Ee | Successfully Specify Three-Phase Separators Here is a stepwise procedure for designing liquid/liquid/vapor separators. Wayne D. Monnery and William ¥.Swrcek, University of Clgary essary t0 Separate (WO immiscible liquids, the light and heavy phases, and a vapor. A ty ‘cal example in petroleum refining is the separation of water, and a hydro- carbon liquid and vapor. Little has been published on three-phase (lig- uuid/liquid/vapor) separation, with most information available only in corporate design files. This article attempts to alleviate this situation by covering the basics of three-phase sep- arator design. The authors provide a Step-by-Step procedure and worked ‘out examples. Further, the examples offer guidance on making assumptions for the calculations, Selecting three-phase separators AS with two-phase designs, three phase units can be either vertical or hor ‘zontal, although they typically are hori- zontal (see Figures 1 and 2). The verti- cal orientation, Figure 1, is only used if there is a large amount of vapor to be separated from a small amount of the light and heavy liguid (< 10-20% by weight). Unfortunately, there are_no simple rules for separator selection Sometimes, both configurations should be evaluated to decide which is more economical. Further, the available plot space (footprint) may be a factor. ‘The design of three-phase separators 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 section calm to promote the separation, ‘There are different variations of hor- izontal three-phase vapor-liquid separa- tors. The liguid separation section is usually a variation of a device to provide interface level control, which may include a boot or a weir. A boot typical- ly i specified when the volume of heavy Tiguid is not substantial (< 15-20% of total Tiquid by weight), while a weir is used when the volume is substantial ‘These horizontal separators are 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 cemuision or a paraffin are present (1). Stokes’ law applies Separating a vapor from alight liquid (two-phase separation) has been covered in a previous anicle (2) and will not be discussed here. However, all necessary information for performing this part of the calculation is provided here. The fo: lowing discussion covers the separation of light and heavy liquids. The flow of rising light droplets in the heavy liquid phase or setting heavy droplets inthe light liquid phase is con sidered laminar and is governed by Stokes’ law: y, = 1488s DiOn— P. w a TSH where 1,488 converts viscosity of the CHEMICAL ENGINEERING PROGRESS © SEPTEMBER te04 © 29MULTIPHASE FLOW sey Wire mesh | | »_ Feed tin, [1 nozzle vent | ntaximum yews 4] surve] |icvet AL toe i Light 4} bint ia is more diff- cult (requires more time) to sot He the droplets out ofthe contin- uous phase with the greater vis- cosity, since Upis, lower. Practically speaking, Up is typically. limited in calculations to 10 in./min For vertical sep- arators, the diame ter required. for Tiquia Batfleto provide had ‘calming zone is ‘vapor disengage- nodace 7} Fecommended ‘ment is calculated heavy liquid Section AA as in our previous ‘ article (2). In siz= ing a separator, the . a heights of the light | Heavy ‘and heavy liquids | liquid ndeele ‘4, | ate assumed, and W Figure 1. Vertical three-phase separators are used with high vapor loadings. ‘continuous phase from Ib/(R)(s) to cP. ‘Simplifying Eq. 1 and converting the units of the terminal settling velocity to in/min from fs result i: p= 2206151 X10“ DiOn~ p 2 where Dy is in microns (1 micron 3.28084 x 10° feet) and Us, in min, Eq, 2 may be rewritten &&: = Pu Pd) Up= =SPe Pe 