flow down the wire and gather at
wire intersections
n Droplets coalesce or combine and grow in size
n As droplets increase in size, they drop lower
in the mesh
(continued)
n When large enough to overcome surface tension

and separate from the mesh, droplets are pulled
down by gravity against the upward gas
velocity
n Droplet size is governed by physical properties:
– Density
– Surface tension
– Viscosity
(continued)
n The higher the viscosity, the larger the droplet
n The higher the surface tension, the larger the droplet
Droplet Capture Mechanisms
Droplet flow doesn’t follow rapid

streamline changes.
SD-R01-26a
(continued)
Droplet flow follows streamlines but is captured

by surface tension or approach distance is less
than the particle radius.
SD-R01-26b
(continued)
Brownian Movement - constant random movement

(caused by collisions with dispersed and continuous
phase particles) of small particles dispersed in a fluid.
This movement brings some particles close enough to
the wire for capture.
SD-R01-26c
Typical Layer of Wire Mesh
SD-R00-43
Mesh Blanket Construction
n Wire is manufactured in a cylinder of

sufficient length to make a blanket module
of the desired thickness and length
n Cylinder is flattened to form a double layer
of the desired width (usually 12 ¼ inches); the
cylinder diameter is set by the desired width
n Wire is folded and refolded lengthwise to the
proper dimensions
WIRE
WIRE SURFACE
DIAMETER DENSITY AREA VOIDS
3 2 3
STYLE (in) (lbs/ft ) (ft /ft ) (%)
A 0.011 9 85 98.0
B 0.011 5 45 99.0
C 0.011 12 110 97.7
(continued)
n Style A
– General purpose mesh used when there
are no special requirements
n Style B
– Used where fouling (such as coking) or solids
are probable
• Wire directions alternated
• Has largest open area
(continued)
n Style C
– Heavy duty, general purpose mesh used where
excellent separation efficiency is required
– Herringbone pattern and alternating crimp
directions reduce sheltering of wires behind
other wires and increase wire surface area
(for more droplet impingement) with a
minimal change in voidage.
UOP Severe Duty Mesh
n Developed due to improved separation

requirements to avoid burner fouling,
compressor damage, etc
n Constructed of 3 - 3 inch layers
n Entrance layer removes solids and larger

drops, drains well, and resists plugging
UOP Severe Duty Mesh
(continued)
n Middle layer removes drops larger than

15 microns
n Exit layer removes drops down to 5 microns
n Installed horizontally
n Mesh blanket style normally used by UOP
Severe Duty Mesh
3 - 3" Zones - Total 9" Thick
WIRE
WIRE SURFACE
DIAMETER DENSITY AREA VOIDS
LAYER (in) (lbs/ft3) (ft2/ft3) (%)
Exit 0.006 8 140 98.4
Middle 0.011 9 85 98.0
Entrance 0.011 5 45 99.0
Installed Thickness
n Styles A, B, or C are installed 4-12" thick

– Most common is style A, 6" thick, to remove
15 micron droplets
n Severe duty mesh is installed 9" thick (3 - 3"

layers) to remove > 5 micron droplets
n If any of the mesh is submerged in liquid (e.g.

to aid liquid from liquid separation), use 2 - 6"
layers of style A, with offset joints
Size Criteria
n Vapor Velocity Effects

– If the velocity is below the lower limit, the droplets
follow the stream of gas without impinging on the
wire
– If the velocity is at the lower limit, the droplets
impinge on the wires due to the change in direction
forced on the gas and the liquid runs off the wire
Size Criteria
(continued)
n Vapor Velocity Effects (continued)

– If the velocity is increased above the minimum, a layer
of liquid begins to form on the mesh and scrubbing
helps to improve further entrainment separation
– If the velocity is further increased, the liquid layer
gradually increases in depth, nearing the exit side
of the mesh
– If the maximum velocity is exceeded, re-entrainment
will occur at the outlet of the mesh
Size Criteria
(continued)
n Several factors govern gas velocity limits

