TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION

1.1 General Description

DISTILLATE

INLET Pressure: 1490.0 kPa

Temperature: 483.15 K
Pressure: 2780.0 kPa Mass Flow: 51122.24 kg/h
Temperature: 373.15 K
Mass Flow: 269835.12 kg/h BOTTOM

Pressure: 3500.0 kPa

Temperature: 488.3327 K
Mass Flow: 218712.88 kg/h
Figure 1. Distillation Column C-104

The design of the distillation column, C-104 is to separate carbon dioxide, water, ammonia,
and ammonium bicarbonate where the top product would consist of carbon dioxide and a tiny
amount of ammonia whereas the bottom product consists of water, ammonia and ammonium
bicarbonate. The operating condition obtained from iCON for this distillation column C-104
is at temperature of 100°C and pressure of 2780 kPa. The condenser condenses enough
amount of liquid to provide reflux flow to the distillation column. This column is designed as
plate type and sieve tray. In order to achieve the product quality as expected, there are 24
trays in the column, assuming 100% efficiency. The height of the column is 11.27 m with
inner diameter of 1.2 m. To prevent corrosion and enhance the resistance capability of the
column, stainless steel is chosen for the material design.
 CHAPTER 2: PROCESS DESIGN

2.1 Introduction

This distillation column (C-104) design report covered the following criterions:

1. Specification of the required degree of separation.

2. Selection of operating parameters.
3. Selection of type of contacting device.
4. Determining number of trays and reflux ratio.
5. Determination of column size.
6. Designing of column internals.
7. Specifying mechanical design of column.

2.2 Determination of Column Operating Condition

An assumption that the distillate contains anything that is not heavier than the heavy key and
the bottom contains nothing lighter than lighter key, are made to estimate the dew point and
bubble points. Generally, dew points and bubble points are estimated using the following
equations:

∑ yi =∑ K i x i=1.0
y
∑ x i=∑ x i =1.0
i

The vapor-liquid equilibrium or distribution coefficient for component i is represented by K i .

The equation K i=Pi /P represents the equilibrium data where Pi is the partial pressure of
each component, evaluated from Antoine equation. P represents the operating pressure of
distillation column in kPa. Table 2.1 shows the operating conditions of the column and Table
2.2 highlights the properties of the distillate and bottom based on the iCON simulation data.
Table 2.3 shows the mole fraction of the main components in the distillation column C-104.
 Table 2.1. C-104 Distillation Column Operating Conditions

Operating Condtions Value

Temperature (°C) 80
Pressure (kPa) 101.325

Table 2.2. Properties of Distillate and Bottom in column C-104

Properties Distillate (Top) Bottom

Temperature (°C) 210.00 215.1827
Pressure (kPa) 1490.0 3500.0
Mole flowrate (kmol/hr) 1161.63 9580.82
Mass flowrate (kg/hr) 51122.24 218712.88
Volume flowrate (m3/hr) 3131.787 290.046

Table 2.3. Mole fraction of the main components in the distillation column C-104

COMPONENT MOLE FRACTION

TOP BOTTOM
Carbon Dioxide 1161.63 0
Ammonia 0.01 0.12125
Water 0 0.79791

A shortcut method, Fenske-Underwood-Gilliland is used for the multicomponent distillation.

Before a multicomponent distillation column can be designed, a decision must be made as to
the two key components between which it is desired to make the separation. The light key
component is the one to be kept out of the bottom product according to some specification.
The heavy key component is the one to be kept out of the top product according to some
specification.

Antoine equation is to calculate the vapour pressure of the components in the column using
the equation below:

𝐿𝑜𝑔 𝑃 = 𝐴 − (B/(C+T))

where, A, B and C are constants for Antoine Equation and T is the stream temperature in °C.

