CHAPTER 5

DESIGN OF SEPARATOR AND DISTILLATION COLUMN

5.1 INTRODUCTION

The design of a distillation column can be divided into the following steps:
1. Specify the degree of separation required : set product specifications
2. Select the operating conditions: batch or continuous; operating pressure
3. Select the type of contacting device : plates or packing
4. Determine the stages and reflux requirements : the number of equilibrium
stages
5. Size the column : diameter ; number of real stages
6. Design the column internals : plates, distributor, packing supports
7. Mechanical design : vessel and internal fittings

5.2 CHEMICAL DESIGN DISTILLATION COLUMN

The separation of liquid mixtures by distillation depends on difference in volatility

between the components. The greater the volatility, the easier the separation.

Table 5.1 Summary of inlet and outlet composition

Component Feed Top Bottom

Molar Mole Molar Mole Molar Mole
flow rate fraction flow rate fraction flow rate fraction
(kmol/hr) (kmol/hr) (kmol/hr)
Butadiene 3.464 0.008 3.464 0.067
Ethylene
glycol 280.082 0.671 280.082 0.766
Water 4.382 0.01 4.382 0.085
Sec-butenyl 44.483 0.107 35.586 0.689 8.897 0.024
n-butenyl 82.459 0.198 8.246 0.16 74.213 0.203
oligomer 2.57 0.006 2.57 0.007
Total 417.441 1 51.679 1 365.762 1

5-1
 5.2.1 Bubble and Dew Point Temperature

To estimate the stages, it required to calculate dew and bubble point. By definition,
a saturated liquid is at its bubble point ( any rise in temperature will cause a bubble
of vapour to form) and a saturated vapour is at its dew point ( any drop in
temperature will cause a drop of liquid to form). It can be calculated in terms of
equilibrium constant, K. Table 5.2 show the constants of Antoine equation for each
components. The data is taken from the Hysis.

Dew points and bubble point can be defined by the following equation:

Bubble point : ∑ 𝑦𝑖 = ∑ 𝐾𝑖 𝑥1 = 1.0

𝑦𝑖
Dew point : ∑ 𝑥𝑖 = ∑
𝐾𝑖

Table 5.2 : Constants in Antoine equations

Component a b c d e f
Butadiene 6.35345 × 101 −4.46031 × 103 0 -7.702 1.08034 × 10−5 2
Ethylene 5.7941 × 101 −8.8607 × 103 0 -5.7166 3.108 × 10−6 2
glycol
Water 6.59278 × 101 −7.22753 × 103 0 -7.17695 4.0313 × 10−6 2
Sec-butenyl 5.5236 × 101 −6.37458 × 103 0 -5.72724 9.53039 × 10−18 6
n-butenyl 5.73985 × 101 −6.7549 × 103 0 -5.99764 8.16422 × 10−18 6
oligomer 6.88845 × 101 −8.84994 × 103 0 -7.42614 4.13075 × 10−18 6

𝑏
Antoine equation : ln(𝑃) = 𝑎 + + 𝑑𝑙𝑛𝑇 + 𝑒𝑇 𝑓
𝑇+𝑐

𝑃0
For ideal mixtures : 𝐾𝑖 =
𝑃𝑇

By using goal seek in the exel programme, with constant operating pressure, the
bubble and dew points is calculate.

Bubble point at feed = 218ᵒ C

Dew point at the top = 169 ᵒC

Bubble point at the bottom = 230 ᵒC

5-2
5.2.2 Relative Volatility

𝐾𝑖
𝛼=
𝐾𝐻𝐾

Ki=K value for component i

𝐾𝐻𝐾 = heavy key component

For this case, ethylene glycol is a heavy key and sec-butenyl is the light key

Table 5.3: The relative volatility for component

Component Top,α Bottom,α Average,α

Butadiene 143 52 97.3
Ethylene glycol 1 1 1
(HK)
Water 19.47 10.87 15.17
Sec-butenyl (LK) 10.2 4.68 7
n-butenyl 7.14 3.47 5.3
oligomer 0.98 0.68 0.8

Sample calculation for α for sec-butenyl

At the top,

Ki(LK) = 0.99

0.99
Ki(HK)=0.097 𝑇𝑜𝑝, 𝛼 = = 10.2
0.097

At the bottom,

Ki(LK)=2.95

2.95
Ki(HK)=0.63 𝐵𝑜𝑡𝑡𝑜𝑚, 𝛼 = 0.63
= 4.68

10.2 + 4.68
𝑎𝑣𝑒𝑟𝑎𝑔𝑒, 𝛼 = =7
2

5-3
5.2.3 Obtained Number of Stages

To determine the stages, we need to

 Drawing the equilibrium curve

 Straight line for top operating line
 Straight line for bottom operating line

For equilibrium curve, equation obtain from Coulson Richardson, Chemical

Engineering Volume 6

𝛼𝐿𝐾 = 7

The equilibrium line is drawn by assuming a constant relative volatility for the light
key

𝛼𝐿𝐾 𝑥
𝑦=
(1 + (𝛼𝐿𝐾 − 1)𝑥)

After substitute all variable, the curve line obtained is

7𝑥
𝑦=
(1 + 6𝑥)

Table 5.4: x-y value ploting

x y
0 0
0.2 0.64
0.4 0.82
0.6 0.91
0.8 0.97
1.0 1

5-4
Top operating line equations,

𝐿𝑛 𝐷𝑥𝐷
𝑦𝑛+1 = 𝑥𝑛 +
𝑉𝑛+1 𝑉𝑛+1

Bottom operating line equation,

𝐿𝑚 𝑊𝑥𝑊
𝑦𝑚+1 = 𝑥𝑚 −
𝑉𝑚+1 𝑉𝑚+1

Where

𝑘𝑚𝑜𝑙
𝐹 = 417.441
ℎ𝑟
𝑘𝑚𝑜𝑙
𝐷 = 51.679
ℎ𝑟

𝑘𝑚𝑜𝑙
𝑊 = 365.762
ℎ𝑟

Reflux ratio, R = 8 (from HYSYS)

Ln=R×D

=413.432

𝑉𝑛+1 = 𝐿𝑛 + 𝐷

=465.111

Lm = Ln + F

=830.873

𝑉𝑚+1 = 𝐿𝑚 − 𝑊

=465.111

5-5
Substitute in the both equations and obtained,

Top operating line,

𝑦𝑛+1 = 0.89𝑥𝑛 + 0.11

Bottom operating line,

𝑦𝑚+1 = 1.7864𝑥𝑚 − 0.02421

5.2.4 Determine The Inlet and Outlet Stages

𝑓𝑙𝑜𝑤 𝐿𝐾 44.483
𝑥𝑓 = 𝑓𝑙𝑜𝑤 (𝐿𝐾+𝐻𝐾)
= 44.483+280.082 = 0.13705 ( at feed)

𝑓𝑙𝑜𝑤 𝐿𝐾 35.586
𝑥𝑑 = 𝑓𝑙𝑜𝑤 (𝐿𝐾+𝐻𝐾)
= 35.586 = 1 (at top)

𝑓𝑙𝑜𝑤 𝐿𝐾 8.897
𝑥𝑤 = = = 0.03079 (at bottom)
𝑓𝑙𝑜𝑤 (𝐿𝐾+𝐻𝐾) 8.897+280.082

5-6
Graph of equilibrium line from Mc Cabe Thiele

Figure 5.1 : Graph equilibrium data

5-7
5.2.5 Determination of The Number of Plates Using Fenske Equation

The Fenske equation can be used to estimate the minimum stages required at total
reflux. The number of stages will be obtain from this equation

𝑥 𝑥
𝑙𝑜𝑔 [𝑥 𝐿𝐾 ] [ 𝑥𝐻𝐾 ]
𝐻𝐾 𝑑 𝐿𝐾 𝑏
𝑁𝑚 =
𝑙𝑜𝑔𝛼𝐿𝐾

𝑥𝐿𝐾 = 𝑙𝑖𝑔ℎ𝑡 𝑘𝑒𝑦 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛

𝑥𝐻𝐾 = ℎ𝑒𝑎𝑣𝑦 𝑘𝑒𝑦 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛

𝛼𝐿𝐾 = 𝑎𝑣𝑒𝑟𝑎𝑔𝑒 𝑟𝑒𝑙𝑎𝑡𝑖𝑣𝑒 𝑣𝑜𝑙𝑎𝑡𝑖𝑙𝑖𝑡𝑦 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑖𝑔ℎ𝑡 𝑘𝑒𝑦

35.586 280.082
𝑙𝑜𝑔 [ 1 ] [ 8.897 ]
𝑁𝑚 =
𝑙𝑜𝑔7

𝑁𝑚 = 3.6

𝑁𝑚 = 4𝑠𝑡𝑎𝑔𝑒𝑠

𝑁𝑇 = 2(𝑁𝑚 )

𝑁𝑇 = 2(4) = 𝟖𝒔𝒕𝒂𝒈𝒆𝒔

5-8
5.2.6 Plate Efficiency

To get the real number of stages, the efficiency of the process must be considered

