Diseño de Plantas Químicas

Docente Camilo Monroy Peña

sPhD Msc Ing. Químico
 OPEN SIMULATION FILE

Propylene-Propane Splitter

C:\Program Files (x86)\AspenTech\Aspen HYSYS

V10.0\Samples

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 VESSELS

1. Introduction
• Example of applications
• Services
2. Type of Vessels
3. Calculation
• Input Documents
• Sizing (Accumulators, Separators)
4. Equipment Specification
• Internals (Vortex Breaker, Mist
Eliminator)
• Nozzles

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 INTRODUCTION - APPLICATIONS
SEPARATOR
SEPARATOR Vapor-Liquid-Liquid
Vapor-Liquid

ACCUMULATOR
(Surge drum)

OTHER
SERVICES
Reactors
Filters
Fract. column

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 INTRODUCTION - APPLICATIONS
FLOW CHART
Identification of Service
based on Process Flow
Scheme
Identification of Type
(accumulator, separator) based on
Service
Definition of Orientation (vert/ horiz)
and of Sizing Parameters (hold-up, K
factor)

Determination of main dimens

(D, L,..) and liquid levels

Internals (Vortex Breaker, Data for mechanical Identification of

Demister,..) design (Design P/T, Nozzles (Number, size and
Materials,..) position)

Process Data Sheet

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 TYPE

ACCUMULATORS are used to provide hold-up between the

upstream supply system(s) of a fluid and the downstream
user(s).

Vessel dimensons are set based on the required residence time

TYPICAL APPLICATIONS

Feed Surge Drum

Column Overhead Accumulator (Total Condenser)

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 TYPE

Scope of SEPARATORS is to:

• Allow separation of a mixed phase stream in two or more

homogeneous phases (L-V, L-L-V, L-S)
• Provide hold-up
Vessels dimensions are set based on the required
• separation efficiency
• residence time

TYPICAL APPLICATIONS
• Column Overhead Reflux Drum (Partial Condenser) (L-V)
• Reactor Effluent Separator (L-V or L-L-V)
• Flash Drum (L-V)

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 TYPE

Special services for “special purposes”.

Fractionators / Absorbers / Strippers
• Column dimensions are set based on fractionation
requirements and hold-up time. They need to be checked with
Manufacturer of internals (trays, packing)
• Design of internals is made by Manufacturer
Filters, Mixers, Coalescers,...
• Sizing made by Manufacturer (Contractor to define equipment
spec.)
Reactors
• Sizing is made by Licensor / Technology Supplier

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CALCULATION

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 CALCULATION

Advantages of a VERTICAL vessel:

• a smaller plot area is required (critical for offshore platforms)
• it is easier to remove solids
• For L-V separators liquid removal efficiency does not vary
with liquid level (vapor area remains constant)
• For L-V separators, vertical vessel are usually selected for
high gas-liquid ratio

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 CALCULATION

Advantages of a HORIZONTAL vessel:

- Horizontal separators more effective than vertical (drops settling
perpendicular to the gas flow instead of countercurrent);
- In an horizontal sep. is easier to accommodate large liquid slugs
(smaller vessel volume on high liquid loading service);
- less liquid head required;
- smaller structure for circuit like column condensers with accumulator
below.
- In an horizontal L-V sep. downward liquid velocity is lower (greater
liquid surface area), resulting in improved de-gassing and foam
breakdown;
- In an horizontal L-V sep. it is easier to achieve also liquid / liquid
separation (e.g. by installing a boot).
For L-V separators, horizontal vessel are usually selected for high
liquid-gas ratio

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 CALCULATION

Application Preferred orientation

Reactor Effluent Separ. (V/L) Vertical
Reactor Effluent Separ. (V/L/L) Horizontal
Reflux Accumulator Horizontal
Compressor KO Drum Vertical
Fuel Gas KO Drum Vertical
Flare KO Drum Horizontal
Condensate Flash Drum Vertical
Steam Disengaging Drum Horizontal