Table 2.4 Antoine Constants (C.L.Yaws, Chemical Properties Handbook, 1999)

Component A B C Boiling point Vapour

pressure
 Carbon 7.58828 861.82 271.883 -78.46 137756.99
Dioxide
Ammonia 4.4854 926.13 240.17 -33.34 7596.63
Water 8.07131 1730.63 233.426 100 354.53

2.3 Minimum Number of Stages (Fenske Equation)

The assumptions as stated in Fenske Equation is that relative volatility is constant. The
relative volatility can be used for minimum stages required determination at total reflux. The
relative volatilities are estimated at the average of distillate and bottom, which gives a rough
indication of the average column temperature. The Fenske equation is represented as:

x LK x HK

N min =
log
[ ][ ]
x HK
d
x LK
b

log α LK

where,
Nmin = minimum number of stages
α LK = average relative volatility of light key to the heavy key

x LK , x HK = light and heavy key mole fraction

Kⅈ
α ij =
Kj

α ij is represented as the relative volatility, the measure of difference between the vapour
pressures of the high volatile component to the less volatile components of a mixture. In
order to design a multi-component distillation process, the components are classified into
light key (LK) components and heavy key (HK) components where a lighter component
means a lower boiling point compare to heavy components. Ammonia is defined as the light
key component and water is defined as the heavy key component. The rule of thumb states
that both the values must be adjacent.
 Table 2.5 Preliminary Calculations Based on Light and Heavy Key Components

Feed Mole Distillate Bottom

Vapour Distribution
Component Fraction Mole Mole α
Pressure Coefficient
(L) Fraction Fraction
Ammonia
0.1243 0.7388 0.0060 7596.63 9.9957 21.45
(LK)
Carbon
0.13514 0.99999 0 137756.99 181.26 388.97
Dioxide
Water (HK) 0.8742 0.0124 0.9940 354.53 0.466 1

K LK
∝𝐿𝐾 = K = 21.45
HK

0.7388 0.9940
N min =
log [ 0.0124
d ][ b ]
0.0060 = 3 stages
log 21.45

2.4 Minimum Reflux Ratio and Theoretical Stages

Underwood Equation
n
α i xi, f
1−q=∑
i=1 α i−θ
n
α i xi , d
Rm +1=∑
i=1 α i−θ

where,

q= 1
α i = relative volatility
x i = concentration of component
Rm = minimum reflux ratio
Choose 𝜃 between the relative volatility of the light key and heavy key. (1<𝜃<11.25)

From excel spread sheet, 𝜃=6.7275

Rm + 1 = 1.0876, Rm = 0.0844, R = 0.1013

2.5 Estimation of Number of Tray Efficiency and Actual Number of Stages
Gilliland Equation

N −Nmin R−Rmin
Y= ∧X =
N +1 R+1

1
𝑌 = 0.2788 − 1.3154𝑋 + 0.4114𝑋0.291 + 0.8268 ln 𝑋 + 0.9020 ln (𝑋 + )
X

0.1013−0.0844
X= = 0.0153
0.1013+1

𝑌 = 0.2788 − 1.3154(0.0153) + 0.4114(0.0153)0.291 + 0.8268 ln 0.0153

1
+ 0.9020 ln (0.0153 + )
0.0153

Y = 0.695
N −Nmin
Y=
N +1
N −3
0.695= , N= 12.11 ≈ 12 stages
N +1

A quick estimate of the overall column efficiency can be obtained from the correlation
expressed by O’Connell in the form of the equation:

𝐸𝑜 = 51 − 32.5 log ( μα α avg )

where

μα = the molar average liquid viscosity, mNs/m2

α avg= average relative volatility of the light key and heavy key

𝜇𝑎 obtained from iCON is 0.2390 mNs/m2

𝛼𝑎 calculated is √ 21.45= 4.63

Estimated tray efficiency, E0 = 51 − 32.5 log (0.2390 x 4.63) = 49.57%

Nunber of stages 12
Nactual= =
Tray efficiency 0.4957

Nactual=24.2 ≈ 24 tray s

2.6 Estimation of Feed Tray Location

Kirkbride’s equation below is used is used to determine feed tray location, number of
stage in rectifying and stripping section

