Seperator Vessels Selection, Sizing and Troubleshooting
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This document provides guidelines for the selection, sizing, and troubleshooting of separator vessels. It discusses different types of separator vessels including two-phase and three-phase separators. Key considerations for separator vessel design covered include vessel orientation, retention time calculations, internals selection, and material of construction. Example problems are provided to demonstrate the sizing and design of various separator configurations. The document is intended as a reference for engineers conducting preliminary separator vessel design and specification.
![KLM Technology
Group
Practical Engineering
Guidelines
for Processing Plant Solutions
Kolmetz Handbook
of Process Equipment Design
SEPARATOR VESSEL
SELECTION, SIZING
AND TROUBLESHOOTING
ENGINEERING DESIGN GUIDELINES
Page 7 of 120
Rev: 03
JAN 2015
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
INTRODUCTION
Scope
Separator vessels are commonly used in refinery, petrochemical plants, or gas
processing plants to separate the vapor-liquid mixtures, and three phase mixtures,
these vessel may be called knockout drums, accumulators, flash drums, vapor/liquid
separators, reflux drums, or three-phase separators. The performance is determined
by the characteristics of the fluid being separated, the size of the vessel and the type of
internals installed. This guideline will provide a review of the important parameters in
separator vessel sizing and selection.
Heterogeneous Separation
Heterogeneous mixtures consist of two or more parts (phases), which have different
compositions. These mixtures have visible boundaries of separation between the
different constituents which can be seen with the naked eye and consist of substances
that do not react chemically. These substances can be elements or compounds.
Components of a mixture can be separated using one or more appropriate techniques.
The separation can be done physically by exploiting the differences in density between
the phases. The phase separations likely to be carried out are [1]:
Gas–liquid (or vapor–liquid)
Gas–solid (or vapor–solid)
Liquid–liquid (immiscible)
Liquid–solid
Solid–solid](https://image.slidesharecdn.com/engineering-design-guidelines-seperator-vessels-rev3-200418222216/85/Seperator-Vessels-Selection-Sizing-and-Troubleshooting-7-320.jpg)
![KLM Technology
Group
Practical Engineering
Guidelines
for Processing Plant Solutions
Kolmetz Handbook
of Process Equipment Design
SEPARATOR VESSEL
SELECTION, SIZING
AND TROUBLESHOOTING
ENGINEERING DESIGN GUIDELINES
Page 13 of 120
Rev: 03
JAN 2015
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Air conditioning
Compressor systems for air or gases
Gas pipelines
Steam condensate flash drums
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 [2]:
1. Primary separation section (entrance): 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.](https://image.slidesharecdn.com/engineering-design-guidelines-seperator-vessels-rev3-200418222216/85/Seperator-Vessels-Selection-Sizing-and-Troubleshooting-13-320.jpg)
![KLM Technology
Group
Practical Engineering
Guidelines
for Processing Plant Solutions
Kolmetz Handbook
of Process Equipment Design
SEPARATOR VESSEL
SELECTION, SIZING
AND TROUBLESHOOTING
ENGINEERING DESIGN GUIDELINES
Page 15 of 120
Rev: 03
JAN 2015
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Enhances flow distribution of gas and liquid phases
Prevents droplet shattering and re-entrainment of bulk liquid phases
Stable liquid level control and reduced foaming
The impingement or settling internal might be added to optimized separation process.
As the descriptive name suggests, the impingement separator allows the particle to be
removed to strike some type of surfaces. There are basically three construction types
for impingement separator: wire mesh, plates (curved, flat, or special shaped), and
packed impingement beds.
The vapor-liquid separators which are generally used in industries might be classified
into followings [3]:
1. Gravity separators
The separation process in this gravity separator occurs by settling and
sedimentation and depends on gravitational force. Liquid droplets or solid
particles will settle out of a gas phase if the gravitational force acting on the
droplet or particle is greater than the drag force of the gas flowing around the
droplet or particle. The same phenomenon happens for solid particles in liquid
phase and immiscible sphere of a liquid immersed in another liquid.
Gravitational forces control separation; the lower the gas velocity and the larger
the vessel size, the more efficient the liquid/gas separation. Because of the
large vessel size required to achieve settling, gravity separators are rarely
designed to remove droplets smaller than 300 microns.
Gravity separators are not recommended as the soul source of removal if high
separation efficiency is required.