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CALCULATION

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 CALCULATION

OPERATING HOLD-UP
Volume between HLL and LLL
EMERGENCY HOLD-UP
Volume between HHLL and
HLL (or LLLL and LLL)
Hold-up is calculated based
on the required residence
time
V=Lxt
V = Hold-up
L = liquid flowrate
t = residence time
Residence Time (t) is set
based on vessel “service”
and process control req’t
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CALCULATION

P = Liquid product m3/min

R = Reflux m3/min
F= Feed m3/min

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 CALCULATION

INPUT DATA
1) WL, ρL = Liquid Flowrate and density
2) te(HHL), te(HL) and te(LL) = Operating
and Emergency Hold-up
VERTICAL (trial and error)
1) Fix a diameter D, vessel cross section
is A=π x D2/4
2) h1 = 300 mm or 20% D (if h2 not req’d)
3) h2 = WL / (A x ρL) x te(HHL)
4) h3= WL / (A x ρL) x te(HL)
5) h4 = WL / (A x ρL) x te(LL)
6) h5 = 300 mm min (to avoid connection
of LG/LT on the vessel btm head)
6) L= h1+h2+h3+h4+h5
4 >L /D > 2 (?)

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CALCULATION

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CALCULATION

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CALCULATION

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 CALCULATION

INPUT DATA
1) WL, ρL = Liquid Flowrate and
density
2) te(HHL), te(HL) and te(LL) =
Operating and Emergency Hold-up
HORIZONTAL (trial and error)
1) Fix a diameter D, vessel cross
section is A=π x D2/4
2) hv = 300 mm or 20% D (highest)
3) hl = based on the required hold-up
4) hlm= 200 mm min (300 mm in case
a heavy phase can settle in the
bottom of the vessel)
5) L= hv+ hl + hlm L = D

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 CALCULATION - SEPARATOR

- Settling of liquid droplets by gravity

(ordinary V-L separator without demister sized for removal of
drops larger than 200-400 μm with a separation efficiency of 95-
99.5%)

Two calculation methods available: RIGOUROUS and

SIMPLIFIED
- Impact and coalescence of liquid droplets on a solid surface
(demister) and settling by gravity of bigger droplets (V-L
separator with demister for removal of drops larger than 5-10 μm
and a separation efficiency of 99.9% and above)

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 CALCULATION - SEPARATOR

- Settling of liquid droplets by gravity

(ordinary V-L separator without demister sized for removal of
drops larger than 200-400 μm with a separation efficiency of 95-
99.5%)

Two calculation methods available: RIGOUROUS and

SIMPLIFIED
- Impact and coalescence of liquid droplets on a solid surface
(demister) and settling by gravity of bigger droplets (V-L
separator with demister for removal of drops larger than 5-10 μm
and a separation efficiency of 99.9% and above)

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 CALCULATION - SEPARATOR

RIGOUROUS

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 CALCULATION - SEPARATOR

RIGOUROUS

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 CALCULATION - SEPARATOR

RIGOUROUS

Vp = terminal settling velocity (m/s)

g = 9.8 m/s2
Dp = droplet diameter (m) – Typical
value 150-300 μm
ρL = liquid density (kg/m3)
ρV = vapor density (kg/m3)
C = dimensionless drag coefficient

Terminal settling velocity of liquid droplet

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 CALCULATION - SEPARATOR

RIGOUROUS

VERTICAL SEPARATORS

Vapor velocity Vvap < Vp

HORIZONTAL SEPARATORS

Vessel Length Length > Vvap x θ

Θ = hv / Vp residence time of liquid droplets
hv = height above liquid level

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 CALCULATION - SEPARATOR

Hv =
Without demister = 0.5 x D (500/900 mm min/max)
With demister = 250 + 0.25 x D (500 mm min)
With demister and slotted tee = 450 mm
L= Hv+di+h1+h2+h3+h4+h5

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 CALCULATION - SEPARATOR

SIMPLIFIED

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 CALCULATION - SEPARATOR

SIMPLIFIED

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 EQUIPMENT SPEC. - INTERNALS

DEMISTERS
Demisters are “separation device” that are installed into
process separators to facilitate the separation of liquid
droplets from vapor by promoting the coalescence of small
mist droplets and allowing the liquid.

