Column & Vessel - NS
Column & Vessel - NS
Column & Vessel - NS
Distillation History
Early distillation consisted of simple batch stills to produce ethanol. Crude ethanol was placed in a still and heated, and the vapor drawn from the still was condensed for consumption. Lamp oil was later produced using the same method, with crude oil heated in batch stills.
Process Design Basics of Column
Distillation History
Furnace
Condenser
Distillation History
Distillation Fractionation
Fractional distillation is the separation of a mixture into its component parts, or fractions, such as in separating chemical compounds by their boiling point by heating them to a temperature at which several fractions of the compound will vaporize. Fractional distillation in a laboratory makes use of common laboratory glassware and apparatuses, typically including a Bunsen burner, a round-bottomed flask and a condenser, as well as the single-purpose fractionating column.
Process Design Basics of Column
Distillation is by far the most important separation process in the petroleum and chemical industries. It is the separation of key components in a mixture by the difference in their relative volatility, or boiling points. It is also known as fractional distillation or fractionation. Distillation can consume more than 50% of a plants operating energy cost. Alternatives to distillation process : Solvent extraction, membrane separation or adsorption process. These processes often have higher investment costs. Therefore, distillation remains the main choice in the industry, especially in large-scale applications.
Process Design Basics of Column
Extractive Distillation
Reactive Distillation
Variations appear due to difficulty in separation when the physical properties of the components in a mixture are very close to one another, such as an azeotropic mixture.
Process Design Basics of Column
Fractional Distillation:
It is the separation of key components in a mixture by the difference in their relative volatility, or boiling points.
Extractive Distillation
An external solvent is added to the system to increase the separation. The external solvent changes the relative volatility between two close components by extracting one of the components, forming a ternary mixture with different properties. The solvent is recycled into the system after the extracted component is separated from it.
Process Design Basics of Column
Extractive Distillation
An external solvent is added to the system to increase the separation. The external solvent changes the relative volatility between two close components by extracting one of the components, forming a ternary mixture with different properties. The solvent is recycled into the system after the extracted component is separated from it.
Process Design Basics of Column
Reactive Distillation
A distillation column may also have a catalyst bed and reaction occurring in it. This type of column is called a reactive distillation column. The targeted component reacts when it is in contact with the catalyst, thereby separated from the rest of the components in the mixture.
Process Design Basics of Column
Reactive Distillation
A distillation column may also have a catalyst bed and reaction occurring in it. This type of column is called a reactive distillation column. The targeted component reacts when it is in contact with the catalyst, thereby separated from the rest of the components in the mixture.
Process Design Basics of Column
Reactive Distillation
Process Design Basics of Column
Industrial distillation
Industrial distillation
Distillation is the most common form of separation technology used in petroleum refineries, petrochemical and chemical plants, natural gas processing and cryogenic air separation plants.
Industrial distillation is typically performed in large, vertical Cylindrical columns known as "distillation or fractionation towers" or "distillation columns" with diameters ranging from about 65 centimeters to 6 meters and heights ranging from about 6 meters to 60 meters or more.
Process Design Basics of Column
Distillation Column/Fractionator
Critera of Distillation Column internals : To provide better mass and heat transfers between the liquid and vapor phases in the column. Include trays, packings, distributors and redistributors, baffles and etc. Promote an intimate contact between both Liq and Vap phases. The type of internals selected would determine the height and diameter of a column for a specified duty because different designs have various capacities and efficiencies.
Process Design Basics of Column
Feed :
Liquid Vapor Mixture of vapor-liquid
The vapor phase that travels up the column is in contact with the liquid phase that travels down.
Rectifying stages
Striping stages
The process below the feed tray is known as stripping Heavier components are being stripped off and concentrated in the liquid phase to form the bottom product. At the top of the column, vapor enters the condenser where heat is removed. Some liquid is returned to the column as reflux to limit the loss of heavy components overhead.
Process Design Basics of Column
All vapors leaving the top of the column is condensed to liquid so that the reflux stream and overhead product have the same composition.
