Project number SD-VH-T-S-2024 Date 5-Nov-2024

Document number SD-VH-T-S-2024 Prepared by Amir Tavakol

Equipment tag V-101
Project name Sizing and Design of a Vertical Two-Phase Separator

Sizing and Design of Separators According to Click-here

Tittle Total & GPSA Procedure

Introduction
Separators play a crucial role in the oil and gas industry, where they are primarily used to separate
mixtures of gas, oil, and water into distinct phases. The design and sizing of separators are vital to
ensure that the separation process is efficient, safe, and economical. There are various types of
separators, including horizontal, vertical, and spherical, each suitable for different operational
conditions and spatial constraints. in designing a separator, factors like pressure, temperature, flow rates,
fluid properties, and particle sizes must be considered to achieve optimal separation. One key design
aspect is determining the proper dimensions and ratios (L/D ratio) of the vessel, which directly affect
the separator’s efficiency and structural weight. The Souders-Brown equation is often applied to
calculate the maximum allowable gas velocity, which helps avoid carryover or excessive entrainment.
separators are generally categorized into vertical and horizontal types, and they can handle either two-
phase or three-phase systems. Typically, when the Gas-to-Liquid Ratio (GLR) is high, vertical
separators are used, whereas when this ratio is low, horizontal separators are preferred. Therefore, in oil
processing, horizontal separators are commonly used, while in gas processing, vertical separators are
more prevalent.

How Separators are Represented in P&ID

1
Introduction to Separator Internals
Internals help improve separation by reducing the velocity and addressing various operational issues.

• Inlet diverters: The inlet diverter is one of the internals for the two-phase fluid inlet to the
separator. It is a plate that, when the incoming fluid hits it, causes turbulence in the flow,
reducing the velocity and enhancing the separation of liquid and gas. The inlet diverter helps in
foam breaking, bubble breaking, and also contributes to the uniform distribution of the flow.

• half Pipe: The half-pipe is another device used at the inlet of the flow into separators. It consists
of a pipe that is cut in a diamond shape and is mainly installed in vertical separators.

• elbow: The elbow is a pipe fitting used to change the direction of the flow in separators. It helps
in directing the flow of gas and liquid in a desired path, and its design can impact the distribution
of the two phases inside the separator.

• Cyclone: A cyclone is a device used for separating fine liquid droplets or solid particles, such
as sand and dust, from a gas or liquid stream.

https://youtu.be/1swI0MYQrUU

2
 • Schoepentoeter :The Schoepentoeter is the latest and most advanced technology for separating
gas and liquid phases, designed and developed by Shell.

https://youtu.be/zuOMzRpHpHk?si=xcTZ31rTvThMnieM
• Vortex-Breaker: Another component installed in separators is the vortex breaker, which is
placed in the path of the liquid outlet nozzle. It helps prevent the formation of negative pressure
by creating a vortex, thus following Bernoulli's principle.

• Demister Pad: a demister pad is a device installed in the gas outlet stream that captures the
vapor in the gas and returns it to the liquid stream, removing particles as small as 5 microns.

3
 • Vane pack: Vane pack, like the demister pad, is used for separating fine liquid droplets carried
by the gas flow. However, it is more efficient and can remove particles as small as 3 microns.

• Coalesing-Pack: used for separating fine liquid droplets carried by the gas flow. However, it
is more efficient and can remove particles as small as one micron.
The equipment placed along the gas outlet includes the demister pad, vane pack, and coalescer. From
last to first, they offer the highest separation efficiency and the greatest pressure drop.

Three-Phase Separator Types

• Separators with weir: It is used where both oil and water are present in significant quantities.

• Separator with Boot: It is used where there is a high amount of oil and a low amount of water.

4
 • Separator with bucket: It is used where there is a high amount of water and a low amount of
oil.

Operational Challenges in the Design and Sizing of Separators

• Carry over: When the gas velocity inside the vessel is high due to a smaller vessel diameter,
liquid droplets may be carried from the gas-liquid interface into the gas phase. This reduces
separation efficiency, can cause significant damage to compressors, and may also result in
excessive flaring, darkening the refinery's flare. Other reasons for carry-over, aside from a
smaller vessel diameter, include high system pressure or blockage of the liquid outlet valve,
which causes the HHLL (High-High Liquid Level) to rise.

• Oil in water: When the oil rate is low, the oil phase can dissolve into the water phase. This is
why demulsifying agents are injected into the fluid at the inlet of the separators to prevent this
issue.

• Water in Oil: The dominant phase here is oil, which is dispersed within the water phase.

• Slug Condition: This phenomenon occurs when sand, gravel, or stones are present in the
upstream flow. When they suddenly enter the vessel, they disrupt the laminar flow. Therefore,
it is crucial during separator sizing to ensure that the vessel is designed with the capacity to
handle potential slug volumes.

5
Three Methods of Gas-Liquid Separation
• Momentum: Momentum separation is a method where the difference in velocities between gas
and liquid phases causes the liquid droplets to separate. The liquid, having higher mass, is
decelerated and falls due to gravity, often aided by internal devices like cyclones or diverters,
improving separation efficiency.

