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3-1

3.4

DESIGN OF SEPARATOR (S-100)

3.4.1

Introduction

Removing liquids and solids from a gas stream is very important in refining
and gas processing applications. Effective removal of these contaminants can
prevent

costly

problems

and

downtime

with

downstream

equipment

like

compressors, turbines, and burners. In compressors that use oil to lubricate


cylinders, the lube oil often gets into the discharge gas causing contamination
downstream. A thin film of hydrocarbon deposited on heat exchangers will thicken
and coke, decreasing heat transfer efficiency, increasing energy consumption and
creating a risk of hot spots and leaks. The operating cost which involves the repair
or a replacement of a separator will further increase the initial cost of the separator.
In industry, vapour-liquid separator are usually used as an equipment that
can separate vapor-liquid mixture. There are two basic equipment for separating
vapor-liquid mixture, which is by using gravitational and centrifugal force. A vaporliquid separator drum is a vertical vessel into which a liquid and vapor mixture is fed
and where the liquid is separated by gravity, falls to the bottom of the vessel, and is
withdrawn.

The vapor travels upward at a design velocity which minimizes the

entrainment of any liquid droplets in the vapor as it exits the top of the vessel. The
figure bellow shows the simple illustration of vapor-liquid separator.

Figure 3.4.1: Simple Illustration of Separator

3-2
During the production of phthalic anhydride, vapor-liquid separator is used to
separate liquid and vapor from the mixture because only liquid form of phthalic
anhydride is needed for the production. There are mainly two types of separator that
can be used which is the vertical separator and the horizontal separator.

Figure 3.4.2: Vertical Separator

Figure 3.4.3: Horizontal Separator


There are differences between these two types of separator. Usually vertical
separator is preferred use when only small load of production, limited plot space and
more importantly when we have desired specific amount of gas and liquid used for

3-3
production. When large quantity of loads, horizontal separator is applied because
the separator consequently hold up will set the size of production. Horizontal flash
separator also comes best when three phases are involved in the production.
A complete separator must have the following (Perry. H., et al., Chemical
Engrs. Handbook, 4th Ed., McGraw-Hill, New York (1963):
1. A primary separation section to remove the bulk of the liquid from the gas.
2. Sufficient liquid capacity to handle surges of liquid and to adequately degas
the liquid.
3. Sufficient diameter and length (height) to allow the small droplets to settle out
by gravity (to prevent undue entrainment).
4. A means of reducing turbulence in the main body of the separator so that
proper settling may take place.
5. A mist extractor to capture entrained droplets and those too small to settle by
gravity.
6. An inlet device to absorb the momentum (kinetic energy) of the entering
fluids.
7. Vortex breaker on liquid outer nozzle(s).
8. A method of solids removal, e.g. sand jets.
9. Manways or hand-holes to access the vessels for inspection and cleaning.
10. Proper pressure and level controls, alarms and shutdowns.
3.4.2

Process Description

In order to get the better and higher percent of product in liquid form which is
Phthalic Anhydride, two-phase separator is used after the reaction occur in the
reactor. Calculations need to be done in order to determine the sizing of the stream
that will enter the separator and flow out to the bottom or top outlet of the separator.
According to our production plant, the separation includes two phases which are
heavy liquid and vapour. The separator operates only at the low pressure and
temperature at 150 kPa and 53 C. The figure shows the separator that we used in
our production.

3-4

Figure 3.4. 4: Separator (S-100)

3.4.3

Chemical Design of Separator

3.4.3.1 Calculations Steps in Chemical Design


There are a few general steps that should be taken when designing a two-phase
separator. The steps involve is shown as below:
1. Calculations of the design flow
2. Calculations of the sizing at the section which covered at the area where
liquid component of the desired product is more at.
3. Calculations of the sizing at the section which covered the whole area of
the two-phase separator.
4. Vapor liquid separation.

3.4.3.2 Types of Phase Separator

3-5
In choosing the type of reactors, it depends on the production of the plant. There two
kinds of separators which are usually used in industry which are the two phase
separator and a 3 phase separator. A simple way to describe a two phase separator
is it was used to separate a mixture of components which exist in two phase. In the
design of separator, a two phase separator is chosen since the production involves
two phase of compound which is the vapor and liquid. In two phase separator it is
needed to determine which orientation is the best which will provide a higher
separation efficiency. There are three orientation involved which is vertical,
horizontal and spherical separator. Spherical design can withstand a high
temperature and pressure. From the operating temperature and pressure of
separator, the design of spherical can be neglected since the separator operates at
a lower temperature and pressure. Thus, the focus is on horizontal and vertical
separator. In order to obtain a higher amount of production of phthalic anhydride
several criteria and consideration need to be followed:
1. Availability of plot area
2. Economics
3. Special Consideration
Then, all the factors should be check first before choosing type of separator
that is suitable for our production. According to W.D Monnery, the orientation of the
vessel depends on its vapor to liquid ratio. If the ratio of vapor is much larger it can
be said that the vessels are vertical in orientation.
Table 3.4.1: Advantages of vertical and horizontal separator
Vertical
Generally

used

in

gas

dominated

Horizontal
Generally used in liquid dominated

service where liquid quantity is low

service, i.e. crude oil systems where

Smaller footprint.

gas flowrate is low.


