CH 4034 Comprehensive Design Project II

Interim Report 1
Flash separator design
Conversion of low-octane n-paraffins
To high-octane iso-paraffins

Name:

130549T SAUMYA A.K.D.D.

Department of Chemical and Process Engineering

University of Moratuwa
Contents
Contents .............................................................................................................................................. ii
List of Figures ..................................................................................................................................... ii
List of Tables ..................................................................................................................................... iii
Nomenclature ..................................................................................................................................... iii
CHAPTER 01: EQUIPMENT SELECTION ......................................................................................1
1.1 PROCESS DISCRIPTION ....................................................................................................1
1.2 REQUIREMENT OF A SEPARATOR ................................................................................2
1.2.1 Separator feed stream .....................................................................................................2
1.3 EQUIPMENT SELECTION .................................................................................................3
1.3.1 Number of phases ..........................................................................................................3
1.3.2 Working principles of separators ........................................................................................3
1.3.2.1 Gravity separators ........................................................................................................3
1.3.2.2 Centrifugal vapor liquid separators ..............................................................................3
1.3.2.3 Vapor-liquid filter separators .......................................................................................3
1.3.3 Shape of the vessel ..............................................................................................................4
1.3.4 Operating Pressure ..............................................................................................................5
1.4 DESCRIPTION ON SELECTED EQUIPMENT .................................................................6
1.4.1 Material Balance ............................................................................................................7
1.4.1.1 Overall Material balance .............................................................................................. 7
1.4.1.2 Inlet stream composition .............................................................................................. 7
CHAPTER 02: SIZE CALCULATION .............................................................................................. 8
Flash Drum Sizing- Summary ........................................................................................................14
References ............................................................................................................................................v

List of Figures
Figure 1. 1 Vertical separator schematic.............................................................................................. 6

Figure 2. 1 Separator vessel dimensions .............................................................................................. 8

Figure 2. 2Liquid holdup and surge times .........................................................................................11
Figure 2. 3 Low liquid level height ....................................................................................................12

ii
List of Tables
Table 1. 1 Separator feed stream..........................................................................................................2
Table 1. 2 comparison of vessel configurations...................................................................................4
Table 1. 3 Material Balance .................................................................................................................7
Table 1. 4 Inlet stream composition .....................................................................................................7

Table 2. 1 Sizing-Summary ...............................................................................................................14

Nomenclature
2MP :2 - Methyl pentane
23DMB :2,3 - Dimethyl butane
22DMB :2,2 - Dimethyl butane
3MP :3 - Methyl pentane
22DMP :2,2 - Dimethyl propane
2MB : 2 - Methyl butane
DV : Vessel diameter
DN : Nozzle diameter
DVD : Vapor disengagement diameter
HD : Disengagement height
HH : Holdup height
HLL : High liquid level
HL IN : HLL to inlet nozzle centerline height
HLLL : Low liquid level height
HME : Mist eliminator to top tank height
HS : Surge height
HT : Total vertical separator height
HV : vapor disengagement area height
K : terminal velocity constant
QL : Liquid volumetric flow
QM : Mixture volumetric flow
QV : Vapor volumetric flow

iii
TH : Hold up time
UT : Terminal velocity
UG : Vapor velocity
λ : mixture liquid fraction

𝜌L : Liquid density

𝜌G : Vapor density

𝜌M : Mixture density

iv
CHAPTER 01: EQUIPMENT SELECTION

1.1 PROCESS DISCRIPTION

When the conversion of light naphtha into gasoline is considered, there are several methods existing
and considering pros and cons, the BP total isomerization process was selected as the most
appropriate method in the ‘Comprehensive Design Project I’. The basic conversion happens in the
process is from low octane n-paraffin to high octane iso-paraffin. Available raw material supply is
an average of 448MT/day of light naphtha from Ceylon Petroleum Corporation refinery.

