Column Flooding Calculations

Column Flooding Calculations
When the Rigorous hydraulics option is used, flooding approach and downcomer
backup are computed using same methods as used in the steady state simulation.
When the Simple Tray/Packing hydraulics option is used, you can specify that the
flooding approach be computed. By default, the flooding approach is not computed.
The required input and results depend on whether tray or packed columns are used.
Trays
Input
 Flooding calculation method (Fair or Kister-Haas)

 Hole area as percentage of column cross-sectional area
 Downcomer escape area as a percentage of column cross-sectional area
 Foaming factor
Results
 Flood factor (fractional approach to flooding)

 Downcomer backup
 Ratio of downcomer backup to tray spacing
Packed Columns
Input
 Flooding calculation method (Eckert or Kister-Gill)

 Packing factor
 Foaming factor
Results
 Flood factor (Fractional approach to flooding)
Flooding in Tray Columns
Flooding in tray columns can occur via two main mechanisms
Entrainment Flooding
For a given liquid rate, increasing the gas rate beyond a certain limit leads to
excessive entrainment of liquid to the tray above. At this point, it is difficult to obtain
a net downflow of liquid and any liquid fed to the column is carried out with the
overhead gas. Furthermore, the column inventory of liquid increases, the pressure
drop in the column becomes large and control becomes difficult.
Two methods are available to compute entrainment flooding for trays:
Fair[1,2]
Kister-Haas[2]
The Kister-Haas correlation for entrainment flooding, which is valid for sieve and
valve trays, is given below:
Downflow Flooding
For a given gas rate, increasing the liquid rate beyond a certain limit will overtax the
capacity of the downcomer. This leads to an accumulation of liquid in the tray, the
pressure drop becomes large and control becomes difficult.
Downcomer backup can be computed from the pressure balance equation[1]:
More details on the calculation of each term can be found in [3]. A correction factor
can be applied to account for foaming of the liquid.
Flooding in Packed Columns
Flooding in a packed column is characterized by a sharp rise in the pressure drop, a
loss of mass transfer efficiency and heavy entrainment of liquid. Two methods are
available to compute flooding approach in packed columns:
Eckert GPDC Correlation[1,3]
The Eckert Generalized Pressure Drop Correlation chart is an empirical chart that
relates (at flooding and other conditions) the flow parameter to a quantity ( )
that describes the balance between the vapor momentum force, that acts to entrain
swarms of liquid droplets and the gravity force, that resists upward entrainment.
This method is usually recommended for random packings with packing factors
exceeding 60.
Kister and Gill Correlation[3]
The Kister-Gill correlation is given by the following equation:
The flooding predictions from the Kister-Gill correlation depend strongly on the
accuracy of the pressure-flow relationship used. It is therefore important ensure that
the pressure profiles specified in the Aspen HYSYS simulation are realistic.
References
"Gas-liquid contacting systems", Perry’s Chemical Engineers’ Handbook, 7th edition,

McGraw-Hill, 1997
"Tray design and operation", Distillation Design, Kister, H. Z., McGraw-Hill, 1992
"Packing design and operation", Distillation Design, Kister, H. Z., McGraw-Hill,

1992
Suggested values for Ballast trays are:
Service System Foaming Factor

Non-foaming systems 1.00
Fluorine systems 0.90
Moderate foamers, such as oil 0.85
absorbers, amine, and glycol
regenerators
Heavy foamers, such as amine and 0.73
glycol absorbers
Severe foamers, such as MEK units 0.60
Foam stable systems, such as caustic 0.30
regenerators
Suggested values for Flexitrays are:

Depropanizers 0.85-0.95
Absorbers 0.85
Vacuum towers 0.85
Amine regenerators 0.85
Amine contactors 0.70-0.80
High pressure deethanizers 0.75-0.80
Glycol contactors 0.70-0.75
Suggested values for Float valve trays are:

Non foaming 1.00
Low foaming 0.90
Moderate foaming 0.75
High foaming 0.60
The following values for the system foaming factor are summarized from H.Z. Kister,
Distillation Design, McGraw-Hill 1992, pp. 292-293. The values were calculated for
trays, but it is common practice to use them for packing as well:
System System Foaming Factor

Non-foaming regular systems 1.00
High pressure (rG > 1.8 lb/ft3) 1.21/rG0.32
Low Foaming Systems
Depropanizers 0.9
H2S strippers 0.85-0.9
Fluorine systems 0.9
Hot carbonate regenerators 0.9
Moderate Foaming Systems
Demethanizers and deethanizers, top 0.8-0.85
section (refrigerated type)
Demethanizers and deethanizers, top 0.85
section (absorbing type)
Demethanizers and absorbing type 1.0
deethanizers, bottom section
Refrigerated type deethanizers, 0.85-1.0
bottom section
Oil absorbers 0.85 (0.8-0.95 below 0°F)
Crude towers, crude vacuum towers 0.85-1.0
Furfural refining towers 0.8-0.85
Sulfolane systems 0.85-1.0
Amine regenerators 0.85
Glycol regenerators 0.65-0.85
Hot carbonate absorbers 0.85
Caustic wash 0.65
Heavy Foaming Systems
Amine absorbers 0.73-0.8
Glycol contactors 0.5-0.73
Sour water strippers 0.5-0.7
Oil reclaimer 0.7
MEK units 0.6
Stable Foam Systems
Caustic regenerators 0.3-0.6
Alcohol synthesis absorbers 0.35

Column Flooding Calculations

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What are the two main mechanisms of flooding in tray columns?

What are the two main mechanisms of flooding in tray columns?

What are the two methods available to compute flooding approach in packed columns?

What are the two methods available to compute flooding approach in packed columns?

Column Flooding Calculations

 Flooding calculation method (Fair or Kister-Haas)

 Flood factor (fractional approach to flooding)

 Flooding calculation method (Eckert or Kister-Gill)

 Flood factor (Fractional approach to flooding)

Flooding in Tray Columns

Flooding in tray columns can occur via two main mechanisms

Downcomer backup can be computed from the pressure balance equation[1]:

Eckert GPDC Correlation[1,3]

Kister and Gill Correlation[3]

The Kister-Gill correlation is given by the following equation:

"Gas-liquid contacting systems", Perry’s Chemical Engineers’ Handbook, 7th edition,

"Packing design and operation", Distillation Design, Kister, H. Z., McGraw-Hill,

Service System Foaming Factor

Suggested values for Flexitrays are:

Service System Foaming Factor

Suggested values for Float valve trays are:

Service System Foaming Factor

System System Foaming Factor

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