Professional Documents
Culture Documents
5.1 INTRODUCTION
The design of a distillation column can be divided into the following steps:
1. Specify the degree of separation required : set product specifications
2. Select the operating conditions: batch or continuous; operating pressure
3. Select the type of contacting device : plates or packing
4. Determine the stages and reflux requirements : the number of equilibrium
stages
5. Size the column : diameter ; number of real stages
6. Design the column internals : plates, distributor, packing supports
7. Mechanical design : vessel and internal fittings
5-1
5.2.1 Bubble and Dew Point Temperature
To estimate the stages, it required to calculate dew and bubble point. By definition,
a saturated liquid is at its bubble point ( any rise in temperature will cause a bubble
of vapour to form) and a saturated vapour is at its dew point ( any drop in
temperature will cause a drop of liquid to form). It can be calculated in terms of
equilibrium constant, K. Table 5.2 show the constants of Antoine equation for each
components. The data is taken from the Hysis.
Dew points and bubble point can be defined by the following equation:
𝑦𝑖
Dew point : ∑ 𝑥𝑖 = ∑
𝐾𝑖
Component a b c d e f
Butadiene 6.35345 × 101 −4.46031 × 103 0 -7.702 1.08034 × 10−5 2
Ethylene 5.7941 × 101 −8.8607 × 103 0 -5.7166 3.108 × 10−6 2
glycol
Water 6.59278 × 101 −7.22753 × 103 0 -7.17695 4.0313 × 10−6 2
Sec-butenyl 5.5236 × 101 −6.37458 × 103 0 -5.72724 9.53039 × 10−18 6
n-butenyl 5.73985 × 101 −6.7549 × 103 0 -5.99764 8.16422 × 10−18 6
oligomer 6.88845 × 101 −8.84994 × 103 0 -7.42614 4.13075 × 10−18 6
𝑏
Antoine equation : ln(𝑃) = 𝑎 + + 𝑑𝑙𝑛𝑇 + 𝑒𝑇 𝑓
𝑇+𝑐
𝑃0
For ideal mixtures : 𝐾𝑖 =
𝑃𝑇
By using goal seek in the exel programme, with constant operating pressure, the
bubble and dew points is calculate.
5-2
5.2.2 Relative Volatility
𝐾𝑖
𝛼=
𝐾𝐻𝐾
For this case, ethylene glycol is a heavy key and sec-butenyl is the light key
At the top,
Ki(LK) = 0.99
0.99
Ki(HK)=0.097 𝑇𝑜𝑝, 𝛼 = = 10.2
0.097
At the bottom,
Ki(LK)=2.95
2.95
Ki(HK)=0.63 𝐵𝑜𝑡𝑡𝑜𝑚, 𝛼 = 0.63
= 4.68
10.2 + 4.68
𝑎𝑣𝑒𝑟𝑎𝑔𝑒, 𝛼 = =7
2
5-3
5.2.3 Obtained Number of Stages
𝛼𝐿𝐾 = 7
The equilibrium line is drawn by assuming a constant relative volatility for the light
key
𝛼𝐿𝐾 𝑥
𝑦=
(1 + (𝛼𝐿𝐾 − 1)𝑥)
7𝑥
𝑦=
(1 + 6𝑥)
x y
0 0
0.2 0.64
0.4 0.82
0.6 0.91
0.8 0.97
1.0 1
5-4
Top operating line equations,
