Two Phase Separator

Horizontal Type Design Procedure

Ali Farrokhzad 1395

Jan 2017
 .
. = . =
2

. As per Table (GPSA, etc. )

 Example:
Size a Horizontal separator with a mist eliminator
pad to separate the following mixture .

The operating pressure is 975 psig and the holdup

and surge are to be 10 min and 5 min respectively.
Use a design temperature of 650F .
Design Procedure: Example:
1)
145600
Qv =3600 4.01 =10.09 ft3/s

2)
46100
QL = 60 38.83 = 19.8 ft3/min

3) As we show in 2-phase vertical presentation:

K York_mist= 0.2714 , K GPSA = 0.2625
Ktheo (=0.01cP, Dp=300 micron) = 0.2766
For Horizontal drum (with/without mesh pad)
K shall be divided by 2.
min {Ki} 0.2625
K= = = 0.1313
2 2

UT = 0.39 ft/s
Uv = 0.75 UT = 0.29 ft/s
Design Procedure: Example:
4)
VH = THQL =1019.8 = 198 ft3

5)
VS = TSQL = 519.8 = 99 ft3

6)

P=975 psig 4 < < 6

Assume L/D = 5
1
4 (198+99) 3
D= =5.01 ft.
0.65

Use D = 5.0 ft.

AT = 19.63 ft2
 Design Procedure: Example:
7)
7.
HLLL = 0.55+7
= 9.5 in.

8)
x = HLLL/D =0.158
From Eq. y = 0.102 ALLL/AT = 0.102
ALLL =0.10219.63 = 2 ft2.
Design Procedure: Example:
9) Acc. to Article: with mesh pad:

Hv=max{0.25 , 2} = 2 ft.

Acc. to modified formula:

145600
q= =0.76 = 0.850.76 =0.65
145600+46100

Hv=max{0.655 , 2} = 3.23 ft.

x = HV/D =0.65
From Eq. y = 0.68 AV/AT = 0.68
AV =0.6819.63 = 13.4 ft2.
 VH VS
Liquid Inventory Length: L
AT AV ALLL
 HV QV
UVA LMIN UVA
UV AV

L
Feed Vapor

HV Av
D A(holdup+surge) AT
+
ALLL

Liquid
Liquid Inventory Length (L) vs Separation Length (LMIN)

L
L > LMIN
HV Design is Acceptable

LMIN

L
L >> LMIN
HV Liquid hold up is controlling

L can on ly be decreased and L MIN increased

LMIN
if Hv is decreased.

Hv may only be decreased if it is greater than

the minimum specified in the step 9
Liquid Inventory Length (L) vs Separation Length (LMIN)

L
L < LMIN
HV Vapor/liquid separation is controlling

Set L= LMIN
LMIN Continue with new L.
This simply results in some extra holdup.

L
L << LMIN
HV
Increase Hv and repeat from step 9.

LMIN
Design Procedure: Example:

197.9 + 98.9
10) L= = 70.16 ft.
19.63 13.4 2

3.23
11) = = 11.14 s
0.29

10.09
12) UVA = = 0.753 ft./s
13.4

13) LMIN= 0.753 11.14 = 8.39 ft.

 MIN

Design is Acceptable
Design Procedure: HV
Example:
L > 1.2 LMIN
LMIN L >> LMIN According to Step9:

Type: 9) HV=max{0.25 , 2} = 2 ft.

AND Acc. to modified formula: HV=max{0.655 , 2} = 3.23 ft.
L So HV shall be in the range of 2~3.23 ft.
L >> LMIN
Our design with 3.23 ft. shows that L is so much greater than LMIN.
HV Liquid hold up is controlling
We should reduce HV to the minimum allowable value: Let HV= 2 ft.
Lnew
With canfigure
on ly be
wedecreased and Lfrom
are continuing MIN increased
step 9:
LMIN
if Hv is decreased.
x = HV/D =0.4 y = 0.374 AV/AT = 0.374 AV =7.33 ft2.
Hv may only be+decreased
197.9 98.9 if it is greater than
10) the minimum
L= = 28.81 ft.
specified in the step 9
19.63 7.33 2
2
11) =0.29 = 6.9 s
10.09
12) UVA = = 1.38 ft./s
7.33

13) LMIN= 1.38 6.9 = 9.48 ft. L >> LMIN

But HV is the min. allowable value and we could not reduce HV.
So this answer is acceptable. L/D = 28.81/5.0 = 5.75 (in the range)
 Calculation of thickness of Head & Shell
Design Pressure & Design Temperature:
Reference: RULES OF THUMB: SUMMARY , Walas Click to see contents:

1. Design temperature between -20F and 650F is 50F above operating temperature; higher safety
margins are used outside the given temperature range.
If -20 oF <OT < 650 oF DT=OT + 50 oF

2. The design pressure is 10% or 10-25 psi over the maximum operating pressure, whichever is
greater.
The maximum operating pressure, in turn, is taken as 25 psi above the normal operation.
MOP= NOP+25 psi DP=max.{1.1MOP , MOP+10~25 psi}

3. Design pressures of vessels operating at 0-10 psig and 600-1000F are 40 psig.
 Calculation of thickness of Head & Shell
P, design pressure, psig
Typically,
operating pressure+(15-30) psi or 10-15%,
whichever greater.

