Equipment Sizing Based on

Heuristics

Equipment Sizing Based on Heuristics – p.1/12

Size does matter
James Cameron

Equipment Sizing Based on Heuristics – p.2/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.

Equipment Sizing Based on Heuristics – p.3/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.
This estimate has an error of 25-40%

Equipment Sizing Based on Heuristics – p.3/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.
This estimate has an error of 25-40%
We will consider equipment sizing heuristics for the
following:

Equipment Sizing Based on Heuristics – p.3/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.
This estimate has an error of 25-40%
We will consider equipment sizing heuristics for the
following:
Vessels

Equipment Sizing Based on Heuristics – p.3/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.
This estimate has an error of 25-40%
We will consider equipment sizing heuristics for the
following:
Vessels
Heat Transfer Equipment

Equipment Sizing Based on Heuristics – p.3/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.
This estimate has an error of 25-40%
We will consider equipment sizing heuristics for the
following:
Vessels
Heat Transfer Equipment
Distillation Columns

Equipment Sizing Based on Heuristics – p.3/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.
This estimate has an error of 25-40%
We will consider equipment sizing heuristics for the
following:
Vessels
Heat Transfer Equipment
Distillation Columns
All these calculations require flow rate, temperatures,
pressures and heat duties from the flowsheet and
energy balance.

Equipment Sizing Based on Heuristics – p.3/12

 Equipment Sizing
An order-of-magnitude estimate is usually sufficient for
preliminary design calculations.
This estimate has an error of 25-40%
We will consider equipment sizing heuristics for the
following:
Vessels
Heat Transfer Equipment
Distillation Columns
All these calculations require flow rate, temperatures,
pressures and heat duties from the flowsheet and
energy balance.

Equipment Sizing Based on Heuristics – p.3/12

 Vessel Sizing
Vessels include flash drums, storage tanks, decanters and
some reactors.

Equipment Sizing Based on Heuristics – p.4/12

 Vessel Sizing
Vessels include flash drums, storage tanks, decanters and
some reactors. Unless specified otherwise by particular
unit requirements, these will be sized by the following
criteria:

Equipment Sizing Based on Heuristics – p.4/12

 Vessel Sizing
Vessels include flash drums, storage tanks, decanters and
some reactors. Unless specified otherwise by particular
unit requirements, these will be sized by the following
criteria:
Select vessel volume V based on a five-minute liquid
holdup time with an equal volume added for vapor flow:


FL τ
V =2
ρL

Equipment Sizing Based on Heuristics – p.4/12

 Vessel Sizing
Vessels include flash drums, storage tanks, decanters and
some reactors. Unless specified otherwise by particular
unit requirements, these will be sized by the following
criteria:
Select vessel volume V based on a five-minute liquid
holdup time with an equal volume added for vapor flow:


FL τ
V =2
ρL

FL liquid flow rate leaving the vessel

ρL density of liquid
τ residence time (5 minutes)

Equipment Sizing Based on Heuristics – p.4/12

Specification of the residence time is dictated by
maintaining a liquid buffer for on/off switching times for
pumps.

Equipment Sizing Based on Heuristics – p.5/12

Specification of the residence time is dictated by
maintaining a liquid buffer for on/off switching times for
pumps.
L
The aspect ratio = 4.
D
This ratio is optimal if bottom and top heads are 4 times
as expensive as sides.

Equipment Sizing Based on Heuristics – p.5/12

Specification of the residence time is dictated by
maintaining a liquid buffer for on/off switching times for
pumps.
L
The aspect ratio = 4.
D
This ratio is optimal if bottom and top heads are 4 times
as expensive as sides.
If D > 4 f t size the unit as a horizontal vessel.
This requires more space but costs less for structural
support.

Equipment Sizing Based on Heuristics – p.5/12

Specification of the residence time is dictated by
maintaining a liquid buffer for on/off switching times for
pumps.
L
The aspect ratio = 4.
D
This ratio is optimal if bottom and top heads are 4 times
as expensive as sides.
If D > 4 f t size the unit as a horizontal vessel.
This requires more space but costs less for structural
support.
As a safety factor, choose the vessel (gauge) pressure
to be 50% higher than the actual pressure from the
material and energy balance.