Gravity separators are sometimes also called scrubbers when the ratio of gas
rate to liquid rate is very high. These vessels have a small liquid collection
section and are recommended only for the following items:
a. Secondary separation to remove carryover fluids from process equipment
such as absorbers and liquid dust scrubbers.
b. Gas line separation downstream from a separator and where flow lines are
not long.](https://image.slidesharecdn.com/engineering-design-guidelines-seperator-vessels-rev3-200418222216/85/Seperator-Vessels-Selection-Sizing-and-Troubleshooting-15-320.jpg)
![KLM Technology
Group
Practical Engineering
Guidelines
for Processing Plant Solutions
Kolmetz Handbook
of Process Equipment Design
SEPARATOR VESSEL
SELECTION, SIZING
AND TROUBLESHOOTING
ENGINEERING DESIGN GUIDELINES
Page 17 of 120
Rev: 03
JAN 2015
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
- Metering and pressure reduction stations at city gates: to remove liquid
hydrocarbons, water, sand and pipe scale.
- Protection of desiccant beds and collection of dust carry-over from beds.
- Gas storage systems: to prevent injection or withdrawal of solids, dust, and
small amounts of liquids.
- Fuel lines to power plants and engines.
Liquid-Liquid Separator [4]
Separating liquid-liquid dispersions can be difficult depending on the physical
properties of the two liquid phases. The specific gravity, viscosity and interfacial
tension (IFT) of the two liquid phases are important parameters in determining how
easy two liquids can be separated.
Liquid-liquid separator might be divided into two broad categories based on their
operation. The first is defined as “gravity separation” where the two immiscible liquid
phases separate within the vessel by the differences in density of the liquids.
Differences in densities of the two liquids cause droplets to rise or fall by their
buoyancy. The greater the difference in densities, the easier the separation becomes.
Rising (or falling) droplets are slowed by frictional forces from viscous effects of the
opposing liquid. Sufficient retention time must also be provided in the separator to
allow for the gravity separation to take place.](https://image.slidesharecdn.com/engineering-design-guidelines-seperator-vessels-rev3-200418222216/85/Seperator-Vessels-Selection-Sizing-and-Troubleshooting-17-320.jpg)
![KLM Technology
Group
Practical Engineering
Guidelines
for Processing Plant Solutions
Kolmetz Handbook
of Process Equipment Design
SEPARATOR VESSEL
SELECTION, SIZING
AND TROUBLESHOOTING
ENGINEERING DESIGN GUIDELINES
Page 21 of 120
Rev: 03
JAN 2015
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
In addition to the numerous coalescing media, Table 4 presents some coalescing
media and their industrial applications with regard to the nature of emulsions they
separate (emulsion source), flowrate and maximum droplet diameter.
Table 3. Coalescing media and their applications
Media Source Max. Droplet
Diameter (μm)
Flow Range
(gpm/ft2
)
Corrugated sheets Separators with
coarse emulsions
and static mixers.
40-1000 15-75
(35-180 m3
/hr/m2
)
Wire mesh, wire
wool
Extraction columns,
Distillation tower
feeds, impeller
mixers.
20-300 7,5-45
(35-180 m3
/hr/m2
)
Co-knits of wire
and polymer
Steam
stripper bottoms,
Caustic wash drums,
High pressure drop
mixing valves.
10-200 7,5-45
(35-180 m3
/hr/m2
)
Glass mat, co-knits
of wire and
fiberglass
Haze from cooling in
bulk liquid phase,
Surfactants giving,
Emulsions with very
low interfacial
tension.
1-25 7,5-45
(35-180 m3
/hr/m2
)
Vapor-solid separator [5]
The most commonly encountered two phase vapor-solid separator in process industry
is the decoking drum. A Decoking drum is provided for decoking of furnace tubes. Inlet
stream to decoking drum may consist of steam, air and coke particles. Separation of
coke particles from gases is essential to prevent coke particles being discharged to
atmosphere or heater stack.](https://image.slidesharecdn.com/engineering-design-guidelines-seperator-vessels-rev3-200418222216/85/Seperator-Vessels-Selection-Sizing-and-Troubleshooting-21-320.jpg)
![KLM Technology
Group
Practical Engineering
Guidelines
for Processing Plant Solutions
Kolmetz Handbook
of Process Equipment Design
SEPARATOR VESSEL
SELECTION, SIZING
AND TROUBLESHOOTING
ENGINEERING DESIGN GUIDELINES
Page 22 of 120
Rev: 03
JAN 2015
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Separation of solid particles from vapor phase occurs under the influence of gravity.
Forces which affect the rate of settling of solid particles are:
(i) gravity force
(ii) drag force due to relative motions
(iii) buoyancy force
Liquid-solid separator [6]
Solid-liquid separation processes are generally based on either one or a combination
of gravity settling, filtration, and centrifugation principles. In gravity settling separation,
solid particles will settle out of a liquid phase if the gravitational force acting on the
droplet or particle is greater than the drag force of the fluid flowing around the particle
(sedimentation).