𝐿𝑛 𝐷𝑥𝐷
𝑦𝑛+1 = 𝑥𝑛 +
𝑉𝑛+1 𝑉𝑛+1
𝐿𝑚 𝑊𝑥𝑊
𝑦𝑚+1 = 𝑥𝑚 −
𝑉𝑚+1 𝑉𝑚+1
Where
𝑘𝑚𝑜𝑙
𝐹 = 417.441
ℎ𝑟
𝑘𝑚𝑜𝑙
𝐷 = 51.679
ℎ𝑟
𝑘𝑚𝑜𝑙
𝑊 = 365.762
ℎ𝑟
Ln=R×D
=413.432
𝑉𝑛+1 = 𝐿𝑛 + 𝐷
=465.111
Lm = Ln + F
=830.873
𝑉𝑚+1 = 𝐿𝑚 − 𝑊
=465.111
5-5
Substitute in the both equations and obtained,
𝑓𝑙𝑜𝑤 𝐿𝐾 44.483
𝑥𝑓 = 𝑓𝑙𝑜𝑤 (𝐿𝐾+𝐻𝐾)
= 44.483+280.082 = 0.13705 ( at feed)
𝑓𝑙𝑜𝑤 𝐿𝐾 35.586
𝑥𝑑 = 𝑓𝑙𝑜𝑤 (𝐿𝐾+𝐻𝐾)
= 35.586 = 1 (at top)
𝑓𝑙𝑜𝑤 𝐿𝐾 8.897
𝑥𝑤 = = = 0.03079 (at bottom)
𝑓𝑙𝑜𝑤 (𝐿𝐾+𝐻𝐾) 8.897+280.082
5-6
Graph of equilibrium line from Mc Cabe Thiele
5-7
5.2.5 Determination of The Number of Plates Using Fenske Equation
The Fenske equation can be used to estimate the minimum stages required at total
reflux. The number of stages will be obtain from this equation
𝑥 𝑥
𝑙𝑜𝑔 [𝑥 𝐿𝐾 ] [ 𝑥𝐻𝐾 ]
𝐻𝐾 𝑑 𝐿𝐾 𝑏
𝑁𝑚 =
𝑙𝑜𝑔𝛼𝐿𝐾
35.586 280.082
𝑙𝑜𝑔 [ 1 ] [ 8.897 ]
𝑁𝑚 =
𝑙𝑜𝑔7
𝑁𝑚 = 3.6
𝑁𝑚 = 4𝑠𝑡𝑎𝑔𝑒𝑠
𝑁𝑇 = 2(𝑁𝑚 )
𝑁𝑇 = 2(4) = 𝟖𝒔𝒕𝒂𝒈𝒆𝒔
5-8
5.2.6 Plate Efficiency
To get the real number of stages, the efficiency of the process must be considered
0.5
𝐸0 =
(𝛼𝜇)0.25
0.5
=
(7 × 0.561)0.25
=0.355
𝑁𝑇
𝑁=
𝐸0
8
= = 𝟐𝟑𝒔𝒕𝒂𝒈𝒆𝒔
0.355
5-9
5.2.7 Feed Point Location
2
𝑁𝑟 𝐵 𝑥𝑓,𝐻𝐾 𝑥𝑏,𝐿𝐾
𝑙𝑜𝑔 [ ] = 0.206𝑙𝑜𝑔 [( ) ( )( ) ]
𝑁𝑠 𝐷 𝑥𝑓,𝐿𝐾 𝑥𝑑,𝐻𝐾
𝑁𝑟
[ ] = 2.4
𝑁𝑠
Nr + Ns = 23
2.4Ns + Ns = 23
3.4 Ns = 23
Nr = 16
5-10
5.2.8 Calculation For Minimum Reflux ratio, Rmin
To get the value of minimum reflux ratio, the Underwood equation was used
1 𝑋𝑑,𝐿𝐾 𝑋𝑑,𝐻𝐾
𝑅𝑚𝑖𝑛 = ( ) {( )−𝛼( )}
𝛼−1 𝑋𝑓,𝐿𝐾 𝑋𝑓,𝐻𝐾
1 0.69 0.02
𝑅𝑚𝑖𝑛 = ( ) {( ) − 7( )}
7−1 0.11 0.67
=1
Where
5-11
5.2.9 Physical Properties
Column diameter
1
2 𝜌𝐿 − 𝜌𝑣 2
𝑢̂𝑣 = (−0.171𝑙𝑡 + 0.27𝑙𝑡 − 0.047) [ ]
𝜌𝑣
1
1111 − 0.9 2
𝑢̂𝑣 = (−0.171(0.5)2 + 0.27(0.5) − 0.047) [ ]
0.9
𝑢̂𝑣 = 2𝑚/𝑠
4𝑉̂𝑚
𝐷𝑐 = √
𝜋𝜌𝑣 𝑢̂𝑣
4(1.5)
𝐷𝑐 = √𝜋(0.9)(2) =1.1m
5-12
Column area
The column area can be calculated from the calculated of internal column diameter
𝜋𝐷𝑐 2
𝐴𝑐 =
4
𝜋(1.1)2
𝐴𝑐 = 4
= 1𝑚2
The overall height of the column will depend on plate spacing. Plate spacing from
0.15m to 1 m are normally used. The spacing chosen will depend on the column
diameter and operating pressure.
Net area 𝐴𝑛 = 𝐴𝑐 − 𝐴𝑑
= 1-0.12 = 0.88m2
=1-(2×0.12)=0.76m2
=(0.76)(1.1)=0.84m
5-13
Take
𝜋(0.005)(0.005)
𝐴1ℎ = = 1.963 × 10−5 𝑚2
4
𝑎𝑟𝑒𝑎
𝑁ℎ =
1 ℎ𝑜𝑙𝑒
0.076
𝑁ℎ = = 3872
1.963 × 10−5
The column height will be calculated based on the equation given below. The
equation determine the height of the column without taking the skirt or any support
into consideration.