• Gravity Settling: is a separation method where the heavier liquid phase settles under the
influence of gravity, allowing the lighter gas phase to rise. This process is commonly used in
separators, where the difference in densities between the phases helps in their separation.

• Coalescing: It is used when conventional separators, which operate based on drag forces, are
not efficient enough. In this type of separation, a series of internals are installed that drastically
reduce the Fluid velocity, resulting in the highest separation efficiency.

6
Parameters Required Before Designing and Sizing Separators
• Phase Behavior: In order to design and size a separator, the first thing needed is to understand
the phase behavior of the fluid being separated .

• Flow Rate: for liquid ang gas (min, average, peak)

• OP & OT: a thinner vessel is required.
• DP & DT: The lower the operating pressure, the better the separation, as the density
difference between gas and liquid increases.
• Slugging or Surging
• Thermodynamic and Fluid mechanics parameters: Liquid and Gas Mass Flow & Density
• Particle Size Diameter
• Percent of impurities: such as sand, paraffin, Stone and etc
• Foaming Tendency
• Corrosion or fouling Tendency

Souders-Brown Eq
Ut: settling velocity of droplets in the liquid phase. (m/s or ft/s)
K: Souders–Brown coefficient, which depends on the type of
separator and operating conditions (usually in m/s or ft/s)
ρL : Liquid density (kg/m³ or lb/ft³)
ρG : Gas density (kg/m³ or lb/ft³)
Dp: Droplets Size
C: Drag Coefficient

7
Drag Coefficient Calculation
To calculate the drag coefficient, we need the value of C′(Re)2 . By determining this parameter, we can
then find the value of K and subsequently, the settling velocity can be established. The following charts
are provided for reference. However, to use this chart, our vessel must not include a demister pad.

Settling Velocity and Reynolds Number

Another method to calculate the settling velocity of droplets from the gas phase to the liquid phase is
by using Reynolds equations.
0.33
1488gD2p (ρl − ρv ) μ2
Re < 2 → Us = → Dp = 0.025 ( )
18μ gρv (ρl − ρv )
0.33
3.49g 0.71 D1.14
p (ρl − ρv )
0.71
μ2
2 < Re < 500 → Us = → Dp = 0.334 ( )
ρ0.29
v − μ0.43 gρv (ρl − ρv )

gDp ((ρl − ρv )
500 < Re < 20000 → Us = 1.74√
ρv

Types of Two-Phase Separators

Two-phase separators include horizontal and vertical vessels, with installation configurations varying
based on specific conditions. These separators often contain internals such as diffusers, demister pads,
and vortex breakers. Vertical separators are typically used when gas flow is high, while horizontal
separators are preferred when liquid volume is greater.

8
Momentum Rate
When an inlet diverter is used to reduce speed, it decreases the momentum J = ρϑ2 and increases
efficiency. Similarly, using a demister pad also reduces momentum, leading to higher efficiency. As a
general rule, when there are more internals in the separator vessel, they reduce the fluid velocity, which
in turn decreases the momentum.
diffuser distributor → 6000~9000
half pipe or elbow or inlet distributor → 1500~3750
V baffle or inlet diverter → 1500~3750

Comparison of Nozzles

9
Evaluation of Separator Length and Diameter

The length of the vessel has a direct impact on separation. The vessel's length must be sufficient to allow
liquid droplets to detach from the gas phase and move into the liquid phase. The vessel diameter is
directly related to the gas velocity within the separator; the smaller the diameter, the higher the gas
velocity, and vice versa. It is also important to note that in vertical separators, the diameter is fixed and
determined by the gas area, while in horizontal separators, the length-to-diameter ratio must be adjusted
to achieve the desired separation.

In-Depth Analysis of Vortex Breaker and Demister Pad

• Demister Pad
It is placed on the gas outlet from the
liquid, known as the "Gas Polishing
Section." It separates 95% of particles up
to 10 microns, and if a higher separation
efficiency is desired, it can be compressed,
increasing the demister thickness. Its
density is usually 192, and sometimes its
diameter is equal to or smaller than the
separator's diameter.

Important Note: If solid particles are

present in the gas flow (such as from
polymerization unit outputs), a mist
eliminator should never be used in the gas
outlet path, as it can lead to plugging. In
such separators, it is better to use a cyclone
at the gas inlet to handle these particles.

10
 • Vertex Breaker
A vortex or whirlpool is created due to the discharge of water, and because of the low pressure
at the vortex center, it can pull the gas down. One of the main signs of a vortex is the sound it
generates inside the separator. When a pump is located downstream of the separator, it can
cause severe damage to the pump. Additionally, this device is placed on the liquid outlet path.

PSV in Separators
A Pressure Safety Valve (PSV) in separators is used to protect the system from overpressure by releasing
excess pressure when it exceeds the predetermined limit. It ensures the safety of the separator and the
entire system by preventing potential damage or failure. If a PSV installation is necessary, it should be taken
from the gas outlet under the equipment, and the distance between the bottom of the demister and the PSV outlet
should be minimized.

Typical Souders Brown K values for mist eliminator devices

11
Separators Configuration
1. Typically, if sand and debris are present in the incoming mixed flow to the separator, a
horizontal type separator is used.

