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BNEGUE109GuideforVesselSizing

BN-EG-UE109 Guide for Vessel Sizing


TableofContents
1.
2.
3.
4.
5.
6.
7.

Scope
Introduction
Selection Criteria for Vapor-Liquid Separators
Design Criteria for Vapor / Liquid Separators
Design of Liquid / Liquid Separators
Computer Programs
Appendices

1. Scope
Thisdocumentshallbeusedfortheprocessdesignofvessels,however,for
specificprojects,thesedesignrulesmaybesupersededormodifiedbyclient
requirements.
ApplicabledesignrulesforaspecificprojectshallbespecifiedintheDesignBasis
and/ortheGeneralInformationandInstructions(GII)fortheproject.

2.Introduction
Ingeneralthefunctionofavesselinaprocessunitistoeitherprovideholduptime
ortomakeaseparationbetweenthevariousphasesofamixedprocessstream.In

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thisdesignguiderulesaregivenforthedimensioningofvessels,whichareusedfor
theseparationofmixedprocessstreams.Theycanbedividedintotwocategories:
Vapor/liquidseparators,whichareusedtoseparatethevaporandliquidpartof
amixedstream.
Liquid/liquidseparators,whichareusedtoseparatethetwoliquidphasesofa
mixedstream.
Forbothtypesofseparatorsthedesignruleswillbegiveninthisdesignguide.

3. Selection Criteria for Vapor-Liquid Separators


Theconfigurationofavapor/liquidseparatordependsonanumberoffactors.Before
makingavesseldesignonehastodecideontheconfigurationofthevesselwith
respecttoamongothers:
Orientation
Typeoffeedinlet
Typeofinternals
Typeofheads
Factorsthathelptomakethechoicebetweenthevariousalternativesare
discussedinthischapter.
3.1OrientationoftheVessel
Theselectionoftheorientationofagasliquidseparatordependsonseveralfactors.
Bothverticalandhorizontalvesselshavetheiradvantages.Dependingonthe
applicationonehastodecideonthebestchoicebetweenthealternatives.
Advantagesofaverticalvesselare:
asmallerplotareaisrequired(criticalonoffshoreplatforms)
itiseasiertoremovesolids
liquidremovalefficiencydoesnotvarywithliquidlevelbecausetheareainthe
vesselavailableforthevaporflowremainsconstant
generallythevesselvolumeissmaller
Advantagesofahorizontalvesselare:
itiseasiertoaccommodatelargeliquidslugs
lessheadroomisrequired
thedownwardliquidvelocityislower,resultinginimproveddegassingandfoam
breakdown
additionaltovapor/liquidseparationalsoaliquid/liquidseparationcanbe
achieved(e.g.byinstallingaboot).
Thepreferredorientationforanumberoftypicalvapor/liquidseparation
applicationsare:
Application

Preferredorientation

ReactorEffluentSeparator(V/L)

Vertical

ReactorEffluentSeparator(V/L/L)

