Dr. Sami D.

Al-Bayati
Biochemical Engineering Department
Al-Khwarizmi College of Engineering
University of Baghdad
GAS-LIQUID SEPARATORS
The separation of liquid droplets and mists from gas or vapor streams is
analogous to the separation of solid particles and, with the possible exception of
filtration, the same techniques and equipment can be used. A vapor-liquid
separator is a vessel into which a liquid and vapor mixture is fed and wherein
the liquid is separated by gravity, falls to the bottom of the vessel, and is
withdrawn. The vapor travels upward at a design velocity which minimizes the
entrainment of any liquid droplets in the vapor as it exits the top of the vessel.
Vapor-liquid separators are very widely used in a great many industries and
applications such as:
▪ Oil refineries
▪ Natural gas processing plants
▪ Petrochemical, chemical and biochemical plants
▪ Refrigeration systems
▪ Air conditioning
▪ Compressor systems for air or gases
▪ Gas pipelines
▪ Steam condensate flash drums
Three general types of separators are generally used
▪ Horizontal separator
(for high-pressure and medium-pressure service)
▪ Vertical separator
(for low-pressure service)
▪ Spherical separator
➢ (more compact and cheaper)
➢ (limited separation space and liquid surge capacity)
➢ (for low-volume remote platforms)

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A vapor-liquid separator might consist simply of an empty vessel, which
causes the fluid velocities in the entering pipe to be reduced by enlarging the
cross-sectional area of flow. Usually, however the separator includes internal
parts, to promote separation of the process, such as:
1. Primary separation section (entrance diverter ): for separating the bulk of
the liquid from the gas. It is desirable to remove the liquid slugs and large
droplets of liquid quickly from the gas stream, and to remove gas from the
liquid.
2. Secondary separation section: for removing smaller particles of liquid by
gravity settling depends to a large extent on the decreased gas velocity and
reducing the turbulence of gas.
3. Liquid separation section (or the liquid accumulation section): for
removing gas bubbles which may be occluded with the liquid, and for
sufficient storage of the liquid to handle the slugs of liquid anticipated in
routine operation.
4. Mist extractor or eliminator section: for removing from the gas entrained
drops of liquid, which did not separate in the secondary separation section.
Mist extractor might be used to decrease the amount of entrained liquid in
the gas and to reduce diameter of the vessel.
5. Vortex breaker (in the bottom of the vessel): prevents potential pump
suction problems if a pump is used to remove collected liquids.

Separators may be designed with or without mist eliminator pads and may also
have inlet diverters. Some separators may also have proprietary impingement
or settling internals.
Separators may be designed with or without mist eliminator pads and may
also have inlet diverters. Some separators may also have proprietary
impingement or settling internals. Mist eliminator pads are frequently used to
improve the performance of separating vessels where the droplets are likely to
be small, down to 1µm, and where high separating efficiencies are required.
Proprietary demister pads are available in a wide range of materials, metals
and plastics; thickness and pad densities. For liquid separators, stainless steel
pads around 100 -150 mm thick would generally be used. Use of a mister pad
allows a smaller vessel to be used. Separating efficiencies above 99% can be
obtained with low pressure drop.
Mist eliminator pads
Souders-Brown equation (Gas Load Factor K)

1
FD = Cd Ad  g u g2
2

l −  g 4 gd d
ug = 
g 3C d

 3
FG = d d g ( l −  g )
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Typically, the allowable vertical velocity ug is set between (0.75-1)ut.
Souder-Brown equation can be arranged as follows;

l −  g
ut = K
g

4 gd d
K = = 0.07m/s (for typical design calculations)
3Cd

where
ut = settling velocity, m/s, ρl liquid density, Kg/m3, ρv vapor density, Kg/m3.
Design procedure:
❑ Vertical gas liquid separator
1. Calculate the vertical terminal gas or vapor velocity:

l −  g
ut = 0.07 (m/s)
g

If a demister pad is not used, the value of ut obtained from equation above
should be multiplied by a factor of 0.15 to provide a margin of safety and to
allow for flow surges).

2. Calculate the vapor volumetric flowrate

mv
Qv = (m3/s)
v
3. Calculate the vessel inside diameter:

4Qv
DvD = (m)
 uv

4. Calculate the liquid volumetric flowrate:

ml
Ql = (m3/s)
l

5. Select the holdup time for liquid (5-10 min) and calculate the liquid
holdup volume:
Vl = 60  th  Ql (m3/s)
5. Calculate the liquid depth required :

Vl (minimum 0.3 m)
Hl =

Dv2
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6. Select the height from liquid level to the center of inlet nozzle = 0.5 Dv
(minimum 0.6 m)
7. Select the height from the center of inlet nozzle to the bottom of mist
eliminator pad center H D = Dv (minimum 1 m)
8. Select the mist eliminator type and thickness (100mm -150mm)
9. Select the segment height from the top of mist eliminator (0-1in)
10. Select the dish ends type for the top and bottom vessel.
❑ Horizontal gas liquid separator
1. Calculate the vertical terminal gas or vapor velocity:

l −  g
ut = 0.07 (m/s)
g

If a demister pad is not used, the value of ut obtained from equation above should
be multiplied by a factor of 0.15 to provide a margin of safety and to allow for flow
surges.
2. Select the liquid height to separator diameter (H/D).
3. Select the separator length to diameter (L/D) for separator based on operating
pressure
4. Calculate the cross section area of vapor flow (Av) as a function of
separator diameter.
Note:
The segment area equation used to for calculate the cross section area of
vapor flow

r −H
Av = A (Circule ) − A (Segment ) =  r 2 − r 2 cos −1 − (r − H ) 2rH − H 2
r
5. Calculate the vapor velocity a function of separator diameter.
6. Calculate the vapor residence time required for droplets to settle to liquid
surface.
7. Calculate the actual residence time (minimum 10 minutes)
8. Calculate the separator diameter ( use standard pipe for pipe diameter
correction)
9. Correct the dimensions and holding time based on standard diameter