Guide

for
Vessel Sizing

Certified
DATE

DESCRIPTION

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Table of Contents

1.

Scope....................................................................................................................................3

2.

Introduction..........................................................................................................................3

3.

Selection Criteria for Vapor-Liquid Separators.....................................................................4

3.1

Orientation of the Vessel.............................................................................................................4

3.2

Feed Inlet....................................................................................................................................5
3.2.1

Inlet Nozzle..........................................................................................................................................5

3.2.2

Inlet device............................................................................................................................................5

3.3

Internals......................................................................................................................................6

3.4

Vessel Head.................................................................................................................................6

4.

Design Criteria for Vapor / Liquid Separators......................................................................7

4.1

Definition of Levels....................................................................................................................7

4.2

Vertical Vessels...........................................................................................................................7

4.3

4.2.1

Diameter of a Vertical Vessel................................................................................................................7

4.2.2

Height of a Vertical Vessel....................................................................................................................8

Horizontal Vessels.......................................................................................................................9
4.3.1

Size of a Horizontal Vessel...................................................................................................................9

4.3.2

Feed Inlet Device for Horizontal Vessels...........................................................................................12

Either a 90 elbow, or a half-open pipe can be used as inlet device for a horizontal vessel. A 90 elbow is
preferred as they are easier to fabricate. The following requirements are applicable for 90 elbow inlets:. .12
The diameter of the elbow must be the same as the nozzle diameter.......................................................12
4.3.3

4.4

4.5

4.6

5.

Boot.....................................................................................................................................................12

Additional Criteria....................................................................................................................14
4.4.1

Degassing............................................................................................................................................14

4.4.2

Foaming..............................................................................................................................................15

Sizing of Nozzles......................................................................................................................15
4.5.1

Feed Inlet Nozzle................................................................................................................................15

4.5.2

Vapor Outlet Nozzle...........................................................................................................................15

4.5.3

Liquid Outlet Nozzle..........................................................................................................................16

4.5.4

Manway..............................................................................................................................................16

4.5.5

Vents and Drains................................................................................................................................16

4.5.6

Nozzle Identification..........................................................................................................................16

Mist Eliminators.......................................................................................................................17
4.6.1

Sizing of Demister Pads.....................................................................................................................17

4.6.2

Demister in Vertical Vapor / Liquid Separators.................................................................................17

Design of Liquid / Liquid Separators..................................................................................18

5.1

Liquid-Filled Separators...........................................................................................................19

5.2

Liquid-Liquid Separators with Vapor Compartment..................................................................20

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6.

7.

1.

Computer Programs............................................................................................................22
6.1

Depsep......................................................................................................................................22

6.2

Separator..................................................................................................................................22

6.3

Excel Functions........................................................................................................................22
6.3.1

Horizontal Vessel Liquid Volume.......................................................................................................22

6.3.2

Horizontal Vessel Liquid Level..........................................................................................................22

6.3.3

Vertical Vessel Liquid Volume............................................................................................................22

6.3.4

Vertical Vessel Liquid Level...............................................................................................................23

6.3.5

Segmental Area from Elevation.........................................................................................................23

Appendices..........................................................................................................................23

Scope
This document shall be used for the process design of vessels, however, for specific
projects, these design rules may be superseded or modified by client requirements.
Applicable design rules for a specific project shall be specified in the Design Basis and
/ or the General Information and Instructions (GII) for the project.

2.

Introduction
In general the function of a vessel in a process unit is to either provide hold-up time
or to make a separation between the various phases of a mixed process stream. In this
design guide rules are given for the dimensioning of vessels, which are used for the
separation of mixed process streams. They can be divided into two categories:
Vapor / liquid separators, which are used to separate the vapor and liquid part of a
mixed stream.
Liquid / liquid separators, which are used to separate the two liquid phases of a
mixed stream.

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For both types of separators the design rules will be given in this design guide.

3.

Selection Criteria for Vapor-Liquid Separators

The configuration of a vapor/liquid separator depends on a number of factors. Before
making a vessel design one has to decide on the configuration of the vessel with
respect to among others:
Orientation
Type of feed inlet
Type of internals
Type of heads
Factors that help to make the chioce between the various alternatives are discussed in
this chapter.

3.1

Orientation of the Vessel

The selection of the orientation of a gas-liquid separator depends on several factors.
Both vertical and horizontal vessels have their advantages. Depending on the
application one has to decide on the best choice between the alternatives.
Advantages of a vertical vessel are:
a smaller plot area is required (critical on offshore platforms)
it is easier to remove solids
liquid removal efficiency does not vary with liquid level because the area in the
vessel available for the vapor flow remains constant
generally the vessel volume is smaller
Advantages of a horizontal vessel are:
it is easier to accommodate large liquid slugs;
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).
The preffered orientation for a number of typical vapor / liquid separation applications
are:
Application

Preferred orientation

Reactor Effluent Separator (V/L)

Vertical

Reactor Effluent Separator (V/L/L)

Horizontal

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Reflux Accumulator

Horizontal

Compressor KO Drum

Vertical

Fuel Gas KO Drum

Vertical

Flare KO Drum

Horizontal

Condensate Flash Drum

Vertical

Steam Disengaging Drum

Horizontal

3.2

Feed Inlet

3.2.1

Inlet Nozzle
The feed nozzle size and the type of feed inlet device (if any) have an impact on the
vapor / liquid separation that can be achieved. 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.

3.2.2

Inlet Device
Various inlet devices are available to improve the vapor / liquid separation. Among
others the following inlet devices may be installed:
A deflector baffle
A slotted tee distributor
A half-open pipe
A 90 elbow
A tangential inlet with annular ring
A schoepentoeter
For verticla drums, preferably a deflector baffle or a half open pipe shal be selected. In
case of a slug flow regime in the inlet piping, or if a high liquid separation efficiency is
required, a tangential inlet nozzle with annular ring can be used. However, in case a
high liquid removal efficiency is required, the application of a wire mesh demister is
preferred.
For horizontal drums normally a 90 elbow or a slotted diverter is installed. In some
cases a submerged inlet pipe is installed, but this shall not be done in the case of a
two-phase feed.
Normally the selected inlet device for a horizontal drum shall be:
a 90 elbow or a slotted diverter in case of an all liquid or vapor-liquid feed
a submerged pipe when the feed is a subcooled liquid and the mixing of liquid and
blanket gas is to be minimized

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 two 90 elbow inlets in case of high vapor loads

3.3

Internals
After passing through the feed inlet, the vapor stream will still contain liquid in the
form of droplets. The maximum soze of these entrained droplets depends on the vapor
upflow velocity. A separation device can reduce this entrainment significantly. Wire
mesh demister are the most commonly used as separation device. They are used for
two reasons:
To minimize entrainment
Of the drum services having such a requirement, suction drum 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 disadvantages of wire mesh demister are:
They are not suitable for fouling services
Their liquid removal decreases significantly at reduced throughput
Although the size of the vessel often can be reduced by applying a wire mesh
demister, there are also many services where there is normally no demister installed.
Reflux accumulators, for example, seldom have mist eliminators.
There are several other types of mist eliminators such as vanes, cyclones, and fiber
beds. They are used when conditions are not favorable for wire mesh screens.
Selection criteria for these types of internals are the required efficiency, capacity,
turndown, ratio, maximum allowable pressure drop and fouling resistance. These
types however will not be further addressed in this design guide.

