E. Check. The results are checked throughout the trial-and-error procedure.

Naturally, they depend upon the validity of data used for the enthalpies and
CP.u callg-mole- o C Ks. At least the results appear to be self-consistent (that is, l: xi = 1.0, l: yi =
1.0) and are of the right order of magnitude. This problem was also solved us-
11.0 (est.)
ing Aspen Plus with the Peng-Robinson equation for VLE (see Chapter 2
39.66
Appendix). The results are xm = 0.0079, xP = 0.5374, xH = 0.4547, L = 1107.8,
45.58 and Ym = 0.7424, Yp = 0.2032, YH = 0.0543, v = 392.2, and Tdrum = 27.99 c.
With the exception of the drum temperature these results, which use differ-
ent data, are close.
F. Generalization. The use of the computer greatly reduces calculation time on
this double trial-and-error problem. Use of a process simulator that includes
VLE and enthalpy correlations will be fastest.

2.8 SIZE CALCULATION

Once the vapor and liquid compositions and flow rates have been determined, the flash
are found from
drum can be sized. This is an empirical procedure. We will discuss the specific procedure
first for vertical flash drums (Figure 2-1) and then adjust the procedure for horizontal flash
drums.
Step 1. Calculate the permissible vapor velocity, uperm'
'I F value. After
27.9 C. Obvi-
uperm- ~
-Kdrum ~~-L
__v

Table 2-6. Note Pv (2-59)

1verged V/F os-
; as the calcula- uperm is the maximum permissible vapor velocity in feet per second at the maximum cross-
sectional area. pL and Pv are the liquid and vapor densities. Kdrum is in ftls. .
Kdrum is an empirical constant that depends on the type of drum. For vertical drums the
value has been correlated graphically by Watkins (1967) for 85% of flood with no demister.
Approximately 5% liquid will be entrained with the vapor. Use of the same design with a
demister will reduce entrainment to less than 1% . The demister traps small liquid droplets on
fine wires and prevents them from exiting. The droplets then coalesce into larger droplets,
which fall off the wire and through the rising vapor into the liquid pool at the bottom of the
flash chamber. Blackwell (1984) fit Watkins' correlation to the equation
Calc T drum
(2-60)
27.903
21.385
25.149
23 .277
where F = - -
lv
WL~v
W p
v L
24.128
23.786 with WL and Wv being the liquid and vapor flow rates in weight units per hour (e.g., lb/hr).
23.930 ~
The constants are (Blackwell, 1984):
~
23.875 i' A= -1.877478097 c = - 0.1870744085 E = -0.0010148518
23.900 ~'
t; B = -0.8145804597 D = -0.0145228667
23.892 ~
' The resulting value for Kdrum typically ranges from 0.1 to 0.35.

?r2 Flash Distillation 2.8 Size Calculation 45

"
). I
 Step 2. Using the known vapor rate, V, convert uperm into a horizontal area. The vapor The height o
flow rate, V, in lb moles/hr is should be 12 in. J
free space is 18 in
u (.!!.)( 3600 s) A (ft2) (Ibm) The depth o
V ( Ib mo Ies) perm _:::__.,.:::::_
= __ S hr _____
c Pv ....:;.:__
ft3
v surge'
hr MW ( Ibm )
vapor lb mole

Solving for the cross-sectional area,

The geometry cm
V(MW.)
(261)

For a vertical drum, diameter D is

should be betwee
larger liquid surg1
' (2-62)
used. Calculator 1
well, 1984).
Usually, the diameter is increased.to the next Iargest ,6-in. increment.
For horizont
Step 3. Set the length/diameter ratio either by rule of thumb or by the required liquid
surge volume. For vertical flash drums, the rule of thumb is that htota/D ranges from 3.0 to
5.0. The appropriate value of htota/D within this range can be found by minimizing the total
vessel weight (which minimizes cost).
Calculate Ac fron
Flash drums are often used as liquid surge tanks in addition to separating liquid and va-
por. The design procedure for this case is discussed by Watkins (1967) for petrochemical ap-
plications.
The height of the drum above the centerline of the feed nozzle, hv, should be 36 in. plus and then the dian
one-half the diameter ofthe feed line (see Figure 2-14). The minimum of this distance is 48 in.

The typical range

v large liquid surge
horizontal drums
that in industries

T EXAMPLl
hv A vertical f

Feed l__ % n-hexan1

vapor that i
Nozzle rium data g
required?
.........-.....,......... Maximum
Level Solution
A. Define.
B. Explore
(2-63). I
L MWV. 1
FIGURE 2-14. Measurements for vertical flash drum and oft

46 Chapter 2 Flash Distillation 2.8 Size Calculatio

tl area. The vapor The height of the center of the feed line above the maximum level of the liquid pool, h1,
should be 12 in. plus one-half the diameter of the feed ljne. The minimum distance for this
free space is 18 in.
The depth of the liquid pool, hL' can be determined from the desired surge volume,
v,urge'

(2-63)