More interfacial area- better for 3-phase

Gas handling capacity is not a function

separation and foaming fluids.


Better at handling surges and slugs.

of liquid level
Level vs. liquid inventory relationship is

Less headroom

linear

3.4.3.3 Design Data


Calculation of Vapor Density

3-6
The information and the data that were needed in order to obtain the gas mixture
density is the critical temperature and the critical pressure. From the data and the
information, the compressibility factor can be determined, Z. All the data that were
needed to determine the value of Z, is being shown in table below.

Table 3.4.2: Molecular Weights of each Component


Component

Molecular Weight

Formula

Phthalic Anhydride
Water
Carbon Monoxide
Carbon Dioxide
Oxygen
Maleic Anhydride
o-Xylene
Nitrogen

(kg/kmol)
148.100
18.016
28.010
44.010
32.000
98.060
106.16
14.007

C6H4(CO)2O
H2O
CO
CO2
O2
C4H2O3
C8H10
N2

Table 3.4.3: Temperature and Pressure Critical Data


Component

Temperature

Pressure Critical

Phthalic Anhydride
Water
Carbon Monoxide
Carbon Dioxide
Oxygen
Maleic Anhydride
o-Xylene
Nitrogen

Critical, Tc (K)
148.100
18.016
28.010
44.010
32.000
98.060
106.16
14.007

Pc (bar)
C6H4(CO)2O
H2O
CO
CO2
O2
C4H2O3
C8H10
N2

Table 3.4.4: Inlet and Outlet Data of Separator


Parameter

Feed

Top outlet

Bottom Outlet

Pressure (kPa)
Temperature (C)
Mass Flow (kg/h)
Mole Flow

180
55
28872
1368

(vapour)
52.21
100
18614
1115

(liquid)
150
52.35
10258
242

(kgmole/hr)
Vapour Fraction
Component Mole

0.84

1.0000

0.0000

3-7
Fractions
Oxygen (O2)
Phthalic anhydride

0.00336
0.02878

0.00409
0.0000

0.0000
0.16102

(C8H4O3)
Maleic anhydride

0.00398

0.0000

0.02230

(C4H2O3)
Water (H2O)
Carbon dioxide

0.14285
0.06317

0.0000
0.02156

0.7994
0.0000

(CO2)
Carbon

0.0177

0.02156

0.0000

(CO)
Nitrogen (N2)

0.7371

0.89743

0.0000

O-xylene

0.00310

0.00000

0.01734

monoxide

Pcm = Pc y +...

Equation 3.184

T cm = T c y +...
3.185
Where,

Pcm = Critical Pressure


T cm = Critical Temperature
y

Tr

T c ,m

Pr =

P
P c, m

Pressure of gas out:

= Mole Fraction

Equation

3-8
n

Pc ,m =

Pc y i
n=1

= (34.94 x 0.02156) + (73.77 x 0.07688) + (49.7 x 0.00409) + (33.5 x


0.89743)
= 36.692 bar

Pr =

P
P c, m
1
36.692

= 0.02725
Temperature of gas out:
n

T c, m =

T c yi
n=1

= (53 x 0.02156) + (304.13 x 0.07688) + (154.6 x 0.00409) + (126.20 x


0.89743)
= 138.412 K

Tr

T
T c ,m
373.15

= 138.412
= 2.696

Thus, with the value of 0.02725 bar and 2.5696 K, the value of Z is 0.972
approximately according to Felder and Rosseau (2005).

3-9
Specific volume of the gas:
PV = znRT

V
n

= Z (RT/ P)

(Equation 3.186)
(Equation

3.187)
Where,
P = absolute pressure, bar
V = volume, m3
n = number of moles
T = absolute temperature, K
Z = compressibility factor
R = universal gas constant, 0.083 bar.m3/kmol

V
n

= Z (RT/ P)

1.5
m3
0.972(0.083 .
x 325.65 K )
kmol

= 16.689 m3 / kmol

Average molecular weight:


MWavg = M1y1 + M2y2 + + Mnyn
=( 0.02156 x 28.01 ) + (0.07688 x 44.01 ) + (0.00409 x 32 ) + ( 0.89743 x
14.007 )

= 16.689 kg/ kmol

Density of gas mixture

pg

MW avg
V
n

(3.188)

3-10

16.689 kg /kmol
17.515 m3 /kmol

= 0.9528 kg/ m3
Thus, the density of gas mixture is 0.9528 kg/ m3

Calculation for Liquid Mixture Density


For liquid mixture density calculations, the data needed as shown in the Table 3.3
below

Table 3.4.5: Outlet data of separator

Component

O-xylene
Phthalic

Bottom outlet
Molecular
Mole

Density

Density

x/density

weight

fraction, x

(kg/m3)

(kmol/m3)

(m3/kmol)

(kg/kmol)
106.16
148.13

(kmol/kmol)
0.01734
016102

861
1530

8.111
10.329

0.00214
0.01559

98.06

0.02230

1480

15.093

0.00148

18.016

0.7994

1000

55.556

0.01440

anhydride
(C8H4O3)
Maleic
anhydride
(C4H2O3)
Water (H2O)