Conditioned feed stock is added with recycle H2 and sent to the lead reactor. The reactor effluent is
cooled before sending to the tail reactor since the overall reaction is exothermic. Then the effluent is
sent to the product separator. From there the separated H2 gas is sent to reactor again with makeup
hydrogen and the liquid is sent to the stabilizer. Overhead is sent via a caustic wash to fuel gas system
and the bottom is the premium grade gasoline. This product stream needs further purifications as
required.

In ‘Comprehensive Design Project 1’ the production flow rate was established, a detailed analysis on
SHE and economic establishment was performed and a material and energy balance was performed
for the entire process.
1.2 REQUIREMENT OF A SEPARATOR

Tail reactor outlet is a gas vapor mixture at 140oC temperature and 20bar pressure. This stream contains
iso-pentane and iso-hexane products, unreacted n-pentanes and n-hexanes and hydrogen. By using a
cooler this stream temperature is reduced to 70oC (according to the overall process design) and further
condensation occurs. There after the separation of hydrogen process occurs.

The main objective here is to separate hydrogen to add back as a recycle stream in to the process
flow. Hydrogen is important in facilitating the reactions in the lead and tail reactors. By recycling
hydrogen stream back, it is possible to reduce the pure hydrogen requirement and it is only required
to add the makeup amount. It is a suitable solution for the bottle neck in hydrogen supply as well. To
separate hydrogen from the hydrocarbon stream a suitable separation process is required.

1.2.1 Separator feed stream

Note: For this overall process Hydrogen must be supplied in the ratio of H2/HC(mol/mol) 0.1-
2. For the previous two modules of semester 6b and 7, it was decided to go for the minimum
requirement which is H2/HC(mol/mol) = 0.1 considering the Hydrogen availability. But since
this low hydrogen flow causes unrealistic vessel dimensions, it was decided to use 6.5 ratio of
H2/HC.

Table 1. 1 Separator feed stream

Mole flow kmol/hr Total Flow kmol/hr 389.812

PENTANE 10.5958 Total Flow kg/hr 18084.11
HEXANE 0.81081 Total Flow l/min 257.273
H2 153.563 Temperature C 50
2MB 86.8396 Pressure bar 20
22DMP 86.8396 Vapor Frac 0.4378
2MP 17.5147 Liquid Frac 0.562
3MP 10.2923 Solid Frac 0
22DMB 17.2769 Density kmol/cum 4.11810
23DMB 6.08024 Density kg/cum 282.418

2
1.3 EQUIPMENT SELECTION

1.3.1 Number of phases

Separators are classified as ‘two phase separators’ if they separate gas from a total liquid stream and
‘thee phase’ if they separate the liquid stream into oil and water components as well. Since the desire
of this design is to separate hydrogen gas from a hydrocarbon stream, the appropriate application is
a two-phase separator.

1.3.2 Working principles of separators

The two-phase separators for vapor liquid separation generally used in industries are classified as
following according to the working principle of it. [1]

1.3.2.1 Gravity separators

In a gravity separator, the separation process happens depending on gravitational forces by settling
and sedimentation. In a gas liquid system, the liquid droplets may settle out of gas phase since the
drag force on liquid particle is greater that around the gas. In this type, the lower the gas velocity and
larger the vessel size, more efficient the separation.

Flash separation is a type of separation process where gravity separator principles are applied. Flash
separator is a vapor-liquid separator in which liquid droplets are separated from a vapor- liquid
mixture (a flashing liquid) and the liquid is separated by gravity, falls to the bottom of the vessel and
then withdrawn. The vapor travels upward at a design velocity which minimizes the entrainment of
liquid droplets in the vapor as it exits the top of the vessel. [2]

1.3.2.2 Centrifugal vapor liquid separators

This might be built in stationary and rotary types and centrifugal action may help in separating
materials of different densities and phases. In this type of separators, as the mixture enters the
cylindrical separator space, a centrifugal force of several times greater than gravity is applied.

1.3.2.3 Vapor-liquid filter separators

This is used in separating liquid and solid particles from a gas stream. Separation efficiency is higher
than a centrifugal separator but, it is required to replace the filter elements periodically. These filter
separators are mostly used in applications like, gas storage systems to prevent withdrawal of solid,

3
dust and small amounts of liquid, compressor stations to protect compressors from free liquid. So,
this separator type is basically for purifying gas streams from vapor and liquid contaminants.