=(23-1)(0.5)+(0.5)(2)+(23-1)(0.005)
=12.11m
5-14
Table 5.5 : Plate design specification
Item Value
Column diameter, Dc 1.1m2
No of plates 23 units
Plate spacing 0.5m
No of stages feed 7
Plate thickness 5mm
Total column height, Ht 13.32m
Plate material SS 304
Down comer area, Ad 0.12 m2
Down comer material SS 304
Column area, Ac 1m2
Net area, An 0.88m2
Active area, Aa 0.76m2
Hole area, Ah 0.076m2
Number of holes 3872 units
Weir length 0.84m
Weir heigh(standard) 0.05m
5-15
5.2.13 Down Comer Liquid Back-Up
The down comer area and plate spacing must be such that the level of the liquid
and froth in the down comer is well below the top of the outlet weir on the plate
above. If the level rises above the outlet weir the column will flood :
= 50-10 = 40mm
Where hap = the height of the bottom edge of the apron above the plate
𝐴𝑎𝑝 = ℎ𝑎𝑝 × 𝑙𝑤
=0.04×0.84=0.0336m2
The main resistance to flow will be caused by the constriction at the down comer
outlet, and the head lost in the down comer can be estimate using the equation
given by Cicalase(1947)
𝐿𝑤𝑑 2
ℎ𝑑𝑐 = 166 [ ]
𝜌𝐿 𝐴𝑚
Where
Am = either the down comer area Ad or the clearance area under the down comer
Aap
2
7.6
ℎ𝑑𝑐 = 166 [ ]
(1111)(0.0336)
= 6.88mm
The height of the liquid crest over the weir can be estimated using the Francis weir
formula. For a segmental down comer this can be written as
5-16
𝐿𝑤𝑑
ℎ𝑜𝑤 = 750 [ ]
𝜌𝐿 𝐼𝑚
Where
Iw = weir length, m
7.6
ℎ𝑜𝑤 = 750 [ ]
(1111)(0.84)
= 6.1 mm
Residual head
12500
ℎ𝑟 =
ρL
=12
𝑢 2𝜌
ℎ𝑑 = 51 [ 𝐶ℎ ] 𝑣
𝜌𝐿
where orifice coefficient C0 = 0.84
0
𝑢ℎ 2 𝜌𝑣
ℎ𝑑 = 51 [ ]
𝐶0 𝜌𝐿
=𝟐
Total drop
ℎ𝑡 = ℎ𝑑 + (ℎ𝑜𝑤 + ℎ𝑤 ) + ℎ𝑟 =2 + (6.1+50)+12=70mm
ℎ𝑏 = (ℎ𝑜𝑤 + ℎ𝑤 ) + ℎ𝑡 + ℎ𝑑𝑐
5-17
With the constraint to satisfy
0.13< ½(0.5+0.05)
<0.275 m
Resident time, t
Sufficient residence time must be allowed in the down comer for the entrained vapor
to disengage from the liquid stream, to pervert heavily ‘aerated’ liquid being carried
under the down comer. At time at least 3 seconds is recommended.
𝐴𝑑 ℎ𝑏𝑐 𝜌𝐿
𝑡𝑟 =
𝐿𝑤𝑑
Where
tr = residence time, s
(0.12)(0.13)(1111)
𝑡𝑟 = = 𝟑𝐬
7.6
𝑙𝑤
𝐴𝑡 =
𝐷𝑐
0.84
𝐴𝑡 = = 𝟎. 𝟕𝟔𝒎𝟐
1.1
Θc = 99ᵒ
=180 – 99 = 81ᵒ
5-18
Mean length for imperforated edge strip,
81
= (Dc − 0.05) × π ×
180
81
= (1.1 − 0.05) × π ×
180
= 2m
As = 2 ×0.05 = 0.1 m2
Ap = Aa –(As +Ac)
= 0.76 - (0.1+0.074)=0.586 m2
𝐴ℎ 0.076
Where 𝐴𝑝
= 0.586 = 𝟎. 𝟏𝟑
5-19
5.3 MECHANICAL DESIGN
To design the pressure vessel, have many terms we must consider. The following
is the terms under considerations:
a) Design pressure
b) Design temperature
c) Materials
d) Design stress
e) Welded joint efficiency and construction categories
f) Corrosion allowance
g) Design loads
5.3.1.2 Material
Pressure vessel are constructed from plain carbon steels, low and high alloy
steels, other alloys, clad plate, and reinforced plastics.
𝑁
Stainless steel design stress = 105 𝑎𝑡 𝑡𝑒𝑚𝑝𝑎𝑟𝑎𝑡𝑢𝑟𝑒 300℃
𝑚𝑚2
5-20
5.3.1.4 Maximum Allowable Joint Efficiency
The strength of a welded joint will depend on the type of joint and the quality of the
welding. For this separator, we take 100% degree of radiography for the type of joint
double-welded butt or equivalent.
The corrosion allowance is the additional thickness of metal added to allow for
material lost by corrosion and erosion, or scaling. The recommended corrosion
allowance is 2 mm.
Major loads
5-21
5.3.1.7 Wall Thickness
The minimum wall thickness required to ensure that any vessel is sufficiently rigid to
withstand its own weight and any incidental loads. The wall thickness of any vessel
should not be less than the value given below; the values include a corrosion
allowance of 2mm.
Minimum thickness,mm
Vessel diameter, m
1 5
1 to 2 7
2 to 2.5 9
2.5 to 3.0 10
3.0 to 3.5 12
5-22
5.3.2 Design Of Thin-walled Vessel Under Internal Pressure
The following equation can be used to calculate the minimum thickness required
𝑃𝑖 𝐷𝑖
𝑒= 2𝐽𝑓−0.2 𝑃𝑖
Where:
𝑃𝑖 = Internal pressure
𝐷𝑖 = Internal diameter
𝐽 = Joint factor
𝑓 = Design stress
𝑃𝑖 = (4.56 − 1)1.1
The design stress is 105 N/mm2 at 300oC from Appendic B Figure B-1
0.4 𝑥 (1.1𝑥103 )
𝑒= 2𝑥1𝑥105−0.2 (0.4)
= 𝟐. 𝟏 × 𝟏𝟎−𝟔 𝒎𝒎 + 2 mm = 2 mm
A much thicker wall will be needed at the column base to withstand the wind and
dead weight loads.As a trial, divide the column in to five section, with the thickness
increasing by 2mm per section. Try 9, 11, 13, 15, 17mm.
