SuccessfullySpecify
Three-Phase
Separators
t is often necessaryto separatetwo
Hereis a stepwise immiscible liquids, the light and
heavy phases,and a vapor. A typi-
procedure for cal example in petroleum refining
is the separationofwater, and a hydro-
designing carbon liquid and vapor. Little has
been published on three-phase (liq-
liquid/Iiquid/vapor uid/liquid/vapor) separarion, with
most information available only in
separutors. corporate design files. This article
attempts to alleviate this situation by
covering the basicsofthree-phase sep-
arator design. The authors provide a
Step-by-Step procedure and worked
out examples. Further, the examples
offer guidanceon making assumptions
for the calculations.
Selectingthree.phareseparatore
As with two-phase designs, three-
phaseunits can be either vertical or hor-
izontal, althoughthey typically are hori-
zontal (seeFigures l and2). The verti-
cal orientation.Figure 1, is only used if
there is a large amount of vapor to be
WayneD.Monnery separatedfrom a small amount of the
andWilliam
light and heavy liquid (< l0-207o by
Y.Svrcek,
weight). Unfortunately, there are no
University
of Calgary
simple rules for separator selection.
Sometimes,both configurationsshould
be evaluatedto decide which is more
economical. Further, the available plot
space(footprint) may be a factor.
The design of three-phaseseparators
is similar to their two-phase counter-
parts, except that the liquid section dif-
fers. For the vertical type, a baffle com-
monly keeps the liquid separation
CHEMTcAL
ENGTNEERTNG
section calm to promote the separation.
There are different variations of hor-
izontal three-phasevapor-liquid separa-
tors. The liquid separation section is
usually a variationof a deviceto provide
interface level control, which may
include a boot or a weir. A boot typical-
ly is specifiedwhen the volume of heavy
liquid is not substantial(< l5-207o of
total liquid by weight), while a weir is
used when the volume is substantial.
Thesehorizontal separatorsare illustrat-
ed in Figure 2. The bucket-and-weir
type design is used when interface level
control may be difficult, such as with
heavy oils or when large amounts of an
emulsionor a paraffin are present(1).
$tokos'lawappliee
Separatinga vapor from a light liquid
(two-phaseseparation)has been covered
in a previous article (2) and will not be
discussedhere. However, all necessary
information for performing this part of
the calculation is provided here. The fol-
lowing discussioncoversthe separation
of light and heavy liquids.
The flow of rising light droplets in
the heavy liquid phase or settling heavy
dropletsin the light liquid phaseis con- ,
sidered laminar and is soverned bv
Stokes'law:
rt -
1,488g,fi(p,- pr) (l)
v T -
18F
where 1,488convertsviscosityof the
pRoGREss. SEpTEMBER
rgga . 29
 MULTIPHASE FLOW

Vapor is more diffi- For horizontal separators with a

nozzle cult (requires given diameter,the heights of the light
more time) to set- and heavy liquids are assumedso that
tle the droplets the cross-sectionalarea can be calcu-
out of the contin- lated. With the vapor disengagement
Wire mesh uous phase with area set by guidelines, the lengths
the greater vis- required by holdup requirements and
+ D - cosity, since U. is vapor/liquid separationare calculated.
i
I
1 -i n .
Feed
nozzle
lower. Practically Then, with the assumedheights of the
speaking, U, is light and heavy liquids and calculated
vent M a x i m u m
I liquid
typically limited values of settling velocities, the set*
H"ls"rg" I level in calculations tling times are calculated.
t
to 10 in./min The actual residence times for the
= maximum. light and heavy liquids are subse-
Baffle
=
^.[- Holdup
il -*
A
For vefiical sep- quently calculated and comparedwith
!
E arators,the diame- the required settling times. as in the
Lioht r- Lishtliq.
: ' ter required for vertical case. If the residence times
tiq"uiO +r'-\ Baffleto provide
_T
nozzle l H '
lnterface
c a l m i n gz o n ei s
recommended
vapor disengage-
ment is calculated
are not greater than the required set-
tling times, then either the diameter
heavyliquid SectionA-A as in our previous should be increased or. for a given
{ Hrl diameter, the length should be
I article (2). In siz-
J ing a separator,the increased(liquid separationis con-
heightsof the light trolling). In the subsequentdesign
I procedures, the laner approach is
and heavy liquids
Heavy
liquidnozzle are assumed, and used, along with the procedures dis-
the settling veloci- cussed in our previous paper for
ties and settling vapor/liquid separationr2).
I Figure l.Vertical three-phase separalors are used with high times are then The following desi-rn procedures
vapor loadings calculated. and heuristics are a result of a review
continuous phasefrom lb/(ft)(s) to cP. The residencetimes of the light and of literature sources and accepted
Simplifying Eq. 1 and converting heavy liquids are determinednext. For industrial design guidelines.
the units of the terminal settling the liquids to separate,the residence Horizontal design proceduresare pre-
velocity to in./min from fUs results in: time of the light liquid must be greater sented for the four separator types
than the time required for the heavy shown in Figure l. The horizontal
droplets to settle out of the light liquid design procedures incorporate opti-
2.0615l xl}-s|f,QH-pL) phase; and the residence time of the mizing the diameter and length by
,r rr = T minimizing the approximate weight
heavy liquid must be greater than the
time required for the light liquid of the shell and heads.To add a degree
(2) droplets to rise out of the heavy liquid of conservatismto the design,the vol-
whereDo is in microns(1 micron = phase.Ifthese conditionsarenot satis- ume available in the headsis ignored.
6
3.28084x 10 feet) andU7,in./min. fied, then liquid
Eq.2 maybe rewrittenas: separationis con-
trolling and the
vessel diameter
rt kt(Pu - Pr)
u r=---T (3) must be increased.
Holdup time for
where liquids must be
addedto residence ...
ks=2.0615t xl\-sfi . time. The height
oi iausti, 121
or causiic 89
Values of ft, are given for some sys- of the vertical Furfural 89 0is3'
tems in Table 1. three-phase sepa- Methylethyl ketone Water 89 0.i63
rator is calculated sec-Butyl alcohol Water 8g 0.163
From Eqs. 1-3, it can be seenthat
Methylisobutylketone Water 89 0.163
the settling velocity of a droplet is in the same man- Water 89 0.163
Nonylalcohol
inverselyproportional to the viscosi- ner as for-the two-
ty of the continuousphase.Hence, it phasecase.