0.5
𝐸0 =
(𝛼𝜇)0.25

0.5
=
(7 × 0.561)0.25

=0.355

Number of real plate

𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑖𝑑𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠

𝐸0 =
𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑟𝑒𝑎𝑙 𝑠𝑡𝑎𝑔𝑒𝑠

Real plate use

𝑁𝑇
𝑁=
𝐸0

8
= = 𝟐𝟑𝒔𝒕𝒂𝒈𝒆𝒔
0.355

5-9
5.2.7 Feed Point Location

Feed point location can be found using Kirkbride(1944) equations

2
𝑁𝑟 𝐵 𝑥𝑓,𝐻𝐾 𝑥𝑏,𝐿𝐾
𝑙𝑜𝑔 [ ] = 0.206𝑙𝑜𝑔 [( ) ( )( ) ]
𝑁𝑠 𝐷 𝑥𝑓,𝐿𝐾 𝑥𝑑,𝐻𝐾

𝑁𝑟 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑎𝑔𝑒𝑠 𝑎𝑏𝑜𝑣𝑒 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑, 𝑖𝑛𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝑎𝑛𝑦 𝑝𝑎𝑟𝑡𝑖𝑎𝑙 𝑐𝑜𝑛𝑑𝑒𝑛𝑠𝑒𝑟

𝑁𝑠 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑠𝑡𝑎𝑔𝑒𝑠 𝑏𝑒𝑙𝑜𝑤 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑, 𝑖𝑛𝑐𝑙𝑢𝑑𝑖𝑛𝑔 𝑡ℎ𝑒 𝑟𝑒𝑏𝑜𝑖𝑙𝑒𝑟

B=molar flow bottom product

D=molar flow top product

𝑥𝑓,𝐻𝐾 = 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 ℎ𝑒𝑎𝑣𝑦 𝑘𝑒𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑

𝑥𝑓,𝐿𝐾 = 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 𝑙𝑖𝑔ℎ𝑡 𝑘𝑒𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑓𝑒𝑒𝑑

𝑥𝑑,𝐻𝐾 = 𝑐𝑜𝑛𝑐𝑒𝑛𝑡𝑟𝑎𝑡𝑖𝑜𝑛 𝑜𝑓 𝑡ℎ𝑒 ℎ𝑒𝑎𝑣𝑦 𝑘𝑒𝑦 𝑖𝑛 𝑡ℎ𝑒 𝑡𝑜𝑝 𝑝𝑟𝑜𝑑𝑢𝑐𝑡

xb,LK = concentration of the light key in the bottom product

𝑁𝑟 365.762 280.082 0.024 2

𝑙𝑜𝑔 [ ] = 0.206𝑙𝑜𝑔 [( )( )( ) ]
𝑁𝑠 51.679 44.483 0.019

𝑁𝑟
[ ] = 2.4
𝑁𝑠

Where, the actual no of plate 23

Nr + Ns = 23

2.4Ns + Ns = 23

3.4 Ns = 23

Ns = 6.8≈7 (feed inlet at stage 7)

Nr = 16

5-10
5.2.8 Calculation For Minimum Reflux ratio, Rmin

To get the value of minimum reflux ratio, the Underwood equation was used

1 𝑋𝑑,𝐿𝐾 𝑋𝑑,𝐻𝐾
𝑅𝑚𝑖𝑛 = ( ) {( )−𝛼( )}
𝛼−1 𝑋𝑓,𝐿𝐾 𝑋𝑓,𝐻𝐾

1 0.69 0.02
𝑅𝑚𝑖𝑛 = ( ) {( ) − 7( )}
7−1 0.11 0.67
=1

Optimum reflux ratio is 1×1.5=1.5

Where

Xd, LK =light key component at top flow

Xd, HK =heavy key component at top flow

Xf, LK =light key component at feed flow

Xf, HK =heavy key component at feed flow

5-11
5.2.9 Physical Properties

Column diameter

Liquid density, 𝜌𝐿 = 1111 kg/m3

Vapor density, 𝜌𝑣 =0.9 kg/m3

1
2 𝜌𝐿 − 𝜌𝑣 2
𝑢̂𝑣 = (−0.171𝑙𝑡 + 0.27𝑙𝑡 − 0.047) [ ]
𝜌𝑣

1
1111 − 0.9 2
𝑢̂𝑣 = (−0.171(0.5)2 + 0.27(0.5) − 0.047) [ ]
0.9

𝑢̂𝑣 = 2𝑚/𝑠

Based on equation below, the column diameter could be determined

4𝑉̂𝑚
𝐷𝑐 = √
𝜋𝜌𝑣 𝑢̂𝑣

𝑢̂𝑣 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑙𝑙𝑜𝑤𝑎𝑏𝑙𝑒 𝑣𝑎𝑝𝑜𝑢𝑟 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦, 𝑏𝑎𝑠𝑒𝑑 𝑜𝑛 𝑡ℎ𝑒 𝑔𝑟𝑜𝑠𝑠(𝑡𝑜𝑡𝑎𝑙)𝑐𝑜𝑙𝑢𝑚𝑛 𝑐𝑟𝑜𝑠𝑠

− 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎, 𝑚/𝑠

𝑙𝑡 = 𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔, 𝑚, (𝑟𝑎𝑛𝑔𝑒 0.5 − 0.15)

𝑉̂𝑤 = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑣𝑎𝑝𝑜𝑢𝑟 𝑟𝑎𝑡𝑒, 𝑘𝑔/𝑠

4(1.5)
𝐷𝑐 = √𝜋(0.9)(2) =1.1m

5-12
Column area

The column area can be calculated from the calculated of internal column diameter

𝜋𝐷𝑐 2
𝐴𝑐 =
4

𝜋(1.1)2
𝐴𝑐 = 4
= 1𝑚2

5.2.10 Determination of Plate Spacing

The overall height of the column will depend on plate spacing. Plate spacing from
0.15m to 1 m are normally used. The spacing chosen will depend on the column
diameter and operating pressure.

5.2.11 Plate Design

Column diameter Dc=1.1 m

Column area Ac = 1m2

Downcomer area Ad = 0.12×1=0.12m2

Net area 𝐴𝑛 = 𝐴𝑐 − 𝐴𝑑

= 1-0.12 = 0.88m2

Active area 𝐴𝑎 = 𝐴𝑐 − 2𝐴𝑑

=1-(2×0.12)=0.76m2

Hole area Ah = 0.1×0.76 = 0.076m2

Weir length Lw = 0.76Dc

=(0.76)(1.1)=0.84m

5-13
Take

Weir height hw = 50mm

Hole diameter dh = 5mm

Plate thickness t = 5mm

For hole diameter=5mm, area of 1 hole

𝜋(0.005)(0.005)
𝐴1ℎ = = 1.963 × 10−5 𝑚2
4

Number of holes per plate

𝑎𝑟𝑒𝑎
𝑁ℎ =
1 ℎ𝑜𝑙𝑒

0.076
𝑁ℎ = = 3872
1.963 × 10−5

5.2.12 Column Size

The column height will be calculated based on the equation given below. The
equation determine the height of the column without taking the skirt or any support
into consideration.

Column height = (No stages -1)(tray spacing)+(tray spacing×2)

+(no stages -1)(thickness of plate)

=(23-1)(0.5)+(0.5)(2)+(23-1)(0.005)

=12.11m

=13.32m (including 10% safety factor)

5-14
 Table 5.5 : Plate design specification

Item Value
Column diameter, Dc 1.1m2
No of plates 23 units
Plate spacing 0.5m
No of stages feed 7
Plate thickness 5mm
Total column height, Ht 13.32m
Plate material SS 304
Down comer area, Ad 0.12 m2
Down comer material SS 304
Column area, Ac 1m2
Net area, An 0.88m2
Active area, Aa 0.76m2
Hole area, Ah 0.076m2
Number of holes 3872 units
Weir length 0.84m
Weir heigh(standard) 0.05m

5-15
5.2.13 Down Comer Liquid Back-Up

The down comer area and plate spacing must be such that the level of the liquid
and froth in the down comer is well below the top of the outlet weir on the plate
above. If the level rises above the outlet weir the column will flood :

Take ℎ𝑎𝑝 = ℎ𝑤 − 10𝑚𝑚

= 50-10 = 40mm

Where hap = the height of the bottom edge of the apron above the plate

Area under apron

𝐴𝑎𝑝 = ℎ𝑎𝑝 × 𝑙𝑤

=0.04×0.84=0.0336m2

Where Aap = the clearance area under down comer

The main resistance to flow will be caused by the constriction at the down comer
outlet, and the head lost in the down comer can be estimate using the equation
given by Cicalase(1947)

𝐿𝑤𝑑 2
ℎ𝑑𝑐 = 166 [ ]
𝜌𝐿 𝐴𝑚

Where

Lwd = liquid flow rate in down comer, kg/s

Am = either the down comer area Ad or the clearance area under the down comer
Aap

whichever is the smaller

2
7.6
ℎ𝑑𝑐 = 166 [ ]
(1111)(0.0336)

= 6.88mm

The height of the liquid crest over the weir can be estimated using the Francis weir
formula. For a segmental down comer this can be written as