5-23
5.3.3 Design Of Separator Subject To Combined Loading
The weight of the vessel and fittings can be calculated from the preliminary design
sketches.
For preliminary calculation the approximate weight of the vessel with domed end
and uniform wall thickness can be estimated from following equation.
Where,
=1.15 for distillation column, or similar vessels, with several manways, and
5-24
𝐻𝑣 = height, or length, between tangent lines ( the length of the cylindrical
section),m
t = wall thickness, mm
𝑘𝑔⁄
ρm = density of vessel material,
𝑚3
These densities should be double to allow for attachment fittings, sealing, and
moisture absorption.
The rough estimate of the weight of vessel by using the average thickness 11mm.
Hv = 13.32 m
t = 13 mm
5-25
Weight of vessel
=56.7 kN
Weight of insulation
Weight of plates
5-26
5.3.3.2 Wind Loading
For a smooth cylindrical column or stack the following semi-empirical equation can
be used to estimate the wind pressure
𝑃𝑤 = 0.05𝑢𝑤 2
Uw=wind speed,km/h
= 1.28 m
𝑤𝑥 2
𝑀𝑥 = 2
Where:
𝑁
W = Fw = load per unit length, (𝑚)
5-27
35.52
𝑀𝑥 = 2
x 13.322
= 𝟑𝟏𝟓𝟏 𝑵𝒎
Pressure Stress
The longitudinal and circumferential stresses due to internal pressure
𝑊𝑣
𝜎𝑤 =
𝜋(𝐷𝑖+𝑡)𝑡
91.72 𝑥 103
= 𝜋(1100+17)17
= 𝟏. 𝟓𝟒 𝑵/𝒎𝒎𝟐
5-28
Bending stresses
The bending stresses will be compressive or tensile, depending on location, and are
given by:
𝑀𝑥 𝐷𝑖
𝜎𝑏 = ± [
𝐼𝑣 2
+ 𝑡]
Where:
𝜋
𝐼𝑣 =
64
(𝐷04 − 𝐷𝑖4 )
𝐷𝑜 = 𝐷𝑖 + 2𝑡
𝐷𝑜 = 1100 + 2 𝑥 17 = 1135 𝑚𝑚
𝜋
𝐼𝑣 = 64 (11354 − 11004 ) = 9.59 𝑥 109 𝑚𝑚4
3151×103 1100
𝜎𝑏 = ± 9.59 𝑥 109
( 2 + 17)
= ± 𝟎. 𝟏𝟖𝟔 𝑵/𝒎𝒎𝟐
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑊 ± 𝜎𝑏
The radial stress is negligible. The greatest different between the principal stress will
be on the down-wind side
5-29
Elastic Stability
𝑡
𝜎𝑐 = 2 × 104 (𝐷 )
0
The maximum compressive stress will occur when the vessel is not under pressure
So design is saticfactory.
5-30
5.3.4 Vessel Support
To chose the support for the vessel, the terms we must consider are the size, shape
and weight of the vessel; the design temperature and pressure; the vessel location
and arrangement; and the internal and external fittings and attachments. The
following is the types of support:
A skirt support consists of a cylindrical or conical shell welded to the base of the
vessel. Skirt support is recommended as it does not impose concentrated loads on
the vessel shell.
π
Approximate weight = ( 4 × 1.12 × 13.32) 735 × 9.81 = 𝟗𝟏. 𝟑𝐤𝐍
1
𝑀𝑠 = 𝐹𝑤 × 2 (𝐻𝑣 + 𝐻𝑠 )2
1
= 35.52 × (13.32 + 1.5)2 = 𝟑𝟗𝟎 𝐤𝐍𝐦
2
5-31
Bending stresses in the skirt
4Ms
σbs = π(D
s +ts )ts Ds
4×390×103 ×103
= = 23.8 𝑵/𝒎𝒎𝟐
𝜋(1100+17)17×1100
W
σws (test) = π(D
s +ts )ts
91.3×103
= = 𝟏. 𝟓𝟑 𝑵/𝒎𝒎𝟐
𝜋(1100+17)17
W
σws (operating) =
π(Ds +ts )ts
91.72×103
= 𝜋(1100+17)17
= 𝟏. 𝟓𝟒 𝑵/𝒎𝒎𝟐
Where:
ts = skirt thickness
5-32
The skirt thickness should be such that under the worst combination of wind and
dead weight loading the following design criteria not exceeded
σs (tensile) ≤ fs Jsinθs
t
σs (compressive) ≤ 0.125E (Ds ) sinθs
s
where
fs = maximum allowable design stress for the skirt material, normally taken at
ambient temperature.
