Appendix A: A.1. Three Phase Separator

1
APPENDIX A
A.1.
Three Phase Separator

There are 3 Three principles used to achieve physical separation of gas and
liquids or solids are momentum, gravity settling, and coalescing. Any separator
may employ one or more of these principles, but the fluid phases must be
"immiscible" and have different densities for separation to occur. A procedure for
designing 3-phase separator will be described as follows by calculated using cas
d'Olivier BURGER (Gas/liquid separator) Toolbox and Aspen HYSYS
Simulation:
The data of operating condition are given from ASPEN HYSYS where it will be
input and calculated with the toolbox.
The above toolbox is used to calculate the results given the data is based from
ASPEN HYSYS below. The operating Condition of the 3-phase separator is given
in the worksheet tab from feed sep.
Genera
lity
Item number
Service
Operating Pressure
Operating Temperature
Fluid :
Gas
Oil
Water
Gas mass flowrate

Gas density at operating
conditions
Gas volumic flowrate at
operating conditions
Oil mass flowrate
Oil density at operating
conditions
Oil volumic flowrate at operating
conditions
P
T
M
v
Ro
v
F3
cas d'Olivier BURGER
(Gas/liquid separator)
1.014
80
43530
0.70
Qv
17.222
Ml
Ro
l
18550
1107.00
0.005
Ql
M
Water mass flowrate
w
62150
Water density at operating
Ro
conditions
w
1004.00
Water volumic flowrate at
Q
operating conditions
0.017
w
Figure A.1 Three phase separator Toolbox Sizing Simulation
(Source: Authors Documentation)
bara
C
Kg/
h
Kg/
m
m/s
Kg/
h
Kg/
m
m/s
Kg/
h
Kg/
m
m/s
Universitas Indonesia
Figure A.2 Three phase separator Operating Condition From ASPEN HYSYS
The mass flow of the gas,oil and water is based from the data in ASPEN HYSYS.
The gas is represented by the HC (Hydro Carbon) feed from HYSYS. Hence the
mass flow and the density of the gas can be seen below and later will be input to
the toolbox before.
Figure A.3 Gas Mass Flow From ASPEN HYSYS

Figure A.4 Mass Density of Gas From ASPEN HYSYS

The mass flow and the density of salt water can be input from the data in ASPEN
HYSYS below, where it is represented by water feed.
Figure A.5 Water Mass Flow From ASPEN HYSYS

Figure A.6 Water Mass Density From ASPEN HYSYS

While the mass flow and the density of the oil represented by MEG material
stream from ASPEN HYSYS and will be input to the toolbox.
Figure A.7 Mass Flow of Oil From ASPEN HYSYS

Figure A.8 Mass Density of Oil From ASPEN HYSYS

In sizing a separator, the heights of the light and heavy liquids are
assumed, and the settling velocities and settling times are then calculated. The
residence times of the light and heavy liquids are determined next. For the liquids
to separate the residence time of the light liquid must be greater than the time
required for the heavy droplets to settle out of the light liquid phase; and the
residence time of the heavy liquid must be greater than the time required for the
light liquid droplets to rise out of the heavy liquid phase. If these conditions are
not satisfied, then liquid separation is controlling and the vessel diameter must be
increased. Holdup time for liquids must be added to residence time.
For horizontal separators with a given diameter, the heights of the light
and heavy liquids are assumed so that the cross-sectional area can be calculated.
With the vapor disengagement area set by guidelines, the lengths required by
holdup requirements and vapor/liquid separation are calculated. Then, with the
assumed heights of the light and heavy liquids and calculated values of settling
velocities, the settling times are calculated. In the subsequent design procedures,
the latter approach is used. The horizontal design procedures incorporate
optimizing the diameter and length by minimizing the approximate weight of the
shell and heads. To add a degree of conservatism to the design, the volume
available in the heads is ignored
Gas
Section
Critical velocity of liquid in gas
Mi
ni
Vc=0.048*sqrt[(Rol-Rov)/Rov]
Velocity coefficient K=Vg/Vc
K= 1.7 without wire mesh
K= 2.2 with wire mesh
K= 3.3 with vane pack
Horizontal gas velocity,
Vg=K*Vc=Qv/Av
Required vapour area, Av=Qv/Vg
Height for gas area ; mini height
with demister(mm)
Demist
er
Hor. Length : for (150) or no (100) mm