5-16
 𝐿𝑤𝑑
ℎ𝑜𝑤 = 750 [ ]
𝜌𝐿 𝐼𝑚

Where

Iw = weir length, m

how = weir crest, mm liquid

Lw =liquid flow rate, kg/s

7.6
ℎ𝑜𝑤 = 750 [ ]
(1111)(0.84)

= 6.1 mm

At minimum rate, clear liquid depth

how + hw = 6.1 + 50 = 56.1 mm liquid

Residual head

12500
ℎ𝑟 =
ρL

=12

Dry plate drop

𝑢 2𝜌
ℎ𝑑 = 51 [ 𝐶ℎ ] 𝑣
𝜌𝐿
where orifice coefficient C0 = 0.84
0

𝑢ℎ 2 𝜌𝑣
ℎ𝑑 = 51 [ ]
𝐶0 𝜌𝐿

=𝟐

Total drop

ℎ𝑡 = ℎ𝑑 + (ℎ𝑜𝑤 + ℎ𝑤 ) + ℎ𝑟 =2 + (6.1+50)+12=70mm

Back-up in down comer

ℎ𝑏 = (ℎ𝑜𝑤 + ℎ𝑤 ) + ℎ𝑡 + ℎ𝑑𝑐

=(6.1 + 50)+70+6.88= 133 mm liquid = 0.13m

5-17
With the constraint to satisfy

ℎ𝑏 < 1⁄2 (𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 + 𝑤𝑒𝑖𝑟 ℎ𝑒𝑖𝑔ℎ𝑡)

0.13< ½(0.5+0.05)

<0.275 m

So, tray spacing 0.5 is acceptable.

Resident time, t

Sufficient residence time must be allowed in the down comer for the entrained vapor
to disengage from the liquid stream, to pervert heavily ‘aerated’ liquid being carried
under the down comer. At time at least 3 seconds is recommended.

𝐴𝑑 ℎ𝑏𝑐 𝜌𝐿
𝑡𝑟 =
𝐿𝑤𝑑

Where

tr = residence time, s

hbc = clear liquid back-up, m

(0.12)(0.13)(1111)
𝑡𝑟 = = 𝟑𝐬
7.6

5.2.14 Perforated area

𝑙𝑤
𝐴𝑡 =
𝐷𝑐

0.84
𝐴𝑡 = = 𝟎. 𝟕𝟔𝒎𝟐
1.1

Θc = 99ᵒ

Angle sustended at plate edge by imperforated strip

=180 – 99 = 81ᵒ

5-18
Mean length for imperforated edge strip,

81
= (Dc − 0.05) × π ×
180

81
= (1.1 − 0.05) × π ×
180

= 2m

Area of imperforated edge strip,

As = 2 ×0.05 = 0.1 m2

Area of calming zones,

Ac = 2×0.05 (lw –(2×0.05))

= 2×0.05 (0.84 –(2×0.05))= 0.074m2

Total area available for perforation

Ap = Aa –(As +Ac)

= 0.76 - (0.1+0.074)=0.586 m2

𝐴ℎ 0.076
Where 𝐴𝑝
= 0.586 = 𝟎. 𝟏𝟑

5-19
5.3 MECHANICAL DESIGN

5.3.1 General Design Considerations

5.3.1.1 Pressure Vessel

To design the pressure vessel, have many terms we must consider. The following
is the terms under considerations:

a) Design pressure
b) Design temperature
c) Materials
d) Design stress
e) Welded joint efficiency and construction categories
f) Corrosion allowance
g) Design loads

5.3.1.2 Material

Pressure vessel are constructed from plain carbon steels, low and high alloy
steels, other alloys, clad plate, and reinforced plastics.

5.3.1.3 Design Stress

𝑁
Stainless steel design stress = 105 𝑎𝑡 𝑡𝑒𝑚𝑝𝑎𝑟𝑎𝑡𝑢𝑟𝑒 300℃
𝑚𝑚2

5-20
5.3.1.4 Maximum Allowable Joint Efficiency

The strength of a welded joint will depend on the type of joint and the quality of the
welding. For this separator, we take 100% degree of radiography for the type of joint
double-welded butt or equivalent.

Table 5.6: Allowable joint factor

Type of joint Degree of radiography

100% Spot None
Double-welded butt or 1.0 0.85 0.70
equivalent
Single-weld butt joint with 0.9 0.80 0.65
bonding strips

5.3.1.5 Corrosion Allowance

The corrosion allowance is the additional thickness of metal added to allow for
material lost by corrosion and erosion, or scaling. The recommended corrosion
allowance is 2 mm.

5.3.1.6 Design Loads

A structure must be designed to resist gross plastic deformation and collapse

under all the conditions of loading. The loads to which a process vessel will be
subject in service are listed below.

Major loads

1. Design pressure; including any significant static head of liquid

2. Maximum weight of the vessel and contents, under operating conditions.
3. Maximum weight of the vessel and contents under hydraulic test conditions
4. Wind loads
5. Loads supported by, or reacting on, the vessel.

5-21
5.3.1.7 Wall Thickness

The minimum wall thickness required to ensure that any vessel is sufficiently rigid to
withstand its own weight and any incidental loads. The wall thickness of any vessel
should not be less than the value given below; the values include a corrosion
allowance of 2mm.

Table 5.7: Wall Thickness due to the vessel diameter

Minimum thickness,mm
Vessel diameter, m
1 5
1 to 2 7
2 to 2.5 9
2.5 to 3.0 10
3.0 to 3.5 12

From the calculation in chemical design, vessel diameter, D=1.1 m

So, the minimum thickness is 7 mm

5-22
5.3.2 Design Of Thin-walled Vessel Under Internal Pressure

5.3.2.1 Head And Closures

For ellipsoidal head

The following equation can be used to calculate the minimum thickness required
𝑃𝑖 𝐷𝑖
𝑒= 2𝐽𝑓−0.2 𝑃𝑖

Where:

𝑃𝑖 = Internal pressure

𝐷𝑖 = Internal diameter

𝐽 = Joint factor

𝑓 = Design stress

𝑃𝑖 = 456 𝑘𝑃𝑎 = 4.56 𝑏𝑎𝑟

Design pressure, take as 10 per cent above operating pressure,

𝑃𝑖 = (4.56 − 1)1.1

𝑃𝑖 = 3.916 𝑏𝑎𝑟 = 𝟎. 𝟒 𝑵/𝒎𝒎𝟐

From the calculation in chemical design, Di = 1.1 x 103mm

The joint factor is 1

The design stress is 105 N/mm2 at 300oC from Appendic B Figure B-1

0.4 𝑥 (1.1𝑥103 )
𝑒= 2𝑥1𝑥105−0.2 (0.4)

= 𝟐. 𝟏 × 𝟏𝟎−𝟔 𝒎𝒎 + 2 mm = 2 mm

The minimum thickness is rounded to 7 mm. (Refer table)

A much thicker wall will be needed at the column base to withstand the wind and
dead weight loads.As a trial, divide the column in to five section, with the thickness
increasing by 2mm per section. Try 9, 11, 13, 15, 17mm.
5-23
5.3.3 Design Of Separator Subject To Combined Loading

The main sources of load to consider are:

a) Pressure
b) Dead weight of vessel and contents
c) Wind

5.3.3.1 Weight Loads

The major sources of dead weight load are:

 The vessel shell
 The vessel fittings
 Insulation

The weight of the vessel and fittings can be calculated from the preliminary design
sketches.

For preliminary calculation the approximate weight of the vessel with domed end
and uniform wall thickness can be estimated from following equation.

𝑊𝑣 = 𝐶𝑣 𝜋𝜌𝑚 𝐷𝑚 𝑔(𝐻𝑣 + 0.8𝐷𝑚 )𝑡 × 10−3

For a steel vessel, equation above can be reduces to:

𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡

Where,

𝑊𝑣 = total weight of the shell, excluding internal fittings, such as plates, N

𝐶𝑣 = a factor to account for the weight of nozzles, manways, internal support,

etc, which can be taken as

=1.08 for vessels with only a few internal fittings

=1.15 for distillation column, or similar vessels, with several manways, and

with plate support rings, or equivalent fittings

5-24
 𝐻𝑣 = height, or length, between tangent lines ( the length of the cylindrical

section),m

g = gravitational acceleration, 9.81 𝑚⁄ 2

𝑠

t = wall thickness, mm

𝑘𝑔⁄
ρm = density of vessel material,
𝑚3

Dm = mean diameter of vessel = (Di + t × 10−3),m

For the insulation, the weight is as equation below:

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝑉 𝑥 𝜌𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑥 𝑔

The density of insulating materials is (kg/m3)

Mineral wool 130

These densities should be double to allow for attachment fittings, sealing, and
moisture absorption.

5.3.3.1.1 Dead Weight Of Vessel

The rough estimate of the weight of vessel by using the average thickness 11mm.

