Training Services

Tray Sizing

EDS-2004/TS-1

1
 Column Internal Design

„ Counter Current Vapor/Liquid Contact

„ Cross Flow Trays

– Cheap
– Rugged
– Tolerant

„ Other Types of Trays

„ Packing

EDS-2004/TS-2

Types of cross flow trays are sieve trays, valve trays, and bubble cap trays.

Other tray types include side-to-side pans and disc and donut trays.

Packing can be structured or random.

2
 Cross Flow Trays

„ Bubbling Area
– Shear vapor/liquid into small drops and bubbles

„ Downcomer
– Separates vapor and liquid

EDS-2004/TS-3

3
 Tray Vendors

„ Koch - Flexitray
„ Glitsch - Ballast Tray
„ Nutter - Float Valve
„ Norton - Hydronyl, Wyatt and GLF
„ Sulzer - Metawa Snap-In-Valves
„ UOP - MD

EDS-2004/TS-4

The course will focus on Koch and Glitsch type valve trays. Glitsch was recently
bought by Koch and there will probably be a melding of the two distinct methods.

4
 Types of Cross Flow Trays

„ Sieve

„ Valve

„ Bubble Cap

EDS-2004/TS-5

Due to the proprietary nature of FRI correlations, the class will not cover sieve
trays. Bubble cap trays were commonly used in the refining industry long ago, but
are not favored today due to their higher cost.

5
 Other Trays

„ Dual Flow

„ Side to Side

„ Disc and Donut

„ Shed Decks

EDS-2004/TS-6

Dual flow trays have no downcomers, as vapor/liquid or liquid/liquid phases pass

through open area counter-currently. Shed decks are commonly used in the bottom
of Coker main fractionators.

6
 Cost of Column

„ 5 to 17% of Total Installation

EDS-2004/TS-7

7
Some Tray Layout Definitions

A - Chord Height
B - Chord Length or Weir Length
C - Flow Path Length
D - Downcomer Width

D
A

EDS-2004/TS-8

8
 One Pass Tray

All the liquid goes

down each downcomer
This Tray

Downcomer
Seal Area
Active Area
or Bubbling
Area

Downcomer Area

Odd and even trays are identical but are rotated 180º from each other

EDS-2004/TS-9

9
 Two Pass Tray
All the liquid goes
down this downcomer

1/2 the liquid goes 1/2 the liquid goes

down each downcomer down each downcomer

Downcomer
Seal Area
This Tray

Downcomer Area
Active Active
Area Area

Downcomer Area

Odd and even trays are not the same

EDS-2004/TS-10

10
 Three Pass Tray
2/
3 of the liquid goes
down this downcomer

1/
3 of the liquid goes down
each side downcomer

This Tray
Downcomer Downcomer Area
Seal Area

Downcomer
Active Active Active Seal Area
Area Area Area

Downcomer
Area

Odd and even trays are identical but are rotated 180° from each other
EDS-2004/TS-11

There are hydraulic imbalances inherent with 3 pass trays. Some refiners exclude
them from their process units.

11
 Four Pass Tray

1/2 of the flow goes down each center and Downcomer Seal Area
intermediate downcomer

Downcomer Downcomer
Area Area

This Tray
This Tray 1/4 ofthe liquid
goes down each
side downcomer

Downcomer
Area

Odd and even trays are not the same

EDS-2004/TS-12

Although 4 pass trays do not have the same “reputation” as 3 pass trays, there are
still hydraulic imbalances that exist here as well.

Although the tray plan may depict otherwise, the flow path lengths are normally
equal in UOP tray designs.

12
Major Tray Design Considerations
Hardware

„ Tray Spacing
„ Downcomer Area
„ Bubbling and Hole Area
„ Number of Passes
„ Other Items (Weir Height, DC Clearance, etc.)

EDS-2004/TS-13

13
Major Tray Design Considerations
Process Items

„ Jet Flood, Entrainment

„ Weeping
„ Efficiency
„ Turndown
„ Pressure Drop
„ Downcomer Backup

EDS-2004/TS-14

14
 Types of Flood

„ Jet

„ Downcomer
– Backup
– Velocity

EDS-2004/TS-15

Downcomer backup and downcomer velocity are related; the larger the downcomer,
the lower the backup and velocity.

15
 Jet Flood

„ Liquid Entrained in Vapor

„ Capacity or C Factor

Q ρv
C= v
A ρl − ρv

ρv
„ V Load = Qv
ρ l − ρv

EDS-2004/TS-16

C is an empirical constant, calculated from a force balance on a drop of unknown

size. When the drag exerted by upward flowing vapor on the average liquid droplet
is equal to or greater than the force of gravity on that drop, massive entrainment
occurs and flooding is the result. Equating upward and downward forces, and
combining the drag coefficient, acceleration of gravity, and the unknown drop size
into one empirical constant results in this equation. Both Koch and Glitsch methods
use this fundamental relationship. Glitsch calls it V Load, while Koch calls it Csf
factor.

