CHAPTER NO.

8 2- Phase Separator Design

2-PHASE SEPARATOR DESIGN

8.1 Introduction
The vapor liquid separators are used to separate two phase inlet into pure vapors
and pure liquid. It basically helps in recovering valuable products and improves
product purity. If two phase separators are used after flashing a hot liquid across a
valve, it is called a flash separator.

8.1.1 Significance in Process

Flash Separators are preferred when the relative volatility difference between
the components is high. In our case it is used to recover the 50% of maleic anhydride
from feed stream coming from the reactor, along with this 2.5% of water and 33% of
quinone are also separated. The theme behind the 50% separation of maleic anhydride
at this point is that; if a high concentration of maleic anhydride is allowed to go along
with the gases in the scrubber, it would cause choking of the plates because of the low
solidification point of 52.4 oC.

8.1.2 Types of Separators

1. Vertical Separator
2. Horizontal Separator
3. Knockout Drum

8.1.2.1 Vertical Separator

 Used where vapor flow is large as compared to liquid flow.
 Good separation efficiency.
 By rule of thumb it is commonly preferable in oil refineries.
 50% LL must be retained in the separator during operation.

8.1.2.2 Horizontal Separator

 Used when the liquid content of the incoming stream is high.

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8.1.2.3 Knockout Drum

 Used when the liquid content of the incoming stream is very low.
 Normally used before a compressor inlet to prevent liquid drops from entering
and damaging the compressor.

8.1.3 L/D ratio specification

 (L/D) ratio is 2 for the case of knockout drum.
 If length to diameter (L/D) ratio lies between 3 and 5, then it will be vertical
separator.
 If length to diameter (L/D) ratio is greater than 5 then it will be horizontal
separator.

Fig 8.1

8.2 Phenomenon

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CHAPTER NO. 8 2- Phase Separator Design

The vapor & liquid mixture is separated by gravity and impaction in the
separator. The mixture enters the separator and strikes the splash plate where it loses
its momentum. Most of the liquid flows downwards and vapors along with liquid drop
flow upward. As the vapor rises, large drops settle to the bottom of separator by
gravity. Normal separation efficiency is 95% which can be increased to 99.9% by
using a mist eliminator. Vortex formation must be prevented to reduce gas
entrainment in the liquid by using a vortex breaker at the bottom.

8.3 Selection of Knockout drum

 Knock-out drum is a special case of a gas-liquid separator, used when the
liquid content of the incoming stream is very low.
 In our case the liquid contents in the feed stream are only 8% by weight.

8.4 Material and energy balance

Vapour outlet
(11)

V-100
T=76.3oC
Feed stream P=152
(9) kPa

Liquid outlet
(10)

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CHAPTER NO. 8 2- Phase Separator Design

8.4.1 Material balance

Components
Liquid
Feed flow Vapour
Mol Wt NBP flow rate
o
rate flow rate
(Kg/Kgmol) C (kg/hr)
(kg/hr) (kg/hr)

Nitrogen 28.01 -195.8 50664.59 --- 50664.59

Oxygen 32 -182.9 10155.51 --- 10155.51
Water 18.02 100 2437.75 60.94 2376.81
CO2 44.01 -78.55 3902.87 --- 3902.87
MAN 98.06 202 2534.17 1267.09 1267.09
Benzene 78.11 80.09 221.38 --- 221.38
Quinone 108.1 180.85 60.25 20.44 39.8072
Total 69976 1348 68628

8.4.2 Energy balance

Liquid stream Vapour stream

Feed stream (9)
(10) (11)
o
Temperature C 76.37 76.37 76.37
Ref. Temp oC 30 30 30
Pressure kPa 152 152 152
Heat Capacity
31.652 167.79 30.697
(Kj/kgmol-0C)
Molar flow
2379 16.51 2362.49
(Kgmol/hr)
Q
3491666 128454.8 3362815
(Kj/hr)

8.5 Standard Design Steps

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CHAPTER NO. 8 2- Phase Separator Design

1) Vapour velocity factor

2) Max vapour velocity
3) Determine the cross-sectional area
4) Determine the diameter
5) L/D Ratio
6) Length of the drum

8.5.1 Operating Conditions


Operating temperature = 76.3o C

Operating pressure = 152 kPa

Design Temperature = 80 o C

Design Pressure = Pd = 167 kPa

Liquid density = δL = 1234.9 kg/m3

Vapour density = δv = 1.5193 kg/m3

Condition: To recover (50% by weight) Maleic Anhydride.