Horizontal

RefluxAccumulator

Horizontal

CompressorKODrum

Vertical

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FuelGasKODrum

Vertical

FlareKODrum

Horizontal

CondensateFlashDrum

Vertical

SteamDisengagingDrum

Horizontal

3.2FeedInlet
3.2.1InletNozzle
Thefeednozzlesizeandthetypeoffeedinletdevice(ifany)haveanimpactonthe
vapor/liquidseparationthatcanbeachieved.Thefeednozzleisnormallysizedto
limitthemomentumofthefeed.Thelimitationdependsonwhetherornotafeed
inletdeviceisinstalled.
3.2.2Inletdevice
Variousinletdevicesareavailabletoimprovethevapor/liquidseparation.Among
othersthefollowinginletdevicesmaybeinstalled:
adeflectorbaffle
aslottedteedistributor
ahalfopenpipe
a90elbow
atangentialinletwithannularring
aschoepentoeter
Forverticaldrums,preferablyadeflectorbaffleorahalfopenpipeshallbeselected.
Incaseofaslugflowregimeintheinletpiping,orifahighliquidseparation
efficiencyisrequired,atangentialinletnozzlewithannularringcanbeused.
However,incaseahighliquidremovalefficiencyisrequired,theapplicationofa
wiremeshdemisterispreferred.
Forhorizontaldrumsnormallya90elboworaslotteddiverterisinstalled.Insome
casesasubmergedinletpipeisinstalled,butthisshallnotbedoneinthecaseofa
twophasefeed.
Normallytheselectedinletdeviceforahorizontaldrumshallbe:
a90elboworaslotteddiverterincaseofanallliquidorvaporliquidfeed
asubmergedpipewhenthefeedisasubcooledliquidandthemixingofliquid
andblanketgasistobeminimized
two90elbowinletsincaseofhighvaporloads
3.3Internals
Afterpassingthroughthefeedinlet,thevaporstreamwillstillcontainliquidinthe
formofdroplets.Themaximumsizeoftheseentraineddropletsdependsonthe
vaporupflowvelocity.Aseparationdevicecanreducethisentrainmentsignificantly.
Wiremeshdemistersarethemostcommonlyusedasseparationdevice.Theyare
usedfortworeasons:
Tominimizeentrainment
Ofthedrumserviceshavingsucharequirement,suctiondrumsforreciprocating
compressorsarethemostnotableexamples
Toreducethesizeofavessel

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Theallowablevaporvelocityinadrumcanbeincreasedsignificantlybyusinga
wiremeshdemister.So,whensizingisgovernedbyvaporliquidseparationcriteria,
thiswillresultinasmallerdiameterofthevessel
Majordisadvantagesofwiremeshdemistersare:
Theyarenotsuitableforfoulingservices
Theirliquidremovaldecreasessignificantlyatreducedthroughput
Althoughthesizeofthevesseloftencanbereducedbyapplyingawiremesh
demister,therearealsomanyserviceswherethereisnormallynodemister
installed.Refluxaccumulators,forexample,seldomhavemisteliminators.
Thereareseveralothertypesofmisteliminatorssuchasvanes,cyclones,andfiber
beds.Theyareusedwhenconditionsarenotfavorableforwiremeshscreens.
Selectioncriteriaforthesetypesofinternalsaretherequiredefficiency,capacity,
turndownratio,maximumallowablepressuredropandfoulingresistance.These
typeshoweverwillnotbefurtheraddressedinthisdesignguide.
3.4VesselHead
Mostvesselshave2:1ellipticalheads,weldedtotheshellofthevessel.However,
insomecasesothertypesofheadsareused.Themajoralternativesare:
Flatheads
Incaseofsmallverticalvessels(diameterlessthanapproximately30)oftena
flangedtopheadisused,whichalsoservestoprovideaccesstothevessel.
Dependingonthepressurerating,thistypeofheadcaneitherbeflatorelliptical,
andshallbeselectedinconsultationwiththemechanicalengineer
Hemisphericalheads
Ahemisphericalheadshouldbeconsideredforanextremelylarge,highpressure
vessel
Adishedheadshouldbeconsideredinthecaseofalargediameter,low
pressurevessel

4. Design Criteria for Vapor / Liquid Separators


4.1DefinitionofLevels
Inthesizingofvesselstheproperdefinitionofholduptimeandliquidlevelsis
important.Forthedesignofvesselsthefollowingshallbeused:
Liquidholdup
time

WorkingvolumebetweenHighLiquidLevel(HLL)andLowLiquidLevel
(LLL)

HLL

Upperendofthecontrolspan

LLL

Lowerendofthecontrolspan

HLA

HighLevelAlarm,normallyat90%ofthecontrolspan

LLL

LowLevelAlarm,normallyat10%ofthecontrolspan

4.2VerticalVessels
4.2.1DiameterofaVerticalVessel
Thedesignofavaporliquidseparatorisbasedontheterminalsettlingvelocityofa
liquiddropletofspecifiedsize,settlingundertheinfluenceofgravity.Thisvelocity
isgivenby:

(4.1)
where

Thevaporhandlingcapacity(Kt)dependsonthetypeofserviceofthevessel.
Typicalvaluesare:
Application

Kt

HorizontalKOdrum

0.25fps

0.08m/s

VerticalKOdrumwithout
demister

0.15fps

0.05m/s

VerticalKOdrumwithdemister

0.25fps

0.08m/s

FlareKOdrum(essentiallydry
vapor)

0.25m/s

FlareKOdrum(wetvapor)