Comparing the above 3 types of separation, the intention of a vapor-liquid filter separator is basically
for purifying gas stream from vapor and liquid contaminants. Both centrifugal and filter separators
are used when a high efficiency of separation is required. These are highly cost methods. For the
required application, the main desire is not to purify the hydrogen gas stream but to separate hydrogen
from the hydrocarbon stream and send as a recycle gas stream just as a solution for bottleneck in
hydrogen supply. Otherwise separating hydrogen is not a must in this stage since, a stabilizer column
is there at the final stage of process where remaining hydrogen can be separated. In the original BP
isomerization process a flash drum was applied in this stage and the conditions for the separation
were found from Aspen simulation for a flash drum in semester 7 design project. Also, a flash
separator which is a gravity separator type, is comparatively less costly.

Considering the above comparison, it is decided to select a flash separator for the process step.

1.3.3 Shape of the vessel

Depending on the configuration, the separator vessel can be either horizontal, vertical or spherical.
Comparison of these configurations are as follows. [1]

Table 1. 2 comparison of vessel configurations

Configuration Advantages Disadvantages

Vertical • Occupies less ground area • Fabrication is more expensive

• Easier to clean • Takes longer diameter
• Provides better surging control separator for a given gas
• Liquid level controlling is not capacity compared to
critical horizontal separators
• Less tendency for re-evaporation
of liquid into the gas phase due to
the relatively greater vertical
distance between liquid level and
gas outlet

4
 Horizontal • Economical for handling large gas • Space requirement is high
volumes (design permits higher • Liquid level controlling is
gas velocities) critical
• Cheaper fabrication when • Surge space is limited
compared to vertical separators • Harder to clean
• Require less piping for field
connections
• Reduces turbulence and foaming
Spherical • Easier to install • Liquid level control is critical
• More compact • Limited surge space
• Adaptable for portable use
• Very inexpensive compared to
other types
• Good for low and intermediate
gas-oil ratios
• Better clean-out

If the ideal usage is considered, vertical vessels are suitable for low to intermediate vapor-liquid ratio,
and where relatively large slugs of liquid are expected. Horizontal vessels are ideal for high vapor-
liquid ratio crudes, foaming crudes, or for liquid-liquid separation and good for a diverse range of
situations. When spherical vessels are considered, these are ideal for intermediate or low vapor-liquid
ratio.

When the feed stream conditions are considered,

Vapor Fraction 0.438

Liquid Fraction 0.562

Vapor-liquid 0.779
ratio

So, it is having a medium vapor-liquid ratio. Since vertical vessels work effectively on low to medium
vapor-liquid ratio and considering above advantages and disadvantages, vertical type was selected
as the suitable shape of the vessel.

1.3.4 Operating Pressure

Separators can be classified according to their operating pressure. [3]Low pressure units handle
pressures of 10 to 180 psi (0.69 to 12 bar), medium pressure separator operates from 230-700 psi (15
bar to 48bar) and high-pressure units handle pressure from 975 to 1500 psi (67 to 103 bar).

5
From aspen simulation for a flash separator (using Aspen V 8.8) by a sensitivity analysis, it was found
out that the optimal separation of hydrogen can be done when the flash separator is operated in a
pressure of 7 bar. So according to the above classification this can be considered as a low-pressure
vessel.

1.4 DESCRIPTION ON SELECTED EQUIPMENT

According to the above selection procedure, the equipment selected was a vertical type flash separator
of low pressure which is basically a two-phase separator.

Figure 1. 1 Vertical separator schematic

In a flash separator, liquid is separated by gravity and falls. Vapor travels upward at a design velocity
and minimizes the liquid droplet entrainment. The major parts of a flash gravity separator are feed
pipe, inlet device, gas gravity separation section, mist extractor and the liquid gravity separation
section.

