Problem 1

Make a preliminary design for a separator to separate a mixture of steam and water;
flow rates: steam 2000 kg/h, water 1000 kg/h; operating pressure 4 bar.

Accomplish a mechanical design by specifying the vessel cylindrical shell and

domed ends thickness, material of construction, and other relevant design
information.

Given:
Pressure, P = 4 bar
Mass flow rate for steam, ṁsteam(v) = 2000 kg/h
Mass flow rate for water, ṁwater(l) = 1000 kg/h

Required:
 Preliminary design and
 The mechanical design of the separator (cylindrical shell and domed head
thickness, material of construction and other relevant design information)

Solution:

To solve this problem,

 Preliminary Design Calculations [1]:
1. Obtain density values from steam tables at 4 bar. The saturation temperature
is 143.6 ° C. Liquid density, ρl = 926.4 kg/m3, vapour density, ρ v = 2.16 kg/m3.
Settling velocity, ut can be determined.
1
ρl− ρv
ut =0.07
[ ]ρv
2
[EQN 1]

Where:
ut = settling velocity, m/s
ρl = liquid density, kg/m3
ρ v = vapour density, kg/m3
 1
926.4−2.16 2
ut =0.07 [2.16 ]
=1.45 m/s

2. Since separating steam and water is unlikely to be critical, demister pad will
not be specified. Thus,
m m
u s=0.15∗ut =0.15∗1.45 =0.218
s s
3. With the settling velocity known, the minimum vessel diameter can now be
calculated.
4Vv
D v =√( ) [EQN 2]
π us

Where:
Dv = minimum vessel of diameter, m
V v = gas, or vapour volumetric flow rate, m3/s
u s=ut , if a demister pad is used, and 0.15ut for a separator without a
demister pad

1 hr 1 kg 1hr 1 m3 m3
V v =ṁsteam ( 3600 s )( )
ρv
=2000 (
h 3600 s )( 2.16 kg )
=0.257
s

4 Vv 4∗0.257 m3 /s
Dv =
√ √
π us
=
π∗0.218 m/ s
=1.23 m

To account for the fabrication, 1.23 m is rounded to 1.25 m.

4. To calculate for the Volume held in the vessel, Liquid Volumetric flow rate ( V l)
is to be determined and a minimum of 10 minutes hold-up is allowed.
1 hr 1 kg 1 hr 1 m3 m3
V l=ṁwater ( 3600 s )( )ρl
=1000 (
h 3600 s )( 926.4 kg )
=3.0 x 104
s

Volume held in vessel = V l ( 160mins )∗10 min

3
m 60 s
s ( 1 min )
4 3
¿ 3.0 x 10 ∗10 min¿ 0.18 m

5. To complete the preliminary design of the separator, the height of the liquid
required in the vessel is computed.
 volume held−up
Liquid depth required, hv = [EQN 3]
vessel cross section−area
0.18 m3 0.18 m3
hV = = =0.15 m
D2v∗π (1.25 m )2∗π
4 4
To allow space for positioning the level controller, hV is increased to 0.3 m.

Next is the,
 Mechanical design calculations
Design Pressure = 4 bar * 1.1 = 4 bar
Design Temperature =
1. To calculate the thickness of the shell, [EQN 4] is used from Table 12-10
of Timmerhaus [2].
P∗r i
t= +c [EQN 4]
S E j−0.6 P c
where: P = maximum allowable internal pressure, kPa
r i = inside radius of shell before c c is added, m
S = maximum allowable working stress, kPa
E j = joint efficiency
c c = allowance corrosion, m

In order to use this equation, the material of construction must first be determined.
From the design conditions of P = 4.4 bar = 400 kPa and T = 143.6 °C, Carbon Steel
(SA – 285, Gr. C) can be a possible material of construction for both the cylindrical
and domed heads since the design temperature fit the temperature range and also
because this type of steel is widely used for the production of reactors, heat
exchangers, separators [3], etc. With this, maximum allowable working stress, S is
identified. The corrosion allowance, c c for carbon steel is 3 mm [4]. As for the joint
efficiency, double-welded butt joints spot-examined will be performed in order to
improve joint efficiency and reduce shell thickness [5], thus E j=0.85.
Plugging in all the values.

