Coloumn and Vessel

Process Design & Engg Cell
Process Design basics of

Column
and
Pressure Vessel
N Shaikh
Manager
Process Design Engineering Cell
IOCL-RHQ
1
Process Design Basics

of
Column
Process Design Basics of Column 2

The First Distillation Still Process Design & Engg Cell
???
The First Distillation Still used in Digboi

Process Design Basics of Column
Distillation History Process Design & Engg Cell
Early distillation
consisted of simple batch
stills to produce ethanol.
Crude ethanol was placed
in a still and heated, and
the vapor drawn from the
still was condensed for
consumption.
Lamp oil was later

produced using the same
method, with crude oil
heated in batch stills.

Furnace Condenser
Batch Still Distillation Process
The next progression in the history of distillation was to

continually feed the still and recover the light product

Still Distillation in Series

Further advancements include placing the stills in series and
interchanging the vapor and liquid from each still to improve recovery.
This was the first type of counter-current distillation column that we have
today

Distillation – Fractionation Process Design & Engg Cell
Fractional distillation is the separation of

a mixture into its component parts, or
fractions, such as in separating chemical
compounds by their boiling point by
heating them to a temperature at which
several fractions of the compound will
vaporize.
Fractional distillation in a laboratory makes

use of common laboratory glassware and
apparatuses, typically including a Bunsen
burner, a round-bottomed flask and a
condenser, as well as the single-purpose
fractionating column.
Distillation vs Other Processes Process Design & Engg Cell
Distillation is by far the most important

separation process in the petroleum and
chemical industries. It is the separation of key
components in a mixture by the difference in
their relative volatility, or boiling points. It is
also known as fractional distillation or
fractionation.
Distillation can consume more than 50% of a

plant’s operating energy cost.
Alternatives to distillation process :
Solvent extraction, membrane separation or
adsorption process. These processes often have
higher investment costs. Therefore, distillation
remains the main choice in the industry,
especially in large-scale applications.
Distillation Processes- Types Process Design & Engg Cell
Fractional Distillation
Extractive Distillation
Reactive Distillation
Variations appear due to difficulty in

separation when the physical properties of
the components in a mixture are very
close to one another, such as an azeotropic
mixture.

Fractional
Distillation:
It is the separation of key

components in a mixture
by the difference in their
relative volatility, or
boiling points.

An external solvent is added
to the system to increase the
separation.
The external solvent changes

the relative volatility between
two ‘close’ components by
extracting one of the
components, forming a ternary
mixture with different
properties.
The solvent is recycled into

the system after the extracted
component is separated from it.
An external solvent is added
to the system to increase the
separation.
The external solvent changes

the relative volatility between
two ‘close’ components by
extracting one of the
components, forming a ternary
mixture with different
properties.
The solvent is recycled into

the system after the extracted
component is separated from it.

A distillation column may

also have a catalyst bed and
reaction occurring in it. This
type of column is called a
reactive distillation column.
The targeted component
reacts when it is in contact
with the catalyst, thereby
separated from the rest of
the components in the
mixture.

A distillation column may

also have a catalyst bed and
reaction occurring in it. This
type of column is called a
reactive distillation column.
The targeted component
reacts when it is in contact
with the catalyst, thereby
separated from the rest of
the components in the
mixture.

Industrial distillation Process Design & Engg Cell
Industrial distillation Process Design & Engg Cell
Distillation is the most common form of

separation technology used in petroleum
refineries, petrochemical and chemical
plants, natural gas processing and
cryogenic air separation plants.
Industrial distillation is typically

performed in large, vertical Cylindrical
columns known as "distillation or
fractionation towers" or "distillation
columns" with diameters ranging from
about 65 centimeters to 6 meters and
heights ranging from about 6 meters to
60 meters or more.

Distillation Column/Fractionator Process Design & Engg Cell

Distillation Column Internals Process Design & Engg Cell
Critera of Distillation Column internals :

To provide better mass and heat transfers
between the liquid and vapor phases in the
column.
Include trays, packings, distributors and

redistributors, baffles and etc.
Promote an intimate contact between both

Liq and Vap phases.
The type of internals selected would

determine the height and diameter of a
column for a specified duty because different
designs have various capacities and
efficiencies.

Column internals:
Two main types
Trays
Sieve
Bubble Cap
Valve Trays
Packing
Random : Rings, saddles

Structure

Feed :
Liquid
Vapor
Mixture of vapor-liquid
The vapor phase that travels up the column

is in contact with the liquid phase that travels
down.

Vap- Liq pathways inside the

column :
The vapor phase that travels up the

column is in contact with the liquid
phase that travels down.

Column distillation is divided two

stages :
Rectifying stages
Striping stages

Rectifying Stages
The process above the feed tray is known

as rectification.
Vapor phase is continually enriched in

the light components which will finally
make up the overhead product.
A liquid recycle condenses the less

volatile components from rising vapor.
To generate the liquid recycle, cooling is

applied to condense a portion of the
overhead vapor and termed as reflux.