2. Considering the required space, known as the plot area, is a very important parameter. Some
separators, such as flare knockout drums, can be up to 20 meters in length, and these should
operate vertically to occupy less space.

3. Transportation limitations and the width of the roads in the country of origin are important
factors to consider when designing separators, especially for large equipment.

4. The interface required for separating two liquid phases is necessary for the effective
separation process.

5. When we have a surge flow, the liquid level must be maintained at a specific height to
prevent it from exceeding a certain limit.

6. Considering the hold-up or retention time parameter, if this time (in minutes) is high, a
horizontal separator should be selected, such as knockout drums in flare systems that require
20 to 30 minutes of retention time.

7. If heating tools are required for the fluid, the necessary space for them should be considered,
and they can be installed in both vertical and horizontal separators.

12
Separator design and construction
• Vertical: This type of separator is chosen when the GLR factor is high, and the economic L/D
ratio for vertical separators is between 2 and 4. If LLLL is not a critical factor, vertical
separators are preferred due to their small volume, which quickly fills the vessel with incoming
liquid and reaches the HHLL, potentially causing a shutdown.
• Horizontal: This type of separator is chosen when the liquid flow rate is high or when there is
a large amount of dissolved gas. The economic L/D ratio for these separators is between 2.5
and 5. Since they have a large liquid surface, the liquid droplets in the gas have more
opportunity to move from the gas phase to the liquid phase. These separators are also more
efficient than vertical ones when the fluid has a tendency to form foam or carry slugs.

Pressure Relationship with L/D Ratio

L
P ≤ 4 bar → 2 ≤ ≤4
D
L
P > 4 bar → 3 ≤ ≤5
D

GPSA Method for Calculating Length and Diameter

The above formula is used for calculating the length of horizontal separators without mist eliminators,
applicable for droplet sizes between 150 and 2000 microns, and it provides the tangent-to-tangent
distance.

Typical Retention Times for Gas/Liquid Separator

13
Separator height according to GPSA procedure

For vertical separators, considering whether a demister pad is present or not, we first calculate the
diameter using the following relationships. Then, we arrange the length from bottom to top as will be
explained.

Diameter Calculation in Vertical Two-Phase Separators

mg 1
∗
((ρ −ρ ) ρg 3600 4∗𝐴𝑟𝑒𝑎
Us = 𝐾√ lρ v → Vg = 0.85 ∗ Us → 𝐴𝑟𝑒𝑎 = Vg
→𝐷= √ 𝜋
v

Separators With Mist Eliminator (GPSA):

The well-known Souders-Brown equation is used to calculate the settling velocity in two-phase
separators.

14
Mesh Pad Separation Performance
• Droplet removal efficiency:99-99.5% removal of 3-10 micron droplets. Higher removal
efficiency is for denser, thicker pads and/or smaller wire/co-knit fiber diameter.
• Gas capacity, K, ft/sec: 0.22-0.39. Generally, the lower capacities correspond to the mesh pad
designs with the highest droplet removal efficiencies.
Typical Vane Pack Separation Performance:

• Droplet removal efficiency: 99% removal of droplets greater than 10-40 microns. Higher
removal efficiency is for thicker packs, with closer vane spacings and more passes (bends).
• Gas capacity, K (ft/sec): Horizontal flow: 0.9-1.0 / Vertical up-flow: 0.4-0.5 - The higher
capacities are generally associated with pocketed vane designs.

2-phase Separators With or Without Mist Eliminator Sizing:

Where:

• 𝜌 liquid or vapour density kg/m³

• Vs-settling velocity m/s
• K - correlating parameter m/s
• D - particle diameter -microns
• C - drag coefficient
• 𝜇 vapour viscosity – centipoise

15
 For medium and low-pressure applications with gases having a viscosity below 0.01 cp, Figure 1
can be referenced to estimate the settling velocity Vs.

For higher pressures (above 50 bar) or viscosities greater than 0.01 cp, it is essential to calculate Vs
directly. The drag coefficient C can be determined using the figure provided below.

16
After calculating the settling velocity, we then calculate the gas velocity, which is 85% of the settling
velocity according to Total's procedure.
𝑉𝑔 = 0.85 ∗ 𝑉𝑠
By calculating the gas velocity, we can directly calculate the required area for gas-liquid separation.
Once the area is determined, we can find the diameter according to the specified procedure.
mg 𝑚 3 1ℎ𝑟
ρ ( ) ∗ 3600𝑠
g ℎ𝑟 4 ∗ 𝐴𝑟𝑒𝑎
𝐴𝑟𝑒𝑎(𝑚2 ) = 𝑚 → 𝐷 = √
Vg ( 𝑠 ) 𝜋

By determining the diameter, we can proceed to calculate the length of the vessel.
Height = h + 𝑫𝒏 + t + X + Y + 0.15Dv

In the above equation, to calculate the vessel height, the inlet nozzle diameter is required. Therefore,
the first step is to size the nozzles.
For a vessel the following velocity ranges should be considered:
• The mixture velocity at the inlet to the nozzle should be between 7 to 13 meters per second.
• The gas outlet velocity from the nozzle should be between 15 to 30 meters per second.
• The liquid outlet velocity should be between 1 to 3 meters per second if the liquid is a
hydrocarbon, or between 2 to 4 meters per second if it is a .
Another method for sizing nozzles is through the relationship between density and velocity, and it is
used when the vessel is equipped with a mist eliminator.
kg
ρm ϑ2m ≤ 6000
m. s 2
kg
ρg ϑ2g ≤ 3750
m. s 2
𝑀
𝜗𝐿 < 1
𝑆
Note: The nozzle sizing calculations are performed with a 10% overdesign according to the Total
procedure.