MWavg = M1y1 + M2y2 + + Mnyn


=( 106.16 x 0.01734 ) + (148.1 x 0.16102 ) + (98.06 x 0.02230 ) + ( 18.016 x
0.7994 )
= 42.28 kg/ kmol

Pl =

MW avg /

x
p

3-11

kg
kmol

= 42.28

/ 0.03361

m3
kmol

kg
m3

= 1257.96

3.4.3.4 Design Flow Rate


To find the design flow rate, the equation below are used:

Q=

(3.189)
Where,

Q = Volumetric flow rate (m3/min)


= Mass flow rate (kg/hr)

p = Density of gas/liquid (kg/m3)

For Vapour Phase:

Qg

g
pg
18614

0.9528

kg
x 60 min
m3

= 325

kg
hr

m
min

3-12
For Liquid Phase:

Ql =

l
pl
10258

1257.96

= 0.13591

kg
hr

kg
x 60 min
m3
m3
min

3.4.3.5 Calculation of Separator Sizing

Volume of Cylinder Section


To find the volume of cylinder section, the value of the residence time need
to be determined. The assumption that were made are the residence time of the two
phase separator is between 5 to 30 minutes. The residence time that were selected
is 30 minutes. Then the volume that is required for 30 minutes is calculated as
below:

V 1 = 0.1359

m
min

x 30 min

= 4.077 m3 = Total liquid operating volume


The Normal Liquid Level (NLL) should be 50% of the vessel diameter so then the
required volume for the cylinder is

V cyl = liquid operating volume / 0.5


= 4.077 m3 / 0.5
= 8.155 m3
For a normal vertical separator, the design of the separator were shown in figure
3.4.5

3-13

Figure 3.4.5: Vertical Two Phase Separator Design

Holdup time and surge volume are calculated from holdup and surges time which
are selected from the guidelines (W.D Monnery, 1993). From the guidelines and
information given the holdup time and residence time is 5 min and 3 min
respectively. The holdup volume and surge volume are then calculated as below:

V H =(T

)(QL )

(3.190)
VH = (5)(0.13591)
= 0.679 m3

V s=(T s )(QL )
(3.191)

3-14
Vs = (3)(0.13591)
= 0.408 m3
The low liquid level height, H LL were obtained from the low liquid level height
information provided by (W.D Monnery, 1993). At diameter of 1.611 m the H LL is
0.381 m. Then, the height of from low liquid level to normal liquid level and the
height from normal liquid level to high liquid level were calculated:

HH =

HH =

VH

( ) D2v
4

0.679
(1.6112 )

= 2.24 m

HH =

Hs=

VS

( ) D2v
4

0. 408
(1.611 2)

= 1.34 m

Diameter and length of Vessel


In determining the diameter of a separator, certain criteria need to be met. The
diameter of the separator cannot be obtained from the length of the separator itself.
According to Sinnott (2005) there is a condition and choices of L/D that were
determined based on the separate operating pressure. Basically, the length of the
diameter to its ratio is in between 2.5 to 5.0. The table below shows the guideline in
selecting the ratio of L/D depending on the operating pressure.

Table 3.4.6: L/D ratio depending to pressure (Sinnott, 2005)


P (kPa)

0 P 1724

1732 P 3447

3454 P

3-15
L/D

Based from the table above and at operating pressure 200 kPa, the ratio of L/D is 3
where,

Lv
Dv

=3

Lv = 3 Dv

Then, the volume of vessel,

cyl=

D2v Lv
4

(3.192)
Next, substitute Lv into the volume equation to get,

cyl=

3 D3v
4

(3.193)

Calculation is performed to get the diameter value,

8.155 m3
Dv=

= 1.611 m
So, the vessel diameter is 1.611 m.

Then, the length of vessel will be,


L1 = Lv = 3Dv
L1 = 3 (1.611 m)
= 4.83 m
Length of the vessel is 4.83 m.

3-16

Volume of Cylinder Section


Volume of the selected separator size is,

V
cyl=

D2v Lv
4
2

( 1.611 m ) ( 4.83 m)
4

= 9.845 m3
New volume of the vessel is 9.845 m3.

3.4.3.6 Vapour- Liquid Separator


A higher separator efficiency will provide a higher benefits. A good separation will be
able to recover valuable products, improving the products purity, reducing emission
and protect the downstream equipment. As stated earlier to achieve each of these
benefits, a vapour-liquid separator is chosen. Since it involves two kinds of phases
(vapour and liquid) a separation of gas and liquid need to be done. The gravity and
impaction are involved in the process of separating the gas and liquid mixtures. In
gravity separation, the bulk of the vapour and liquid have segregated at the gravity
separation section. In this section, liquid droplets large enough to settle by gravity
(150-300m) will do so. In vertical separation, the droplet velocity is working against
gravity, which makes the separation more difficult. In order to keep separator height
reasonable, allowable velocities are often lower than in horizontal vessels. Sufficient
length is needed only for the droplet velocity to become zero and the droplet start
falling. (H.Van Der Poel,1982).
The wire-mesh eliminator is used when the separation requirements is above
95%. Wire-mesh eliminator was installed near the vapour outlet. There are small
drops are separated by impaction at the top of the separator. The efficiency of the
wire-mesh pad is 99% or greater than that. (Seader and Earnest, 1998). To lower
the number liquid droplets from being entrained into gas, the gas velocity must be
reduced first,so that sizing a gas-liquid must be performed as it also is the main