2
Nr B Xf , HK Xb , HK
log [ ]
Ns
=0.206 log [ (
D Xf , LK )( Xd , LK )]
where
Nr = number of stages above the feed, including any partial condenser,
Ns = number of stages below the feed, including the reboiler,
B = molar flow bottom product,
D = molar flow top product,

𝑥𝑓,𝐻𝐾= concentration of the heavy key in the feed,

𝑥𝑓,𝐿𝐾= concentration of the light key in the feed,
𝑥𝑑,𝐻𝐾= concentration of the heavy key in the top product,
𝑥𝑏,𝐿𝐾 = concentration of the light key if in the bottom product.

2
Nr 0.033 0.8742 0.9940
log [ ]
Ns
=0.206 log [ (
0.985 0.1243 )( 0.7388 )]
Nr
=0.83 9
Ns

𝑁 = 𝑁𝑟 + 𝑁𝑠 ,
 N −Ns
=0.839 𝑁𝑠 = 13.05 ≈ 13 trays
Ns

𝑁𝑟 = 24 − 13 = 11

Hence, the feed tray is the 11th tray from the top.

2.7 Estimation of Tower Height

Actual height of the tower can be calculated using following equation.

2 Nactual
𝐻= + Ho
Eo
The space between top side of column with the tray is 5-15 ft. Same goes to the bottom
side (normal practice applied in industries). Thus,

𝐻𝑜 = 5ft + 5ft = 10ft

2(24 )
H= + 10
0.4957

H = 96.83 ft ≈ 29.51 m

2.8 Sizing of Column Internal

Table 2.6 shows the parameters need for the column sizing, extracted from iCON.

Liquid Phase (l) Vapor Phase (g)

Molecular Weight (kg/kmol) 24.220 44.009
Molar flow (kmol/hr) 7397.34 1155.94
Density (𝑘𝑔/𝑚3) 731.8822 44.6984
Viscosity (cP) 0.1263 0.0227

2.8.1 Gas Loading Calculation and Design Value of Gas Load

The maximum gas load in a tray column is limited when gas blows the liquid off the tray in
the form of fine droplets.

Assumption: Relative free area, Ф = 0.1 m

Thus, 𝐹𝑚𝑎𝑥 = 2.5[Ф2𝜎(𝜌𝐿 − 𝜌𝐺)𝑔]1/4

𝐹𝑚𝑎𝑥 = 2.5[0.12 0.01(731.8822− 44.6984 )9.81]1/4

1
𝐹𝑚𝑎𝑥 = 2.27 Pa 2

For the minimum gas loading, the formula is as below:

𝐹𝑚𝑖𝑛 = Ф√ 2 σ /d h

Hole diameter, 𝑑ℎ assumed to be 0.005 m

Thus, 𝐹𝑚𝑖𝑛 = 0.1√2(2.561)/0.005 =3.20 Pa 1/2

The liquid is prevented from leaking through a sieve tray by the condition below:

1.25
0 ⋅37 d ℏ g [ ρL −ρG ]
F min=ϕ
√ ρG 0.25
1.25
0 ⋅37∗0.005∗9.81∗[ 731.8822−44.6984 ]
F min=0.1
√ ( 44.6984)0.25
=¿¿ 2.39 Pa
1/2

For design value of gas load, it is selected in between maximum and minimum value of
gas load. Formula below can be used to determine gas load design value

F design = 0.68 F max

F design = 0.68(2.27 Pa 1/2)

F design = 1.5436 Pa 1/2

2.8.2 Column Diameter Estimation

To estimate column diameter, superficial gas velocity and volumetric gas flow need to be
determine first as below:
Superficial gas velocity, 𝑢𝑔
Fdesign
u g=
ρg

