LIQUID LIQUID

SEPARATOR
Selection and Design
 INTRODUCTION

It is commonly encountered in different

phases:

in the unit operation of liquid-liquid extraction

in the separation of small quantities of

entrained water from process streams (oil)

in the separation of water polluted by

hydrocarbons, before discharge
 INTRODUCTION

The simplest form of equipment used to

separate liquid phases is the gravity settling
tank (decanter)
they are designed for continuous operation,
but batch operation is also possible
the feed to the decanter is a mixture of a
dispersed and a continuous liquid phase
(they can be more or less stable)
 INTRODUCTION

The aim of the separator is to provide a

sufficiently large volume to allow:
sufficient residence time for the dispersed-
phase drops to separate and reach (rise or
drop) the liquid-liquid interface, and
sufficient residence time for the droplets to
coalesce.
Thus, the residence time has two
components.
 INTRODUCTION
In an operating decanter three zones can be identified:
clear heavy liquid;
separating dispersed liquid (the dispersion zone);
clear light liquid.

The separating zone can be further subdivided in two zones:

a settling out dispersion zone, where dispersed drops rise
or settle out through the continuous phase
a zone of densely packed dispersed drops that coalesce
more or less quickly
Gravity Settling

Increased density difference makes the separation easier increased viscosity of the
continuous phase
Contd

In more typical cases, the fluids flow horizontally in a vessel at Reynolds

numbers well into the turbulent regime. This turbulence can deform the
droplets from a spherical shape to an irregular shape

Turbulance can also create eddy currents that carry droplets along with them
in the wrong direction
 Enhanced gravity settling

Enhanced gravity settling minimizes the turbulence effects by dividing the

stream into a number of separate channels. Dividing the flow into separate
channels provides four primary benefits:
1. Decreases the effective diameter, thus reducing the Reynolds number of
the fluid and producing laminar flow environment that enhances the settling
rate
2.Isolates the fluid in separate channels thereby limiting how far droplets
wander and reducing the negative impact of eddy currents
3.Decrease the distance a droplet needs to rise or fall before reaching the
interface, thus greatly reducing the settling time requirement
Provides Multiple interfaces where the droplets can coalesce thereby
increasing the coalescence process.
 ENHANCED GRAVITY SETTLING

Enhanced gravity settling is the recommended design rather than an empty

settler vessel working on gravity alone.
Despite thee improvements, sometimes the droplets are so small, the density
difference is so low, or the continuous phase viscosity is so high that gravity
forces alone cannot make an effective separation. In these cases designs
often add a coalescing step.
 DECANTERS SIZING

Even though settling and coalescing occur simultaneously, it will be

assumed that first the drops flow to the interface, and then the drops
coalesce with the appropriate phase
 DECANTERS SIZING

There is no universally accepted procedure

for decanters sizing.

Accurate sizing must be supplemented by

testing
 DECANTERS SIZING
The first step in developing Result
a sizing procedure is to <0.3 Light phase dispersed
determine which phase is 0.3-0.5 Light phase probably
dispersed dispersed
0.5-2 Design for the worst
the parameter , can be case
used as a guide to
2-3.3 Heavy phase probably
determine the dispersed dispersed
phase
>3.3 Heavy
phase
dispersed
Q= volumetric flow rate
L= light phase
H= heavy phase
VERTICAL DECANTERS
The decanter size is based on the settling velocity
of the droplets of the dispersed phase (e.g. Stokes
equation):
gD p 2 ( H L )
UT =
18c
where c is the viscosity of the continuous phase.
The calculation of UT requires the knowledge of the
droplets diameter (reference Dp= 150 m)
A maximum of 4 mm/s is usually assumed
VERTICAL DECANTERS
The velocity of the continuous phase must be less
than the settling velocity (plug flow is assumed)
The velocity of the continuous phase is calculated
using the area of the interface

Qc
vc U T
AI
Then, a hold-up time of 5 to 10 min is usually
assumed (sufficient where emulsions are not likely
to form)
 INTERFACE

The position of the interface can be controlled, with or without the

use of instruments, by use of a siphon take-off for the heavy liquid

The height of the take-off can be determined by making a pressure

balance

z2
z1 z3 L z3
H
 INTERFACE
An alternative approach for the automatic control
of the interface:

The height of the liquid interface should be controlled

accurately when the liquid densities are close, when one
component is present only in small quantities, or when the
throughput is very small
 INTERFACE
Where one phase is present only in small amounts
it is often recycled to the decanter feed to give
more stable operation

Drain valves should be fitted at the interface so

that any tendency for an emulsion to form can be
checked; and the emulsion accumulating at the
interface drained off periodically as necessary
 HORIZONTAL DECANTERS
Liquid-liquid separation is markedly influenced
(hindered) by turbulence
Re Effect
The separator
diameter is calculated <5000 Negligible effect
to minimize 5000- Some hindrance
turbulence 20000
The Reynolds 20000- Major problem
numbers must be 50000
calculated for both the Probable
light and heavy >50000 poor
separation
phases
 HORIZONTAL DECANTERS
The Reynolds number must be calculated with
the equivalent diameter:

Deq,i ivi
Rei D Di
i eq,i
2
where i = L, H the light and heavy phases.