t shell =
400 kPa ( 1.252 m ) +3 x 10−3 m=6.122 x 10−3 m
( 94,500 kPa∗0.85 )−( 0.6∗400 kPa )
t shell =6.122 mm
2. For the calculation of the thickness of the domed heads, [EQN 5] is used.
0.885 P∗La
t= +c [EQN 5]
S E j−0.1 P c
where: P = maximum allowable internal pressure, kPa
La = inside radius of hemispherical head or inside crown radius of torispherical
head, before c c is added, m
S = maximum allowable working stress, kPa
E j = joint efficiency
c c = allowance corrosion, m
The same values are used for this equation except for the value of La where for a
torispherical head La=Diameter of vessel. Torispherical heads are used since they are
typically used for vertical vessels [6].
0.885∗400 kPa∗1.25 m
t head= +3 x 10−3 m=8.512 x 10−3 m
( 94,500 kPa∗0.85 )−( 0.1∗400 kPa )
t head=8.51 mm
Since the thickness of the dished head is greater than the thickness of the vessel
shell, torispherical heads are therefore not appropriate for the shape of the domed
heads because it is not economical and practical for the fabrication since it has a
greater thickness than that of the shell’s thickness. As such, ellipsoidal head will be
used instead having a formula of:
P Da
t= + c [EQN 6]
2 S E j−0.2 P c
Da = Diameter of the vessel
400 kPa∗1.25 m
t head= + 3 x 10−3 m=6.11 x 10−3 m
( 2∗94,500 kPa∗0.85 )−( 0.2∗400 kPa )
t head=6.11 mm
 3. Calculate surface area (SA) of shell and heads.
SA shell=πDL [EQN 7]
For a vertical separator, optimum L/D = 3 is a common rule of thumb. Therefore,
Length of the shell = 3 * Diameter of vessel = 3*1.25 m = 3.75 m
SA shell=πDL=π∗1.25 m∗3.75 m=14.726 m 2
For an ellipsoidal head [7],
SAhead =¿ 1.09D2 [EQN 8]
SAhead =¿ 2(1.09D2) = 2*[1.09 * (1.25m)2] = 3.406 m2
4. Compute for the weight (W) of the vessel.
W =¿ ¿ [EQN 9]
Density of Carbon Steel SA 285, Grade C = 7800 kg/m 3
kg
W =[ 14.726 m 2 ( 6.122 x 10−3 m ) +3.406 m 2 ( 6.11 x 10−3 m ) ]∗7800 3
m
W =865.52 kg
5. As for the design support [6], since the volume being held in the vessel is
less than 10, 000 gal (V= 0.18 m3 = 47.55 gal), therefore a skirt support
will be used with a skirt height of 1.875 m.
6. Summary

Volume hold-up V 0.18 m3

Length of vessel L 3.75 m
Diameter of vessel D 1.25 m
Shell Thickness tshell 6.122 mm
Head Thickness thead 6.11 mm
Weight of vessel W 865.52 kg
Skirt height 1.875 m

Diagram:
 7. Specification Sheet
Equipment No. V- 101
Sheet No. 1
Equipment Type Vertical Separator
Design Data
Pressure 4 bar = 400 kPa
Temperature 143.6 °C
Materials to be Steam and Water
Separated
Types of Operation Batch
Hold-up Time 10 minutes
Settling velocity 0.218 m/s
Material Property
Flow Rate (kg/h) Density (kg/m3)
Steam 2000 2.16
Water 1000 926.4
Design
Shell Vertical Cylinder
Head Ellipsoidal
Shell thickness 6.122 mm
Head thickness 6.11 mm
Diameter 1.25 m

Length 3.75 m
Weight 865.52 kg
Support Skirt support
Material of construction Carbon Steel

Problem 2
Design a horizontal separator to separate 10,000 kg/h of liquid, density 962.0 kg/m 3,
from 12,500 kg/h vapour, density 23.6 kg/m 3. The vessel operating pressure will be
21 bar.

Accomplish a mechanical design by specifying the vessel cylindrical shell and

domed ends thickness, material of construction, and other relevant design
information.