16
 Downcomer Velocity Limit

„ Vapor Entrained in Liquid

– Tray spacing
– Vapor and liquid densities

EDS-2004/TS-17

If downcomer velocity is too high, vapor will be entrained in the liquid. The
purpose of the downcomer is to allow separation of the vapor from the liquid. As
the vapor density approaches the liquid density, the downcomer velocity needs to be
directionally lower.

17
 Downcomer Backup

„ Exit Loss

„ Liquid Head on Tray

„ Tray Pressure Drop

– Dry pressure drop
– Head on tray

EDS-2004/TS-18

These are the three main factors that influence downcomer backup. Exit loss is the
loss attributed to liquid flow under the downcomer. Tray pressure drop is based on
a “dry” tray pressure drop, and then wet tray factor is added to get the total tray
pressure drop.

18
 Downcomer Backup Limit

„ High Vapor Density

– ~33% tray spacing

„ Low Vapor Density

– ~50% tray spacing

EDS-2004/TS-19

These are UOP general guidelines.

19
 Tray Spacing

„ 24" if not more than 60 trays

„ 18" if more than 60 trays
„ 30" or 36" if governing pump around
„ Additional considerations
– Downcomer backup
– Jet flood for given diameter
– Column L/D ratio

EDS-2004/TS-20

Normal tray spacing is 24" unless there is reason to change it.

Go to 18" TS when there are many trays (reduce cost by decreasing column height).

Go to 18" to minimize column length-to-diameter ratio (ratio over 14 may warrant

special structural considerations).

Use 30" or 36" TS to avoid swaging the column for various column sections.

20
 Setting Number of Passes

„ Weir rate of 4-8 gpm/in desirable

„ Fewer passes desirable
„ 16" minimum flow path length

Number Recommended
of Passes Minimum Diameter
2 4.5 ft
3 9 ft
4 12 ft

EDS-2004/TS-21

Weir rate is UOP guideline. (4 < L/NW < 8), where L is liquid rate in GPM, N is
the number of passes, and W is the flow path width (use tray diameter). The 16"
minimum flow path length is to leave sufficient room for installation of a manway.

21
 Swaging May Be Cost Effective If

„ Swage is 1.5 ft or more

„ Swage is 20% or more of column diameter

EDS-2004/TS-22

If swage does not meet either of these two UOP guidelines, then the additional cost
for the swage section and resultant additional column height might not justify the
savings achieved with the smaller diameter section.

22
 Downcomer Clearance

„ The larger of
– 1.5 inches
– Height to yield exit velocity of 1.5 ft/s

EDS-2004/TS-23

Exit velocity of 1.5 ft/sec is a UOP guideline.

23
 Weir Height

„ Set to provide downcomer seal

„ Normal weir height is 0.25 to 0.5 inches more

than downcomer clearance

EDS-2004/TS-24

24
 Number of Valves or Sieve Holes

„ Vapor velocity prevents weeping

„ Vapor velocity contributes to downcomer

backup and entrainment

EDS-2004/TS-25

Vapor velocity contributes to downcomer backup due to its relationship with tray
pressure drop.

25
 Foaming Derating Factor

„ Systems that are known to foam are normally

derated by a factor
– Normally applies to both downcomer and
bubbling areas

EDS-2004/TS-26

Foam factors are known through experience, they are not calculated. Both the Koch
and Glitsch manuals give some factors for various foaming systems.

26
 Downcomer Width

„ Side downcomer 5 inch min.

„ Center downcomer 8 inch min.

„ Intermediate downcomer 8 inch min.

EDS-2004/TS-27

These are UOP guidelines. Side downcomer less than 5" can result in too high of a
gpm/inch liquid flow across the weir. Center and intermediate downcomer widths
less than 8" could result in liquid “jumping” across downcomer and interfering with
hydraulics of liquid on the other side.

27
 Tray Sizing Procedure

1. Estimate preliminary diameter and number

of passes

2. Make trial layout of tray

3. Rate tray

4. Repeat Steps 1-3 until done

EDS-2004/TS-28

Both Koch and Glitsch have methods to estimate a preliminary diameter. UOP also
has some experience factors (e.g. barrel factors, etc.).

28
 Tray Sizing Procedure

„ Next Diameter Guess

Percent Flood 1st Trial

d 2 2 = d12
Percent Flood Desired

where d 1 = Previous diameter tried

d 2 = Next diameter to try

EDS-2004/TS-29

Say d1 is 7'-0" with 93% flood. Estimate next diameter guess as (d2)2 = (7)2(93/75)
= 60.76, which results in d2 = 7.8 ft.

29
 Preliminary Diameter Estimate
Barrel Factor

Service Barrel Factor Basis

Crude Tower 100-150 lift
Vacuum Tower 50-65 lift
Sidecut Stripper 450 product
Debutanizer 175-250 feed
Deethanizer 100 feed
C3/C4 Splitter 150-200 feed
F
Barrel Factor = where F is barrels/day
d2
d is column bottom diameter in feet
EDS-2004/TS-30

Estimate a Debutanizer preliminary diameter using a barrel factor of 250. F/d2 =

250. F = 16,000 BPD. d2 = (16000/250) = 64, which results in d = 8.

30
 Preliminary Diameter Estimate
Heat Factor

Q
= 350 ,000
d2

Where Q = reboiler duty in Btu/h

d = column bottom diameter in feet

EDS-2004/TS-31

Estimate preliminary diameter for Q = 35,000,000 Btu/hr. d2 =

(35,000,000/350,000) = 100, which results in d = 10.