It is generally assumed that the liquid-liquid

interface is at the center of the vessel.
 HORIZONTAL DECANTERS

Assuming a limiting value of Re for each

phase, two values of D are obtained.
The largest of the diameters is adopted.
(Dmin=10 cm due to wall effects)
The velocity of the phases is calculated
as:
vi
Qi D 2
Ai
Ai where 8
 HORIZONTAL DECANTERS
The total length of the decanter is the sum of the
lengths required for settling and coalescence
The settling velocity for the dispersed liquid drops is
calculated using the Stokes' Law (with Dp=150 m)

The time taken for the dispersed phase to reach the

interface and the length of the settling zone are:
D
ts and Ls vdts
2U T
vd is the velocity of the dispersed phase
where
HORIZONTAL DECANTERS

The dispersed phase drops finally

accumulate near the interface to form a
coalescing zone

The length of the coalescing zone of the

decanter is determined by the time required
for the dispersed phase to coalesce.
HORIZONTAL DECANTERS

No relationship can predict the time required

for coalescence (from seconds to many
hours, by experiments)

Coalescence is enhanced by:

low viscosity of the continuous phase,
large density difference between the phases,
large interfacial tension,
and high temperature.
HORIZONTAL DECANTERS
It is usually recommended that the thickness of the
coalescing zone be Hc 10% of the decanter
diameter
It is also assumed that the drops occupy about half
of the volume of the coalescing zone volume.
If the liquid-liquid interface is at the center of the
separator, the dispersion zone volume is
approximately equal to:
Vc H c AI
where AI is the area of the interface.
 INTRODUCTION

The residence time, tc, of the drops in the

coalescing zone is given by:
where QD is the
tc 1 2 Vc 1 2 H c A
volumetric flow rate I

of the dispersed phase QD QD

tc is specified by experience, and the interfacial

area required for coalescence (AI) is calculated.
HORIZONTAL DECANTERS

The length of the coalescing zone, Lc, is

calculated from (neglecting the actual shape
of the shell):
Lc AI / D

and thus the total length of the separator is

calculated:
L Ls Lc
 SUMMARY OF THE SIZING
PROCEDURE
1.Calculate to determine the dispersed phase
2. Calculate the inside diameter of the decanter,
assuming that the light phase determines the
diameter.
3. Calculate the inside diameter of the decanter,
assuming that the heavy phase determines the
diameter.
4. The decanter diameter is the larger of the
diameters calculated in Steps 2 and 3.
5. Calculate UT, the droplet velocity
 SUMMARY OF THE SIZING
PROCEDURE
6.Calculate ts, the dispersed-phase settling time
7. Calculate Ls, the decanter length required for
settling of the dispersed phase
8. Determine Hc, the coalescing-zone height
9. Calculate AI, the interfacial area required for
coalescing the dispersed phase
10.Calculate Lc, the decanter length required for
coalescing the dispersed phase
11. Calculate L, the total length of the decanter
PIPING ARRANGEMENT
To prevent generating turbulence and entraining in
the vessel, both the inlet and outlet liquid streams
velocities should be kept relatively low:
the inlet velocity should be below 1 m/s
the liquid velocity in each outlet nozzle should not
be greater than 10 times the average velocity of
each phase in the decanter

This rules allow sizing the inlet and outlet nozzles

SPECIAL CONFIGURATIONS
When separation is a problem, different
arrangements are used:
proprietary equipment (baffles, parallel plates, etc.)
centrifugal separation (centrifuges, hydrocyclones)

Ddrum Dpot (mm)

When a small amount of (mm)
heavy phase is present, it
is preferable to use a 1000 Ddrum
settling pot on the bottom
of the drum to save 1000- 500
space and cost: 1500
1500 1/3 Ddrum
 Plate separators

Stacks of horizontal, parallel, plates are used in some proprietary

decanter designs to increase the interfacial area per unit volume and
to reduce turbulence. They, in effect, convert the decanter volume
into several smaller separators connected in parallel.
 Coalescence

Coalescence is the process of which two or more droplets, bubbles or

particles merge during contact to form a single daughter droplet, bubble or
particle.
These larger droplets are easier to settle downstream.
Coalescers
Equipment is often used for the coalescence and
separation of nely dispersed droplets. A
medium is chosen that is preferentially wetted
by the dispersed phase; knitted wire or plastic
mesh, beds of brous material, or special
membranes are used. To hold up the dispersed
droplets need long enough time for them to
form globlets of sufcient size to settle. A
typical unit is shown in Figure 10.41.

