Process Design

VESSEL SIZING
(Liquid & Vapour Separators)
Content
 Vessel Configuration
 Sizing fundamentals
 SettlingVelocity
 Vapour-Liquid Separator
 Mist Eliminators
 Heavy Liquid Phase separation

 Other Aspects
Nozzle Sizing
Vessel Configuration
 Vertical Vessel
 High Vapour Rate, Low Liquid Rate and only one liquid phase
 Horizontal Vessel
 Low Vapour Rate, High Liquid Rate and only one liquid phase
 No Vapour Phase and Two Liquid Phase
 Vapour Phase and Two Liquid Phases
 Heavy liquid Phase is of smaller rate – Boot
 Light Liquid Phase is of smaller rate – Baffled Outlet end for the
heavy liquid
 Liquid Phases of approx equal rates – Baffled Outlet end for each
liquid phase.
 L/D ratio of 3 results in most economical vessel shell design.
Applications
Service Residence time Outlet size Vessel Devices
Orientation
Compressor KOD - 1 micron Vertical Proprietary
(Axial) Coalescer
Compressor KOD - 10 microns Vertical Wire mesh
(Reciprocating)
Compressor KOD - 100 microns Vertical Wire mesh
(Centrifugal)
Fuel Gas KOD - 10-50 micron Vertical Wire mesh

Flare KOD - 600 microns Horizontal None

Applications
Service Residence time Outlet size Vessel Devices
Orientation
Reflux Drum 5 min (reflux only) 200 microns Horizontal None
8 min (reflux +
Storage)
3 phase 1 - 3 minutes (V-L) 70 microns Horizontal Vane pack
separator 3 - 10 minutes (L-L) Antifoam device
Sizing Fundamental
 Horizontal Separator
 Liquid settles at right angle to flow
 Criteria: Time taken for vapour travel > time taken for liquid to
separate
L/V >= D/Vs
Vm = L/D Vs

V = Vapour Velocity
Vm = Maximum Vapour Velocity
Vs = Liquid Settling Velocity
L = Distance between feed inlet and Vapour outlet
D = Vessel dia ( or more exactly distance from top of drum to liquid
surface)
Sizing Fundamental
 Horizontal Vessel
 With L/D > 1, Vapour velocity can exceed
settling velocity
 Vertical Vessel
 Liquid settles directly opposed to the vapour
 Vertical: Vapour velocity cannot exceed
settling velocity
Sizing Fundamental
 Basic approach for vessel sizing
 Vapour/liquid flowrates & Properties.
 Liquid droplet size and settling velocity
 Allowable vapour velocity & Xsection area of
vapour space
 Max Liquid Level
 Vapour phase & liquid phase Residence time
Sizing Fundamental
 Max Droplet size
 Misty:Stratified Wavy, Annular, Dispersed, Bubble, Froth,
Slug, Plug
 Droplets: Bubbly, Smooth stratified
Settling Velocity
Settling Velocity
Drag Coeff. C, is function of Reynold
number.
3.354 10 9  V  d 3  (  L  V )
C  Re 2  2
v
Settling Velocity
Settling Velocity Correlation
 For Vapor viscosity < 0.01 cp, curves of
Vs versus the Density function were
developed for following droplet sizes
 500 micron( non-critical separation, or design
using demister)
 150 micron (for critical separation services)
Settling Velocity
High Pressure Cases
 For cases where pressure exceed 50 barg
andvapour viscocity > 0.01cp, settling
velocity is computed using drag coeff.
Vapour-Liquid Separator Sizing
 Vertical Separator
 The Diameter is determined as follows
 With mist eliminator: Use 500 curve for Vs
 Without mist eliminator: Use 150 curve for Vs

 Using Vapour flow rate, calculate diameter @ 85%

settling velocity
 Calculate working volume
 Retention Time (for gas break out)
 Residence Time (for downstream consumers)

 LLL 6” from BTL, HLL 6” below feed inlet

Vertical Separator
Vapour-Liquid Separator Sizing
 Retention Time (API 12J)
Vapour-Liquid Separator Sizing
 Residence Time
Feed from other unit, storage 15 - 20 min
Charge to column 5 min
Product (pumped) 5 min
Product (un-pumped) 2 min
Charge to fired heater 10 min
HP Separator 4 min
Vapour-Liquid Separator Sizing
 Horizontal Separators
Vapour-Liquid separators
 Horizontal
 Vapour Velocity = 0.85* L/D*Vs = F*Vs
 Set L/D = 3.0 (F = 2.55)
 Compute Vapour flow area
 Assume H/D, Fraction of dia occupied by liquid.
 Estimate Liquid flow area
 Calculate diameter from total X section area
 Calculate L from Liquid Flow area and liquid rate
 Check L/D. If L/D >= 3, OK
 If L/D < 3 then iterate by reducing H/D.
 Liquid Surge from Residence Time <= Calculated
Surge Including head volume
Mist Eliminators
Mist
Eliminators
 Wire mesh type
Mist Eliminators
 Vane type
Liquid-liquid Separation
Liquid-liquid Separation

For settling diameter = 0.005 inch (127 microns)

Settling velocity = 10 inch/min max, for design
Liquid-liquid Separation
 Retention Time (API 12J)
Three-phase separators
 Horizontal
 Calculate
L, D, for Vapour-Liquid separation
 Check Water separation at HLL, LLL
 Check Retention time
 Iterate
Three-phase separators
 Design aspects
 Settlewater from liquid HC
 Coalescing pad across full diameter
 Boot dia < 33% vessel dia (40% max)
 ‘Remote’ boot, if required
 Internal Baffle for high water ratio
Three-phase separators
Other aspects
 Process Nozzles
Pump suction, Reboiler inlet 2 – 4 fps
Pump discharge, Pressure out 5 – 10 fps
Liquid Feed, Reflux inlet 5 – 10 fps
Vapour Feed 30 – 80 fps
Vapour outlet 50 – 150 fps
Mixed Phase Feed 25 – 45 fps
Mixed Phase Reboiler return 35 – 50 fps
Other aspects
 Level Nozzles
 Controllable High and Low Levels
 Standard Displacer lengths 14” – 120”
 Trip levels usually 1 min below alarm levels
We talked about
 Types of vessels
 Sizing fundamentals
 Other aspects

 Reference: Separator Design Guide

 3DG-V04E-00101
Tutorial
0.5 0. 5
3.354 10 9  V  d 3  (  L  V ) d    L  v 
C  Re 
2
Vs  0.01186    
v
2
C   v 

Vapour Lb/hr 60000

Liquid Lb/hr 60000
Vapour density Lb/ft3 0.18
Liquid density Lb/ft3 40
Vapour viscosity cp 0.01
Design separation micron 150