3.4

Vessel Head
Most vessels have 2:1 elliptical heads, welded to the shell of the vessels. However, in
some cases other types of heads are used. The major alternatives are:

Flat heads
In case of small vertical vessels (diameter less than approximately 30) often a
flaged top head is used, which also serves to provide access to the vessel.
Depending on the pressure rating, this type of head can either be flat or elliptical,
and shall be selected in consultation with the mechanical engineer
Hemispherical heads

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 A hemispherical head should be considered for an extremely large, high-pressure

vessel
A dished head be considered in the case of a large diameter, low-pressure vessel

4.

Design Criteria for Vapor / Liquid Separators

4.1

Definition of Levels
In the sizing of vessels the the proper definition of hold-up time and liquid levels is
important. For the design of vessels the following shall be used:
Liquid hold-up time

Working volume between High Liquid Level

(HLL) and Low Liquid Level (LLL)

HLL

Upper end of the control span

LLL

Lower end of the control span

HLA

High Level Alarm, normally at 90% of the control span

LLL

Low Level Alarm, normally at 10% of the control span

4.2

Vertical Vessels

4.2.1

Diameter of a Vertical Vessel

The design of a vapor-liquid separator is based on the terminal settling velocity of a
liquid droplet of specified size, settling under the influence of gravity. This velocity is
given by:
v1

4 gDP ( l v )
l v
K1
3vC
v

(4.1)

where
v1

terminal settling velocity (m/s),

liquid density (kg/m3),

vapor density (kg/m3),

Dp

droplet diameter (m),

gravitational constant (9.81 m/s2),

dimensionless drag coefficient,

Kt

separation factor, or gas handling capacity )m/s2.

The vapor handling capacity (Kt) depends on the type of service of the vessel. Typical
values are:
Application
Horizontal KO drum
Vertical KO drum without demister

Kt
0.25 fps 0.08 m/s
0.15 fps 0.05 m/s

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Vertical KO drum with demister

Flare KO drum (essentially dry vapor)
Flare KO drum (wet vapor)

0.25 fps 0.08 m/s

0.25 m/s
0.10 m/s

The separator shall be large enough to handle the gas flow rate under the most severe
process conditions. For systems, which have a foaming tendency, sugh as glycol and
amine solutions, a derating factor of 0.7 0.8 shall be used for K t. A derating factor of
0.7 0.8 shall also be used for compressor suction knockout drums.
See paragrap 4.6 for the sizing of the demister mat.
4.2.2

Height of a Vertical Vessel

The total vessel height is the sum of the following contributions:
1. The height required for the Low Liquid Level (LLL)
The level instrument determines the LLL. For mechanical reasons, the nozzel of this
instrument should be at least 150 mm above the bottom tangent line. The level
instrument requires an additional 50 mm. Therefore the LLL is about 200 mm above
the bottom TL of a vessel. In case of doubt the instrument engineer shall be consulted
on the minimum required LLL.
2. The height required for the liquid hold-up
The liquid hold-up is defined as the volume between the High Liquid Level (HLL) and
the Low Liquid Level (LLL). This volume consists of the standard hold-up plus
additional volume in case of slug or trip-alarm levels. Typical hold-up times are:

Service
Feed to distillation column, reactor, heater
Reflux vessel
Flare KO drum
Condensate Flash drum
Fuel gas KO drum

Recommended hold-up
5-15 min.
3-5 min.
20-30 min.
3-5 min.
1)

1) As a minimum a Fuel Gas KO drum shall be sized to contain a slug of liquid

equivalent to the content of 6 mtr inlet piping.
If slugs of liquid can be expected, additional volume shall be provided to ensure that
the required vapor / liquid separation can still be achieved.
3. The clearance between the High Liquid Level and the inlet nozzle.
The clearance between the HLL and the inlet nozzle shall be 0.3 times the vessel
diameter, with a minimum of 0.3 m.
4. The diameter of the inlet nozzel.
The diameter of the inlet device depends on the inlet flow and on the type of inlet
device. See section 4.5.1 for the sizing criteria of the inlet nozzle.
5. The clearance between the inlet device and the top TL.
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The required clearance between the inlet nozzle and the top TL depends on the presence
of a demister.
Without a demister the clearance shall be 0.7 times the vessel diameter with a
minimum of 0.9 m.
With a demister the clearance shall be:
0.45 times the vessel diameter, with a minimum of 0.9 m to the demister, plus, 0.1 m
for the demister, plus
0.15 times the vessel diameter, with a minimum of 0.15 m for the clearance between
the demister and the top TL
The sizing is for a vertical vessel with and without a demister is summarized in figure
4.1.

4.3

Horizontal Vessels

4.3.1

Size of a Horizontal Vessel

The calculation of the diameter and the length of a horizontal vessel can not be
separated. The cross-section area of the vapor space is based on a maximum allowable
vapor velocity given by equation 4.1. The sizing of a horizontal vapor / liquid
separator is based on a trial-and-error method. The sizing method consists of the
following steps:
1. Calculate the required liquid volume (VLiq) based on the selected liquid dold-up
time. The liquid is given by:
VLiq = Liq V, Liq
where:
VLiq

the liquid volume for hold-up (m3)

Liq

the liquid hold-up (s)

V, Liq

the liquid volumetric flow rate (m3/s)

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Figure 4.1
2. As a first estimate, assume that the liquid volume is 60 % of the total volume.
Select an L/D ratio and calculate the vessel diameter. The vessel diameter is given
by:

D=

V Liq

1 L
0.6
4
D

(4.3)

where:
D

the diameter of the vessel (m),

L/D

the ratio between the length and the diameter (-).

If there are no other factors, which determine the L/D ratio of a vessel, the design
pressure is normally used to select this ratio. Recommended L/D ratioss are:
Vessel design pressure (Barg)

Recommended L/D

0<Pdesign<17

2.5

17< Pdesign<35

3.0 4.0

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Pdesign<35

4.0 6.0

3. Select the Low Liquid Level (LLL). Typically the LLL is set at 0.2 m, but it shall
be checked with the mechanical engineer whether is feasible. Calculate the crosssection area is given by:
ALLL sin
H

, and LLL 1 2 1 cos 2

ATot
2

(4.4)

where:
ALLL

the cross-sectional area below the LLL (m2);

ATot

the cross-sectional area of the vessel, D2 (m2)

the angle between the center and

the liquid-vapor interface at the vessel surface (-)

HLLL

the height of the low liquid level (m)

In Excel a special function is available for this calculation.

4. Calculate the total cross-sectional area required for the liquid by adding to the
cross-sectional area below the LLL the area required for the liquid hold-up. The
total liquid cross-sectional area is given by:
ATot, Liq = ALLL +

V Liq

(4.5)

5. Calculate the HLL, using similar formulas as in step 4, or the special function in
Excel. Determine the remaining vapor cross-sectional area.
6. Calculate maximum allowable vapor velocity using
vmax = Kt

l v
v

(4.6)

where:
vmax

maximum vapor velocity (m/s),

liquid density (kg/m3),

vapor density (kg/m3),

Kt

separation factor or gas handling

capacity (m/s).

For horizontal vessels Kt shall be taken as 0.25 fps (0.08 m/s).

7.

Check the actual vapor velocity.

