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

Document number SD-V-T-S-2024 Prepared by Amirmasoud-Tavakol

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

Sizing and Design of a Vertical Two-Phase

Tittle Separator According to Total’s Procedure
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Introduction

The purpose of this document is to outline the sizing and design process for a vertical two-phase separator
following Total’s standard criteria. A two-phase separator is essential in separating gas and liquid phases in
industrial processes, ensuring the purity and stability of each phase for downstream processing. In this project,
we designed a vertical separator based on specific operational parameters, including flow rates, densities, and
required separation efficiency. The separator’s sizing was calculated to accommodate the gas and liquid
volumetric flows under given conditions while adhering to industry safety standards .

Key criteria used include:

1. Ensuring optimal gas-liquid separation efficiency

2. Determining the inlet and outlet nozzle sizes
3. Calculating the required vessel length and diameter based on holdup time and fluid characteristics .

This document details each step of the design process, along with explanations of the formulas and criteria
applied to achieve the final separator dimensions.

Design Criteria

In this design, where the knockout drum is for a compressor, the Length-to-Diameter (L/D) ratio should be
maintained between 2.5 and 5 to optimize economic conditions. This ratio directly impacts the weight of the
vessel, meaning that selecting an appropriate L/D can reduce construction costs and enhance the separation
efficiency within the vessel.

Process Description

The knockout drum is part of the sour gas sweetening unit's compressor and is designed to remove condensate
and water before the gas enters the absorption column. This separation step is essential to prevent potential
damage to the downstream compressor, ensuring smooth operation and reducing maintenance risks.
Calculations
data
- Operating Pressure: 3 bar
Operating Temperature: 15°C
Gas Mass Flow: 97690 kg/hr
Gas Density: 27.99 kg/m³
Liquid Mass Flow: 8514 kg/hr
Liquid Density: 755.4 kg/m³
Particle Size: 150 micron

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 755.4 − 27.99
= = 25.988 → 𝑉𝑠 = 0.18 𝑚/𝑠
𝜌𝑣 27.99
Based on the data and calculations, the settling velocity is equal to 0.18 meters per second. To calculate the gas
velocity, the settling velocity should be multiplied by 0.85 according to Total's criteria.
𝑚 𝑚
𝑉𝑔 = 0.18 ∗ 0.85 = 0.153
𝑠 𝑠
Calculation of Separator Area
𝑚𝑔 97690 1
𝜌𝑔 ∗
𝐴= = 27.99 3600 = 6.33𝑚2
𝑉𝑔 0.153

To calculate the diameter of a cylinder using the cross-sectional area, we use the following formula:

𝜋𝑑 2 4𝐴
𝐴= →𝑑= √ → 2.84𝑚
4 𝜋

The diameter of the vessel has been calculated and is equal to 2.84 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.

𝑚𝑙 + 𝑚𝑣 8514 + 97690
𝜌𝑚𝑖𝑥 = 𝑚 𝑚 = = 30.33
𝑙
+ 𝑣 8514 97690
𝜌𝑙 𝜌𝑣 +
755.4 27.99
𝑚𝑙 + 𝑚𝑣 8514 + 97690 m³ 1ℎ𝑟 m³
𝑚𝑚𝑖𝑥 = = = 3501 ( ) ∗ ∗ 1.1 = 1.07
𝜌𝑚𝑖𝑥 30.33 ℎ𝑟 3600𝑠 𝑠
m³
𝑚𝑚𝑖𝑥 1.07 𝑠 𝑚
𝑁𝑜𝑧𝑧𝑙𝑒 𝐴𝑟𝑒𝑎 = 2 = = 131.97
𝜋 ∗ (𝐷) 25.4 𝑠
𝜋 ∗ (4 ∗ 1000)2
4 𝑚 2
4
𝑚 𝑚 𝑚
5𝑖𝑛𝑐ℎ → 84.46 10𝑖𝑛 → 21 13𝑖𝑛 → 12.49
𝑠 𝑠 𝑠

• 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 =27.99 kg/m³

kg
97690 1hr m3
hr
mg = kg ∗ ∗ 1.1 = 1.0664
27.99 3 3600s s
m

m³
𝑚𝑔 1.07 𝑚
Nozzle Area = = 𝑠 = 17.38
𝜋 ∗ (𝐷) 2 25.4 𝑠
𝜋 ∗ (11 ∗ 1000)2
4 𝑚2
4

• 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 water discharge and between
2 and 4 meters per second for hydrocarbon 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
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 300 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 8514 1ℎ𝑟 1
• 2 min∗ ∗ ∗ = 2𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗ ∗ ∗ 1000 = 59.35𝑚𝑚
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦 60𝑚𝑖𝑛 𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎 755.4 3 60𝑚𝑖𝑛 6.33𝑚2
𝑚
• The value of h7 was found to be 59 millimeters, so we will select 150 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 8514 1ℎ𝑟 1
• 5 min∗ ∗ ∗ = 5𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗ ∗ ∗ 1000 = 148.37 𝑚𝑚
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦 60𝑚𝑖𝑛 𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎 755.4 3 60𝑚𝑖𝑛 6.33𝑚2
𝑚
• Since the minimum value provided is greater than the calculated height, we will consider the height of
this section to be 300 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 8514 1ℎ𝑟 1
• 2 min∗ ∗ ∗ = 2𝑚𝑖𝑛 ∗ ℎ𝑟
𝑘𝑔 ∗ ∗ ∗ 1000 = 59.3 𝑚𝑚
𝑙𝑖𝑞𝑢𝑖𝑑 𝑑𝑒𝑛𝑐𝑖𝑡𝑦 60𝑚𝑖𝑛 𝑉𝑒𝑠𝑠𝑒𝑙 𝐴𝑟𝑒𝑎 755.4 3 60𝑚𝑖𝑛 6.33𝑚2
𝑚
• 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 * (d)) or (400 + d/2) mm

25.4 13∗25.4
• 1.5 ∗ (13 ∗ 1000) = 0.4953 ∗ 1000 = 495.3 𝑚𝑚 𝑜𝑟 400 + ( 2
) = 565.1 𝑚𝑚
• h4 = 565.1 mm
h3 : has the greatest value of : ( 0.5 * (Vessel diameter)) , (minimum 600) mm

• 0.5*2.84*1000 =1420 mm or 600 mm

• h3 = 1420 mm

h2 :100 mm if mesh-pad selected or150 mm for compressor KOD

• h2 = 150 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) = 426 + 150 + 1420 + 565.1 + 200 + 300 + 150 + 300 =
3511.1 mm = 3.511 m
 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
Reflux Drum product
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.
3.511 𝑚
= 1.23
2.84 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.

Conclusion
In conclusion, the sizing and design of the vertical two-phase separator according to Total's criteria have been
thoroughly discussed. We have analyzed the operational parameters and calculated various dimensions and
specifications crucial for the effective functioning of the separator. The findings indicate that maintaining an
optimal L/D ratio is essential for performance efficiency. Although we encountered limitations due to fixed
diameter constraints in vertical separators, careful consideration of length adjustments can help balance the
economic viability with operational efficiency. This study reinforces the importance of precise calculations and
adherence to industry standards in ensuring the successful implementation of separation processes in the oil and
gas industry.