The geometry can now be checked, since

(2-61) k_ hv+hf+hL
D - D

should be between 3 and 5. These procedures are illustrated in Example 2-4. If h 101./D < 3, a
larger liquid surge volume should be allowed. If h101./D > 5, a horizontal flash drum should be
(2-62)
used. Calculator programs for sizing both vertical and horizontal drums are available (Black-
well, 1984).
For horizontal drums Blackwell (1984) recommends using
1e required liquid
anges from 3.0 to
nimizing the total Khorizontal = 1.25 Kvertical (2-64a)

ing liquid and va-

Calculate Ac from Eq. (2-61) and empirically determine the total cross sectional area Ar as,
Jetrochemical ap- (2-64b)

mid be 36 in. plus and then the diameter of the horizontal drum is,
s distance is 48 in.
Dhorizontal =~4 AT/ 1T (2-64c)

The typical range for h101./D is from 3 to 5. Horizontal drums are particularly useful when
large liquid surge capacities are needed. More detailed design procedures and methods for
horizontal drums are presented by Evans (1980), Blackwell (1984), and Watkins (1967). Note
that in industries other than petrochemicals that sizing may vary.

EXAMPLE 2-4. Calculation of drum size

A vertical flash drum is to flash a liquid feed of 1500 lb moles/hr that is 40 mole
% n-hexane and 60 mole % n-octane at 101.3 kPa (1 atm). We wish to produce a
vapor that is 60 mole % n-hexane. Solution of the flash equations with equilib-
rium data gives xH = 0.19, Tdrum = 378K, and V/F = 0.51. What size flash drum is
required?
Solution
A. Define. We wish to find diameter and length of flash drum.
B. Explore. We want to use the empirical method developed in Eqs. (2-59) to
(2-63). For this we need to estimate the following physical properties: pL' Pv'
MW v To do this we need to know something about the behavior of the gas
vertical flash drum and of the liquid.

Flash Distillation 2.8 Size Calculation 47

 C. Plan. Assume ideal gas and ideal mixtures for liquid. Calculate average pL by
assuming additive volumes. Calculate Pv from the ideal gas law. Then calcu-
late uperm from Eq. (2-59) and diameter from Eq. (2-63).
D. Do It.
1. Liquid Density
The average liquid molecular weight is Kdrum j
with V
4.

where subscript H is n-hexane and 0 is n-octane. Calculate or look up the

molecular weights. MW H = 86.17 and MW0 = 114.22. Then MW L =
(0.19)(86.17) + (0.81)(114.22) = 108.89. The specific volume is the sum of
mole fractions multiplied by the pure component specific volumes (ideal
mixture):

5.

From the Handbook of Chemistry and Physics, pH = 0.659 g/mL and p0 =

0.703 g/mL at 20 o C. Thus,

- 86.17 114.22
VL = (0.19) . + (0.81) 0. = 156.45 mL/g- mole
0 659 703

Then

_ MWL _ 108.89 = 0. 6960.g/mL

PL - VL - 156.45 Use a
6. If u:
2. Vapor Density E. Check.
Density in moles per liter for ideal gas is Pv = n/V= p/RT, which in grams per Note tl
liter is Pv = p MWv/RT. with m
The average molecular weight of the vapor is F. Gener:
be inse
lation <
practic
where yH = 0.60 and y0 = 0.40, and thus MWv = 97.39lb/lb-mole. This gives tombu

Pv= (l.Oatm)(97.39g/mole) 3.14 xlQ -3g/mL

(82.0575 mL atm )(378K) 2.9. USING EJ
moleK
Individual piece:
3. Kdrum Calculation. then available ei1
Calculation of flow parameter F1v: as used equipme
V = (VIF)(F),: (0.51)(1500) = 765lb moles/hr be used instead c
Wv = (V)(MW.) = (765)(97.39) = 74,503 lb/hr new equipment
L = F- V = 735 lb moles/hr new equipment;

48 Chapter 2 Flash Distillation 2.9 Using Existin~

 average PL by W L=(L)(MW L) =(735)(108.89) =80,034lb/hr
w. Then calcu-
F = '!!.J.,_) Pv = 80034 3.14 x w-3 = o.on2
lv Wv pL 74503 0.6960

Kdrum from Eq. (2-60) gives Kdrum = 0.4433, which seems a bit high but agrees
with Watkin's (1967) chart.
4.

tr look up the
uperm -K
- drum ~PL
-- -pv
-
'hen MWL =
Pv
is the sum of
olumes (ideal
= 0.4433 ~ 0 696~~~i~0314 = 6.5849ft/s

5.

mL and p0 = Ac=
uperm (3600) p v
(765)(97.39)( 454 g/lb)
(6.5849)(3600)(0.00314 g/mL)(28316.85 mL/ft3)
le
= 16.047 ft 2

D= r~c = 4.01 ft

Use a 4.0 ft diameter drum or 4.5 ft to be safe.