30 . 1994.
SEpTEMBER pRocREss
ENGTNEERTNG
CHEMIcAL
 3. Interfacecontrol with weir
Feed
inlet
l,v
Min.12in.
Min.12in.

Heavy Light
liquid liquid
outlet outlet
* l N , *l L NI*-
',l^n. - l
* * u,n.l
2. InterJacecontrol with boot 4. Bucketand weir
Vapor Vapor
outlet outlet

Lightliquidholdu/surge

Heavy Light
liquid liquid
outlet outlet
| -t -t -t -l

I L, lLzlLslL4l
Heavyliquid
outlet Note:N= 112d7,1+6in.
I
t - L -
drv= Nozzledia'

I Figure 2. Basic designs of horizontal three-phase separators,

5. Similarly, calculate the rising

Vertical design.procedur€ 140-,\"' velocity of the light liquid out of the
Refer to Figure 1 for dimensions:
D""=l# | (6)
heavy liquid phaseusing Stokes' law:
1. Calculate the verlical terminal
\nu, )
vapor velocity: If there is a mist eliminator, add 3-6
in. Io D, to accommodatea support ur ru . J-- k t ( P r - P t ) (8)
ring and round up to the next 6-in. ILH
Pv (4)
U- = ylPt - rtt2 increment to obtain D; if there is no 6. Calculate the light and heavy
Pv mist eliminator,D = Dur. liquid volumetric flow rutes, Q* and
Calculate the K value, using one of 4. Calculate the setting velocity of QnL:
the methods in Thble 2 and set Uu = the heavy liquid out of the light liquid
A.l5Ur for a conservativedesign. using Stokes'law (the maximum is 10
o
w--
"LL (9)
2. Calculate the vapor volumetric in./min): w-r .L-_
flow rate: 60pL

WV kt(Pn - Pr)
Qv= 3,600pu
(s) vr tH L -- 0\ n -Wrt
unr- 60pa (10)
ltr
3. Calculate the vessel internal where ft, is obtained from Table 1 or is 7. Assume Hr = I ft (minimum)
diameter,Dur: calculated(seeEq. 3). and calculate the settling time for the

. sEprEMBERrggr
CHEMTCALENGTNEERTNGpRocREss . 31
 MULTIPHASE

^ =(t.+aeal\/oo
o,in{ (0- .0rl\
a, r,
l- I--T-/\----G-/
) Equation13

- 0.6973=2.14ftJs
Ur =0' 313 53.95
I EquationEl
-
-* 415.000lb/h =165.32ft'ls
Qv=
= 3.600s/hx 0.69731Vff
: lEquation E2
=
--
=
^
r-\o= 1TVT4STFIs
--irISHs - r0.13ft
V
I
2
lEquation E3

16.5000lb/h = 5.10ft'lmin
ou -
60 minthx 53.95lbtftt
a EquationE4

"=,{*t#d) vnr=ffi
l,3o0lb/h = 0.35ft'lmin

whereD"is inft. lEquation E5

Note:1 micron= 3.28084
x 10{ft

g. Use Table 3 to determineAo lA. basedon the required holduP

heavy liquid droplets to settle through
this distance(12 is a conversionfactor h. CalculateA= (nl4)D2.
for ft to in.): i. Calculate Ar.
j. Selectthe larger value ofAr.
k. Calculate the area of the baffle
H.=+ ( 1s )

t -
l2H,
----------= (11) plate - settling area for the light liq- Check this r-alueu'ith that assumed
,HL_
U,, uid;A.-A-Ao. in Step 9b to ensurethat the assumed
8. Assume Hn = | ft (minimum) 10. Calculate the residence time value is reasonable. ft- surge is not
and calculate the settling time for the of each phasebased on the volumes specified, calculate the surge height
light liquid droplets to rise through occupied by the light and heavY basedon surgetime:
this distance:
( 12 )
phases:
(eu* eo)r, (16)
t -
,LH -
LzH ,
---:
TI
uLH

9. If there is a baffle Plate, calcu-

s*=w (I4a)
Hs=\---TL

The minimum is 6 in.

12. Calculate the vessel height
late the area:
A - HuAu (14b) using the guidelines:
a. Calculate(P. - P). vHL-
Qrt He= 6 in. minimum.
b. Assume 11* (use 9 in. as a mini-
If eLL < tu, or Iur 1 trr, \tctease H aio= h d. + greater of (2 ft or /1t
mum) and calculate Ht+ H^.
the diameter and repeat the procedure + 0.5 f0.
c. Use Figure 3 to obtain G.
from Step 7 (liquid separationis con- Ho=0.5D or a minimum of:
d. CalculateAr:
trolling). Note that An= A. 3 6 i n . + V z d r( w i t h o u t m i s t
S e eE q . ( l 3 ) i n t h eb o x .
e. Assume Wo = 4 in. 11. Calculate the height of the eliminator), or
light liquid above the outlet (holdup 24 in. + t/zd* lwith mist eliminator):
f. Calculate WD/D.