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Based on the vapor space above the HLL, the actual vapor space must be
calculated and compared against the maximum allowable vapor velocity. In case
of a large required vapor area, two vapor inlet nozzles shall be considered,
thereby reducing the required vapor space by 50 %.
Based on the application some additional criteria aply:
A. Limitations on HLL
The HLL shall not be higher than 80 % of the diameter with a minimum heigh of
the vapor space of 0.3 m. If a demister is installed, the minimum height of the
vapor space is 0.6 m.
B. Space for inlet device
The vapor space must be sufficiently high to accommodate the feed inlet device.
At least 150 mm shall be available between the bottom of the inlet device and the
HLL .
4.3.2

Feed Inlet Device for Horizontal Vessels

Either a 90 elbow, or a half-open pipe can be used as inlet device for a horizontal
vessel. A 90 elbow is preferred as they are easier to fabricate. The following
requirements are applicable for 90 elbow inlets:
The diameter of the elbow must be the same as the nozzle diameter.
An impingement baffle should be installed opposite to the elbow to protect the
drum shell. The baffle diameter should be twice the inlet nozzle diameter. A
thickness of for the baffle plate is recommended.
The minimum distance between the elbow and the HLL is 150 mm (6).
The elbow should be installed as close as possible to the tangent line considering
reinforcement and fabrication requirements (150 mm).
Short radius elbows shall be used with 3 straight pipe inside the drum.

4.3.3

Boot
When there is a chance that the liquid contains some water or other immiscible fluid a
boot can be provided to collect the heavier fluid phase. A boot will only be selected if
the following criteria are satisfied:
De-oiling of the heavy liquid phase is not important
The ratio of the volumetric flow rates of the heavy and light liquid phase is smaller
than 0.2
In all other cases overflow/underflow weirs shall be used for proper liquid/liquid
separation.
The sizig of the boot diameter shall satisfy the following criteria:
The boot diameter shall not be more than 0.5 times the vessel diameter

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 the minimum boot diameter depends on the diameter of the vessel and shall be as
listed below:
Vessel Diameter (mm)

Min. Boot Diameter (mm)

D < 900

300

900<D<1400

400

D>1400

500

The aheavy liquid draw-off velocity shall not exceed 80% of the rising velocity of
the light liquid. Because of the small size of the droplets, in most cases the Stokes
law can be applied to calculate the rising velocity of the droplets. This results in:
vd

g Dd2 h l
18
c

(4.7)

where
vd

rising velocity of the droplet (m/s)

gravitational constant (9.81 m/s2)

Dd

the droplet diameter (m)

the density of the light liquid phase (kg/m3)

the density of the heavy liquid phase (kg/m3)

the dynamic viscosity of the continuous phase (Pa s)

The following criteria for droplet diameter (Dd) of the light phase are recommended:

Density (kg/m3)

Droplet diameter (m)

>850

125 (0.0005 inch)

<850

90 (0.0003 inch)

Moreover, the design settling velocity should be limited to 10 inch per minute even if
a higher rate is calculated.
The length of a boot shall be based on the following criteria:
Typically, allow about 5 minutes hold up for the heavy phase

The length of the boot (i.e the distance between the bottom of the vessel and the
bottom tangent line of the boot) should be at least 900 mm to allow a proper
interface level control and to accommodate all the nozzles for the control
instruments
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 The low liquid level for the liquid-liquid interface should be 200 mm above the
bottom tangent line. The high liquid level should be 200 mm below the bottom of
the vessel. This results in a distance between the low and high level of the liquidliquid interface of at least 500 mm
Additional vessel requirements when providing a boot:
The light liquid phase outlet shall extend 100 to 150 mm above the bottom of the
vessel, and be equipped with a vortex breaker
The light liquid phase outlet shall be located downstream of the boot and as close
as possible to the tangent line of the vessel
The boot shall be located on the opposite side from the inlet, as close as possible to
the tangent line. The distance is not determined by process reasons, but by the
saddle support. Therefore, contact with the mechanical department is required

4.4

Additional Criteria

4.4.1

Degassing
When good degassing of liquid is required, the dimensioning of the vessel shall also
satisfy criteria for the separation of gas bubbles out of the liquid phase. Because of the
small size of the bubbles, in most liquids the Stokes law can be applied to calculate the
rising velocity of the bubbles. This results in:
vv

g Dv2 l v
18

(4.8)

where
vv

rising velocity of the bubble (m/s)

gravitational constant (9.81 m/s2)

Dv

the bubble diameter (m)

the density of the light liquid (kg/m3)

the density of the vapour (kg/m3)

the dynamic viscosity of the liquid (Pa s)

It is generally assumed that proper liquid degassing is achieved when bubbles of 200
micron and larger are removed. In this case formula 4.8 can be simplified to:
vv 2.2 x10 8

l v

(4.9)

For vertical vessels it shall be ensured that the downward liquid velocity in the vessel
doesnt exceed the calculated rising velocity of the bubbles.

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For horizontal vessels it shall be ensured that the residence time below the low liquid
level will allow the selected minimum size bubble to travel the distance between the
vessel bottom and the loe liquid level.
4.4.2

Foaming
In case the handled has a tendency to foam, the design shall take this into
consideration. Although is no solid basis to do so, the following can be used as a
guide:
For horizontal vessels, add the height of the foam above the high liquid level, to
allow for the reduced vapor space for vapor/liquid disengagement. (typically 0.3
mtr or 1 ft)
For vertical vessels, Shell limits the downwards liquid velocity to:
vl 1.4 x10 4

l v

(4.10)

4.5

Sizing of Nozzles

4.5.1

Feed Inlet Nozzle

The internal nozzle diameter may be taken equal to that of the feed pipe, but also the
following momentum criteria shall be satisfied:
No inlet device:

2
m vm
< 1000

(4.11)

Half open pipe:

2
m vm
< 1500

(4.12)

Where:
m

the density of the mixture (MG + ML) / (QG + QL) (kg/m3)

vm

the velocity of the mixture (QG + QL) / (1/4 D2) (m/s)

Other momentum criteria are applicable for high vacuum units or other units where
the inlet velocity can be very high because of the low gas density.
4.5.2

Vapor Outlet Nozzle

The diameter of the gas nozzlet should normally be equal to that of the outlet pipe,
but also the following criterion shall be satisfied:

G vG2 < 3750

where:
G

the vapor density (kg/m3)

vG

the

vapor velocity (m/s)

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In High Vacuum Units this criterion may result in a high outlet velocity, leading to a
pressure drop which is too high. In that case, the gas outlet nozzle shall be sized such
that the pressure drop requirements between column and downstream system are met.
4.5.3

Liquid Outlet Nozzle

The diameter of the outlet nozzle shall be chosen in relation to the outlet line size
selected, and is often based on a liquid velocity of 1 m/s. As liquid circulating above
the liquid outlet nozzle may result in vortex formation, design shall include measures
to avoid this. This can be done in two ways:
Above adequate liquid height above the outlet nozzle. For checking the required
minimum liquid height above the outlet nozzle see graphs in Appendix I.
Install a vortex breaker
Normally vortex breakers are provided on outlet nozzles that serve as outlet to
pump.

4.5.4

Manway
The size of a manway is usually 24, unless internal devices require larger size for
installation. If the vessel diameter is 30 or less, a flaged head may be considered in
stead of a manway. For mechanical reasons, manway should be smaller that one-half
of the vessel inside diameter.

4.5.5

Vents and Drains

As defined in the Engineering Guide for the Preparation of Engineering Floe
Diagrams (BN-EG-UE208), para 5.2.4 the size of vents and drains on vessels shall be:
Vessel volume Drain ConnectionVent Connection
Up to 17 m3

17 to 200 m3

200 to 400 m3

400 to 700 m3

700 m3 and above

Additional to vents and drains vessels may be provided with steam out and utility
connections. Normally these connections are 2:.
4.5.6

Nozzle Identification
If not specifically defined for the project, the nozzles on a vessel shall be identified as
follows:
Process nozzles

N1, N2, N3 etc.

Instrument nozzles

K1, K2, K3, etc., where multiple nozzles for a single

instrument shall be identifiedK1A\B\C etc

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Manways

M1, M2 etc.

Relief Valves

RV1, RV2 etc.

Vents

V1, V2 etc.