Given:
Pressure, P = 21 bar
Mass flow rate for liquid, ṁ(l) = 10,000 kg/h ;ρl =962.0 kg /m3
Mass flow rate for vapour, ṁ(v) = 12,500 kg/h ; ρ v =23.6 kg /m3

Required:
 Designing a horizontal separator
 The mechanical design of the separator (cylindrical shell and domed head
thickness, material of construction and other relevant design information)

Solution:
 Designing the Horizontal Separator [1]:
1. Calculate the Settling velocity, ut thru
1
ρl− ρv
ut =0.07
[ ]
ρv
2
[EQN 1]

Where:
ut = settling velocity, m/s
ρl = liquid density, kg/m3
ρ v = vapour density, kg/m3

1
962.0−23.6 2
ut =0.07 [23.6 ]
=0.44 m/ s

For a separator without a demister pad,

m m
ua =0.44 ∗0.15=0.066
s s
2. Vapour properties
1 hr
Vapour Volumteric flowrate , V v =ṁv ( 3600 )s ( 1ρ )
v

kg 1 hr 1m 3 m3
V v =12,500 (
h 3600 s )( )
23.6 kg
=0.147
s
The operating pressure is 21 bar, therefore L/D = 4 and
Height above the liquid, hv = 0.5Dv [EQN 2]
π 2
Cross sectional area for vapour flow = D ∗0.5=0.393 D 2v [EQN 3]
4 v
m3
0.147
Vapour velocity, uv = s [EQN 4]
2
=0.374 D−2
v
0.393 D v
Vapour residence time required for the droplets to settle to liquid

hv 0.5 D v
surface, = = =7.58 D v [EQN 5]
ua 0.066 m/s
3. Solving for the Diameter of the vessel
Actual residence time = vessel length/vapour velocity
Lv 4 Dv 3
= = =10.70 D v [EQN 6]
u v 0.374 D v
−2

For satisfactory separation required residence time = actual.

So, 7.58 Dv =10.70 Dv 3
Therefore D v =0.84 mbut to adapt to the standards, Dv is adjusted to
0.92 m.
4. Liquid properties
Liquid Volumetric flow rate (V l)

1 hr 1 kg 1 hr 1 m3 m3
V l=ṁl ( 3600 s )( )
ρl
=10,000 (
h 3600 s )( 962.0 kg )
=0.00289
s
π
Liquid cross−sectional area= ∗( 0.92 m )2∗0.5=0.332 m 2
4
Vessel Length, Lv = 4 * 0.92 m = 3.7 m
Hold-up volume = 0.332 m2 * 3.7 m = 1.23 m3
Hold-up time = hold-up volume/liquid flow rate
 1.23 m3
=426 seconds 7 minutes
= m3
0.00289
s
5. The obtained values are unsatisfactorily because the hold-up time for a
horizontal separator should be at least 10 minutes. Therefore, the liquid
volume/hold-up volume should be increased and to do this the diameter of
the vessel should be increased. If the liquid height, hv is kept at half of the
vessel diameter, then the diameter must be increased by a factor of
roughly (10/7)0.5 = 1.2
Thus, the new D v =0.92m∗1.2=1.1 m.
6. Computing for the new liquid residence time/hold-up time,
π∗( 1.1 m)2
New liquid volume = ∗0.5∗( 4∗1.1m )=2.09 m3
4
2.09 m3
New residence time = =723 seconds 12 minutes
0.00289 m3 / s

Next is the,
 Mechanical design calculations
1. To calculate the thickness of the shell, [EQN 7] is used from Table 12-10 of
Timmerhaus [2].
From the preliminary design calculations,
P = 21 bar = 2100 kPa
Dv =1.1m
Volume held in the vessel = 2.09 m3
P∗r i
t= +c [EQN 7]
S E j−0.6 P c
where: P = maximum allowable internal pressure, kPa
r i = inside radius of shell before c c is added, m
S = maximum allowable working stress, kPa
E j = joint efficiency
c c = allowance corrosion, m
In order to use this equation, the material of construction must first be determined.
Carbon Steel (SA – 285, Gr. C) will be the material of construction since this type of
steel is widely used for the production of reactors, heat exchangers, separators [3]
and good for medium to low tensile strength. With this, maximum allowable working
stress, S is identified. The corrosion allowance, c c for carbon steel is 3 mm [4]. As for
the joint efficiency, double-welded butt joints spot-examined will be performed in
order to improve joint efficiency and reduce shell thickness [5], thus E j=0.85.