8.5.2 Design Calculations

 Vapour velocity factor :

Kv = 0.107 m/s with a mist eliminator

 Max vapour velocity (Shouder Brown Eq.):

Uv = Kv*{(δL-δv)/δv} ^0.5
Uv = 3.04 m/s

 Vapour volumetric flow rate :

Qv = (Fv / δv )* (1/3600)
Qv =12.54 m3 /s

 Cross-sectional area:

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CHAPTER NO. 8 2- Phase Separator Design

Av = Qv / Uv
Av = 4.11 m2

 Diameter :
D= (4 Av /π) ^0.5
D= 2.29 m

 Round off Diameter:

D= 2.29 + 0.152
D= 2.44 m

 L/D Ratio for knock-out drum:

L/D = 2

 Length of drum:
L = 4.88 m

8.6 Mechanical Design

1) Material of construction
2) Volume of the vessel
3) Shell thickness
4) Head selection
5) Head thickness
6) Support
7) Weight calculations
8) Wind design calculations
9) Seismic design calculations
10) Internal accessories
11) Design verification using PV-Elite.

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CHAPTER NO. 8 2- Phase Separator Design

8.6.1 Material of construction

• Head/shell material : SA-516 Grade 70
• Moderate temperature service
• Design strength = 20,000 Psi
• More economical as compared to stainless steel
• Nozzle material : SA-106 Grade B
• Bolt material : SA-193 Grade B7
• Skirt material : SA-36
• Flange material : SA-105

8.6.2 Volume of the vessel

Volume of the shell = Vs = (π/4) D2 L
Vs=22.81 m3
And,
Volume of the head = Vh = 0.0847D3
Vh = 1.23 m3 * 2 = 2.46 m3
So,
Volume of the vessel = V = 25.27 m3

8.6.3 Shell thickness

Shell factor (αs) = Pd/ (2ЄS-1.2Pd)
Where:
αs = Shell factor
Є = Weld efficiency = 1
S = Design strength = 13789 kPa
Pd = Design pressure (1.10*Po)
So,
Shell factor = αs = 0.00061

Shell thickness (Ts) = (αs*D) +tc

Where:
Ts = Shell thickness
tc = Corrosion allowance = 3.2mm

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CHAPTER NO. 8 2- Phase Separator Design

D = Diameter
So,
Shell thickness = Ts= 0.00468m
(4.68mm)
8.6.4 Head selection
i) Torispherical (for P<1134.97 kPa)
ii) Ellipsoidal (for P>1134.97 kPa)
iii) Hemispherical for very high pressure

In our case the design pressure = 167 Kpa

So,
Head selected is torispherical head

Fig 8.2

8.6.5 Head thickness

Head Factor (αh) =1.104*Pd/ (2ЄS-0.2Pd)
Where:
αh = Head factor
Є = Weld efficiency = 1
S = Design strength = 13789 kPa
Pd = Design pressure (1.10*Po)
So,
Head factor = αh= 0.00067

Head thickness (Th) = (αh*D) +tc

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CHAPTER NO. 8 2- Phase Separator Design

Where:
Th = Head thickness
tc = Corrosion allowance = 3.2mm
D = Diameter
So,
Head thickness = Th= 0.00483m
(4.83mm)

8.6.6 Support
These types of supports are available:
 Saddle support
 Skirt support
 Bracket support

Saddle type support is used for horizontal vessels. Skirt type is used for very tall
vessels. Bracket type is used for all types of vessels, normally for low height vessels.
Therefore, I am using Skirt support. It is a carbon steel plate welded in a round shape
at the bottom of the vessel for its support.

Skirt support results

 Skirt thickness 0.1875 in
 Skirt height 48 in
 Thickness of Base ring 1.00 in.
 Inside Diameter of Base ring 96.063 in.
 Outside Diameter of Base ring 110 in.
 Number of Bolts required 8

8.6.7 Weight calculations

1) Empty weight
2) Operational weight
3) Test weight

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8.6.7.1 Empty weight of the vessel

WE = WS + WH
Where :

Ws: weight of the shell

WH: weight of the heads

Weight of the shell

WS = π × D × ts × L × δ
Where:
D = diameter of the vessel = 2.44 m
ts = shell thickness = 0.00468 m
Ls = length of the shell = 4.88 m
δ = density of carbon steel = 7849.87 kg/m3
So,
Ws = 1374 kg

Weight of the heads

Wh = 0.9286D2*th*δ
Where:
D = diameter of the vessel = 2.44 m
th = head thickness = 0.00483 m
δ = density of carbon steel = 7849.87 kg/m3
So,
Weight of the head = 210 kg * 2 = 420 kg

So,
Empty Weight of the vessel= WE = 1794 kg

8.6.7.2 Operational weight of the vessel

Wo = WE + WF
Where:
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CHAPTER NO. 8 2- Phase Separator Design