Partial Condenser
In a partial condenser , only a portion of the vapor entering the condenser is condensed to liquid. Condensed liquid is refluxed into the column and the overhead product drawn is in the vapor form. In many cases only part of the condensed liquid is refluxed. In these cases, there will be two overhead products, one a liquid with the same composition as the reflux stream while the other is a vapor product that is in equilibrium with the liquid reflux.
Condenser
Total Condenser
All vapors leaving the top of the column is condensed to liquid so that the reflux stream and overhead product have the same composition.
Partial Condenser
Partial Condenser
In a partial condenser , only a portion of the vapor entering the condenser is condensed to liquid. Condensed liquid is refluxed into the column and the overhead product drawn is in the vapor form. In many cases only part of the condensed liquid is refluxed. In these cases, there will be two overhead products, one a liquid with the same composition as the reflux stream while the other is a vapor product that is in equilibrium with the liquid reflux.
Packed Column
Baffle Tray Random Packed Column Structur ed Packed Column Grid Packed Column
Valve Tray
Utilize a pressure and temperature differential to separate the products. For most tray columns, the weir holds a liquid level of each tray. Liquid enters from the downcomer of the tray above. The vapor must overcome this liquid head to move up the column. On the tray the vapor and liquid are contacted becomes bubble or froth where the mass transfer takes place and then above the tray they are separated where froth flows over the outlet weir and vapor with the light volatile compound is disengaged.
Process Design Basics of Column
Tray column performs well in high liquid and vapor loading. Tray have higher pressure drop than packed. Tray also have high resistance to corrosion.
Tray Column-Types
Five major types of tray column : Bubble Cap Sieve Dual Flow Valve Baffle
Shed Deck, Side to Side, Disk and donuts
Process Design Basics of Column
A bubble cap tray is perforated flat which has a riser (chimney) for each hole cover with a cap mounted. Equipped with slots to allow the passage of vapor then the vapor will contact with liquid forming bubble on the next tray. It is able to operate at low vapor and liquid rates (less than 2 gpm per foot of average of flow width).
Process Design Basics of Column
A bubble cap tray is perforated flat which has a riser (chimney) for each hole cover with a cap mounted. Equipped with slots to allow the passage of vapor then the vapor will contact with liquid forming bubble on the next tray. It is able to operate at low vapor and liquid rates (less than 2 gpm per foot of average of flow width).
Process Design Basics of Column
A bubble cap tray is perforated flat which has a riser (chimney) for each hole cover with a cap mounted. Equipped with slots to allow the passage of vapor then the vapor will contact with liquid forming bubble on the next tray. It is able to operate at low vapor and liquid rates (less than 2 gpm per foot of average of flow width).
Process Design Basics of Column
Sieve deck tray is perforated plate with holes punched into the plate usually has holes 3/16 to 1 diameter. Vapor comes out from the holes to give a multi orifice effect. The vapor velocity keeps the liquid from flowing down through the holes (weeping). The number and hole size are based on vapor flow up the tower. The liquid flow is transported down the tower by down-comers, a dam and overflow device on the side on the plate. Sieve deck tray has a minimum capacity approximately 70%
Process Design Basics of Column
Sieve deck tray is perforated plate with holes punched into the plate usually has holes 3/16 to 1 diameter. Vapor comes out from the holes to give a multi orifice effect. The vapor velocity keeps the liquid from flowing down through the holes (weeping). The number and hole size are based on vapor flow up the tower. The liquid flow is transported down the tower by down-comers, a dam and overflow device on the side on the plate. Sieve deck tray has a minimum capacity approximately 70%
Dual flow is a sieve tray without down comer. The term dual flow comes from the countercurrent flow of the vapor and liquid through the perforations. Vapor move up to the tray above through the hole while the liquid turn down in the same hole that result maldistribution and low efficiency. Typical perforation sizes range between 1/2 and 1 in diameter. Dual flow trays best suit systems containing a moderate to high solids content or polymerizable compounds. High open area dual flow trays have a higher capacity and lower pressure drop than comparably spaced fractionation trays.
Process Design Basics of Column
Valve Tray is using valve which is rise as vapor rate increase and then reduce as vapor rate fails.
Valve Tray is using valve which is rise as vapor rate increase and then reduce as vapor rate fails.