32, . CHEMICALENGINEERINGPRoGRESS
sEprEMBERlggd
 10,000
c 24in.
o_

o
F
c
9,000
-
-o
G 8,000

G
r.i
High liquid levelaboveinterface

/= 4.0184a8
. = _ J . 9 t 6 4tt
= -i.801705
= :l 1.i5348
pr- pu,lblft3
t. \, to H/D+
= HID
= \/.\r I Figure 3. G is found from the downconterallowableflow.

= 0.00153756
' = 16.787101 the time lbr the
= 1.299201
light liquid to
: - i.2.923932 rise out of the
. = 1.1.353518 heavy liquid
'= 11.844824 phase:
- = -36.999376 trH=(12)(1.0)
: = 10.529572 ll.lJ=6.9min
: = 9.892851 9. Calculate
2 . C a l c u l a t et h e r a p o r '\ r r l u r r - t r i " iili ti-:,r-r' :'1:ri- i1f-;1:
:.luivalent
expressions,
suchasH',/D _ r _ i l , ) <
flow rate,seeEq. El in the bor. r r l n t l l l _ i l ) S

3. Calculatethe vesselinner diam- lL.it'

eter,seeEq. E3 in the box. . . \ : > . r 1 .H' t -. = I ) i n . .H r + H n = 2 4
n, = Hn+ H, + HR+ O^* Ufii Use 1J = 10.5fi. i n . L ' . : r g F r , r L r r-e1 .G = 9 . 8 0 0g p h / f t z .
.a - jr
4 . C a l c u l a tl h
e c : e t t l i n \ge l o c i l r, r l {. = 0 i n i h )( 5 . 1 0
_ c a l i i t ' r r 6m
the heavyliquid out of the iight liqLrid - o.-1-i r ii' 9..\00gph/iir = 0.25 ft2
It' a mist eliminatorpad is used, p h a s e .U s i n g T a b l e l , f t s = 0 . 1 6 3 ..\...ll ti ll = J jp..
-,-riionalheightis addedas shownin Then: \ \ . , D= - 1 l r 1xl 1 0 . 5=) 0 . 0 3 1 7
: - - l r eI . Um = 0.163(62.11 53.95)/0.630
= 2 .1 1 i n . / m i n
E x a m p l e1 5. Calculatethe settlingvelocitl of
Sizea verticalseparatorwith a baf'- the light liquid out of the heavyliquicl
': :lltc
and wire-meshmist elimina- phase:
: i,.r separatethe mixture given in U r a = 0 . 1 6 3 ( 6 2 . 1-1 5 3 . 9 5 ) / 0 . 7 6 1
. -,rleJ. The operatingpressureis 165 = l.l4 tn.lmin
'..,:, rrild it is
Jr'(rcarbon
necessaryto have a
liquid holduptime of 25
6. Calculatethe light and hearr
Iiquid volumetric flow rates. see Eq. ^=#6
:: and a surgetime of only 5 min. E4 and E5 in the box.
1. Calculatethe vertical terminal 7 . A s s u m eH r = 1 f t a n d c a l c u l a t e 1oa,r= Ar+A, ft3ls
- .iitr'. Using Table 2, calculateK the tirne fbr the heavy liquid to sertle
- ' i t h e Y o r k D e m i s t e re q r r r t i o n s . out of the light liquid phase: Q , -- vr ,u : . 60
Tt:2
. . . E q . E 1 i n t h eb o x . ,fF;
t n , . =( 1 2 )( 1 . 0 )l 2 . l 1 = 5 . 7m i n 4u,
, : n JL ' 1= 0 . 7 5x 2 . 1 4= 2 . 0 5f t l s . 8. AssumeHn = 1 fi and calculate

CHEMICAL
ENGINEERING . SEPTEMBER
PROGRESS 1994. 33
MULTIPHASE FLOW

. Using Table 3, AD/A = 0.0095:

1= (nl4)(10.5 ft)2 = 86.59 ftz
A, = (0.0095)(86.59ft2)= g.g21r2
. Use A, = 0.82 ft2.
A, = 86.59- 0.82 = 85.11 ft2
10. Calculate the residencetime of
eachphase:
0r. = (1.0 fI) (85.77 112115.10
ft3lmin = 16.8min
lnr = (1.0 f0 (86.59 ftz)10.35
ft3lmin = 241.4 min
11. Calculate the height of the light
liquid above the outlet, based on
holdup:
tlo = (5.10 ft3imin) (25 min)/85.77
ftz = 1.5 ft
/1s = (5.10 + 0.35)(ft3/min)(5
min)i86.59 ft2 = 0.31 ft
Use I/r = 0.5 ft.
12. Calculate d, according to
Table 5:
)"= Qrl(Qr + Q) = (5.10 +
0 . 3 5 Y ( 5 . 1 0+ 0 . 3 5 + 1 6 5 . 3 2x 6 0 ) =
0.0006
Use Eq. E6 (see box) to calculate
Pr
pu = pLX+ pll - l.) = (54.55)
(0.0006) + (0.6913) (l - 0.0006) =
F Fuelgasknock-out drum 0.730
fuelgaslinebetween
ZOft.ilug in theincoming NLt andhighlevelshutdown Qu = 165.32+ (5.10 + 0.35)/60=
165.4I ft3/s
G.FlareKnock-outdrum Use Eq. E7 (seebox) to calculated*
20to 30minto Hll dN > 2l in.; use dt = 24 in.
Calculate Ho'.
factors(optionall:
bythefollowing
Multiply
Ho = 0.5 (10.5)= 5.25ft or
Personnel Factor Instrumentation Factor Ho = 24 + 2412= 36 in. = 3.0 ft
(minimum)
Experienced 1.0 WellInstrumented 1.0 Use 11, = 5.5 ft. From Figure 1, I1t
= I ft and s = 0.5 ft. Calculate Ilur:
Trained 1.2 Instrumented
Standard 1.2
Hsw='/,(2.0 f0 + 2 ft = 3 ft
Inexperienced 1.5 PoorlvInstrumented 1.5 Set 11, = 0.5 ft. Final dimensions:
D = 10.5 ft, HH= I.0 ft^ HL = 1.0 ft,
Hn= 1.5 fr, Ho = 0.5 ft. HB.,= 3.0 ft,
andHo = 5.5 ft. Add 1.5ft for the mist
eliminator.
p,=## . +ffi x62.It= 54.55
x 53.es rbtft3 Hr= l4'0 ft
HID=14.0i10.5=1.3
Add 2 ft to H, (Hp = 2.0 ft, Ho =
l EquationE6 7.0 f0 so that HlD = 1.52 (HlD
shouldbe in the rangeof 1.5 to 6.0).
=r.rrr, Horizontaldesign procedure:
)''' no boot or weir
I EquationE7 1. Calculate the vapor volumetric
flow rate, Qu, using Eq. 5.