𝑵
𝟐𝟓 ≤ 𝟖𝟗 𝒎𝒎𝟐
ts
ˆσs (compressive) ≤ 0.125E sinθ
Ds
17
𝟐𝟐 ≤ (0.125)(200,000) (1100) 𝑠𝑖𝑛 900
𝑵
𝟐𝟐 ≤ 𝟒𝟎 𝒎𝒎𝟐
Both criteria are satisfied, add 2mm for corrosion, gives a design thickness of 19mm
5-33
5.3.4.2 Base Ring And Anchor Bolt Design
Area of bolt
Assumptions:
1300π
= = 𝟔. 𝟖 ≈ 7
600
Ms = 𝟑𝟗𝟎 𝐤𝐍𝐦
1 4M
Ab = N [ D s − W]
b fb b
Where:
Nb = number of bolts
N
fb = maximum allowable bolts stress, typical design = 125 mm2
5-34
1 4 × 390 × 103
Ab = [ − 91.72 x103 ] = 𝟏𝟐𝟔𝟕𝒎𝒎𝟐
7 × 125 1.3
1470×4
= √ π
= 𝟒𝟑𝒎𝒎
The base ring must be sufficiently wide to distribute the load to the foundation. The
total compressive load on the base ring is given by,
4M W
Fb = [πD2s + πD ]
s s
Where:
Fb = the compressive load on the base ring, Newtons per linear metre
Ds = skirt diameter, m
5-35
The minimum width of the base
Fb 1
Lb = fc
× 103
N
Taking bearing pressure,( 5 mm2
)
Where:
437×103
Lb = = 𝟖𝟕𝒎𝒎
5×103
M24 353 76
M30 561 76
5-36
Actual width required
= Lr + t s + 50mm
Fb
f′c =
Actual width required
437×103 𝑵
f′c = 196×103
= 𝟐. 𝟐 𝒎𝒎𝟐
3f′c
t b = Lr √ fr
=
Where:
Lr = the distance from the edge of the skirt to the outer edge of the ring,mm
3 × 2.2
t b = 127√ = 𝟐𝟕. 𝟓 𝐦𝐦 ≈ 𝟑𝟎𝐦𝐦
140
5-37
5.3.5 Pipe Sizing
The pipe diameter for fluid stream can be obtained from the following equation
below,
Where,
D = optimum diameter of the pipe, mm
𝑘𝑔
G = flow rate of fluid in the pipe, 𝑠
𝑘𝑔
ρ = density of fluid,𝑚3
Feed stream
kg
Flow rate, G = 9.12
s
kg
Density of stream, ρ = 701 m3
=260(9.12)0.52(701)-0.37
=73mm≈80mm
Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1
5-38
Vapor outlet stream
kg
Flow rate, G = 1.5 s
kg
Density of stream, ρ = 11.3 m3
=260(1.5)0.52(11.3)-0.37
=130mm≈150mm
Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1
kg
Flow rate, G = 7.6 s
kg
Density of stream, ρ = 735 m3
=260(7.6)0.52(735)-0.37
=65mm
Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1
5-39
5.3.6 Summary
5-40
5.4 CHEMICAL DESIGN SEPARATOR
5.4.1 Introduction
A vapor liquid separator is one of the types of separator. Vapor liquid separator
has two types that is horizontal and vertical separator. The advantages of vertical
separator are required smaller plot area, it is easier to remove solids, liquid removal
efficiency does not vary with liquid level because the area in the vessel available for
the vapor flow remains constant and generally the vessel volume is smaller. The
advantages of horizontal separator are it is easier to accommodate large liquids
slugs, required less head room, the downward liquid velocity is lower and additional
to vapor/liquid separation also a liquid/liquid separation.
A vapor liquid separator may also be referred to as a flash drum, knock-out drum,
knock-out pot, compressor suction drum or compressor inlet drum.
5-41
Figure 5.2 : A typical vapor-liquid separator
5.4.1.3 Demister
A demister is a device often used in vapor liquid separator to prevent liquid
droplets from being entrained in the vapor. In vertical separator, demister pads is
installed with the minimum thickness 6in. The demister pad should extend from the
top of the vessel to 0.1m above the bottom. The area between the mat and the
bottom of the vessel shall allow free passage of liquid. The distance between the
inlet device and the front face of the demister mat shall be at least 0.6m or 0.5times
the vessel diameter. The distance between the downstream of the outlet and the
rear face of the demister mat shall be at least 0.5D.
5-42
5.4.1.4 Selection Criteria For Vapor Liquid Separator
a) Orientation
b) Type of feed inlet
c) Type of internals
d) Type of heads
2. Feed inlet
The feed nozzle size and the type of feed inlet device have an impact on the
valor liquid separation that can be achieved. The feed nozzle is normally sized
to limit the momentum of the feed. The limitation depends on whether or not a
feed inlet device is installed.
5-43
3. Internals
After passing through the feed inlet, the vapor stream will still contain liquid in
the form of droplets. The maximum size of these entrained droplets depends on
the vapor upflow velocity. A separation device can reduce this entrainment
significantly. Wire mesh demister are the most commonly use as separation
device. They are used for two reasons:
To minimize entrainment
To reduce the size of a vessel
4. Vessel head
Most vessels have 2:1 elliptical heads, welded to the shell of the vessel.
