Gee eee LUC en ty _ Design Two-Phase _ Separators Within ES Here is a proven, step-by-step method. Univrsity of Calgary WY. Svreok, W.D. Monnery iquid/vapor separators are one of the most common types of process ‘equipment. Many technical papers have been written on separator design and vast amounts of information are also available in corporate process ‘engineering design guidelines. The basic equations used for sizing are widely known; however, subjectivity exists dur- ing the selection ofthe parameters used in these equations. This article attempts to address the basics of two-phase separator design and provide step-by-step proce- dures and examples for two-phase -vaporfliquid separator design, ‘Two-phase separator types and selection ‘Two-phase separators may be oriented cither vertically or horizontally. In some it may be necessary to compare both designs to determine which is more economic. Separators may be designed with or without mist eliminator pads and may also have inlet diverters. Some sepa- rators may have proprietary impingement ‘or settling internals, The vendor should be contacted to design these types of vessels Vertical vaporfliquid separators are pre- ferred for separating liquid from mixture with a high vaporiliquid ratio while hori- zontal separators are preferred for sepa- rating vapor from mixtures with a low vapor/liquid ratio. Background Vapor/liquid separation is usually accomplished in three stages. The first | the Right Limits stage, primary separation, uses an inlet diverter so that the momentum of the lig uid entrained in the vapor causes the largest droplets to impinge on the diverter and then drop by gravity. The next stage, secondary separation, is gravity separ tion of smaller droplets as the vapor flows through the disengagement area. The final stage is mist elimination where the small- fest droplets are coalesced so that larger droplets are formed which will separate by gravity For secondary separation, the allow- able velocity must be calculated so that disengagement area can be subsequently determined. Performing a force balance (on the liquid droplet settling out provides the necessary relationship. When the net gravity force, given by Eq. 1, M,@c~ pve a ar 1, balances the drag forte, given by Eq. 2, _GI9)GDU py = TEN Pe fy the heavier liquid droplets will settle at a constant terminal velocity, U,. Equating Eqs. | and 2 results in, Hence, as long as U, < Uy, the liquid droplets will settle out. Typicall allowable vertical velocity, Uy, is set ‘CHEMICAL ENGINEERING PROGRESS # OCTOBER 1993 » 53FLUIDS/SOLIDS HANDLING a between 0.75U, and U;, Eq. 3 can be rearranged as Eq. 4, a Sauders-Brown type equation (1). : (-r) w % Pr where where K= ® Practically, very small droplets ean- not be separated by gravity alone. ‘These droplets are coalesced to form larger droplets which will settle by gravity. Coalescing devices in separa- tors force the gas to follow a tortuous path and the momentum of the ‘roplets causes them to collide with other droplets or the coalescing device, forming larger droplets. The coalesced droplet diameter is not ade~ a When calculating U,, for a horizontal separator, a “no mist eliminator K value” should be used. quately predictable so the K values for mist eliminators are typically empirical. This is where subjectivity first enters separator design. There are several literature sources of K val- uues such as the Gas Processor's Supplier Association (GPSA) “Engineering Data Book” (2), numer us technical publications and ven- dor's recommendations. The GPSA (2) and York Mist Eliminator (3) val Peace 54 © OCTOBER 1880 + CHEMICAL ENGINEERING PROGRESS tues have been curve fitted and are given in Table 1. If there is no mist eliminator, it is recommended to use one half of the above values (2) or the “theoretical value K can be calculated from Eq. 5 if the liquid droplet size is known, The drag coefficient, C, has been curve fit ted and is given in Table 1 or can be ‘obtained from Figure 7-3 in the GPSA. “Engineering Data Book” (2). Before proceeding, itis worthwhile to clarify some definitions and criteria. Holdup is defined as the time it takes to reduce the liguid level from normal (NLL) to empty (LLL) while maintain- ing @ normal outlet flow without feed makeup. Surge time is defined as the time it takes forthe liquid level to rise from normal (NLL) to maximum (HLL) while maintaining a normal feed without any outlet flow. Some guidelines base “surge” on the volume between low (LLL) and high (HLL) liquid levels. Holdup time is based on the reserve required to maintain good control and safe operation of down: stream facilities. Surge time is usually based on requirements to accumulate liquid as a result of upstream