8) where ks = 2.06151 x 10“Ds ‘Values of ky are given for some sys tems in Table 1 From Eqs. 1-3, it ean be seen that the settling velocity of a droplet is inversely proportional to the viscosi- ty of the continuous phase. Hence, it the setting veloci ties and settling times are then calculated, ‘The residence tries ofthe light and hheavy liquids are determined next, For the liquids to separate, the residence time ofthe light liquid must be greater than the time required for the heavy droplets to setle out of the Tight iguid phase; and the residence time of the heavy liquid must be greater than the time required for the light liquid droplets to rise out of the heavy liquid phase. If these conditions are not sais- fied, then liquid separation is con- uwolling and the vessel diameter must be increased. Holdup time for liquids must be added to residence time, The height of the vertical three-phase sepa- rator is calculated ‘sor Butyl alecal Inthe some mage Methyl bobunl ketone ner as for the two Narm ate! phase ease. 30 = SEPTEMBER 196 © CHENCAL ENGREERING PROGRESS PUTEe eke ula RS ers / Metifethy! Ketone For horizontal separators with given diameter, the heights of the light and heavy liquids are assumed so that the cross-sectional area can be calcu- lated. With the vapor disengagement area set by guidelines, the lengths required by holdup requirements and ‘vaporliquid separation are calculated. ‘Then, with the assumed heights of the light and heavy liquids and calculated values of settling velocities, the set- ting times are calculated. ‘The actual residence times for the light and heavy liquids are subse~ quently calculated and compared with the required settling times, asin the vertical case. IF the residence times are not greater than the required set- ding times, then either the diameter should be increased or, for a given diameter, the length’ should be Increased (liquid separation is con- trolling). In the subsequent design procedutes, the latter approach. is used, along with the procedures dis- cussed in our previous paper for ‘vaporliquid separation (2) ‘The following design procedures and heuristics are a result of a review of literature sources and accepted industrial design guidelines Horizontal design procedures are pre= sented for the four separator types shown in Figure 2. The horizontal design procedures’ incorporate opti- ing the diameter and length by rminimizing the approximate weight ‘ofthe shell and heads. To add a degree ‘of conservatism tothe design, the vol- vininun Water Water“interface contol Interface control with weir Feed Vapor Feed Vapor init att inlet outet aE The NF Tn in. in Minin 5 nue "| Min 12, ae Minr2in.t Weir ae THhoiapmge pa, iaeeal m an Uightigud — fH oo gem] 7 Heavier) 7 Lo Heavy quid Ha |S uu ‘outlet L aa ae a & cite outlet }_-» —| ty 1 by — b™ Min. N+ i 2. etorface control with boot 4. Buckot and weir Feed Vapor Feed Vapor inet att inlet utet ue tN Minny 4 vin inf (_ > Hu > usrtiaddhoipeuge | me |) ght Huw] | A ry — Interface |S } [FEE outlet Heavy | | us fiquid | Hy | 4 bye Pee Heavy Til “stat Noe: N= 12 dyin L y= Norcia Wi Figure 2. Basie designs of horizontal tree Vertical design procedure Refer to Figure | for dimensions: 4. Calculate the vertical terminal vapor velocity = Kft Puy” DERG, Calculate the K value, using one of the methods in Table 2 and set Uy = 0.75U; for a conservative design. 