0.10m/s

Theseparatorshallbelargeenoughtohandlethegasflowrateunderthemost
severeprocessconditions.Forsystems,whichhaveafoamingtendency,suchas
glycolandaminesolutions,aderatingfactorof0.70.8shallbeusedforKt.A
deratingfactorof0.70.8shallalsobeusedforcompressorsuctionknockout
drums.
Seeparagraph4.6forthesizingofthedemistermat
4.2.2HeightofaVerticalVessel
Thetotalvesselheightisthesumofthefollowingcontributions:
1. TheheightrequiredfortheLowLiquidLevel(LLL)
ThelevelinstrumentdeterminestheLLL.Formechanicalreasons,thenozzleof
thisinstrumentshouldbeatleast150mmabovethebottomtangentline.The
levelinstrumentrequiresanadditional50mm.Therefore,theLLLisabout200
mmabovethebottomTLofavessel.Incaseofdoubttheinstrumentengineer
shallbeconsultedontheminimumrequiredLLL.
2. Theheightrequiredfortheliquidholdup
TheliquidholdupisdefinedasthevolumebetweentheHighLiquidLevel(HLL)
andtheLowLiquidLevel(LLL).Thisvolumeconsistsofthestandardholdup
plusadditionalvolumeincaseofslugortripalarmlevels.Typicalholduptimes
are:
Service

Recommended

holdup

Feedtodistillationcolumn,reactor,heater

515

min

Refluxvessel

35

min

FlareKOdrum

2030

min

CondensateFlashdrum

35

min

FuelGasKOdrum1)FuelGasKOdrum

1)

1)AsaminimumaFuelGasKOdrumshallbesizedtocontainaslugofliquid
equivalenttothecontentof6mtrinletpiping.
Ifslugsofliquidcanbeexpected,additionalvolumeshallbeprovidedtoensure
thattherequiredvapor/liquidseparationcanstillbeachieved.
3. TheclearancebetweentheHighLiquidLevelandtheinletnozzle
TheclearancebetweentheHLLandtheinletnozzleshallbe0.3timesthe
vesseldiameter,withaminimumof0.3m.
4. Thediameteroftheinletnozzle
Thediameteroftheinletdevicedependsontheinletflowandonthetypeof
inletdevice.Seesection4.5.1forthesizingcriteriaoftheinletnozzle.
5. TheclearancebetweentheinletdeviceandthetopTL
TherequiredclearancebetweentheinletnozzleandthetopTLdependsonthe
presenceofademister.
Withoutademister,theclearanceshallbe0.7timesthevesseldiameter
withaminimumof0.9m.
Withademister,theclearanceshallbe:
0.45timesthevesseldiameter,withaminimumof0.9mtothedemister,plus,
0.1mforthedemister,plus
0.15timesthevesseldiameter,withaminimumof0.15mfortheclearance
betweenthedemisterandthetopTL
Thesizingisforaverticalvesselwithandwithoutademisterissummarizedin
figure4.1.
4.3HorizontalVessels
4.3.1SizeofaHorizontalVessel
Thecalculationofthediameterandthelengthofahorizontalvesselcannotbe
separated.Thecrosssectionalareaofthevaporspaceisbasedonamaximum
allowablevaporvelocitygivenbyequation4.1.Thesizingofahorizontalvapor/
liquidseparatorisbasedonatrialanderrormethod.Thesizingmethodconsistsof
thefollowingsteps:
1. Calculatetherequiredliquidvolume(Vliq)basedontheselectedliquidholdup
time.Theliquidvolumeisgivenby:

(4.2)

1. Asafirstestimate,assumethattheliquidvolumeis60%ofthetotalvolume.
SelectanL/Dratioandcalculatethevesseldiameter.Thevesseldiameteris
givenby:

(4.3)
where:
D

thediameterofthevessel(m),

L/D

theratiobetweenthelengthandthediameter().