However, in some cases other types of heads are used. The major alternatives
are:
Flat heads (in case of small vertical vessels, diameter less than
approximately 30’’)
Hemispherical heads (for an extremely large, high-pressure vessel)
Dished head ( in case of a large diameter, low pressure vessel)
5-44
5.4.2 Chemical Design Calculation
The design of a vapor liquid separator is based on the terminal settling velocity of a
liquid droplets of specified size, settling under the influence of gravity. This velocity
is given by
(𝜌𝐿 − 𝜌𝑉 ) 1/2
(𝑈𝑉 )𝑚𝑎𝑥 = 𝐾 [ ]
𝜌𝑣
Where
𝑊 𝜌
Figure relates the K factor for a vertical vessel (K) to 𝑊𝑙 √ 𝜌𝑣
𝑣 𝑙
L = 48.221 𝑙𝑏⁄ 3
𝑓𝑡
v = 0.015504 𝑙𝑏⁄ 3
𝑓𝑡
Separation factor
𝑊𝑙 𝜌𝑣 1.139×104 0.015504
√ = √ = 0.22
𝑊𝑣 𝜌𝑙 917.9 48.221
5-45
Figure 5.4 : Graph to find K value
1/2
(𝜌𝐿 − 𝜌𝑉 )
(𝑈𝑣 )𝑚𝑎𝑥 = 𝐾 [ ]
𝜌𝐿
𝑓𝑡
= 19.5 𝑠
= 𝟓. 𝟗𝟒 𝒎⁄𝒔
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝑉𝑎𝑝𝑜𝑟 𝑣𝑜𝑙𝑒𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒, 𝑄𝑣 =
𝑣𝑎𝑝𝑜𝑟 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
416.4
= 3600 𝑥 0.24835
= 𝟎. 𝟒𝟔𝟔 𝒎𝟑 /𝒔
𝑄𝑣
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑒𝑠𝑠𝑒𝑙 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎, 𝐴𝑚𝑖𝑛 = (𝑈𝑣 )𝑚𝑎𝑥
0.466
= 5.94
= 𝟎. 𝟎𝟕𝟖 𝒎𝟐
5-46
Minimum vessel diameter
4𝐴min
𝐷𝑚𝑖𝑛 = √( 𝜋
)
4𝐴min
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑒𝑠𝑠𝑒𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝐷𝑚𝑖𝑛 = √( 𝜋
)
4(0.078)
= √( 𝜋
)
Vessel height:
𝑉𝑒𝑠𝑠𝑒𝑙 ℎ𝑒𝑖𝑔ℎ𝑡, 𝐿𝑣 = ℎ𝑙 + ℎ𝑓 + ℎ𝑣
Where:
hl = height of liquid holdup level in vessel (for a given residence time, typically
5 minutes)
hv = disengagement height = D
5-47
Set the diameter/length ratio L/D ranges from 3 to 5.
=5(0.47)=2.35m
The minimum height of drum above the centerline of the feed nozzle,hv is 1.2192m.
The minimum height of the center of the feed line above the maximum level of the
liquid pool, hf is 0.4572m
D
hv=1.2192 m
hf =0.4572m
feed
hL =0.6736m
Approximate the vapor-liquid inlet nozzle based on the following velocity criteria:
𝑓𝑡
(𝑈𝑚𝑎𝑥 )𝑛𝑜𝑧𝑧𝑙𝑒 = 100 √𝜌𝑚𝑖𝑥 = 100 √48.5 = 696 =212 m/s
𝑠
𝑓𝑡
(𝑈𝑚𝑖𝑛 )𝑛𝑜𝑧𝑧𝑙𝑒 = 60 √𝜌𝑚𝑖𝑥 = 60 √48.5 = 418 =127 m/s
𝑠
5-48
The required vessel surge volume
𝑓𝑡 3⁄
Where 𝑄𝑙 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤, 𝑠𝑒𝑐
𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑒𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒, 𝑄𝐿 =
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
5167
= 3600 𝑥 772.42
= 𝟏. 𝟖𝟓𝟖 × 𝟏𝟎−𝟑 𝒎𝟑 /𝒔
= 𝟎. 𝟓𝟔 𝒎𝟑
5-49
5.4.3 Summary Of Chemical Design
101.3 kPa
Design pressure
60 °C
Design temperature
5 min
Hold up time
0.56
Volume of vessel m3
0.47
Diameter m
2.35
Height m
0.4572 m
Depth of the liquid pool, hf
5-50
5.5 MECHANICAL DESIGN
To design the pressure vessel, have many terms we must consider. The following
is the terms under considerations:
h) Design pressure
i) Design temperature
j) Materials
k) Design stress
l) Welded joint efficiency and construction categories
m) Corrosion allowance
n) Design loads
5.5.1.2 Material
Pressure vessel are constructed from plain carbon steels, low and high alloy
steels, other alloys, clad plate, and reinforced plastics.
