PRINCIPLES

VAPOR

OF

DROP

SEPARATION

FROM

OR G A S S T R E A M S

Yu.L.
Sorokin,
L.N.
and N.P.
Kuz'min

UDC 621.928.001.2

Demidova,

This a r t i c l e c o m p a r e s s o m e s e p a r a t o r designs for r e m o v i n g liquid drops f r o m v a p o r or gas s t r e a m s

and d e t e r m i n e s the m o s t p r o m i s i n g of t h e s e as m e a s u r e d by allowable velocities and r e s i d u a l vapor m o i s ture.
The s e p a r a t i o n devices shown in Fig. 1, a - e are, in effect, packings which a r e i n s e r t e d into the top
section of a p p a r a t u s in the f o r m of a horizontal l a y e r 80-200 m m high. In power engineering, w a v e f o r m
(Fig. la), zigzag (Fig. Ib), and more complex [i, 2] shaped plates are used. They are called baffle separators. Raschigrings(Fig. lc) fabricated in a variety of materials, are used in the chemical industry [3-5].
Woven wire mesh packings, called demisters (Fig. id) are widely used abroad. Corrugated metallic or

(l-x), wt.%

a)

4)

b)

e)

'f)

Fig. 1

ql

~2

a3

~4 ~5 a8 aTas~

Fig. 2

Fig. 1. E l e m e n t s of s e p a r a t o r devices. With dropwise r e m o v a l of s e p a r a t e d liquid: a, b) h o r i z o n tat baffles, c) R a s c h i g r i n g s d) w i r e mesh, and e) angle. With f i l m - t y p e r e m o v a l of s e p a r a t e d
liquid: i) v e r t i c a l baffles and g) inverted channel.
Fig. 2. Final m o i s t u r e content ( 1 . x ) as a function of the k n u m b e r for various s e p a r a t o r s with
dropwise liquid r e m o v a l : 1-4) a i r at a t m o s p h e r i c p r e s s u r e bubbling through a l a y e r of w a t e r [2]
in a v e r t i c a l column equipped with horizontal baffles, at various heights of the baffles (Hb.s)
above the p e r f o r a t e d plate: 1) Hb. s =350 ram, 2) Hb. s =550 ram, 3) ttb. s =650 ram, and 4) Hb. s
=710 ram. 5-7) Vertical column with horizontal baffles (water drops w e r e injected into the air
s t r e a m by an atomizing nozzle) operating at a t m o s p h e r i c p r e s s u r e [2] at v a r i o u s liquid flow
r a t e s (G) through the a t o m i z e r : 5) G =82 kg/h, 6) G =120 kg/h, and 7) G =170 kg/h, 8) s t e a m at
P a b s =17 k g / c m 2 bubbling through a l a y e r of w a t e r [1] in a v e r t i c a l column with horizontal b a f ties, 9) as 8) except P a b s =91 k g / c m 2, 10) baffle device installed inside the s t e a m d r u m of the
Mironov GRES (State Regional E l e c t r i c Power Station) operating at Pabs =110 k g / c m 2, 11) as 10)
except at the Darnitsk t h e r m a l power station, 12) and 1 3 ) e v a p o r a t o r s with baffle s e p a r a t o r s and
R a s c h i g r i n g p a c k i n g [4] operating at P a b s = l k g / c m 2 and 0.18 k g / c m 2 r e s p e c t i v e l y .
T r a n s l a t e d f r o m Khimicheskoe i Neftyanoe Mashinostroenie, No. 8, pp. 20-22, August, 1968.

664

polyn~eric m e s h is laid down in s e v e r a l l a y e r s in such a m a n n e r that the c o r r u g a t i o n s of each mesh are

perpendicular to the c o r r u g a t i o n s of the preceding one [6-14]. Wire d i a m e t e r s r a n g e from 0.07 to 0.40 ram,
with 0.28 m m being used most frequently. Active a r e a fraction of the m e s h is ~98%.
F i g u r e 2 p r e s e n t s the r e s u l t s of t e s t s run on baffle s e p a r a t o r s and Raschig ring packings on various
test stations and industrial units with various m e d i a at p r e s s u r e s of 18-110 k g / c m 2. It is evident that the
c r i s i s of the p r o c e s s c o r r e s p o n d i n g to the minimum of the c u r v e s o c c u r s at a Kutateladze number k = 0.350.45, although it is not well defined for all cases. At values of k = 0 . 4 5 - 0 . 7 m o i s t u r e entrainment can be as
high as s e v e r a l per cent.
The Kutateladze number k is
k -

w " ~r-,"~
4

'