Example 1: Calculate the diameter, height, and size of a separator with the
following information:
• Operating pressure: 1 bar
• Operating temperature: 34°C
• Gas flow rate: 7290 kg/h

17
 • Gas density: 2.1 kg/m³
• Liquid mass flow rate: 10890 kg/h
• Liquid density: 810 kg/m³
• Droplet size in gas: 150 microns
Assume that due to limited plot area, this separator must be installed vertically.
Solve:
Since the pressure is below 50 bar and the gas phase viscosity is less than 0.01 centipoise, we will use the
Souders-Brown equation and the table below to calculate the settling velocity.

𝜌𝑙 − 𝜌𝑣 810 − 2.1
= = 384 → 𝑉𝑠 = 0.45 𝑚/𝑠
𝜌𝑣 2.1

Based on the data and calculations, the settling velocity is equal to 0.45 meters per second. To calculate
the gas velocity, the settling velocity should be multiplied by 0.85 according to Total's criteria.

18
 𝑚 𝑚
𝑉𝑔 = 0.45 ∗ 0.85 = 0.3825
𝑠 𝑠

Calculation of Separator Area

𝑘𝑔
7290
𝑚𝑔 ℎ𝑟 ∗ 1ℎ𝑟
𝑘𝑔 3600𝑠
𝜌𝑔 2.1
𝐴= = 𝑚3 = 2.52𝑚2
𝑉𝑔 𝑚
0.3825
𝑠
To calculate the diameter of a cylinder using the cross-sectional area, we use the following formula:

𝜋𝑑 2 4 ∗ 2.52
𝐴= →𝑑= √ → 1.79𝑚 = 1.8 𝑚
4 𝜋

The diameter of the vessel has been calculated and is equal to 1.8 meters. Please note that in a vertical
separator, the diameter is fixed and cannot be manipulated or changed. Therefore, we will proceed to
calculate the length of the vessel.

First, to better understand the calculations, we will size the inlet and outlet nozzles of the vessel.

• Calculate inlet nozzle Diameter: To calculate the inlet nozzle diameter, we need the volumetric flow rate
and the inlet nozzle area. The volumetric flow rate is calculated by dividing the sum of the gas and liquid
mass flows by the density of the inlet mixed phase. The inlet nozzle area is initially estimated by
assuming a diameter in inches. Finally, if the mix velocity is between 7 and 13 meters per second, the
guessed diameter is correct.

19
 𝑘𝑔 𝑘𝑔
𝑚𝑙 + 𝑚𝑣 10890 ℎ𝑟 + 7290 ℎ𝑟 𝑘𝑔
𝜌𝑚𝑖𝑥 = 𝑚 𝑚 = = 5.2168
𝑙 𝑣 𝑘𝑔 𝑘𝑔 𝑚3
𝜌𝑙 + 𝜌𝑣 10890 ℎ𝑟 7290 ℎ𝑟
+
𝑘𝑔 𝑘𝑔
810 𝑚3 2.1 𝑚3
𝑘𝑔 𝑘𝑔
𝑚𝑙 + 𝑚𝑣 10890 ℎ𝑟 + 7290 ℎ𝑟 m³ 1ℎ𝑟 m³
𝑚𝑚𝑖𝑥 = = = 3483 ( ) ∗ ∗ 1.1 = 0.97
𝜌𝑚𝑖𝑥 𝑘𝑔 ℎ𝑟 3600𝑠 𝑠
5.2168 𝑚3
m3
𝑚𝑚𝑖𝑥 0.97 𝑠 𝑚
𝑚𝑖𝑥𝑡𝑢𝑟𝑒 𝑣𝑒𝑙𝑜𝑐𝑖𝑡𝑦 = 2 = 2 = 131.4
𝜋 ∗ (𝐷) 25.4 𝑠
4 𝜋 ∗ (4 ∗ 1000)
𝑚 2
4
According to Total’s procedure, the inlet velocity of the mixture should be between 7 and 13
m/s. The current diameter is too small, so it needs to be increased to reduce the cross-
sectional area, thereby increasing the inlet velocity of the mixture.

𝑚
5𝑖𝑛𝑐ℎ → 84.46
𝑠
𝑚
10𝑖𝑛 → 21
𝑠
𝑚
13𝑖𝑛 → 12.49
𝑠

A diameter of 13 inches is suitable as it brings the incoming mixture velocity within the 7 to
13 meters per second range.

• Calculate Gas outlet nozzle Diameter: To calculate the diameter of the gas outlet nozzle, we
follow the same sizing procedure as for the inlet nozzle, with the difference that the gas outlet
velocity should be between 15 and 30 meters per second.