Equipment Sizing Based on Heuristics – p.5/12

Specification of the residence time is dictated by
maintaining a liquid buffer for on/off switching times for
pumps.
L
The aspect ratio = 4.
D
This ratio is optimal if bottom and top heads are 4 times
as expensive as sides.
If D > 4 f t size the unit as a horizontal vessel.
This requires more space but costs less for structural
support.
As a safety factor, choose the vessel (gauge) pressure
to be 50% higher than the actual pressure from the
material and energy balance.
For desired temperature range, consider the required
material of construction.
Equipment Sizing Based on Heuristics – p.5/12
Heat Transfer Equipment

Equipment Sizing Based on Heuristics – p.6/12

 Heat Transfer Equipment
T1 T2
Heat
Exchanger
Q
t2 t1

Consider a counter-current shell-and-tube heat exchanger.

Equipment Sizing Based on Heuristics – p.6/12

 Heat Transfer Equipment
T1 T2
Heat
Exchanger
Q
t2 t1

Consider a counter-current shell-and-tube heat exchanger.

Heat transfer area can be found from:

Q = U A∆Tlm

where
(T1 − t2 ) − (T2 − t1 )
∆Tlm =

T1 − t2
ln
T2 − t1

Equipment Sizing Based on Heuristics – p.6/12

 Heat Transfer Equipment
T1 T2
Heat
Exchanger
Q
t2 t1

Consider a counter-current shell-and-tube heat exchanger.

Heat transfer area can be found from:

Q = U A∆Tlm

where
(T1 − t2 ) − (T2 − t1 )
∆Tlm =

T1 − t2
ln
T2 − t1
The overall heat transfer coefficient, U , can be
estimated from heuristics or from standard references
(e.g. Perry’s Handbook)
Equipment Sizing Based on Heuristics – p.6/12
If there is a phase change, the overall heat transfer
coefficient, U , changes.

Equipment Sizing Based on Heuristics – p.7/12

If there is a phase change, the overall heat transfer
coefficient, U , changes.
This case is modeled as two heat exchangers in series,
each with a different U and A.

Equipment Sizing Based on Heuristics – p.7/12

If there is a phase change, the overall heat transfer
coefficient, U , changes.
This case is modeled as two heat exchangers in series,
each with a different U and A.
T1

Tc
T2
T

t2
t1
t3

Q Q
vap con
V V
vap con
A A
vap con

T versus Heat Exchanged

Equipment Sizing Based on Heuristics – p.7/12

If there is a phase change, the overall heat transfer
coefficient, U , changes.
This case is modeled as two heat exchangers in series,
each with a different U and A.
Qvap
Avap = a
T1
Uvap ∆Tlm Tc

a = (T 1 − t2 ) − (T c − t3 ) T2
where ∆Tlm
 T

T1 − t2 t2
ln
Tc − t3 t3
t1

Qcon
Acon = b Q Q
Ucon ∆Tlm V
vap
V
con
con
vap

b (Tc − t3 ) − (T2 − t1 ) A
vap
A
con
where ∆Tlm =

Tc − t3 T versus Heat Exchanged
ln
T2 − t1

Equipment Sizing Based on Heuristics – p.7/12

If there is a phase change, the overall heat transfer
coefficient, U , changes.
This case is modeled as two heat exchangers in series,
each with a different U and A.
Qvap
Avap = a
T1
Uvap ∆Tlm Tc

a = (T 1 − t2 ) − (T c − t3 ) T2
where ∆Tlm
 T

T1 − t2 t2
ln
Tc − t3 t3
t1

Qcon
Acon = b Q Q
Ucon ∆Tlm V
vap
V
con
con
vap

b (Tc − t3 ) − (T2 − t1 ) A
vap
A
con
where ∆Tlm =

Tc − t3 T versus Heat Exchanged
ln
T2 − t1
We choose 10, 000 sq. f t. as the maximum exchanger
area. If more area is required, multiple heat exchangers
in parallel are used. Equipment Sizing Based on Heuristics – p.7/12
Distillation Column

Equipment Sizing Based on Heuristics – p.8/12

 Distillation Column
1. Determine actual number of trays and reflux ratio.