Stripping Stages
The process below the feed tray is

known as stripping
Heavier components are being

stripped off and concentrated in the
liquid phase to form the bottom
product.
At the top of the column, vapor enters

the condenser where heat is removed.
Some liquid is returned to the column

as reflux to limit the loss of heavy
components overhead.

Distillation Column Overhead Process Design & Engg Cell
Condenser
Total Condenser
All vapors leaving the top of the column is
condensed to liquid so that the reflux
stream and overhead product have the same
composition.
Partial Condenser
In a partial condenser , only a portion of the
vapor entering the condenser is condensed to
liquid. Condensed liquid is refluxed into the
column and the overhead product drawn is in
the vapor form.
In many cases only part of the condensed liquid is
refluxed. In these cases, there will be two overhead
products, one a liquid with the same composition
as the reflux stream while the other is a vapor
product that is in equilibrium with the liquid
reflux.
Distillation Column Overhead Process Design & Engg Cell
Total Condenser Condenser

Total Condenser
All vapors leaving the top of the column is
condensed to liquid so that the reflux
stream and overhead product have the same
composition.
Partial Condenser
In a partial condenser , only a portion of the
vapor entering the condenser is condensed to
Partial Condenser liquid. Condensed liquid is refluxed into the
column and the overhead product drawn is in
the vapor form.
In many cases only part of the condensed liquid is
refluxed. In these cases, there will be two overhead
products, one a liquid with the same composition
as the reflux stream while the other is a vapor
product that is in equilibrium with the liquid
reflux.
Distillation Column
Tray Column Packed

Column
Bubble Sieve Dual Structur

Valve Random Grid
Cap Deck Flow Baffle Tray ed
Tray Packed Packed
Tray Tray Tray Packed
Column Column
Column
Shed Side to Disk and

Decks Side Donuts
Tray Tray Tray

Tray Column
Utilize a pressure and temperature differential

to separate the products.
For most tray columns, the weir holds a liquid

level of each tray. Liquid enters from the down-
comer of the tray above.
The vapor must overcome this liquid head to

move up the column.
On the tray the vapor and liquid are contacted

becomes bubble or froth where the mass transfer
takes place and then above the tray they are
separated where froth flows over the outlet weir
and vapor with the light volatile compound is
disengaged.
Tray Column-advantages
Tray column performs well in high liquid and

vapor loading.
Tray have higher pressure drop than packed.
 Tray also have high resistance to corrosion.
Tray Column-Types
Five major types of tray column :
•Bubble Cap
•Sieve
•Dual Flow
•Valve
•Baffle
Shed Deck, Side to Side, Disk and donuts
Distillation Column Tray Process Design & Engg Cell
Bubble Cap Tray
A bubble cap tray is

perforated flat which has a
riser (chimney) for each hole
cover with a cap mounted.
Equipped with slots to allow
the passage of vapor then the
vapor will contact with liquid
forming bubble on the next
tray.
It is able to operate at low
vapor and liquid rates (less
than 2 gpm per foot of average
of flow width).

Bubble Cap Tray

tray.
of flow width).

Bubble Cap Tray

tray.
of flow width).

Sieve Deck Tray

Sieve deck tray is perforated plate with
holes punched into the plate usually has
holes 3/16” to 1” diameter.
Vapor comes out from the holes to give a
multi orifice effect.
The vapor velocity keeps the liquid from
flowing down through the holes (weeping).
The number and hole size are based on
vapor flow up the tower.
The liquid flow is transported down the
tower by down-comers, a dam and overflow
device on the side on the plate.
Sieve deck tray has a minimum capacity
approximately 70%

Sieve Deck Tray

Sieve deck tray is perforated plate with
holes punched into the plate usually has
holes 3/16” to 1” diameter.
Vapor comes out from the holes to give a
multi orifice effect.
The vapor velocity keeps the liquid from
flowing down through the holes (weeping).
The number and hole size are based on
vapor flow up the tower.
The liquid flow is transported down the
tower by down-comers, a dam and overflow
device on the side on the plate.
Sieve deck tray has a minimum capacity
approximately 70%

Dual flow tray

Dual flow is a sieve tray without down comer.
The term dual flow comes from the
countercurrent flow of the vapor and liquid
through the perforations.
Vapor move up to the tray above through the
hole while the liquid turn down in the same
hole that result maldistribution and low
efficiency.
Typical perforation sizes range between 1/2”
and 1” in diameter.
Dual flow trays best suit systems containing a
moderate to high solids content or
polymerizable compounds.
High open area dual flow trays have a higher
capacity and lower pressure drop than
comparably spaced fractionation trays.
Valve Tray
Valve Tray is using valve which is rise as
vapor rate increase and then reduce as
vapor rate fails.
This stop the liquid from weeping.
 Valve can be round or rectangular, with

or without caging structured.
Valve disk rise as vapor rate increase.
Valve tray has minimum capacity

approximately 60%.