2. Calculate the vapor volumetric flow rte: We 2. = 5500p, 3. Calculate the vessel internal diameter, Dy: “ 6 phase separators, 4Qy (ie) If there is a mist eliminator, add 3-6 in, to Dyp to accommodate a support ring and round up to the next 6-in. increment to obtain D; if there is no mist eliminator, D = Dy, 4. Calculate the setting velocity of the heavy liquid out ofthe light liquid using Stokes" law (the maximum is 10, inJmin): Da © = ku Pd) He here kis obtained from Table 1 oris calculated (see Eq. 3), Un. o 5. Similarly, calculate the rising velocity of the light liquid out of the heavy liquid phase using Stokes’ law: @) 6, Calculate the light and heavy liquid volumetric flow rates, Qz, and On: W, Ou = Rae » Den 7. Assume H, = 1 ft (minimum) ‘and calculate the settling time for the (10) CHEMICAL ENGINEERING PROGRESS © SEPTEMBER E04 © 31MULTIPHASE FLOW ——— Pea a are Equation 13 -0313, (3330S U,=0.313, 0.6973 = 2.74 fs Equation B1 Oy = 415,000 lbh. _ 165.39 ft/s 3,600 sfh x 0.6973 lb/ft uation 52 | Dyp= PB EABE — 10.13 8 1{ ‘Mi Equation E3- 16,5000 Ib/h ; = ——18:5000 lbh ___ 5.10 x | 01. SO minh x 53.95 Toe mm | Equation £4 | | 1,300 b/s ; =. = 0.35 On = SO mini x 62.11 THA mm Equation ES Net on = 288410 : heavy liquid droplets to sete through Use Table 3o determine Ap /A. eight) based on the required holdup : this distance (12s a conversion factor Calculate A= (nd8)D® dime: for fttoin): icatelate Ay, 4, Select the larger value of Ay. as) LH, K. Calculate the area ofthe batle tn = pe (11) plate = song area forthe light ig: _Check this value with that assumed ln. tA, =A~Ap in Step 9b to ensure thatthe assumed 8. Assume Hy 1 f (minimum) 10" Calculate the residence time value is reasonable. If surge is not and calculate the settling time for the of each phase based on the volumes specified, calculate the surge height light liquid droplets to rise through occupied by the light and heavy based on surge time: this distance phases 12H, a2) H (Qu+On)ls (16) t= Ta HA, a fal On= (14a) 9. IF there is a baffle plate, caleu- Ou “The minimum is 6 in. Inte the area: 12. Calculate the vessel height 2 Calulate (9, - py). Oya = Aw (140) using the guidelines D, Assume Hy (use 9 in. as a mini- Qu, H, =6 in. minimum. smut) and calculate Hy, + He 0, < ty, OF Op, < ty increase Vid + eeatr of (2 ft or Hy Use Figure 3 to obain the diameter nd repeat the procedure +031). 4. Calculate As from Step 7 (guid separation iscon- ‘Hp = 0.SD ora minimum of: See Bg. (13) inthe box. trolling). Note that y= A 36 in. + Yady (without mist Assume Wp = 4, 1. Calculate the height of the eliminator), or Calculate WD. light liguid above the outlet (holdup 24 n+ Yd (with mis eliminator 32 © SEPTEMBER 1904 + CHEMICAL ENGINEERING PROGRESSTable 3. Cylindrical height renner’ #=9892851 == Or equraleot expressions, such as yD WoAVAy Hy = Hy + Hy + Hy + Hy + Hy + Ho an, If a mist eliminator pad is used, additional height is added as shown in Figure 1 Example 1 Size a vertical separator with a baf- fle plate and wire-mesh mist elimina tor to separate the mixture given in ‘Table 4. The operating pressure is 165 psia, and it is necessary to have a hydrocarbon liquid holdup time of 25 min and a surge time of only 5 min. 1. Calculate the vertical terminal velocity. Using Table 2, calculate K using the York Demister equations, see Eq, E! in the box. and Uy= 0.75 x 2.74 = 2.05 fu. 11900 0000 | 000 lovable downfiow, gph? 8 T G: High iquid level above interface the time for the light liquid to rise out of the heavy liquid phase: HydeecePbon Wau | Wis Ves00 | Per8S | HA06 | 5, = (12) (1.0) Water Ve = 1300 pee [we d7 | 174-69 min 2. Calculate the vapor volumetric flow rate, see Eq, E2 in the box. 3. Calculate the vessel inner diam- ter, see Bg. E3 in the box. Use D=105 ft. 4, Calculate the settling velocity of the heavy liquid out ofthe light liquid phase. Using Table 1, ky = 0.163 ‘Then: Uy = 0.163(62.11 ~ 53.95)10.630 2.1 indmin 5. Calculate the setling velocity of the light liquid out of the heavy liquid phase: Uyy = 0.163(62.11 ~ 53.950.764 1.74 in/min 6. Calculate the light and heavy liguid volumetric flow rates, see Eg, A and ES in the box. 7. Assume H,='l ft and calculate the time for the heavy liquid to settle ‘ut ofthe Tight liquid phase: fyy.