31
 Gas Oil Stripper
(Using Glitsch Bulletin 4900 Sixth Edition)
Loadings

Vapor Rate V (cfs) 62.2

3
Vapor Density dv (lb/ft ) 0.146
Liquid Rate L (gpm) 763
3
Liquid Density dl (lb/ft ) 41.9
Non-Foaming System
Customer wants 75% of flood and 24" tray spacing

Downcomer design velocity (Glitsch Page 13)

– System is non-foaming; therefore, the system factor
is 1.0 from Glitsch Table 1a
EDS-2004/TS-32

Example problem using Glitsch method.

32
 Downcomer Sizing

„ Glitsch Equation 1a

VDdsg = (250 )( System Factor ) = (250 )(1) = 250 gpm ft 2

„ Glitsch Equation 1b

VDdsg = (41)( d l − d v )( System Factor )

VDdsg = (41)( 41.9 − 0.146 )(1) = 265 gpm ft 2

EDS-2004/TS-33

33
 Downcomer Sizing

„ Glitsch Equation 1c

VDdsg = (7.5 )( TS )( d l − d v )( System Factor )

VDdsg = (7.5 )( 24 )( 41.9 − 0.146 )(1) = 237 gpm ft 2

„ Choose the lowest value from Equations 1a, 1b,

and 1c
„ Therefore, the downcomer design velocity, VDdsg
= 237 gpm/ft2

EDS-2004/TS-34

Choose the lowest downcomer velocity to get the largest (most conservative)
downcomer size.

34
 Vapor Capacity
(Glitsch Page 14)

„ Vapor capacity factor, CAF, is a function of

vapor density and tray spacing
„ From Glitsch Figure 5a
– CAFO = 0.455
– (Off Chart)
– CAFO = (24)0.65 (0.146)1/6/12 = 0.477
– Smallest Value = 0.455
– CAF = (0.455)(1.0) = 0.455
„ Alternatively, or as a check, Chart 5b can
also be used; it reads CAFO = 0.457

EDS-2004/TS-35

Smallest value will give the largest (most conservative) bubbling area.

35
 Preliminary Estimate
of Column Diameter

„ Glitsch Equation 2b

dv 0.146
Vload = (CFS ) = (62.2 ) = 3.68
dl − dv 41.9 − 0.146

– From Glitsch Figure 6, using a 2-pass tray, try 5 ft-6 in

(1-pass tray would be 6 ft-6 in)

EDS-2004/TS-36

A 2 pass tray appears to be a more cost effective design since the preliminary
diameter is smaller than the 1 pass tray design.

36
 Preliminary Estimate
of Column Diameter

„ Glitsch Equation 3
– Flow path length (approximate)

 DT   5.5 
FPL = (9 )  = (9 )  = 24.75 in
 NP   2 

EDS-2004/TS-37

37
 Preliminary Estimate
of Column Diameter

„ Active area - The minimum active area (AAM) is

a function of vapor and liquid loads, system
properties, flood factor, and flow path length
„ Glitsch Equation 4

V + ( gpm )(FPL ) 13000

AAM = load
(CAF )(FF )
3.68 + (763 )(24.75 ) 13000
AAM = = 15.04 ft 2
(0.455 )(0.75 )

EDS-2004/TS-38

38
 Downcomer Area

„ The minimum downcomer area (ADM) is a function of

liquid rate, downcomer design velocity, and flood factor
„ Glitsch Equation 5
gpm 763
ADM = = = 4.29 ft 2
(VDdsg )(FF ) (237 )(0.75 )
Check:

 ADM   4.29 
 (100%) =  (100%) = 28.5% (> 11% OK )
 AAM   15.04 

EDS-2004/TS-39

At this point Glitsch has us check the downcomer area in relation to the bubbling
area. If the ratio is too small, an adjustment should be made.

39
 Column Area (ATM)

„ ATM equals the minimum tower cross-

sectional area

„ Glitsch Equation 6a
ATM = AAM + (2 )( ADM )

ATM = 15.04 + (2 )(4.29 ) = 23.62 ft 2

EDS-2004/TS-40

The “2” in this equation is not because we are considering a two pass tray. The
reason that the downcomer area is doubled is to account for the downcomer seal
area. For straight downcomers, this will be true. For sloped or stepped
downcomers, further calculations will be required. (Many new students get this
confused.)

40
 Column Area (ATM)

„ Glitsch Equation 6b
Vload
ATM =
(0.78 )(CAF )(FF )
3.68
ATM = = 13.83 ft 2
(0.78 )(0.455 )(0.75 )
– Use the larger of the two areas

ATM = 23.62 ft 2

EDS-2004/TS-41

41
 Column Area (ATM)

„ Finally, the preliminary tower diameter can be

calculated
„ Glitsch Equation 7

ATM 23.62
DT = = = 5.48 Say 5 ft - 6 in
0.7854 0.7854
– This diameter corresponds to an actual tower
area of

AT = (π )
(5.5 )2
= 23.76 ft 2
4

EDS-2004/TS-42

The actual column area is slightly larger than our “minimum” area. A “maximum
capacity design” re-adjusts the downcomer area based on the ratio of the actual tray
area to the minimum tray area.