This stop the liquid from weeping. Valve can be round or rectangular, with or without caging structured. Valve disk rise as vapor rate increase. Valve tray has minimum capacity approximately 60%.
Baffle trays are trays of low fouling pot ential, with low efficiency. They have open areas approaching 50% where a high efficiency tray will have an open area of less than 15%. The down-comers require a disengaging area to separate the liquid from the vapor. This area requires a minimum distance that normally sets the tray spacing. The liquid is required to travel across the deck to the next down-comer. Baffle tray has three types: Shed Decks Trays Side to Side Trays Disk and Donuts Trays
Process Design Basics of Column
Because of their open design, baffle trays are used in applications requiring high capacity, fouling resistance and low pressure drop. Vapor-liquid contacting takes place when the vapor passes through a curtain of liquid falling between trays, or through rivulets of liquid flowing through tray deck perforations. Tray decks may be level or slightly inclined and typically occupy 40-60% of the tower cross-sectional area. . Baffle trays are well suited for heat transfer applications including heavy oil refining and petrochemical oil refining and petrochemical heat transfer services with high solids or petroleum coke content.
Process Design Basics of Column
Baffle Tray
Disk and donut trays
Disk and donut trays are slightly sloped trays that allow the liquid to splash from inner circle ring to outer circle ring. Fouling potential of this tray is low along with the efficiency.
Baffle Tray
Disk and donut trays
Disk and donut trays are slightly sloped trays that allow the liquid to splash from inner circle ring to outer circle ring. Fouling potential of this tray is low along with the efficiency.
Schematic of a disk and donut baffle tray column for use as a steam condenser
Baffle Tray
Disk and donut trays
Disk and donut trays are slightly sloped trays that allow the liquid to splash from inner circle ring to outer circle ring. Fouling potential of this tray is low along with the efficiency.
Shed decks are essentially angle iron beams of various sizes from two to ten inches that are placed in rows across the column. They typically are at on 24 inch tray spacing. They may be set in overlapping rows or rotated 90 degrees from tray to tray.
Packed column utilize packing to contact between the phases (liquid-vapor) on the surface. A major advantage to packed columns is the reduction in pressure across the column. Typically the column pressure drop for a packed column is less than that of a trayed col umn because of the percent open area. Typical percent open area of a trayed column is 8 to 15%, whereas a packed column can approach 50%. Packed column is advantageous than tray for reduced foaming since generates thin films instead of fine droplets for mass and heat transfer.
They have high open area, resulting in high capacity, low pressure drop, and high tolerance to fouling.
A tower design is normally divided into two main steps a process design followed by a mechanical design. The purpose of the process design is to calculate the number of required theoretical stages, column diameter and tower height. On the other hand, the mechanical design focuses on the tower internals and heat exchanger arrangements.
Determine the separation sequences, which depends on the relative volatility and concentration of each component in the feed
Performing a material balance for the column Determining the tower operating pressure (and/or temperature) Calculating the minimum number of theoretical stages using the Fenske equation Calculating the minimum reflux rate using the Underwood equations Determining the operating reflux rate and number of theoretical stages Selection of column internals (tray or packings)
The selection of column internals has a big impact on the column performance and the maintenance cost of a distillation tower.
There are several choices of column internals and the two major categories are trays and packing. The choice of which to utilize depends on the Pressure Fouling potential Liquid to vapor density ratio Liquid Loading Life Cycle Cost
Tower operating pressure is determined most often by the temperature of the available cooling medium in the condenser or by the maximum allowable reboiler temperature.
Economically optimum reflux ratio is about 120% to 150% of the minimum reflux ratio. The economically optimum number of stages is about 200% of the minimum value. A safety factor of at least 25% about the reflux should be utilized for the reflux pumps. Reflux drums are almost always horizontally mounted and designed for a 5 min holdup at half of the drum's capacity.
Limit tower heights to 175 ft (53 m) due to wind load and foundation considerations.
The Length/Diameter ratio of a tower should be no more than 30 and preferably below 20.
A rough estimate of reboiler duty as a function of tower diameter is given by: Q = 0.5 D2 for pressure distillation Q = 0.3 D2 for atmospheric distillation Q = 0.15 D2 for vacuum distillation Where, Q : Energy in Million Btu/hr D : Tower diameter in feet.