– Surface tension of liquid
– Viscosity of liquid
– Wire surface area
– Liquid entrainment loading
– Suspended solids content
– Gas and liquid densities
n Liquid and gas densities have the most
influence
Size Criteria
(continued)
– From Stokes’Law and Souders-Brown

Correlation
ρl - ρg 0.5
V=K 
ρ
 g 
V = Optimum velocity, ft/s

ρl = Density of liquid, lbs/ft3
ρg = Density of vapor, lbs/ft3
K = Constant based on system pressure
VDesign = 0.7 VOptimum
Optimum Velocity
n V Optimum is the velocity at which re-entrainment is

about to occur
– Is the maximum velocity, hence maximum
throughput, for which the desired separation will
occur
– Is the maximum pressure drop
Mesh Blanket Efficiency
n Mesh blanket efficiency is fairly constant

through a wide range of velocities
n For 15 micron and larger removal, the range
is 30 - 110% of VOptimal
n For smaller than 15 micron removal, the
range is 50 - 110% of VOptimal
n Use of VDesign = 0.7V Optimal provides an
allowance for actual velocity variations
Velocity vs. Removal Efficiency
Style A, 6" Mesh Blanket
SD-R01-34
K vs. Pressure
PRESSURE 9" SEVERE 6" NORMAL

(inches of Hg absolute) DUTY MESH DUTY MESH
Less than 1” 0.14 0.17
1" 0.14 0.17
5" 0.18 0.23
10" 0.22 0.28
20" 0.26 0.32
30" 0.28 0.35
K vs. Pressure
PRESSURE 9" SEVERE 6" NORMAL

(psia) DUTY MESH DUTY MESH
15 0.28 0.35
50 0.27 0.34
100 0.26 0.32
200 0.25 0.31
300 0.24 0.30
500 0.22 0.28
1000 0.22 0.27
Greater than 1000 0.22 0.27
Mesh Blanket Size Criteria
n Vdesign = (0.7) * K [(ρ1 - ρv)/ρv]0.5
DM n CFSactual = from process data
n AREA = CFSactual/Vdesign
Dv
n Mesh diameter = (4 * AREA/π)0.5
n K is a function of pressure
Dv can be sized for gravity settling if critical service or Dv

can be sized for the mesh blanket diameter if not critical
SD-R00-31
Extended Surface Arrangements
for Various Size Ranges
θ θ
Up to 36 inch 36 in to 72 inch
Diameter Diameter
72 inch and Larger

Diameter
EDS-R01-3404
Size Criteria for a Sloped
Mesh Blanket
ρl - ρg 0.5
n V θ = KΘ  
 ρg 
n KΘ = K + 0.3 SINΘ
n Maximum angle (Θ ) = 45 degrees
n V θ is the optimum vapor velocity

over the vessel cross section
Mesh Blanket Location
for Vertical Vessels
SD-R02-32
Mesh Blanket Location
SD-R02-33
Pressure Drop
2
0.193fctad g Vact
∆PD =
g ce 3
Where: ∆PD = Pressure drop across the mesh blanket with

no entrainment (i.e., dry), inches of water
fc = Friction factor, dimensionless
t = Thickness of mesh blanket, ft
a = Surface area of wire, ft2/ft3
dg = Gas density, lb/ft3
gc = Gravitational constant, 32.2 ft/lbm/lbf /sec2
e = Void fraction of mesh blanket
V act = Actual superficial gas velocity, ft/sec
Friction Factor vs. Reynolds Number
of Mesh Blanket
SD-R01-35
Pressure Drop
n The total pressure drop across an operating

mesh blanket is sum of the dry pressure drop
plus additional pressure drop caused by
liquid loading within the mesh
n The total pressure drop may be determined

by:
∆PT = ∆PD + ∆PL
(Total) (Dry) (∆P Due to
Liquid Load)
Pressure Drop for Entrainment Load
A B A B C
1.0 1.0
D
C
0.1 0.1
00.1 0.01
0.1 0.2 0.3 0.4 0.5 0.1 0.2 0.3 0.4 0.5
A 2200 lb/hr•ft2
Vact. Vact.
dl - dg 0.5 B 935 lb/hr•ft2 dl - dg 0.5
( dg ) C 160 lb/hr•ft2
( dg )
Style B, 6 inch thick mesh blanket D 16.5 lb/hr•ft2 Style C, 6 inch thick mesh blanket
DPL for style “A” is the average of styles “B” and “C.”
SD-R03-36
Total Pressure Drop
n Total pressure drop may be estimated as:

2
 VActual 
∆PT = 1.5 
VOptimal 
 
n This is based upon a normal total pressure

drop of 1.5" of water at VOptimal
Typical Horizontal Installation
of a Sectional Mesh Blanket
SD-R01-37
Typical Vertical Arrangement
of a Sectional Mesh Blanket
SD-R02-38
Typical Horizontal One-Piece
Mesh Blanket
SD-R02-39
Installation and Removal from Top
3 /4 inch
3 /4 inch
1 1/2 inch x 1/4 inch plate ring
furnish in minimum number
of pieces to pass thru manway Spacers - 1/2 inch standard pipe
Nominal blanket
thickness +2 inch Grids (1 inch each)
3 /16 in 2 inch x 3/8 inch plate support ring

3 /16 in 1-6
1 1/4 in Tack weld bolt head to ring
Centerline, 1/2 inch diameter alloy bolts 3 /4
Max. spacing 13 inch centers inch
SD-R04-40
Installation and Removal from Bottom
3/4 inch Inside Diameter

clearance Vessel Ring
Top Grid Diameter Width
1/8 inch diameter staple Up to 8’ 2"
8' to 15’ 2½"
Over 15’ 3"
1 inch
Bottom Grid
Tie Wire
1/ 4 inch Diameter Holes, 5 inch Centers
Annular Ring, 2 inch to 3 inch Wide
SD-R03-41
Support Strength
n Mesh must be firmly supported to resist

dislodging from back pressures due to
blowdown or upset conditions, and pressure
due to limited plugging
Support Grids
n Support grids are constructed from 1" x 1/8"

bars on 5¼" centers (3 bars to a 12¼" module)
n Ordinary grating is not used because the

closer bar spacing will interfere with liquid
drainage and the function of the mesh blanket
Materials of Construction
Mesh Material
Even small amounts of corrosion may damage

the fine wire of the mesh; therefore, use:
n Austenitic Stainless
n Monel
n Polyethylene (limited to 170°F)
n Polypropylene (limited to 170°F)
n Teflon (limited to 350°F)
n Proprietary Materials
Materials of Construction
Support Grid Material
n Austenitic Stainless
n Monel
n Carpenter 20
n Hastelloy
n Titanium
Sample Problem
n Design a mesh blanket for a vertical separator

with the following data:
Pressure 110 psig

Temperature 115ºF
Vapor Flow Rate 257,760 lb/h
Vapor Density 0.147 lb/ft3
Vapor Viscosity 0.013 Cp
Liquid Density 50.1 lb/ft3
Calculate Optimum Velocity
0.5
d l − d g 
V = K 

 g 
d 
0.5
50.1 − 0.147 
V = 0.32
 0.147  
V = 5.9 ft/s
Calculate Design Velocity
n Entrainment would fall into the spray

category with a droplet size of 20 microns
and larger
n Efficient separation is accomplished over

a range of 30% to 110% (70% average)
of optimum allowable velocity
V d = 0.7V
V d = 0.7 (5.9) = 4.13 ft/s
Calculate Required
Mesh Blanket Area
257,760
AR =
0.147(3600)4.13
A R = 117.9 ft 2
Calculate Required
Mesh Blanket Diameter
0.5
A 
D = 2 
 π
0.5
117.9 
D = 2  = 12.25 ft.
 3.14 
Because support ring is 2.5" wide, add 5" to diameter