Drains

4.6

D1, D2 etc.

Steam out connections

SO

Utility connections

UC

Mist Eliminators
In case a high liquid separation efficiency is required, a mist eliminator can be installed
to ensure the removal of smaller liquid droplets. Also a mist eliminator can be installed
to reduce the size of a vertical vapor/liquid separator. Normally a demister pad is
installed as mist eliminator.
Important:

4.6.1

In case a vessel is provided with a demister pad, the relief valve

protecting the vessel shall be mounted upstream of the demister pad to
reduce the change of blockage in the relief valve inlet and to reduce
pressure drop.

Sizing of Demister Pads

The demister pad is sized based on a maximum allowable vapor velocity through the
pad, given by vendor rules. A typical sizing rule for demister pads is given by equation
4.13 however for separators operating under vacuum conditions vendor information
shall be consulted.
vmax K t

l v
v

(4.13)

where:
vmax

Maximum vapor velocity through the demister (m/s),

liquid density (kg/m3),

vapor density (kg/m3),

Kt

separation factor, typically 0.11 m/s (0.35 fps).

The demister thickness is normally 100 mm or 4.

4.6.2

Demister in Vertical Vapor / Liquid Separators

For vertical vessels the following applies for the use of demister pads.
Horizontally installed demister pads:
The minimum clearance between the top of the vessel and the demister pad is the
larger of 12 or half the length of the longer side of the pad.

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 The design of the vessel remains the same as for a horizontal vessel without mist
eliminator, except for the minimum length, which is not specified from inlet to
outletnozzle but from inlet to demister pad.
In case separation efficiency of the vessel should be very high, two vertical and one
horizotal demister can be installed in the vapor phase. The vessel requires an inlet
nozzle at each end, terminated by an elbow or a half-open pipe, and one vapor
outlet nozzle at the center of the vessel. This setup reduces the required crosssectional vapor area by 50%. However, with small low-pressure vessels, the
savings from the smaller diameter may be offset by the cost of the vertical
demisters and the extra inlet.
For vertically installed demister pads:
The minimum thickness of the demister pad is 6.
The demister pad should extend from the top of the vessel to 0.1 m above the
bottom. The area between the mat and the bottom of the vessel shall allow free
pasage of liquid.
The distance between the inlet device and the front face of the demister mat shall
be at least 0.6 m or 0.5 times the vessel diameter D.
Typical cleint rules for this distance are:
SHELL: The distance shall be at least D.
EXXON: The verticla demister shall be located immediately downstream of the inlet
nozzle.
The distance between the downstream side of the outlet nozzle and the rear face of
the demister mat shall be at least 0.5D.

5.

Design of Liquid / Liquid Separators

Normally, liquis / liquid separation is achieved in a horizontal vessel, providing
adequate residence time to properly separate the required droplet size from both the
liquid phases.
Completely filled vessels with liquid draw-off via nozzles at the top and bottom of
the vessel
Vessels also providing vapor space, with overflow and underflow baffles, which are
separating the liquid / liquid separation compartment from compartments for liquid
draw-off
The former type of separators is used when there is no chance of vapor formation,
while the latter is used when there is a chance of vapor formation.
Rules for the design of calescor type liquid / liquid separators, where the separation is
enchaced by internals (e.g. plate packs, wire mesh), are not given in this design guide.
Design rules for this type of separator shall be based on vendor information.

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5.1

Liquid-Filled Separators
The sizing of a liquid filled liquid / liquid separator is based on the required residence
time for:
separating small droplets of light fluid from the heavy phase fluid
separating small droplets of heavy fluid from the light phase fluid
Based on the type of application, one of the two above metioned criteria may be
skipped.
The sizing of this type of liquid / liquid separators is based on trial end error and
requires the following steps:
1. Select vessel dimensions and interface levels (min. and max.)
Initial vessel dimensions can be selected based on an overall liquid residence time,
e.g. 15 minutes. Initial high and low rface levels can be selected to get a holduptime for both phases, with the interface at the normal level.
2. Calculate the droplet settling velocity for both phases
Because of the small size of the droplets , in most cases the Stokes law ca nbe
applied to calculate the settling velocity of the droplets. This results in:
vd

g Dd2 h l
18
c

(5.1)

where
Vd

settling velocity of the droplet

ravitational constant (9.81 m/s2)

Dd

the droplet diameter (m)

the density of the heavy fluid (kg/m3)

the density of the light fluid (kg/m3)

the dynamic viscosity of the continuous phase (Pa s)

3. Calculate the required residence time for both phases

The required residence time must be calculated for both phases, to allow the selected
droplet size to travel between the interface and the top or bottom of the vessel. These
residence times must be compared with the actual residence time of both phases at the
interface. Because of the shape of the vessel, it is required to check the required
residence time of both phases against the actual at various interface levels, e.g. the
low and high interface level.
Based on the outcome of the calculations a new set of (high and low) interface levels
Cn be selected, or a new size vessel.
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5.2

Liquid-Liquid Separators with Vapor Compartment

A liquid / liquid separator with a vapor compartment is well known, and often used as
the accumulator of an ejector based vacuum system. The sizing of these horizontal
vessels includes the sizing based on vapor / liquid separation as described before and
the sizing of the liquid / liquid separation. In this section only the sizing for liquid /
liquid separation is discussed. In case there is only a very small amount of vapor
flowing through the vessel, the High Level shall be taken at max. 80% of the diameter
of the vessel.
The liquid / liquid separators with a vapor compartment have three liquid
compartments, one for the liquid / liquid separation and one for the hold-up of the
separated light and heavy phase. These compartments are separated by overflow and
underflow baffles, which ensure a proper hold up time of the two phases in the
separating compartment.
Also the sizing of this type of liquid / liquid separator is based on trial and error and
requires the following steps:
1. Select vessel dimensions
Initial vessel dimensions can be selected based on an overall liquid residence time,
e.g. 15 minutes wit a HLL at 80% of the vessel diameter.
2. Select the heavy phase overflow baffle height and calculate the resulting interface.
By selecting the height of the heavy phase overflow baffle the liquid / liquid interface
can be calculated based on a pressure balance, using the following equation:
H1 x h = Hh x h + (H2-Hh) x l
where:
H1

the height of the heavy phase overflow baffle

H2

the height of the light phase overflow baffle

Hh

the height of the heavy phase in the separation compartment

the density of the heavy fluid (kg/m3)

the density of the light fluid (kg/m3)

As a starting value for H1 take it approximately 200 mm below H2.

3. Position the baffles
The overflow baffles must be positioned to get adequate hold in the overflow
compartments for proper control of the outgoing fluid. Normally a hold up of
approximately this shall be checked to minimize pressure drop.
The distance between heavy phase underflow and overflow normally is 200 mm,
however this shall be checked to minimize pressure drop.
4. Check the liquid / liquid separation
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To check the liquid / liquid separation the droplet dettling velocity for both phases
must be calculated. Because of the small size of the droplets, in most cases the Stokes
law can be applied to claculate the settling velocity of the droplets. This results in:
g Dd2 h l
vd
18
c

(5.2)

where
vd

settling velocity of the droplet (m/s)

gravitational constant (9.81 m/s2)

Dd

the droplet diameter (m)

the density of the heavy fluid (kg/m3)

the density of the light fluid (kg/m3)

the dynamic viscosity of the continuous phase (Pa s)

Based on the calculated interface level and settling velocities the required residence
time for the light and heavy fluid must be calculated and compared with the actual
residence times.
Based on the outcome og the calculations some of the assumed values have to be
adjusted. In case there are only minor differences between the actual and required
residence time, adjustment of the overflow and underflow baffles (in height and / or
location) will be sufficient, in the case of larger differences, the overall size of the
vessel will have to be adjusted.
Because of the fixed overflow baffles, the interface level will change with changes in
fluid densities. As this affects the separation, the design shall be checked for possible
changes in these densities. For the same reason it is recommended to have the top of
the heavy fluid overflow baffle adjustable (e.g. +/- 100 mm).