Mechanical separation by filtration involves passage of most of the fluid through a
porous barrier which retains most of the solid particulates or liquid contained in the
mixture. Centrifugal separation occurs by changing the direction of two phase stream
sharply, thus the greater momentum will not allow the particles of heavier phase to turn
as rapidly as the lighter fluid and separation occurs.
Some commonly used liquid-solid separators are filters, centrifuges, hydrocyclones,
and gravity settlers.](https://image.slidesharecdn.com/engineering-design-guidelines-seperator-vessels-rev3-200418222216/85/Seperator-Vessels-Selection-Sizing-and-Troubleshooting-22-320.jpg)
![KLM Technology
Group
Practical Engineering
Guidelines
for Processing Plant Solutions
Kolmetz Handbook
of Process Equipment Design
SEPARATOR VESSEL
SELECTION, SIZING
AND TROUBLESHOOTING
ENGINEERING DESIGN GUIDELINES
Page 23 of 120
Rev: 03
JAN 2015
These design guideline are believed to be as accurate as possible, but are very general and not for specific design
cases. They were designed for engineers to do preliminary designs and process specification sheets. The final
design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will
greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines
are a training tool for young engineers or a resource for engineers with experience.
This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied,
reproduced or in any way communicated or made accessible to third parties without our written consent.
Three Phase Separator
Vapor-liquid-liquid separator [7]
Three phase separation is commonly applied when there are water, liquid hydrocarbon
and hydrocarbon gases in the process stream. As with two phase design, three phase
units can be either vertical or horizontal.
Vertical vessel is mainly applied when there is a large amount of vapor to be separated
from a small amount of the light and heavy fluid (less than 10-20% by weight).
Horizontal vessels are most efficient where large volumes of total fluid and large
amounts of dissolved gas are present with the liquid. An example for vertical vessels is
the compressor suction drums while good representative of horizontal vessel is the
spent caustic deoiling drum.
Figure 7. Horizontal 3-phase separator](https://image.slidesharecdn.com/engineering-design-guidelines-seperator-vessels-rev3-200418222216/85/Seperator-Vessels-Selection-Sizing-and-Troubleshooting-23-320.jpg)
Seperator Vessels Selection, Sizing and Troubleshooting
- 1. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Engineering Solutions www.klmtechgroup.com Page : 1 of 120 Rev: 03 Rev 01 Jan 2011 Rev 02 Oct 2013 Rev 03 Jan 2015 KLM Technology Group P. O. Box 281 Bandar Johor Bahru, 80000 Johor Bahru, Johor, West Malaysia Kolmetz Handbook of Process Equipment Design SEPARATOR VESSELS SELECTION, SIZING AND TROUBLESHOOTING (ENGINEERING DESIGN GUIDELINES) Co Author Rev 01 Viska Mulyandasari Rev 02 Aprilia Jaya Rev 03 Riska Ristiyanti Editor / Author Karl Kolmetz TABLE OF CONTENT INTRODUCTION Scope 7 Heterogeneous Separation 8 Separator Vessel 10 Two Phase Separator 12 Three Phase Separator 20 GENERAL DESIGN CONSIDERATION Vessel Orientation 27 General Separator Design Consideration 29
- 2. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions www.klmtechgroup.com Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 2 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. General Separator Design Criteria 29 Equipment Protection Requirements 31 DEFINITIONS NOMENCLATURE
- 3. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 3 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. THEORY Gravity Separation (Sedimentation) 33 Centrifugation 36 Heads Selection 37 Material of Construction 38 Separator Vessel Sizing 39 Internals 62 APPLICATION Example Case 1: Retention-Time Method 73 Example Case 2: Droplet-Settling Method 75 Example Case 3: Vapor-Liquid Vertical Vessel Sizing 76 Example Case 4: Vapor-Liquid Horizontal Vessel Sizing 78 Example Case 5: Vessel Thickness 82 Example Case 6: Liquid-liquid vertical separator vessel 85 Example Case 7: Liquid-liquid horizontal separator vessel 87 Example Case 8: Vapor-liquid-liquid vertical separator vessel 89
- 4. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 4 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Example Case 9: Vapor-liquid-liquid horizontal separator vessel 95 REFERENCES 117 LIST OF TABLES Table 1. Efficiency of centrifugal separator 15 Table 2. Coalescing media 18 Table 3. Coalescing media and their application 19 Table 4. Comparison of different gravity separator types 28 Table 5. Liquid retention time for 2-phase separator 40 Table 6. Typical retention time for 3-phase separator 40 Table 7. Recommended K value 41 Table 8. Separator K value 42 Table 9. Liquid holdup and surge times 44 Table 10. Low liquid level height 45 Table 11. L/D ratio 47 Table 12. Cylindrical height and area conversion 47