DR = 12.25 + 0.42 = 12.67 ft (12'-8")
Use Style A, 6" thick mesh blanket with diameter of 12'-8"
Estimated Pressure Drop
2
0.193fctad g Vact
∆PD =
g ce 3
Vact = 4.13 ft s
For Style “A” mesh:
a = 85 ft 2 ft 3
e = 0.98
(continued)
µ = (0.013Cp )(0.000672)= (0.0000087 lb/ft ⋅s )
d g Vact 0.147(4.13)
Re ynolds Number = = = 821
aµ 85(0.0000087 )
From the curve: fc = 0.20
(continued)
(0.193)(0.20)(0.5)(85)(0.147)(4.13)2
∆PD =
32.2(0.98)3
∆PD = 0.136 inch water
(continued)
n Pressure drop due to liquid on the mesh
257,760
Superficial Velocity, = 2186 lb/hr ⋅ft 2
117.9
Vact 4.13
= = 0.224
0.5 0.5
d l − d g  50.1 − 0.147 
   
 dg   0. 147 
 
(continued)
∆P L for Style B ≈0.12 inches water
∆P L for Style C ≈1.0 inches water
Average ∆P L ≈0.56 inches water
(continued)
∆P = ∆PD + ∆PL = 0.136 + 0.56 = 0.696 inches of water
Determine with simplified method:
2
 Vact  2
∆P = 1.5  = 1.5

4 . 13 
 = 0.74 inches of water
VOptimal   5.9 
 

Gravity Separation

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Gravity Separation

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n Absorbs variations in the incoming flow,

n Allows time for problem correction or shut

n May be a dedicated vessel or provided as

n Normal time a fluid remains within a vessel,

n May be defined to give the needed surge

n Requirement set by process or operational

n Smoothes liquid flow variations resulting from

Size a feed surge drum for a Tatoray Unit. The

Set the volume of the vessel equal to the volume of

n The Act or Process of Separating

n The State of Being Separate

n To Isolate From a Mixture

n To Divide Into Constituent Parts

n Remove unwanted fluids, such as water

n For gravity separation to occur, fluids must

n The closer the fluid densities, the more

n No separation method is complete. The

Incapable of being mixed without the

Separation using a combination of these methods is

n Denser fluid changes direction more slowly

n Often used for initial or “bulk” separation

n Denser fluids sink and lighter fluids “rise”

n Most common means of separation used in

n To unite into a whole

n Droplets follow a torturous path through a

n Generally used for fine droplet removal,

n Usually four zones in a separator

n For Vessel Design

n Steady state velocity at which a dispersed

n Reached when the forces acting on the

n The predominant, or carrying fluid in the

n Fluid scattered within and being carried by

and u = ut = terminal velocity

Substitute and solve for ut:

4D p g(ρp − ρ)

n Terminal velocity for a particle can now be

Particle Reynolds Number, NRe = Dpρut

n For: 500 < N Re < 200 , 000

n Where: Particle Reynolds Number D p ρu t

gDp (ρp − ρ)

Particle Reynolds Number, NRe = µ Newton CD = 0.44

4Dp g(ρL − ρV ) 4(1.75)(32.2)

n For: 2 < N Re < 500

Particle Reynolds Number, NRe = µ Newton CD = 0.44

n The closer the fluid densities are, the more

n Consider effect upon downstream equipment,

n Default particle sizes used for gravity

The relevant portion of the heat and material

n Tabulate data and calculate volumetric flows

HYDROCARBON WATER TOTAL

n Determine Liquid Residence Time

n Determine Normal Liquid Level

n Calculate Diameter to Satisfy Residence Time

n Calculate the diameter required for each

n Coalescing blankets are often used to

NLL = Normal Liquid Level

n Calculate diameter based on residence time

– Calculate liquid volume

– If the vessel is 1/2 full, then the full vessel

n V V is a cylinder with L/D = 3. Ignoring the

n Normal liquid level (NLL) is usually set at the

n High and low liquid levels (HLL and LLL)

n Calculate the diameter based on vapor from