5. Check vapor / liquid separation

As a final check on the dimensions, the vapor / liquid separation must be checked
based on the vapor residence time and settling velocity of the light fluid droplets to be
removed from the vapor.

6.

Computer Programs
Various computer applications have been developed for the sizing of vapor / liquid
separators. These are:

6.1

Depsep
This program has been developed to size vapor / liquid separators based on the
Shell rules, as defined in Shell DEP no. 31.22.05.11-Gen. Of February 1991.

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The program is located on the network L drive, in the directory

L/Process/Bbvprog/Depsep.235. The program can be started from this directory.
A typical output is given in Appendix IV.

6.2

Separator
This program, originally a Lotus 123 spreadsheet, has been developed to size vapor /
liquid separators based on Badger and Shell rules, as defined in the Badger
Standard Data Book, section 7.1 of July 1976 and Shell DEP no. 31.22.05.11-Gen. of
February 1991. The program is now available as a standard Excel template.
Some typical outputs are given in Appendix V.

6.3

Excel Functions
In Excel a number of special functions have been developed to calculate vessel
characteristics. Among other the folowing functions have been developed:

6.3.1

Horizontal Vessel Liquid Volume

Calculates the volume of liquid in a horizontal vessel based on vessel diameter, vessel
length, liquid level and type of head.

6.3.2

Horizontal Vessel Liquid Level

Calculates the liquid level in a horizontal vessel based on:
Vessel Diameter
Vessel Length
Liquid Volume
Type of Head

6.3.3

Vertical Vessel Liquid Volume

Calculates the volume of liquid in a vertical vessel based on:
Vessel Diameter
Vessel Length
Liquid Level
Type of Head

6.3.4

Vertical Vessel Liquid Level

Calculates the liquid level in a horizontal vessel based on:
Vessel Diameter

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 Vessel Length
Liquid Volume
Type of Head
6.3.5

Segmental Area from Elevation

Calculates the cross sectional area of a horizontal vessel below a given level based on:
Vessel diameter
Level height

7.

Appendices
I

Graphs

II

Typical Vessel Calculations

III

Typical Data Sheet

IV

DEPSEP Output

SEPARATOR Output

Typical Vessel Calculations

PROCESS CALCULATION
GENERAL
Title

Demo

Project

Design Guides

Client

Design Guide

Signature

AGO

Unit

Vapor / liquid separation

Location

Nowhere

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Design of a vertical vapor / liquid separator

Liquid
Vapor
Flow
20000
12000 kg/hr
Density
650
3.5 kg/m3
Volume
30.77
Selected vessel configuration

Note

Bold numbers are input values

3428.57 m3/hr
No demister
No inlet device

VESSEL DIAMETER
Selected K value

0.15 fps
0.0457 m/s
0.62 m/s
1.53 m2
1.40 m

Max. vapor velocity

Min. cross sectional area
Min. diameter

Use

1.400 mtr

VESSEL HEIGHT
Step 1 Set the Low Liquid Level
LLL
Step 2 Set the height for liquid hold-up
Required liquid hold-up
5 min.
2.56 m3
LLL->HLL
1.67 mtr

Use

1.700 mtr

Step 3 Set clearance HLL to inlet nozzle

1 Min. distance
0.3 mtr
2 0.3 x diam.
0.42 mtr

Use

0.420 mtr

Step 4 Inlet nozzle

Sizing basis inlet nozzle:rho v2
rho mix
v2
v
Total volume
Amin nozzle
Dmin

1000
9.25 kg/m3
108.10
10.40 m/s
3495.34 m3/hr
0.96 m3/s
0.092 m2
0.343

Use

0.356 mtr

0.9 m
0.98 m

Use

1.000 mtr

Total TL to TL diastance
Use

3.676 mtr
Vessel TL / TL
Vessel diameter

Step 5 Inlet nozzle to Top TL

1 Min. distance
2 0.7 x diam.

Nozzle sizes
Feed nozzle
Vapor outlet nozzle
Sizing basis:
rho vapor
v2
v
Total volume
Amin nozzle
Dmin
Liquid outlet nozzle
Sizing basis:
Total volume

3.700 mtr
1.400 mtr

14 inch minimum
rho v2

v max

Amin nozzle
Dmin

3750
3.50 kg/m3
1071.43
32.73 m/s
3428.57 m3/hr
0.95 m3/s
0.029 m2
0.192 mtr
1 m/s
30.77 m3/hr
0.1 m3/s
0.009 m2
0.104 mtr

Use

8 inch

Use

5 inch

PROCESS CALCULATION
GENERAL
Title

Demo

Project

Design Guides

Client

Design Guide

Signature

AGO

Unit

Vapor / liquid separation

Location

Nowhere

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Design of a horizontal vapor / liquid separator

Liquid
Vapor
Flow
20000
12000 kg/hr
Density
650
3.5 kg/m3
Volume
30.77
3428.57 m3/hr
Vessel configuration
No demister
No inlet device
Step 1 Required volum for liquid hold-up
Required liquid hold-up
5 min.
2.56 m3
Step 2 Set the diameter and L/D ratio
HLL as percentage of diameter
Selected L/D
Vessel diameter
Vessel TL/TL
Step 3 Set the Low Liquid Level
LLL
Area below LLL

50.00 % (estimate)
2.5
1.377 m tr
3.443 mtr

Note

Use
Use

Bold numbers are input values

1.500 mtr
3.750 mtr

0.2 mtr
0.14 m2

Step 4 Calculate required area below HLL

Area required for liquid hold up
0.68 m2
Area required below HLL
0.82 m2
Step 5 Calculate required HLL for liquid hold up
HLL required for liquid hold up
0.710 mtr
Step 6 Calculate the allowable vapor velocity
Selected K value
0.25 fps
0.0762 m/s
Max. vapor velocity
1.04 m/s
Step 7 Calculate the actual vapor velocity based on HLL
Area available above HLL
0.94 mtr
Actual vapor velocity
1.01 m/s
Nozzle sizes
Sizing basis inlet nozzle: rho v2
rho mix
v2
v
Total volume

1500 (half open pipe)

9.25 kg/m3
162.16
12.73 m/s
3459.34 m3/hr
0.96 m3/s
0.075 m2
0.310 mtr

Amin nozzle
Dmin
Vapor outlet nozzle
Sizing basis:
Rho vapor
v2
v
Total volume
Amin nozzle
Dmin
Liquid outlet nozzle
Sizing basis:
Total volume

rho v2

v max

Amin nozzle
Dmin

3750
3.50 kg/m3
1071
32.73 m/s
3428.57 m3/hr
0.95 m3/s
0.029 m2
0.192 mtr
1 m/s
30.77 m3/hr
0.1 m3/s
0.009 m2
0.104 mtr

Use

14 inch

Use

8 inch

Use

5 inch

PROCESS CALCULATION
GENERAL
Title

Demo

Project

Design Guides

Client

Design Guide

Signature

AGO

Unit

Vapor /Liquid / Liquid separation

Location

Nowhere

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Design of a horizontal vapor / liquid separator