The various internal parts must be included in this vessel for promoting separation as required as
shown in Figure 1.1.

6
1.4.1 Material Balance

1.4.1.1 Overall Material balance

Table 1. 3 Material Balance

Component Inlet stream Vapor outlet Liquid outlet

(kg/hr) stream (kg/hr) stream (kg/hr)
PENTANE 764.490 111.764 652.7257
HEXANE 69.873 3.679 66.194
H2 309.564 308.657 0.907
2MB 6265.501 1153.588 5111.914
22DMP 6265.501 1758.834 4506.667
2MP 1509.367 104.096 1405.271
3MP 886.961 55.7670 831.1942
22DMB 1488.874 143.856 1345.018
23DMB 523.978 39.038 484.940
Total 18084.11 3679.28 14404.83

1.4.1.2 Inlet stream composition

Table 1. 4 Inlet stream composition

Component Total (kg/hr) Vapor (kg/hr) Liquid (kg/hr)

PENTANE 764.490 43.873 720.617
HEXANE 69.873 1.436 68.437
H2 309.564 306.244 3.319
2MB 6265.501 461.130 5804.372
22DMP 6265.501 734.615 5530.886
2MP 1509.367 40.547 1468.82
3MP 886.961 21.701 865.260
22DMB 1488.874 55.884 1432.991
23DMB 523.978 15.163 508.815

7
CHAPTER 02: SIZE CALCULATION

Vapor-liquid separation occurs in 3 stages [4]. First stage is the primary separation, where an inlet
diverter is used, which causes momentum of the liquid entrained in vapor causes largest droplets to
impinge on the diverter and then drop under the gravity force. Then in the secondary separation stage,
when vapor flows through the disengagement area, the smaller droplets get separated under gravity.
Then in the final stage of separation, mist elimination happens and in this stage smaller droplets
coalesced and larger droplets are formed, which then get separated by gravity.

Figure 2. 1 Separator vessel dimensions

8
Reference followed [5]

Step 1: Vertical terminal vapor velocity

This is the maximum allowable vapor velocity and can be calculated by Sounders-Brown equation.
This is based on the force balance on a droplet falling through vapor.

𝜌𝐿 − 𝜌𝐺
𝑈𝑡 = 𝐾 √
𝜌𝐺

𝜌𝐿 − liquid density= 600.244kg/m3= 37.472lb/ft3

𝜌𝐺 − 𝑔𝑎𝑠 𝑑𝑒𝑛𝑠𝑖𝑡𝑦= 4.970kg/m3= 0.310lb/ft3

𝐾-terminal velocity constant (vapor loading factor)

The “K: value largely independent on system variables. Reliable estimation of this K factor is crucial
in sizing flash drum.

Since the separated hydrogen stream is sent to a compressor, removing liquid droplets in the gas
stream is a must. It is to remove entrained liquid droplets from a vapor stream. With a mist eliminator,
a 99.99% of efficiency is achievable. So, k value selection when a mist eliminator is there is
considered.

The flash vessel pressure=P=7 bar=101.526psia

So 𝐾 = 0.430 − 0.023 ln 𝑃 = 0.324 𝑓𝑡/𝑠

37.472 − 0.31024
𝑡𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 𝑈𝑡 = 0.324√ = 3.543ft/s
0.31024

= 1.081𝑚/𝑠

For conservation design, vapor velocity UG=0.75Ut

𝑉𝑎𝑝𝑜𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 𝑈𝐺 = 0.75 × 3.543 = 2.657𝑓𝑡/𝑠 = 2917.742𝑚/ℎ𝑟

9
Step 2: Vapor volumetric flow rate

Vapor volumetric flow rate can be directly found from the simulation results.