Overall column height depends on tray spacing. Tray spacing should from 18 to 24 (ease of maintenance to be kept in mind).
For tower dia > 4 ft, Tray spacing ~ 24 and for tower dia < 4 ft, Tray spacing is ~18. Peak tray efficiencies usually occur at linear vapor velocities of 2 ft/s (0.6 m/s) at moderate pressures, or 6 ft/s (1.8 m/s) under vacuum conditions. A typical pressure drop per tray is 0.1 psi (0.007 bar).
Tray efficiencies for aqueous solutions are usually in the range of 6090% while gas absorption and stripping typically have efficiencies closer to 10-20%
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Vertical
a.Knockout drums (except flare knockout drums) b.Flash drums c.Blowdown drums d.Driers
Horizontal
a. Distillate drums reflux vessels b. Surge vessels c. Steam drums d.Settling drums e.Flare knockout drums
Process Design Basics of Pressure Vessel
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A smaller plot area is required (critical on offshore platforms) Large Vapor throughput with small liquid hold up Generally the vessel volume is smaller
Application
Reactor Effluent Separator (V/L) Reactor Effluent Separator (V/L/L) Reflux Accumulator Compressor KO Drum Fuel Gas KO Drum Flare KO Drum Condensate Flash Drum
Preferred Orientation
Vertical Horizontal Horizontal Vertical Vertical Horizontal Vertical
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2:1 ELLIPSOIDAL HEAD 15+3 THK CLAD (MIN.) AFTER FORMING (TYP.) MIN
N2
M1
N1
M11
M10
M17
M16
M18
M5
MIN
WEAR PLATE
N12A
HHLL 10 FT
NAME PLATE
HLL 9 FT NLL 6 FT
12.5 ft
M2
N14A
VORTEX BREKER
N12B
N14B
N15A
N8
N13A
1:120
4 ft.
12 10+3 THK CLAD (MIN) 4.16 ft
5 ft
200
N13B
N6
LIL 1 FT
2 ft.
165
MIN
N3
N9
12
MIN MIN
2:1 ELLIPSOIDAL HEAD 10+3 THK CLAD (MIN.) AFTER FORMING (TYP.)
N4
VORTEX BREKER
N7
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The allowable vapor velocity (VA) is obtained by applying a factor to the critical velocity (Vc - maxm allowable design velocity). VA = Factor x Vc VC =
L 0.15 1 G
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Factor 1.0
2.0
1.7
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20 15 10 5 2 2 1
In case surge must be provided for both product and reflux, the larger volume is used, not the sum of the two volumes. When the discharge rate is unimportant, a nominal surge (or holdup) time of approximately two (2) minutes is provided.
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For guidance, the following minimum levels may be used: Horizontal drums 6 inches (15 centimeters) above bottom Vertical drums 6 inches above lower tangent line With Water Settling Provide five (5) minutes holdup at the total hydrocarbon rate below the low liquid level for the settling out of water.
In case no pot is employed, holdup for the water itself must also be provided in the bottom of the drum.
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Minimum 20% of the drum diameter or 12 inches (30 centimeters) or clearance for feed inlet device, whichever is greater, to top of drum. Vertical Drums 1'-0" to the bottom of the inlet arrangement (bottom of nozzle, elbow, or impingement baffle) when vapor is present. If no vapor is present, 15% of the drum diameter or 12 inches (30 centimeters) or clearance for feed inlet device, whichever is greater, to the upper tangent line
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% of Total vapor area= (Minimum vapor area (step-1)/ Total area )x100 Height of vapor area can be calculated from the standard chart
b. Vapor space check w.r.t.feed inlet device Take the larger height of the check a and b
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1 1 2 3 4 6 8 10 12 14
13 14 14 15 16 18 24 30 36 42
14 15 15 17 18 21 28 35 42 49
4 5 6 7 9 12 15 18 21 23
10 11 11 13 14 17 20 23 26 29
5 6 7 8 11 15 19 23 27 30
10 11 12 14 16 20 24 28 32 36
16
18 20 24
48
54 60 72
56
63 70 84
26
29 32 38
32
35 38 44
34
38 42 50
40
44 48 56
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Increase the water velocity as required up to 10 inches per minute (25 centimeters per minute) to avoid exceeding these values.