34 . 1994.
SEpTEMBER pRocREss
ENGTNEERTNG
CHEMTCAL
 2. Calculate the light and heavy
liquid volumetric flow rates, Q' and
O711, using Eqs. 9 and 10.
3. Calculate the vertical terminal
velocity, Ur, using Eq. 4. (selecta K
r alue from Table 2) and set Uu =
0.75Ur.
4. Select holdup and surge times
t-romTable 6 and calculate the holdup
and surgevolumes,V, atd Vr, (unless
surgeis otherwisespecified,suchas a
>lus volume):
Vo= To Q, (18)
Vs=TsQr (19)
5. Obtain an UD from Table 7 and
initially calculate the diameter
accordingto:
(20)
Calculate the total cross-sectional
ilea:
A _ TED' (2r)
4
6. Set the vapor space height, 11,
, rhe larger of 0.2D or 2 ft; I ft if
:.-,ereis no mist eliminator. Using
1 ,/D in Table 3, obtainAr/A, andcal-
--llateAu.
7. Set the heightsof the heavy and
;ht liquids, Hrrand Hr,
8. Find (AnL+ AL)lAr, using (I1",
- fl -tlD inTable 3,andcalculateA*
9. Calculatethe minimum length to
-- -,rmmodatethe liquid holdup/surge:
r _ V, +V,
L _
(22)
tr-Au_ (our*,4rr)
10. Calculate the liquid dropout
-:a:
I = H,./L't Q3)
| [. Ca]culate the actual vapor
velocity:
Uw= Qr/Av ()L\
12. Calculatethe minimum length
required for vaporiliquid separation:
Lum= UvlQ (2s)
13. If L 1 Lr,,,r, then set L = Lr,*
(here, vapor/liquid separation con-
trols). This simply results in some
extra holdup and residencetime. If I
11 Lr,*, then increase Hu and recal-
culate Au, and repeat, starting from
Step 9. If L > L*n, the design is
acceptable for vapor/liquid separa-
tion. If L )) Lr,,.,(liquid holdup con-
trols). I can onlr,be reducedand l.rrr.
increasedif H,, is reduced. F1, ma1'
only be reducedif it is _ureater than the
minimum specifiedin Step 6. (With
reduced 11* recalculateAu and repeat
the procedurefrom Step9.) Note: For
this and other calculations, "much
greater than" (>>) and "much less
than" (<<) mean a variance of greater
than 20Vo.
14. Calculate the settling velocities
of the heavy liquid out of the light liq-
uid phaseand the light liquid out of the
heavyliquid phase,U". and U.o, using
Eqs. 7 and 8 (find ft, from Thble 1).
15. Calculatethe settling times of
the heavy liquid out of the light phase
and the light liquid out of the heavy
phase:
tur= 12 (D - Hv- HH)IUHL (26)
tro= 12 HHL/ULH (21)
16. Calculate the residencetimes
of the light and heavy liquids:
0ur= AorLlQu, (28)
CHEMTcAL pRocREss. SEpTEMBER
ENGTNEERTNG
I\ A ', - A , -. A 1u , l\ L 1 ?| q r
' . /
Qrr=
Q,,
17.If gHL< tLHor 0,-, < t", then
increasethe vessellength (liquid sep-
arationcontrols):
trrQ* tntQ,
'= -"{
e*'(h-Av-o*)
(30)
18. CalculateUD.If UD << 1.5,
decreaseD (unlessit is alreadyat its
minimum), and if UD >> 6.0 then
increaseD; repeatfrom Step 5.
19. Calculate the thickness of the
shell and headsaccording to Table 8.
20. Calculate surface area of the
shell and headsaccordingto Table 8.
21.Calculate t h e a p p r o x i m a tvee s -
sel weight accordingto Table 8.
22. Increaseor decreasethe vessel
diameter by 6-in. increments and
repeat the calculations :until the UD
ratio ran-eesfrom 1.5-6.0.
23. Using the optimum vesselsize
(minimum wei-eht).calculatethe nor-
mal and high liquid levels:
Hau= D - H, ( 31 )
Anrr= (Am+ Arr) + Vo/L (32)
Obtain 11r.. using Table 3 with the
value of A*ro/Ar.
Horizontaldesign procedure:
heavy liquid boot
1. Calculate the vapor volumetric
flow rate, Q, using Eq. 5.
2. Calcrilate the light and heavy
liquid volumetric flow rates, Q* and
Q n r , p e rE q s . 9 a n d 1 0 .
3. Calculate the vertical terminal
velocity, Ur, using Eq. 4 (the K value
comes from Table 2) and set Uu =
0.15 Ur.
4. Select holdup and surge times
from Table 6 and calculate the holdup
and surge volumes, V, and Vr, from
Eqs. 18 and 19 (unlesssurgeis other-
rgs+ . 35
?=
:.::
:-=
:-:
-.
:: MULTIPHASE FLOW

,,,:

wise specified,such as slug volume).