Take Cv = 1.15 for distillation column

Dm = 1.1 + 13 × 10−3= 1.113 m

Hv = 13.32 m

t = 13 mm

insulation, mineral wool =75mm thick

5-25
Weight of vessel

𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡

= 240 x 1.15 x 1.113(13.32 + 0.8 x 1.113)13
= 56748 N

=56.7 kN

Weight of insulation

Mineral wool density = 130 kg/m3 with 75mm thick

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝜋 𝑥 1.1 x 13.32 x (75 x 10-3) = 3.45 m3

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝑉 𝑥 𝜌𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑥 𝑔

=3.45 ×(130×2) ×9.81 = 8.8 kN

The densities is double to allow for fittings

Weight of plates

Plate area = π/4×(1.1)2 =0.95m2

Weight of plate = 1.2 ×0.95 = 1.14 kN

23 plates = 23 ×1.14 = 26.22 kN

The total weight of the dead stresses

𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑣𝑒𝑠𝑠𝑒𝑙 = 56.7 + 8.8 + 26.22 = 𝟗𝟏. 𝟕𝟐 𝒌𝑵

5-26
5.3.3.2 Wind Loading

Dynamic wind pressure

For a smooth cylindrical column or stack the following semi-empirical equation can
be used to estimate the wind pressure
𝑃𝑤 = 0.05𝑢𝑤 2

Where Pw = wind pressure, N/m2

Uw=wind speed,km/h

Wind speed = 6.544m/s =23.56 km/h

𝑃𝑤 = 0.05(23.56)2 =27.75 N/m2

Mean diameter, including insulation = 1.1 + 2(13 + 75) x 10-3

= 1.28 m

Loading Fw =𝑃𝑤 𝐷𝑒𝑓𝑓

Where Pw=wind pressure,𝑁⁄ 2

𝑚

𝐷𝑒𝑓𝑓 =effective column diameter,m

Fw=27.75 x 1.28 = 35.52 N/m

Bending moment at bottom tangent line

𝑤𝑥 2
𝑀𝑥 = 2

Where:

X = distance measured from the free end, (𝐿)

𝑁
W = Fw = load per unit length, (𝑚)

5-27
 35.52
𝑀𝑥 = 2
x 13.322

= 𝟑𝟏𝟓𝟏 𝑵𝒎

5.3.3.3 Analysis Of Stresses

Pressure Stress
The longitudinal and circumferential stresses due to internal pressure

For longitudinal stresses

𝑃𝐷𝑖 0.4 𝑋 1.1 𝑋 103

𝜎𝐿 = = = 𝟔. 𝟒𝟕𝑵/𝒎𝒎𝟐
4𝑡 4 𝑋 17

For circumferential stresses

𝑃𝐷𝑖 0.4 𝑋 1.1 𝑋 103 𝑵

𝜎ℎ = 2𝑡
= 2 𝑋 17
= 𝟏𝟐. 𝟗 𝒎𝒎𝟐

Dead weight stress

𝑊𝑣
𝜎𝑤 =
𝜋(𝐷𝑖+𝑡)𝑡

Where, W= the total weight which is supported by the vessel wall

91.72 𝑥 103
= 𝜋(1100+17)17

= 𝟏. 𝟓𝟒 𝑵/𝒎𝒎𝟐

5-28
Bending stresses

The bending stresses will be compressive or tensile, depending on location, and are
given by:
𝑀𝑥 𝐷𝑖
𝜎𝑏 = ± [
𝐼𝑣 2
+ 𝑡]

Where:

𝜋
𝐼𝑣 =
64
(𝐷04 − 𝐷𝑖4 )

𝐷𝑜 = 𝐷𝑖 + 2𝑡

𝐷𝑜 = 1100 + 2 𝑥 17 = 1135 𝑚𝑚
𝜋
𝐼𝑣 = 64 (11354 − 11004 ) = 9.59 𝑥 109 𝑚𝑚4
3151×103 1100
𝜎𝑏 = ± 9.59 𝑥 109
( 2 + 17)

= ± 𝟎. 𝟏𝟖𝟔 𝑵/𝒎𝒎𝟐

The resultant longitudinal stress is:

𝜎𝑧 = 𝜎𝐿 + 𝜎𝑊 ± 𝜎𝑏

w is compressive and therefore negative.

𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 6.47 − 1.54 + 0.186 = + 𝟓. 𝟏 𝑵/𝒎𝒎𝟐

𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 6.47 − 1.54 − 0.186 = −𝟒. 𝟕 𝑵/𝒎𝒎𝟐

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

The radial stress is negligible. The greatest different between the principal stress will
be on the down-wind side

𝜎ℎ − 𝜎𝑧 = 12.9 − (−4.7) = 𝟏𝟕. 𝟔 𝑵/𝒎𝒎𝟐

5-29
Elastic Stability

Critical buckling stress:

𝑡
𝜎𝑐 = 2 × 104 (𝐷 )
0

= 2 x 104 (17/1135) = 300 N/mm2

The maximum compressive stress will occur when the vessel is not under pressure

𝜎𝑤 + 𝜎𝑏 = 1.54 + 0.186 = 1.7 (below critical buckling stress)

So design is saticfactory.

5-30
5.3.4 Vessel Support

To chose the support for the vessel, the terms we must consider are the size, shape
and weight of the vessel; the design temperature and pressure; the vessel location
and arrangement; and the internal and external fittings and attachments. The
following is the types of support:

a) Saddle support ( for horizontal vessel)

b) Skirt support ( used for tall and vertical column)
c) Brackets or lugs support (used for all types of vessel)

5.3.4.1 Skirt Support Design

A skirt support consists of a cylindrical or conical shell welded to the base of the
vessel. Skirt support is recommended as it does not impose concentrated loads on
the vessel shell.

π
Approximate weight = ( 4 × 1.12 × 13.32) 735 × 9.81 = 𝟗𝟏. 𝟑𝐤𝐍

Weight of vessel =91.72 kN

Total weight = 91.72 + 91.3 =183 kN

Bending moment at the base of skirt

Wind loading, 𝐹𝑤 = 𝟑𝟓. 𝟓𝟐 kN/m

Height of skirt support, Hs = 1.5m

1
𝑀𝑠 = 𝐹𝑤 × 2 (𝐻𝑣 + 𝐻𝑠 )2

1
= 35.52 × (13.32 + 1.5)2 = 𝟑𝟗𝟎 𝐤𝐍𝐦
2

5-31
Bending stresses in the skirt

4Ms
σbs = π(D
s +ts )ts Ds

4×390×103 ×103
= = 23.8 𝑵/𝒎𝒎𝟐
𝜋(1100+17)17×1100

W
σws (test) = π(D
s +ts )ts

91.3×103
= = 𝟏. 𝟓𝟑 𝑵/𝒎𝒎𝟐
𝜋(1100+17)17

W
σws (operating) =
π(Ds +ts )ts

91.72×103
= 𝜋(1100+17)17
= 𝟏. 𝟓𝟒 𝑵/𝒎𝒎𝟐

Where:

Ms = maximum bending moment

W = total weight of the vessel and contents

Ds = inside diameter of skirt

ts = skirt thickness

Resultant stresses on skirt

The resultant stresses in the skirt will be:

σs (compressive) = σbs + σws

= 23.8 + 1.53 = 𝟐𝟓 𝑵/𝒎𝒎𝟐

σs (tensile) = σbs − σws

= 23.8 − 1.54 = 𝟐𝟐 𝑵/𝒎𝒎𝟐

5-32
The skirt thickness should be such that under the worst combination of wind and
dead weight loading the following design criteria not exceeded

σs (tensile) ≤ fs Jsinθs
t
σs (compressive) ≤ 0.125E (Ds ) sinθs
s

where

fs = maximum allowable design stress for the skirt material, normally taken at
ambient temperature.

J = weld joint factor, if applicable

s= base angle of a conical skirt (80o to 90o)

Criteria for design:

Take the joint factor J as 0.85

ˆσs (tensile) ≤ fs Jsinθ

𝟐𝟓 ≤ (105)(0.85) 𝑠𝑖𝑛 900

𝑵
𝟐𝟓 ≤ 𝟖𝟗 𝒎𝒎𝟐

ts
ˆσs (compressive) ≤ 0.125E sinθ
Ds

17
𝟐𝟐 ≤ (0.125)(200,000) (1100) 𝑠𝑖𝑛 900

𝑵
𝟐𝟐 ≤ 𝟒𝟎 𝒎𝒎𝟐

Both criteria are satisfied, add 2mm for corrosion, gives a design thickness of 19mm

5-33
 5.3.4.2 Base Ring And Anchor Bolt Design

Area of bolt

Assumptions:

Approximate pitch circle diameter ≈ 1.3 m

Circumference of bolt circle = 𝟏𝟑𝟎𝟎𝝅

Number of bolts required, at minimum recommended bolt spacing

1300π
= = 𝟔. 𝟖 ≈ 7
600

Take the bolt design stress = 125 N/mm2

Ms = 𝟑𝟗𝟎 𝐤𝐍𝐦

Take W = operating value = 91.72kN

1 4M
Ab = N [ D s − W]
b fb b

Where:

Ab = area of one bolt at the root of the thread, mm2

Nb = number of bolts

N
fb = maximum allowable bolts stress, typical design = 125 mm2

Mbs = bending (overturning) moment at the base

W = weight of the vessel, N

Db = bolt circle diameter, m

5-34
 1 4 × 390 × 103
Ab = [ − 91.72 x103 ] = 𝟏𝟐𝟔𝟕𝒎𝒎𝟐
7 × 125 1.3

Use M48 bolts (BS 4190:1967) root area = 1470 mm2

Bolt root diameter

Area ×4
DBolt = √ π

1470×4
= √ π
= 𝟒𝟑𝒎𝒎

Total compressive load on the base ring

The base ring must be sufficiently wide to distribute the load to the foundation. The
total compressive load on the base ring is given by,

4M W
Fb = [πD2s + πD ]
s s

Where:

Fb = the compressive load on the base ring, Newtons per linear metre

Ds = skirt diameter, m

4 × 390 × 103 91.72 x 103 𝑵

Fb = [ 2
+ ] = 𝟒𝟑𝟕 × 𝟏𝟎𝟑
π × 1.1 π × 1.1 𝒎

5-35
The minimum width of the base

Fb 1
Lb = fc
× 103

N
Taking bearing pressure,( 5 mm2
)

Where:

Lb = base ring width, mm

fc = the maximum allowable bearing pressure on theconcrete foundation pad,

N
which will depend on the mix used, and will typically range from 3.5 to 7 mm2

(500 to 1000 psi)

437×103
Lb = = 𝟖𝟕𝒎𝒎
5×103

Minimum width anchor bolts

Table 5.8: The distance edge of skirt to outer edge of ring, Lr

Bolt size Root area,mm2 Lr,mm

M24 353 76

M30 561 76

M36 817 102

M42 1120 102

M48 1470 127

M56 2030 150

M64 2680 152

5-36
Actual width required

= Lr + t s + 50mm

= 127 + 19 + 50mm = 𝟏𝟗𝟔𝒎𝒎

Actual bearing pressure on concrete foundation

Fb
f′c =
Actual width required

437×103 𝑵
f′c = 196×103
= 𝟐. 𝟐 𝒎𝒎𝟐

Anchor bolt thickness

3f′c
t b = Lr √ fr
=

Where:

Lr = the distance from the edge of the skirt to the outer edge of the ring,mm

tb = base ring thickness,mm

f’c = actual bearing pressure on base, N/mm2

fr = allowable design stress in the ring material,typically 140 N/mm2

3 × 2.2
t b = 127√ = 𝟐𝟕. 𝟓 𝐦𝐦 ≈ 𝟑𝟎𝐦𝐦
140

5-37
 5.3.5 Pipe Sizing

The pipe diameter for fluid stream can be obtained from the following equation
below,

Stainless steel pipe:

doptimum = 260G0.52 ρ−0.37

Where,
D = optimum diameter of the pipe, mm
𝑘𝑔
G = flow rate of fluid in the pipe, 𝑠
𝑘𝑔
ρ = density of fluid,𝑚3

Feed stream

doptimum = 260G0.52 ρ−0.37

kg
Flow rate, G = 9.12
s

kg
Density of stream, ρ = 701 m3

=260(9.12)0.52(701)-0.37

=73mm≈80mm

Table 5.9: Detail Specification for Feed stream

Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1

80 88.9 190 16 34 128 3 M16 4 18 150 102 10 8

5-38
Vapor outlet stream

doptimum = 260G0.52 ρ−0.37

kg
Flow rate, G = 1.5 s

kg
Density of stream, ρ = 11.3 m3

=260(1.5)0.52(11.3)-0.37

=130mm≈150mm

Table 5.10: Detail Specification for vapor outlet stream

Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1

150 168.3 265 18 48 202 3 M16 8 18 225 184 12 10

Liquid outlet stream

doptimum = 260G0.52 ρ−0.37

kg
Flow rate, G = 7.6 s

kg
Density of stream, ρ = 735 m3

=260(7.6)0.52(735)-0.37

=65mm

Table 5.11: Detail Specification for liquid outlet stream

Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1

65 76.1 160 14 38 110 3 M12 4 14 130 88 9 6

5-39
5.3.6 Summary

Table 5.12: Summary of Mechanical Specification Design

ITEMS VALUES UNITS

Design Pressure, P 456 kPa

Design Temperature, T 227.6 K

Stainless Steel Design Stress,

95 N/mm2
σSS

Thickness of Vessel, e with

19 mm
Corrosion Allowance 2 mm

Height of vessel, H 13.32 m

Weight of Shell, W s 56.7 kN

Weight of Plates, W t 26.22 kN

Weight of insulation 8.8 kN

Total Weight, W v 91.72 kN

Dead Weight Stress, σw 1.54 N/mm2

Wind Loading, Fw 35.52 N/m

Bending Moment, Mx 3151 Nm

Buckling Stress, σc 300 N/mm2

Bending Moment of Skirt, Ms 390 kNm

Area of Bolt, Ab 1470 mm2

Bolt Root Diameter, Dbolt 43 mm

5-40
5.4 CHEMICAL DESIGN SEPARATOR

5.4.1 Introduction

5.4.1.1 Separation Process

A separation process is used to separate a mixture of substances into two or more

distinct products. The separated products could differ in chemical properties or
some physical property, such as size.

A vapor liquid separator is one of the types of separator. Vapor liquid separator
has two types that is horizontal and vertical separator. The advantages of vertical
separator are required smaller plot area, it is easier to remove solids, liquid removal
efficiency does not vary with liquid level because the area in the vessel available for
the vapor flow remains constant and generally the vessel volume is smaller. The
advantages of horizontal separator are it is easier to accommodate large liquids
slugs, required less head room, the downward liquid velocity is lower and additional
to vapor/liquid separation also a liquid/liquid separation.

5.4.1.2 Vapor Liquid Separator

A vapor-liquid separator is vertical vessel used to separate vapor-liquid mixture.

The fluid is pressurized and heated and then passed through the valve into the
vessel. Because of the large drop in pressure, part of the fluid is vaporizes. The
vapor is taken off overhead and liquid drains to the bottom of vessel, where it is
withdrawn. A demister is used to prevent liquid droplets from being entrained in the
vapor.

A vapor liquid separator may also be referred to as a flash drum, knock-out drum,
knock-out pot, compressor suction drum or compressor inlet drum.

5-41
 Figure 5.2 : A typical vapor-liquid separator

5.4.1.3 Demister
A demister is a device often used in vapor liquid separator to prevent liquid
droplets from being entrained in the vapor. In vertical separator, demister pads is
installed with the minimum thickness 6in. The demister pad should extend from the
top of the vessel to 0.1m above the bottom. The area between the mat and the
bottom of the vessel shall allow free passage of liquid. The distance between the
inlet device and the front face of the demister mat shall be at least 0.6m or 0.5times
the vessel diameter. The distance between the downstream of the outlet and the
rear face of the demister mat shall be at least 0.5D.

Figure 5.3: Demister pad

5-42
5.4.1.4 Selection Criteria For Vapor Liquid Separator

The configuration of a vapor liquid separator depends on a number of factors.

Before making a vessel design we have to decide on the configuration below of the
vessel.

a) Orientation
b) Type of feed inlet
c) Type of internals
d) Type of heads

1. Orientation of the vessel

The selection of the orientation of a vapor liquid separator depends on several

factors. Both vertical and horizontal vessels have their advantages.
Advantages of a vertical vessel:

 A smaller plot area is required

 It is easier to remove solids
 Liquid removal efficiency does not vary with liquid level
 Generally the vessel volume is smaller

Advantages of a horizontal vessel:

 It is easier to accommodate large liquid slugs

 Less head room is required
 The downward liquid velocity is lower

2. Feed inlet

The feed nozzle size and the type of feed inlet device have an impact on the
valor liquid separation that can be achieved. The feed nozzle is normally sized
to limit the momentum of the feed. The limitation depends on whether or not a
feed inlet device is installed.