Plugging in all the values.

t shell =
2100 kPa ( 1.12m ) +3 x 10−3 m=0.0176 m=17.61 mm
( 94,500 kPa∗0.85 )−( 0.6∗2100 kPa )
2. For the calculation of the thickness of the domed heads, [EQN 8] is used.
0.885 P∗La
t= +c [EQN 8]
S E j−0.1 P c
where: P = maximum allowable internal pressure, kPa
La = inside radius of hemispherical head or inside crown radius of torispherical
head, before c c is added, m
S = maximum allowable working stress, kPa
E j = joint efficiency
c c = allowance corrosion, m
The same values are used for this equation except for the value of La where for a
torispherical head La=Diameter of vessel. Torispherical heads are used since they are
typically used domed heads [6].
0.885∗2100 kPa∗1.1 m
t head= + 3 x 10−3 m=0.0285 m
( 94,500 kPa∗0.85 )−( 0.1∗2100 kPa )
t head=28.52 mm
3. Calculate surface area (SA) of shell and heads.
SA shell=πDL [EQN 9] SA shell=πDL=π∗1.1 m∗4.4 m=4.84 m 2
For a dished head [7],
SAhead =¿ 0.842D2 [EQN 8]
SAhead =¿ 2(0.842D2) = 2*[0.842 * (1.1m)2] = 2.038 m2
4. Compute for the weight (W) of the vessel.
W =¿ ¿ [EQN 9]
 Density of Carbon Steel SA 285, Grade C = 7800 kg/m 3
kg
W =[ 4.84 m2 ( 0.0176 m )+ 2.038m2 ( 0.0285 m ) ]∗7800
m3
W =1117.48 kg
5. For this vessel, which is a cylindrical and horizontal one, it is recommended to
have saddles as supports. It would be only 2 saddles, because the distribution
of the loading would be uncertain if more than 2 saddles are used. The
material for saddles can be bricks, concrete or steel plate. The contact angle
of the saddles should not be less than 120˚ and will not normally be greater
than 150˚. The saddle supports also would be located nearer the ends of the
vessel, to make use of the stiffening effect of the ends.

6. Summary

Volume hold-up V 2.09 m3

Length of vessel L 4.4 m
Diameter of vessel D 1.1 m
Shell Thickness tshell 17.61 mm
Head Thickness thead 28.52 mm
Weight of vessel W 1117.48 kg

Diagram:
 7. Specification Sheet
Equipment No. V- 101
Sheet No. 1
Equipment Type Vertical Separator
Design Data
Pressure 21 bar = 2100 kPa
Temperature -
Materials to be Liquid and Vapour
Separated
Types of Operation Batch
Hold-up Time 12 minutes
Settling velocity 0.066 m/s
Material Property
Flow Rate (kg/h) Density (kg/m3)
Vapour 12,500 23.6
Liquid 10,000 962.0
Design
Shell Horizontal Cylinder
Head Torispherical (Dished)
Shell thickness 17.61 mm
Head thickness 28.52 mm
Diameter 1.10 m

Length 4.40 m
Weight 1117.48 kg
Support Saddle support
Material of construction Carbon Steel

Problem 3
References:
[1] Sinnott, R. K., Coulson, J. M., & Richardson, J. F. (2005). 4th Ed. Coulson &
Richardson's chemical engineering: Vol. 6. Oxford: Elsevier Butterworth-Heinemann.
pp 461-462
[2] Peters, Timmerhaus,, & West. (2003). Plant design and economics for chemical
engineers: Max S. Peters, Klaus D. Timmerhaus, Ronald E. West (5th ed.). Boston:
McGraw-Hill
[3] SA 285 GR C equivalent material|SA285 GR.C Steel plate Supplier. 2019.
Retrieved from https://gangsteel.com/sa285grc-equivalent-material-and-sa285grc-
steel-plate-supplier/
[4] Materials Selection. (1994, December 1). M-DP-001. Retrieved from
https://www.standard.no/pagefiles/1174/m-dp-001r1.pdf
[5] Hopgood, M. (2017, September 15). Joint Efficiency. Retrieved from
https://www.pveng.com/joint-efficiency/
[6] Vessels. 1998. Icarus Corporation. Retrieved from https://instruct.uwo.ca/engin-
sc/cbe497/Doc/Icarus/ir10.pdf
[7]Couper, James R.. (2005). Chemical Process Equipment Selection and
Design . Oxford: Elsevier.