Calculation of a Gas-Liquid Separator or Flash Drum

The Mott Souders - George Granger Brown Equation is:

Vmax = (K) [ (rL - rV) / rV ]0.5

where,
Vmax = the maximum allowable superficial vapor velocity through the vessel = 7.5 ft/sec
rL = the density of the liquid entering the vessel = 54.00 lb/ft3
rV = the density of the vapor entering the vessel = 0.06 lb/ft3
K = an empirical constant whose value depends on the type of vessel, the
use of internals, and the height of the disengaging space above any
mesh employed. = 0.25

Values of "K" are found in Ernest Ludwig's "Applied Process Design for Chemical and Petrochemical Plants",
Volume 1, chapter 4:
K Values for Knitted Mesh
(Bottom of mesh shuld be at least 12 inches above the liquid surface)
Service Conditions K" Value General type mesh

Clean fluids, moderate liquid load; fits 90% 0.36 Standard design
of process situations and applications. 0.35 High efficiency (?)
(the rating description is probably backwards…) 0.25 Very high efficiency (?)

High viscosity; dirty, suspended solids 0.40 Low density or Herringbone, high
through-put
Vacuum operations:
2" Hg absolute 0.20 Standard design
16" Hg absolute 0.27 High Efficiency
Corrosive chemical 0.21 Plastic coated wire, or plastic strand

Variations of K with Disengaging Height

Disengaging height above
Allowable "K" value
mesh, inches
3 0.12
4 0.15
5 0.19
6 0.22
7 0.25
8 0.29
9 0.32
10 0.35
11 0.38
12 0.40
13 0.42
14 0.43
This table is from Otto H. York data.
Values based on 12 lb/ft3 wire mesh. Design practice
normally does not exceed k of 0.4 even for higher
disengaging height.

Additionally, the GPSA Engineering Data Book (11th Edition, electronic) states that vertical separators
have a K factor (in ft/sec) value of 0.18 to 0.35. It recommends adjustment of the K factor due to system
pressure:
Pressure % of K
atm. 100
150 psi 90
300 psi 85
600 psi 80
1,150 psi 75

For Vertical Separator Design:

Maximum vapor flow rate = 100 lb/hr = 0.463 ft3/sec

Separator cross-sectional area = 0.062 ft2

Separator inside diameter = 0.28 ft = 3.37 inches

The GPSA states that separators without mist extractors are sized using the above equation with a K
that is typically 1/2 of that used for vessel with mist extractors.

John M. Campbell, in his book "Gas Conditioning and Processing", states: "(Separator sizing).. Is
a semi-empirical approach since one cannot measure things like droplet size and other variables.
Furthermore, many of the assumptions in the derivation of the Souders-Brown equation are not satisfied in
actual practice.

"The value of K depends on all factors that affect separation other than density - such as vortex action,
foaming, pulsating flow, liquid flowing in heads, presence of solids, degree of separation needed, separation
length, varying gas to liquid ratios, and the like. It is not surprising that K varies widely in different
applications. How does one predict it? From experience!

"Do not be naïve. Most published capacity curves are for ideal conditions. Use them cautiously. Consider a
factor like pulsating flow from a well head or a two-phase line. The liquid enters in "heads". During this time
the gas rate is low. Between "heads" the gas rate is normal but little liquid enters. Using some average 24
hour gas and liquid rate to size the separator would be criminal, or at least unprofessional. There must be
sufficient capacity to handle properly the instantaneous rates expected.

"The value of K used in the Souders-Brown equation thus varies. The normal range of values is:

K = 0.06 to 0.35