(1)

w h e r e w" is the inlet gas s t r e a m velocity in m / s e e , .yT and T" are the liquid and gas densities in k g / m 3, g
is the a c c e l e r a t i o n of g r a v i t y in m / s e e 2, and r is s u r f a c e tension in k g / m .
D.A. F r a n k - K a m e n e t s k i i showed that the equilibrium velocity of relative motion of a large spheriodal
drop in a gas s t r e a m o c c u r s at k ~ 1.28. It is evident f r o m Fig. 2 that liquid entrainment r e a c h e s significant p r o p o r t i o n s at k ~ 1 which indicates the c e s s a t i o n of dropwise r e m o v a l of separated m o i s t u r e f r o m the
s e p a r a t o r . For ealcutation of m a x i m u m gas velocities for wire m e s h packings [7, 10-13] the SoudersBrown equation is r e c o m m e n d e d . This equation is based on the predominant influence of liquid and gas
densities on the separation p r o c e s s :
CV

T' - - "f"

(2)

~,

According to available data for d e m i s t e r s [7, 10, 12], c =0.107

c~ ~

~,_-Z~,,),

(3)

where r is a coefficient independent of the physical p r o p e r t i e s of the liquid and gas.

V ~ ~i

m"~

i i
-+i

~0~ ~ 8 ~ 1

~2

ill

0,4 ~6~g#

.`
i

3 4 5 6 8 10

i!:

20 3Cp,,~kg/cm 2

Fig. 3.

Steam velocity w" and the p a r a m e t e r V ~-~'~

c - f * __Tttas a function of p r e s s u r e (p) for s e p a r a t o r s with d r o p wise remo~cal of s e p a r a t e d liquid: I and II) region of
m i n i m u m and high liquid entrainment r e s p e c t i v e l y for
horizontal baffle s e p a r a t o r s and Raschig ring packings,
bounded by c u r v e s drawn f r o m Eq. (1); III) region of m a x imum allowable velocities for mesh, bounded by c u r v e s
drawn f r o m Eq. (2).

665

F o r m a n y s u b s t a n c e s the v a l v e s of ] ) / (~,-g'~~,') a r e n e a r l y equal and a r e a l m o s t independent of p r e s s u r e