From Aspen simulation results,

𝑉𝑎𝑝𝑜𝑟 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 𝑄𝐺 = 12339.22𝑙/𝑚𝑖𝑛 = 740.353𝑚3 /ℎ𝑟

Step 3: Vessel inside diameter

4𝑄𝐺 1/2 4 × 740.353 1/2

𝑉𝑎𝑝𝑜𝑟 𝑑𝑖𝑠𝑒𝑛𝑔𝑎𝑔𝑒𝑚𝑒𝑛𝑡 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝐷𝑉𝐷 = ( ) =( ) = 0.568𝑚
𝜋𝑈𝐺 𝜋 × 2917.742

Here to find the final vessel diameter, it is needed to decide whether to put a mist eliminator or not.
Mist eliminators are used to remove liquid droplets in a gas stream. In the process flow after the flash
drum, the gas stream goes to a compressor. So, for removing liquid droplets, it was decided to put a
mist eliminator.

If a mist eliminator is there, 3 to 6 inches must be added to the DVD value.

If 6 inches (0.1524m) were added,

𝑉𝑒𝑠𝑠𝑒𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 = 𝐷𝑣 = (0.568 + 0.1524) = 0.721𝑚

Step 4: Liquid volumetric flow rate

Liquid volumetric flow rate also can be directly found from the simulation results.

From Aspen simulation results,

𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = 𝑄𝐿 = 399.971𝑙/𝑚𝑖𝑛 = 23.998𝑚3/ℎ𝑟

Step 5: Holdup time and hold up volume

For this, the table in Figure 2.2 was referred.

Hold up time(Th) selected is 2min.

𝐻𝑜𝑙𝑑 𝑢𝑝 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝑉𝐻 = (𝑇ℎ × 𝑄𝐿 ) = 2 × 399.97𝑙 = 28.250𝑓𝑡 3 = 0.800𝑚3

10
 Figure 2. 2Liquid holdup and surge times

Step 6: Surge time and surge volume

For this calculation, referring Figure 2.1;

Surge time (TS)= 1 min

𝑆𝑢𝑟𝑔𝑒 𝑣𝑜𝑙𝑢𝑚𝑒 = 𝑉𝑆 = (𝑇𝑠 × 𝑄𝐿 ) = 1 × 399.97𝑙 = 14.125𝑓𝑡 3 = 0.40𝑚3

11
Step 7: Low liquid level height

Referring the below figure,

Figure 2. 3 Low liquid level height

𝐿𝑜𝑤 𝑙𝑖𝑞𝑢𝑖𝑑 𝑙𝑒𝑣𝑒𝑙 ℎ𝑒𝑖𝑔ℎ𝑡 = 𝐻𝐿𝐿𝐿 = 15 𝑖𝑛𝑐ℎ = 0.381m

Step 8: Hold up height

This gives the height from low liquid level to normal liquid level

𝑉𝐻
𝐻𝐻 = 𝜋
( ⁄4)𝐷𝑉2

0.800
= 𝜋 = 1.96𝑚
( ⁄4) × 0.7212

Step 9: Surge height

This gives the height from normal liquid level to high liquid level (or high-level alarm)

𝑉𝑠
𝐻𝑠 = 𝜋
⁄4 𝐷𝑉2

0.40
=𝜋 = 0.980𝑚
⁄4 × 0.7212

Step 10: Height from high liquid level to the centerline of the inlet nozzle

For this, it must be decided whether put an inlet diverter or not.

The feed stream to the separator is typically a high velocity turbulent mixture of gas and liquid.
Because of this high velocity, the fluids enter with a high momentum and from an inlet diverter, the

12
direction of the flow can be abruptly changed by absorbing the momentum of the liquid. That allows
the liquid and gas to separate. The inlet diverter also referred as the primary separation section.

So, considering that an inlet diverter is to be used,

𝐻𝑒𝑖𝑔ℎ𝑡 𝑓𝑟𝑜𝑚 ℎ𝑖𝑔ℎ 𝑙𝑖𝑞𝑢𝑖𝑑 𝑙𝑒𝑣𝑒𝑙 𝑡𝑜 𝑡ℎ𝑒 𝑐𝑒𝑛𝑡𝑒𝑟𝑙𝑖𝑛𝑒 𝑜𝑓 𝑡ℎ𝑒 𝑖𝑛𝑙𝑒𝑡 𝑛𝑜𝑧𝑧𝑙𝑒 = 𝐻𝐿 𝐼𝑁
= 12 + 𝑑𝑁 (𝑖𝑛𝑐ℎ)

dN is the nozzle diameter (inlet or outlet, vapor or liquid as specified.