5. Obtain UD from Table 7 and
initially set the diameter according to:

/ l?\

I Then calculate the total cross-sec-

lt
14
tional area,A, using Eq. 21.
6. Set the Yapor spaceheight, F1*
F to the larger of 0.2D or 2 ft (l ft if
F
there is no mist eliminator). Using
7
HutD in Table 3, obtainAv/Ar and cal-
E
F culate Au. DishedHeads
F
7. Set the light liquid heights in the
vessel and boot, HrN and Hrrt. Approximate
8. Calculate the cross-sectional
area of the light liquid above the bot-
'=(t+
tom of the vessel,Ar., using Hrtt/D
in Table 3.
9. Calculatethe minimum length to
accommodatethe liquid holdup/surge:

V., +V"o
f - n (34)
"- Ar-Au-ArN
10. Calculate the liquid droPout
time, $, using Eq. 23.
1L. Calculate the actual vaPor
velocity, Uuo,using Eq.24.
12. Calculate the minimum length
required for liquid/vaporseparation.
Lrr*, usingBq.25.
13. If L 1 Lr,*, then set L = Lr,*
\ (vapor/liquid separation controls).
: (,q,,-e,)r
This simply results in some extra
holdup and residence time. If I
11Lr,*, then increaseH, and recalcu-
lateAr, thenrepeatfrom Step9.If L>
Lr,*, the design is accePtable for
vapor/liquid separation.If L >> LMrN,
liquid holdup controls. I can only be
reduced atd L*,* increased if I1u is
reduced.Humay only be reducedif it
is greater than the minimum specified
in Step 6.
With reduced Hu, recalailate A,
and repeat from Step 9.
14. Calculate the settling velocity
of the heavy liquid out of the light liq-
uid phase, U"., using Eq. 7 (obtain ks
from Table 1).
15. Calculate the settling time of
the heavy liquid out of the light liquid
phase:
tm= 12 (Hrrn + D - H)IUHL Q5)
16. Calculate the residencetime of
the light liquid:
(36)
ou=
eu
Note: This volume of light liquid
ignores the light liquid volume in the
boot.
I7. If 1LL < to, then increase the
vessellength (liquid separationcon-
trols):
(37)
18. CalculateUD.If UD << 1.5
then decreaseD (unlessit is already at
a minimum) and if UD >> 6.0 then
increaseD; rcpeatfrom SteP5.
19. Calculate the thickness of the
shell and headsaccording to Table 8.
20. Calculate the surface area of
the shell and headsaccording to Table
8.
21. Calculate the aPProximate
weight of the shell and heads accord-
ing to Table 8.
22.Increaseor decreasethe vessel
diameter by 6-in. increments and
repeat the calculations until 1,/D
rangesfrom 1.5-6.0.
23. With the optimum vessel size
(minimum weight), calculate the nor-
mal and high liquid levels:
Hnu= D - Hu (38)
Attrr= Arru + VrlL (39)
Determine H*rrusingTable 3 from
A*r/Ar.
24. Design the heavy liquid boot:
Set the height of the heavY liquid,
Hur; calculate the rising velocity of
the light liquid out of the heavy liquid
phase,Uru, using Eq. 8 (find ft, from