3-17
objective of sizing a gas liquid. The diameter must be determined first meanwhile the
height is calculated to dampen the flow rate variations of the liquid streams by
permitting sufficient time. The vapour bubbles to flow upwards before it stuck to the
outlet of the bottom those liquid heights.
All of the separators equations are derived from gravity setting equation. The
critical must be determined using the equation given below,

Lv
10

p l pg

pg
V c =K

( 3.194)

Where,

Vc

= critical gas velocity (m/s)

= empirical constant

pl =density of the liquid (kg / m3)


pg

= density of the gas (kg /m3)

Lv

= length of the vessel (m)

Based on the table 3.3, the value of K obtained is 0.107. The value are taken based
on the orientation on the separator which is horizontal or vertical. The value of the
critical gas velocity are then performed as below

Lv
10

p l pg

pg
V c =K

3-18

= 0.107

kg
kg
0.9528 3
3
m
m 4.83 0.56
(
)
kg
10
0.9528 3
m

1257.96

= 3.17 m/s
The value of critical gas velocity calculated, Vc is 3.17 m/s.

Table 3.4.7: K factors for the sizing of mesh diameters


Type of separator
Horizontal (with vertical pad)
Spherical
Vertical or horizontal (with horizontal

K factor (m/s)
0.122 to 0.152
0.061 to 0.107
0.055 to 0.107

pad)
At atmospheric pressure

0.101

At 2100 kPa

0.091

At 4100 kPa

0.082

At 6200 kPa

0.064

At 10300 kPa
Wet steam
Most vapours under vacuum
Salt and caustic vapours

0.076
0.061
0.046
(Source: IPS-E-PR-880, 1997)

Area of vapour
Ag = Qg/Vc
(3.195)
Qg = 325 m3/min
= 5.42 m3/s
Vc = 3.17 m/s
Ag = Qg/Vc
= 1.7 m2

3-19

Area of liquid
Total area of the vessel is
2

A v=

D
4

A v=

(1.611 m)
4

A v =2.039m2
Al = 2.039 1.7
= 0.34 m2

Vapor/Liquid Ratio
Vapor / liquid ratio of the vessel is

ratio=

Qg
Ql

(3.196)

m3
min
3
m
0.1359
min
325

= 2391

3.4.4 Summary of Chemical Design of Separator


Based on the type of separator chosen is vertical separator because based
on the value that we calculated and the production needed. By referring to Table 3.1
which is selection criteria of the type of separator, the production is including the
major component of liquid flow and only less vapor load in the separator. So thats

3-20
how the horizontal separator is chosen. The table below shows the summary of
chemical design of flash separator.

Table 3.4.8: Summary of Chemical Design


Type of column
Critical Velocity, Vc
Area of Vessel, Av
Area of Vapour
Area of Liquid
Diameter
of
the

Vertical Separator
3.17 m/s
2.039 m2
1.7 m2
0.34 m2
1.611 m

Column, Dv
Length of the Vessel
Volume of the Vessel
Vapour/liquid Ratio
Surge Volume
Holdup Volume
Low Liquid Level
LLL to NLL, HH
NLL to HLL, HS

4.83 m
9.845 m3
2391
0.408 m3
0.679 m3
0.381 m
2.24 m
1.34 m

3.4.5

Mechanical Design

Most separator and pressure vessels are constructed to applicable codes


established by the government agencies, professional and by individual companies.
In these codes it guides and specify all the designs needed and the standards for
the design. It also specify the inspection requirements, over-pressure protection.
Until nowadays the codes do provide the stability and consistency towards the
pressure vessels designed and was recognized to bring a much safer working
environment for personnel. In most states and countries, manufacture of pressure
vessels to an acceptable code is mandated by law (Perry,J.H.,1963) There are 7
commonly used codes, that is:
1) ASME Pressure Vessel Code
2) B 5500 Specification for Unfired Fusion Welded Pressure Vessels
3) CSA B51-97,Part 1 Boiler, Pressure Vessel, and Pressure Piping Code

3-21
4)
5)
6)
7)

Australian Pressure Vessel Code, AS 1210 Unfired Pressure Vessels


CODAP 95 French Code for Construction of Unfired Pressure Vessels
The Dutch Pressure Vessel Code
A.D. Merkblatt Code

There two codes that most widely recognized pressure code in worldwide
(Perry, J.H., 1963). That is, ASME Section VII Division 1 and 2 and BS 5500. In
mechanical design of a separator several steps and specification need to be
followed from the standard codes, That is:
I.
II.
III.
IV.
V.
VI.
VII.
VIII.
IX.
X.