Liquid
Vapor
Flow
20000
12000 kg/hr
Density
650
3.5 kg/m3
Volume
30.77
3428.57 m3/hr
Vessel configuration
No demister
No inlet device
Step 1 Required volum for liquid hold-up
Required liquid hold-up
5 min.
2.56 m3
Step 2 Set the diameter and L/D ratio
HLL as percentage of diameter
Selected L/D
Vessel diameter
Vessel TL/TL
Step 3 Set the Low Liquid Level
LLL
Area below LLL

50.00 % (estimate)
2.5
1.377 m tr
3.443 mtr

Note

Use
Use

Bold numbers are input values

1.500 mtr
3.750 mtr

0.2 mtr
0.14 m2

Step 4 Calculate required area below HLL

Area required for liquid hold up
0.68 m2
Area required below HLL
0.82 m2
Step 5 Calculate required HLL for liquid hold up
HLL required for liquid hold up
0.710 mtr
Step 6 Calculate the allowable vapor velocity
Selected K value
0.25 fps
0.0762 m/s
Max. vapor velocity
1.04 m/s
Step 7 Calculate the actual vapor velocity based on HLL
Area available above HLL
0.94 mtr
Actual vapor velocity
1.01 m/s
Nozzle sizes
Sizing basis inlet nozzle: rho v2
rho mix
v2
v
Total volume

1500 (half open pipe)

9.25 kg/m3
162.16
12.73 m/s
3459.34 m3/hr
0.96 m3/s
0.075 m2
0.310 mtr

Amin nozzle
Dmin
Vapor outlet nozzle
Sizing basis:
Rho vapor
v2
v
Total volume

rho v2

Amin nozzle
Dmin
Liquid outlet nozzle
Sizing basis:
Total volume

v max

Amin nozzle
Dmin

3750
3.50 kg/m3
1071
32.73 m/s
3428.57 m3/hr
0.95 m3/s
0.029 m2
0.192 mtr
1 m/s
30.77 m3/hr
0.2 m3/s
0.009 m2
0.104 mtr

Use

14 inch

Use

8 inch

Use

5 inch

PROCESS CALCULATION
GENERAL
Title

Demo

Project

Design Guides

Client

Design Guide

Signature

AGO

Unit

Vapor /Liquid / Liquid separation

Location

Nowhere

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Design of a horizontal liquid / liquid separator

Flow
Density
Viscosiy

Light fluid
50000
650
0.0004

Volume

76.9

Step 1

Heavy fluid
50000 kg/hr
880 kg/m3
0.0009 Pa s
56.8 m3/hr

Select vessel dimensions and interface levels (min. and max.)

Volume for

11 min. hold up
2.5
2.32 mtr
5.80 mtr

D min
L min
Volume for

Use

3 min. hold up of largest flow

HIL selected
NIL selected
LIL selected

Step 2

24.5 m3

1.28 mtr
1.15 mtr
1.02 mtr

3.85 m3

Volume below HIL

Volume below NIL
Volume below LIL

15.64 m3
13.64 m3
11.64 m3

Volume between LIL and HIL

4.00 m3

Calculate the droplet settling velocity for both phases

Droplet to be separated

100 micron
0.1
mtr
light fluid
droplet
1.31914E-03
0.10

Settling velocity
Check on Reynolds
Step 3

2.3 mtr
5.8 mtr

heavy fluid
droplet
3.1306E-03 m/s
0.69

Calculate the required residence time for both phases

Residence time continuous phase required at Low Interface Level

Actual residence time continuous phase

733
738

409 sec
603 sec

Residence time continuous phase required at Normal Interface Level

Actual resicende time continuous phase

827
864

367 sec
509 sec

Residence time continuous phase required at High Interface Level

Actual residence time continuous phase

920
991

326 sec
416 sec

Note:

Bold numbers are input values

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Step 4

Check the liquid / liquid separation

Separation compartment
Volume below light fluid overflow baffle
Volume below interface

12.72 m3
10.33 m3

Light fluid volume in separation compartment

Heavy fliud volume in separation compartment

2.39 m3
10.33 m3

Droplets to be separated

100 micron
0.0001 mtr

Settling velocity
Check on Reynolds
Travelling distance
Residence time continuous phase required
Actual residence time continuous phase
Step 5

heavy drop
4.7639E-03 m/s
1.19
0.34 mtr
72 sec
112 sec

Check vapor / liquid separation

Settling velocity light phase droplet in vapor

Travelling distance (top of vessel to light fluid overflow baffle)
Residence time vapor phase required
Actual residence time

Note:

light drop
2.1173E-03
0.15
1.58
745
744

0.87 m/s
0.48 mtr
0.55 sec
232 sec

Bold numbers are input values

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PROCESS DATA SHEETS FOR:

B211
Benzeen Destillaat Vat

UNIT:
CLIENT:
PROJECT:
LOCATION:
CLIENT REF.:

1100
BASF - Antwerp
2215.20
Antwerp - Belgium
1696

This document contains proprietary information belonging to Washington Group International its parent and/or affiliated companies and shall be used
only for the purpose for which it was supplied. It shall not be copied, reproduced or otherwise used, nor shall such information be furnished in whole or
in part to others, except in accordance with the terms of any agreement under which it was supplied or with the prior written consent of Washington
Group International and shall be returned upon request.
CLIENT

16/01/2002
ISSUE

Certified

DATE
ID. NO.

BASF

DESCRIPTION

Washington Group
Romania S.R.L.

DOC.NO.

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Process Data sheet for:

B211

TOWER / VESSEL / REACTOR

1
2

CASE1

Controlling: Yes

OPERATING / MECHANICAL DATA

Service
Orientation

Benzeenkolom Reflux Vat

Horizontal

Description
DRUM
Average liquid density
Operating temepratures - max. / normal / min.
Operating pressure
- max. / normal / min.
- normal / min. vac. conditions
Design temperature, max. min.
Design pressure, internal
Design vacuum condition, pressure / temperature
Steam-out condition, pressure / temerature
Pressure drop over trays / packing
Packing type
Packing bulk density
Number / height per packed bed
Total packed height
Trays, type
Trays, number / spacing
Total operating liquid volume, trays / packing
Tracing type / min. holding temperature
Hazardous service
Sour service / wet H2S severity category
Special service conditions
Max. H2 partial pressure
Max. H2S partial pressure
Inside diameter of shell
Length between tangent lines
Type of heads
Insulation type
Stress relieve for process reasons
Max. liquid volume, bottom

Units

MATERIAL SPECIFICATION / GENERAL

Shell
Internal cladding
Internals, removable
Corrosion allowance, internal / external
Corrosion allowance, removable internals
Internal cllading / weld overlay
Internal coating
Internal refractory lining

NOTES

ID. NO.

DOC.NO.

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Process Data sheet for:

B211

TOWER / VESSEL / REACTOR

CASE1

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Controlling: Yes
DOC

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1
2

OPERATING / MECHANICAL DATA

Service
Orientation

Benzeenkolom Reflux Vat

Horizontal

Description
DRUM
Average liquid density
Operating temepratures - max. / normal / min.
Operating pressure
- max. / normal / min.
- normal / min. vac. conditions
Design temperature, max. min.
Design pressure, internal
Design vacuum condition, pressure / temperature
Steam-out condition, pressure / temerature
Pressure drop over trays / packing
Packing type
Packing bulk density
Number / height per packed bed
Total packed height
Trays, type
Trays, number / spacing
Total operating liquid volume, trays / packing
Tracing type / min. holding temperature
Hazardous service
Sour service / wet H2S severity category
Special service conditions
Max. H2 partial pressure
Max. H2S partial pressure
Inside diameter of shell
Length between tangent lines
Type of heads
Insulation type
Stress relieve for process reasons
Max. liquid volume, bottom

Units

MATERIAL SPECIFICATION / GENERAL

Shell
Internal cladding
Internals, removable
Corrosion allowance, internal / external
Corrosion allowance, removable internals
Internal cllading / weld overlay
Internal coating
Internal refractory lining

NOTES

ID. NO.