= (12) (1.0) (2.11 = 5.7 min S Assume Hy = 1 ft and calculate 9. Calculate the baffle plate area Pr — Py = 53.95 ~ 0.697: wt ‘+ Assume Hy= I2in., Hy + H_=24 in, Using Figure 3, G = 9,800 gplvft. Ap = (748 gal/l®)(60 minfh) (5.10 +0.35)(f0/9,800 gphvft = 0.25 1 \ Assume W, = 4 in, W,/D = 41(12 x 10.5) = 0.0317 = 53.25 Cae? ‘CHEMICAL ENGINEERING PROGRESS * SEPTEMBER 1984 + 33MULTIPHASE FLOW Table 6. Liquid holdup and surge ti ata 8 owing et optional Porsomel Factor Instrumentation xpeenced —10.—=—_‘Wel instrumented 10 Tenet 12 Standardinswumentod 12 Inoxpeienced —15.——=—*Pooty instrumented 18 _ 16,500 1,300 i = 77:80 ©5395 + 77800 62.11 = 54.55 lb/ft i Equation 6 Equation 7 34 © SEPTEMBER 1994 * CHEMICAL ENGINEERING PROGRESS + Using Table 3, A,/A = 0.0095: A= (RA) (10.5 fi? = 86.59 f ‘Ay = (0.0095) (86.59 fe) = 0.82 ft A, = 86.59 - 0.82 30, Clete the residence tine of each. 1.0 fi) (85.77 £25.10 f0/min = 16.8 min Oy, = (0 A) (86.59 f)/0.35 fe/min = 247.4 min 14, Calculate the height ofthe light liquid above the outlet, based on holdup: 5,10 f0hmin) (25 min)85.77 feast = (6:10 + 0.35)(f2%min) 5 min) /86,59 f= 031 fe Use Hy=05 i 12. Calculate dy according ‘Table 5 de ONO, + Oy) = (5:10 + 0.35)15:10 + 0.35 + 165.32 x 60) = 0.0006 ‘Use Eg. B6 (see box) to calculate Pe By = Prat pull — 2) = (54.55) (0.0006) + (0.6973) (1 = 0.0006) = 0.730 Oy = 165.32 + (5.10 + 0.35)/60 = 165.41 ts ‘Use Eg, E7 (ee box) to calculate dy. dy 2 21 ing use dy = 24 in Calculate Hi Hy = 05 (105) = 5.25 ft or H, = 24 + 2472 = 36 in. = 3.0 ft (cninimom) eliminator. Hy= 140 HD = 1401105 = 13 Add 2 ft to Hy (Hy = 2.0 ft, Hy = 7.0 ft) so that HD = 1.52 (HyD should be in the range of 1.5 to 6.0). Horizontal design procedure: no boot or weir 1. Calculate the vapor volumetric flow rate, Q,, using Eq. 5.2. Calculate the light and heavy liquid volumetric flow rates, Q,, and Qn, sing Eqs. 9 and 10. 3. Calculate the vertical terminal velocity, Up, using Eq, 4. (select a K value ffom ‘Table 2) and set Uy, = 075U,, 4, Select holdup and surge times from Table 6 and calculate the holdup and surge volumes, Vy and Vy, (unless surge is otherwise specified, such asa slug volume): Var 0 Qt as) Vs= Ts Oe a9) 5. Obtain an L/D from Table 7 and, initially calculate the diameter according to: 4+ ¥) ro) Calculate the total cross-sectional =D 4 66. Set the vapor space height, Hy to the larger of 0.2D or 2 ft 1'ftif there is no mist eliminator. Using HD in Table 3, obtain A/A; and cal- cola Ay, 7. Set the heights of the heavy and Tight liquids, Hy, and H,, 8. Find (Ay, + Ay,VAy using (Hyp, +H,)ID in Table 3, and calculate Ay, + Au. 9. Calculate the minimum length to accommodate the liquid holdup/surge: en Vy #V5 Ar~Ay~ (Aw +Au) 10. Calculate the liguid dropout time: L 22) Hy ay 11, Calculate the actual vapor Cea keer aces velocity: Uy = Ov/Ay ey 12, Calculate the minimum length required for vaporiliquid separation: Laay= Ui ® 25) 1B. IF L < Lag then set L = Ly (here, vaporiliquid separation con- trols). This simply results in some extra holdup and residence time. If L << [yp then increase Hy and recal- culate’ Ay, and repeat, starting. from Step 9. If L > Lys the design is acceptable for vaporliquid separa tion, If L >> Ly (liquid holdup con- trols), Lean only be reduced and Lyy increased if Hy is reduced. Hy may only be reduced if tis greater than the ‘minimum specified in Step 6. (With reduced Hy, recalculate Ay and repeat the procedure from Step 9.) Note: For this and other calculations, “much greater than” (>>) and “much less than” (<<) mean a variance of greater than 20%. 