1.5436 Pa1/ 2
u g= =0.231m/s
√ 44.6984 kg /m3

Volumetric gas flow, V𝑔

G MG
V G=
ρg
kmol 44.009 kg
0. 321 x
s kmol
V G= 3
=0.316 m3 / s
44.6984 kg/m

Active area, Aac is calculated as follow:

V G 0.316
Aac = = =1.368 m 2
ug 0.231

Relative weir length and ratio as stated by Sinnot (2006):

Lw
=0.65
Dc
Ad
=0.4
Ac

Ad
Cross sectional area, Ac based on the ratio = 0.4
Ac

1.368
Ac =
1−2 Ad / A c

1.368
Ac = =6.84 m2
1−2( 0.4)
Column diameter, Dc determine as follow:

4 Ac 4 x 6.84
Dc =
√ √
π
=
π
=2.95 m

Downcomer area, Ad determine based on ratio Ad / Ac = 0.4

Ad =0.4 A c

Ad =0.4 ( 6.84 )=2.74 m2

Net area, An
An =A c − A d

An =4.1 m 2

10 10
Hole area, Ah = A ac = (1.368)=0. 14 m 2
100 100
Area of one hole,

' π d 2 π x 0.0052 2
Ah = = =0.00001963 m
4 4

Number of holes,
Ah 0.14
= =713 2 holes
A h ' 0.00001963m 2

2.8.3 Pressure Drop across column

i. Pressure drop of dry tray, ∆ Pd

Assumption plate thickness, s = 0.003 m

s/d h = 0.6. Hence for sieve tray, s/d h → 0, ξ = 2.67

Pressure drop of dray tray calculated using equation as follow:

P ξ F 2
∆ d= ( )
2 ∅

2.67 6.46 2 2
∆ Pd = ( ) =5571.17 N /m
2 0.1

ii. Pressure drop of clear liquid height on tray, ∆ P L

∆ P L = h L ρ L g= h f ε L ρ L g

h L = ε L h f = 0.011 𝑚

∆ P L = (0.011 × 731.8822 × 9.81) = 78.98 N/m2

iii. Pressure drop due to other factor, ∆ P R is small and neglected (∆ P R = 0)

Thus, total pressure drops,

∆P = (∆ Pd + ∆ P L + ∆ P R ¿

∆P = 5571.17 + 78.98 +0

∆P = 5650.15 N/m2 = 565 mm clear liquid height

2.8.6 Check of Downcomer Capacity

ε Ld =0.4 ( for non foaming system)

∆P 565
hp= = =0.079 m
P L x g 731.8822 x 9.81

Skirt clearance, h cl calculated as follow:

h cl=0.8 x hw

h cl=0.8 x 0.04=0.032m

Max liquid flow/weir length,

The actual liquid load 10.35 m3 /mh, which is lower than the maximum downcomer capacity

CHAPTER 3: MECHANICAL DESIGN OF DISTILLATION COLUMN

CHAPTER 4: SPECIFICATION AND TECHNICAL DRAWING
CHAPTER 5: OPERATING PROCEDURE
CHAPTER 6: COSTING
Liquid flows down the column through the downcomer due to gravity. There are several rule
of thumbs applied to determine the maximum liquid flowrate : i. Liquid weir load (VL/lW)
should be between 2 m3 /(mh) and 60 m3 /(mh). ii. Liquid velocity in the downcomer should
not exceed 0.1 m/s. iii. Froth height must be less than half of tray spacing. iv. Height of clear
liquid in downcomer must be less than half of tray spacing.

For liquid weir load determination:

Weir length,

l w =0.85 D c

l w =0.85 Dc =m

Volumetric liquid flow, V L

L ML
V L=
ρL
kmol kg
internal flow of liquid phase x 24.220
s mol
V L= 2
=m3 /s
731.8822 kg /m

Liquid weir load,

V L V L m 3 / s 3600 s 3
= x =m /mh
lw lw m h

The value is between 2 m3/(mh) and 60 m3/(mh), so first rule is followed.