T, design temperature , oF
Typically,
if Top > 200F, DT=operating temperature +25-50F. D, Vessel diameter, in.
If Top < 200F, DT=250F S, allowable stress, psi (ASME Pressure Vessel Code, Section VIlI.
Division I, Table UCS-2J , p. 270 - 21771 (1986) )
E, joint efficiency, (0.6-1.0), 0.85 for spot examined joints, 1.0
under 650Fdoesnot reduce wall thickness for 100% x-ray joints
1 1
if overpressure caused by boiling, should be TBP . tc , corrosion allowance, in, typically to in.
16 8
1
t, thickness of plate , in. , larger of tS and tH (to nearest in.)
8
 Allowable Stress of Alloy
Pressure Vessel Handbook-Megyesy

Evaluate Design Temperature for the selected alloy

and then read S from the Table.
Design Procedure: Example:
Tips:
DT = 650 oF
According to Walas Rules of Thumbs
for Pressure Vessels NOP=975 psig
MOP=975+25=1000 psig
Corrosion allowance:
0.35 in. for known corrosive conditions, DP=max{1000+25, 1.11000}=1100 psig
0.15 in. for non-corrosive streams, and
0.06 in. for steam drums and air receivers. Alloy: SA 516 70 Carbon Steel

From Table: 17.5 S= 17500 psi

Let C.A. tC= 1/16 = 0.06 in. & Joint Efficiency (E) = 0.85

Head Type:
D < 15 ft. & P > 100 psig 2:1 Elliptical
Design Procedure: Example:
15)
Head Thickness & Area:
PD 1100 (5 12)
tH tC 0.06 2.295 in.
2 SE 0.2 P 2 17500 0.85 0.2 1100

Shell Thickness & Area:

PD 1100 (5 12)
tS tC 0.06 2.381in.
2 SE 1.2 P 2 17500 0.85 1.2 1100

Alloy plate thickness: t max{t H , t S } 2.38 in.

16) AS DL 3.14 5 28.81 452.5 ft 2

AH 1.09 D 2 1.09 (52 ) 27.3 ft 2

17)
t 2.38
W 490 ( ) ( AS 2 AH ) 490 ( ) (452.5 2 27.3) 49,281 lb 24.5 tone
12 12
Design Procedure:

Example:
D (ft.) L (ft.) LMIN (ft.) Hv (ft.) W (lb) L/D Status
5 28.81 9.48 2 49281 5.8 Weight is not optimum.
5.5 21.56 8.91 2 46797 3.9 L/D out of Range
4.5 40.88 10.18 2 54589 9.1 L/D out of Range
5.47 21.89 8.94 2 46887 4.0 Optimized Case.
Nozzles Orientation:
Nozzle Sizing: Example:
Usually 10% overdesign shall be considered in Nozzle Sizing. Inlet Nozzle:
Inlet Nozzle: Q=QL+QV 1. Based on CEP method: 8.5<D

U=7~13 m/s or 2.
41.10.295
<D<
41.10.295
7<D<9.6
13 7
U2 = 1000 Pa (for no inlet device)

U2 = 1500 Pa (for half open pipe) 3. No inlet device: U2 = 1000 U= =3.5 m/s D>13.5

1,2,3 DF = 10 (Selected)
4
Note: All units in SI system. D=

Liquid Outlet:
Liquid Outlet:
41.10.009 41.10.009
<D< 2.3<D<4.5 DL=3
U=1~4 m/s (min 2). 4 1

Vapor Outlet: Vapor Outlet:

U=15~30 m/s or U2 = 3750 Pa. 41.10.286

<D<
41.10.286
4.5 < D < 6.4
30 15
DV=6
3750 41.10.286
U2 = 3750 U= =7.6 m/s D= D=9
v 7.6
 Feed Nozzle 10" 6" Vapor outlet

16" Min 12" 12"

Hv= 610 mm

Min 12"
D=1668 mm

High Liquid Level H HLL = 1058 mm

Surge
Normal Liquid Level H NLL = 804 mm

HoldUp
Low Liquid Level H LLL = 247 mm
9"

Liquid Outlet 3"

L=6671 mm
 Home Work: References:
Design a Horizontal flash drum by considering below conditions.
Feed enters at 5 barg & 40 oC.
Vapor density is 8 kg/m3 & liquid density is 780 kg/m3.
Flow rate of feed is 12,000 kg/hr.
Feed is non corrosive, use your own assumption during sizing. 1. Wayne D. Monnery and William Y. Svrcek.
Report required data as much as possible. "Design Two-Phase Separators Within
The Right Limits"; ,University of
Calgary; October 1993. Chemical
Assume previous (Vertical H.W.) assumptions and compare the both Engineering Progress (CEP).
design cases.

1) Unit Feed Drum with q=40% , with Mesh pad.
2) Flare K.O. Drum with q=0 , without Mesh pad
3) Unit Feed Drum with q=40% and without mesh pad.
4) Unit Feed Drum with q=80%, with mesh pad.
5) Unit Feed Drum with q=100%, with mesh pad.
Extra Example:
Slug catcher with q=20% and 40 m3 slug volume as unit feed drum.
2. Eugene F. Megyesy. "Pressure Vessel
Handbook", 10th Edition, University of
Tulsa, 1997.
3. Stanley M. Walas, "Chemical Process
Equipment Selection and Design",
University of Kansas, 1990.