carbone deposit service
Vc
Theoretical
30
0
m/
s
1.91
Chose
n
2.20
Vg/Vc
2.20
Vg max
Av req
4.19
4.11
Vg
Av
Hgas
Enter 0
if no
demister
1745
h1
4.19
4.11
174
5
h2
150
15
Height between demister and liquid
0
h3
150
Figure A.9 Three phase separator Toolbox Sizing Simulation in the gas section
m/
s
m
m
m
m
m
m
m
Gas Section:
Step 1.Determining the gas volumetric flow rate at operating conditions (QV)
calculated by the toolbox:
Where: QV = the gas volumetric flow rate at operating condition

MV = the gas mass flow at operating condition
V=
the gas density at operating condition
Step 2.Determining the oil volumetric flow rate at operating conditions (QL)
Where: QL = the oil volumetric flow rate at operating condition

ML = the oil mass flow rate at operating condition
L=
the oil density at operating condition
Step 3.Determining the water volumetric flow rate at operating conditions (QW)
Where: QW= the volumetric flow rate at operating condition

MW= the water mass flow rate at operating condition
W=
the water density at operating condition
Step 4.Determining the critical velocity of liquid in gas (VC) calculated by the
toolbox:
Where: VC = the critical velocity of liquid in gas

L = the liquid density at operating condition
V = the vapor density at operating condition
Step 5.Determining the velocity coefficient (K), here the K values is chosen
whereas the value is 2.20 with wire mesh:
Where: Vg = the horizontal gas velocity

K = the velocity coefficient
The value of Vg calculated by the toolbox is; whereas the theoretical value is 4.19
m/s
Step 6.Determining the vapor area (AV) calculated by the toolbox:
Where: AV = vapor area in gas section

QV = gas volumetric flow rate at operating condition
Vg = horizontal gas velocity at gas section
Whereas the theoretical value of the required vapor area is 4.11 m2
Step 7. Determining the height of the gas area (hgas) calculated by the toolbox:
Step 8. Determining the Demister part (horizontal length h2 for 150 mm carbon
deposit; and the height between demister and liquid h3) calculated by toolbox
Water
Section
Oil and
Water
Level
Water residence time between NIL
and bottom
Separation
in water
phase
Corresponding volume
LIH - NIL
Hold-up time between LIH and NIL
Mi
ni
Height between NIL and bottom
100
Theoretical
Thwat
42
req
0
Vwat
7.2
req
2
48
hcalwat
5
Thw1
req
60
1.0
Vw1 req
3
Generally
Height between LIH and NIL
NIL - LIL
Hold-up time between NIL and LIL
hcalw1
Thw2
req
Vw2 req
45
30
0
5.1
6
Chosen
45
twat
8
Qwa 7.8
t
8
hwa 51
t
5
13
tw1
3
Qhw 2.2
1
8
10
hw1
0
29
tw2
8
Qhw 5.1
2
3
s
m
m
m
s
m
m
m
s
m
10
Generally
LIL - LILL
Generally
LILL Bottom
Height between NIL and LIL

Hold-up time between LIL and LILL
hcalw2
Thw3
req
Vw3 req
Height between LIL and LILL

Hold-up time (enough to close valve)
100
100
hcalw3
Thw4
req
26
5
hw2
60
1.0
3
tw3
Qhw
3
72
hw3
26
5
m
m
85
1.4
6
10
0
tw4
75
60
1.0 Qhw 1.2
Vw4 req
3
4
9
Mini 150 mm for bottom LT, 300 for
13
15
side LT
hcalw4
150
0
hw4
0
Figure A. 10 Three phase separator Toolbox Sizing Simulation in the Water Section
m
m
m
s
m
m
m
Water section:
Step 9. Determining the water residence time between NIL (high liquid level) and
bottom (Twat) calculated by toolbox:
Whereas the theoretical water residence time between NIL and bottom
(Thwat = 420 s)
Step 10 Determining the corresponding volume between NIL and bottom (Vwat)
calculated by toolbox:
Whereas the value of the theoritical corresponding volume is 7.22 m3