Downcomer area, Ad =m 2

Downcomer liquid velocity, V L/ Ad is determined as follow:

V L V L m3 /s
= 2
=m3 /s
Ad Ad m

Downcomer liquid velocity less than 0.1 m/s, thus second rule is satisfied.
Third rule say that froth height must be lower than tray spacing. ℎ𝑓 is calculated step by step
as in next page.

Relative liquid content, ε L

F 0.28
ε L =1−( )
F max

6.46 Pa1 /2 0.28

ε L =1−( )
9.50 Pa1 /2

ε L =0.1024
 CHAPTER 7: MINOR EQUIPMENT DESIGN – PUMP (P-104)

8.1 Pump P-104

8.2 Design Methodology
8.3 Process Design
The data presented in Table 8.2 presents the simulation parameters that were used to run the
iCON simulation software.

Table 3. Operating parameters of Stream 26 and 27

Parameter Pump Inlet Line Pump Outlet Line

Pressure, kPa 101.325 141.325
Temperature (℃) 31.6 31.6
Molecular weight
Flowrate, kg/hr 225576.56 225576.56
Mass Flowrate, Kg/s 62.660156 62.660156
Liquid level elevation (assume), m 0 4
Density, p, kg/m3 1021.0384 1021.0262
Volumetric flowrate, Q, m3/hr 220.929 220.931
Volumetric flowrate, m3/s 0.06136 0.06137
Viscosity, µ, poise (Poise= stoke*Density) 0.0008745 0.0008742
Viscosity, Kg/ms 0.0008745 0.0008742
Upstream and downstream pipe length 10 10
(assume), m
Equivalent Length (2 90° Bends, 1 Check valve) 10 13
Inner diameter, mm (assume) 202.74 254.56
Specific Gravity, SG 1.02 1.02
Velocity, m/s 0.69 1.21

Pipe Specifications

Inlet: SCH STD, Outer Diameter (OD)= 219.1mm/8 inch

Outlet: SCH STD, Outer Diameter (OD)= 273.1mm/10 inch

Cross sectional area of outlet pipe:

π ID2 2
A= =0.051 m
4
Where,
A: Cross-Sectional Area, m2
ID: Inner pipe diameter, m

Inner pipe diameter of outlet pipe:

OD - (Wall thickness x 2) = 254.56 mm

Absolute Roughness (Stainless Steel), ε: 0.05 mm
The Stainless Steel is chosen for the Monoethanolamine Line. The Monoethanolamine
solution by itself is not corrosive, however when CO2 is absorbed into the amine solvent it
can cause corrosion to occur. Since the line would regenerate the amine that is used to absorb
CO2 there could be trances of the gas, hence as a precaution the stainless-steel pipe is chosen.

Pressure Drop across Pipeline Outlet

Assumed Efficiency: 75%

Q̇ m
Max Fluid Velocity: V = =1.21
A s
Where,
V: Fluid Velocity, m/s
Q: Volumetric Flowrate, m3/s

ρ× V × ID
Reynold’s Number: ℜ= =3,584,503
μ
Where,
ρ: Density, Kg/m3
V: Fluid Velocity, m/s
ID: Inner pipe diameter, m
μ: Viscosity, Kg/ms
Since the Reynold’s Number is ≥ 3000 the fluid flow in the pipe is turbulent.

E
Relative Roughness: =0.00005893 mm
ID

Moody Friction Factor : 0.0109 is obtained from the Moody Chart.

 Figure 2. Moody Diagram

ρ× v 2 × F × 100
Pressure Drop, Δ𝑃: =3.169 Kp a /100 m
2× ID
Where,

ΔP 3.169 kPa
P F= × Equivalent Length= ×13 m=0.412 kPa
100 100 m

Head Calculation

PF
H L= = 0.403 m
ρg

P F = Pressure drop calculated from suction and discharge, Pa

𝜌 = density, Kg/m3
𝑔 = gravitational constant, 9.81
Power Required

∆P ∆V2 W
+∆ Z + = −H L
ρg 2g g
W = workdone
Δ𝑧 = difference in elevation, m
Δ𝑃 = pressure difference in system, Pa.