𝜌𝑔 =2.1 kg/m³
kg
7290 1hr m3
hr
mg = kg ∗ 3600s ∗ 1.1 = 1.06 s
2.1 3
m

m³
𝑚𝑔 1.06 𝑚
gas Velocity = = 𝑠 = 130.76
𝜋 ∗ (𝐷) 2 25.4 𝑠
𝜋 ∗ (4 ∗ 1000)2
4 𝑚2
4
According to Total's procedure, the gas exit velocity from the nozzle should be between 15 to
30 meters per second, and a diameter of 4 inches is too small, so it should be increased.

𝑚
7𝑖𝑛 → 49.69
𝑠
𝑚
10𝑖𝑛 → 20.91
𝑠

• Calculate Liquid outlet nozzle Diameter: To calculate the diameter of the liquid outlet nozzle, the
liquid outlet velocity should be between 1 and 3 meters per second for hydrocarbon discharge and
between 2 and 4 meters per second for water liquid discharge. It is worth mentioning that since the
composition of water is higher than hydrocarbon materials in this case, the liquid outlet velocity is

20
 considered to be between 1 and 3 meters per second. By performing the calculations as described
above, we find that the outlet liquid nozzle diameter is 2 inches.

Now, let's move on to calculating the vessel height according to Total's criteria.

h8: 150 mm for bottom connected LT or 300 mm for side connected LT

• To calculate the height h8 (from the bottom tangent line to the LLLL) according to Total's
criteria, we consider the value to be 150 millimeters.

h7: 1 - 2 minutes of residence time (mini 150 mm)

• To calculate the height h8 (LLLL-LLL) we first consider the hold-up time to be between 1 to
2 minutes. We then calculate the corresponding height and compare it with 150 millimeters.
The greater of the two values will be taken as the height for this section.
𝑘𝑔
𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 1 1 10890 1ℎ𝑟 1
• 2 min∗
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦
∗
60𝑚𝑖𝑛
∗
𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎
= 2𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗
60𝑚𝑖𝑛
∗
2.52𝑚2
∗ 1000 =
810 3
𝑚
177.83𝑚𝑚
• The value of h7 was found to be 177.83 millimeters, so we will select 178 millimeters as the
height for this section.

h6: To calculate h6 (from LLL to HLL), first refer to Table 1 to determine the holdup time (minimum
300 mm)

• We consider the vessel as a product drum with a pump; thus, the holdup time is set to 5
minutes, and the remaining calculations proceed similarly to the calculation of h7.
𝑘𝑔
𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 1 1 10890 1ℎ𝑟 1
• 5 min∗ 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦
∗ 60𝑚𝑖𝑛 ∗ 𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎 = 5𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗ 60𝑚𝑖𝑛 ∗ 2.52𝑚2 ∗ 1000 =
810 3
𝑚
444.59 𝑚𝑚
• Since the calculated value is greater than the 300mm, we will consider the height of this
section to be 445 millimeters as well.

h5: Calculate based on 1-2 minutes of residence time at maximum inflow (min 200 mm)

• H5 is the height (HLL - HHLL). Note that here, the height of HHLL becomes significant for
us since it is the KOD of a compressor.
𝑘𝑔
𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 1 1 10890 1ℎ𝑟 1
• 2 min∗ 𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦
∗ 60𝑚𝑖𝑛 ∗ 𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎 = 2𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗ 60𝑚𝑖𝑛 ∗ 2.52𝑚2 ∗ 1000 =
810 3
𝑚
177.83𝑚𝑚
• Since the minimum value provided is greater than the calculated height, we will consider the
height of this section to be 200 millimeters as well.
h4: has the greatest value of: (1.5 * (inlet nozzle Diameter)) or (400 + inlet nozzle Diameter /2) mm
25.4 13∗25.4
• 1.5 ∗ (13 ∗ 1000) = 0.4953 ∗ 1000 = 495.3 𝑚𝑚 𝑜𝑟 400 + ( ) = 565.1 𝑚𝑚
2

21
 • h4 = 565.1 mm
h3: has the greatest value of: (0.5 * (Vessel diameter)) or (minimum 600) mm

• 0.5*1.8*1000 =1420 mm or 900 mm

• h3 = 1420 mm
h2:100 mm if mesh-pad selected or150 mm for compressor KOD

• h2 = 100 mm
h1: has the greatest value of: (0.15 * (Vessel diameter)),(minimum 400) mm

• 0.15*2.84*1000 = 426 mm or 400 mm

• h1 = 426 mm
The total length of the vessel is the sum of (h1) to (h8) = 2950

Liquid distillate feeding directly another column for which 15 min on the other
a constant feed flowrate is required. column feed
5 min on the reflux
Liquid distillate sent to storage 2 min on the product
Reflux Drum 5 min on the reflux
Vapor distillate only 5 min on the reflux

Product Drum 5 min with pump or 3 min without pump

Heater Feed 8 min
HP separator to LP separator 3 min

Table 1

Now, let's examine the ratio of length to diameter (L/D), which for vertical separators should be between 2 and 4.