Iftherearenootherfactors,whichdeterminetheL/Dratioofavessel,the
designpressureisnormallyusedtoselectthisratio.RecommendedL/Dratios
are:

2. SelecttheLowLiquidLevel(LLL).TypicallytheLLLissetat0.2m,butitshall
becheckedwiththemechanicalengineerwhetherthisisfeasible.Calculatethe
crosssectionalareabelowtheLLL,usingthefollowingsetofequations:

(4.4)
InExcelaspecialfunctionisavailableforthiscalculation.
3. Calculatethetotalcrosssectionalarearequiredfortheliquidbyaddingtothe
crosssectionalareabelowtheLLLthearearequiredfortheliquidholdup.The
totalliquidcrosssectionalareaisgivenby:

(4.5)
4. CalculatetheHLL,usingsimilarformulasasinstep4,orthespecialfunctionin
Excel.Determinetheremainingvaporcrosssectionalarea.
5. Calculatemaximumallowablevaporvelocityusing

(4.6)
ForhorizontalvesselsKtshallbetakenas0.25fps(0.08m/s).
6. Checktheactualvaporvelocity.
BasedonthevaporspaceabovetheHLL,theactualvaporspacemustbe
calculatedandcomparedagainstthemaximumallowablevaporvelocity.In
caseofalargerequiredvaporarea,twovaporinletnozzlesshallbeconsidered,
therebyreducingtherequiredvaporspaceby50%.
Basedontheapplicationsomeadditionalcriteriaapply:
A.LimitationsonHLL
TheHLLshallnotbehigherthan80%ofthediameter,withaminimumheightofthe
vaporspaceof0.3m.Ifademisterisinstalled,theminimumheightofthevapor
spaceis0.6m
B.Spaceforinletdevice
Thevaporspacemustbesufficientlyhightoaccommodatethefeedinletdevice.At
least150mmshallbeavailablebetweenthebottomoftheinletdeviceandtheHLL
4.3.2FeedInletDeviceforHorizontalVessels
Eithera90elbow,orahalfopenpipecanbeusedasinletdeviceforahorizontal
vessel.A90elbowispreferred,astheyareeasiertofabricate.Thefollowing
requirementsareapplicablefor90elbowinlets:
Thediameteroftheelbowmustbethesameasthenozzlediameter.
Animpingementbaffleshouldbeinstalledoppositetotheelbowtoprotectthe

drumshell.Thebafflediametershouldbetwicetheinletnozzlediameter.A
thicknessofforthebaffleplateisrecommended.
TheminimumdistancebetweentheelbowandtheHLLis150mm(6).
Theelbowshouldbeinstalledascloseaspossibletothetangentline
consideringreinforcementandfabricationrequirements(150mm).
Shortradiuselbowsshallbeused,with3straightpipeinsidethedrum.
4.3.3Boot
Whenthereisachancethattheliquidcontainssomewaterorotherimmisciblefluid
abootcanbeprovidedtocollecttheheavierfluidphase.Abootwillonlybe
selectedifthefollowingcriteriaaresatisfied:
"Deoiling"oftheheavyliquidphaseisnotimportant
Theratioofthevolumetricflowratesoftheheavyandlightliquidphaseis
smallerthan0.2
Inallothercasesoverflow/underflowweirsshallbeusedforproperliquid/liquid
separation.
Thesizingofthebootdiametershallsatisfythefollowingcriteria:
Thebootdiametershallnotbemorethan0.5timesthevesseldiameter
Theminimumbootdiameterdependsonthediameterofthevessel,andshall
beaslistedbelow:

VesselDiameter(mm)

Min.BootDiameter(mm)

D<900

300

900<D<1400

400

D>1400

500

Theheavyliquiddrawoffvelocityshallnotexceed80%oftherisingvelocityof
thelightliquid.Becauseofthesmallsizeofthedroplets,inmostcasesthe
Stokeslawcanbeappliedtocalculatetherisingvelocityofthedroplets.This
resultsin:

Moreover,thedesignsettlingvelocityshouldbelimitedto10inchperminute
evenifahigherrateiscalculated.
Thelengthofabootshallbebasedonthefollowingcriteria:

Typically,allowabout5minutesholdupfortheheavyphase
Thelengthoftheboot(i.e.thedistancebetweenthebottomofthevesseland
thebottomtangentlineoftheboot)shouldbeatleast900mm
toallowaproperinterfacelevelcontrolandtoaccommodateallthenozzlesfor
thecontrolinstruments
Thelowliquidlevelfortheliquidliquidinterfaceshouldbe200mmabovethe
bottomtangentline.Thehighliquidlevelshouldbe200mmbelowthebottomof
thevessel.Thisresultsinadistancebetweenthelowandhighlevelofthe
liquidliquidinterfaceofatleast500mm
Additionalvesselrequirementswhenprovidingaboot:
Thelightliquidphaseoutletshallextend100to150mmabovethebottomof
thevessel,andbeequippedwithavortexbreaker
Thelightliquidphaseoutletshallbelocateddownstreamofthebootandas
closeaspossibletothetangentlineofthevessel
Thebootshallbelocatedontheoppositesideformtheinlet,ascloseas
possibletothetangentline.Thedistanceisnotdeterminedbyprocess
reasons,butbythesaddlesupport.Therefore,contactwiththemechanical
departmentisrequired
4.4AdditionalCriteria
4.4.1Degassing
Whengooddegassingofliquidisrequired,thedimensioningofthevesselshallalso
satisfycriteriafortheseparationofgasbubblesoutoftheliquidphase.Becauseof
thesmallsizeofthebubbles,inmostliquidstheStokeslawcanbeappliedto
calculatetherisingvelocityofthebubbles.Thisresultsin:

Forverticalvesselsitshallbeensuredthatthedownwardliquidvelocityinthe
vesseldoesn'texceedthecalculatedrisingvelocityofthebubbles.
Forhorizontalvesselsitshallbeensuredthattheresidencetimebelowthelow
liquidlevelwillallowtheselectedminimumsizebubbletotravelthedistance
betweenthevesselbottomandthelowliquidlevel.
4.4.2Foaming
Incasetheliquidhandledhasatendencytofoam,thedesignshalltakethisinto
consideration.Althoughthereisnosolidbasistodoso,thefollowingcanbeused
asaguide:
Forhorizontalvessels,addtheheightofthefoamabovethehighliquidlevel,to

allowforthereducedvaporspaceforvapor/liquiddisengagement.(typically0.3
mtror1ft)
Forverticalvessels,Companylimitsthedownwardsliquidvelocityto:

(4.10)
4.5SizingofNozzles
4.5.1FeedInletNozzle
Theinternalnozzlediametermaybetakenequaltothatofthefeedpipe,butalso
thefollowingmomentumcriteriashallbesatisfied:

Othermomentumcriteriaareapplicableforhighvacuumunitsorotherunitswhere
theinletvelocitycanbeveryhighbecauseofthelowgasdensity.
4.5.2VaporOutletNozzle
Thediameterofthegasoutletnozzleshouldnormallybeequaltothatoftheoutlet
pipe,butalsothefollowingcriterionshallbesatisfied:

InHighVacuumUnitsthiscriterionmayresultinahighoutletvelocity,leadingtoa
pressuredropwhichistoohigh.Inthatcase,thegasoutletnozzleshallbesized
suchthatthepressuredroprequirementsbetweencolumnanddownstreamsystem
aremet.
4.5.3LiquidOutletnozzle
Thediameteroftheliquidoutletnozzleshallbechoseninrelationtotheoutletline
sizeselected,andisoftenbasedonaliquidvelocityof1m/s.Asliquidcirculating
abovetheliquidoutletnozzlemayresultinvortexformation,thedesignshall
includemeasurestoavoidthis.Thiscanbedoneintwoways:
Allowadequateliquidheightabovetheoutletnozzle.Forcheckingtherequired
minimumliquidheightabovetheoutletnozzleseegraphsinAppendixI.
Installavortexbreaker
Normallyvortexbreakersareprovidedonoutletnozzlesthatserveasoutlettoa
pump.
4.5.4Manway
Thesizeofamanwayisusually24,unlessinternaldevicesrequirelargersizefor
installation.Ifthevesseldiameteris30orless,aflangedheadmaybeconsidered
insteadofamanway.Formechanicalreasonsmanwaysshouldbesmallerthan
onehalfofthevesselinsidediameter.
Asanalternativetoamanway,smallervesselscanbeprovidedwithaninspection
hole,whichisnormally8.