Hence,

∆P ∆V 2
W= + g ∆ Z+ +H L
ρ 2

(141325−101325) (1.21−0.69)2 412

W= + ( 9.81× 4 )+ +
1021.03 2 1021.03
W =¿78.953 KJ/kg
W =¿4.95 kW

W 4.95
Wactual = = =6.60 kW
n 0.75

Volumetric Flowrate in gal/min, Q̇ ( gpm )=¿993.18

J
78.953
W kg 1 N .m
H= = × = 8.048 m
g N 1J
9.81
kg

Q̇(100)( H ) 993.18 ×100 ×8.048

Brake Horsepower, WBHP¿ = =2.69 BHP
3960(n) 3960 ×75

Net Positive Suction Head (NPSH)

P Pf P v
NPS H avail= + H− −
pg pg pg
 (141325−101325 ) 412 (1.21−0.69 )2
¿ + 8.048− −
1021 ×9.81 1021× 9.81 1021× 9.81

¿ 14.43 m
Equipment Costing
The formula for cost calculation is based on the lecture notes provided by PDP II course
coordinator as below:

Q M
C E =C B ( )
QB

Where,

C E : cost of equipment for carbon steel at moderate temperature and pressure with capacity Q
C B: base cost with capacity QB
M: constant (based on type of equipment)

From the table of equipment capacity with the capital cost relations in Smith (2005), the cost
estimation for the pump is as follows:

3 4.95 0.55
C E =(9.84 x 10 )( )
4
C E =$ 10,434.223

However, this is the cost for the year 2005. In order to do the estimation for the current price,
the cost index is used:
C1 INDEX 1
=
C2 INDEX 2

Where,

C 1: cost of equipment in year 1

C 2: cost of equipment in year 2
INDEX 1: cost index in year 1
INDEX 2: cost index in year 2

As there is no index for 2020, the index for 2018 is used; 603.1

$ 10,434.223 468.2
=
C2 603.1

C 2=$ 13,440.58

In Ringgit Malaysia:
RM 4.20
C 2=$ 13440.58 x =RM 56,450.44
$1
Centrifugal Pump Data Sheet

CENTRIFUGAL PUMP DATA EQUIPMENT NO. P-04

SHEET
DESCRIPTION PUMP
SHEET NO. 1/1
OPERATING DATA
NO. OF INSTALLED 1 WORKING 1 STANDBY 0
UNITS
TYPE SINGLE STAGE CENTRIFUGAL PUMP
LIQUID MIXTURE OF
MEDIUM

CAPACITY MAX 25.00 MIN 2.50 NORMAL 19.45

3
(m /hr)
101.3
PRESSURE SUCTION 25 DISCHARGE 141.325 DIFFERENTIAL 40
(kPa)

ELECTRIC VOLTAGE 240 PHASE 1 CYCLES (Hz) 50

SUPPLY (V)

LIQUID MEDIUM
TEMPERATURE (0C) 31.6
PRESSURE (kPa) 141.325

FLOWRATE (m3/hr) 225.58

VISCOSITY (Pa.s) 0.0008742
3
DENSITY (kg/m ) 1021.0262
pH 7.00 (neutral)
TECHNICAL DATA
TYPE OF MOTOR ELECTRIC
SPEED CONTROL YES
PUMP EFFICIENCY (%) 75.00
MOTOR EFFICIENCY (%) 75.00
SHAFT POWER (kW) 25.79
PUMP POWER (kW) 6.60
MATERIAL CARBON STEEL
 CHAPTER 7: MINOR EQUIPMENT DESIGN – FLASH SEPARATOR
(U-102)