Determination of design pressure


Determination of design temperature
Determination of suitable material of construction
Determination of design stress
Determination of cylindrical wall thickness
Determination of head and closures
Determination of weight loads
Determination of selection of a suitable support for two phase separator
Determination of nozzles sizes
Determination of flanges

3.4.5.1 Design Pressure


The design pressure of a vessel need to be designed with the main purpose to
withstand the maximum pressure which are likely to be subjected during the
operation. It is advisable to increase the normal working pressure up to 10% in order
to allow for possible surges in operation of the two phase separator.
Operating Pressure = Pi = 1.5 bar (absolute pressure)
Taking 10% of absolute pressure as a safety factor for operating the separator and
adding to the operating pressure will give Pdesign.

10 x 1.5

P design=
1.65
0.165 N /mm

3-22

3.4.5.2 Design Temperature


Since the strength of metals decreases with increasing temperature, the maximum
allowable design stress depends on the material temperature. The design
temperature will be used to determine the design stress. It is advisable to increase
the temperature by 10% from its operating normal temperature.
Operating Temperature = 52.35 0C
Design temperature = ( T (0C) + 273 ) x 1.1
= (52.35 + 273)K x 1.1
= 358.05K = 850C

3.4.5.3 Material of Construction


There are many factors that need to be considered when selection construction
material, but in chemical industry which involves chemical processes, the main
consideration is that the ability of a material to resist corrosion. Depends on the
corrosivity of the compounds involves in the process, suitable material need to be
selected in order to withstand the corrosiveness of the compound. A better materials
will enable the equipment to operate for a long time until maintenance took place.
Another consideration is the cost of the material itself. A much lower and economical
material cost will lower the costing of the production. A much lower cost of material
will allow a lower cost of maintenance and replacement of the equipment. Another
factor that need to be considered when choosing material is the product
contamination and process safety. Table 3.5 below shows the characteristics of the
material that is possible to choose for the separator used. Taking a melting point and
corrosion allowance abilities as a main criteria in order to choose the material of
construction. Table 3.5.1 shows the basic cost of materials in middle of 2004
according to Sinnot (2005). The costing also must taking as a main consideration
also in selecting the material of construction.

Table 3.4.9: Characteristics of Material of Construction

Criteria

Material of Construction
Aluminium
Stainless

Carbon

Lead

Copper

3-23

Melting

660

Steel 304
1371 - 1399

Steel
1540

327

1084

Point (0C)
Density

2700

8300

7900

11340

8940

(kg/m3)
Corrosion

Low

High

High

Low

Low

Resistance

Table 3.4.10: Basic cost metals (Sinnott, 2005)


Metal
Aluminium
Stainless Steel 304
Carbon Steel
Lead
Copper

/tonne
900
1600
300
400-700
800

From the data provided the best materials that is chosen is carbon steel. Carbon
steel have a high corrosion resistance and the highest melting point. From the table
3.5.1 it can be seen that the cost of the carbon steel is the lowest compared to other
metal. This proves that carbon steel is the best metal can be chosen.

3.4.5.4 Design Stress


The design data can be found using the table below (Sinnott, 2005). The design
stress can be found if the material and the temperature is known. Below, where
carbon steel for material at pressure and temperature at 0.165 N/mm2 and 85 C.

3-24

Figure 3.4.6: Typical Design for Stress Plate

Since the temperature is 850C, the interpolation has to do to get the more accurate
design stress and tensile strength. The interpolation is been calculated as shown
below

( 1000 C850 C )

( 125f ) N /mm2
0
0
2
(100 C50 C ) ( 125135 ) N /mm
=

Design stress, f = 129 N/mm2, Tensile strength = 360 N/mm2


3.4.5.5 Vessel Thickness
Minimum Wall Thickness
To ensure that any vessel is sufficiently rigid to withstand its own weight and any
incidental loads, the minimum wall thickness is required in design of separator. It is
also to ensure the safety when the production is working. The Figure 3.7 below
show the guideline for the wall thickness to make sure the thickness of any vessel
not been less than the values given. Note that the values of minimum thickness
including the value of corrosion allowance, 2 mm.

3-25

Figure 3.4. 7: Guideline for Minimum Wall Thickness with its Vessel Diameter
(Sinnott, 2005)

The equation of minimum wall thickness is shown as below,

t=

P i Di
+C
2 Jf Pi

Where,

= minimum wall thickness

Pi = operating pressure (N/mm2)


D i = internal diameter (mm)
f

= design stress (N/mm2)

= joint factor ( J=1 )

= corrosion allowance ( C=2mm )

N
0.165
(1611 mm)
(
mm )
t=
+2 mm
N
N
2 ( 1 ) 129
( mm )(0.165 mm )
2

= 3.032 mm 3 mm

(3.197)

3-26
Following the guideline for minimum wall thickness with its vessel diameter (Sinnott,
2005), the minimum thickness of wall according to the vessel diameter of vessel at
1.611 mm, the diameter should be 7 mm. So, 7 mm is taken to as the wall thickness
since it larger than 3mm that been calculated.

3.4.5.6 Design of Heads and Closures


The end of a cylindrical vessel are closed by heads of various shapes. Based from
Sinnott (2005), there are many types of head and closures that come with different
types of principal and various shapes such as:
1.
2.
3.
4.

Flat plates and formed flat heads


Hemispherical heads
Ellipsoidal heads
Torispherical heads

During the separator design for phthalic anhydride production, the type of heads and
closures need to be determined. In this case, Ellipsoidal heads are chosen because
it is commonly used by the industrial and it can stand up to 15 bar of operating
pressure (Sinnott, 2005).

