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Fuel Gas Knock Out Drum

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OFF GAS KNOCK OUT DRUM DESIGN
1

2

AGENDA
 PROCESS

VESSELS  KNOCK OUT DRUM  KNOCK OUT DRUM DESIGN

3

PROCESS VESSELS
 Constitute  Smooth

a major cost in a process plant.

operation of several critical equipment in

a process plant largely depends upon the performance and adequacy of process vessels.

4

CLASSIFICATION OF PROCESS VESSELS
 Two

phase separator separator  Vapor-liquid  Liquid-liquid

separator

 Three

phase separator separator  Vapor-liquid-liquid

 Hold

up drums

5

GENERAL GUIDELINES
 Various

factors taken into account while designing the vessel are as follows
 Type

of Vessel:

 Vertical  Horizontal  Spherical

6

GENERAL GUIDELINES

  

Selection guidelines for type of vessel (H or V)
Large vapor to liquid loads by vol. Large liquid to vapor loads by vol. : Select vertical vessel : Select horizontal vessel

Large liquid and large vapor loads by vol.

: Select horizontal vessel with split flow (*)

 

Liquid-liquid separation Liquid-solid separation

: Select horizontal vessel : Select vertical vessel

(*) Split flow vessel consist of single entry in center and two vapor outlets on each end.

7

GENERAL GUIDELINES
 Liquid

hold up volume:

The liquid hold up volume should be decided

based on the type of service and flow rates.


Height/ Length to Diameter Ratio


Vessel diameter should always be as per standard dished end sizes available.



Increasing the diameter reduces the height/ length and but increases thickness .

8

VERTICAL KNOCK OUT DRUM



It is a two-phase separator.
A vessel designed to handle streams with high gas-to-liquid ratios. The liquid is generally entrained as mist in the gas or is free-flowing along the pipe wall.





These vessels usually have a small liquid collection section.

9

PARTS OF A KOD

10

MECHANISM OF SEPARATION
 Three


stages:

Primary separation
 Uses

an inlet diverter



Secondary separation
 Gravity

separation of smaller drops



Mist elimination
 Mist

coalesced by mist eliminator

11

MECHANISM OF SEPARATION
 For

secondary separation, the allowable velocity

is calculated to determine disengagement area.
 Force

balance is performed on the liquid droplet

settling out.
 Terminal

velocity attained when gravity force is

balanced by the drag force.

12

MECHANISM OF SEPARATION
 Force

of gravity-

 Drag

force-

 Terminal

velocity-



……..Eqn 1

13

MECHANISM OF SEPARATION
 For

the liquid droplets to settle out, allowable velocity is kept between 0.75 UT - UT. 1 can be rearranged to get the Sauder’s Brown Equation:

 Equation

14

MECHANISM OF SEPARATION
 Since

the coalesced drop diameter is not adequately predictable, K value is calculated from empirical formulae.

15

MECHANISM OF SEPARATION
 Hold-up

time: Time required for the liquid

level to drop from NLL to LLL.

 Surge-time:

Time required by the liquid level

to rise from NLL to HLL.

16

Case study : BPCL BBU V-11 plant gas KOD is taken for designing. The below are the process details.

17

DESIGN PROCEDURE

18

DESIGN OF THE KNOCK OUT DRUM
 Select

diameter so that the actual vapor velocity in the vessel does not exceed the terminal velocity. of the vessel should be based on the required liquid hold up inside the vessel.  Holdup depends on service of the vessel H/D (L/D) is between the allowable range and adjust diameter to achieve the desired H/D (L/D)

 Height

 Check

19

DESIGN OF THE KNOCK OUT DRUM
BASIS:  Liquid Density = 46.725 lb/ft3 = 740 kg/m3  Vapour Density = (P*M)/(Z*R*T)  Pressure (P) = 1.2 kg/cm2 (a)  Molecular weight of the vapour = 26  Compressibility factor Z = 1  Gas constant R = 82.053  Temperature = 323 K  Therefore, Vapour density = (1.2*26)/(1*82.053*323) = 1.177 kg/m3 = 0.0733 lb/ft3

20

DESIGN OF THE KNOCK OUT DRUM





 





Viscosity (μ) = 0.012 cP Particle Size ( Dp ) = 250 microns = 0.0008202 ft Mass Flow Rate (W) = 120T/D = 5000 kg/hr = 11023.11 lb/hr Percentage liquid in the stream = 10% Vapour mass flow rate (Wv)= 0.9*W =( 0.9*11023.11)/3600 lb/s = 2.75 lb/s Liquid mass flow rate (WL) = 0.1*W = 0.1*11023.11 lb/hr = 0.305 lb/s Nozzle diameter DN = 10 inch