- 5. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 5 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Table 13. Wall thickness, surface area, and approximate vessel weight 49 Table14. Typical Retention Times for Liquid-Liquid Separation 51 Table 15. Typicaly values of ks for liquid-liquid separation 57 Table 16. The most commonly used mesh pads 73 LIST OF FIGURES Figure 1. General types of separator vessel 10 Figure 2. Major components of horizontal separator 11 Figure 3. Internal parts of (a) vertical separator and (b) horizontal vapor-liquid separator 13 Figure 4. Typical arrangement of gravity settler 16 Figure 5. Vertical coalescer 17 Figure 6. Horizontal coalescer 18 Figure 7. Horizontal 3-phase separator 21 Figure 8. Vertical 3-phase separator 21 Figure 9. Drag coefficient for rigid spheres 34
- 6. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 6 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Figure 10. Typical vessel heads 38 Figure 11. Vertical liquid-liquid separator vessel design 54 Figure 12. Basic design of vertical three-phase separator 55 Figure 13. Determining the downcomer allowable flow 57 Figure 14. Basic design of horizontal three-phase separator with interface control no boot or weir 59 Figure15. Basic design of horizontal three-phase separator with interface Control with boot 62 Figure 16. Basic design of horizontal three-phase separator with interface Control with weir 64 Figure 17. Basic design of horizontal three-phase separator with interface control With bucket and weir 67
- 7. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 7 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. INTRODUCTION Scope Separator vessels are commonly used in refinery, petrochemical plants, or gas processing plants to separate the vapor-liquid mixtures, and three phase mixtures, these vessel may be called knockout drums, accumulators, flash drums, vapor/liquid separators, reflux drums, or three-phase separators. The performance is determined by the characteristics of the fluid being separated, the size of the vessel and the type of internals installed. This guideline will provide a review of the important parameters in separator vessel sizing and selection. Heterogeneous Separation Heterogeneous mixtures consist of two or more parts (phases), which have different compositions. These mixtures have visible boundaries of separation between the different constituents which can be seen with the naked eye and consist of substances that do not react chemically. These substances can be elements or compounds. Components of a mixture can be separated using one or more appropriate techniques. The separation can be done physically by exploiting the differences in density between the phases. The phase separations likely to be carried out are [1]: Gas–liquid (or vapor–liquid) Gas–solid (or vapor–solid) Liquid–liquid (immiscible) Liquid–solid Solid–solid
- 8. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 8 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. The principal methods for the separation of heterogeneous mixtures could be classified as: 1. Settling and sedimentation Sedimentation or settling can be used to separate any particle from any fluid, whether it is a liquid from a gas, a solid from a liquid, or a liquid from a liquid (with different densities). In settling processes, particles with higher density are separated from a fluid by gravitational forces acting on the particles. The separation of suspended solid particles from a liquid by gravity settling into a clear fluid and a slurry of higher solids content is called sedimentation. 2. Inertial and centrifugal separation This method is similar to sedimentation, but some forces are added in order to get a better separation. Inertial separation is done by giving the particles downward momentum, in addition to the gravitational force. In a centrifugal device, the centrifugal force is generated to increase the force acting on the particles. Particles that do not settle readily in gravity settlers often can be separated from fluids by centrifugal force. Centrifugal separation results a much shorter period of time than could be accomplished solely by gravity. It has mainly been used to separate fluids in static state, i.e. specific volumes, which needed to be separated. 3. Electrostatic precipitation It is generally used to separate particulate matter that is easily ionized from a gas stream by using an electric charge. The principal actions are the charging of particles and forcing them to the collector plates. The amount of charged particulate matter affects the electrical operating point of the electrostatic precipitator.