42
 Allocation of Areas for a Fixed
Column Diameter
(Glitsch Page 19)

„ Maximum capacity design

„ Glitsch Equation 8
 ADM   4.29 
AD = ( AT )  = (23.76 )  = 4.32 ft
2
 ATM   23 .62 
– Where AD = the total downcomer area
requirement
– Check that AD is > 10 percent of AT

 AD   4.32 
 (100%) =  (100%) = 18.2% (> 10% OK )
 AT   23.76 
EDS-2004/TS-43

Again, Glitsch has us check to see that the downcomer area is at least 10% of the
total tray area.

43
 Two Pass Tray

gpm gpm
=
in (NP) (DT) (12)
H1 FPL H3 FPL H1

763
1-pass: = 11.6
(1)(5.5)(12)

763
2-pass: = 5.8
(2)(5.5)(12)

763
3-pass: = 3.85
(3)(5.5)(12)

TS-R00-06
EDS-2004/TS-44

L/NW correlation reinforces our selection of a 2 pass tray (4 < L/NW < 8).

44
 Allocation of Areas for a Fixed
Column Diameter
(Glitsch Page 21)

„ From Glitsch Table 2 (for a 2-pass tray)

AD1 = (0.5 )( AD ) = (0.5 )(4.32 ) = 2.16 ft 2 (each)

AD3 = (1.0 )( AD ) = (1)(4.32 ) = 4.32 ft 2

EDS-2004/TS-45

Each side downcomer is sized for half of the total downcomer area. The center
downcomer is sized for the total downcomer area.

45
 Allocation of Areas for a Fixed
Column Diameter
(Glitsch Page 21)

„ Side downcomer width using Glitsch Table 4

AD1 2.16
= = 0.0909
AT 23.76

H1
∴ = 0.1465
D

H 1 = (0.1465 )(5.5 ) = 0.81 ft = 9.7 in

EDS-2004/TS-46

46
 Allocation of Areas for a Fixed
Column Diameter
(Glitsch Page 21)

„ Center Downcomer Width

„ Glitsch Equation 9

H 3 = (WF )( AD DT ) = (12 )(4.32 5.5 ) = 9.4 in

EDS-2004/TS-47

47
 Flow Path Length
(Glitsch Page 21)

„ Glitsch Equation 10

FPL =
(12 )( DT ) − (2 H 1 + H 3 )
NP

FPL =
(12 )(5.5 ) − [(2 )(9.7 ) + (9.4 )]
2

FPL = 18.6 in (OK )

EDS-2004/TS-48

The flow path length is greater than 16" (UOP minimum).

48
 Active Area (AA)

„ Active Area is the area available on the tray

for ballast units (valves); assume straight
downcomers (Glitsch page 22)

„ Glitsch Equation 12a

AA = AT − (2 AD1 + AD3 )

AA = 23.76 − [(2 )(2.16 ) + (4.32 )] = 15.12 ft 2

EDS-2004/TS-49

Straight downcomers are used in the vast majority of new unit designs.

49
 Active Area (AA)

„ Glitsch Equation 12b

Applies to Sloped Downcomers

EDS-2004/TS-50

Sloped (and stepped) downcomers are used sometimes in revamp situations.

50
Percent of Flood at Constant V/L Ratio
(Glitsch Page 26)

„ Glitsch Equation 13

V + ( gpm )(FPL ) 13000

pct Flood = load (100 )
( AA)(CAF )
3.68 + (763 )(18.6 ) 13000
pct Flood = (100 )
(15.12 )(0.455 )
pct Flood = 69.4 pct

EDS-2004/TS-51

51
 Pressure Drop
(Glitsch Page 27)

„ Pressure drop of ballast trays is a function of vapor

and liquid rates; number, type, metal density, and
thickness of the valves; weir height; and weir length.
„ Dry tray pressure drop
„ We’ll use Glitsch Figure 8.
– First, calculate hole area, then hole velocity
„ Glitsch Equation 19
NU
Hole Area = AH =
78.5

EDS-2004/TS-52

52
 Pressure Drop
(Glitsch Page 27)

„ Where NU = number of valve units/tray. We could

calculate this, but 12 units/ft2 of AA is a good average.

Number of valves = (12 )(15.12 ) = 181

181
Hole area = AH = = 2.31 ft 2
78.5

Hole velocity = VH = CFS = 62.2 = 26.9 ft s

AH 2.31

d   0.146 
V H 2  v  = (26.9 )2   = 2.52
 dl   41.9 
EDS-2004/TS-53

There are some equations on page 31 to calculate the approximate number of units.
A value of 12 units/ft2 is a good average.