4.5.5VentsandDrains
AsdefinedintheEngineeringGuideforthePreparationofEngineeringFlow
Diagrams(BNEGUE208),para.5.2.4thesizeofventsanddrainsonvesselsshall
be:
Vesselvolume

DrainConnection

VentConnection

Upto17m3

17to200m3

200to400m3

400to700m3

700m3andabove

Additionaltoventsanddrainsvesselsmaybeprovidedwithsteamoutandutility
connections.Normallytheseconnectionsare2.
4.5.6NozzleIdentification
Ifnotspecificallydefinedfortheproject,thenozzlesonavesselshallbeidentified
asfollows:
Processnozzles

N1,N2,N3etc.

Instrumentnozzles

K1,K2,K3etc.,wheremultiplenozzlesforasingle
instrumentshallbeidentifiedK1A\B\Cetc

Manways

M1,M2etc.

ReliefValves

RV1,RV2etc.

Vents

V1,V2etc.

Drains

D1,D2etc.

Steamoutconnections

SO

Utilityconnections

UC

4.6MistEliminators
Incaseahighliquidseparationefficiencyisrequired,amisteliminatorcanbe
installedtoensuretheremovalofsmallerliquiddroplets.Alsoamisteliminatorcan
beinstalledtoreducethesizeofaverticalvapor/liquidseparator.Normallya
demisterpadisinstalledasmisteliminator.
Important:Incaseavesselisprovidedwithademisterpad,thereliefvalve
protectingthevesselshallbemountedupstreamofthedemisterpadtoreducethe
changeofblockageinthereliefvalveinletandtoreducepressuredrop.
4.6.1SizingofDemisterPads
Thedemisterpadissizedbasedonamaximumallowablevaporvelocitythrough
thepad,givenbyvendorrules.Atypicalsizingrulefordemisterpadsisgivenby
equation4.13howeverforseparatorsoperatingundervacuumconditionsvendor
informationshallbeconsulted.

Thedemisterthicknessisnormally100mmor4.
4.6.2DemistersinVerticalVapor/LiquidSeparators
Forverticalvesselsthedetailsondemisterinstallationandvesselsizingaregiven
inpara.4.2.
4.6.3DemistersinHorizontalVapor/LiquidSeparators
Forhorizontalvesselsthefollowingappliesfortheuseofdemisterpads.Horizontally
installeddemisterpads:
Theminimumclearancebetweenthetopofthevesselandthedemisterpadis
thelargerof12orhalfthelengthofthelongersideofthepad.
Thedesignofthevesselremainsthesameasforahorizontalvesselwithout
misteliminator.exceptfortheminimumlength,whichisnotspecifiedfrominlet
tooutletnozzlebutfrominlettodemisterpad.
Incasetheseparationefficiencyofthevesselshouldbeveryhigh,twovertical
andonehorizontaldemistercanbeinstalledinthevaporphase.Thevessel
requiresaninletnozzleateachend,terminatedbyanelboworahalfopenpipe,
andonevaporoutletnozzleatthecenterofthevessel.Thissetupreducesthe
requiredcrosssectionalvaporareaby50%.However,withsmalllowpressure
vessels,thesavingsfromthesmallerdiametermaybeoffsetbythecostofthe
verticaldemistersandtheextrainlet.
Forverticallyinstalleddemisterpads:
Theminimumthicknessofthedemisterpadis6
Thedemisterpadshouldextendfromthetopofthevesselto0.1mabovethe
bottom.Theareabetweenthematandthebottomofthevesselshallallowfree
passageofliquid.
Thedistancebetweentheinletdeviceandthefrontfaceofthedemistermat
shallbeatleast0.6mor0.5timesthevesseldiameter
Thedistancebetweenthedownstreamsideoftheoutletnozzleandtherear
faceofthedemistermatshallbeatleast0.5D.

5. Design of Liquid / Liquid Separators


Normally,liquid/liquidseparationisachievedinahorizontalvessel,providing
adequateresidencetimetoproperlyseparatetherequireddropletsizefromboththe
liquidphases.Themostcommonlyusedtypesare:
Completelyfilledvesselswithliquiddrawoffvianozzlesatthetopandbottom
ofthevessel
Vesselsalsoprovidingvaporspace,withoverflowandunderflowbaffles,which
areseparatingtheliquid/liquidseparationcompartmentfromcompartmentsfor
liquiddrawoff
Theformertypeofseparatorisusedwhenthereisnochanceofvaporformation,
whilethelatterisusedwhenthereisachanceofvaporformation.