Valve Tray
Valve Tray is using valve which is rise
as vapor rate increase and then reduce
as vapor rate fails.
This stop the liquid from weeping.
 Valve can be round or rectangular,

with or without caging structured.
Valve disk rise as vapor rate increase.
Valve tray has minimum capacity

approximately 60%.

Baffle Tray
Baffle trays are trays of low fouling pot
ential, with low efficiency.
They have open areas approaching 50%
where a high efficiency tray will have an
open area of less than 15%.
The down-comers require a disengaging
area to separate the liquid from the vapor.
This area requires a minimum distance
that normally sets the tray spacing.
The liquid is required to travel across the
deck to the next down-comer.
Baffle tray has three types:

Shed Decks Trays
Side to Side Trays
Disk and Donuts Trays
Baffle Tray
Because of their open design, baffle trays are
used in applications requiring high capacity,
fouling resistance and low pressure drop.
Vapor-liquid contacting takes place when the
vapor passes through a curtain of liquid falling
between trays, or through rivulets of liquid
flowing through tray deck perforations.
Tray decks may be level or slightly inclined
and typically occupy 40-60% of the tower
cross-sectional area. “.
Baffle trays are well suited for heat
transfer applications including heavy oil
refining and petrochemical oil refining and
petrochemical heat transfer services with
high solids or petroleum coke content.

Baffle Tray
Side to side baffle trays
Side-to-side trays are trays that

allow the liquid to splash from
side to side.
The decks can be sloped.
Fouling potential of this tray is

low, as with efficiency.

Baffle Tray
Disk and donut trays
Disk and donut trays are slightly

sloped trays that allow the liquid to
splash from inner circle ring to outer
circle ring.
Fouling potential of this tray is low

along with the efficiency.

Baffle Tray

Schematic circle ring.
of a disk
and donut
baffle tray Fouling potential of this tray is low
column for
use as a
steam
condenser

Baffle Tray

circle ring.
Fouling potential of this tray is low


Baffle Tray
Shed Decks trays
Shed decks are essentially angle iron beams of

various sizes from two to ten inches that are
placed in rows across the column.
They typically are at on 24 inch tray spacing.
They may be set in overlapping rows or

rotated 90 degrees from tray to tray.

Distillation Column with packing Process Design & Engg Cell
Packed Column
Packed column utilize packing to contact between
the phases (liquid-vapor) on the surface.
A major advantage to packed columns
is the reduction in pressure across the column.
Typically the column pressure drop for a
packed column is less than that of a trayed col
umn because of the percent open area.
Typical percent open area of a trayed column
is 8 to 15%, whereas a packed column can
approach 50%.
Packed column is advantageous than tray for
reduced foaming since generates thin films instead
of fine droplets for mass and heat transfer.
Packed column is divided by
Random, Structured and Grid Packed
Schematic diagram of a typical packed
Columns
bed absorption column
Packed Column—
random packing
Random packing is packing of

specific geometrical shapes which
are dumped into the tower and
orient themselves randomly.
Random packing has more risk

than structured packing and less
ability to handle maldistributed
liquid.

Packed Column-structured
packing
Structure Packed column is crimped

layers or corrugated sheets which is
stacked in the column.
Each layer is oriented at 70° to 90° to

the layer below.
Structured packed offers 30%

capacities higher than random packed for
equal efficiency up to 50% higher at the
same capacity.

Packed Column-Grid
packing
Grid packed column is

systematically arranged packing
use an open-lattice structure.
This device is composed of

panels that promote mass transfer
and enhance entrainment removal.
They have high open area,

resulting in high capacity, low
pressure drop, and high tolerance
to fouling.

Distillation Column Design Process Design & Engg Cell
General Considerations
A tower design is normally divided into two main steps a process

design followed by a mechanical design.
 The purpose of the process design is to calculate the number of

required theoretical stages, column diameter and tower height.
On the other hand, the mechanical design focuses on the tower
internals and heat exchanger arrangements.

Steps :
Determine the separation sequences, which depends on the relative volatility
and concentration of each component in the feed
 Performing a material balance for the column
Determining the tower operating pressure (and/or temperature)
Calculating the minimum number of theoretical stages using the Fenske

equation
Calculating the minimum reflux rate using the Underwood equations
Determining the operating reflux rate and number of theoretical stages
Selection of column internals (tray or packings)
Calculating the tower diameter and height

The Selection of Column Internals :

The selection of column internals has a big impact on the column
performance and the maintenance cost of a distillation tower.
There are several choices of column internals and the two major categories
are trays and packing. The choice of which to utilize depends on the
Pressure
Fouling potential
Liquid to vapor density ratio
Liquid Loading
Life Cycle Cost

Criteria for Tray Column

Criteria for Packed Column

Important Thumb rule :

Tower operating pressure is determined most often by the temperature of the
available cooling medium in the condenser or by the maximum allowable reboiler
temperature.
Economically optimum reflux ratio is about 120% to 150% of the minimum reflux
ratio.
The economically optimum number of stages is about 200% of the minimum value.
A safety factor of at least 25% about the reflux should be utilized for the reflux
pumps.
Reflux drums are almost always horizontally mounted and designed for a
5 min holdup at half of the drum's capacity.