36 . 1994.
SEpTEMBER PRocREss
ENGINEERING
cHEMICAL
 Table 1); set U, - 0.15 ULHicalculate
the heavy liquid boot diameter:
Then calculate the settling time of the
light liquid out of the heavy liquid
phase:
ttr= l2Hu1/Us1 (4r)
Calculate the residencetime of the
heavyliquid:
A -ndH*
- (42)
"ut 4en
If eHr < tru, then the boot
diameter.
Horizontaldesign prooedure:
weir
1. Calculate the vapor volumetric
flow rate, Qu, using Eq. 5.
2. Calculate the light and heavl'
liquid volumetric flow rates, Qu and
Q11y.as per Eqs.9 and 10.
3. Calculate the vertical terminal
vapor velocity, Ur, using Eq. 4 (find K
tiom Table 2) and set Uv = 0.l5Ur.
4. Select holdup and surge times
tiom Table 6, and calculatethe holdup
and surge volumes, V, and V., from
Eqs. 18 and 19 (unlesssurgeis other-
ir ise specified,suchas a slug volume).
5. Obtain UD from Table 7 and
initially calculate the diameter
accordingto:
(43)
Then calculatethe total cross-section-
1 a r e aA
. . . u s i n gE q . 2 l .
"l
6. Set the vapor spaceheight.Hu.
ro the larger of 0.2D or 2 ft (1 ft if
t. lhere is no mist eliminator). Using
{
ft H../D in Table 3, obtainAu/A, and cal-
I
u ;ulateAu.
n 7. Calculatethe low liouid level
the light liquid comparlment using
Eq. 44 or read it from Table 9.
Htu= 0.5D + 1 (44)
where D is in feet andHrrrin inch-
es (round up to nearestin.). If D < 4.0
ft, then Hrm= 9 in. Using HoytD in
Table 3, CalculateArrr.
8. Calculate the weir heisht:
Hw=D-Hv (4s)
If Hw< 2 ft, increaseD, and repeat
the calculationsfrom Step 6.
9. Calculate the minimum length
of the light liquid compartment to
accommodate holdup/surge, 1,. in
Figure 2 :
Vn+V, (-+6)
Ar- Ar.- AuL
Round to the nearest 7: ft. The
minimum for Lr= d, + 12 in.
10. Set the interface at the height
H,*12, obtaining the heights of the
heavy and light liquids, Hrrand Hrr.
11. For the liquid settling com-
partment,calculatethe cross-section-
al area of the heavy liquid, using
Hr/D in Table 3 and calculate the
cross-sectionalareaof the light liquid
from:
Arr=Ar- A,- A* (4',7)
12. Calculate the settling velocity
of the heavy liquid out of the light liq-
uid phase,Uur, andthe light liquid out
of the heavy liquid phase, U"r, using
Eqs 7 and 8 (find ft, from Table 1).
13. Calculate the settling times of
the heavy liquid out of the light liquid
phase and the light liquid out of the
heavy liquid phase:
tur= l2Hr1/U* (48)
CHEMTCAL pRoGREss. SEpTEMBER
ENGTNEERTNG
tru= l2Hrx/Uro (4e)
14. Calculate minimum I, to facil-
itate liquid-liquid separation as the
larser of:
( t,,o-, trrQrr\ (50)
L1 =maxl:ff , A,, I
\ nur
Round to the nearest % ft.
15. Find l,:
L= Lt+ Lz ( s 1)
16. Calculate the liquid dropout
time, Q, using Eq. 23.
17. Calculate the actual vapor
velocity. U,,.,.using Eq.24.
18. Calculatethe minimum length
required for vapor/fliquid separation,
1.,rr,..using Eq. 25.
19. lf L ( Zr'.r- then set L = L*r
(vapor/liquid separation controls).
This simply results in some extra
holdup and residence time. If L <<
Lr,*, then increase Hr, recalatlate A,
and repeat the calculations from Step
6. If L > L*,r, the design is acceptable
for vapor/liquid separation. If Z >>
.Lrr, (liquid separation and holdup
control), Z can only be reduced and
Lr,* increased if Hv is reduced. //u
may only be reduced if it is greater
than the minimum specifledin Step 9.
With reduced Hr, recalculate A, and
repeat from Step 9.
20. CalculateUD.If UD << 1.5,
then decreaseD (unlessit is already at
a minimum) and repeat from Step 6.
If UD >> 6.0, then increase D and
repeat from Step 5.
21. Calculatethe thicknessof the
shell and headsaccording to Table 8.
22. Calculate the surface area of the
shell and headsaccordins to Table 8.
1994. 37
MULTIPHASE FLOW

23. Calculate the approximate ves- there is no mist eliminator). Using

sel weight according to Table 8.
24. Increase or decreasethe diam-
eter by 6-in. incrementsand repeatthe
calculations untiT UD ranges from
1.5-6.0.
25. With the optimum vessel size
(minimum weight), calculate normal
and high liquid levels:
Hnu=D-H, (52)
Atrrr= Arrr+ V,1L, (53)
Obtain Hr' using Table 3 with
ANLL|Ar.
Horizontaldesign procedure:
bucket and weir
1. Calculate the vapor volumetric
flow rate, Qu, using Eq. 5.
2. Calculate the light and heavy
liquid volumetric flow rates, Q, and
Qnr,perEqs.9 and 10.
3. Calculate the vertical terminal
vapor velocity, Ur, using Eq. 4 (flnd K
from Table 2) and set Uv= 0.75 Ur.
4. Select residencetimes for light
and heavy liquids, 0r, and 0o.. For
sour water stripper feed drums, 0o. =
60 min for reflnery service,or 10-15
min for chemical-plant service. For
amine regeneratorfeed drums, 0o. =
10-15 min.
5. Obtain UD from Table 7 and
initially setthe diameteraccordingto:
+(e,,0,,re,,,O,,(s4)
,=(
0J0n(r1r)
Then calculatethe total cross-section-
. . u s i n gE q . 2 1.
a l a r e aA
6. Set the vapor spaceheight, 11u,
to the larger of 0.2D or 2 ft. (1 ft if
Hr/D inTable 3, obtainAu/Arand cal-
culateAu.
7. Calculatel,:
(o,,e,,+o-,e-,1
-,'.''.] 155)
f -
L l -
Ar-4,
8. Calculate the liquid dropout
time, Q, usingEq. 23.
9. Calculatethe actualvapor veloc-
Uuo,usingEq.24.
10. Calculate the minimum length
required for vapor/liquid separation,
L*,r, using Eq. 25 .
ll.If Ll 1 Lr,*, then set Lt = Luru
(vapor/liquid separation controls).
This simply results in some extra
holdup and residencetime. lf Lt <<
LM,N,th.enincreaseIlr,. recalculateAu
and repeat the calculations from Step
1. If Lt ) Lr,*, the design is accept-
ablefor vapor/liquidseparation.
12. Calculatethe light liquid layer
thicknessbased on the heavy liquid
settlins out:

g,, = 235'ooolblh =343.5'7ft3/s Ur = 0' 175

3.600s/hx 0.190lb/ff
I EquationE8 I Equation811

o,,=
45'ooorblh -=18.52ft'lmin -, ,-- ( 4 r 2xt.7
7 r . 8 0 " ' ' = 11'15
ft' usel1'0ft
60min/hx 40.5lb/ft' \0.6ru xr/i)
I Equation E9 I EquationE12