Ellipsoidal Heads

Most standard ellipsoidal heads are manufactured with a major and minor axis ratio
of 2 : 1 (Sinnott, 2005). For this ratio, the following equation can be used to calculate
the minimum thickness required.

e=

Where,
J = joint factor
f = design stress

P i Di
2 Jf 0.2 Pi

(3.198)

3-27
Table 3.4.11: Welded Joint Efficiencies
Join

Acceptable Joint categories

Degree of Radiographic Examination


Full
Spot
None

A,B,C,D
A,B,C,D (See ASME code for limitations)
A,B,C
A,B,C (See ASME code for limitations)
B,C (See ASME code for limitations)
A,B (See ASME code for limitations)

1
0.9
NA
NA
NA
NA

t
type
1
2
3
4
5
6

e=

0.85
0.8
NA
NA
NA
NA

0.7
0.65
0.6
0.55
0.5
0.45

P i Di
2 Jf 0.2 Pi

N
(1611 mm)
mm 2

N
N
2 ( 1 ) 129
0.2( 0.165
)
2
mm
mm2

(
(

0.165

= 1.030 mm

3.4.5.7 Weight Loads


Dead Weight of Vessel
The approximate weights of cylindrical vessel with ellipsoidal heads can be
estimated with the equation below.

W v =240C v D m ( H v + 0.8 Dm ) t

(3.199)

Where,

W v = Total weight of the shell (N)


C v = A factor to account for the weight of nozzles, manways and internal
supports

(for separator with a few internal fittings = 1.08)

H v = Height or length, between the tangent lines (m)

3-28

Dm=

Mean diameter of the vessel (m)

t = Thickness of the wall of vessels (m)

Mean diameter, Dm :

D m=(Di +t x 103)m

( 3.200)

(1.611+7 x 10 )m
1.618 m

Though the equation only applies strictly to vessel with uniform thickness, it can be
used to get a rough estimate of the weight of this vessel by using the average
thickness in the equation, 11 mm.
Therefore,

W v =2 40(1.08) (1.618) ((4.83+0.8(1.618)) 11


= 28253.33 N = 28.253 kN

Weight of Insulation
In this production, mineral wool has been chosen for insulation for two-phase
separator due to its capability to absorb heat.
Mineral wool density = 130 kg/m3
Thickness of insulation = 75 mm

Approximate volume of insulation,

V i= Di H v t i
(3.201)

3-29
= ( 1.611 m ) ( 4.83 m )( 0.075 m )
= 1.834 m3
Weight of insulation,

W i=V i pg

(3.202)

1.834 m3 (130

kg
m
)(9.81 2 )
3
m
s

= 2339 N =2.339 kN
Weight of Demister Pad
Stainless steel pads was chosen as the material for the demister pad
Demister pad density = 150 kg/m3
Demister pad thickness = 144 mm
Pad area,
A=

( r 2 ) m2

(3.203)
=

( x 0.80552 ) m2

= 2.038 m

Weight of pad,

W p= A x p x t x g
2.038 m2 x 144

kg
kg
x 0.15 m x 9.81 3
3
m
m

= 431.85 N=0.431 Kn

Total Weight of Vessel

(3.204)

3-30

W T =W v +W i +W p

(3.205)

28.253+2.339 kN +0.431 kN

31.023kN

3.4.5.8 Wind Loading


Wind pressure, Wo is obtained by calculating the wind pressure based on wind
pressure, Vo that taken in India.( N. Lakshmanan, Structural Engineering Research
Centre,2009)

1
W o = p air V o2
2
1
(1.225 kg /m3 x (23.61m/ s)2)
2
341

kg
m s2

= 341 N/m2

Mean diameter, including insulation


= 2 + 2( twall + tins )
=

2+2 7 + 75) x 10-3

= 2.164 m
Loading (per linear metre),Fw = 341 x 2.164
= 737.924 N/m
Bending moment at bottom tangent line:

M x=
(3.207)

737.924
2
x 4.83
2

Fw
x H v2
2

(3.206)

3-31

8607.48 Nm

3.4.5.9 Analysis of Stresses


At bottom tangent line
Pressure stress:

L=
0.165

Pi D i
4t

(3.208)

Pi D i
2t

(3.209)

N
x 1611 mm
mm2
4 x 7 mm

9.494 N /mm2

h=
0.165

N
mm x 1611 mm
2 x 7 mm
2

18.987 N / mm2

Dead weight stress:

w=

Wc
( D i +t ) t

(3.210)

28.256 x 103
( 1611+7 ) 7

0.794 N /mm2 (Compressive)


Bending stresses:

D o=1611+ 2 x 7=1625 mm
I v=

( 1625 41611 4 ) =1.165 x 1010 mm 4


64

3-32

b =

8607.48 x 103 1611


(
+7)
2
1.165 x 1010

0.600 N /mm 2

The resultant longitudinal stress is:

z= L + w b
w

(3.211)

is compressive and therefore negative.

z (upwind) = 9.4940.794+ 0.600=+9.3 N /mm 2


z (downwind) = 9.4940.7940.600=+8.1 N /mm2

As there is no torsional shear stress, the principal stresses will be

z and h .