4𝑄𝑚
𝑑𝑁 ≥ ( )1/2
60𝜋
⁄√𝜌
𝑚

𝑄𝑚 = 𝑄𝐿 + 𝑄𝐺

𝜌𝑚 = 𝜌𝐿 𝜆 + 𝜌𝐺 (1 − 𝜆)

𝑄𝐿
𝜆=
𝑄𝐿 + 𝑄𝐺

23.998
𝜆= = 0.0314
740.353 + 23.998

𝜌𝑚 = 37.472 × 0.0314 + 0.310 × (1 − 0.0314) = 1.477𝑙𝑏/𝑓𝑡 3

3
𝑄𝑚 = 𝑄𝐿 + ℎ𝑄𝐺 = 23.998 + 740.353 𝑚 ⁄ℎ = 7.498𝑓𝑡 3 /𝑠

1
2
4 × 7.498
𝑑𝑁 ≥ ( ) = 0.440𝑓𝑡 = 5.276𝑖𝑛𝑐ℎ
60𝜋⁄
√1.477
So dN=5.276inch

𝐻𝐿 𝐼𝑁 = 12 + 5.276 = 17.276 𝑖𝑛𝑐ℎ = 0.438 𝑚

Step 11: The disengagement height from the centerline of the inlet nozzle to the bottom of the
demister pad

With a mist eliminator,

𝐻𝐷 = 24 + 1⁄2 𝑑𝑁 (𝑖𝑛𝑐ℎ𝑒𝑠)

𝐻𝐷 = 24 + 1⁄2 × 5.276 = 26.638(𝑖𝑛𝑐ℎ𝑒𝑠) = 0.677𝑚

13
Step 12:

Since there is a mist eliminator;

For the mist eliminator pad= 6 inch=0.1524m

From top of the mist eliminator to the top tangent line of vessel= 1ft=0.3048m

𝐻𝑀𝐸 = 0.1524 + 0.3048𝑚 = 0.4572𝑚

Step 13: Total height

𝐻𝑇 = 𝐻𝐿𝐿𝐿 + 𝐻𝐻 + 𝐻𝑆 + 𝐻𝐿𝐼𝑁 + 𝐻𝐷 + 𝐻𝑀𝐸

𝐻𝑇 = 0.381𝑚 + 1.96𝑚 + 0.980𝑚 + 0.438 𝑚 + 0.677𝑚 + 0.4572𝑚

= 4.89𝑚

Flash Drum Sizing- Summary

Table 2. 1 Sizing-Summary

Dimension Value(m)

DV 0.721

DN 0.134

HLLL 0.381

HH 1.960

HS 0.980

HL IN 0.438

HD 0.677

HT 4.89

14
References

[1] Mulyandasiri V, "KLM Technology Group," January 2011. [Online]. Available:

http://kolmetz.com/pdf/EDG/ENGINEERING_DESIGN_GUIDELINE__separator%20vessel_
REV01.pdf. [Accessed 03 September 2017].

[2] Brainmass, "Brainmass.com," 2008. [Online]. Available:

https://brainmass.com/file/1539641/Flash%2Bvaporization.pdf. [Accessed 12 9 2017].

[3] "Schlumberger- Oilfield Glossary," [Online]. Available:

http://www.glossary.oilfield.slb.com/en/Terms/s/separator.aspx. [Accessed 11 09 2017].

[4] Svrcek.W.Y and Monnery.W.D, "Scribd," October 1993. [Online]. Available:

https://www.scribd.com/document/70426273/Design-Two-Phase-Sep. [Accessed 12 september
2017].

[5] Svrcek.W.Y and Monnery.W.D, "Design of two phase separators within right limits," 1993.

[6] Philip.C.Wankat, Equilibrium staged separation, Prentice Hall, 1988.