V
(Fig. 3). T h i s explains why f o r m u l a (2) c o r r e c t l y r e p r e s e n t s the allowable velocity in m a n y c a s e s . Howe v e r , if the s u r f a c e tension and densities v a r y considerably, coefficient c will not be constant, as can be
s e e n f r o m e x p r e s s i o n {3). This has been c o n f i r m e d e x p e r i m e n t a l l y [10, 11].
Values of s t e a m velocity calculated by f o r m u l a e (1) and (2) a r e p r e s e n t e d in Fig. 3 for c o m p a r i s o n .
F r o m the c u r v e it is evident that the region of c r i t i c a l velocity in which m i n i m u m r e s i d t ~ m o i s t u r e o c c u r s
is lower than the region f o r r e c o m m e n d e d velocities for w i r e m e s h e s (IIl). However, the region of high
c a r r y o v e r (II) p r a c t i c a l l y coincides with region III. R e c o m m e n d e d velocities for horizontal baffle s e p a r a t o r s and Raschig rings a r e b a s e d on c r i t i c a l velocity which c o r r e s p o n d s to m i n i m u m m o i s t u r e entrainment.
R e c o m m e n d e d velocities for w i r e m e s h e s a r e based on a velocity for which liquid c a r r y o v e r does not r e a c h
significant p r o p o r t i o n s . This p a r t l y explains the difference in r e c o m m e n d e d velocities for these two g r o u p s
of s e p a r a t i n g devices.
We should note p o s s i b l e deviations f r o m th e r e l a t i o n s h i p s d i s c u s s e d . Certain a r t i c l e s r e c o m m e n d e d
the use of c ~ 0 , 1 2 - 0 . 1 3 and c o r r e s p o n d i n g l y k ~ 0 . 7 5 - 0 . 8 5 [10, 11]. A n u m b e r of publications indicate the
n e c e s s i t y of designing s e p a r a t o r s with a velocity 25% lower than calculated. In the f i r s t instance a low initial m o i s t u r e content is a s s u m e d , in the second, high initial m o i s t u r e content or dense m e s h design is a s sumed.
Initial m o i s t u r e content has an effect on c r i t i c a l velocity, when the quantity of d r o p s f o r m e d on the
lower edges of the e l e m e n t s is so g r e a t that it c o v e r s a significant f r a c t i o n of the f r e e a r e a . In e x p e r i m e n t s with horizontal baffle s e p a r a t o r s on an a i r - w a t e r t e s t station, i n c r e a s i n g the initial m o i s t u r e content
to 30-40% by weight did not affect the c r i t i c a l veJocity (Fig. 2) [2]. Poppele, who investigated the effect of
initial m o i s t u r e content on allowable velocity for w i r e m e s h e s in the s y s t e m a i r - w a t e r r e c o m m e n d s that
this effect be taken into account by making coefficient c in f o r m u l a (2) equal to 0.13-0.05 [10, 11]. It has
been found in p r a c t i c e that if m o i s t u r e content r e a c h e s 40-50% b e f o r e the s e p a r a t o r in a bubbling type app a r a t u s , the m o i s t u r e content can i n c r e a s e to 70-80 with a slight change in operating conditions which can
occur during operation. The p r o c e s s in a r a n g e of high m o i s t u r e content is unstable in other t y p e s of
equipment, and one cannot r e l y on effective operation of the s e p a r a t o r s examined above under such conditions. It is n e c e s s a r y to l o w e r the initial m o i s t u r e content either by reducing the gas velocity in the app a r a t u s u p s t r e a m of the s e p a r a t o r or by installation of a special s e p a r a t o r for rough s e p a r a t i o n of the m i x ture.
In c e r t a i n p o o r l y designed installations, for example in the design shown in Fig. le, gas velocity in
the channels is significantly higher than inlet g a s velocity and the gas i n t e r a c t s with the drops f o r m e d on
each deck of angles. T e s t s have shown that such s e p a r a t o r s flood at r e l a t i v e l y low inlet v e l o c i t i e s [3].
It should be noted that d r o p s a r e f o r m e d on the l o w e r edges of e a c h l a y e r in c o r r u g a t e d w i r e m e s h e s .
The possibility of drop f o r m a t i o n in l a y e r s of fiat w i r e m e s h a n d R a s c h i g r i n g packing should not be e x cluded. Since the g a s velocity in the packing is g r e a t e r than inlet velocity, the c r i s i s of the s e p a r a t i o n p r o c e s s o c c u r s as a r e s u l t of interaction of drops with the s t r e a m in the body of the packing. This is i n s i g nificant for typical m e s h e s , since the f r e e a r e a f r a c t i o n for t h e s e is 95-98%. However, this interaction
does cause p r e m a t u r e r e e n t r a i n m e n t in dense w i r e m e s h and Raschig ring packings. It is r e c o m m e n d e d that
calculated velocity be reduced by up to 50% [12] for dense m e s h e s . The possibility of drop f o r m a t i o n within the w i r e m e s h l a y e r and Raschig ring packing distinguishes t h e s e devices f r o m baffle s e p a r a t o r s , w h e r e
the c r i s i s o c c u r s as a r e s u l t of the interruption of f r e e downflow f r o m the l o w e r edge of the plates and accumulation of liquid on the edges.
Moisture content in the p r e c r i s i s region (Fig. 2) f o r baffle s e p a r a t o r s and R a s c h i g ring packings
amounts to 10-2-10-4% and is p r i m a r i l y a function of d r o p size. Due to the i n a c c u r a c y of m o i s t u r e d e t e r mination in the p r e c r i s i s region, the instability of the p r o c e s s , and the influence of s e c o n d a r y f a c t o r s ( p r e s ence of s u r f a c e active agents, salt content, the salt composition of solutions, etc.), the s c a t t e r of e x p e r i mental data f r o m differential investigations is considerable, amounting to as much as one o r d e r of m a g n i tude. According to published data [6] s t a n d a r d m e s h e s s e p a r a t e up to 99% of the liquid with drop s i z e s of
2-100 ~. Separation efficiency approaching 100% for a i r velocities of 0.85-1.75 m / s e c (k=0.18-0.37) w e r e
obtained on an a i r - w a t e r t e s t station [3]. ~ x t r e m e l y low r e s i d u a l m o i s t u r e (1 p a r t by weight of liquid p e r
10 billion p a r t s of steam) have been obtained on v e r y dense thin w i r e m e s h e s at low inlet velocities [11].

666

~'~f

~5

~ 8 7 8 91o

15

20

*o 5o uo W so ~#

(1-X)ini, %
Fig. 4. k number as a function of initial m o i s t u r e (1-x)ini
for s e p a r a t o r s with dropwise and film type r e m o v a l of
s e p a r a t e d liquid: I and II) regions of m i n i m u m and high
liquid entrainment for s e p a r a t o r s with dropwise liquid
removal.

Dirnensio~{i- I
cal baffle separator t
__j~ackage, mm
1
System

r
>

i?