53
 Pressure Drop
(Glitsch Page 27)

„ From Glitsch Figure 8: (Using Type V-1 valves,

10 gauge deck thickness, and 16 gauge valves)

∆PD (a ) = 1.5 inches liquid

∆PD (b ) = 2.05 inches liquid

„ The larger value applies

∆PD = 2.05 inches liquid

EDS-2004/TS-54

54
 Pressure Drop
(Glitsch Page 27)

„ Total Tray Pressure Drop

„ Glitsch Equation 20
2 3
 gpm 
∆P = ∆Pdry + 0.4  + 0.4 ( H w )
 Lwi 

Hw = weir height, inches

Lwi = length of weir, inches

EDS-2004/TS-55

We know every value in this equation except for the weir height (Hw) and the weir
length (Lwi).

55
 Pressure Drop
(Glitsch Page 27)

„ We’ll use a 2" weir (HW = 2)

„ We must calculate Lwi for both types (side

downcomer trays and center downcomer
trays), since the total pressure drop for each
type will be different

EDS-2004/TS-56

Pressure drops for the side downcomer trays will be different from the center
downcomer trays due to the different geometry. Rigorous method to calculate
column pressure drop is to calculate each tray type separately and multiply each tray
type’s pressure drop times the number of trays of that type.

56
 Pressure Drop
(Glitsch Page 27)

„ Side Downcomer Weir Length, L1 (Using

Glitsch Table 4)

AD1 2.16
= = 0.0909
AT 23.76
L
∴ 1 = 0.7072
D

L1 = (0.7072 )(5.5 )(12 ) = 46.7 in

Total Lwi = (2 )(46.7 ) = 93.4 in

EDS-2004/TS-57

57
 Pressure Drop
(Glitsch Page 27)

„ Glitsch Equation 20

2 3
 gpm 
∆P = ∆Pdry + 0.4  + 0.4 ( H w )
 Lwi 

2 3
∆P = 2.05 + 0.4 
763 
 + 0. 4 ( 2 )
 93.4 

∆P = 4.47 inches liquid

EDS-2004/TS-58

58
 Pressure Drop
(Glitsch Page 27)

„ Glitsch Equation 21b

∆P = 4.47 
41.9 
 = 5.6 mm Hg
 33.3 

EDS-2004/TS-59

59
 Pressure Drop
(Glitsch Page 27)

„ Center Downcomer Weir Length, L3 (Using

Glitsch Table 3)

L3 = ( SF )( DT ) = (1.0 )(5.5 )(12 ) = 66 in

Total Lwi = (2 )(66 ) = 132 in

∆P = 4.14 inches liquid (5.2 mm Hg )

EDS-2004/TS-60

As expected, the pressure drop for the center downcomer trays is less than that of
the side downcomer trays.

60
 Downcomer Backup
(Glitsch Page 28)

„ Glitsch Equation 22

2 3
 gpm   dl 
H dc = H w + 0.4   + (∆P + H ud ) 
 Lwi   dl − dv 

EDS-2004/TS-61

61
 Downcomer Backup
(Glitsch Page 28)

„ We know all terms for this equation except for Hud

(head loss under the downcomer)

H ud = 0.65 (Vud )2

– Where Vud = velocity of liquid under the downcomer

Vud = ( gpm ) (448.8 )( Aud )

EDS-2004/TS-62

Equation 23 (head loss under the downcomer) can also be expressed in terms of
liquid flow rate, downcomer exit length, and downcomer clearance.

62
 Downcomer Backup
(Glitsch Page 28)

– Where Aud = cross-sectional area under the downcomer

Aud = ( DCL 12 )( Lw )

– Where DCL = downcomer clearance (we’ll use 1.75

inches)

Aud = (1.75 12 )(3.89 )(2 ) = 1.135 ft 2

EDS-2004/TS-63

We have chosen a downcomer clearance of 1.75 inches in order to keep the velocity
under the downcomer reasonable.

63
 Downcomer Backup
(Glitsch Page 28)

„ Note that the two side downcomer weir lengths

(3.89 ft) were used, which is the most conservative

Vud =
(763 ) = 1.5 ft s
(448.8 )(1.135 )
H ud = Head loss under the downcomer

H ud = 0.65 (Vud )2 = (0.65 )(1.5 )2 = 1.46 inches liquid

EDS-2004/TS-64

64
 Downcomer Backup
(Glitsch Page 28)

„ Finally, we can calculate the downcomer backup (side

downcomer is governing)
2 3
 gpm   dl 
H dc = H w + 0.4   + (∆P + H ud ) 
 Lwi   d l − dv 
2 3
 763   41.9 
H dc = 2 + 0.4   + (4.47 + 1.46 ) 
 (3.89 )(2 )(12 )   41.9 − 0.146 

H dc = 9.6 inches liquid OK (< 1 2 TS )

EDS-2004/TS-65

Since the downcomer backup is less than one-half of tray spacing, the tray
downcomer geometry is acceptable. If this were a high vapor density system, we
would consider reducing the downcomer backup to less than one-third of tray
spacing. The center downcomer backup will be lower because (1) the weir length
(Lwi) will be larger and (2) the tray delta P will be lower.