Rulesforthedesignofcoalescortypeliquid/liquidseparators,wherethe
separationisenhancedbyinternals(e.g.platepacks,wiremesh),arenotgivenin
thisdesignguide.Designrulesforthistypeofseparatorshallbebasedonvendor
information.
5.1LiquidFilledSeparators
Thesizingofaliquidfilledliquid/liquidseparatorisbasedontherequiredresidence
timefor:
separatingsmalldropletsoflightfluidfromtheheavyphasefluid
separatingsmalldropletsofheavyfluidfromthelightphasefluid
Basedonthetypeofapplication,oneofthetwoabovementionedcriteriamaybe
skipped.
Thesizingofthistypeofliquid/liquidseparatorisbasedontrialanderrorand
requiresthefollowingsteps:
1.Selectvesseldimensionsandinterfacelevels(min.andmax.)
Initialvesseldimensionscanbeselectedbasedonanoverallliquidresidencetime,
e.g.15minutes.Initialhighandlowinterfacelevelscanbeselectedtogetahold
uptimeforthelargerofthetwophasesofapproximately3minutes(forcontrol
purposes),andaboutidenticalholduptimesforbothphases,withtheinterfaceat
thenormallevel.
2.Calculatethedropletsettlingvelocityforbothphases
Becauseofthesmallsizeofthedroplets,inmostcasestheStokeslawcanbe
appliedtocalculatethesettlingvelocityofthedroplets.Thisresultsin:

(5.1)

Therequiredresidencetimemustbecalculatedforbothphases,toallowthe
selecteddropletsizetotravelbetweentheinterfaceandthetoporbottomofthe
vessel.Theseresidencetimesmustbecomparedwiththeactualresidencetimeof
bothphasesattheinterface.Becauseoftheshapeofthevessel,itisrequiredto
checktherequiredresidencetimeofbothphasesagainsttheactualatvarious
interfacelevels,e.g.atthelowandhighinterfacelevel.
Basedontheoutcomeofthecalculationsanewsetof(highandlow)interface
levelscanbeselected,oranewsizevessel.
5.2LiquidLiquidSeparatorswithVaporCompartment
Aliquid/liquidseparatorwithavaporcompartmentiswellknown,andoftenused
astheaccumulatorofanejectorbasedvacuumsystem.Thesizingofthese
horizontalvesselsincludesthesizingbasedonvapor/liquidseparationas
describedbeforeandthesizingoftheliquid/liquidseparation.Inthissectiononly

thesizingforliquid/liquidseparationisdiscussed.Incasethereisonlyavery
smallamountofvaporflowingthroughthevessel,theHighLiquidLevelshallbe
takenatmax.80%ofthediameterofthevessel.
Theliquid/liquidseparatorswithavaporcompartmenthavethreeliquid
compartments,onefortheliquid/liquidseparationandoneeachfortheholdupof
theseparatedlightandheavyphase.Thesecompartmentsareseparatedby
overflowandunderflowbaffles,whichensureaproperholduptimeofthetwo
phasesintheseparatingcompartment.
Alsothesizingofthistypeofliquid/liquidseparatorisbasedontrialanderrorand
requiresthefollowingsteps:
1.Selectvesseldimensions
Initialvesseldimensionscanbeselectedbasedonanoverallliquidresidencetime,
e.g.15minuteswithaHLLat80%ofthevesseldiameter.
2.Selecttheheavyphaseoverflowbaffleheightandcalculatetheresulting
interface
Byselectingtheheightoftheheavyphaseoverflowbaffletheliquid/liquidinterface
canbecalculatedbasedonapressurebalance,usingthefollowingequation:
H1xh=Hhxh+(H2Hh)xl
Where:
H1theheightoftheheavyphaseoverflowbaffle
H2theheightofthelightphaseoverflowbaffle
Hhtheheightoftheheavyphaseintheseparationcompartment
hthedensityoftheheavyfluid(kg/m3)
lthedensityofthelightfluid(kg/m3)
AsastartingvalueforH1takeitapproximately200mmbelowH2.
3.Positionthebaffles
Theoverflowbafflesmustbepositionedtogetadequateholdupintheoverflow
compartmentsforpropercontroloftheoutgoingfluid.Normallyaholdupof
approximatelythreeminutesbetweenaHLLandLLLisadequate.Thedistance
betweenheavyphaseunderflowandoverflownormallyis200mm,howeverthis
shallbecheckedtominimizepressuredrop.
4.Checktheliquid/liquidseparation
Tochecktheliquid/liquidseparationthedropletsettlingvelocityforbothphases
mustbecalculated.Becauseofthesmallsizeofthedroplets,inmostcasesthe
Stokeslawcanbeappliedtocalculatethesettlingvelocityofthedroplets.This
resultsin:

(5.2)
where
Vdsettlingvelocityofthedroplet(m/s)
ggravitationalconstant(9.81m/s 2)
Ddthedropletdiameter(m)
hthedensityoftheheavyfluid(kg/m3)
lthedensityofthelightfluid(kg/m3)
cthedynamicviscosityofthecontinuousphase(Pas)

Basedonthecalculatedinterfacelevelandsettlingvelocitiestherequiredresidence
timeforthelightandheavyfluidmustbecalculatedandcomparedwiththeactual
residencetimes.
Basedontheoutcomeofthecalculationssomeoftheassumedvalueshavetobe
adjusted.Incasethereareonlyminordifferencesbetweentheactualandrequired
residencetimes,adjustmentoftheoverflowandunderflowbaffles(inheightand/or
location)willbesufficient,inthecaseoflargerdifferences,theoverallsizeofthe
vesselwillhavetobeadjusted.
Becauseofthefixedoverflowbaffles,theinterfacelevelwillchangewithchangesin
fluiddensities.Asthisaffectstheseparation,thedesignshallbecheckedfor
possiblechangesinthesedensities.Forthesamereasonitisrecommendedto
havethetopoftheheavyfluidoverflowbaffleadjustable(e.g.+/100mm)
5.Checkvapor/liquidseparation
Asafinalcheckonthedimensions,thevapor/liquidseparationmustbechecked
basedonthevaporresidencetimeandthesettlingvelocityofthelightfluiddroplets
toberemovedfromthevapor.

6. Computer Programs
Variouscomputerapplicationshavebeendevelopedforthesizingofvapor\liquid
separators.Theseare:
6.1Depsep
Thisprogramhasbeendevelopedtosizevapor\liquidseparatorsbasedonthe
"Company"rules.AtypicaloutputisgiveninAppendixIV.
6.2Separator
Thisprogram,originallyaLotus123spreadsheet,hasbeendevelopedtosizevapor
\liquidseparatorsbasedon"Company"rules.
SometypicaloutputsaregiveninAppendixV.
6.3ExcelFunctions
InExcelanumberofspecialfunctionshavebeendevelopedtocalculatevessel
characteristics.Amongotherthefollowingfunctionshavebeendeveloped:
6.3.1HorizontalVesselLiquidVolume
Calculatesthevolumeofliquidinahorizontalvesselbasedonvesseldiameter,
vessellength,liquidlevelandtypeofhead.
6.3.2HorizontalVesselLiquidLevel
Calculatestheliquidlevelinahorizontalvesselbasedon:
VesselDiameter
VesselLength
LiquidVolume
TypeofHead
(Foraquickestimaterefertothe'Tools'sectionoftheRedBagwebsite.)
6.3.3VerticalVesselLiquidVolume
Calculatesthevolumeofliquidinaverticalvesselbasedon:
VesselDiameter
VesselLength
LiquidLevel

TypeofHead
6.3.4VerticalVesselLiquidLevel
Calculatestheliquidlevelinahorizontalvesselbasedon:
VesselDiameter
VesselLength
LiquidVolume
TypeofHead
6.3.5SegmentalAreafromElevation
Calculatesthecrosssectionalareaofahorizontalvesselbelowagivenlevelbased
on:
Vesseldiameter
Levelheight

7. Appendices

Graphs

II

TypicalVesselCalculations

III

TypicalDataSheet

IV

DEPSEPOutput

SEPARATOROutput

Typical Vessel Calculations

PROCESS DATA SHEETS FOR:


B211
BenzeenDestillaatVat

DEPSEP OUTPUT

SEPARATOR OUTPUT

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