~J

Salt

SO

Air - water
150

f191

1
,I

VisualAirkerosine

5
G
7

Air-water

4~O--GO0

i,and Na20
solution
f

0,7-1,2

Salt and visual

[Is1

80

Salt
10

I2

,5

water

1 ioo

1171

Visual

116l

B a s e d on the above it can be stated that allowable velocities and residual m o i s t u r e a r e p r a c t i c a l l y

equal for standard m e s h e s , baffle s e p a r a t o r s and Raschig packings.
The m a j o r s h o r t c o m i n g of the type of s e p a r a t o r s examined above is the dropwise r e m o v a l of the
s e p a r a t e d liquid. S e p a r a t o r s with film type liquid r e m o v a l are theoretically better, since r e e n t r a i n m e n t
o c c u r s at significantly higher inlet velocities. Typical s e p a r a t o r s with film type liquid r e m o v a l a r e verticai
or inclined baffle separators (Fig. If).
Reentrainment
occurs in vertical separators at low inlet velocities due to excessive actual velocities
in the flow channels.
For this reason the critical loading for inverted channel separators (Fig. Ig), for
example, is considerably lower than for vertical baffle separators [16]. Figure 4 presents results of investigations of waveform
vertical baffle separators with 5 mm and I0 mm plate spacing under various conditions [17-18]. For comparison, the regions for minimum
(I) and high moisture (If) for horizontal separators and Raschig ring packing are reproduced on this figure.
It is evident f r o m Fig. 4 that the critical velocity for vertical baffle s e p a r a t o r s with 5 m m plate s p a c ing is somewhat higher than for horizontal baffle s e p a r a t o r s or wire m e s h e s . The critical velocity for
vertical baffle s e p a r a t o r s with 10 m m spacing is 2-4 t i m e s g r e a t e r than the critical velocity for horizontal
s e p a r a t o r s with 10-20% initial m o i s t u r e . The r e s u l t s of testing of vertical baffle s e p a r a t o r s on a i r - w a t e r
and s t e a m test stations indicates that residual m o i s t u r e in the p r e c r i s i s region is equal to 10-4-10-3% and
10-3-10-2% r e s p e c t i v e l y (at p r e s s u r e s of 17-150 k g / c m 2) [18].

667

Vertical and inclined baffle separators can be considered to be the most promising and can be r e c ommended for wide application since they operate at very high inlet velocities and provide the same ior
somewhat lower) residual moisture as horizontal baffle separators, Aaschigring packings and standard
meshes.
LITERATURE

i.
2,
3.
4.
5.
6.
7.
8.
9.
I0.
II.
12.
13.
14.

15.
16.
17.
18.
19.

668

CITED

L.S. Sterman, Investigation of Baffle Separator Operation at Various P r e s s u r e s [in Russian], Mashgiz,
Moscow (1954).
Yu.L. Sorokin, t~nergomashinostroenie, No. 2 (1961).
I.A. Aleksandrov and A.I. Skoblo, Novesti Neftyanoi i Gasovoi Techniki. Neftepererobotka, No. 7
(1960).
A.N. Krasikov and K, N. Shabalin, Khimicheskoe Mashinostroenie, No. 5 (1961).
E.M. Movalev, Khimicheskoe i Neftyanoe Mashinostroenie, No. 1 (1965).
Demisters.
Catalog B-Coil Demisters (England) (1960).
Demisters and Separators for Chemical Industry, Neat Mesh Catalog (USA) (1961).
S.C. Reynolds, Chemical Engineering Progress, 50, No. i0 (1954).
Oil and Gas Journal, 57, No. 35 (1959).
J.M. Campbell, Oil an--dGas Journal, 54, No. 44(1956).
O.H. York, Chemical Engineering Progress, 50, No. 8 (1954).
O.H. York and E.W. Poppele, Chemical Engineering Progress, 59, No. 6 (1963).
E.R. Niemeyer, Petroleum Refiner, 40, No.6 (1961).
Ernest E. Ludwig, Applied Process Design for Chemical and Petrochemical Plants, Gulf Publishing
Co., Houston (1965).
A.D. Schieman, Hydrocarbon Processing and Petroleum Refiner, 43, No. 5 1964).
K.A. Blinov and Yu. L. Sorokin, Gazovaya Promyshlenn0st', No. 17 (1963).
N.D. Panasenk and Yu. V. Kozlov, Teplo6nergetika, No.8 {1962).
N.P. Kuz'min, Yu. L. Sorokin, and A. E. Roizman, Tsvetnye Metally, No. 2 1965).
Yu. L. Sorokin, Energomashinostroenie, No. 4 {1962).