65
 Gas Oil Stripper
(Using Koch Bulletin 960-1)

„ Loadings

Vapor Rate V (cfs) 62.2

3
Vapor Density dv (lb/ft ) 0.146
Liquid Rate L (gpm) 763
3
Liquid Density dl (lb/ft ) 41.9

Customer wants 75% of flood and 24 in tray spacing

EDS-2004/TS-66

Example problem using Koch method.

66
 System Factor
(Koch Page 6)

„ System is non-foaming; therefore, the system

factor is 1.0
„ Vapor density is less than 1.8; therefore, the
system factor is 1.0
„ Design Rating Procedure
– Tray space factor
• Use 24” tray spacing
(Therefore, the tray space factor, with
a vapor density less than 1.5 lb/ft3, is 1)

EDS-2004/TS-67

If the “foaming” system factor is less than 1.0 and the “vapor density” system factor
is less than 1.0, calculate the total system factor by multiplying the two factors
together.

67
 Preliminary Sizing
(Koch Page 7)

„ Get the vapor rate

ACFS = 62.2 ( from loadings )

„ Calculate the square root factor

dv 0.146
Factor = = = 0.059
dl − dv 41.9 − 0.146

„ Calculate the Vload

dv
Vload = ACFS = (62.2 )(0.059 ) = 3.68
dl − dv
EDS-2004/TS-68

68
 Preliminary Sizing
(Koch Page 7)

„ Calculate the corrected Vload and liquid rate

Vload 3.68
Corrected Vapor Load Factor = = = 3.68
(TSF )( SF ) (1)(1)

gpm 763
Corrected Liquid Rate = = = 763
(TSF )( SF ) (1)(1)

EDS-2004/TS-69

In this case, the corrected loads are the same as the normal loads since the system
factor and tray space factor are both 1.0.

69
 Preliminary Sizing
(Koch Page 7)

„ Plot on Chart A (Koch Page 13)

Estimated Diameter = 5.2 ft ( Double Flow )

– Try 5 ft - 6 in diameter with 2 passes and 24

inch tray spacing

AT =
(π )(5.5 )2
= 23.76 ft 2
4
L 763
2 - Pass : = = 5.8 gpm in (Good )
( NP )( DT ) (2 )(5.5 )(12 )

EDS-2004/TS-70

The L/NW correlation evaluates to a good value (8 < L/NW < 4).

70
 Detailed Sizing

„ Vapor Rate = 62.2 cfs (use non-corrected values)

– Liquid rate = 763 gpm

„ Size the Downcomers

– We must correct the Koch Correlation to a basis
of 75 percent flood

75
85
( )
175 gpm ft 2 = 154 gpm ft 2

EDS-2004/TS-71

For the remainder of the sizing method, use the non-corrected (i.e. normal) loads.
Since the Koch correlation is based on 85% of flood, we must correct the
downcomer rate to a 75% flood basis.

71
 Detailed Sizing

– (a) Minimum Downcomer Area:

Koch Equation 1:

 gpm  24  1   763  24  1  2
Adc =    =    = 4.95 ft
 154  
TS SF   154   
24 1
– (b) Does not apply here since dl-dv = 41.75 lb/ft3
(therefore, no need to use Chart B).

EDS-2004/TS-72

Equation 1(b) is applied when the difference in liquid and vapor densities is less
than 30 lb/ft3, which usually occurs when there is a high vapor density.

72
 Detailed Sizing

„ Find side downcomer chord height using Koch

Chart D
– Remember that it’s a 2-pass tray, so side
downcomer area equals (4.95/2) = 2.475 ft2

(Diameter = 5'-6"; Adc = 2.475 ft2)

H = 10.7 in

EDS-2004/TS-73

73
 Detailed Sizing

– Koch doesn’t indicate how to calculate the center

downcomer width, so we’ll do it this way

DC Area
Center DC Width =
Tray Diameter

4.95
Center DC Width = = 0.9 ft = 10.8 in
5.5

EDS-2004/TS-74

For a center downcomer, the weir length is very close to the diameter of the tray.

74
 Detailed Sizing

„ Bubbling Area

Ab = At − Adt − Adb − Ae

At = Tower Cross - Sectional Area

At = πD 2 4 = (π )(5.5 )2 4 = 23.76 ft 2

Adt = Downcomer Area at Top = 4.95 ft 2

EDS-2004/TS-75

75
 Detailed Sizing

„ Bubbling Area

Adb = Downcomer Area at Bottom

Adb = Adt because we are using straight downcomers

Ae = Edge Loss ≈ 0 (Because column > 3 ft - 6 in )

Therefore, Ab = 23.76 − 4.95 − 4.95 − 0 = 13.86 ft 2

EDS-2004/TS-76

Edge loss becomes significant in columns less than or equal to 3.5 ft since the
support ring reduces the area where valves may be installed. (Draw sketch on
board.)

76
 Detailed Sizing

„ Find side downcomer chord length (weir length)

using Koch Chart E

(Diameter = 5'-6"; H = 10.7”)

LW = 4.1 ft

Note that Total Lw = (4.1)(2 ) = 8.2 ft

EDS-2004/TS-77

Side downcomer weir length is chosen because it is shorter than the center
downcomer weir length, which will result in a higher percent of flood.