DOC.NO.

3 of 5

Process Data sheet for:

1
Mark
2
3

TOWER / VESSEL / REACTOR

Service

B211

Size

Remarks

PROCESS CONNECTIONS

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Inlet

Hall open pipe with open end

Pump Min. Flows

PSV discharge
Reflux Outlet
Product Outlet
Vapor Out
Drain
Equalizing Line
Steam Out
Vent

Vortex breaker
Vortex breaker

INSTRUMENT CONNECTIONS

14
15

Level gauge
Level gauge
Level Control
Level Control
Pressure Control
Pressure Gauge
OTHER CONNECTIONS

22
23

Manhole

NOTES

ID. NO.

ISSUE

SHEET

4 of 5

-F

Process Data sheet for:

1

DOC.NO.

B211

TOWER / VESSEL / REACTOR

CASE1

Controlling: Yes

REMARKS

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DEPSET Output

DEPSET, Gas/Liquid Separator Design (v. 1.11)

SIGN
: AGO
TITLE
: Nowhere
SUBJECT : Separating vapor & liquid
DATE
: 01-Aug 2000
TIME : 11.35 AM

BADGER B.V.
JOB NO : Design Gu
UNIT
: V-1000
SHEET : 1 of 2

VESSEL CONFIGURATION:
Horizontal vessel
No inlet device
No demister
Flowmargin 0%

Eliptical vessel heads

De-foaming is not required
De-degassing is not required

PROCESS DATA:

Vapor

Liquid

Water

Mixed

Mass flow
[kg/s]
3.33
Volume flow
[m3/s]
0.9514
Density
[kg/m3]
3.50
Viscosity
[cP]
0.001
Slug volume
Required liquid holdup for control purposes

5.56
0.0086
650.00
0.100

0.00
0.0000
967.00

8.89
0.9600
9.26

PROGRAM DEFAULTS:

LZA(LL)

Minimum distances
[m]
Intervention time
[s]
Required Length / Diameter
NOZZLES:
Nominal diameter used
Required accord. DEP

0.0 m3 (0 s holdup)
300 s
(5.00 min)

LA(L)
0.200
2.500 -

[inch]
[inch]

Inside diameter
[m]
Outside diameter
[m]
Velocity
[m/s]
Calc. rho*vel2
[Pa]
Max. rho*vel2
[Pa]
Pressure drop
[kPa]
Total pressure drop is 1.00 kPa
LIQUID DROPLET IN VAPOR:
Max. liquid droplet diam.
Max. liquid droplet diam.

Inlet
16.0
16.0
0.381
0.406
8.42
657
1000
0.33

36 micron
37 micron

LA(H)
0.000
0

Vapor
8.0
8.0

Liquid
5.0
5.0

0.203
0.219
29.48
3041
3750
0.67

0.128
0.141
0.66

LZA(HH)
0.000
0

At low level, LA(L)

At high level, LA(H)

!! WARNING ARE PRINTED ON SHEET 2 !!

ID. NO.
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FOAM
0.000

DEPSET, Gas/Liquid Separator Design (v. 1.11)

SIGN
: AGO
TITLE
: Nowhere
SUBJECT : Separating vapor & liquid
DATE
: 01-Aug 2000
TIME : 11.35 AM

BADGER B.V.
JOB NO : Design Gu
UNIT
: V-1000
SHEET : 1 of 2

VESSEL CONFIGURATION:
Horizontal vessel
No inlet device
No demister
Flowmargin 0%

Eliptical vessel heads

De-foaming is not required
De-degassing is not required

PROCESS DATA:

Vapor

Liquid

Water

Mixed

Mass flow
[kg/s]
3.33
Volume flow
[m3/s]
0.9514
Density
[kg/m3]
3.50
Viscosity
[cP]
0.001
Slug volume
Required liquid holdup for control purposes

5.56
0.0086
650.00
0.100

0.00
0.0000
967.00

8.89
0.9600
9.26

PROGRAM DEFAULTS:

LA(L)

LA(H)

LZA(HH)

0.200

0.000
0

0.000
0

LZA(LL)

Minimum distances
[m]
Intervention time
[s]
Required Length / Diameter
NOZZLES:
Nominal diameter used
Required accord. DEP

0.0 m3 (0 s holdup)
300 s
(5.00 min)

2.500 [inch]
[inch]

Inside diameter
[m]
Outside diameter
[m]
Velocity
[m/s]
Calc. rho*vel2
[Pa]
Max. rho*vel2
[Pa]
Pressure drop
[kPa]
Total pressure drop is 1.00 kPa
LIQUID DROPLET IN VAPOR:
Max. liquid droplet diam.
Max. liquid droplet diam.

Inlet
16.0
16.0
0.381
0.406
8.42
657
1000
0.33

36 micron
37 micron

Vapor
8.0
8.0

Liquid
5.0
5.0

0.203
0.219
29.48
3041
3750
0.67

0.128
0.141
0.66

At low level, LA(L)

At high level, LA(H)

!! WARNING ARE PRINTED ON SHEET 2 !!

ID. NO.
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FOAM
0.000

DEPSET, Gas/Liquid Separator Design (v. 1.11)

SIGN
: AGO
TITLE
: Nowhere
SUBJECT : Separating vapor & liquid
DATE
: 01-Aug 2000
TIME : 11.35 AM

BADGER B.V.
JOB NO : Design Gu
UNIT
: V-1000
SHEET : 1 of 2

VESSEL CONFIGURATION:
Horizontal vessel
No inlet device
No demister
Flowmargin 0%

Eliptical vessel heads

De-foaming is not required
De-degassing is not required

PROCESS DATA:

Vapor

Liquid

Water

Mixed

Mass flow
[kg/s]
3.33
Volume flow
[m3/s]
0.9514
Density
[kg/m3]
3.50
Viscosity
[cP]
0.001
Slug volume
Required liquid holdup for control purposes

5.56
0.0086
650.00
0.100

0.00
0.0000
967.00

8.89
0.9600
9.26

PROGRAM DEFAULTS:

LZA(LL)

Minimum distances
[m]
Intervention time
[s]
Extra distance BTL-LZA (LL) for mounting of
NOZZLES:
Nominal diameter used
Required accord. DEP

[inch]
[inch]

Inside diameter
[m]
Outside diameter
[m]
Velocity
[m/s]
Calc. rho*vel2
[Pa]
Max. rho*vel2
[Pa]
Pressure drop
[kPa]
Total pressure drop is 1.00 kPa
VESSEL HEIGHT:
High level LZA(HH)
X1 (LZA(HH) inlet)
X2 (OD inlet)
X3 (inlet top)

Inlet
16.0
16.0
0.381
0.406
8.42
657
1000
0.33

0.0 m3 (0 s holdup)
300 s
(5.00 min)

LA(L)

LA(H)

LZA(HH)

0.200
0.000

0.000

0.000

0
levelgauge nozzle is 0.000 m.
Vapor
8.0
8.0

Liquid
5.0
5.0

0.203
0.219
29.48
3041
3750
0.67

0.128
0.141
0.66

Used
1.900 m
0.420 m
0.406 m
1.260 m

DEP default
0.420 m
0.406 m
1.260 m

!! WARNING ARE PRINTED ON SHEET 2 !!

ID. NO.
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FOAM

DEPSET, Gas/Liquid Separator Design (v. 1.11)

BADGER B.V.