2.950 𝑚
= 1.638
1.8 𝑚

The L/D ratio did not fall within the range of 2 to 4, and we can’t make any adjustments since the diameter in
vertical separators is fixed and cannot be changed. To increase the L/D ratio, we would need to extend the length,
but this would negatively impact us because increasing the length results in a higher vessel weight, which
complicates the economic feasibility of the design.

Click here to download excel Sheet

Another formula derived from the Souders-Brown equation, providing highly accurate calculations for
settling velocity, is shown below:

22
And to calculate the gas velocity, we proceed as follows:

The parameter K is also calculated based on the separator's application, using the table below.

Example 2
Calculate the diameter, height, and size of a Compressor suction drum with the
following information:
• Operating pressure: 1 bar
• Operating temperature: 34°C
• Gas flow rate: 71545 kg/h
• Gas density: 8.438 kg/m³
• Liquid mass flow rate: 52600 kg/h
• Liquid density: 538.7 kg/m³
Solve:
𝜌𝑙 − 𝜌𝑣 0.5
0.048 ∗ ( ) = 0.380 𝑚/𝑠
𝜌𝑣

𝑉𝑔 = 𝐾 ∗ 𝑉𝑠 = 1.7 ∗ 0.380 = 0.6468 m/s

𝑘𝑔 𝑘𝑔
mg ( ) 71545( )
ℎ𝑟 ∗ 1ℎ𝑟 ℎ𝑟 ∗ 1ℎ𝑟
𝑘𝑔 3600𝑠 𝑘𝑔 3600𝑠
ρg (𝑚3) 8.438 (𝑚3) 4 ∗ 3.641
2 √
𝐴𝑟𝑒𝑎 = 𝑚 → 𝑚 = 3.641𝑚 → 𝐷 = = 2.153𝑚
Vg ( 𝑠 ) 0.6468( 𝑠 ) 𝜋

23
The vessel diameter has been calculated, and now we proceed to calculate the vessel length. in Total's
procedure, it is specified that if the liquid outlet nozzle is bottom-connected, the height from the bottom
tangent line to the Low-Low Liquid Level (LLLL) should be 150 mm, and if it is side-connected, it
should be 300 mm. In this case, because the upstream equipment is a compressor and no dust or solid
particles should accompany the gas flow, we take the liquid outlet nozzle from the side to provide a
dead volume for any possible slug.

• BTM-LLLL = 300mm
The distance between the Low-Low Liquid Level (LLLL) and the Low Liquid Level (LLL) is calculated
using a holdup time of 1 to 2 minutes. Additionally, note that the minimum value it can have is 150 mm.

𝑘𝑔
52600
• 2 min∗
𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦
∗
1
60𝑚𝑖𝑛
∗
1
𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎
= 2𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗
1ℎ𝑟
60𝑚𝑖𝑛
∗
1
2.153𝑚2
∗ 1000 = 1511𝑚𝑚
538.7 3
𝑚

To calculate the distance between the Low-Low Liquid Level (LLL) and the High Liquid Level (HLL),
the liquid holdup is required, which is determined using Table 1- (min 300 mm)

𝑘𝑔
𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 1 1 52600 1ℎ𝑟 1
• 3 min∗ ∗ ∗ = 3𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗ ∗ ∗ 1000 = 2267.59 𝑚𝑚
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦 60𝑚𝑖𝑛 𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎 538.7 3 60𝑚𝑖𝑛 2.153𝑚2
𝑚

To calculate the height between the High Liquid Level (HLL) and the High-High Liquid Level (HHLL),
the holdup time is needed, which is 1 to 2 minutes for this section- (min 200 mm).

𝑘𝑔
𝑙𝑖𝑞𝑢𝑖𝑑 𝑚𝑎𝑠𝑠 𝑓𝑙𝑜𝑤 1 1 52600 1ℎ𝑟 1
• 2 min∗ ∗ ∗ = 2𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗ ∗ ∗ 1000 = 1511𝑚𝑚
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦 60𝑚𝑖𝑛 𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎 538.7 3 60𝑚𝑖𝑛 2.153𝑚2
𝑚

According to the Total procedure, the distance from the High-High Liquid Level (HHLL) to the bottom
of the inlet nozzle should be 300 mm also the distance from top of inlet nozzle to the bottom of the
demister pad should be 600 mm.

• HHLL to the bottom of the inlet nozzle = 300 mm

• from top of inlet nozzle to the bottom of the demister pad = 600 mm
According to the Total procedure, if the downstream equipment after the separator is a compressor, the
mesh pad thickness should be set at 150 mm; otherwise, the mesh pad thickness should be 100 mm.

• mesh pad thickness = 150 mm

The distance from the top of the demister pad to the top tangent line is also set to 300 mm according to
the Total procedure an important point is that we have not yet calculated the inlet nozzle diameter in
this design guide, so we now need to perform the sizing for both inlet and outlet nozzles.

Inlet nozzle Diameter

Note: When the vessel diameter is greater than 2.5 to 3 meters, the inlet nozzle should be equipped with
an inlet diverter or deflector or diffuser. Here, it is assumed that there is no inlet nozzle, and the
momentum value should be below 6000.