- 9. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 9 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. 4. Filtration Filtration is commonly the mechanical or physical operation which is used for the separation of solids from fluids (liquids or gases) by interposing a medium (a permeable fabric or porous bed of materials) through which only the fluid can pass. The solid can be retained on the surface of the filter medium, which is cake filtration, or captured within the filter medium, which is depth filtration. 5. Scrubbing This method is commonly used to separate gas-solid mixtures. Very high particles collection efficiencies are possible with venturi scrubbers. The main problem with venturi scrubbers is the high pressure loss across the device. 6. Flotation Flotation is a gravity separation process that exploits the differences in the surface properties of particles. The separation process is based on the use of very fine gas bubbles that attach themselves to the solid particles in suspension to make them buoyant and drive them toward the free surface of the liquid. Flotation is especially useful to separate very small particles or light particles with low settling velocities. A number of chemicals can be added to the flotation medium to meet the various requirements of the flotation process. Flotation requires the generation of small bubbles which can be produced by: a. dispersion, in which the bubbles are injected directly by some form of sparging system b. dissolution in the liquid under pressure and then liberation in the flotation cell by reducing the pressure c. electrolysis of the liquid
- 10. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 10 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. 7. Drying Drying is the removal of water moisture or moisture from another substance, by a whole range of processes, including distillation, evaporation and even physical separations such as centrifuges. Separator Vessel Generally, there are two types of vessel in chemical processing service: those substantially without internals and those with internals. The first types are commonly used as an intermediate storage or surge of a process stream for a limited or extended period, or to provide a phase separation by settling. The second category includes the shells of equipment such as heat exchangers, reactors, mixers, fractionators, and other equipment whose housing can be designed and constructed largely independently of whatever internals are necessary. Separator vessel thus simply means as a vessel or tank without internals to provide a phase separation. This separator vessel furthermore can be classified into several categories based on their function. However, generally the classification in this guideline as pictured on Figure 1 below.
- 11. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 11 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Figure 1. General types of separator vessel Solid-solid separator is not included here since the separation process mostly takes part on a sieve, not in a vessel as the other phases separation. Separator vessels usually contain as follow: 1. Primary section. 2. Secondary section (gravity settling). 3. Coalescing section. 4. Sump or liquid collecting section.
- 12. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 12 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Figure 2. Major components of horizontal separator Geometrically, all process vessels might be horizontal, vertical, or spherical. The horizontal and vertical types are commonly used, while the spherical separators are occasionally used for high pressure service where compact size is desired and liquid volumes are small. Two Phase Separator Vapor-Liquid Separator 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 and chemical plants Refrigeration systems
- 13. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 13 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Air conditioning Compressor systems for air or gases Gas pipelines Steam condensate flash drums 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 [2]: 1. Primary separation section (entrance): 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.
- 14. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 14 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Figure 3. Internal parts of (a) vertical separator and (b) horizontal vapor-liquid separator 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. An inlet diverter produces the initial gross separation of liquid and vapor, as the sudden change in momentum occurs when the fluid enters the separator and hit it. Commonly, the inlet diverter contains a downcomer that directs the liquid flow below the oil or water interface. The inlet diverter assures that little gas is carried with the liquid. Some functions of inlet devices are: Reduces momentum of inlet stream Provides primary (bulk) separation of gas and liquid
- 15. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 15 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Enhances flow distribution of gas and liquid phases Prevents droplet shattering and re-entrainment of bulk liquid phases Stable liquid level control and reduced foaming The impingement or settling internal might be added to optimized separation process. As the descriptive name suggests, the impingement separator allows the particle to be removed to strike some type of surfaces. There are basically three construction types for impingement separator: wire mesh, plates (curved, flat, or special shaped), and packed impingement beds. The vapor-liquid separators which are generally used in industries might be classified into followings [3]: 1. Gravity separators The separation process in this gravity separator occurs by settling and sedimentation and depends on gravitational force. Liquid droplets or solid particles will settle out of a gas phase if the gravitational force acting on the droplet or particle is greater than the drag force of the gas flowing around the droplet or particle. The same phenomenon happens for solid particles in liquid phase and immiscible sphere of a liquid immersed in another liquid. Gravitational forces control separation; the lower the gas velocity and the larger the vessel size, the more efficient the liquid/gas separation. Because of the large vessel size required to achieve settling, gravity separators are rarely designed to remove droplets smaller than 300 microns. Gravity separators are not recommended as the soul source of removal if high separation efficiency is required. Gravity separators are sometimes also called scrubbers when the ratio of gas rate to liquid rate is very high. These vessels have a small liquid collection section and are recommended only for the following items: a. Secondary separation to remove carryover fluids from process equipment such as absorbers and liquid dust scrubbers. b. Gas line separation downstream from a separator and where flow lines are not long.