The greatest difference between the principal stresses will be on the down-wind side

18.987 N /mm28.1 N /mm2


10.878 N /mm2

3.4.5.10 Design of Skirt Support


There are two kinds of support that were can be used in designing a separator,
which is saddle and skirt support. Based on Sinnott (2005) the type of saddle
support is based on the orientation of the separator itself. Since the separator that
was used is vertical in orientation, the support design that was chosen is skirt
support. There are two types of skirt support which is cylindrical and conical. The
type of the skirt support are based on the design of the pressure vessel itself.
The support is referred to as skirt because it resembles a skirt. Since larger
pressure vessels are subjected to high intensity loads, it is important to transmit
them effectively (Gurvinder Arora, 2014).Symmetry of supports is critical which is
achieved in smaller pressure vessels by equidistant placing of legs

3-33

Figure 3.4.8: Straight Cylindrical Skirt Support

Skirt thickness
The skirt thickness must be sufficient to withstand the dead weight loads and
bending moments imposed on the vessel.

approximate weight= x

1.611
x 4.83 x 1000 x 9.81
4
96582.202 N =96.582 kN

weight of vessel=31.023 kN
Total weight =96.582+ 31.023=127.605 kN

Bending moment, Ms at base of skirt

Bending moment , M s=wind loading x


0.737 x

(Height ( skirtvessel))2
2

6.832
=17.19 kNm
2

(3.212)

3-34
Height of vessel as calculated before = 4.83 m
Height of skirt = 2m
Bending stress in skirt,

bs

Use thickness skirt as same as thickness of bottom section of vessel = 15 mm

bs=

4 Ms
(D s+t s )D s t s

4 (17.19 x 103 x 103 )


( 1611+15 ) 1611 x 15

0.557 N /mm

Dead weight stress in the skirt,

ws =
Where

W
(Ds +t s )t s
W =total weight ( weight of vesseldead weight )=127.605 kN

ws (test )=

127.605 x 103
( 1611+15 ) 15

1.67 N /mm
Where

ws

W v =weight of vessel=28.253 N

ws ( operating )=

28.253 x 103
(1611 +15 ) 15

0.37 N / mm2

Maximum

s ( compressive )=0.557+1.67=2.227 N /mm

Maximum

s ( tensile ) =0.5570.37=0.187 N /mm2

Check whether this design can be accepted or not:


Take joint efficiency as, E= 1 (full radiograph).
Criteria for design:

s ( tensile ) f s J sin

3-35

0.187

N
N
( 1 ) 129
sin 90
2
mm
mm2

0.187

N
N
129
2
mm
mm2

s ( compressive ) 0.125 E

ts
sin
Ds

2.227

N
15
0.125 x 200000(
)sin 90
2
1611
mm

0.035

N
N
232
2
2
mm
mm

Both criteria are satisfied, by adding 2 mm for corrosion allowance. Then, the design
thickness of skirt is 17 mm.

Base Rings and Anchor Bolts


Assume pitch circle diameter, Db = 1.8 m
Circumference of bolt circle,

Db = 1.8
= 5654.89 mm

According to (Coulson Richardson Chemical engineering volume 6, page 848),


recommended spacing between bolts = 600 mm
Minimum number bolt required, Nb =

5654.89 mm
600 mm
9.424

Closest multiple of 4 = 12 bolts


Bolt stress design, fb =

125 N /mm2

Bending moment at base skirt, Mb = 17.19 kNm

3-36

Area of bolt, Ab was obtained as below


Weight of vessel, W = 72.385kN

area of bolt , A b=

1 4 Ms
(
W )
N b f b Db

(3.213)

4 ( 17.19 x 103 )
1

(
31.023 x 10 3)
1.8
12 ( 125 )

= 4.5mm2

Bolt root diameter =

4.5 mm2 4

= 2.3 mm

3.4.5.11 Nozzle Sizing


Nozzle was designed to have a size that able to minimize erosion/corrosion,
pressure drop and entrainment. By using flowrates of both phases, nozzle can be
sized. That is by using an appropriate margin. Nozzles should be designed
according to the following criteria shown below (PTS, 2000).
For Inlet:
No inlet device

pV 2<1400 kg /m s2

Half pipe inlet device :

pV 2<2100 g/ m s 2

Inlet device

pV 2< 8000 kg/m s 2

pV <1500 kg /m s

For Outlet:
Gas Outlet

3-37

Liquid Outlet

pV 2<2 m/s

Inlet Nozzle Sizing


The total volumetric flow rate:
3

Qg =325

m
min

Q l= 0.1359

m
min
3

Qtotal=Q g+ Ql=325

m
m
+0.1359
min
min
3

= 325.13590

m
min = 5.418

m
s

The total density of component:

pg =0.9528

kg
m3
kg
m3

pl= 1257.96

pmixture=

p g Q g+ p l Q g
Q g+ Q l

(3.214)