14, Calculate the settling velocities of the heavy liquid out ofthe light lig- uid phase and the light liquid out of the heavy liquid phase, Uy and U yy using gs. 7 and 8 (ind k from Table 1) 15, Calculate the settling times of the heavy liquid out ofthe light phase and the light liquid out of the heavy phase: f= 12(D~ Hy Hg IU, (26) fay = 12 Ayal py en 16. Calculate the residence times of the light and heavy liquids: On = ALI Oni, 28) 17. If Opp < ty, OF Bx. < ty, then increase the vessel length (liquid sep- aration controls): nu, A= Au) 0) 18, Calculate I/D. If L/D << 1.5, decrease D (unless it is already at its minimum), and if L/D >> 6.0 then increase D; repeat from Step 5. 19. Calculate the thickness of the shell and heads according to Table 8 20, Calculate surface area of the shell and heads according to Table 8, 21. Caleulate the approximate ves- sel weight according to Table 8. 22. Increase or decrease the vessel diameter by 6-in. increments. and repeat the calculations until the L/D ratio ranges from 1.5-6.0. 23. Using the optimum vessel size (minimum weight), calculate the nor- ‘mal and high liquid levels: Hy = D~ Hy BD Anus = Aut Au) + Vif 32) Obtain Ay, using Table 3 with the value of Ayu/Ay Horizontal design procedure: heavy liquid boot 1. Caleulate the vapor volumetric flow rate, Oy using Ba. 5. 2. Calculate the light and heavy ligoid volumetric low rates, Q,, and On, per Eqs. 9 and 10. 5. Calculate the vertical terminal velocity, Up using Bq 4 (he X value comes from ‘Table 2) and set Uy = 075 Up 4, Sclect holdup and surge times from Table 6 and calculate the holdup and surge volumes, Vi and Vg fom Eqs. 18 and 19 (unless surge is other- ‘CHENNCAL ENGINEERING PROGRESS © SEPTEMBER 1004 + 35MULTIPHASE FLOW wise specified, such as slug volume). '$. Obiain L/D from Table 7 and initially set the diameter according to: et ¥)) Gy 0.6n(4ip) ‘Then calculate the total cross-sec- tional area, Ar, using Eq. 21 6. Set the Vapor space height, Hy, to the larger of 0.2D or 2 ft (1 ft if there is no mist eliminator). Using H,/D in Table 3, obtain A,/A,-and cal- calate Ay, 7, Set the light liquid heights in the vessel and boot, Hyyy and Hyp. 8. Calculate the cross-sectional ‘area ofthe light liquid above the bot- tom of the vessel, Aju using Hy/D in Table 3. 9. Calculate the minimum length to accommodate the liguid holdup/surge: 10. Calculate the liquid dropout time, 6, using Eq. 23 11. Calculate the actual vapor velocity, Uy, using Eq, 24 12, Calculate the minimum length required for liguid/vapor separation, Lyqy using Eq. 25. 1B. IF L < Ly then Set L = Lagy (vaporiliquid. seperation controls) This simply resulls in some extra holdup and residence time. If L “< Lys the design is acceptable for vaposliquid separation. If L >> Ly Tiquid holdup controls. L can only be reduced and Lyjy increased if Hy is reduced. Hy may only be reduced if it is greater than the minimum specified in Step 6 With reduced Hy recalculate Ay and repeat from Step 9. 