24
 𝑘𝑔
• 𝑗 = 𝜌𝜗 2 ≤ 6000 𝑚.𝑠2
ml +mv kg
• ρmix = ml mv = 14.47 m3
+
ρl ρv
𝑚𝑙 +𝑚𝑣 1 𝑚3
• 𝑄𝑚𝑖𝑥 = ∗ = 2.62
𝜌𝑚𝑖𝑥 3600 𝑠

• Inlet nuzzle diameter: 10 in

kg 2.62 𝑘𝑔
• 𝜌𝜗 2 = 14.47 m3 ∗ ( 25.4 2
) = 38716 𝑚.𝑠2
𝜋∗(10∗ )
1000
4
𝑘𝑔 𝑘𝑔
• 16 → 5907.6 𝑚.𝑠2
, 20 → 2419.7 𝑚.𝑠2
• 16 inch *25.4 = 406.4 mm

Total = 7346 mm
𝐿 7346
= = 3.41
𝐷 2.153
1000

Since the L/D ratio is within the range of two to four, there is no issue, and our design is correct.

Sizing of Horizontal Two-Phase Separators

We will proceed with the sizing of a horizontal two-phase separator, and the relevant explanations will
be provided in the example.
Example 4: A two-phase mixture at a temperature of 40°C and a pressure of 6 bar enters a separator.
The gas flow rate is 17,950 kg/h, and the liquid flow rate is 121,650 kg/h. The densities of the liquid
and gas are 756.8 kg/m³ and 18 kg/m³, respectively. The aim is to separate droplets as small as 150
microns from the gas stream. Determine the length, diameter, and liquid height in this separator.

25
 𝜌𝑙 − 𝜌𝑔 765.8 − 18
( )= = 41.54
𝜌𝑔 18

𝑚
𝑉𝑠 = 0.23
𝑠

𝐿 𝑚
𝑉𝑔 = 0.85 ∗ 𝑉𝑠 ∗ → 0.85 ∗ 0.23 ∗ 3 = 0.5865
𝐷 𝑠

𝑚𝑔 17950 𝑚3 1ℎ𝑟
𝑄𝑔 𝜌𝑔 18 ( ) ∗ 3600𝑠
𝑔𝑎𝑠 𝑎𝑟𝑒𝑎 = = = ℎ𝑟 = 0.4732𝑚2
𝑉𝑔 𝑣𝑔 𝑚
0.5865( 𝑠 )

Nozzle sizing

• Inlet nozzle diameter:

ml +mv 1.1
∗
▪ vmix =
Qmix
Area
=
ρmix 3600
π∗D2
→ 8𝑖𝑛 = 10.89
𝑚
𝑠
4

Since the calculated velocity falls within the range of 7 to 13 meters per second, the inlet nozzle diameter
is correct.

26
 • Vapor outlet nozzle Sizing:

mg 1
𝑄𝑔 ∗ ∗1.1
𝜌𝑔 3600 𝑚
o 𝑉𝑔 = = 𝜋∗𝐷 2 → 𝐷 = 10𝑖𝑛 → 𝑉𝑔 = 6.013, 𝐷 = 6𝑖𝑛 → 𝑉𝑔 = 16.7
𝐴 𝑠
4

The outlet gas velocity from the separator falls within the range of 15 to 30 meters per second; therefore,
the selected diameter of 6 inches is correct.

• Liquid outlet nozzle Sizing:

ml 1
𝑄𝑙 ∗ ∗1.1 𝑚
𝜌𝑙 3600
o 𝑉𝑙 = 𝐴
= 𝜋∗𝐷 2 → 𝐷 = 2𝑖𝑛 → 𝑉𝑙 = 23.94, 𝐷 = 6𝑖𝑛 → 𝑉𝑙 = 2.66 𝑠
4

In this design, we assumed that the liquid phase exiting the horizontal separator is water; therefore, the
water outlet velocity should be between 2 to 4 meters per second. However, if the exiting liquid were a
hydrocarbon, the outlet velocity should range between 1 to 3 meters per second.

A New Parameter: h/D

In the following calculations, a new parameter is defined as the ratio of the maximum liquid height in
the vessel to the vessel diameter. This value is an estimate but is typically assumed to be 0.7.

ℎ
= 0.7
𝑑
ℎ
𝜃 = 2 ∗ cos −1 (1 − 2 ∗ ) → 2 ∗ cos−1(1 − 2 ∗ 0.7) = 3.96
𝑑
𝐴𝑙 𝜃 − 𝑆𝑖𝑛(𝜃) 3.96 − 𝑆𝑖𝑛(3.96)
= = = 0.7468
𝐴𝑇 2𝜋 2 ∗ 3.14
𝐴𝑣 𝐴𝑙
=1− → 1 − 0.7468 = 0.2523
𝐴𝑇 𝐴𝑇

𝐴𝑣 0.4732 4 ∗ 1.87𝑚2
𝐴𝑇 = → = 1.87𝑚2 → 𝐷 = √ = 1.543 𝑚 ≈ 1550 𝑚𝑚
𝐴𝑣 0.2523 3.14
𝐴𝑇
We have calculated the diameter, and now we need to check whether the liquid levels we have are
sufficient for this diameter or not. Therefore, we must calculate the volume between the LLLL and
HHLL levels. To determine this volume, we need the holdup time and the vessel length. The holdup
time is typically 4 to 5 minutes.