0.9528

kg
m3
kg
m3
325
+
1257.96
(0.1359
)
min
min
m3
m3
m3
m3
(325
+0.1359
)
min
min

)(

)(

1.478 kg / m3

3-38
Assume half pipe inlet device:

pV 2=2100 kg/m s 2

Allowable

Allowable velocity,

v = p V 2 / p

(2100 kg /ms 2 )/(1.478

kg
)
m3

= 37.694 m/s
So then the nozzle area,

A=Q total /v

5.418

m
/ 37.694 m/s)
s

0.1437 m2

Required nozzles diameter,

d nozzleinlet = 4 A /
4 (0.1437 m2)/
0.428 m

Vapor Outlet Nozzle Sizing


The volumetric flow for vapour outlet:

Qg =325

m3
min

= 5.417

m3
s

3-39
Gas outlet density:

pg =0.9528

Allowable

kg
m3
pV 2=1500 kg/m s 2

Allowable velocity,

v = p V 2 / p
(3.215)

(1500 kg /ms 2) /(0.9528

kg
)
m3

= 39.68 m/s
Thus the nozzle area,

A=Q g /v
A=(5.41 m3 / s) / (39.68m/s)
A=0.13651m 2
Required nozzle diameter,
dnozzle gas=

dnozzle gas=

4 (0.13651)/

dnozzle gas= 0.41691m = 416 mm

Liquid Outlet Nozzle Sizing


The volumetric low for vapour outlet:

4 A /

(3.216)

3-40

Ql=0.13591 m3 /min

0.00227 m3 /sec

Gas outlet density

l=1257.96 kg /m

Allowable Velocity

v =2.0 m/s

So then the nozzle area

A=Q l /v
A=(0.00227 m 3 /sec ) /(2.0 m/s)
A=0.00114 m 2
Required nozzle diameter

d nozzleliquid= 4 A /
d nozzleliquid= 4 (0.00114)/
d nozzleliquid=0.03810 m=38.098mm

3.4.5.12 Standard Flanges


Standard flanges are available in a range of types, sizes and materials and are used
extensively for pipes, nozzles and other attachments to pressure vessels (Sinnott,
2005). The figure 3.4.9 below shows the illustration of dimension of standard
flanges.

3-41

Figure 3.4.9: The Dimension of Standard Flange

Table 3.4.12: Standard Flanges Specifications (Sinnott, 2005)

Table 3.4.13 shows the flange design of the separator, for the feed inlet and
the outlet of the gas, the value of the nozzle is high which is 418 and 426 mm

3-42
respectively. Based on table 3.4.12, the highest value is 300 mm, thus the data for
the feed inlet and outlet gas are taken at nozzle sizing of 300mm.

Table 3.4.13: Flange design for the separator


Nozzl

Nom

Pipe

o.d.

Inlet

Size
300

d1
323.

Outlet
Gas
Outlet

Flange

Raise d

Boltin
g

Faced
d4
f

440

22

44

365

300

9
323.

440

22

44

365

40

9
48.3

130

14

26

80

Liquid
3.4.6

Drilling

Bos

No.

d2

s
d3

M20

12

22

395

355

M20

12

22

395

355

M12

14

100

70

Summary Of Mechanical Design Of Separator

The table below shows the summary of mechanical design of a separator.

Table 3.4.14: Summary of Mechanical Design of Separator


Item
Design Pressure
Design Temperature
Material Used
Design Stress
Tensile Stress
Wall Thickness
Ellipsoidal Wall Thickness
Weight Loads
Type of Support

Value
0.165 N/mm2
358.05K
Carbon Steel
129 N/mm2
360 N/mm2
7mm
1.030mm
28.253 kN
Skirt Support

3-43

References
Sinnot, R.K., Coulson, J.M., Richardson, J.F., (2005), Chemical Engineering Design,
4th Edition, Vol. 6, UK: Butterworth-Heinemann.
IPS-E-PR-880, (1997), Engineering Standard for Process Design of Gas (Vapour)Liquid Separators, Original Edition.
Barker, W.F., Oil and Gas J. (1982), p. 186.
Polderman, H. G., Bourna, J. S., and H. van der Poel, Design Rules for Dehydration
Tanks and Separator Vessels, SPE38816, San Antonio, Texas (5-8 Oct., 1997).
Watkins,R.N.,Sizing Separators and Accumulators, Hydrocarbon Processing.
46(11),p. 253-256 (1967).
Gerunda,Arthur. How To Size Liquid Vapor Separators,Chem Eng.,p. 81-84(1981).
ASME Pressure Vessel Code,Section VIII, Division 1, Table UCS-23,p. 27021771(1986).
Perry,Robert H. and Cecil H. Chilton,eds.,Chemical EngineersHandbook,5th
edition,Chapter 2,p. 2-6 (1973).
Carpentler,P.I,,,Important Parameters For Cost Effective Separator Design, Shell
Oil Company-Head(1988).
Gas Processors Suppliers Association, Engineering Data Book, 10th edition, Vol 1,
Chapter 7(1987)
Otto II. York Company Inc.,Mist Elimination in Gas Treatment Plants and
Refineries, Engineering,Parsippany,NJ.
Sauders M., and G.G. Brown,Ind. Eng.Chem.,26(1),p.98(1934)
American Petroleum Institute, Recommended Practice 521 (1982)

3-44

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