14, Calculate the setting velocity of the heavy liquid out ofthe light lig- uid phase, Up, using Eq. 7 (obtain k from Table 1) 15, Calculate the settling time of Table 8. Wall thickness, surface area, Br ck Rc the heavy liquid out of the light liquid phase: typ = 12 Hing + D = Hy Up, 85) 16, Calculate the residence time of the light liquid: G6) Note: This volume of light liquid ignores the light liquid volume in the oot. 17. If O,, < fy, then increase the ‘vessel length (liquid separation con- trols): 2, G7) L=7l# (4r-Ay) 18, Calculate LD. If LD << 1.5 then decrease D (unless itis already at a minimum) and if L/D >> 60 then increase D; repeat from Step 5, ‘36 + SEPTEMBER 188¢ + CHEMICAL ENGINEERING PROGRESS 19. Calculate the thickness of the shell and heads according 10 Table 8 20, Calculate the surface area of the shell and heads according to Table 8 21, Calculate the approximate ‘weight of the shell and heads accord: ing to Table 8. 22, Increase or decrease the vessel diameter by Gin, increments and repeat the calculations until L/D ranges from 1.5-6.0. 23, With the optimum vessel size (minimum weight), calculate the nor- ‘mal and high liquid levels: Hy, = D Hy 38) Ayu Auy + Vid G9) Determine Hy, using Table 3 from Anal 34. Design the heavy liquid boot Sot the height of the heavy gui, Hyg calla the rising velocity of the lighs igi ot ofthe heavy iui phase, Uy using Bq. 8 (find from‘Table 1); set U, the heavy lig Ee d= \/ OF 40) ‘Then calculate the settling time of the light liquid out of the heavy liquid phase: 75 j,i calculate boot diameter: fy = W/V ay Calculate the residence time of the heavy liquid: RD Ey, 40, ay Su IF Bye. < typ then increase the boot diameter Horizontal design procedure: weir 1. Calculate the vapor volumetric flow rate, Oy, using Ea, 5. 2. Calculate the light and heavy liguid volumetric flow rates, Qu, and Op, as per Eqs. 9 and 10. 3. Calculate the vertical terminal vapor velocity, Up, using Bq. 4 (find K from Table 2) and set Uy = 0.75Up. 4. Select holdup and surge times from Table 6, and calculate the holdup and surge volumes, Vj, and Vs, from Eqs. 18 and 19 (unless surge is other- wise specified, such asa slug volume). 5. Obiain L/D from Table 7 and initially calculate the diameter according to: 16(Vj+ 4) 7 0.6n{L/p) ‘Then calculate the total eross-section- al area, A, using Eq. 21 6, Set the vapor space height, Hy. to the larger of 0.2D or 2 (I'it if there is no. mist eliminator). Using HD in Table 3, obtain A\/A, and cal- cola Ay, 7. Calculate the low liquid level in 3) Pree e Le the Tight liquid compartment using 15. 44 or read it from Table 9. Hy, =05D 47 a here Dis in fet and Hz, in inch- es (round up to nearest in). ID < 4.0 ft then Hy, = 9 in, Using H,,,/D in Table 3, Calculate A; 8, Calculate the weir height Hy=D-Hy as) If Hy-<2 fy, increase D, and repeat the calculations from Step 6. 9. Calculate the minimum length of the light liquid compartment to accommodate holdup/surge, L;, in Figure 2 Vy +Ve 46) 1 Ay Round to the nearest 4 ft. The ‘minimum for Ly = dy + 12 ia, 40, Sct the interface at the height Hy2, obtaining the heights of the hheavy and light liquids, Hj, and Hy, Ai. For the liquid settling com- partment, calculate the cross-section- al area of the heavy liquid, using Hy/D in Table 3 and calculate the cross-sectional area ofthe light liquid from: A= Ar~Ay~ Ag an 12, Calculate the setting velocity ofthe heavy iguid out of the Tight lig- uid phase, Uj, and the light liquid out of the heavy'liguid phase, U;yy using Eqs 7 and 8 (find ky from Table 1). 13, Calculate the settling times of the heavy liquid out ofthe light liquid pphase and the light liguid out of the heavy liquid phase: typ = 12H y/Uy, (48) 14, Calculate minimum L, to facil- itate liquid-liquid separation as the larger of: Round to the nearest ft 15, Find L: Leth oD 16, Calculate the liquid dropout time, 6, using Eq. 23. 17, Calculate the actual vapor velocity, Uy using Eq. 24. 18, Calculate the minimum length required for vapor/liquid separation, Tag, using Eq, 25. 