5-43
3. Internals

After passing through the feed inlet, the vapor stream will still contain liquid in
the form of droplets. The maximum size of these entrained droplets depends on
the vapor upflow velocity. A separation device can reduce this entrainment
significantly. Wire mesh demister are the most commonly use as separation
device. They are used for two reasons:

 To minimize entrainment
 To reduce the size of a vessel

Major disadvantages of wire mesh demister are:

 They are not suitable for fouling device

 Their liquid removal decreases significantly at reduced throughput

4. Vessel head

Most vessels have 2:1 elliptical heads, welded to the shell of the vessel.
However, in some cases other types of heads are used. The major alternatives
are:

 Flat heads (in case of small vertical vessels, diameter less than
approximately 30’’)
 Hemispherical heads (for an extremely large, high-pressure vessel)
 Dished head ( in case of a large diameter, low pressure vessel)

5-44
5.4.2 Chemical Design Calculation

The design of a vapor liquid separator is based on the terminal settling velocity of a
liquid droplets of specified size, settling under the influence of gravity. This velocity
is given by

(𝜌𝐿 − 𝜌𝑉 ) 1/2
(𝑈𝑉 )𝑚𝑎𝑥 = 𝐾 [ ]
𝜌𝑣

Where

(𝑈𝑉 )𝑚𝑎𝑥 = settling velocity, ft/s

𝜌𝐿 = liquid density, lb/ft3

𝜌𝑉 = vapour density, lb/ft3

𝑊 𝜌
Figure relates the K factor for a vertical vessel (K) to 𝑊𝑙 √ 𝜌𝑣
𝑣 𝑙

Data from Hysys:

L = 48.221 𝑙𝑏⁄ 3
𝑓𝑡

v = 0.015504 𝑙𝑏⁄ 3
𝑓𝑡

Mass flowrate (vapor) = 917.9 lb/hr

Mass flowrate (liquid) = 1.139 x 104 lb/hr

Separation factor

𝑊𝑙 𝜌𝑣 1.139×104 0.015504
√ = √ = 0.22
𝑊𝑣 𝜌𝑙 917.9 48.221

5-45
 Figure 5.4 : Graph to find K value

From the graph, K=0.35

So, Uvapor max

1/2
(𝜌𝐿 − 𝜌𝑉 )
(𝑈𝑣 )𝑚𝑎𝑥 = 𝐾 [ ]
𝜌𝐿

(48.221− 0.015504) 1/2

= 0.35 [ ]
0.015504

𝑓𝑡
= 19.5 𝑠
= 𝟓. 𝟗𝟒 𝒎⁄𝒔

Minimum vessel cross section

𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝑉𝑎𝑝𝑜𝑟 𝑣𝑜𝑙𝑒𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒, 𝑄𝑣 =
𝑣𝑎𝑝𝑜𝑟 𝑑𝑒𝑛𝑠𝑖𝑡𝑦
416.4
= 3600 𝑥 0.24835

= 𝟎. 𝟒𝟔𝟔 𝒎𝟑 /𝒔

𝑄𝑣
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑒𝑠𝑠𝑒𝑙 𝑐𝑟𝑜𝑠𝑠 − 𝑠𝑒𝑐𝑡𝑖𝑜𝑛𝑎𝑙 𝑎𝑟𝑒𝑎, 𝐴𝑚𝑖𝑛 = (𝑈𝑣 )𝑚𝑎𝑥

0.466
= 5.94
= 𝟎. 𝟎𝟕𝟖 𝒎𝟐

5-46
Minimum vessel diameter

4𝐴min
𝐷𝑚𝑖𝑛 = √( 𝜋
)

Where 𝐷𝑚𝑖𝑛 = minimum vessel diameter , m

𝐴𝑚𝑖𝑛 = Cross sectional area , m2

4𝐴min
𝑀𝑖𝑛𝑖𝑚𝑢𝑚 𝑣𝑒𝑠𝑠𝑒𝑙 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟, 𝐷𝑚𝑖𝑛 = √( 𝜋
)

4(0.078)
= √( 𝜋
)

=0.32m + 0.1524 = 0.47m

Usually, the diameter is increased to the next largest 6-in/0.1524m increment

Vessel height:

𝑉𝑒𝑠𝑠𝑒𝑙 ℎ𝑒𝑖𝑔ℎ𝑡, 𝐿𝑣 = ℎ𝑙 + ℎ𝑓 + ℎ𝑣

Where:

hl = height of liquid holdup level in vessel (for a given residence time, typically
5 minutes)

hf = height of liquid level to feed line

hv = disengagement height = D

5-47
Set the diameter/length ratio L/D ranges from 3 to 5.

Vessel height, L=5D

=5(0.47)=2.35m

The minimum height of drum above the centerline of the feed nozzle,hv is 1.2192m.

The minimum height of the center of the feed line above the maximum level of the
liquid pool, hf is 0.4572m

So, hL = 2.35 - 1.2192 - 0.4572 =0.6736m

D
hv=1.2192 m

hf =0.4572m
feed

hL =0.6736m

Figure 5.5 : Measurement for vertical flash drum

Approximate the vapor-liquid inlet nozzle based on the following velocity criteria:

𝑓𝑡
(𝑈𝑚𝑎𝑥 )𝑛𝑜𝑧𝑧𝑙𝑒 = 100 √𝜌𝑚𝑖𝑥 = 100 √48.5 = 696 =212 m/s
𝑠

𝑓𝑡
(𝑈𝑚𝑖𝑛 )𝑛𝑜𝑧𝑧𝑙𝑒 = 60 √𝜌𝑚𝑖𝑥 = 60 √48.5 = 418 =127 m/s
𝑠

Where U=max,min velocity, ft/sec

𝜌𝑚𝑖𝑥 =mixture density, lbs/ft3

5-48
The required vessel surge volume

𝑉 = 𝑄𝑙 𝑥 𝑑𝑒𝑠𝑖𝑔𝑛 𝑡𝑖𝑚𝑒 𝑡𝑜 𝑓𝑖𝑙𝑙 𝑖𝑛 𝑠𝑒𝑐𝑜𝑛𝑑 ,ft3

𝑓𝑡 3⁄
Where 𝑄𝑙 = 𝑙𝑖𝑞𝑢𝑖𝑑 𝑓𝑙𝑜𝑤, 𝑠𝑒𝑐

𝑀𝑎𝑠𝑠 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝐿𝑖𝑞𝑢𝑖𝑑 𝑣𝑜𝑙𝑒𝑚𝑒𝑡𝑟𝑖𝑐 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒, 𝑄𝐿 =
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑠𝑖𝑡𝑦

5167
= 3600 𝑥 772.42

= 𝟏. 𝟖𝟓𝟖 × 𝟏𝟎−𝟑 𝒎𝟑 /𝒔

𝑉𝑜𝑙𝑢𝑚𝑒 ℎ𝑒𝑙𝑑 𝑖𝑛 𝑣𝑒𝑠𝑠𝑒𝑙 = 1.858 × 10−3 (5𝑚𝑖𝑛 𝑥 60𝑠𝑒𝑐)

= 𝟎. 𝟓𝟔 𝒎𝟑

5-49
5.4.3 Summary Of Chemical Design

Table 5.13 : Summary of chemical design

Item Value Unit

101.3 kPa
Design pressure

60 °C
Design temperature

5 min
Hold up time

0.56
Volume of vessel m3

0.47
Diameter m

2.35
Height m

Height of the vessel above the centerline of the feed 0.2192 m

nozzle, hv

Height of the centerline of the feed line above the 0.6736

maximum level of the liquid pool, hl m

0.4572 m
Depth of the liquid pool, hf

5-50
5.5 MECHANICAL DESIGN

5.5.1 General Design Considerations

5.5.1.1 Pressure Vessel

To design the pressure vessel, have many terms we must consider. The following
is the terms under considerations:

h) Design pressure
i) Design temperature
j) Materials
k) Design stress
l) Welded joint efficiency and construction categories
m) Corrosion allowance
n) Design loads

5.5.1.2 Material

Pressure vessel are constructed from plain carbon steels, low and high alloy
steels, other alloys, clad plate, and reinforced plastics.

5.5.1.3 Design Stress

𝑁
Stainless steel design stress = 150 𝑎𝑡 𝑡𝑒𝑚𝑝𝑎𝑟𝑎𝑡𝑢𝑟𝑒 60℃
𝑚𝑚2

5-51
5.5.1.4 Maximum Allowable Joint Efficiency

The strength of a welded joint will depend on the type of joint and the quality of the
welding. For this separator, we take 100% degree of radiography for the type of joint
double-welded butt or equivalent.

Table 5.14: Allowable joint factor

Type of joint Degree of radiography

100% Spot None
Double-welded butt or 1.0 0.85 0.70
equivalent
Single-weld butt joint with 0.9 0.80 0.65
bonding strips

5.5.1.5 Corrosion Allowance

The corrosion allowance is the additional thickness of metal added to allow for
material lost by corrosion and erosion, or scaling. The recommended corrosion
allowance is 2 mm.

5.5.1.6 Design Loads

A structure must be designed to resist gross plastic deformation and collapse

under all the conditions of loading. The loads to which a process vessel will be
subject in service are listed below.

Major loads

6. Design pressure; including any significant static head of liquid

7. Maximum weight of the vessel and contents, under operating conditions.
8. Maximum weight of the vessel and contents under hydraulic test conditions
9. Wind loads
10. Loads supported by, or reacting on, the vessel.

5-52
5.5.1.7 Wall Thickness

The minimum wall thickness required to ensure that any vessel is sufficiently rigid to
withstand its own weight and any incidental loads. The wall thickness of any vessel
should not be less than the value given below; the values include a corrosion
allowance of 2mm.