or down- stream variations or upsets, for exam- pile, slugs. In the absence of specific requirements, surge time may be taken as one half of holdup time. Vertical separators. For vertical separators, the vapor disengagement areais the entre cross-sectional area of the vessel so that vapor disengagement diameter can be calculated from Ea. 6: ag © x ‘Technically, this is the mist eliminator diameter andthe inside diameter of the ‘vessel must be slightly larger so that the mist eliminator can be installed inside the vessel. Typically, the calcu- lated value is taken up to the next six in, This value is taken as the required diameter of the vessel, D, and the cor- responding cross-sectional area, A, is calculated using this diameter. ‘The next step in sizing a vertical separator is to determine the height. Doo =o ere einen enFor a two-phase vertical separator, the total height can be broken into sec~ tions, as shown in Figure 1. The sepa- rator height is then calculated by adding the heights of these sections, as per Eq, 7 y= Hy Hy Hy Hay + Hy If a mist eliminator pad is used, additional height is added, as shown in Figure 1. The calculations of diameter and height are detailed in the “Design Procedures” section of this article. Horizontal separators. For hori- zontal two-phase separators, the cross-section is occupied by both vapor and liquid, as shown in Figure 2. When sizing horizontal two-phase separators, usually a diameter is assumed, LLL is selected or calculat ed, NLL is set by liquid holdup, and HLL is set by liquid surge. The cross sectional area between HLL and the top of the vessel is used for vapor disengagement. The length of the vessel is then calculated to accom- ‘modate holdup and surge or to facili tate vapor liquid separation, Hence, this approach to sizing horizontal separators, or variations of it, are iterative calculations The following will develop the basie equation used for calculating the size of a horizontal separator, For a horizontal separator cross section, a “volume balance” is written V,+Vy y-Ay~Au) (8) Holdup and surge volumes are calcu lated from holdup and surge times ‘which are selected according to guide- lines, The low liquid level area is a function of the low liquid level height, ‘obtained from guidelines, and the ves- sel inside diameter. The minimum vapor disengagement area , Ayp, is typically specified as one to two ft or 20% of the vessel inside diameter, whichever is greater. The sizing method in the "Design Procedures” section of this article assumes this for Ayp and only increases it ifthe length veh Vepor Without Mit Eiminetr let Mit Eliminator aid owt Naxtle W Figure I. Vertical two-phase separator. required for vapor-liquid separation is much greater than the length required for holdup and surge, for a given diameter. Equation 8 is then a func tion of the inside diameter, D, and length, L For horizontal separators, the li uid droplet to be separated from the ‘gas has a horizontal drag force which is not directly opposite to gravity as in the vertical case. Without detailed treatment of two-dimensional particle ‘motion, most literature sources recog- nize that the allowable horizontal velocity can be higher than the termi- nal velocity (2, 5, 7). This can be SE If a mist eliminator pad is used, additional height is added. shown simply by equating the “resi- dence” times of the liquid droplet to be settled. That is, the time it takes to travel the horizontal length between, inlet and outlet must be greater than the time it takes to settle the vertical distance to the liquid surface Hy het © ‘This canbe rearanged in terms of the allowable horizontal velocity, Umsf-U, ‘The length, , divided by the eight of the vapor disengagement area, # would always be greater than unity ‘The allowable horizontal velocity isa very subjective topie with several Empitical approaches to modify the vertical "A" valve available inthe it ture (2,5, 7,8) For horizontal sep arator desig, the subsequent design procedures use a “droplet setting fpproach” similar to the API proce: dure (6) which does not require empirical modification ofthe “Kval te for vertical stlers. It should be nated that when calculating U, fora horizontal sparta, ano mist ci nator value” shouldbe used (a0) Design Procedures The following design procedures ‘nd heuristics are a result of a review of literature sources and accepted industrial design guidelines. The hori- zontal design procedure incorporates ‘optimizing the diameter and length by ‘minimizing the weight of the shell and. heads. To add a degree of conser- vatism to the design, the volume available in the heads is ignored. Vertical design procedure (See Figure 1) 1. Calculate the vertical terminal vapor velocity: (2,320) fils OD 0.75U, for a conservative design. Calculate the K value from Table 1 CHEMICAL ENGINEERING PROGRESS * OCTOBER 1999 + 55FLUIDS/SOLIDS HANDLING | woe Nomenclature eo : ‘gar dvengageret sea ree. Gp diag content Dyes dane, ori D, opel dats, 1D, nont ing n Gate or out Ie yaparige as pie) jp ® vapor dsenggenert ameter, "= vee jit liens 1 adag fret, Fy = gravity ope, f° gravitational constant, 32.17 tus? B.