7'5oolb/h
o-, =
60 min/hx62.0lblfr'
=2.y2ft'lmin 4=ffi=14.54ft
I Equation810 - Equation813

tutQrt - 2.0 min x2.02ft3hn1n=0.45ft

A,, s.%ft
I Equation814
trrQo - 2.0 min x 18.52ft3lmin =2.41
ft
ALL rs.02ff
I Equation E15

rr ff ls = 4.83ftls
Q u = 343.51
ure=
T 7r.08
te
I Equation816

38 . 1994.
SEPTEMBER PROGRESS
ENGINEERING
CHEMICAL
 w,D,
tlni

prop€r- Nomenclbture

"'
engli
lne
:, =;il;:::T:1",,-*lllllJli,
=
0
S
= v o l u m e t r i cf i o w . f l r / s o r l t r / m i n
- vessem l l l e r i a l s t r e s sv a l u e .p s i
^- liquidabor.e
vessel
bor- ASu = 5psqif. gravity differenceberween

==,1'l :#, ?:light I i g h ra n d h e a v yl i q u i d r

l: = :-i;iliill,1l11;1",, "'*ftJil],."',0,'o TC

'7\
il,,l,l,1l;; "'"'.'"
l,'.;l:l
= 0,"0,",,
TH
tut

D = ressel
diemeler.
n ttu = *'
o u t o l l i g h t I i q u i d 'm i n

" r p r e l so u l
"r'llu'
iiii,r;
i:i::';i'J'
of Western
degreesin
3' =llJli';,ilr,.ormicrons
D , = r 3 p r l r ' J i s e n g a g e m edni a
t =
t . .f r
e f f i c i e n c yd. i m e n s i o n -
1s
TH =;5.,ff::;l
= \ u r g et r m r .m i n .
TS

0.00128e'(AsG)Dpr
r-i6,
-'
;::]o.oLoint
= c f a \ i t a r i o n acl o n s t a n tJ, 2 . 1 7 f r , / s r Y:,
vHL
= a l l o r l a b l eb o r i z o r r n lv c l o c i t l . f r l s
= s e t t l i n qr e l o c i t vu f h e r v r l i o u i d
u 6 = baffle liquid toad.gph/fr) d r o p l e i so L r o
r f l i g h r l i q u i d .i n . t m i n
V,' H = h e i g h r .f t u,., = r i s i n g v e l o c i t )o f l i g h r l i q u i d d r o p l e r s
H.. = liquid level above baffle, in. or ft o u t o f h e a v yl i q u i d ,i n . i m i n
,.hereD" is in microns.
HB,. = liquid height from abor.ebaffle to Un = mixture velocity, tVs
13. Calculate the differenc- rl
leed nozzle.ft Up = boot velocitr'.in.lmin
:rsht betweenthe light and he;:,,., = disengagementheight. fi
H;, f = l c f r n i l r Jilg l 6 . i 1 _ 1 r i.. ' .c r i n . / r r i n
quid weirs: = htrldupheisht. fi
H. L = \ i - L p i \rre l . r c i t r .f L l :
H- = t e i , s h tl r . . = l i ; . : : i : : : : : = : : ii li
i o. r : : , z z : : .: '
_\H=H --\r r l l - X l i: -.
Pu l ,
a,
= --- .-.-:.:. :'
H,,;
1 - 1D . e s i g nt h e l i g h t l i q u i d b u c k e r : H,,-
': the top of light liquid u eir'= D
H,.. - - - :-- - : - - - . . ' - _ - .
, i l s s u m et h e b o t t o n rr s a t 0 . 1 l 5 D l = :::::::::-::::,
. . r t t i e a h o l d u p / s u r g e( t 1 , p r c a l l r .
H,,,u ::-
HP. = heiSi:t:i,'::r iiir:
' . -i min.); assume
HLL is 6 in. fle. 11 = ::-:: ailrdenaa time. min
, rrl the weir height andLLL is 6 in.
Hs = irrroe heiohr ri - ::'.:::,i:. liquid ifaction
i e the bottom of the bucket. g
= totai vertical separarorheight.ii = l\:.:::\. !-P
. r,c Table 3 with HrrrlD and
nv = vapor disengagementareaheighi. ir = :::.:::.lbr'ft]
D. calculate Au' and Arr.r. = weir height. ft
H,,, = :, :: j irLrloui time- s
-ulateL,: = h e i g h ld r f l e r e n c eb e l i i e e nl i g h i u n J
heavy iiquid weirs. in. )lr'-:-

lro + r,)9,, fts = S t o k e s l' a u .t e r m i n a lr e l o c i r r c o n - li. l';L I - , ; i

T _ (58) l s r a n t .r i n . / m i n )cr P r i t l b / f r r ;JL: :.::: l;;iri,l ;evei

(Ar,'r_ Arr,') K = t e r m i n a lr e l o c i t yc o n s L a n fl .r , i s L, L; i:i:i .;;iriti

L = vessellengrh.ft LLL : , , . r , r q l i i i e re l
l : . \ssume 1., is the largerof D/l2 L*,* = v a p o r , 4 i q u isde p a r a r i o m
n irrrrnum 1/
l in. -:.
.\ lI r I li.','i,l l-. ^l
t 6 , Design the heavy liquid com-
rnt: Set the top of the heavy liq-
. - i r ' = D - H v - A 1 1 ;a s s u m ea
;'':liilr,r-Hj I ',:a.tI

:r \Lrr_se(typically, 5-15 min);