7.1
7.2 Separator Operating Condition and Required Parameter

Table 4. Separator Inlet Information

Parameter Value
Vapor Fraction 0.9156
Pressure, kPa 2490
Temperature, DC 25
Gas Flowrate, MMSCFD 52.10
Liquid Flowrate, Bbl/day 10035.52
Mixture Density, kg/m3 11.606
Gas Density, kg/m3 9.315
Liquid Density, kg/m3 840.82
Molecular Weight of Vapor 9.273
Compressibility Factor 0.9182
Viscosity, cP 0.022889

7.3 Separator Design

The vessel design is based on the PTS 16.52.09 (2015) two phase gas and liquid separator.
Assume:

 The maximum liquid droplets are spherical with a diameter of 10 μm.

 The maximum allowable gas load factor Kmax is 0.12 m/s.
 K-factor for wire mesh is 0.1 m/s
 Flow Design margin is 0%.

Terminal Settling Velocity and Drag Coefficient

V=
√
4 g D p ( ρL −ρG )

Where,
3 ρG C '
=¿
4(9.81)(1 x 10−5)(840.82−9.315)
√ 3(9.315)C '
=¿ 0.0026 m/ s ¿ ¿

V: terminal gas velocity necessary for particles of size D p to drop or settle out of gas, m/s
P L: Liquid phase density, kg/m3
PG: Gas phase density, kg/m3
g: acceleration due to gravity, 9.81 m/s2
D p: Droplet diameter, m (assume=10m)

The drag coefficient C’ is based on the graph of correlation between drag coefficient and
Reynolds number as in figure below:

3
'
( 1.31 ) ( 107 ) ρG D p3 ( ρ L −ρG ) (1.31 ) ( 107 ) ( 9.315 ) ( 1 x 10−5 ) (840.82−9.315) 0.55
C (ℜ¿¿ 2)= ¿¿ ¿
μ2 (9.81)2

Where,
C’: Drag coefficient of particle, dimensionless
P L: Liquid phase density, kg/m3
PG: Gas phase density, kg/m3
D p: Droplet diameter, m
μ: acceleration due to gravity, 9.81 m/s2

Figure 3

The
Reynolds Number is 0.018.
 0.55
C '= 2
=1690.70
(0.018)
Based on the calculated value using the formula above, the value of C’ is 1690.70.

Gas Load Capacity

The separator shall be designed to handle the gas flowrate under the most severe process
conditions and thus, the minimum design margin should be considered.

ρG
Q L=Q G
√ ( ρ L −ρG )
=0.7074 m3 /s

Where,
Q L: Maximum volumetric gas load
Q G: Maximum gas flowrate, m3/s
ρ L: Liquid phase density, kg/m3
ρG : Gas phase density, kg/m3

Vessel Dimensions
Table 5

Vessel Input Units Value

Selected Vessel Diameter, D mm 20000
Selected Vessel Height (T/T), H mm 50000
H/D (2.5<-H/D<-5) - 2.5
Vessel End Type - Eliptical
Inlet Device - Half Open
Inlet Device Position - Top
Coalescence Type Wiremesh
K calc m/s 0.0023

Assume Kmax = 0.12

Assume K=0.1

Minimum Required Vessel Diameter

 2 4 ∙Q ' max
D= =3001.16 mm
π ∙ k max

Where,
k max: Maximum allowable gas load factor, m/s
Dmin: Minimum required vessel diameter, m
Q ' max : highest value of volumetric gas load factor, m3/s

Particle terminal falling velocity

ρL −ρG 840.82−9.315
V max =k

Where,
√ ρG
=0.1
√ 9.315
=¿ 0.9448 m/s ¿

V max : Particle terminal falling velocity, m/s

K: Empirical constant, m/s
ρ L: Liquid phase density, Kg/m3
ρG : Vapour phase density, Kg/m3