77
 Detailed Sizing

„ Calculated Tray Capacity

„ Koch Equation 3

pct Capacity =
(100 ) 
C sf (net ) + (0.001327 )
gpm 

(TSF )( SF )(0.51)  Lw 

EDS-2004/TS-78

We know every term in this equation except for Csf(net).

78
 Detailed Sizing

– Where:

 ACFS  dv
C sf (net ) =  
 Ab  d l − d v

62.2 0.146
C sf (net ) = = 0.265
13.86 41.9 − 0.146

pct Tray Capacity =

(100 ) 
0.265 + (0.001327 )
(763 ) = 76.2 pct

(1.0 )(1.0 )(0.51)  (8.2 ) 

EDS-2004/TS-79

79
 Detailed Sizing

„ Try next larger diameter (6'-0")

At = Tower Cross - Sectional Area

At = πD 2 4 = (π )(6 )2 4 = 28.27 ft 2

EDS-2004/TS-80

80
 Detailed Sizing

„ Find side downcomer chord height using Koch

Chart D
– Remember that it’s a 2-pass tray, so side
downcomer area equals (4.95/2) = 2.475 ft2

(Diameter = 6'-0"; Adc = 2.475 ft2)

H = 10.3 in

EDS-2004/TS-81

81
 Detailed Sizing

– For center downcomer

DC Area
Center DC Width =
Tray Diameter

4.95
Center DC Width = = 0.825 ft = 9.9 in
6. 0

EDS-2004/TS-82

For a center downcomer, the weir length is very close to the diameter of the tray.

82
 Detailed Sizing

„ Bubbling Area

Ab = At − Adt − Adb − Ae

Ae = Edge Loss ≈ 0 (Because column > 3 ft - 6 in )

Ab = 28.27 − 4.95 − 4.95 − 0 = 18.37 ft 2

EDS-2004/TS-83

Edge loss becomes significant in columns less than or equal to 3.5 ft since the
support ring reduces the area where valves may be installed.

83
 Detailed Sizing

„ Find side downcomer chord length (weir length)

using Koch Chart E

(Diameter = 6'-0"; H = 10.3”)

LW = 4.2 ft

Total Lw = (4.2 )(2 ) = 8.4 ft

EDS-2004/TS-84

Side downcomer weir length is chosen because it is shorter than the center
downcomer weir length, which will result in a higher percent of flood.

84
 Detailed Sizing

„ Calculated Tray Capacity

 ACFS  dv
C sf (net ) =  
 Ab  d l − d v

62.2 0.146
C sf (net ) = = 0.200
18.37 41.9 − 0.146

pct Tray Capacity =

(100 ) 
0.200 + (0.001327 )
(763 ) = 62.8 pct

(1.0 )(1.0 )(0.51)  (8.4 ) 
EDS-2004/TS-85

85
 Detailed Sizing

„ Downcomer Capacity (Koch Page 9)

Koch Equation 4
 gpm  75  1  24 
pct Capacity =     
 Ad  154  SF  TS 

 763  75  1  24 
pct Capacity =      = 75 pct
 4.95  154  1  24 

(Note the modification of Koch Equation 4 to be

consistent with 75 percent of flood)
EDS-2004/TS-86

Equation 4 is based on 85% of flood and needs to be modified for the 75% flood
basis.

86
 Detailed Sizing

„ Compare tray capacity and downcomer capacity

pct Tray Capacity = 62.8

pct Downcomer Capacity = 75.0

EDS-2004/TS-87

Both capacities are equal to or less than our 75% limit. Their values could be
somewhat closer to each other. Adjust downcomers for a closer balance.

87
 Detailed Sizing

– Adjust downcomers to get a balanced design

– Try downcomer area = 5.6 ft2 (instead of 4.95 ft2)

At = Tower Cross - Sectional Area

At = πD 2 4 = (π )(6 )2 4 = 28.27 ft 2

EDS-2004/TS-88

The downcomer area of 5.6 ft2 is selected because it leads us to a good solution!

88
 Detailed Sizing

– Side downcomer from Koch Chart D

For downcomer area = (5.6 2 ) = 2.8 ft 2

H = 11.3 in

EDS-2004/TS-89

89
 Detailed Sizing

– For Center Downcomer

DC Area
Center DC Width =
Tray Diameter

5.6
Center DC Width = = 0.933 ft = 11.2 in
6

EDS-2004/TS-90

90
 Detailed Sizing

– Bubbling area

Ab = 28.27 − 5.6 − 5.6 − 0 = 17.07 ft 2

– Weir length of side downcomer from Koch Chart E

LW = 4.3 ft

Total Lw = (4.3 )(2 ) = 8.6 ft

EDS-2004/TS-91

91
 Detailed Sizing

– Calculated Tray Capacity

 ACFS  dv
C sf (net ) =  
 Ab  d l − d v

62.2 0.146
C sf (net ) = = 0.215
17.07 41.9 − 0.146

pct Tray Capacity =

(100 ) 
0.215 + (0.001327 )
(763 ) = 65.2 pct

(1.0 )(1.0 )(0.51)  (8.6 ) 