Table 5.15: Wall Thickness due to the vessel diameter

Minimum thickness,mm
Vessel diameter, m
1 5
1 to 2 7
2 to 2.5 9
2.5 to 3.0 10
3.0 to 3.5 12
From the calculation in chemical design, vessel diameter, D=0.47 m

So, the minimum thickness is 5mm

5-53
5.5.2 Design Of Thin-walled Vessel Under Internal Pressure

5.5.2.1 Head And Closures

For ellipsoidal head

The following equation can be used to calculate the minimum thickness required
𝑃𝑖 𝐷𝑖
𝑒= 2𝐽𝑓−0.2 𝑃𝑖

Where:

𝑃𝑖 = Internal pressure

𝐷𝑖 = Internal diameter

𝐽 = Joint factor

𝑓 = Design stress

𝑃𝑖 = 101.3 𝑘𝑃𝑎 = 1.013 𝑏𝑎𝑟

Design pressure, take as 10 per cent above operating pressure,

𝑃𝑖 = (1.013 − 1)1.1

𝑃𝑖 = 0.0143 𝑏𝑎𝑟 = 𝟏. 𝟒𝟑 × 𝟏𝟎−𝟑 𝑵/𝒎𝒎𝟐

From the calculation in chemical design, Di = 0.47 x 103mm

The joint factor is 1 refer to table 2

The design stress is 150 N/mm2 at 60oC from table

1.43×10−3 𝑥 (0.47𝑥103 )
𝑒= 2𝑥1𝑥150−0.2 (1.43×10−3 )

= 𝟎. 𝟎𝟎𝟐𝟐𝟒 𝒎𝒎 + 2 mm = 2.00224 mm

The minimum thickness is rounded to 5 mm. (Refer table)

A much thicker wall will be needed at the column base to withstand the wind and
dead weight loads.As a trial, divide the column in to five section, with the thickness
increasing by 2mm per section. Try 7,9,11,13,15mm.

5-54
5.5.3 Design Of Separator Subject To Combined Loading

The main sources of load to consider are:

d) Pressure
e) Dead weight of vessel and contents
f) Wind

5.2.3.1 Weight Loads

The major sources of dead weight load are:

 The vessel shell
 The vessel fittings
 Insulation

The weight of the vessel and fittings can be calculated from the preliminary design
sketches.

For preliminary calculation the approximate weight of the vessel with domed end
and uniform wall thickness can be estimated from following equation.

𝑊𝑣 = 𝐶𝑣 𝜋𝜌𝑚 𝐷𝑚 𝑔(𝐻𝑣 + 0.8𝐷𝑚 )𝑡 × 10−3

For a steel vessel, equation above can be reduces to:

𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡

Where,

𝑊𝑣 = total weight of the shell, excluding internal fittings, such as plates, N

𝐶𝑣 = a factor to account for the weight of nozzles, manways, internal support,

etc, which can be taken as

=1.08 for vessels with only a few internal fittings

=1.15 for distillation column, or similar vessels, with several manways, and

with plate support rings, or equivalent fittings

5-55
 𝐻𝑣 = height, or length, between tangent lines ( the length of the cylindrical

section),m

g = gravitational acceleration, 9.81 𝑚⁄ 2

𝑠

t = wall thickness, mm

𝑘𝑔⁄
ρm = density of vessel material,
𝑚3

Dm = mean diameter of vessel = (Di + t × 10−3),m

For the insulation, the weight is as equation below:

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝑉 𝑥 𝜌𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑥 𝑔

the density of insulating materials is(kg/m3)

Mineral wool 130

These densities should be double to allow for attachment fittings, sealing, and
moisture absorption.

5-56
5.5.3.1.1 Dead Weight Of Vessel

The rough estimate of the weight of vessel by using the average thickness 11mm.

Take Cv = 1.08 for vessel with only a few internal fittings

Dm = 0.47 + 11 × 10−3= 0.481 m

Hv = 2.35 m

t = 11 mm

insulation, mineral wool =75mm thick

𝑊𝑣 = 240𝐶𝑣 𝐷𝑚 (𝐻𝑣 + 0.8𝐷𝑚 )𝑡

= 240 x 1.08 x 0.481(2.35 + 0.8 x 0.481)11
= 3750.6 N

=3.7506 kN

Weight of insulation

Mineral wool density = 130 kg/m3 with 75mm thick

𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝜋 𝑥 0.47 x 2.35 x (75 x 10-3) = 0.26 m3

𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 = 𝑉 𝑥 𝜌𝑖𝑛𝑠𝑢𝑙𝑎𝑡𝑖𝑜𝑛 𝑥 𝑔

=0.26 ×(130×2) ×9.81 = 0.663 kN

The densities is double to allow for fittings

Weight of demister

Weight capacity of wire mesh demister =163 kg/m3

Volume of demister = vessel cross sectional area × demister thickness

= 0.078 × 0.1

=0.0078m3

5-57
 𝑊𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑑𝑒𝑚𝑖𝑠𝑡𝑒𝑟 = 𝑉 𝑥 𝜌𝑑𝑒𝑚𝑖𝑠𝑡𝑒𝑟 𝑥 𝑔

=(0.0078)(163)(9.81)=0.012kN

The total weight of the dead stresses

𝑇𝑜𝑡𝑎𝑙 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑣𝑒𝑠𝑠𝑒𝑙 = 3.7506 + 0.663 + 0.012 = 𝟒. 𝟒𝟑 𝒌𝑵

5.5.3.2 Wind Loading

Dynamic wind pressure

For a smooth cylindrical column or stack the following semi-empirical equation can
be used to estimate the wind pressure
𝑃𝑤 = 0.05𝑢𝑤 2

Where Pw = wind pressure, N/m2

Uw=wind speed,km/h

Wind speed = 6.544m/s =23.56 km/h

𝑃𝑤 = 0.05(23.56)2 =27.75 N/m2

Mean diameter, including insulation = 0.47 + 2(11 + 75) x 10-3

= 0.642 m

5-58
Loading Fw =𝑃𝑤 𝐷𝑒𝑓𝑓

Where Pw=wind pressure,𝑁⁄ 2

𝑚

𝐷𝑒𝑓𝑓 =effective column diameter,m

Fw=27.75 x 0.642 = 17.82 N/m

Bending moment at bottom tangent line

𝑤𝑥 2
𝑀𝑥 = 2

Where:

X = distance measured from the free end, (𝐿)

𝑁
W = Fw = load per unit length, (𝑚)

17.82
𝑀𝑥 = 2
x 2.352

= 𝟒𝟗. 𝟐 𝑵𝒎

5.5.3.3 Analysis Of Stresses

Pressure Stress
The longitudinal and circumferential stresses due to internal pressure

For longitudinal stresses

𝑃𝐷𝑖 1.43×10−3 𝑋 0.47 𝑋 103

𝜎𝐿 = 4𝑡
= 4 𝑋 15
= 𝟎. 𝟎𝟏𝟏𝟐𝑵/𝒎𝒎𝟐

For circumferential stresses

𝑃𝐷𝑖 1.43×10−3 𝑋 0.47 𝑋 103 𝑵

𝜎ℎ = = = 𝟎. 𝟎𝟐𝟐𝟒
2𝑡 2 𝑋 15 𝒎𝒎𝟐

5-59
Dead weight stress

𝑊𝑣
𝜎𝑤 = 𝜋(𝐷𝑖+𝑡)𝑡

Where, W= the total weight which is supported by the vessel wall

4.43 𝑥 103
= 𝜋(470+15)15

= 𝟎. 𝟏𝟗 𝑵/𝒎𝒎𝟐

Bending stresses

The bending stresses will be compressive or tensile, depending on location, and are
given by:
𝑀𝑥 𝐷𝑖
𝜎𝑏 = ± [
𝐼𝑣 2
+ 𝑡]

Where:

𝜋
𝐼𝑣 = 64 (𝐷04 − 𝐷𝑖4 )

𝐷𝑜 = 𝐷𝑖 + 2𝑡

𝐷𝑜 = 470 + 2 𝑥 15 = 500 𝑚𝑚
𝜋
𝐼𝑣 = 64 (5004 − 4704 ) = 0.673 𝑥 109 𝑚𝑚4
49.2×103 470
𝜎𝑏 = ± ( + 15)
0.673 𝑥 109 2

= ± 𝟎. 𝟎𝟏𝟖𝟑 𝑵/𝒎𝒎𝟐

5-60
The resultant longitudinal stress is:

𝜎𝑧 = 𝜎𝐿 + 𝜎𝑊 ± 𝜎𝑏

w is compressive and therefore negative.

𝜎𝑧 (𝑢𝑝𝑤𝑖𝑛𝑑) = 0.0112 − 0.19 + 0.0183 = + 𝟎. 𝟏𝟔 𝑵/𝒎𝒎𝟐

𝜎𝑧 (𝑑𝑜𝑤𝑛𝑤𝑖𝑛𝑑) = 0.0112 − 0.19 − 0.0183 = −𝟎. 𝟏𝟗𝟕 𝑵/𝒎𝒎𝟐

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

The radial stress is negligible. The greatest different between the principal stress will
be on the down-wind side

𝜎ℎ − 𝜎𝑧 = 0.0224 − (−0.197) = 𝟎. 𝟐𝟐 𝑵/𝒎𝒎𝟐

Elastic Stability

Critical buckling stress:

𝑡
𝜎𝑐 = 2 × 104 (𝐷 )
0

= 2 x 104 (15/500) = 600 N/mm2

The maximum compressive stress will occur when the vessel is not under pressure

𝜎𝑤 + 𝜎𝑏 = 0.19 + 0.0183 = 0.2083 (below critical buckling stress)

So design is saticfactory.