Coalescing lters are suitable for separating

small quantities of dispersed liquids from large
throughputs. Electrical coalescers, in which a
high voltage eld is used to break down the
stabilising lm surrounding the suspended
droplets, are used for desalting crude oils and
for similar applications
Hydrocyclones
Hydrocyclones are used for some liquid-liquid separations, but are
not so effective in this application as in separating solids from
liquids. VAF Hydrocyclone Separators are effective in removing
suspended particles from any flow stream of water where the
specific gravtity (density) of the particle(s) is heavier than the
water it is in; the more significant the difference in the gravity
between the water and the particle, the greater the efficiency of
the removal process. Depending on the specific gravity of the
particle and the viscosity of the flow stream, very small and denser
particles can be removed. NOTE: Particulate removal can be
enhanced if multiple passes of the stream can be achieved.
Consider a separator's use where any source of water contains
contanimants with a weight of 2.6 specific gravity or higher, such as
well water to remove sand. Separators are also excellent for use as
a pre-removal device for filters with river or ditch water that
contain high levels of sand or other large organic debris.
Applications would include, but not be limited to, wells, industrial
processes, water recycling and reuse, river and ditch water intake
systems, food processing nozzle systems and irrigation water.
An automatic purge controller and valve can be used on all
applications. This eliminates the need for manual flushing, turning
the separator into an automatic system.
Small separators can be wall mounted, hung on the main piping, or
placed on legs if desired.
 How it Works
Liquids and solids enter the unit and begin traveling in a circular
flow. This centrifugal action forces heavier particles downward in a
spiral motion to the separation chamber. The particles collect in this
separation chamber and are purged from the system. The filtered water
is drawn to the separators vortex and up through the outlet.

Specifications
To select the optimal separator, match your flow-rate to the listed flow
range. Operating below the specified flow range will result in low
efficiency. Operating above the specified flow range will impose
unnecessary pressure drop across the separator.
Unless otherwise noted, ALL models are installed vertically.
Operating Pressure: 1.5 to 10 bar (25 to 150 psi)
 FLOW LINE SIZE LENGTH WEIGHT FLUSH SIZE
MODEL
GPM M3/hr IN CM IN CM LBS KG IN CM
VHS-10 4 - 10 1-2 0.5 1.3 20 50.8 13 6
VHS-20 10 - 20 2-5 0.75 1.9 20 50.8 15 7
VHS-40 18 - 38 4-9 1.0 2.5 30.5 77.5 26 12 1 2.54
VHS-50 26 - 52 6 - 12 1.25 3.2 30.5 77.5 26 12
VHS-80 38 - 79 9 - 18 1.5 3.8 30.5 77.5 26 12
VHS-120 63 - 120 14 - 27 2.0 5.1 36 91.4 44 20
VHS-180 100 - 180 23 - 41 2.5 6.4 44 111.8 55 25
2 5.08
VHS-260 125 - 260 28 - 59 3.0 7.6 48 121.9 75 34
VHS-340 190 - 345 43 - 78 4.0 10.2 52 132.1 120 55
VHS-400A 200 - 400 45 - 91 4 10.2 80 203.2 280 127

VHS-700A-LF 365 - 700 83 - 159 6 15.2 106.25 269.9 493 224

VHS-950A-HF 500 - 950 114 - 216 6 15.2 106.25 269.9 493 224

VHS-1600A 800 - 1600 182 - 363 8 20.3 114 289.6 722 328

VHS-2300A 1300 - 2300 295 - 522 10 25.4 123.5 313.7 840 382
2 5.08
VHS-3400A 2025 - 3400 460 - 772 12 30.5 139 353.1 1400 636

VHS-5000A 2975 - 5000 676 - 1136 14 35.6 152.5 387.4 2000 907

VHS-6200A 4000 - 6200 909 - 1408 16 40.6 160 406.4 2310 1048

VHS-7800A 5000 - 7800 1136 - 1772 18 45.7 177 449.6 2750 1248

Standard construction material is Carbon Steel. Stainless Steel is available upon request.
Automatic-Purge Timer Controller & Motorized Ball Valve
PVB-1LT-120 1" Auto-Purge Timer
PVB-2LT-120 2" Auto-Purge Timer
Auto-Purge timer includes 120 VAC controller with LCD display with push button controls and brass ball valve. Other options, voltages and materials available.
Notes: VHS = VAF Hydrocyclone Separator, A= Mounted at 22.5 degree angle. Supplied with support legs, LF = Low Flow, HF = High Flow
THANK YOU