𝑁
Stainless steel design stress = 150 𝑎𝑡 𝑡𝑒𝑚𝑝𝑎𝑟𝑎𝑡𝑢𝑟𝑒 60℃
𝑚𝑚2
5-51
5.5.1.4 Maximum Allowable Joint Efficiency
The strength of a welded joint will depend on the type of joint and the quality of the
welding. For this separator, we take 100% degree of radiography for the type of joint
double-welded butt or equivalent.
The corrosion allowance is the additional thickness of metal added to allow for
material lost by corrosion and erosion, or scaling. The recommended corrosion
allowance is 2 mm.
Major loads
5-52
5.5.1.7 Wall Thickness
The minimum wall thickness required to ensure that any vessel is sufficiently rigid to
withstand its own weight and any incidental loads. The wall thickness of any vessel
should not be less than the value given below; the values include a corrosion
allowance of 2mm.
Minimum thickness,mm
Vessel diameter, m
1 5
1 to 2 7
2 to 2.5 9
2.5 to 3.0 10
3.0 to 3.5 12
From the calculation in chemical design, vessel diameter, D=0.47 m
5-53
5.5.2 Design Of Thin-walled Vessel Under Internal Pressure
The following equation can be used to calculate the minimum thickness required
𝑃𝑖 𝐷𝑖
𝑒= 2𝐽𝑓−0.2 𝑃𝑖
Where:
𝑃𝑖 = Internal pressure
𝐷𝑖 = Internal diameter
𝐽 = Joint factor
𝑓 = Design stress
𝑃𝑖 = (1.013 − 1)1.1
1.43×10−3 𝑥 (0.47𝑥103 )
𝑒= 2𝑥1𝑥150−0.2 (1.43×10−3 )
= 𝟎. 𝟎𝟎𝟐𝟐𝟒 𝒎𝒎 + 2 mm = 2.00224 mm
A much thicker wall will be needed at the column base to withstand the wind and
dead weight loads.As a trial, divide the column in to five section, with the thickness
increasing by 2mm per section. Try 7,9,11,13,15mm.
5-54
5.5.3 Design Of Separator Subject To Combined Loading
The weight of the vessel and fittings can be calculated from the preliminary design
sketches.
For preliminary calculation the approximate weight of the vessel with domed end
and uniform wall thickness can be estimated from following equation.
Where,
=1.15 for distillation column, or similar vessels, with several manways, and
5-55
𝐻𝑣 = height, or length, between tangent lines ( the length of the cylindrical
section),m
t = wall thickness, mm
𝑘𝑔⁄
ρm = density of vessel material,
𝑚3
These densities should be double to allow for attachment fittings, sealing, and
moisture absorption.
5-56
5.5.3.1.1 Dead Weight Of Vessel
The rough estimate of the weight of vessel by using the average thickness 11mm.
Hv = 2.35 m
t = 11 mm
=3.7506 kN
Weight of insulation
Weight of demister
= 0.078 × 0.1
=0.0078m3
5-57
𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑑𝑒𝑚𝑖𝑠𝑡𝑒𝑟 = 𝑉 𝑥 𝜌𝑑𝑒𝑚𝑖𝑠𝑡𝑒𝑟 𝑥 𝑔
=(0.0078)(163)(9.81)=0.012kN
For a smooth cylindrical column or stack the following semi-empirical equation can
be used to estimate the wind pressure
𝑃𝑤 = 0.05𝑢𝑤 2
Uw=wind speed,km/h
= 0.642 m
5-58
Loading Fw =𝑃𝑤 𝐷𝑒𝑓𝑓
𝑤𝑥 2
𝑀𝑥 = 2
Where:
𝑁
W = Fw = load per unit length, (𝑚)
17.82
𝑀𝑥 = 2
x 2.352
= 𝟒𝟗. 𝟐 𝑵𝒎
Pressure Stress
The longitudinal and circumferential stresses due to internal pressure
5-59
Dead weight stress
𝑊𝑣
𝜎𝑤 = 𝜋(𝐷𝑖+𝑡)𝑡
4.43 𝑥 103
= 𝜋(470+15)15
= 𝟎. 𝟏𝟗 𝑵/𝒎𝒎𝟐
Bending stresses
The bending stresses will be compressive or tensile, depending on location, and are
given by:
𝑀𝑥 𝐷𝑖
𝜎𝑏 = ± [
𝐼𝑣 2
+ 𝑡]
Where:
𝜋
𝐼𝑣 = 64 (𝐷04 − 𝐷𝑖4 )
𝐷𝑜 = 𝐷𝑖 + 2𝑡
𝐷𝑜 = 470 + 2 𝑥 15 = 500 𝑚𝑚
𝜋
𝐼𝑣 = 64 (5004 − 4704 ) = 0.673 𝑥 109 𝑚𝑚4
49.2×103 470
𝜎𝑏 = ± ( + 15)
0.673 𝑥 109 2
= ± 𝟎. 𝟎𝟏𝟖𝟑 𝑵/𝒎𝒎𝟐
5-60
The resultant longitudinal stress is:
𝜎𝑧 = 𝜎𝐿 + 𝜎𝑊 ± 𝜎𝑏
The radial stress is negligible. The greatest different between the principal stress will
be on the down-wind side
Elastic Stability
𝑡
𝜎𝑐 = 2 × 104 (𝐷 )
0
The maximum compressive stress will occur when the vessel is not under pressure
So design is saticfactory.