Limit tower heights to 175 ft (53 m) due to wind load and foundation
considerations.
The Length/Diameter ratio of a tower should be no more than 30 and preferably

below 20.
A rough estimate of reboiler duty as a function of tower diameter is given by:
Q = 0.5 D2 for pressure distillation

Q = 0.3 D2 for atmospheric distillation
Q = 0.15 D2 for vacuum distillation
Where,
Q : Energy in Million Btu/hr
D : Tower diameter in feet.


Overall column height depends on tray spacing. Tray spacing should from 18“ to 24“
(ease of maintenance to be kept in mind).
For tower dia > 4 ft, Tray spacing ~ 24 “ and for tower dia < 4 ft, Tray spacing is
~18”.
Peak tray efficiencies usually occur at linear vapor velocities of 2 ft/s (0.6
m/s) at moderate pressures, or 6 ft/s (1.8 m/s) under vacuum conditions.
A typical pressure drop per tray is 0.1 psi (0.007 bar).
Tray efficiencies for aqueous solutions are usually in the range of 60-
90% while gas absorption and stripping typically have efficiencies closer to 10-20%

Process Design Basics

of
Pressure Vessel
58
Process Vessel --- why required??? Process Design & Engg Cell
Process Vessel are necessary for providing:
Hold up time of fluid
Phase-Separation
-separation between various phases of mixed process stream
a. Liquid-Liquid
b. Vapor-Liquid
c. Vapor-Liquid-Liquid
Process Design Basics of Pressure Vessel 59

Process Vessel --- types ??? Process Design & Engg Cell
Process Vessel can be classfied as :

Vertical
a.Knockout drums (except flare knockout drums)
b.Flash drums
c.Blowdown drums
d.Driers
Horizontal
a. Distillate drums – reflux vessels
b. Surge vessels
c. Steam drums
d.Settling drums
e.Flare knockout drums

Vertical vs. Horizontal Vessels Process Design & Engg Cell
Advantages of a vertical vessel are:

 A smaller plot area is required (critical on offshore platforms)
 Large Vapor throughput with small liquid hold up
 Generally the vessel volume is smaller
Advantages of a horizontal vessel are:

 It is easier to accommodate large liquid flow
 Less head room is required
 The downward liquid velocity is lower, resulting in improved de-gassing
and foam breakdown
 Additional to vapor / liquid separation also a liquid / liquid separation can
be achieved (e.g. by installing a boot).

Vertical vs. Horizontal Vessels--services Process Design & Engg Cell
The preferred orientation for a number of typical vapor / liquid separators
Application Preferred Orientation

Reactor Effluent Separator Vertical
(V/L)
Reactor Effluent Separator Horizontal
(V/L/L)
Reflux Accumulator Horizontal
Compressor KO Drum Vertical
Fuel Gas KO Drum Vertical
Flare KO Drum Horizontal
Condensate Flash Drum Vertical
62
Drum sizing- Vapor/Liquid Separation

Drum sizing- Vapor/Liquid Separation Process Design & Engg Cell
41.5 ft
17+3 THK CLAD

(MIN.)
2:1 ELLIPSOIDAL HEAD
N2
15+3 THK CLAD (MIN.)
M1
N1
AFTER FORMING (TYP.)
M11
M10
M17
M16
M18
M5
MIN
MIN
WEAR
PLATE
RADIUS ELBOW
900 SHORT
N12A
150 MM MINIMUM (HHLL TO

HHLL 10 FT NAME
BOTTOM OF PIPE)
PLATE
HLL 9 FT
12.5 ft
M2
N14A
NLL 6 FT
VORTEX BREKER
LLL 3 FT N12B
LLLL 10 Inch
N14B
`
N15A
N8
6 Inch (min)
N13A
HIL 2 FT
1:120 4 ft.
12
10+3 THK CLAD 4.16 ft
(MIN)
5 ft
NIL 1 FT
SADDLE 2 NOS.
200
N6
LIL 1 FT
N13B
2 NOS. EARTHING LUGS 2 ft. MIN
N3
N9
165
12
STIFFENER RING-1 NO
AT CENTER
MIN
2:1 ELLIPSOIDAL HEAD MIN

N4
VORTEX BREKER
N7


Major steps for Vapor/Liquid vessel sizing

Step 0: Assume L/D ratio and % vapour area
Assume L/D ratio
Assume % Vapour area from the standard