WF: weight of fluid inside the vessel

WF = 111 kg
So,
Operational weight of the vessel = Wo = 1905 kg
8.6.7.3 Test weight
WT = WE + Ww
Where:
Ww : Weight of the water if completely filled in the vessel

Ww = 25270 kg
So,
Test weight = WT = 27064 kg

8.6.8 Wind design calculations

F = AfCfGhqz

Where :
F = design wind force, lbf
Af = projected area , ft2
Cf = shape factor (0.6)
Gh = exposure factor (1.27)
qz = wind pressure , psi

Projected area:
Af = h*De
where :
h = height including skirt = 21 ft
De = equivalent diameter = 1.4D= 11.2 ft Fig.8.3
So Forces and loadings
on uniform vessel
Af = 235.2 ft2

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CHAPTER NO. 8 2- Phase Separator Design

Wind pressure:
qz =0.00256Kz(IV)2
Where:
Kz= velocity pressure exposure coefficient = 0.93
I = importance factor = 1 for vessels
V= basic wind speed = 100 mph
So
qz = 23.81 psi

Design wind force:

F = 4593.86 lbf

8.6.9 Seismic design calculations

T=0.000265(H/D) 2√ (WoD/Ht)
Where:
T = period of vibration, sec
H = total height including skirt = 20 ft
D = diameter = 8 ft
Wo= operating weight of vessel, kips = 1905 kg = 4.19 kips
t = thickness of vessel = 0.1843 in
So,
T = 0.0003 sec

Structure response factor:

C=1/15√T
C = 3.9
Base shear:

V = ZICKSW

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CHAPTER NO. 8 2- Phase Separator Design

Where:
V = base shear, kips
Z = seismic zone factor = 0.375
I = occupancy importance factor = 1 for vessel
C = structure response factor
K = structural coefficient = 1.33 for vessel
S = structure resonance coefficient = 1.5
W = test weight of vessel = 59.66 kips
So,
V = 174 kips
Note:
If H/D≤3, then Ft=0
Ft= portion of seismic force applied at the top the vessel, kips

Lateral force:
F = V - Ft
Where:
F = lateral force, kips
V = base shear, kips
Ft = portion of seismic force applied at the top of the vessel, kips
So,
F = 174 kips
Overturning moment at base:
Mb = Ft H + 2/3(FH)
Mb = 2320 ft-kips

Moment at plane x:
Mx = Ft (H-hi) + F (2/3H-hi)
Where:
Mx = moment at plane x, ft-kips
hi = height from base to plane under consideration = 10 ft
So,
Mx = 580 ft-kips
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CHAPTER NO. 8 2- Phase Separator Design

8.6.10 Internal Accessories

1 Splash Plate
2 Vortex Breaker
3 Mist Eliminator

Fig 8.4

8.6.10.1 Splash Plate

It is used to cause the initial bulk separation of liquid and gas. It provides a
means to cause a sudden and rapid change of momentum (velocity and direction) of
the entering stream. If it is not present then the vapors will escape very rapidly
without contacting with liquid to establish equilibrium. See fig 8.5

8.6.10.2 Vortex Breaker

A vortex breaker is normally installed on the liquid outlet to prevent formation
of vortex when the liquid outlet valve is open. The formation of a vortex at the liquid
outlet may result in withdrawal and entrainment of gas with the exiting liquid. This
causes the loss of valuable vapors, pump damage and abnormal liquid level readings.
See fig 8.6

8.6.10.3 Mist Eliminator

Mist elimination or demisting can be defined as the mechanical separation of
liquids from gases. Mesh usually consists of 0.011inch diameter wires to form a pad
of 4 to 6 inches thick & pressure drop is less than 1inch of water.

Types of Mist Eliminator

1. Mesh type
2. Vane type
3. Fiber type

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 CHAPTER NO. 8 2- Phase Separator Design

8.6.10.3 (a) Mesh Type Mist Eliminator

It is efficient and economical for a wide range of applications. Porous blankets
of knitted metal or plastic wire mesh are designed. It is ideal for use in absorption and
drying towers, evaporators, distillation towers, stripping columns, scrubbers, steam
drums, separators, and knockout drums.
It has high collection efficiency, low pressure drop, lowest installed cost. But it
is not suitable for viscous fluids. See fig 8.7

8.6.10.3 (b) Vane Type Mist Eliminator

It consists of series of closely spaced parallel, corrugated plates or zigzag blades
either vertical or horizontal flow installations. As the gas and entrained liquid droplets
flowing between the plates change flow direction due to corrugations , the liquid
droplets impinge on the surface of the plates, where they coalesce and fall down into
the liquid collection section.
Ideal for applications where solids or viscous, sticky liquids rapidly plug a wire
mesh type mist eliminator. It has greatest resistance to fouling. These are usable in
either vertical (upward) or horizontal flow designs. Provide the lowest pressure drop
of any type mist eliminator. See fig 8.8
Mist Eliminator

