Vapor-Liquid Flash Separator Design 35

CHAPTER
7
Vapor-Liquid
Flash Separator

7.1 Introduction
The vapor liquid separators are used to separate two phase inlet into pure vapors and pure
liquid. It basically helps in recovering valuable products and improves product purity. If two
phase separators are used after flashing a hot liquid across a valve, it is called a flash
separator.

7.2 Significance in Process

Flash Separators are preferred when the relative volatility difference between the components
is high. In our case it is used to separate water, gasoline and light diesel from the incoming
feed.
 Dewatering
 Defueling

7.3 Types of Separators

1. Vertical Separator
2. Horizontal Separator
3. Knockout Drum

7.3.1 Vertical Separator

 Used where vapor flow is large as compared to liquid flow.
 Good separation efficiency.
 By rule of thumb it is commonly preferable in oil refineries.

7.4 Selection Criteria

 If length to diameter (L/D) ratio lies between 3 and 5, then it will be vertical
separator.
 If length to diameter (L/D) ratio is greater than 5 then it will be horizontal separator.
Vapor-Liquid Flash Separator Design 36

Fig 7.1

7.5 Phenomenon
Feed coming at its bubble after passing through throttling valve gives two phase flow along
with reduction in pressure. The vapor & liquid mixture is separated by gravity and impaction
in the separator. The mixture enters the separator and strikes the splash plate where it loses its
momentum. Most of the liquid flows downwards and vapors along with liquid drop flow
upward. As the vapor rises, large drops settle to the bottom of separator by gravity. Normal
separation efficiency is 95% which can be increased to 99.9% by using a mist eliminator.
Vortex formation must be prevented to reduce gas entrainment in the liquid by using a vortex
breaker at the bottom.

Fig 7.2
Vapor-Liquid Flash Separator Design 37

7.6 Internals
1 Splash Plate
2 Vortex Breaker
3 Mist Eliminator

Fig 7.3
Splash Plate

Fig 7.4
Vapor-Liquid Flash Separator Design 38

7.6.1 Splash Plate

It is used to cause the initial bulk separation of liquid and gas. It provides a means to cause a
sudden and rapid change of momentum (velocity and direction) of the entering stream. If it is
not present then the vapors will escape very rapidly without contacting with liquid to
establish equilibrium.

7.6.2 Vortex Breaker

A vortex breaker is normally installed on the liquid outlet to prevent formation of vortex
when the liquid outlet valve is open. The formation of a vortex at the liquid outlet may result
in withdrawal and entrainment of gas with the exiting liquid. This causes the loss of valuable
vapors, pump damage and abnormal liquid level readings.

7.6.3 Mist Eliminator

Mist elimination or demisting can be defined as the mechanical
separation of liquids from gases. Mesh usually consists of 0.011inch diameter wires to form a
pad of 4 to 6 inches thick & pressure drop is less than 1inch of water.

Types of Mist Eliminator

1. Mesh type
2. Vane type
3. Fiber type

7.6.3a Mesh Type Mist Eliminator

It is efficient and economical for a wide range of applications. Porous blankets of knitted
metal or plastic wire mesh are designed. It is ideal for use in absorption and drying towers,
evaporators, distillation towers, stripping columns, scrubbers, steam drums, separators, and
knockout drums.
It has high collection efficiency, low pressure drop, lowest installed cost. But it is not suitable
for viscous fluids.

7.6.3b Vane Type Mist Eliminator

It consists of series of closely spaced parallel, corrugated plates or zigzag blades either
vertical or horizontal flow installations. As the gas and entrained liquid droplets flowing
between the plates change flow direction due to corrugations, the liquid droplets impinge on
the surface of the plates, where they coalesce and fall down into the liquid collection section.
Ideal for applications where solids or viscous, sticky liquids rapidly plug a wire mesh type
mist eliminator. It has greatest resistance to fouling. These are usable in either vertical
(upward) or horizontal flow designs. Provide the lowest pressure drop of any type mist
eliminator.
Vapor-Liquid Flash Separator Design 39

Fig 7.5 Vortex Breakers

 Vapor-Liquid Flash Separator Design 40

Mist Eliminator Mesh type

Vane type Fiber type

Fig 7.6
Vapor-Liquid Flash Separator Design 41

7.6.3c FIBER Type Mist Eliminator

It has highest collection efficiency of submicron particles. It consists of a packed fiber bed
between either two concentric screens or two flat parallel screens. It captures submicron mist
particles 0.1 microns or smaller.

Fig 7.7

7.7 Material Balance

Table 7.1
Components Material in Vapor out Liquid out
kg /hr kg/hr kg/hr
Stream 2 Stream 3 Stream 4
H2O 514 512.555 1.45

Gasoline 148.495 120.525 27.97

Diesel 349.882 115.325 234.557

Lube 3868.629 0 3868.629

Residue 197.251 0 197.251

Sulphur 61.68 0 61.68

Total 5140 748.4 4391.6

IN = OUT
5140kg/hr = 5140kg/hr
Vapor-Liquid Flash Separator Design 42

7.8 Energy Balance

Reference: T=25oC ; P=101.3KPa
Table 7.2
Energy in Energy with vapor Energy with liquid
ΔHF * FF ΔHv * Fv ΔHL * FL
kj/hr kj/hr kj/hr

15630740 -7141981.2 -8418697.2

Q =ΔHv*Fv + ΔHL*FL - ΔHF*FF

=70061.6 kj/hr
Where
ΔH=Change in enthalpy kj/kg
F=Mass flow rates kg/hr

7.9 Standard Design Steps

1 Bubble point & Dew point temperature calculations
2 Calculation of vapor velocity
3 Calculation of crossectional area
4 Calculation of diameter
5 Calculation of vapor height
6 Calculation of volume
7 Calculation of liquid height
8 Calculation of total length
9 Check L/D rati