Major steps for Vapor/Liquid vessel sizing

Step 1: Calculate Minimum allowable vapor area
 For both Horizontal & vertical vessels
Area =flow volume per second/ allowable velocity per second
 The allowable vapor velocity (VA) is obtained by applying a factor

to the critical velocity (Vc - maxm allowable design velocity).
VA = Factor x Vc
L
VC = 0.15   1
G

ALLOWABLE VELOCITY FACTORS
Drum Type Factor
Vertical knockout drum without internals 1.0
Vertical knockout drum with baffles

1.5
Vertical knockout drums with horizontal crinkled

wire mesh pad. (Pad at least 4 inches (10
centimeters) thick) 2.0
Horizontal drums (With or without crinkled wire

mesh pad) 1.7

Step 2: Calculate Liquid Space

a. Liquid Surge Volume (LLL-HLL) -- guidelines for liquid surge time
Service Surge Time, Minutes

Feed to Tower or Furnace
Drum Diameter, feet
Below 4 20
4 to 6, inclusive 15
Above 6 10
Reflux to Tower 5
Product to Storage 2
Flow to Heat Exchanger 2
Flow to Sewer or Drain 1
In case surge must be provided for both product and reflux, the larger volume is used, not the sum of the two volumes.
When the discharge rate is unimportant, a nominal surge (or holdup) time of approximately two (2) minutes is provided.


b. Surge Volume (BTM-LLL) – Locating LLL
Without Water Settling
For guidance, the following minimum levels may be used:

Horizontal drums 6 inches (15 centimeters) above bottom
Vertical drums 6 inches above lower tangent line
With Water Settling

Provide five (5) minutes holdup at the total hydrocarbon rate below the
low liquid level for the “settling out“ of water.
In case no pot is employed, holdup for the water itself must also be provided in
the bottom of the drum.


b. Surge Volume (BTM-HLL) – Locating HLL
Following minimum distance are maintained above HLL

Horizontal Drums
Minimum 20% of the drum diameter or 12 inches (30 centimeters) or clearance for feed
inlet device, whichever is greater, to top of drum.
Vertical Drums
1'-0" to the bottom of the inlet arrangement (bottom of nozzle, elbow, or

impingement baffle) when vapor is present. If no vapor is present, 15% of the drum
diameter or 12 inches (30 centimeters) or clearance for feed inlet device, whichever is
greater, to the upper tangent line


c. Total Liquid Volume
Volume (LLL-HLL ) + Volume (BTM-LLL)
Step 3: Drum Dia and Length calculation
 π d2  x % of Total Drum Volume Occupied by Liquid

 x L
 4 
 
= Total Volume of Liquid
“D” and “L” is calculated from above assuming L/D ratio

Vessels - Important guidelines Process Design & Engg Cell
Length to Diameter (L/D) ratio:
Design Pressure, in Psig Length to Diameter Ratio (L/D)
50 and less 2:1 to 3:1
greater than 50 4:1 to 5:1
Note: 3.5 kg/cm2 gauge is equivalent to 50 psig

Check A: Vapor Space Check
a. Check that height of Vapor area >=0.20 x Drum Dia
% of Total vapor area= (Minimum vapor area (step-1)/ Total area )x100
Height of vapor area can be calculated from the standard chart
b. Vapor space check w.r.t.feed inlet device
Take the larger height of the check “a” and “b”


Required Distance for 900 Elbows

Nominal Vertical Drums Horizontal Drums
Elbow
Diameter, High Liquid Level to Nozzles High Liquid Level to Top of Drums, Inches
Inches Centerline, Inches
Short Long Radius Short Radius Elbow Long Radius Elbow
Radius Elbow Elbow
Minimum Recommended Minimum Recommended
1 13 14 4 10 5 10
1½ 14 15 5 11 6 11
2 14 15 6 11 7 12
3 15 17 7 13 8 14
4 16 18 9 14 11 16
6 18 21 12 17 15 20
8 24 28 15 20 19 24
10 30 35 18 23 23 28
12 36 42 21 26 27 32
14 42 49 23 29 30 36
16 48 56 26 32 34 40
18 54 63 29 35 38 44
20 60 70 32 38 42 48
24 72 84 38 44 50 56
Step 4: Height (BTM-LLL) calculation

Area (BTM-LLL) =Volume (BTM-LLL ) / Length
% Area (BTM-LLL) = Area (BTM-LLL) / Total Area
Height (BTM-LLL) can be calculated using the chart
Step 5: Height (BTM-HLL) calculation

Volume (BTM-HLL)= Volume (BTM-LLL ) +Volume (LLL-HLL)
Area (BTM-HLL) =Volume (BTM-HLL ) / Length
% Area ( BTM-HLL) = Area (BTM-HLL) / Total Area
Height (BTM-HLL) can be calculated using the chart

Step 6: Locating Normal Liquid Level
NLL = (LLL+HLL)/2

Drum sizing- Vapor/Liq/Liq Separation Process Design & Engg Cell
Water Settling (Draw off Pots) --- Boot Calculation
MAXIMUM POT DIAMETER
Drum Diameter Max. Pot Diameter
Below 60 inches (150 centimeters) 1/2 drum diameter
60 inches and larger 1/3 drum diameter
Increase the water velocity as required up to 10 inches per minute (25 centimeters per
minute) to avoid exceeding these values.