5-61
5.5.4 Vessel Support
To chose the support for the vessel, the terms we must consider are the size, shape
and weight of the vessel; the design temperature and pressure; the vessel location
and arrangement; and the internal and external fittings and attachments. The
following is the types of support:
A skirt support consists of a cylindrical or conical shell welded to the base of the
vessel. Skirt support is recommended as it does not impose concentrated loads on
the vessel shell.
π
Approximate weight = ( 4 × 0.472 × 2.35) 777 × 9.81 = 𝟑. 𝟏𝐤𝐍
1
𝑀𝑠 = 𝐹𝑤 × 2 (𝐻𝑣 + 𝐻𝑠 )2
1
= 0.01782 × (2.35 + 1.5)2 = 𝟎. 𝟏𝟑𝟐 𝐤𝐍𝐦
2
5-62
Bending stresses in the skirt
4Ms
σbs = π(D
s +ts )ts Ds
4×0.132×103 ×103
= 𝜋(470+15)15×470 = 𝟎. 𝟎𝟓 𝑵/𝒎𝒎𝟐
W
σws (test) = π(D
s +ts )ts
3.1×103
= 𝜋(470+15)15 = 𝟎. 𝟏𝟑𝟔 𝑵/𝒎𝒎𝟐
W
σws (operating) = π(D
s +ts )ts
4.43×103
= = 𝟎. 𝟏𝟗 𝑵/𝒎𝒎𝟐
𝜋(470+15)15
Where:
ts = skirt thickness
5-63
The skirt thickness should be such that under the worst combination of wind and
dead weight loading the following design criteria not exceeded
σs (tensile) ≤ fs Jsinθs
t
σs (compressive) ≤ 0.125E (Ds ) sinθs
s
where
fs = maximum allowable design stress for the skirt material, normally taken at
ambient temperature.
𝑵
−𝟎. 𝟏𝟒 ≤ 𝟏𝟎𝟔. 𝟐𝟓 𝒎𝒎𝟐
ts
ˆσs (compressive) ≤ 0.125E sinθ
Ds
15
𝟎. 𝟏𝟖𝟔 ≤ (0.125)(200,000) (470) 𝑠𝑖𝑛 900
𝑵
𝟎. 𝟏𝟖𝟔 ≤ 𝟕𝟗𝟖 𝒎𝒎𝟐
Both criteria are satisfied, add 2mm for corrosion, gives a design thickness of 17mm
5-64
10.2.4.2 Base Ring And Anchor Bolt Design
Area of bolt
Assumptions:
800π
= 600
= 𝟒. 𝟏 ≈ 4
Ms = 𝟏𝟑𝟐 𝐤𝐍𝐦
1 4Ms
Ab = [ − W]
Nb fb Db
Where:
Nb = number of bolts
N
fb = maximum allowable bolts stress, typical design = 125 mm2
5-65
1 4 × 132 × 103
Ab = [ − 4.43 x103 ] = 𝟏𝟑𝟏𝟏𝒎𝒎𝟐
4 × 125 0.8
7861×4
= √ π
= 𝟒𝟏𝒎𝒎
The base ring must be sufficiently wide to distribute the load to the foundation. The
total compressive load on the base ring is given by,
4Ms W
Fb = [ + πD ]
πD2s s
Where:
Fb = the compressive load on the base ring, Newtons per linear metre
Ds = skirt diameter, m
5-66
The minimum width of the base
Fb 1
Lb = ×
fc 103
N
Taking bearing pressure,( 5 mm2
)
Where:
764×103
Lb = = 𝟏𝟓𝟑𝒎𝒎
5×103
M24 353 76
M30 561 76
5-67
Actual width required
= Lr + ts + 50mm
Fb
f′c =
Actual width required
764×103 𝑵
f′c = = 𝟑. 𝟗𝟒 𝒎𝒎𝟐
194×103
3f′c
tb = Lr √ fr
=
Where:
Lr = the distance from the edge of the skirt to the outer edge of the ring,mm
3 × 3.94
tb = 127√ = 𝟑𝟔. 𝟗 𝐦𝐦 ≈ 𝟒𝟎𝐦𝐦
140
5-68
5.5.5 Pipe Sizing
The pipe diameter for fluid stream can be obtained from the following equation
below,
Where,
D = optimum diameter of the pipe, mm
𝑘𝑔
G = flow rate of fluid in the pipe, 𝑠
𝑘𝑔
ρ = density of fluid,𝑚3
Feed stream
kg
Flow rate, G = 1.55
s
kg
Density of stream, ρ = 3.3173 m3
=260(1.55)0.52(3.3173)-0.37
=210mm≈250mm
Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1
5-69
Vapor outlet stream
kg
Flow rate, G = 0.116 s
kg
Density of stream, ρ = 0.24835 m3
=260(0.116)0.52(0.24835)-0.37
=142mm≈150mm
Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1
kg
Flow rate, G = 1.435 s
kg
Density of stream, ρ = 772.42 m3
=260(1.435)0.52(772.42)-0.37
=27mm≈32mm
Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1
5-70
REFERENCE
5-71