Required diameter for wire mesh demister

QG 6.684
AG = = =7.075
V max 0.9448

(4 x A G)
D=
√ π
=3001.16 mm

Q G: Actual gas flowrate, m3/s

V max : Particle terminal falling velocity, m/s
AG : Required area, m2

Minimum Total Vessel height

 H total=hliq +h1 +h 2+ h3+ hwiremesh + h4 =4.39 m

Where,
hliq: Total liquid Holdup, m
h1: LAHH to inlet device, m
h2: Inlet device height, m
h3: Inlet device to wire mesh height, m
hwiremesh: Height of wire mesh, m
h4: Wire mesh to Top Tangent Line height, m

Nozzle and Momentum Criteria

Table 6

Feed Inlet Nozzle Size & Momentum Criteria

2
ρv ≤ 1500 kg/ms2 ρvin2 kg/ms2 1315.14
Min. Required Feed Inlet Nozzle Diameter DF, Req. mm 866.38
Feed Inlet Nozzle Diameter DF mm 895.34
Gas Outlet Nozzle Size & Momentum Criteria
ρv2 ≤ 4500 kg/ms2 ρvG2 kg/ms2 1699.46
Min. Required Gas Outlet Nozzle Diameter DGO, Req. mm 622.23
Gas Outlet Nozzle Diameter DGO mm 793.74
Liquid Outlet Nozzle Size & Momentum Criteria
Liquid Velocity < 1.0 m/s ρvL2 kg/ms2 0.25
Min. Required Liquid Outlet Nozzle Diameter DLO, Req. mm 153.34
Liquid Outlet Nozzle Diameter DLO mm 304.84

Vessel Hold-up Calculations

Table 7

PTS 16.52.04 Criteria

Available
Level Height from Gap Volume Hold-Up
Level Gap Min Level Min Hold-Up
Setting Bottom (mm) (m3) Time (min)
(mm) Gap (mm) Time (min)

Bottom 0 --- 0.0000 0.00 --- ---

LZALL 100 100 31.4159 28.35 100 ---
LAL 650 550 172.7876 155.95 100 1.5
NLL 700 50 15.7080 14.18 --- ---
  --- ---
LAH 1800 1100 345.5752 311.89 300 3.0
LZAHH 2400 600 188.4956 170.12 100 1.5
TOP 50000 47600 16001.18 --- --- ---

2-PHASE VERTICAL FLASH SEPARATOR

Equipment No. (U-102) Sheet No. 1
Temperature (℃) 25
Pressure (kPa) 2490
Inlet Gas Outlet Liquid Outlet
Flowrate (kg/h) 280021.36 224124.07 55897.29
Vessel Height (m) 50
Vessel Diameter (m) 20
H/D 2.5
Inlet Device Half Open
Coalescence Type Wiremesh
Coalescence Diameter (m) 3001
Coalescence Height (m) 0.15
Feed Inlet Nozzle I.D (mm) 895.34
Gas Outlet Nozzle I.D (mm) 793.74
Liquid Outlet Nozzle I.D (mm) 304.0

Figure 4
APPENDIX

Half-Open Pipe Inlet Distributor

h1: 0.3D (minimum is 300mm)
h2: di
h3: 0.3D (minimum is 900mm)
hwiremesh: 150 mm
h4: 0.3D (minimum is 150mm)
h1: 0.05D (minimum is 150mm)
h2: di + 20mm
h3: di (minimum is 300mm)
hwiremesh: 150 mm
h4: 0.15D (minimum is 150mm)

ℎ𝑙𝑖𝑞𝑢𝑖𝑑 Total liquid holdup from Bottom Tangent Line (BTL) to LAHH, mm
ℎ1 LAHH to inlet device, mm
ℎ2 The height of inlet device, mm
ℎ3 Above inlet device to wire mesh mist eliminator, mm
ℎ𝑤𝑖𝑟𝑒𝑚𝑒𝑠ℎ Wire mesh mist eliminator height, mm
ℎ4 Wire mesh top to Top Tangent Line (TTL), mm
D Vessel Diameter, mm
di Inlet Nozzle Diameter, mm
REFERENCES
APPENDICES