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Centimeters 30 45
24
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If extremely low water velocities, less than 0.10 inches per minute (0.25 centimeters per minute) are obtained with the above diameters, do not provide a pot. Instead, extend the hydrocarbon outlet above the bottom of the drum to provide disengaging.
Process Design Basics of Pressure Vessel
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Step2 : Consider boot liquid hold-up time of ~ 10 mins between LIL & HIL Step3: Calculate Length of boot Step 4: Check Min. length of 3 ft betn. HIL & LIL for controller connection
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2:1 ELLIPSOIDAL HEAD 15+3 THK CLAD (MIN.) AFTER FORMING (TYP.) MIN
N2
M1
N1
M11
M10
M17
M16
M18
M5
MIN
WEAR PLATE
N12A
HHLL 10 FT
NAME PLATE
HLL 9 FT NLL 6 FT
12.5 ft
M2
N14A
VORTEX BREKER
N12B
N14B
N15A
N8
N13A
1:120
4 ft.
12 10+3 THK CLAD (MIN) 4.16 ft
5 ft
200
N13B
N6
LIL 1 FT
2 ft.
165
MIN
N3
N9
12
MIN MIN
2:1 ELLIPSOIDAL HEAD 10+3 THK CLAD (MIN.) AFTER FORMING (TYP.)
N4
VORTEX BREKER
N7
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1 inch in 10 feet down towards the outlet or low point drain so that the vessel may be completely drained during shutdown.
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Inlet device
Impacts vapor / liquid separation that can be achieved
Slotted Tee
Half Open Pipe
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Table 3
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Table 3
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Vessels - Internals
Vortex Breaker
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Feed Inlet
Vapor + Liquid
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Vessel Diameter, ft (m) Vapor Density, lb/ft3 (kg/m3) Liquid Density, lb/ft3 (kg/m3)
2
0.05 0.0 (0.0)
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2 20 (13.6)
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Step2. Calculate Rising Rate (V) of Light Liquid through Heavy Liquid ---Calculation require droplet diameter
DROPLET SIZES System Caustic - 0.85 specific gravity oils Water - Naphtha or heating oils Propane - oil deresining
Process Design Basics of Pressure Vessel
Inches
0.005 each phase 0.012 each phase 0.005 each phase 0.012 each phase 0.004 each phase 0.010 each phase
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Step3. Calculate Rising Rate (V) of Light Liquid through Heavy Liquid a. Calculate Rising Velocity Stokes law (Reynolds number less than 1) V = 8.3 x 105 x d2 x S / uc Intermediate law (Reynolds number between 1 and 1,000) V = 1.04 x 104 x d1.14 x S0.71 / ( Sc0.29 x uc0.43 ) Newtons law (Reynolds number between 1,000 and 200,000) V = 2.05 x 103 (d S)0.5 / ( Sc ) Where the Reynolds number = 10.7 d V Sc / uc
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b. Select Rising velocity based on Re value from point a. But if rising velocity exceeds 10"/min then take 10/min.
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Step4. Calculate Settling Rate (V) of Heavy Liquid through Light Liquid a. Calculate Settling Velocity Stokes law (Reynolds number less than 1) V = 8.3 x 105 x d2 x S / uc Intermediate law (Reynolds number between 1 and 1,000) V = 1.04 x 104 x d1.14 x S0.71 / ( Sc0.29 x uc0.43 ) Newtons law (Reynolds number between 1,000 and 200,000) V = 2.05 x 103 (d S)0.5 / ( Sc ) Where the Reynolds number = 10.7 d V Sc / uc
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b. Select Settling velocity based on Re value from point a. But if settling velocity exceeds 10"/min then take 10/min.