- 16. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 16 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. c. Miscellaneous separation where the gas-liquid ratio is extremely high 2. Centrifugal vapor-liquid separators Utilize centrifugal action for the separation of materials of different densities and phases, might be built in stationary and rotary types. In centrifugal separators, centrifugal forces act on droplets at forces several times greater than gravity as it enters a cylindrical separator. Generally, centrifugal separators are used for removing droplets greater than 100 μm in diameter, and a properly sized centrifugal separator can have a reasonable removal efficiency of droplet sizes as low as 10 μm. Centrifugal separators generally might be divided into three types: stationary vane separator, cyclone separator, and inertial centrifugal separator. Cyclones and knock-out drums are recommended for waxy or coking materials. The efficiency of each of three types can be estimated using Table 1 below. Table 1. Efficiency of centrifugal separator Types Efficiency Range High velocity stationary vanes 99% or higher of entering liquid. Residual entrainment 1 mg/kg (ppm) or less. Cyclone separator 70-85% for 10 micrometers, 99% for 40 micrometers, and larger. For high entrainment, efficiency increases with concentration. Rotary 98% for agglomerating particles 3. Vapor-liquid filter separators They are used in separation of liquid and solid particles from gas stream. Gas filter separator has a higher separation efficiency than the centrifugal separator, but it uses filter elements which must periodically be replaced. Typical applications of gas filter separators are as follows: - Compressor stations to protect compressors from free liquid and prevent cylinder wear from solids.
- 17. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 17 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. - Metering and pressure reduction stations at city gates: to remove liquid hydrocarbons, water, sand and pipe scale. - Protection of desiccant beds and collection of dust carry-over from beds. - Gas storage systems: to prevent injection or withdrawal of solids, dust, and small amounts of liquids. - Fuel lines to power plants and engines. Liquid-Liquid Separator [4] Separating liquid-liquid dispersions can be difficult depending on the physical properties of the two liquid phases. The specific gravity, viscosity and interfacial tension (IFT) of the two liquid phases are important parameters in determining how easy two liquids can be separated. Liquid-liquid separator might be divided into two broad categories based on their operation. The first is defined as “gravity separation” where the two immiscible liquid phases separate within the vessel by the differences in density of the liquids. Differences in densities of the two liquids cause droplets to rise or fall by their buoyancy. The greater the difference in densities, the easier the separation becomes. Rising (or falling) droplets are slowed by frictional forces from viscous effects of the opposing liquid. Sufficient retention time must also be provided in the separator to allow for the gravity separation to take place.
- 18. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 18 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Figure 4. Typical arrangement of gravity settler The second category is defined as “coalescing separation”. This is where small particles of one liquid phase must be separated or removed from a large quantity of another liquid phase. Liquid-Liquid coalescers are used to accelerate the merging of many droplets to form a lesser number of droplets, but with a greater diameter. Settling of the larger droplets downstream of the coalescer element then requires considerably less residence time. There are three-step methods of coalescing separation: collection of individual droplets; combining of several small droplets into larger ones; and rise (or fall) of the enlarged droplets by gravity. This application is common in the quench section, compression section and hot fractionation section. The coalescers might be designed vertically or horizontally. The vertical design is used to separate water from hydrocarbons when the interfacial tension is greater than 3 dyne/cm. In the horizontal configuration, a settling zone achieves separation by gravity. This configuration is used when the interfacial tension is less than 3 dyne/cm or for the separation of oil from the water phase.
- 19. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 19 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Here is a picture of vertical and horizontal coalescer. Figure 5. Vertical coalescer
- 20. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 20 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Figure 6. Horizontal coalesce Different coalescing materials have been found suitable for different applications. Commercially, fiberglass seems to be the most popular medium due to its availability and low cost. Table 3 below shows different coalescing medias with their different surface properties, cost and fouling properties. Table 2. Coalescing media Media Surface Characteristic Porosity Size Fouling/sot Metal/plastic corrugated sheets Hydophilicity, oleophilicity 98-99% 9,5-25,4 mm Spacing/Crimps Low/Low Wire/Plastic Mesh Hydrophilicity, Oleophilicity 95-99% 0.05-0.279 mm Wire wool Hydrophilicity 95-99% 0.05-0.279 mm
- 21. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 21 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. In addition to the numerous coalescing media, Table 4 presents some coalescing media and their industrial applications with regard to the nature of emulsions they separate (emulsion source), flowrate and maximum droplet diameter. Table 3. Coalescing media and their applications Media Source Max. Droplet Diameter (μm) Flow Range (gpm/ft2 ) Corrugated sheets Separators with coarse emulsions and static mixers. 40-1000 15-75 (35-180 m3 /hr/m2 ) Wire mesh, wire wool Extraction columns, Distillation tower feeds, impeller mixers. 20-300 7,5-45 (35-180 m3 /hr/m2 ) Co-knits of wire and polymer Steam stripper bottoms, Caustic wash drums, High pressure drop mixing valves. 10-200 7,5-45 (35-180 m3 /hr/m2 ) Glass mat, co-knits of wire and fiberglass Haze from cooling in bulk liquid phase, Surfactants giving, Emulsions with very low interfacial tension. 1-25 7,5-45 (35-180 m3 /hr/m2 ) Vapor-solid separator [5] The most commonly encountered two phase vapor-solid separator in process industry is the decoking drum. A Decoking drum is provided for decoking of furnace tubes. Inlet stream to decoking drum may consist of steam, air and coke particles. Separation of coke particles from gases is essential to prevent coke particles being discharged to atmosphere or heater stack.
