FLUIDS/SOLIDS HANDLING Design Two-Phase Separators Within the Right Limits Ss Here is a proven, step-by-step method. WY. Svrcek, W.D. Monnery University of Calgary iquid/vapor separators are one of the most common types of process equipment. Many technical papers Jhave been written on separator design and vast amounts of information are also available in corporate process engineering design guidelines. The basic equations used for sizing are widely known; however, subjectivity exists dur- ing the selection of the parameters used in these equations. This article attempts to address the basics of two-phase separator design and provide step-by-step proce- dures and examples for two-phase vapor/liquid separator design. ‘Two-phase separator types and selection ‘Two-phase separators may be oriented either vertically or horizontally. In some cases, it may be necessary to compare both designs to determine which is more economic. Separators may be designed with or without mist eliminator pads and may also have inlet diverters. Some sepa- rators may have proprietary impingement or settling internals. The vendor should be contacted to design these types of v Vertical vapor/liquid separators are pre ferred for separating liquid from mixtures with a high vapor/liquid ratio while hori zontal separators are preferred for sep: rating vapor from mixtures with a low vaporfliquid ratio. Background Vapor/liquid separation is accompli ly ed in three stages. The first stage, primary separation, uses an inlet diverter so that the momentum of the liq- uid entrained in the vapor causes the largest droplets to impinge on the diverter and then drop by gravity. The next stage, secondary separation, is gravity separa- tion of smaller droplets as the vapor flows through the disengagement area. The final stage is mist elimination where the small- est droplets are coalesced so that larger droplets are formed which will separate by gra For secondary separation, the allow- able velocity must be calculated so that disengagement area can be subsequently determined. Performing a force balance on the liquid droplet settling out provides the necessary relationship, When the net gravity force, given by Eq. 1, a balances the drag force, given by Eq. 2, (2/8) RU py the heavier liquid droplets will settle at a constant terminal velocity, U,. Equating Eqs. | and 2 results in, / 48 D.(e.-Pv) 3CpPv Hence, as long as U, < U,, the liquid droplets will settle out. Typically, the allowable vertical velocity, Uy, is set U,= CHEMICAL ENGINEERING PROGRESS © OCTOBER 1993 * 53FLUIDS/SOLIDS HANDLING between 0.75U, and U,. Hg. 3 can be rearranged as Eq. 4. a Sauders-Brown ype equation (1) (eo. ~P. Po u, where [4D 5) where K= V 3G, Practically. very small droplets not be separated by gravity alone. These droplets a er droplets which will settle by gravity. Coaleycing devices in separa tors force the gas to follow a tortuous path and the momentum of the Groplets causes them to collide with other droplets or the coalescing device, forming larger droplets. The coalesced droplet diameter is not ade- coalesced to form ——— When calculating U, for a horizontal separator, a “no mist eliminator K value” should be used. quately predictable so the K values Tor mist climinators are typically empirical. This 1 where subjectivity First enters separator design. There are several literature sources of K val- ues such as the Gas Processor’s Supplier (GPSA) “Engineering Data Book” (2), numer- ous technical publications and ven- dor's recommendations, The GPSA 2) and York Mist Eliminator (3) val- Association SECA Te Cl OCU Mist Eliminator 1s PENS ‘K=0.1821 + 0.00297 + 0.0480Ln (A) 15s Psa K=035 Prpsia 40s P5500 K=0430- 0028101) Psa OsPsi30 K=035-001(P- 100/100) Psio ‘*Mostvapars under vacuum K= 0.20, ‘For glycol and amine solutions, multiply Kby 0608, +For vertical vessels without mis eliminatars, divide K by 2, ‘For compressor suction scrubbers, mole sieve scrubbers and expander inlet ‘Separators multiply Kby 07-08. ‘Theoretical (no mist eliminator) Ye R411 ~2248X + 0.273X'~ 1.8656 -2%+ 5201 ~ xt ed vfesacsepion ta) He Notes: Dt Pte wer ‘micron = 328084 x 10¥ft 54 © OCTOBER 1999 + CHEMICAL ENGINEERING PROGRESS tues have been curve fitted and are given in Table | If there is: no mist eliminator. itis recommended to use one half of the above values (2) or the “theoretical value & can be calculated from Eg, $ if the Tiguid droplet size is known. The drag coefficient, C,, has been curve fit ted and is given in Table 1 or can be obtained thom Figure 7-3 in the GPSA Engineering Data Book” (2). Betore proceeding, itis worthwhile to clarify some definitions and criteria. Holdup is detined ay the time it takes to reduce the liquid level from normal (NLL) to empty (LLL) while maintain ing a normal outlet flow without feed makeup. Surge time iy defined as the time it takes for the liquid level to rise from normal (VEL) to maximum (HLL) while maintaining a normal feed without any outet flow, Som guidelines base “Surge” on the volum between low (LLL) and bigh (HLL) liquid levels. Holdup time is based on the reserve required to maintain good control and safe operation of down: Stream facilities. Surge time is usually based on requirements to accumulate Jiquid as a resull of upstream or down- Stream variations oF upsets, for exam- plo. slugs. In the absence of specific requirements. surge time may be taken as one half of holdup time. Vertical separators. For vertical separators, the vapor disengagement area is the entire cross-sectional arew of e vessel so that vapor disengagement diameter cant be calculated from Ey. 6: ) RU cchnically, this is the mist eliminator ameter and the inside diameter of the vessel must be slightly larger so that the mist climinator can be installed inside the vessel. Typically, the caleu- lated value is taken up to the next six in, This value is taken as the required diameter of the vessel, D. and the cor responding cross-sectional are, A, is calculated using this diameter The next step in sizing a vertic separator is to determine the heiFor a two-phase vertical sep. total height can he broken tions, ay shown in Fi rator he adding the hy as per Eq. 7. ated by ts of these sections, MeHg +H, tH eH, +H, Ia mist eliminator pad is used. additional height is added, as shown in Figure 1, The calculations of diameter and height are detailed in the “Design Procedures” section of this article Horizontal separators, For hoti- zontal two-phase separators, the cross-section is oceupied by both vapor and liquid, as shown in Figure 2. When sizing horizontal two-phase separators, usually a diameter is assumed, LLL is selected or caleulat= ed. NLL is set by liquid holdup, and HLL. is set by liquid surge. The eross- sectional area between HLL and the Lop of the vessel is used for vapor disengagement. The length of the vessel is then calculated lo accom- modate holdup and surge or to facili- tate vapor liquid separation. Hence, this approach to sizing horizontal separators. oF variations of it, are iterative calculations, The following will develop the asic equation used for calculating the size of a horizontal separator. For a horizontal separator cross section, a ‘volume balance” iy written. Vy tMELA, AA) (8) Holdup and surge volumes are caleu- lated from holdup and surge times which are selected according to guide- lines. The low liquid level area is a Function of the lov tiquid level height, ‘obtained from guidelines, and the ve sel inside diameter. The minimum vapor disengagement area , Ay, is lypically specified as or wo two fh or 20% of the vessel inside diameter, whichever is greater, The sizing method in the “Design Procedures” section of this article assumes this for A,,,and only inereases it if the length Wahaxt Mist liminator wat Vapor Mist Eliminator Outlet igus urlet Nozzle Figure T. Vertical two-phase separator. required for vapor-liquid separation is much greater than the length requited for holdup and surge, for # given diameter, Equation 8 is then a fune- tion of the inside diameter. D, and length, l. For horizontal separators, the lig- uid droplet to be separated from the sas has @ horizontal drag force which is not directly opposite to gravity yin the vertical case, Without detailed treatment of two-dimensional particle motion, most literature sources reco- nize that the allowable horizontal velocity can be higher than the termi- nal velocity (2, 5, 7). This ean be ioereececeoenr reel If a mist eliminator pad is used, additional height is added. shown simply by equating the “resi- ce" times of the Fiquid dropiet w be settled. That i, the time it takes ¥9 travel the horizontal Hength between inet and outlet must be greater than dei the time it tikes wo settle the vertical distance 1 the Figuid surface Lath Wu? U, ° This can be rearranged in terms of the allowable horizontal velocity i) ‘The length, L, divided by the heigit of the vapor disengagement area, Hy, would always be greater than unity The allowable horizontal velocity isa very subjective topic with several empirical approaches to modify the vertical "A" value available in the lit erature (2, 5. 7, 8). For horizontal sep- arator design, the subsequent design procedures use a “droplet settlin approach” similar to the API proce- dure (6) which does not require empirical modification of the "A val- ue for vertical settlers. It should be noted that when calculating U, for a horizontal separator. “no mist elini- nator K value” should be used. Design Procedures ‘The Following design procedures and heuristics are a result of a review of literature sources and accepted industrial design guidelines. The hori- vontal design procedure incorporates optimizing the diameter and length by minimizing the weight of the shell and heads. To add a degree of conser vatism to the design, the volume available in the heads iy ignored. Vertical design procedure (See Figure 1): 1, Calculate the vertical terminal vapor velocity x [Pu Pe k [Pa u Set U, = 0.75U, for a conservative design. Culeulate the K value from Table 1. CHEMICAL ENGINEERING PROGRESS © OCTOBER 1982 © 55