21

22

DESIGN OF THE KNOCK OUT DRUM
STEP 1 Calculate the terminal vapour velocity: Using Sauder’s Brown equation UT = K*(ρL-ρV)0.5 ft./s ΡV0.5 K= (4*g*DP)0.5 (3*CD)0.5 CD = (5.0074/ln(X)) + (40.927/(X)0.5) + (44.07/X) X= (0.95*108*DP3*ρv*(ρL-ρv) μ2 = (0.95*108*0.00082023*0.0733*(46.725-0.0733) 0.0122 = 1245.47

23

DESIGN OF THE KNOCK OUT DRUM
CD = (5.0074/ln(1245.47)) + (40.927/(1245.47)0.5) + (44.07/1245.47) = 1.89765 K= (4*32.17*0.0008202)0.5 (3*1.89765)0.5 = 0.13616 ft/s UT = 0.13*(46.725-0.0733)0.5 0.07330.5 = 3.434 ft/s Set Uv (allowable vapour velocity) = 0.75* UT = 0.75*3.434 ft/s = 2.575 ft/s

24

DESIGN OF THE KNOCK OUT DRUM
STEP 2:
Calculate the vapour volumetric flow rate

Qv = (Wv)/(ρv) ft3/s
= 2.75/0.0733

= 37.46 ft3/s

25

DESIGN OF THE KNOCK OUT DRUM
STEP 3: Calculate the vessel (inside) diameterDVD = (4*Qv)0.5/ (π*Uv)0.5 ft = (4*37.469)0.5/ (π*2.57)0.5 ft = 4.304 ft If there is a mist eliminator, add 3 to 6 in to the above diameter to accommodate a support ring and round up to the next 6 in increment to obtain D. If there is no mist eliminator, D = DVD Thus, D = 4.305 + 0.5 = 4.804 ft

26

DESIGN OF THE KNOCK OUT DRUM
STEP 4:
Calculate the liquid volumetric flow rateQL = (WL)/(ρL) ft3/s

= (0.305/46.275)
= 0.0065 ft3/s

=0.3923 ft3/min

27

DESIGN OF THE KNOCK OUT DRUM
STEP 5:
Hold up time TH = 30 min Hold up volume VH = TH * QL = 0.3923 * 30 = 11.77 ft3

STEP 6:
Surge time TS = 30 min Surge volume = Ts * QL = 0.3923 * 30 = 11.77 ft3

28

DESIGN OF THE KNOCK OUT DRUM
STEP 7: Obtain low liquid level height, HLLL, from the following table

Thus from the above table, HLLL = 15 inch = 1.25 ft

29

DESIGN OF THE KNOCK OUT DRUM
STEP 8: Calculate the height from low liquid level to normal liquid levelHH = (VH)/((π/4)*D2) ,ft = (11.77)/((π/4)*4.8042) = 0.649 ft But 1 ft minimum is required. Thus, HH = 1 ft

30

DESIGN OF THE KNOCK OUT DRUM
STEP 9: Calculate the height from normal liquid level to high liquid level (or high level alarm)Hs = (Vs)/((π/4)*D2) ,ft = (11.77)/((π/4)*4.8042) ,ft = 0.649 ft But 0.5 ft minimum is required. Thus, Hs = 0.5 ft

31

DESIGN OF THE KNOCK OUT DRUM
STEP 10: Calculate the height from high liquid level to the centreline of the inlet nozzle: HLIN = 12 + DN (with inlet diverter) = 12 + 10 =22 inch = 1.833 ft

STEP 11: Calculate the disengagement height, from the centreline of the inlet nozzle to the bottom of the demister pad. HD = 24 + 0.5*DN inches = 24+ 0.5*10 inches = 29 inches = 2.41 ft

32

DESIGN OF THE KNOCK OUT DRUM
STEP 12: If there is a mist eliminator, take 6 inches for the mist eliminator pad and take 1ft from the top of the mist eliminator to the top tangent line of the vessel.
STEP 13: Calculate the total height, HT of the vessel: HT = HLLL + HH + HS+ HLIN + HD + HME , ft Where HME is the height from step 12. HT = 1.25 + 1 + 0.5 + 1.833 + 2.41 + 1.5 = 8.5 ft

33

DESIGN OF THE KNOCK OUT DRUM
 Check

that L/D is in between 1.5 to 3. If not, change the diameter and repeat the calculations.  Here, L/D = 1.77.This is within the range.

34

DESIGN OF THE KNOCK OUT DRUM
Thus, final drum dimensions are:
Height
Diameter

2.59 m
1.46 m

35

MIST ELIMINATOR
 Device

in which a gas stream having entrained liquid is passed through fixed elements interposed in the gas stream. Greater inertia results in the tendency of the liquid particles to deposit on this element. types of eliminators used are
  

 Various

Knitted wire mesh

Staggered baffles or channels
Perforated Plates

Thank You

36

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