EDS-2004/TS-92

92
 Detailed Sizing

– Downcomer Capacity

 gpm  75  1  24 
pct Capacity =     
 Ad  154  SF  TS 

 763  75  1  24 
pct Capacity =      = 66.4 pct
 5.6  154  1  24 

EDS-2004/TS-93

93
 Detailed Sizing

– Compare tray capacity and downcomer capacity

pct Tray Capacity = 65.2

pct Downcomer Capacity = 66.4

– Close agreement
– Continue with the rest of the design

EDS-2004/TS-94

These values are very close and represent a balanced design. Note that the
downcomer capacity was more sensitive to the downcomer area adjustment than the
tray capacity. Downcomer capacity decreased from 75 to 66.4 while the tray
capacity only increased from 62.8 to 65.2.

94
 Detailed Sizing

„ We’ll use a 2 inch weir to compare with Glitsch

„ For downcomer clearance, we’ll use 1.75 inches

EDS-2004/TS-95

We are using same downcomer weir height and downcomer clearance that was used
for the Glitsch tray design.

95
 Pressure Drop

„ Convert Vapor Rate to Air Equivalent

dv
CFM ( Air Equiv ) = (60 )( ACFS )
0.0735

0.146
CFM ( Air Equiv ) = (60 )(62.2 ) = 5260
0.0735

EDS-2004/TS-96

Koch converts the hydrocarbon vapor rate to an air equivalent vapor rate.

96
 Pressure Drop

„ Use 11.5 valves per ft2 (Koch Page 10)

„ Calculate cfm (air equivalent) per valve:
5260
CFM Valve = = 26.8
(11.5 )(17.07 )

„ From Koch Chart G, using “A” type valves (typical)

Dry Tray ∆P = 1.28 in H 2 O

EDS-2004/TS-97

Use 11.5 valves per square foot for a 6 foot tray diameter from page 10 chart.
Interpolate 11 valves per square foot for a 5.5 ft tray diameter on page 7 chart. “A”
type valves are typical for most Koch tray applications (see sketches on page 2).

97
 Pressure Drop

„ Read effective depth of liquid from Koch Chart J

 763 
  = 88.7 gpm ft weir
 8. 6 

2.2 Inches Clear Liquid

EDS-2004/TS-98

98
 Pressure Drop

„ Convert effective liquid depth to inches of water

 d 
Liquid ∆P = ( Effective Liquid Depth) l 
 62.4 

 41.9 
= 2. 2   = 1.48 in H 2 O
 62.4 

EDS-2004/TS-99

99
 Pressure Drop

„ Total Tray ∆P = Dry Tray ∆P + Liquid ∆P

Total Tray ∆P = 1.28 + 1.48

Total Tray ∆P = 2.76 in H 2 O

EDS-2004/TS-100

100
 Pressure Drop

„ Convert to mmHg

Total Tray ∆P = (2.76 )(1.865 ) = 5.2 mm Hg

EDS-2004/TS-101

101
 Flow Path Length

„ Note: Koch does not offer a procedure for

calculating the downcomer backup. The Glitsch
method could be used if desired. Further, Koch
does not check for a sufficient flow path length.
In this example, the flow path length is:

FPL =
(12 )(6 ) − (2 )(11.3 ) − 11.2 = 19.1 in
2

„ This is sufficient.

EDS-2004/TS-102

The recommended minimum flow path length is 16 inches.

102
Gas Oil Stripper Design Comparison

Glitsch Koch
Tray diameter, ft - in 5'-6" 6'-0"
Number of passes 2 2
Downcomer area, ft2 4.32 5.6
Active area, ft2 15.12 17.07
Percent Flood * 69.4 65.2
Pressure drop, mmHg* 5.6 5.2
Downcomer backup, in liquid* 9.6 –
*Based on trays with side downcomers

EDS-2004/TS-103

103
 Class Problem #1

„ Use the Koch method to size the following

column section
„ Use a 24" tray spacing and 75% flood

STABILIZER - TOP SECTION

Summer Winter
Known Data Operation Operation
3
Vapor Rate ft /s 16.56 12.19
3
Vapor Density lb/ft 1.673 2.702
Liquid Rate gpm 366.0 486.0
3
Liquid Density lb/ft 31.1 29.39

EDS-2004/TS-104

104
 Class Problem #2

„ Use the Glitsch method to size the following

column section
„ Use a 24" tray spacing and 75% flood

STABILIZER - BOTTOM SECTION

Summer Winter
Known Data Operation Operation
3
Vapor Rate (ft /s) 31.9 24.2
3
Vapor Density (lb/ft ) 2.82 5.05
Liquid Rate (gpm) 2245.0 2848.0
3
Liquid Density (lb/ft ) 36.3 34.3
6
Reboiler Duty (10 Btu/h) 37.23 43.52
Feed Rate = 31,900 BPSD (both cases)
EDS-2004/TS-105

105