7.10 Flash Calculations

Table 7.3
Components P=101.3KPa P=101.3KPa
T=96.78C T=437.9C
Bubble Point Dew Point
Yi=Ki*Xi Xi=Yi/Ki
H2O 0.89 0.004
Gasoline 0.09 0.0009

Diesel 0.011 0.0027

Lube negligible 0.51
Residue negligible 0.47
Sum 0.991=1.00 0.998=1.00
Vapor-Liquid Flash Separator Design 43

Summation
Yi=Zi*Ki/ {1+V (Ki-1)} =1
After calculation at V=0.71moles
the Yi = 0.97; which is approximately equal to 1
F=L+V; L=1 - 0.71 =0.29moles
Table 7.4
Y1 0.94 X1 0.006

Y2 0.039 X2 0.021

Y3 0.022 X3 0.122

Y4 0.003 X4 0.828

Y5 0 X5 0.023

Sum 1.00 Sum 1.00

Operating Conditions:
 Operating Pressure = 101.3KPa
 Design Pressure = 111.43 K Pa
 Operating Temperature = 131.5 oC
 Design Temperature = 150 oC
 Bubble Point Temperature = 96.78 oC
 Dew Point Temperature = 437.9 oC
 Density of mixture coming in:
pmix = 5.04 kg/m3
 Density of vapor leaving top:
pv = 0.747 kg/m3
 Density of liquid going to bottom:
pL = 801 kg/m3

7.11 Design Calculations

7.11.1 Vapor Velocity
[eq 7.1]
Vv = Kv [(pL- pv)/pv] 0.5
= 0.106[(801-0.747)/0.747]0.5
= 3.45 m/sec
Where, velocity factor , Kv= 0.106 m/sec
Fig 7.8
Vapor-Liquid Flash Separator Design 44

7.11.2 Areamin:
A = Qv/Vv
= 0.278/3.45
= 0.082 m2
Where; Qv = volumetric flow rate of vapor m3/sec

7.11.3 Diameter:
D = (4A/π) 0.5
= (4*0.082/π)0.5
= 0.3232m
Therefore an increment of 0.1524m is added in to diameter.
= 0.323+0.1524
= 0.48m
7.11.4 Hold up volume
VH =TH*QL
VH =( 3*0.08137)
VH = 0.24411m3

7.11.5 Surge Volume:

(Vs) = Ts * QL
Vs = 2*0.09137
Vs = 0.18m3

7.11.6 Vapor Height hv:

hv = 1.5*D + 1.5
Vapor-Liquid Flash Separator Design 45

= 1.5*0.48 + 0.45
= 1.07 m
7.11.7 Liquid Height:
hL = (Vol * 4)/π D2
= (0.25*4)/π*0.482
= 1.3 m

7.11.8 Total length:

L = hv + hL
=1.07+1.3
= 2.37 m
7.11.9Check geometery (Hl+Hv)/D must be between 3 and 5:
(Hl+Hv)/D
= 1.3 + 1.07/.48
= 4.9
7.11.10 Length to Diameter ratio
L/D = 2.37/0.48
= 4.9
As in this case L/D ratio lies between 3 and 5, therefore it also proves that it will be a vertical
separator.

7.12 Mechanical Design

1 Shell thickness
2 Head Selection
3 Head thickness
4 Material of Construction
5 Support Selection

7.12.1 Shell thickness (TS)

Ts =Pri/SEj-0.6P +Cc
Design Pressure; Pd = 1.1*Po (here Po=Operating pressure)
=111.43 KPa
S= 79300kPa
Cc= 3mm= .003m ; Ej=Joint Efficiecy =0.85
Ts = (111.43)(0.2378m)/(79300)(0.85)-(0.6)(111.43) +0.003
Ts= 0.0033m
7.12.2 Head Selection

There are two types of Head:

1 Torispherical (for P<1134.97KPa)
Vapor-Liquid Flash Separator Design 46

2 Ellipsoidal (for P>1134.97KPa)

3 Hemispherical for very high pressures
According to my range of pressure I am using torispherical.

Fig 7.9

7.12.3 Head Thickness

Head Factor:
Xh = 1.104*Pd/(2ES-0.2Pd)
= (1.104*111.43)/(2*.085*79300-0.2*111.43)
= 0.00091)
Head Thickness:
Th= Xh*D + tc
= 0.00091*0.4756+0.003
= 0.0034m

7.12.4 Material of Construction

 Material of construction is stainless steel 316 (SA-240).

 Because it is corrosion resistant.
 It is also economical.
 It is not affected by high temperature.

7.12.5 Support
There types of supports are available:
Vapor-Liquid Flash Separator Design 47

 Saddle support
 Skirt support
 Bracket support
Saddle type support is used for horizontal vessels. Skirt type is used for very tall vessels.
Bracket type is used for all types of vessels, normally vertical and cylindrical. Therefore, I am
using Bracket support.

Saddle type

Fig 7.10

Specification Sheet
Vapor-Liquid Flash Separator Design 48

Unit Name Vertical Flash Separator

Equipment code V-100

No. Required 1

Mist Eliminator Vane Type

Feed Saturated Liquid

Pressure 101.3KPa

Temperature 131.5 oC

Diameter 0.49m

Length 2.41m

Material of construction Stainless steel 316(SA-240)

Shell thickness 0.0035m

Surge time 3 min

References
Vapor-Liquid Flash Separator Design 49

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Engineers, 5th Edition,McGraw Hill Publishing
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1995, United States of America.