MINIMUM POT DIAMETER
Drum Diameter Pot Diameter
Feet Centimeters Inches Centimeters
Below 5 Below 150 12 30
5 to 8 150 to 240 18 45
inclusive inclusive
Above 8 Above 240 24 60
If extremely low water velocities, less than 0.10 inches per minute (0.25 centimeters per
minute) are obtained with the above diameters, do not provide a pot. Instead, extend
the hydrocarbon outlet above the bottom of the drum to provide disengaging.

Step1 : Consider boot diameter as per the guideline
Step2 : Consider boot liquid hold-up time of ~ 10 mins between LIL & HIL
Step3: Calculate Length of boot
Step 4: Check Min. length of 3 ft betn. HIL & LIL for controller connection
Step5 : Keep minimum distance of 1 ft betn. LIL & BTL of Boot

41.5 ft
17+3 THK CLAD

(MIN.)
2:1 ELLIPSOIDAL HEAD
N2
M1
N1
M11
M10
M17
M16
M18
M5
MIN
MIN
WEAR
PLATE
RADIUS ELBOW
900 SHORT
N12A
150 MM MINIMUM (HHLL TO

HHLL 10 FT NAME
BOTTOM OF PIPE)
PLATE
HLL 9 FT
12.5 ft
M2
N14A
NLL 6 FT
VORTEX BREKER
LLL 3 FT N12B
LLLL 10 Inch
N14B
`
N15A
N8
6 Inch (min)
N13A
HIL 2 FT
1:120 4 ft.
12
10+3 THK CLAD 4.16 ft
(MIN)
5 ft
NIL 1 FT
SADDLE 2 NOS.
200
N6
LIL 1 FT
N13B
2 NOS. EARTHING LUGS 2 ft. MIN
N3
N9
165
12
STIFFENER RING-1 NO
AT CENTER
MIN
2:1 ELLIPSOIDAL HEAD MIN

N4
VORTEX BREKER
N7


Slop for Horizontal vessel:
1 inch in 10 feet down towards the outlet or low point drain so

that the vessel may be completely drained during shutdown.
This slope is equivalent to a slope of 1:120.

Location of Feed Inlet Nozzle

Feed Inlet
Inlet Nozzle
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.
Inlet device
Impacts vapor / liquid separation that can be achieved
Some Typical Inlet Device are as follows:
A Deflector Baffle
Slotted Tee
Half Open Pipe
86
Table 3
Feed Inlet device

Table 3
Feed Inlet device

Vessels - Internals Process Design & Engg Cell
Vortex Breaker

Vessel Internals-Wire Mesh
Vapor (Liquid Free)
Wire Mesh
Liquid
Feed Inlet Vapor (Entrained Liquid)
Vapor + Liquid
90
91
92
They are used for two reasons:

To minimize entrainment
 Suction drums for reciprocating compressors are the most notable examples
To reduce the size of a vessel
The allowable vapor velocity in a drum can be increased significantly by using a

wire mesh demister.
So, when sizing is governed by vapor-liquid separation criteria, this will result in a
smaller diameter of the vessel
Major disadvantage of wire mesh demisters is:
They are not suitable for fouling services
93
Inlet / Outlet Nozzle sizing guideline

Inlet / Outlet Nozzle sizing guideline

Vapor Nozzles sizing guideline


TYPICAL LIMITS FOR VAPOR-LIQUID SEPARATOR

PARAMETER LOWER LIMIT UPPER LIMIT
Vessel Diameter, ft (m) 0.7 (0.2) 25 (7.6)
Vapor Density, lb/ft3 (kg/m3) 0.005 (0.08) 5 (80)
Liquid Density, lb/ft3 (kg/m3) 20 (320) 80 (1280)
Surface Tension, dynes/cm or mN/m 2 75
Liquid Viscosity, cP or mPa•s 0.05 2
CWMS Liquid Loading, gpm/ft2

0.0 (0.0) 20 (13.6)
(dm3/s•m2)
Foaming Tendency NONE, except for Crude Flash Vessels

Drum sizing- Liquid/Liquid Separation

Drum sizing- Liquid/Liquid Separation Process Design & Engg Cell

Major steps for Liquid/Liquid vessel sizing
Step1. Liquid /Liquid Separators are generally horizontal
L/D ratio ~ 4:1 or 5:1
Step2. Calculate Rising Rate (V) of Light Liquid through Heavy Liquid
---Calculation require droplet diameter

DROPLET SIZES
Droplet Diameter
System Inches Centimeters
Caustic - 0.85 specific gravity oils 0.005 each phase 0.012 each phase
Water - Naphtha or heating oils 0.005 each phase 0.012 each phase
Propane - oil deresining 0.004 each phase 0.010 each phase