5-61
5.5.4 Vessel Support

To chose the support for the vessel, the terms we must consider are the size, shape
and weight of the vessel; the design temperature and pressure; the vessel location
and arrangement; and the internal and external fittings and attachments. The
following is the types of support:

d) Saddle support ( for horizontal vessel)

e) Skirt support ( used for tall and vertical column)
f) Brackets or lugs support (used for all types of vessel)

5.2.4.1 Skirt Support Design

A skirt support consists of a cylindrical or conical shell welded to the base of the
vessel. Skirt support is recommended as it does not impose concentrated loads on
the vessel shell.

π
Approximate weight = ( 4 × 0.472 × 2.35) 777 × 9.81 = 𝟑. 𝟏𝐤𝐍

Weight of vessel =4.43 kN

Total weight = 4.43 + 3.1 =7.53 kN

Bending moment at the base of skirt

Wind loading, 𝐹𝑤 = 𝟎. 𝟎𝟏𝟕𝟖𝟐 kN/m

Height of skirt support, Hs = 1.5m

1
𝑀𝑠 = 𝐹𝑤 × 2 (𝐻𝑣 + 𝐻𝑠 )2

1
= 0.01782 × (2.35 + 1.5)2 = 𝟎. 𝟏𝟑𝟐 𝐤𝐍𝐦
2

5-62
Bending stresses in the skirt

4Ms
σbs = π(D
s +ts )ts Ds

4×0.132×103 ×103
= 𝜋(470+15)15×470 = 𝟎. 𝟎𝟓 𝑵/𝒎𝒎𝟐

W
σws (test) = π(D
s +ts )ts

3.1×103
= 𝜋(470+15)15 = 𝟎. 𝟏𝟑𝟔 𝑵/𝒎𝒎𝟐

W
σws (operating) = π(D
s +ts )ts

4.43×103
= = 𝟎. 𝟏𝟗 𝑵/𝒎𝒎𝟐
𝜋(470+15)15

Where:

Ms = maximum bending moment

W = total weight of the vessel and contents

Ds = inside diameter of skirt

ts = skirt thickness

Resultant stresses on skirt

The resultant stresses in the skirt will be:

σs (compressive) = σbs + σws

= 0.136 + 0.05 = 𝟎. 𝟏𝟖𝟔 𝑵/𝒎𝒎𝟐

σs (tensile) = σbs − σws

= 0.19 − 0.05 = 𝟎. 𝟏𝟒 𝑵/𝒎𝒎𝟐

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The skirt thickness should be such that under the worst combination of wind and
dead weight loading the following design criteria not exceeded

σs (tensile) ≤ fs Jsinθs
t
σs (compressive) ≤ 0.125E (Ds ) sinθs
s

where

fs = maximum allowable design stress for the skirt material, normally taken at
ambient temperature.

J = weld joint factor, if applicable

s= base angle of a conical skirt (80o to 90o)

Criteria for design:

Take the joint factor J as 0.85

ˆσs (tensile) ≤ fs Jsinθ

−𝟎. 𝟏𝟒 ≤ (125)(0.85) 𝑠𝑖𝑛 900

𝑵
−𝟎. 𝟏𝟒 ≤ 𝟏𝟎𝟔. 𝟐𝟓 𝒎𝒎𝟐

ts
ˆσs (compressive) ≤ 0.125E sinθ
Ds

15
𝟎. 𝟏𝟖𝟔 ≤ (0.125)(200,000) (470) 𝑠𝑖𝑛 900

𝑵
𝟎. 𝟏𝟖𝟔 ≤ 𝟕𝟗𝟖 𝒎𝒎𝟐

Both criteria are satisfied, add 2mm for corrosion, gives a design thickness of 17mm

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 10.2.4.2 Base Ring And Anchor Bolt Design

Area of bolt

Assumptions:

Approximate pitch circle diameter ≈ 0.8 m

Circumference of bolt circle = 𝟖𝟎𝟎𝝅

Number of bolts required, at minimum recommended bolt spacing

800π
= 600
= 𝟒. 𝟏 ≈ 4

Take the bolt design stress = 125 N/mm2

Ms = 𝟏𝟑𝟐 𝐤𝐍𝐦

Take W = operating value = 4.43kN

1 4Ms
Ab = [ − W]
Nb fb Db

Where:

Ab = area of one bolt at the root of the thread, mm2

Nb = number of bolts

N
fb = maximum allowable bolts stress, typical design = 125 mm2

Mbs = bending (overturning) moment at the base

W = weight of the vessel, N

Db = bolt circle diameter, m

5-65
 1 4 × 132 × 103
Ab = [ − 4.43 x103 ] = 𝟏𝟑𝟏𝟏𝒎𝒎𝟐
4 × 125 0.8

Use M48 bolts (BS 4190:1967) root area = 1470 mm2

Bolt root diameter

Area ×4
DBolt = √
π

7861×4
= √ π
= 𝟒𝟏𝒎𝒎

Total compressive load on the base ring

The base ring must be sufficiently wide to distribute the load to the foundation. The
total compressive load on the base ring is given by,

4Ms W
Fb = [ + πD ]
πD2s s

Where:

Fb = the compressive load on the base ring, Newtons per linear metre

Ds = skirt diameter, m

4 × 132 × 103 4.43 x 103 𝑵

Fb = [ + ] = 𝟕𝟔𝟒 × 𝟏𝟎𝟑
π × 0.472 π × 0.47 𝒎

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The minimum width of the base

Fb 1
Lb = ×
fc 103

N
Taking bearing pressure,( 5 mm2
)

Where:

Lb = base ring width, mm

fc = the maximum allowable bearing pressure on theconcrete foundation pad,

N
which will depend on the mix used, and will typically range from 3.5 to 7 mm2

(500 to 1000 psi)

764×103
Lb = = 𝟏𝟓𝟑𝒎𝒎
5×103

Minimum width anchor bolts

Table 5.16: The distance edge of skirt to outer edge of ring, Lr

Bolt size Root area,mm2 Lr,mm

M24 353 76

M30 561 76

M36 817 102

M42 1120 102

M48 1470 127

M56 2030 150

M64 2680 152

5-67
Actual width required

= Lr + ts + 50mm

= 127 + 17 + 50mm = 𝟏𝟗𝟒𝒎𝒎

Actual bearing pressure on concrete foundation

Fb
f′c =
Actual width required

764×103 𝑵
f′c = = 𝟑. 𝟗𝟒 𝒎𝒎𝟐
194×103

Anchor bolt thickness

3f′c
tb = Lr √ fr
=

Where:

Lr = the distance from the edge of the skirt to the outer edge of the ring,mm

tb = base ring thickness,mm

f’c = actual bearing pressure on base, N/mm2

fr = allowable design stress in the ring material,typically 140 N/mm2

3 × 3.94
tb = 127√ = 𝟑𝟔. 𝟗 𝐦𝐦 ≈ 𝟒𝟎𝐦𝐦
140

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5.5.5 Pipe Sizing

The pipe diameter for fluid stream can be obtained from the following equation
below,

Stainless steel pipe:

doptimum = 260G0.52 ρ−0.37

Where,
D = optimum diameter of the pipe, mm
𝑘𝑔
G = flow rate of fluid in the pipe, 𝑠
𝑘𝑔
ρ = density of fluid,𝑚3

Feed stream

doptimum = 260G0.52 ρ−0.37

kg
Flow rate, G = 1.55
s

kg
Density of stream, ρ = 3.3173 m3

=260(1.55)0.52(3.3173)-0.37

=210mm≈250mm

Table 5.17: Detail Specification for Feed stream

Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1

250 273 375 22 60 312 3 M16 12 18 335 290 15 12

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Vapor outlet stream

doptimum = 260G0.52 ρ−0.37

kg
Flow rate, G = 0.116 s

kg
Density of stream, ρ = 0.24835 m3

=260(0.116)0.52(0.24835)-0.37

=142mm≈150mm

Table 5.18: Detail Specification for vapor outlet stream

Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1

150 168.3 265 18 48 202 3 M16 8 18 225 184 12 10

Liquid outlet stream

doptimum = 260G0.52 ρ−0.37

kg
Flow rate, G = 1.435 s

kg
Density of stream, ρ = 772.42 m3

=260(1.435)0.52(772.42)-0.37

=27mm≈32mm

Table 5.19: Detail Specification for liquid outlet stream

Pipe Raise
Nom Flange Drilling Neck
o.d Face Bolting
Size D b h1 d4 f No d2 k d3 h2 r
d1

32 42.4 120 14 35 70 2 M12 4 14 90 55 6 6

5-70
 REFERENCE

1. R.K.Sinnott. (1999).Chemical Engineering Design, Coulson & Richardson

Chemical Engineering .3rd Edition. Volume 6

2. Separation & Separators - Types of Separator - Gas / Liquid Separators

Retrieved from http://articles.compressionjobs.com/articles/oilfield-101/1008-
separation-separators-well-fluid-coalescing?start=4

3. Wikipedia The Free Encyclopedia.(2010).Demister (vapor)

Retrieved from http://en.wikipedia.org/wiki/Demister_%28vapor%29

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