19, IE < Ly, then set L = Lye (vaporfliquid separation controls) This simply results in some extra holdup and residence time. If L << yy then increase H, recalculate Ay and repeat the calculations from Step 6.1L > Lys the design is acceptable for vaporiliquid separation. If L >> Lyyy (liquid separation and holdup contro), L can only be reduced and Lyqy increased if Hy is reduced. Hy may only be reduced if it is greater than the minimum specified in Step 9. With reduced Hy, recalculate Ay and repeat from Step 9 20, Calealate L/D. If L/D << 1.5, then decrease D (unless itis already at a minimum) and repeat from Step 6. If LD >> 60, then increase D and repeat from Step 5. 21. Calculate the thickness of the shell and heads according to Table 8. 22, Calculate the surface area of the shell and heads according to Table 8. ‘CHEMICAL ENGINEERING PROGRESS * SEPTEMBER 190¢ © 37MULTIPHASE FLOW 23. Calculate the approximate ves- sel weight according (0 Table 8. 24, Increase or decrease the diam- ‘ler by 6-in, increments and repeat the calculations until L/D ranges from 15-60. 25, With the optimum vessel size (rninimum weight), calculate normal and high liquid levels: Hy, =D ~ Hy 62) Ay = Aust Villa 63) Obtain Hyys, using Table 3 with Anuar Horizontal design procedure: bucket and we 1, Calculate the vapor volumetric flow rate, Qy, using Eq. 5. 2. Calculate the Tight and heavy liquid volumetric flow rates, Q,,, and Opi, per Es, 9 and 10. ‘3. Caleulate the vertical terminal vapor velocity, Up, using Eq. 4 (find K from Table 2) and set Uy = 0.75 Uy. 4, Select residence times for light and heavy liquids, 8,, and @,,. For sour water stripper feed drums, By, = 235,000 Ib/h. Equation BS os = 18.52 fi min D Equation £9 Qn ation E10 3,600 s/h x 0.190 Ibvft’ 7,500 Ib/h =2.02 ft'/min L, 60 minh x 62.0 Ibvft? 60 min for refinery service, or 10-15, ‘min for chemical-plant service. For amine regenerator feed drums, Oy, = 10-15 min, §. Obiain L/D from Table 7 and initially set the diameter according to 4{2101.+0nu) 0.70n{t/p) ‘Then calculate the total eross-section- al area, A;, using Eg. 21 6. Set the vapor space height, Hy to the larger of 0.2D or 2 ft (1 ftif (54) 343.57 ft/s U,=0. Mi quation ELL Equation E12 95.0: Equation £13 Equation E14 Qu 2.0 min x 18.52 ft/min Equation B16 3B + SEPTEMBER 1994 + “CHENICAL ENGINEERING PROGRESS 4x277.80_\" 0.6m x 1.7 x Ya, 277.80. there is no mist eliminator). Using Din Table 3, obtain A\/Ap and cal culate Ay, 7. Caleulate L; (20+ Onn re 8 Calculate the liquid dropout time, 6, using Eq. 23, 9. Caleulate the actual vapor veloc- ity, Uy, using Eq. 24 10. Calculate the minimum length required for vaporiliquid separation, Lay, wsing Bq. 25. TILL, < Ly then set Ly = Lay (vaporiliquid separation controls). ‘This simply results in some extra holdup and residence time, If L, << Ly then increase Hy, recalculate Ay and repeat the calculations from Step T.IE Ly > Ly the design is accepl- able for vapor/liquid separation. 12. Calculate the light liquid layer thickness based on the heavy liquid settling out: (5) = 11.15 ft, use 11.0 ft = 14.54 ft 485 AT fti= 0. .001280,(ASc)De 66) a a where Dp is in microns. 13. Calculate the difference in height between the light and heavy liquid weirs: : 7) AH= auf fi) 14, Design the light liquid bucket: Set the top of light liquid weir = D — Hi; assume the bottom is at 0.125D; assume a holdup/surge (typically, 5-15 min.); assume HLL is 6 in, below the weir height and LLL is 6 in. above the bottom of the bucket. Using Table 3 with Hy,/D and HyJD, calculate Ay, 80d Ary, Caleatate Zs (ru (58) (A= Aus) 15. Assume Lis the larger of D2 or 12in, 16. Design the heavy liquid com- partment: Set the top of the heavy liq- uid weir = D ~ Hy ~ AH; assume a hholdup/surge (typically, 5-15 min); assume HLL is about 6 in. below the weir height and LLL is about 6 in, above the bottom of the vessel. Using | Table 3 with Hyz,/D and Hyy/D, cal- | Calculate Ly: culate Aj, and Apzy. (T+ TJQm (Anu — A) 17.Caloulate L-= Ly + Ly +154 Ly 18, Caleulate L/D. If LD << 1.5, 9) then decrease D and repeat from Step 5.1 LD >> 60, then inerease D and repeat from Step 5... 