Step3. Calculate Rising Rate (V) of Light Liquid through Heavy Liquid
a. Calculate Rising Velocity
Stokes’ law (Reynolds number less than 1)

V = 8.3 x 105 x d2 x Δ S / uc
Intermediate law (Reynolds number between 1 and 1,000)

V = 1.04 x 104 x d1.14 x Δ S0.71 / ( Sc0.29 x uc0.43 )
Newton’s law (Reynolds number between 1,000 and 200,000)

V = 2.05 x 103 (d Δ S)0.5 / ( Sc )
Where the Reynolds number = 10.7 d V Sc / uc

V = settling rate in each phase, inches per minute

d = droplet diameter, inches
S = droplet specific gravity
Sc = continuous phase specific gravity
Δ S = specific gravity differential between phases
uc = continuous phase viscosity, centipoise
b. Select Rising velocity based on Re value from point “a”. But if rising
velocity exceeds 10"/min then take 10”/min.

Step4. Calculate Settling Rate (V) of Heavy Liquid through Light Liquid
a. Calculate Settling Velocity
Stokes’ law (Reynolds number less than 1)

V = 8.3 x 105 x d2 x Δ S / uc
Intermediate law (Reynolds number between 1 and 1,000)

V = 1.04 x 104 x d1.14 x Δ S0.71 / ( Sc0.29 x uc0.43 )
Newton’s law (Reynolds number between 1,000 and 200,000)

V = 2.05 x 103 (d Δ S)0.5 / ( Sc )

V = settling rate in each phase, inches per minute

d = droplet diameter, inches
S = droplet specific gravity
Sc = continuous phase specific gravity
Δ S = specific gravity differential between phases
uc = continuous phase viscosity, centipoise
b. Select Settling velocity based on Re value from point “a”. But if settling
velocity exceeds 10"/min then take 10”/min.

Step5. Calculate Vessel Diameter
D= 2 +1.7 (flow rate / V) ½
“flow rate“ = that of light phase, cubic feet per minute
V= settling rate of heavy droplet,inches/min
D = drum diameter, feet
Step6. Calculate “L” Keeping L/D ratio 4:1 to 5:1

Step6. Calculate Low & High Interface levels
a. Bottom Tangent Line (BTL) to Low Interface Level (LIL)

-----Recommended 12 inches minimum
(i) Calculate Height (BTL-LIL)/Radius of Drum

(ii) Calculate % Area occupied by BTL-LIL from chart---y
b. Bottom Tangent Line (BTL) to High Interface Level (HIL)
Low Interface level (LIL) to High interface level (HIL)

-----Recommended 14 inches minimum
(i) Calculate Height (BTL-HIL)/Radius of Drum
(ii) Calculate % Area occupied by BTL-HIL from chart-----x


Step7. Residence time of Heavy Liquid settling through Light Liquid
a. Area between high and low interfaces

=(x-y)*0.01*cross sectional area of vessel
b. Residence time of Heavy Liquid between high and low interface level
=area in”a”*L/Heavy Liquid volume flow
CHECK: Residence time should be more than 2 min

Step8. Light phase space settling time
a. Distance Heavy Liquid must fall from top of drum to High Interface level
=Vessel dia - Height(BTL-HIL)
d. Heavy Liquid settling time (between top of drum and high interface level)
required for separation
= Distance “a”/ Heavy Liq settling velocity

Step9. Light phase space residence time
a. Light Space Area

=(100 - % area occupied below HIL)*Vessel cross sectional area*0.01
b. Light Space volume

= Light space area*L
c. Light phase Space residence time= Light space volume/Light Liq flow rate
CHECK : Light phase space residence time

> Heavy Liquid settling time through Light phase

Step10. Heavy phase space rising time
a. Distance Light Liquid must travel from bottom of drum to low Interface
level =Height (BTL-LIL)
d. Light Liquid rising time (between bottom of drum and low interface level)
required for separation = Height (BTL-LIL) /Light Liq rising velocity

Step11. Heavy phase space residence time
a. Heavy Space Area

=( % area occupied below LIL)*Vessel cross sectional area*0.01
b. Heavy Space volume

= Heavy space area*L
c. Heavy phase Space residence time

= Heavy space volume/Heavy Liq flow rate
CHECK : Heavy phase space residence time

> Light Liquid rising time through Heavy phase


Drum sizing- Vertical Flash Drum

Drum sizing- Vertical Flash Drum Process Design & Engg Cell

Vapor (Liquid Free)
Wire Mesh
Liquid
Feed Inlet Vapor (Entrained Liquid)
Vapor + Liquid
117
They are used for two reasons:

To minimize entrainment
 Suction drums for reciprocating compressors are the most notable examples
To reduce the size of a vessel
The allowable vapor velocity in a drum can be increased significantly by using a

wire mesh demister.
So, when sizing is governed by vapor-liquid separation criteria, this will result in a
smaller diameter of the vessel
Major disadvantage of wire mesh demisters is:
They are not suitable for fouling services
118
Major steps for Vertical Flash Drum Sizing
Step1. Vessel with CWMS or without CWMS
a. The use of a crinkled wire mesh pad or screen would not permit a large
reduction in vessel size for vessels lower than 4 ft in diameter, and since a
crinkled wire mesh pad or screen is fairly expensive, it is not used much in
diameters less than 4 ft. When used, it would be to prevent large slugs of
liquid from going to the compressor.
Step 2: Calculate with Crinkled Wire Mesh Screen
a. Calculate critical vap velocity

b. Calculate allowable vap velocity ( with CWMS, allowable factor – 2.0)
c. Calculate min vap area (Vap Flow rate/allowable vap velocity)
d. Calculate minimum diameter

Step3. Calculate without Crinkled Wire Mesh Screen

b.Calculate allowable vap velocity ( without CWMS, allowable factor – 1.0)
d.Calculate minimum diameter
Step4. Liquid surge volume and height calculation
a.Consider liquid hold–up time (between LLL-HLL) as per standard

b.Calculate LLL-HLL height

Step5. Drum height
a. Height of CWMS (if there)

b. Height of inlet +elbow - min recommended 2.5 ft
c. Height (Vessel top tangent line to top of inlet nozzle)
- min recommended 2.5 ft
d. Height HLL to bottom of Inlet nozzle – min recommended 1 ft
e. Height (LLL to Bottom Tangent line)– min recommended 0.5 ft
f. Height (HLL-LLL)
f. Total Drum Height Calculated
g. Check L/D - as per previous table. If L/D is not OK, calculate with new Dia

Drum sizing- Vertical KOD

Drum sizing- Vertical KOD Process Design & Engg Cell
Major steps for Vertical KOD Sizing
Step1. Vessel with CWMS or without CWMS
a. The use of a crinkled wire mesh pad or screen would not permit a large
reduction in vessel size for vessels lower than 4 ft in diameter, and since a
crinkled wire mesh pad or screen is fairly expensive, it is not used much in
diameters less than 4 ft. When used, it would be to prevent large slugs of
liquid from going to the compressor.
Step 2: Calculate with Crinkled Wire Mesh Screen

b. Calculate allowable vap velocity ( with CWMS, allowable factor – 2.0)

Step3. Calculate without Crinkled Wire Mesh Screen

b. Calculate allowable vap velocity ( without CWMS, allowable factor – 1.0)
Step4. Liquid surge volume and height calculation
a.Consider liquid hold–up time (between LLL-HLL)

– min recommended 24 hrs
b.Calculate LLL-HLL height
– min recommended 1.5 ft

Step5. Drum height
a. Height of CWMS (if there)

b. Height of inlet +elbow - min recommended 2.5 ft
c. Height (Vessel top tangent line to top of inlet nozzle)
- min recommended 2.5 ft
d. Height HLL to bottom of Inlet nozzle – min recommended 1 ft
e. Height (LLL to Bottom Tangent line)– min recommended 0.5 ft

f. Height (HLL-LLL) – min recommended for KOD is 1.5 ft
g. Total Drum Height Calculated
h. Check L/D - typical L/D for KOD is 2:1

Drum sizing- Flare KOD

Drum sizing- Flare KOD Process Design & Engg Cell
Typical Flare KOD


Major steps for Flare KOD Sizing
Step1. Drum sizing based on maximum single risk vapor load condition
a. Sp. Garvity of HC liq from chart at 3200F and 19 psia

b. Dropout Velocity(VD) -- Critical velocity
c. Allowable Velocity (VA) – Generally 1.0 for conservative case
d. Assume vapor space Height (HLL-top of drum)
e. Liquid space Height (BTL-HLL)- Generally zero(0)
f. Residence time – Vapor Space height / Allowable velocity
g. Find vapor volume = maxm vap Flow rate/residence time
= drum volume
a. Drum Dia = maxm vap space height
b. Find drum length
c. Check L/D ratio– within 3:1 to 5:1


Step2. Check Drum sizing based on maximum liquid relief condition
a. Maximum liquid relief load after flash at operating condn

– generally 3200F and 19 psia
b. Liq flow time – Generally 2 hrs recommended
c. Pump capacity for liquid out
d. Net Liq fill up flow = “a*b” – “c”
e. Net liq fill up volume= “d” * “b”
f. Find Drum volumetric capacity = 3.14*0.25*D2*L
( using D & L calculated in Step-1)
CHECK: Net Liq Fill up Volume (for maxm liquid relief condition)
<= 50% of Drum Volumetric capacity( for maxm vapor load condition)
If not satisfied, recalculate

Example

Example

Example

Example

Example

Example

Example

Example

Example

Example

Example

Example

144

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