: HLL is about 6 in. below the then decreaseD trndlepeatfi'onl Step
:r,ght and LLL is about 6 in. (r, + rr)9,, 5 Ii UD >> 6.0. then increaseD and
I _ (5e)
.h- bottomof the vessel.Using repeatfi'om Step-5.
: v,trh Hrrr/D and Hr,,y/D, ca7- lAorr- Arrr) 19. Calculatethe thicknessof the
i . ...andAr_r... 17. CalculateL = L, + Lr+ L. + L^. shel1and headsaccordingto Table8.
- L L l . i t eL . , : 1 8 . C a l c u l a t eU D . I f U D < < 1 . 5 . 20. Calculate tl're surf'acearea of

cHEMTCAL pRocnEss. sEpTEMBER

ENGTNEERTNG 1994. 39
MULTIPHASE FLOW
shell and headsaccordingto Table 8.
21. Calculatethe approximateves-
sel weight according to Table 8.
22. Increase or decreasethe diam-
eter by 6-in. incrementsand repeatthe
calculations until UD ranges from
t.5-6.0.
Example2
Design a three-phasehorizontal
separatorwith a weir to separatethe
mixture in Table 10. The operating
pressure and temperature are 25 psig
and 100, respectively,and it is neces-
sary to have a liquid holdup and surge
time of 15 min.
1. SeeEq. E8, box, p. 38
2. SeeEqs.E9 and E10, box, p. 38
3. K = 0.175 (the Gas Processors
Suppliers'Associationvalue in Table
2 was divided by 2 since there is no
mist eliminator).
S e eE q . E 1 1 ,b o x , p . 3 8
U v = 0 . 7 5 x 2 . 5 5 = 1 . 9 1f t l s
4. Holdup + surgeas specified= 15
min.
Vu+ V, = (15 min) (18.52ft3lmin)
= 211.80 ft3
Assume 10 min holdup, 5 min
surge.
5 . A s s u m eU D = l . l .
SeeEq. El2, box, p. 38
Ar=n/4 (11.0f|'z = 95.03ft2
6. Since the mass rate of vaoor is
1_ 55xI32
"-2xl7M
I Equation 817
. .-= = , = 0 . - -x8l=! f8 1-10?. 1? - - * r , 1=60 . 4 9i5n .
'rH
2 x 1 7 . 5 0x00 . 8 5
I EquationE18
t =
ff'ltff#(on.at
I EquationE19
40 . 1994.
sEpTEMBER CHEMTCAL pRocnEss
ENGTNEERTNG
w h e r eP: = d e s i g p
n r e s s u raen dD = d r u md i a ,
about827oof theloading,setF1yto be 18. LurN = (4.83 ftls)(4.03 s ) =
much greaterthan the minimum. 19.5fr
AssumeHv = 0.70D= (0.70)(1 1.0f0 19. Since L 1 Lr,*, set -L = 19.5 ft
= 7.70 ft. Using Table 3, Av/Ar = (setZ, = 16.0ft, lr = 3.5 ft)
0.148, Av= 71.08ft2 20. UD = 19.5/11.0= L78
7 , H r r r =( 0 . 5 ) ( 1 1 .+07) = I 2 . 5 i n . , 21. Assume dished heads per
use13in. Table11.
Hrr/D = 13/(11.0 x 12)= 0.098 AssumeE = 0.85
UsingTable3, ALLrj/Ar = 0.051 Use SA-516 70 carbon steel,
Aur= (0.051X95.03 fP) = 4.95112 design temperature= 650o
8. H, = 11.0- 1.10= 3.30ft S = 17,500psi; from Ref. (3).
9. SeeEq.El3, box,p. 38 Corrosionallowance= Vrsin.
Usel,r = 15.0ft. P=25+30=55psig
10.HHL- Hrr= 3.3012 = 1.65ft SeeEq. E17, box on this page.
ll. HH//D= 1.65111.0 = 0.150 Use r, - 7s in.
FromTable3, AH/A, = 0.094 SeeEq. E18, box on this page.
Aur= (0.094X95.03 ft2)= 8.93ft2 Use /" = Vz in; use t = Vzin.
Au=95.03- 71.08 - 8.93= 15.02 ftl 2 2 . A s = ? I ( 1 1 . 0f 0 ( 1 9 . 5 f 0 =
12.FromTable1, ks= 0.333 673.81ftz
Uur= (0.333)(62.0 - 40.5)/0.24 = Au= (0.842)(11.0fO'z= 101.88ft2
29.83in./min 23. SeeEq. E19, box on this page.
Use 10in./min(maximum) 24. In this example, calculations
Uro= (0.333)(62.0 - 40.5)10.682 = were performed for only one diame-
10.50in./min ter. However, nearly the minimum
Use 10in./min(maximum) UD corcespondedto a diameter of
13, tHL = Q2 in./ft)(1.65ft)ilo 11.0 fU therefore. the next diameter
in./min= 1.98min, use2.0mins should be smaller, resulting in a
tr, = tnr = 2.0 min laryer UD. Also, calculationsshould
14. SeeEqs.E14 and E15. box, be performed using a diameter of
p .3 8 I 1 . 5f t .
Uselr = 3.0ft. 25. For the light liquid compartment:
1 5 .L = 3 . 0+ 1 5 . 0= 1 8 . 0f t Hnrr= Hw= 3'3 ft - 3 ft, 4 in'
'7.10
16.0 = ftll.gI ftls = 4.03s A x L r = 4 . 8 5+ 1 8 5 . 2 0 1 1 6=.106 . 4 3 f P
17.SeeEq.El6, box.p. 38 A*t/Ar= 16.43/95.03 = 0.713
Using Table 3, HNLrt/D= 0.229
Htrrr= (0.229)(11.0)= 2.52 ft - 2
ft, 6 in.
*l|rc= 0.307in. HLLL= 13 in'
Comment: Due to the small
amount of heavy liquid and large
amount of vapor, a better design
would have used a boot. A vertical
x 55
vessel should be comoared. as
we11. @
rt2 n')= ' 7.s20tb
+2x r0r.88 Toreceivea free copyof this article,
sendin theReader Inquirycardin this
issuewith the number153circled,