27
Calculation of Length

𝐿
𝐿= ∗ 𝐷 → 3 ∗ 1.55 = 4.65 𝑚 (𝑓𝑙𝑜𝑤 𝑝𝑎𝑠𝑠)
𝐷
25.4
𝐿′ = 𝐿 + 1.5 ((𝑖𝑛𝑙𝑒𝑡 𝑛𝑜𝑧𝑧𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 + 𝑔𝑎𝑠 𝑜𝑢𝑡𝑙𝑒𝑡 𝑛𝑜𝑧𝑧𝑙𝑒 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟) ∗ ) = 5.184 ≈ 5.2𝑚
1000

Calculation of Liquid Heights in the Vessel

• BTL – LLLL = 0.2 m

• LLLL-LLL = 0.2 m

• Vol (BTM-LLL) = (𝐴𝐵𝑇𝑀−𝐿𝐿𝐿 ) ∗ 𝐿′ → 0.3857 ∗ 5.2 = 2𝑚3

LLL 0.2+0.2 ABTM−LLL πD2

o D
= 1.55 m
= 0.2580 , θ = 2.13, AT
= 0.204 → 0.204 ∗ 4
= 0.3857

𝐻𝐻𝐿𝐿 𝐴𝐻𝐻𝐿𝐿 𝜋∗𝐷 2

• 𝐷
= 0.7, 𝜃 = 3.96, 𝐴𝑇
= 0.7476 → 𝐴𝐵𝑇𝑀−𝐻𝐻𝐿𝐿 = 0.7476 ∗ 4
= 1.410𝑚2

• Vol (BTM-HHLL) = 1.410 * 5.2 = 7.33𝑚3

• Vol (LLLL-HHLL) = 7.33 – 2 = 5.33 𝑚3

28
Holdup-Time Calculation

VLLLL−HHLL 5.33m3
ℎ𝑜𝑙𝑑𝑢𝑝 − 𝑡𝑖𝑚𝑒 = = = 2.01 𝑚𝑖𝑛
liquid volume flow 121650 1
∗
765.8 60

The calculated time was less than the required time, so our calculations encountered an error. To resolve
this, we need to increase the diameter. Since we did not reach a result with a diameter of 1.55, we will
consider a new diameter of 1.65 and repeat the calculations. To simplify the process, we will use Excel
for solving.
Excel Sheet

Example 4:
Design of the Reflux Drum for the De-Ethanizer Unit at Bid Boland Refinery
The operating temperature and pressure are 0.3°C and 24 bar, respectively. The mass flow rates and
densities of the gas and liquid phases are as follows:
• Gas: Mass flow rate = 95,818.15 kg/h, Density = 46.73 kg/m³
• Liquid: Mass flow rate = 178,933.35 kg/h, Density = 403.9 kg/m³

29
Answer:
We want to size this reflux drum according to the GPSA criteria, and it is important to note that this
reflux drum require a demister pad.

• K = 0.13 * 0.85 = 0.1105 m/s

ρl −ρv m
• Vs = K √ = 0.3054
ρv s
L
• Selected d
=3

To simplify the calculations, the sizing process will be continued in the Excel environment.

Click here to download excel sheet

3 Phase Separator

30
Internals of Three-Phase Separators
• Clamming Baffles

• Coalescing plate pack

• Anti Foam

• Double Plate Pack

31
3 Phase Separators Sizing:
• In the first step, separation is performed based on gas and liquid phases, and the vessel
dimensions are calculated.

• We set the L/D ratio equal to 3

• We consider the holdup time to be 4 minutes.

• We calculate the values of HLL and LLL. With these two values, we can determine the height
of the baffle
• The height of the baffle must be 75 mm less than the LLL of the light phase.

Boundary Conditions
• First Boundary Condition: Heavy Phase Droplet on the HLL of the Light Phase.

• Second Boundary Condition: Heavy Phase Droplet on the LLL of the Light Phase.

32
First Boundary Condition
Heavy Phase Droplet on the HLL of the Light Phase

Qw +QL
• Horizental Velocity at HLL → VHLL =
HLL Area

Ut,W 2
• Vertical fall from HLL → B ∗ VHLL
wich B is 3 L′

• HLL - Vertical fall shall be less than Baffle heights.

Second Boundary Condition:

Heavy Phase Droplet on the LLL of the Light Phase

Qw +QL
• Horizental Velocity at LLL → VLLL = LLL Area

Ut,W 2
• Vertical fall from LLL → B ∗ VLLL
wich B is 3 L′

• LLL - Vertical fall shall be less than Baffle heights.

The points mentioned refer to water droplets, which must fall before the baffle and reach below the
interface level of water and oil.

Boundary Conditions for oil

Qw +QL
• Horizental Velocity at LLL → VLLL = LLL Area

Ut,L 2
• Vertical Rise to LLL → B ∗ VLLL
wich B is 3 L′

If the vertical rise is greater than the baffle height, the calculations are correct.

33
Example 5:

Excel Sheet

34