6. If use h1013 /D =4, htotal =4(4.5 ft) =18.0 ft.
E. Check. This drum size is reasonable. Minimums for hv and hr are easily met.
in grams per Note that units do work out in all calculations; however, one must be careful
with units, particularly calculating Ac and D.
F. Generalization. If the ideal gas law is not valid, a compressibility factor could
be inserted in the equation for Pv Note that most of the work involved calcu-
lation of the physical properties. This is often true in designing equipment. In
practice we pick a standard size drum (4.0 or 4.5 ft diameter) instead of cus-
le. This gives tom building the drum.

2.9. USING EXISTING FLASH DRUMS

Individual pieces of equipment will often outlive the entire plant. This used equipment is
then available either in the plant's salvage section or from used equipment dealers. As long
as used equipment is clean and structurally sound (it pays to have an expert check it), it can
be used instead of designing and building new equipment. Used equipment and off-the-shelf
new equipment will often be cheaper and will have faster delivery than custom-designed
new equipment; however, it may have been designed for a different separation. The chal-

Flash Distillation 2.9 Using Existing Flash Drums 49

 lenge in using existing equipment is to adapt it with minimum cost to the new separation
problem. Barnicki, S. D., "1
The existing flash drum has its dimensions htotai and D specified. Solving Eqs. (2-61) and Blackwell, W. W.,
(2-62) for a vertical drum for V, we have New York, 1984, c
Boublik, T., V. Fr:
7T(D )2 uperm (3600) Pv dam, 1984.
vmax 4MWv (2-65) Carlson, E. C., ''
Progress, 92 (10), .
This vapor velocity is the maximum for this existing drum, since it will give a linear vapor ve- Chien, H. H.-y., '~l
locity equal to uperm 957 (1994).
The maximum vapor capacity of the drum limits the product of (V/F) multiplied by F, Dadyburjor, D. B.
since we must have (April 1978).
Evans, F. L., Jr., E
(2-66) ed., Gulf Publishit
(V/F) F < VMax
Fredenslund, A., !
Group-Contributi,
If Eq. (2-66) is satisfied, then use of the drum is straightforward. If Eq. (2-66) is violated,
something has to give. Some of the possible adjustments are: Himmelblau, D.l\
tice-Hall, UpperS
a. Add chevrons or a demister to increase VMax or t~ reduce entrainment (Woinsky, 1994). King, C. J., Separa
b. Reduce feed rate to the drum. Lazzaroni, M. J., I
c. Reduce V/F. Less vapor product with more of the more volatile components will be pro- MOSCED Paramo
duced. search, 44, 4075 (2
d. Use existing drum~ inparallel. This reduces feed rate to each drum. Maxwell, J. B., Da
e. Use existing drums in series (see Problems 2.D2 and 2.D5). McWilliams, M. L
f. Try increasing the pressure (note that this changes everything-see Problem 2.Cl). Engineering, 80 (2
g. Buy a different flash drum or build a new one. Marsh, K. N., "T
h. Use some combination of these alternatives. Mixtures," Chemi
i. The engineer can use ingenuity to solve the proble~ in the cheapest and quickest way. Nelson, A. R., J. I
Operation to VLE
Perry, R. H., C. H
ed., McGraw-Hill,
2.10 SUMMARY-OBJECTIVES Perry, R. H. and I
Hill, New York, 1~
This chapter has discussed VLE and the calculation procedures for binary and multicompo- Poling, B. E., J. M.
nent flash distillation. At this point you should be able to satisfy the following objectives: McGraw-Hill, Ne\
Prausnitz, J. M., 1
1. Explain and sketch the basic flash distillation process Computer Calcutt
2. Find desired VLE data in the literature or on the Web Prentice-Hall, Up
3. Plot and use y-x, temperature-composition, enthalpy-composition diagrams; explain the Prausnitz, J. M., F
relationship between these three types of diagrams Fluid-Phase Equil
4. Derive and plot the operating equation for a binary flash distillation on a y-x diagram; Sandler, S. I., Che1
solve both sequential and simultaneous binary flash distillation problems Schad, R. C., "Ma
5. Define and use K values, Raoult's law, and relative volatility 1998).
6. Derive the Rachford-Rice equation for multicomponent flash distillation, and use it with Seider, W. D., J. I
Newtonian convergence to determine V/F 1999.
7. Solve sequential multicomponent flash distillation problems Smith, B. D., Desi
8. Determine the length and diameter of a flash drum Smith, J. M., H. C
9. Use existing flash drums for a new separation problem modynamics, 71h e
Smith, J. M. and f.
ed., McGraw-Hill,

50 Chapter 2 Flash Distillation References

~-
 1 .... 1

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i

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i
-- + s
- -+------'-- ---- -;------ ,-------

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------------~- -
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I
I

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;
- 1-
I

--.:
I

- ----- j __ __; _________ ..-! _ _ _ , --

-- ~ - t(~~u~--~
I
i.
.--- ,: - 4~

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i
----T ---~-----

1 ' '
-- ~------~---,---~----- -----
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-~
- -j
-,I - -:-----1--
'
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! I I
j
-i--'--~-; -~-.-- -
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