8.6.10.3 (c) Fiber Type Mist Eliminator

It has highest collection efficiency of submicron particles. It consists of a
packed fiber bed between either two concentric screens or two flat parallel screens. It
captures submicron mist particles 0.1 microns or smaller. See fig 8.9

Figures

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CHAPTER NO. 8 2- Phase Separator Design

Fig 9.9

Fig 8.5 Fig 8.6

Fig 8.7 Fig 8.8

Fig 8.9

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CHAPTER NO. 8 2- Phase Separator Design

8.6.11 Design verification using PV Elite

8.7 Cost Front

estimation
view Fig 8.10 Right end view Fig 8.11

Right end transparentCross

view Fig
sectional
8.12 view Fig 8.13

8.7.1 Shell cost

Shell cost = π*D*ts*Ls*δ*cost factor
Where:

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CHAPTER NO. 8 2- Phase Separator Design

D = diameter of shell = 2.44 m = 96.063 in

ts = shell thickness = 4.68 mm = 0.1843 in
Ls = length of the shell = 4.88 m = 192.126 in
δ = density of carbon steel = 0.283 lb/in3
Shell cost factor = 1.35 $/lb
So,
Shell cost = $ 4080

8.7.2 Head cost

Head thickness = 4.83 mm = 0.1902 in
Market price of torispherical head of such thickness = $ 1700
Total head cost = $ 3400

8.7.3 Skirt cost

Skirt cost = π*Dm*tsk*Lsk*δ*cost factor
Where:
tsk = skirt thickness = 0.1875 in
Dm = mean dia = ID of skirt + skirt thickness = 96.063+0.1875= 96.25
in
Lsk = length of skirt = 48 in
δ = density of carbon steel = 0.283 lb/in3
Skirt cost factor = 1.25 $/lb
So,
Skirt cost = $ 962

8.7.4 Skirt base ring cost

Cost = π/4(Do2-Di2)*tskb*δ*cost factor
Where:
Do = outside dia of base ring = 110 in
Di = inside dia of base ring = 96.063 in
tskb = base ring thickness = 1 in
δ = density of carbon steel = 0.283 lb/in3
Skirt cost factor = 1.25 $/lb

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CHAPTER NO. 8 2- Phase Separator Design

So,
Base ring cost = $ 797

8.7.5 Internal accessories cost

Splash plate + Vortex breaker + Mesh pad = $ 500
8.7.6 Total material cost

Total material cost = $ 9739

8.7.7 Fabrication cost

Fabrication cost = 0.35 * total material cost
= $ 3409
8.7.8 Total cost
Material + Fabrication Cost = $ 13148

8.8 Specification Sheet

Unit name Knock out drum

Tag number V-100

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CHAPTER NO. 8 2- Phase Separator Design

No. required 1

Material Carbon steel: SA-516 Grade 70

Temperature 76.3o C

Pressure 152 KPa

Diameter 2.44 m

Length 4.88 m

Shell thickness 4.68 mm

Head thickness (Torispherical) 4.83 mm

Empty weight 1794 kg

Operational weight 1905 kg

Test weight 4321 kg

Support Skirt support

References
1. Harry Silla, Chemical Process Engineering Design & Economics, Marcel
Dekker,Inc. 2003, United States of America.
2. Alain Chauvel & Gilles Lefebvre, Petrochemical processes
3. ASME Codes section II Part D Table (1A)

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4. Specialty Process Equipment Corporation Pvt. Ltd. (SPEC)

5. Branan C.R., Rules of Thumb for Chemical Engineers, Gulf Publishing
Company, 1995, United States of America.
6. Dennis R. Moss, Pressure Vessel Design Manual, Gulf Publishing company
Houston London, Paris Tokyo.
7. Eugene F. Megyesy, Pressure vessel handbook, 12th Ed, Pressure Vessel
Handbook Publishing Inc.
8. Coulson & Richardson, Chemical Engineering Design, 6th Volume, 3rd Edition,
Butterworth-Heinemann, Reviewed 2001, 2003. Great Britian.
9. Smith J.M., Van Ness H.C., Abbott M.M., Introduction to Chemical
Engineering Thermodynamics, Ed. 6, Tata McGraw Hill Publishing Company
Limited, New Delhi (2006).
10. Perry R.H.,Green D.,Perry’s Chemical Engineers Handbook - 7th Edition,
McGraw Hill Publishing Company Limited

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