- 22. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 22 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Separation of solid particles from vapor phase occurs under the influence of gravity. Forces which affect the rate of settling of solid particles are: (i) gravity force (ii) drag force due to relative motions (iii) buoyancy force Liquid-solid separator [6] Solid-liquid separation processes are generally based on either one or a combination of gravity settling, filtration, and centrifugation principles. In gravity settling separation, solid particles will settle out of a liquid phase if the gravitational force acting on the droplet or particle is greater than the drag force of the fluid flowing around the particle (sedimentation). Mechanical separation by filtration involves passage of most of the fluid through a porous barrier which retains most of the solid particulates or liquid contained in the mixture. Centrifugal separation occurs by changing the direction of two phase stream sharply, thus the greater momentum will not allow the particles of heavier phase to turn as rapidly as the lighter fluid and separation occurs. Some commonly used liquid-solid separators are filters, centrifuges, hydrocyclones, and gravity settlers.
- 23. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 23 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Three Phase Separator Vapor-liquid-liquid separator [7] Three phase separation is commonly applied when there are water, liquid hydrocarbon and hydrocarbon gases in the process stream. As with two phase design, three phase units can be either vertical or horizontal. Vertical vessel is mainly applied when there is a large amount of vapor to be separated from a small amount of the light and heavy fluid (less than 10-20% by weight). Horizontal vessels are most efficient where large volumes of total fluid and large amounts of dissolved gas are present with the liquid. An example for vertical vessels is the compressor suction drums while good representative of horizontal vessel is the spent caustic deoiling drum. Figure 7. Horizontal 3-phase separator
- 24. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 24 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Figure 8. Vertical 3-phase separator The three phase separation vessel commonly contains four major sections as listed below: a. The primary separation section used to separate the main portion of free liquid in the inlet stream b. The secondary or gravity section designed to utilize the force of gravity to enhance separation of entrained droplets. c. The coalescing section utilizes a coalescer or mist extractor. Our normal application is using a knitted wire mesh pad on top of vessel. d. The sump or liquid collection section acts as receiver for all liquid removed from gas in the primary, secondary, and coalescing section.
- 25. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 25 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. A vane-inlet device might be used in this separator to gradually reduce the inlet momentum and evenly distribute the gas phase across the vessel diameter. Such device can also act as the first-stage gas-liquid separation. In the gas-liquid portion of the vessel, a wire-mesh mist eliminator provides high separation efficiency. For the liquid-liquid separation in the bottom of the drum, the first-stage is typically some type of enhanced-gravity separation media. If very high separation is required, adding a second “polishing” stage provides the ability to remove the last remnants of entrainment.
- 26. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 26 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. DEFINITIONS Accumulators- These are storage tanks following distillation column condensers. For partial condensers, this flow may be a mixture of vapor and liquid. The outlet flow may be regulated by a level controller in order to avoid the tank either flooding (liquid out the top) or going dry (vapor out the bottom). Coalescer- A mechanical process vessel with wettable, high-surface area packing on which liquid droplets consolidate for gravity separation from a second phase (for example gas or immiscible liquid). Control Volume- A certain liquid volume necessary for control purposes and for maintaining the velocity limit requirement for degassing and to counter foam in separators. Conventional Gas-Liquid Separator- Vertical or horizontal separators in which gas and liquid are separated by means of gravity settling with or without a mist eliminating device. Critical Diameter- Diameter of particles larger than which will be eliminated in a sedimentation centrifuge. Demister Mist Extractor- A device installed in the top of scrubbers, separators, tray or packed vessels, etc. to remove liquid droplets entrained in a flowing gas stream. Disengaging Height- The height provided between bottom of the wire-mesh pad and liquid level of a vapor-liquid separator. Fabric Filter- Commonly termed "bag filters" or "baghouses", are collectors in which dust is removed from the gas stream by passing the dust-laden gas through a fabric of some type. Filter- A piece of unit operation equipment by which filtration is performed. Filter Medium- The "filter medium" or "septum" is the barrier that lets the liquid pass while retaining most of the solids; it may be a screen, cloth, paper, or bed of solids.