Equipment Sizing Based on Heuristics – p.8/12

 Distillation Column
1. Determine actual number of trays and reflux ratio.
2. Calculate column diameter and height as follows:

Equipment Sizing Based on Heuristics – p.8/12

 Distillation Column
1. Determine actual number of trays and reflux ratio.
2. Calculate column diameter and height as follows:

L
D
F L=RD
V=L+D
L+F

Equipment Sizing Based on Heuristics – p.8/12

 Distillation Column
1. Determine actual number of trays and reflux ratio.
2. Calculate column diameter and height as follows:
To determine the diameter, design
L
the column to run at 80% of the D
flooding velocity. F L=RD
V=L+D
L+F

Equipment Sizing Based on Heuristics – p.8/12

 Distillation Column
1. Determine actual number of trays and reflux ratio.
2. Calculate column diameter and height as follows:
To determine the diameter, design
L
the column to run at 80% of the D
flooding velocity. F L=RD
At the flooding velocity, the vapor V=L+D
L+F
flow rate is so high that no net liquid
flow occurs and entrainment begins.

Equipment Sizing Based on Heuristics – p.8/12

Calculate dimensionless flow parameter Flv

 0.5
L ρg
Flv =

V ρl


L
where
is the liquid/gas mass ratio at the point of
V
ρg
consideration and is the gas/liquid density ratio.
ρl

Equipment Sizing Based on Heuristics – p.9/12

Calculate capacity parameter Csb,f from the chart below
for a given tray spacing:

Equipment Sizing Based on Heuristics – p.10/12

Calculate linear flooding velocity (ft/s) from
 0.5 
ρl − ρg σ 0.2
Unf = Csb,f
ρg 20

where ρg and ρl are the gas and liquid mass densities

and σ is the liquid surface tension in dynes/cm.

Equipment Sizing Based on Heuristics – p.11/12

Calculate linear flooding velocity (ft/s) from
 0.5 
ρl − ρg σ 0.2
Unf = Csb,f
ρg 20

where ρg and ρl are the gas and liquid mass densities

and σ is the liquid surface tension in dynes/cm.


V
Calculate area of cross-section from A =
0.8Unf ρg
where  is the fraction of area available for vapor flow
(0.6 for bubble cap trays and 0.75 for sieve trays).

Equipment Sizing Based on Heuristics – p.11/12

Calculate linear flooding velocity (ft/s) from
 0.5 
ρl − ρg σ 0.2
Unf = Csb,f
ρg 20

where ρg and ρl are the gas and liquid mass densities

and σ is the liquid surface tension in dynes/cm.


V
Calculate area of cross-section from A =
0.8Unf ρg
where  is the fraction of area available for vapor flow
(0.6 for bubble cap trays and 0.75 for sieve trays).
Calculate column diameter from

4A
D=
π

Equipment Sizing Based on Heuristics – p.11/12

Calculate linear flooding velocity (ft/s) from
 0.5 
ρl − ρg σ 0.2
Unf = Csb,f
ρg 20

where ρg and ρl are the gas and liquid mass densities

and σ is the liquid surface tension in dynes/cm.


V
Calculate area of cross-section from A =
0.8Unf ρg
where  is the fraction of area available for vapor flow
(0.6 for bubble cap trays and 0.75 for sieve trays).
Calculate column diameter from

4A
D=
π
If D > 20 f t, then split the column into two columns
running in parallel. Equipment Sizing Based on Heuristics – p.11/12
 NT
The number of actual trays is given by where the
η
efficiency is assumed to be 80%. Assume a tray



spacing of 24 to calculate column height.

Equipment Sizing Based on Heuristics – p.12/12

 NT
The number of actual trays is given by where the
η
efficiency is assumed to be 80%. Assume a tray



spacing of 24 to calculate column height.
Calculate heat duties for condenser and reboiler from
energy balance.

Equipment Sizing Based on Heuristics – p.12/12