19, Calculate the thickness of the shell and heads according to Table 8 20, Calculate the’ surface area of (CHEMICAL ENGINEERING PROGRESS ©. SEPTEMBER 1864 © 39MULTIPHASE FLOW ——— Table 10. Data for Example 2. shell and heads according to Table 8. 21. Caleulate the approximate ves- sel weight according (0 Table 8, 22. Increase or decrease the diam- increments and repéat the eter by 6 calculations until 1/D ranges. from 15-60. Example 2 Design three-phase horizontal separator with a weir to separate the mixture in Table 10. The operating pressure and temperature are 25 psig and 100, respectively, and itis neces- sary to have aliquid holdup and surge time of 15 min. 1. See Eq. E8, box, p. 38 2. Sce Eqs. £9 and E10, box, p. 38 K = 0.175 (the Gas Processors Suppliers’ Association value in Table 2 was divided by 2 since there is no ‘mist eliminator. ‘See Eq. Ell, box, p. 38 Uy= 0.95 x2.55 = 191 fds 4. Holdup + surge as specified Vy + Ve= (US min) (18.52 £6/min) =277.8080 ‘Assume 10 min holdup, 5 min surge 5, Assume 1/D = 1.7. See Ea. E12, box, p.38 ‘Ar= m/4 (11.0 £9)? = 95.03 f 6. Since the mass rate of vapor is Equation E18 4901b ,, 0.500 fe” WinJit Equation E19 55x 132 ‘hen XTT5D0<0.85 = 1.255 1i6= 0.307 in. Equation 17 . 1 O885 x 55x 132 4354 = 0.495 in, «= TX77,500 x 0.85 ~ 0.1 X55 673.87 8 +2 101.88 f°) about 82% of the loading, set Hy to be much greater than the minimum. ‘Assume Hy = 0,70D = (0:70)(11.0 £1) = 7.70 ft. Using Table 3, Ay/Ay = 0.748, Ay = 71.08 fe TH = (0-5)(11.0) +7 use 13 fn Hyy/D = 13(11.0 x 12) = 0.098. Using Table 3, Ayy/Ay = 0.051 051)(95.03 fe 1.85 fe 8. fly =11.0-7.70= 330 9.86 Ea £13; ox p38 2.5 in 1, Hiy/D = 1.65111.0 =0.150 From Table 3, Ajy/Ay = 0.094 = (0.094)(95.03 fe) 95.03 71.08-893= 15024 12. From Table 1, ky = 0.333, Uyy, = 0.333)(62.0 ~ 40.50.24 = 29.83 inJmin Use 10 in/min (maximum) Uzy = (0.333)(62.0 - 40.5)/0.682 = 10.50 inJmin ‘Use 10 in./min (maximum) AB. tq, = C12 inJAN(1.65 fH/10 98 min, use 2.0 mins tay = fy, = 20 min 1d, See Eqs. E14 and E15, box, Ant 17. See Ea, E16, box p38 7,920 Ib 40 + sepremaen 04 + CHEMICAL ENGINEERING PROGRESS ns PUN kee 19, Since L< Ly, set Got Ly "3.5 8) .0 = 1.78 21.“ Assume dished heads per ‘Table 11, ‘Assume E = 0.85 Use SA-516 70 carbon steel, design temperature = 650° 7,500 psis from Ref. (3) Corrosion allowance = Ye in. 25 + 30=55 psig ‘See Eq. E17, box om this page. Use t= % in, See Eq E18, box on this page Use fy = ¥4 ins use t= ¥ in, 22, Ay = RIL 1) (19.5 f) = 673.87 fe 842) (11.0 M9)? = 101.88 f° 23. See Eq. E19, box on this page. 24, In this example, calculations were performed for only one diame- ter. However, nearly the minimum L/D corresponded to a diameter of 11.0 % therefore, the next diameter should be smaller, resulting in a larger L/D. Also, calculations should be performed using a diameter of 1S ft 25, For the light liquid compartment: 33-31, 4 in 6.43 fe Hyuz = (0.229) (11.0) = 2.52 ft~ 2 Comment: Due to the small amount of heavy liquid and large amount of vapor, a better design would have used a boot. A vertical vessel should be compared, as ‘a froe copy oft the Reader Inquiry card inthis issue withthe number 153 circled.