-=3247 Obmmy/abys) Hy = dogenggenent height ai, Lalspheight Hig, =i Soimiet rors ceterine cts ‘i righigid ever ow Lio Level hig, Hg ~ ia ciinatorto pak eae HE song het overt seperate sigh ‘apo uspngomert ce ight, terial velocity constant Us peel net ‘slow ii Ken ~seprigid epenion nim lenth rope is, ermal igi vel pres, igo sa = liga hime fo, in rae vost tow, ce apc yl ow, min vee snl sess vale, ps ‘holdup time, min, ‘head thickness, in” shel hicks, in allowable orzo vlc, teal elo, is minute ely fs vapor velo, te ap vote, TILL lun, org volume, tal ome hiatal vee, ven wie Ih, Greok Letters 4 =mixure gid faction iy vapr viscosity

> L, then increase H,, and repeat from the step 9.1FL> Lys the design is acceptable for vaporiliquid separation. If L >> Lyqo (Liquid holdup is controlling), L can only be decreased and Lyyy increased if H, is decreased. H, may only be decreased if it is greater than the minimum specified in the step 9. | | | | | iTable 8. Conditions for PO rc (ne Recon) SC oad head types. (Calculations would have to be repeated from the step 9 with reduced 11). Calculate 17D. If L/D > 6.0 then increase D and repeat calculations from the step 6. If L/D < 1.5, then decrease D and repeat calculations from the step 6 | 18. Calculate the thickness of the shell and heads according to Table 7 | 16. Calculate the surface area ofthe shell and heads according to Table 7. 17. Caleulate the approximate ves- sel weight according to Table 7 18, Increase and decrease the diameter by 6 in, inerements and repeat the ealeulations until L/D has ranged from 1.5 1 6°. 19, With the optimum vessel size (xinimum weight), calculate normal and high liquid levels 4, unt Vfl 29) With A,,,/A, obtain H,,, from Table 6 Hy, =D=H, 0) 1 Example: Size a horizontal sepa- rator with a mist eliminator pad to 0.09 fs (3.600%; os Equation A. = Soi = 19.79 fs (ons) Equation B. u,= 03) Equation C. (197.90 + 98.95) 7(0.6)(5.0) \ Bi Equation D. Ay= Ay Aa W Equation E: Equation F. Size a horizontal separator with a mist eliminator pad. separate the following mixture. The operating pressure is 975 psig and the holdup and surge ae to be 10 min and 5 min respectively. Use a design tem: perature of 650°F. See Table 8. 1. Calculate the vapor volumetric flow rate (Eq. A) 2, Calculate the liquid volumetric flow rate (Eq. B). 3. Calculate the vertical terminal velocity (Eq. C: K'= 0.13 (GPSA val- ue divided by two since “no mist climinator” value is used) U,=0.75U,=0.29 us =501 fils, use 5.0ft 197.90 +91 19.63 — 7.34 — 2.16" ~ 95_ 9.3, say29.5 ft 4, Calculate the holdup volume: Vy = (10 min.) (19.79 fe/min.) 197.90 fe 5. Calculate the surge volume: min.) (19.79 f/min,) = 98.95 fe 6, Assume I/D = 5.0, Initially set the diameter (Eq. D) 9.63 fe, 7. Calculate low liquid height: Hy, = (0.5(50) +7 =9.5 in. use 10 in. 4. Calculate the low liquid level H,,/D=0.161 Using Table 6, A,,,/AT = 0.110 Ay, = (0110) (19.63 fe) = 2.16 f° 9, Set H,=2 ft, H/D= 2/5 = 04 From Table 6, /A, = 0.374 Ay = (0.373)(19.63) = 7.34 10, Calculate the length to accom- ‘modate holdup/surge (Eq. E). 1. Calculate the liquid dropout time (Eq, F. ‘CHEMICAL ENGINEERING PROGRESS * OCTOBER 880 + 59'S/SOLIDS HANDLING 12, Calculate the actual vapor velocity (Eq. G). 13. Calculate Lyjy = (1.37 £05)(6.90 8) =9.45 ft V4. L >> Lygy but Hy is minimum ‘and cannot be reduced so L cannot be reduced. UD= 29.55, 1B. Calculate he thickness ofthe shell and heads according to Table 7: * Table 9, use 2:1 elliptical heads + Assume E= 0.85 + Assume SA 516 70 Carbon Steel, Design Temp. = 650°F + From (9), § = 17,500 psi + Assume corrosion allowance = Yein, + P= 975 x 1.1 = 1,072 psig (See Eq. H). use 1, = 2-% in, (See Ba. I) use ¢, = 2-Yein,, and use 1 = 2% in, 16. Calculate the surface area of the shell and heads according to Table 7: (5.0 ft) 29.5 ft) = 463.38 fe and ‘y= (1.09) (5.0192 = 27.25 fe 17, Calculate the approximate vessel weight (Eq.9):= 50.224 Ib. 18. Try D=55 fe and repeat calcula: tions until minimum weight of shell and heads is obtained a Fora tree copy ofthis article, sendin ‘the Reader Inquiry card inthis issue with the No, 158 circled. 10.09 fils 7.34 fr Equation G. 1,072) Equation H. = 1.37 fils ara er $07 2K60) 2(17,500\0.85)- (1.2(1,073)* ik =2.322in (1072)(60) 27500 (0.85) Equation (1072) + jb =2.240in = 22401 i (463.38 ff +(2)(27.25) fi)