SIGN
: AGO
TITLE
: Nowhere
SUBJECT : Separating vapor & liquid
DATE
: 01-Aug 2000
TIME : 11.35 AM

JOB NO : Design Gu
UNIT
: V-1000
SHEET : 1 of 2

MAXIMUM DROPLET SIZES:

Liquid in vapor outlet
[micron]

at LA (L)
112

at LA (H)
112

RESULTS:
Volumetric gas load factor
Maximum allowable gas load factor
Min. vessel cross-sectional area for gas flow
Liquid control volume between LA (L) and LA (H)
Selected diameter
Cros-sect. Area
Gas cap height
Vessel volume
Vessel H / D
Vessel height
Holdup LZA (HH)

1.400 m
1.539 m2
2.086 m
6.85 m3
2.847 3.986 m
342 s

0.070 m3/s
0.070 m/s
1.000 m2
2.617 m3
SIZING CRITERIA [m]
Gas handling capacity
Liquid de-gassing
Liquid de-foaming
Normal level

:
1.128
: N.A.
: N.A.
1.050 m

CONTROL LEVELS:
LZA(LL)

LA(L)

LA(H)

LZA(HH)

0.200
0.200
36
36

0.000
0.200
0
36

1.700
1.900
306
342

0.000
1.900
0
342

0.000
1.900

MINIMUM REQUIRED: (from DEP)

Distance
[m]
0.200
Level
[m]
0.200
Incremental holdup [s]
0
Cumulative holdup [s]
0

0.000
0.200
0
0

0.000
0.200
300
300

0.000
0.200
0
300

0.000
0.200

USED:
Distance
[m]
Level
[m]
Incremental holdup [s]
Cumulative holdup [s]

WITH FOAM

WARNINGS:
The selected diameter is not equal to the minimum diameter provided
The Shell DEP prefers an inlet device for vertical vessels
The selected diameter and/or level distances are not optimal

ID. NO.
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SEPARATOR Output
PROCESS CALCULATION
VAPOR / LIQUID SEPARATOR DESIGN
Title
Client
Unit
Item Name

Process Design Guide

RE & C
U100
Vapor Liquid Separator

Project
Signature
Location
Item number

B0030
AEO
The Hague, Netherlands
MS-101

Flows and properties

Mass flow rate
Density
Viscosity

Vapor
12000
3.5
0.001

Liquid 2)
20000
650
1

Water 2)
kg/h
kg
cP

Vessel sizing and design

Orientation
Demister
Inlet device
Head type

Estimates for preliminary sizing:

L/D
LLL from TL
HLL from TL
Hold-up LLL-HLL
Water droplet

Vertical
Yes
Yes
Eliptical

Inlet nozzle v2

1500

kg/m.s2 (max, default = 1500)

Vapor Out v2
Liq. Out velocity

3750
1

kg/m.s2 (max, default = 3750)

m/s (max, default = 1)

Minimum Diameter calculated from estimates:

Based on:
Vap/Liq. Sep.
1082
mm
Hold-up LLL+HLL
1478
mm
Water droplet size
mm
Degassing
922
mm
Defoaming
1519
mm

Minimum Length calculated from estimates:

Based on:
Hold-up LLL+HLL

Selected dimensions
Diameter
Height
LLL
HLL

User selected dimensions

Change:
Change:
Change:
Change:

1550
3900
310
930

mm
mm
mm
mm

Results from selected dimensions

Hold-up LLL+HLL
Total Volume

5.1
6.7

min
m3

Liquid Velocity
Vapor Velocity

0.01
0.62

m/s
m/s

K-value Calcd
Max

0.15
0.25

ft/s (=0.05 m/s)

ft/s (=0.08 m/s)

Droplets/Bubbles:
Liquid in Vapor
Vapor in Liquid
Water in Liquid

118
126
-

Micron (no demister)

Micron
Micron

Pressure drop

0.01

bar

2.5
200
600
5

mm
mm
min
Micron

3696

mm

1400
200
1900

mm (1400 mm used)
mm (3900 mm used)
mm (200 mm used)
mm (1900 mm used)

1400
3900
2.79

mm
mm
-

Selected LLL
Selected HLL
HLL Feed
Feed Demister
Demister size
Demister - TTL

200
1900
443
900
100
222

mm
mm
mm (minimum)
mm (minimum)
mm (used)
mm (minimum)

Feed nozzle
Vapour out nozzle
Liquid

14
8
5

Vessel dimensions summary:

Selected Diameter:
Selected Length:
L/D Calculated:

inch (= 336.6 mm)

inch (= 202.7 mm)
inch (= 128.2 mm)

Notes:
1) Reference: BADGER Standard Databook Section 7.1 (July 1976) and Design Vessel Sizing (August 2000)
2) The Water phase is reffered to only as 2nd liquid phase. In case of e.g. a steam drum, use Liquid phase column for water data

ID. NO.
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PROCESS CALCULATION
VAPOR / LIQUID SEPARATOR DESIGN
Title
Client
Unit
Item Name

Process Design Guide

RE & C
U100
Vapor Liquid Separator

Project
Signature
Location
Item number

B0030
AEO
The Hague, Netherlands
MS-101

Flows and properties

Mass flow rate
Density
Viscosity

Vapor
12000
3.5
0.001

Liquid 2)
20000
650
1

Water 2)
kg/h
kg
cP

Vessel sizing and design

Orientation
Demister
Inlet device
Head type

Estimates for preliminary sizing:

L/D
LLL from TL
HLL from TL
Hold-up LLL-HLL
Water droplet

Horizontal
None
None
Eliptical

Inlet nozzle v2
2

Vapor Out v
Liq. Out velocity

1500

kg/m.s2 (max, default = 1500)

3750
1

kg/m.s2 (max, default = 3750)

m/s (max, default = 1)

Minimum Diameter calculated from estimates:

Based on:
Vap/Liq. Sep.
1406
mm
Hold-up LLL+HLL
1638
mm
Water droplet size
730
mm
Degassing
575
mm
Defoaming
851
mm
Selected dimensions
Diameter
Length
LLL
HLL

1650
4200
200
600

mm
mm
mm
mm

Minimum Length calculated from estimates:

Based on:
Hold-up LLL+HLL
4094

User selected dimensions

Change:
Change:
Change:
Change:

Results from selected dimensions

Hold-up LLL+HLL
Total Volume

6.9
9.5

min
m3

Liquid Velocity
Vapor Velocity

0.01
0.95

m/s
m/s

K-value Calcd
Max

0.23
0.25

ft/s (=0.07 m/s)

ft/s (=0.08 m/s)

Droplets/Bubbles:
Liquid in Vapor
Vapor in Liquid
Water in Liquid
Pressure drop

33
68
0.01

Micron (no demister)

Micron
Micron
bar

2.5
200
600
5

Vessel dimensions summary:

Selected Diameter:
Selected Length:
L/D Calculated:

Selected LLL
Selected HLL
HLL Feed
Feed Top TL

Feed nozzle
Vapour out nozzle
Liquid

1600
300
800

mm
mm
min
Micron

mm

mm (1600 mm used)
mm (4200 mm used)
mm (300 mm used)
mm (800 mm used)

1600
4200
2.63

mm
mm
-

300
800
Vert. Vessel only
Vert. Vessel only
Vert. Vessel only
Vert. Vessel only

mm
mm

14
8
5

inch (= 336.6 mm)

inch (= 202.7 mm)
inch (= 128.2 mm)

Notes:
Reference: BADGER Standard Databook Section 7.1 (July 1976) and Design Guidelline Vessel Sizing (August 2000)
The Water phase is reffered to only as 2 nd liquid phase. In case of e.g. a steam drum, use Liquid phase column for water data

1)
2)

ID. NO.
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