- 27. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 27 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Filtrate- The liquid that passes through the filter medium is called the filtrate. Flash drums- Vessels into which flow a mixture of liquid and vapor. The goal is to separate the vapor and liquid. For design calculations it is normally assumed that the vapor and liquid are in equilibrium with one another and that the vessel is adiabatic (no heat lost or gained). One must simultaneously satisfy a material balance, a heat balance, and equilibrium. Flash Tank- A vessel used to separate the gas evolved from liquid flashed from a higher pressure to a lower pressure. Hold-Up Time- A time period during which the amount of liquid separated in a gas- liquid separator is actually in the vessel for the purpose of control or vapor separation. Knock-Out- A separator used for a bulk separation of gas and liquid. Line Drip- A device typically used in pipelines with very high gas-to-liquid ratios to remove only free liquid from a gas stream,and not necessarily all the liquid. Mesh- The "mesh count" (usually called "mesh"), is effectively the number of openings of a woven wire filter per 25 mm, measured linearly from the center of one wire to another 25 mm from it. Open Area- A percentage of the whole area of a woven wire filter. Overflow- The stream being discharged out of the top of a hydrocyclone, through a protruding pipe, is called "overflow". This stream consists of bulk of feed liquid together with the very fine solids. Scrubber- A type of separator which has been designed to handle flow streams with unusually high gas-to-liquid ratios. Slug Catcher- A particular separator design able to absorb sustained in-flow of large liquid volumes at irregular intervals.
- 28. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 28 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Surge tanks- These are storage tanks between units, and can serve a variety of purposes. They can dampen fluctuations in flow rate, composition or temperature. They can allow one unit to be shut down for maintenance without shutting down the entire plant. Target Efficiency- The fraction of particles or droplets in the entraining fluid of a separator, moving past an object in the fluid, which impinge on the object. Terminal Velocity or Drop-Out Velocity- The velocity at which a particle or droplet will fall under the action of gravity, when drag force just balances gravitational force and the particle (or droplet) continues to fall at constant velocity. Underflow- The stream containing the remaining liquid and the coarser solids, which is discharged through a circular opening at the apex of the core of a hydrocyclone is referred to as "underflow". Vapor Space- The volume of a vapor liquid separator above the liquid level.
- 29. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 29 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. NOMENCLATURE A Vessel cross-sectional area, ft2 Ah Head surface area, ft2 ALLL Low liquid level area, ft2 ANLL Normal liquid level Area, ft2 As Shell surface area, ft2 AV Vapor disengagement area, ft2 D Vessel diameter, ft Dp Diameter of particle or droplet, ft DVD Vessel inside diameter, ft E Joint efficiency, % G Gravitational force, ft/s2 HD Disengagement height, in HH Hold-up height, ft HLLL Low liquid level height, in HME Mist eliminator height, ft HNLL Normal liquid level height, ft Hs Surge height, ft HUN HLLL to the centerline of nozzle height, in HV Height of vapor disengagement area, ft K Sounders-Brown constant, ft/s L Vessel Length, ft Lmin Minimum vessel length requirement, ft M Fraction of vertical area filled with liquid ML Liquid mass flow rate, lb/h MV Vapor or gas mass flow rate, lb/h P Vessel design pressure, psia or psig Pop Vessel operating pressure, psia QL Liquid volumetric flow rate, ft3/min QV Vapor or gas volumetric flow rate, ft3/s Qo Oil volumetric flow rate, ft3/s Qw Water volumetric flow rate, ft3/s S Allowable stress, psig T Vessel design temperature, °F TH Hold-up time, min
- 30. KLM Technology Group Practical Engineering Guidelines for Processing Plant Solutions Kolmetz Handbook of Process Equipment Design SEPARATOR VESSEL SELECTION, SIZING AND TROUBLESHOOTING ENGINEERING DESIGN GUIDELINES Page 30 of 120 Rev: 03 JAN 2015 These design guideline are believed to be as accurate as possible, but are very general and not for specific design cases. They were designed for engineers to do preliminary designs and process specification sheets. The final design must always be guaranteed for the service selected by the manufacturing vendor, but these guidelines will greatly reduce the amount of up front engineering hours that are required to develop the final design. The guidelines are a training tool for young engineers or a resource for engineers with experience. This document is entrusted to the recipient personally, but the copyright remains with us. It must not be copied, reproduced or in any way communicated or made accessible to third parties without our written consent. Top Vessel operating pressure, °F TS Surge time, min tc Corrosion allowance, in t Shell thickness, in th Head thickness, in tr Retention time, min tro Oil retention time, min trw Water retention time, min VT Terminal velocity, ft/s Vmax Maximum allowable gas velocity, ft/s VV Vapor velocity, ft/s W Vessel weight, lb Greek Letters μ Viscosity of flowing fluids, cp ρV Vapor or gas density, lb/ft3 ρL liquid or oil density, lb/ft3 ø Liquid drop out time, s