Typical mist eliminator

application in a distillation
column

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 EQUIPMENT SPEC. - INTERNALS

DEMISTERS

Mesh Type Vane Type Fiber Bed Type

5 µm< dp < 100 µm 20 µm< dp < 100 dp < 10 µm
µm

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 EQUIPMENT SPEC. - INTERNALS

VORTEX BREAKER
A free surface vortex can form when a liquid exit via a nozzle or
hole below the liquid surface and the liquid height between liquid
surface and nozzle/hole is below a minimum submergence
height.
When free vortex is formed, gas entrainment occurs and
vapor/gas above liquid surface exit together with liquid through
the nozzle/hole.

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 EQUIPMENT SPEC. - INTERNALS

VORTEX BREAKER

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 EQUIPMENT SPEC. - INTERNALS

VORTEX BREAKER

Typical application of vortex breaker are:

Connections to pump suction

Connections to reboiler
Liquid draw-off from tray
Connections to control valve

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 COLUMNS

SEPARATION REQUIREMENTS

Equilibrium of the System

– (L-V, L-L-V, others)

Feed Conditions and Composition

Product composition/flowrates required

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 STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION
Process data definition (fouling, system factor, flooding
factor, min/max rate, etc)

Select the type of contacting device: trays or packing.

Calculate the number of actual trays (for trayed columns

only)

Estimate the required bed height (only for packed columns,

to be confirmed by Vendor)

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 STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION
1. Process data definition (fouling, system factor, flooding factor, min/max rate,
etc)

2. Select the type of contacting device: trays or packing.

3. Calculate the number of actual trays (for trayed columns only)

4. Estimate the required bed height (only for packed columns, to be confirmed
by Vendor)

5. Selection of Tray Type / Packing type (usually defined / confirmed by Vendor)

6. Definition of number of passes, Tray spacing (usually confirmed by Vendor)

7. Column sizing: Diameter, number of real stages, holdup, total length

8. Other requirements for the Column as a vessel : insulation, nozzles, etc

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 STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION
TRAYED COLUMNS PACKED COLUMNS
1. Predictable hydraulic and mass 1. Low pressure drop / smaller
transfer behavior diameter
2. Moderate to high pressure 2. Random packing scale-up for
drop per tray HETP is difficult; structured
3. Can be scaled to large packing scale-up is predictable
diameters 3. HETP prediction less well
4. Low cost developed than for trays
5. Suitable for fouling service 4. Low to moderate cost for
6. Feed point flexibility is easy random packing; high cost for
structured packing
5. Not suitable for fouling service
6. Feed point flexibility is difficult

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 STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION
Flooding Factor

Current practice consists in calculating a column in order to ensure proper

operation at a given percentage of the flooding limit (flooding factor).

In calculations, the flooding factor shall have the following values:

Atmospheric or pressure columns 0.82

Vacuum columns 0.77

Column with a diameter lower then a 900 mm 0.65 – 0.75

In case of revamping (using special valves) 0.92

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 STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION
System (Foam) Factor

This value indicates the foaming tendency of the fluid that decreases the tray
hydraulic capacity (de-rating factor)

Typical suggested values :

Non foaming, regular system 1.0

Fluorine system, Freon, Depropanizer, H2S Stripper,
Hot Carbonate Regenerator 0.9
Moderate foaming (oil absorber, amine and glycol
regenerator), Topping, Vacuum Tower for Residue 0.85
Heavy foaming (amine and glycol absorbers) 0.73
Caustic Soda Washing 0.65
Severe foaming (MEK units) 0.6
Foam stable system (caustic regenerator) 0.3 – 0.6

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STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION

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STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION

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STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION

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STEPS FOR COLUMN AND COLUMN
INTERNALS SPECIFICATION

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