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Step7. Residence time of Heavy Liquid settling through Light Liquid a. Area between high and low interfaces =(x-y)*0.01*cross sectional area of vessel
b. Residence time of Heavy Liquid between high and low interface level =area ina*L/Heavy Liquid volume flow
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Distance Heavy Liquid must fall from top of drum to High Interface level =Vessel dia - Height(BTL-HIL)
d. Heavy Liquid settling time (between top of drum and high interface level) required for separation = Distance a/ Heavy Liq settling velocity
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Light Space Area =(100 - % area occupied below HIL)*Vessel cross sectional area*0.01
b. Light Space volume = Light space area*L c. Light phase Space residence time= Light space volume/Light Liq flow rate
CHECK : Light phase space residence time > Heavy Liquid settling time through Light phase
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Distance Light Liquid must travel from bottom of drum to low Interface level =Height (BTL-LIL)
d. Light Liquid rising time (between bottom of drum and low interface level) required for separation = Height (BTL-LIL) /Light Liq rising velocity
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Feed Inlet
Vapor + Liquid
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The use of a crinkled wire mesh pad or screen would not permit a large reduction in vessel size for vessels lower than 4 ft in diameter, and since a crinkled wire mesh pad or screen is fairly expensive, it is not used much in diameters less than 4 ft. When used, it would be to prevent large slugs of liquid from going to the compressor.
a. b. c. d.
Calculate critical vap velocity Calculate allowable vap velocity ( with CWMS, allowable factor 2.0) Calculate min vap area (Vap Flow rate/allowable vap velocity) Calculate minimum diameter
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b.Calculate allowable vap velocity ( without CWMS, allowable factor 1.0) c. Calculate min vap area (Vap Flow rate/allowable vap velocity) d.Calculate minimum diameter Step4. Liquid surge volume and height calculation a.Consider liquid holdup time (between LLL-HLL) as per standard b.Calculate LLL-HLL height
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g. Check L/D - as per previous table. If L/D is not OK, calculate with new Dia
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The use of a crinkled wire mesh pad or screen would not permit a large reduction in vessel size for vessels lower than 4 ft in diameter, and since a crinkled wire mesh pad or screen is fairly expensive, it is not used much in diameters less than 4 ft. When used, it would be to prevent large slugs of liquid from going to the compressor.
a. b. c. d.
Calculate critical vap velocity Calculate allowable vap velocity ( with CWMS, allowable factor 2.0) Calculate min vap area (Vap Flow rate/allowable vap velocity) Calculate minimum diameter
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b. Calculate allowable vap velocity ( without CWMS, allowable factor 1.0) d. Calculate minimum diameter Step4. Liquid surge volume and height calculation a.Consider liquid holdup time (between LLL-HLL) min recommended 24 hrs b.Calculate LLL-HLL height min recommended 1.5 ft
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b. Height of inlet +elbow - min recommended 2.5 ft c. Height (Vessel top tangent line to top of inlet nozzle) - min recommended 2.5 ft d. Height HLL to bottom of Inlet nozzle min recommended 1 ft e. Height (LLL to Bottom Tangent line) min recommended 0.5 ft f. Height (HLL-LLL) min recommended for KOD is 1.5 ft g. Total Drum Height Calculated h. Check L/D - typical L/D for KOD is 2:1
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Step1. Drum sizing based on maximum single risk vapor load condition
Sp. Garvity of HC liq from chart at 3200F and 19 psia Dropout Velocity(VD) -- Critical velocity Allowable Velocity (VA) Generally 1.0 for conservative case Assume vapor space Height (HLL-top of drum) Liquid space Height (BTL-HLL)- Generally zero(0) Residence time Vapor Space height / Allowable velocity Find vapor volume = maxm vap Flow rate/residence time = drum volume a. Drum Dia = maxm vap space height b. Find drum length c. Check L/D ratio within 3:1 to 5:1 a. b. c. d. e. f. g.
Process Design Basics of Pressure Vessel
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Step2. Check Drum sizing based on maximum liquid relief condition a. Maximum liquid relief load after flash at operating condn generally 3200F and 19 psia b. Liq flow time Generally 2 hrs recommended c. Pump capacity for liquid out d. Net Liq fill up flow = a*b c e. Net liq fill up volume= d * b f. Find Drum volumetric capacity = 3.14*0.25*D2*L ( using D & L calculated in Step-1) CHECK: Net Liq Fill up Volume (for maxm liquid relief condition) <= 50% of Drum Volumetric capacity( for maxm vapor load condition) If not satisfied, recalculate
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Example
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