Step 11.Determining the height between NIL (high liquid level) and bottom (hwat)
calculated by the toolbox in Microsoft excel is:
Whereas the theoretical value of the height is 485. The value of chosen
height is bigger than the theoretical value; this explains the undergone liquid level
in water phase must be given a bigger space to the account of the theoretical.
11
Step 12.Determining the holdup time (Thw1), corresponding volume (Vwat1), and
the height between (hcalw1) NIL (High liquid level) and LIH (High liquid alarm),
calculated by the toolbox, hence the value the holdup time: is 133 s whereas the
theoretical value is 60 s.
The corresponding volume calculated by toolbox from the holdup time:
Whereas the theoretical corresponding volume is 1.13 m3

The height between LIH and NIL(hcalw1 calculated by the toolbox is 100 mm.
On the other hand, the theoretical value is 45 mm.
Step13.Determining the holdup time (Tw2), corresponding volume (Vw2), and
height (hcalw2) between NIL and LIL calculated by toolbox:
Tw2 = 298 s; whereas the theoretical = 300 s
Vw2 = 5.13 m3; whereas the theoretical = 5.16 m3
hcalw2 = 265 mm; whereas the theoretical is the same = 265 mm
Step 14.Determining the holdup time (Tw3), corresponding volume (Vw3), and
height (hcalw3) between LIL and LILL calculated by toolbox:
hcalw3 = 100 mm; whereas the theoretical = 72 mm
Step15.Determining the holdup time (Tw4), corresponding volume (Vw4), and
height between LIL and bottom (hcalw4) calculated by toolbox:
hcalw4= 150 mm; whereas the theoretical = 130 mm
Oil Section
Level
Oil and
Water
Separation
Separation residence time
in oil phase
Height between NOL and NIL
Mi
ni
250
Theoretical
Thsep
req
Vsep_re
q
hcalsep
30
0
1.4
0
62
Chosen
tsep
Qse
p
hse
p
127
8
5.9
5
250
s
m
m
m
12
LAHH LAH
Hold-up time between LAHH and

LAH
Generally
Height between LAHHand LAH
LAH - NOL
Hold-up time between LAH and

NOL
Generally
NOL - LAL
Height between LAH and NOL
100
100
Hold-up time between NOL and LAL

Generally
Height between NOL and LAL
LAL LALL
Hold-up time between LAL and

LALL
Generally
LALL Bottom
Height between LAL and LALL
100
100
Hold-up time (enough to close valve)

Th4 req
60
th4
656
V4 req
0.2
8
Qh
4
h4
3.0
5
100
hcal4
Th5 req
60
th5
634
V5 req
0.2
8
Qh
5
h5
2.9
5
100
hcal5
Th6 req
60
th6
V6 req
0.2
8
Qh
6
h6
158
2
7.3
7
360
hcal6
Th7 req
60
th7
60
V7 req
0.2
8
Qh
7
h7
0.2
8
105
hcal7
Th8 req
20
th8
20
V8 req
0.0
9
Qh
8
h8
0.0
9
300
Mini 150 mm for bottom LT, 300 for 300

hcal8
side LT
Figure A.11 Three phase separator Toolbox Sizing Simulation in the Oil Section
m
m
s
m
m
m
s
m
m
m
s
m
m
m
s
m
m
m
(Source : Authors Documentation)
Oil Section:
Step 16.Determining the separation residence time (Thsep), corresponding e
theoretical = 1.40 m3
hcalsep = 250 mm; whereas the theo
etical = 62 mm
Step 17.Determining the holdup time (Th4), corresponding volume (V4), and
height between LAHH and LAH (hcal4) calculated by toolbox:
Th4= 656 s; whereas the theoretical= 60 s
V4 = 3.05 m3; whereas the theoretical= 0.28 m3
hcal4 = 100 mm
13
height between LAH and NOL (hcal5) calculated by toolbox:
V5= 2.95 m3; whereas the theoretical= 0.28 m3
hcal5 = 100 mm
height between NOL and LAL (hcal6) calculated by toolbox:
hcal6= 360 mm
height between LAL and LALL (hcal7) calculated by toolbox:
Th7= 60s; whereas the theoretical= 60 s
hcal7= 105 mm
height between LALL and Bottom (hcal8) calculated by toolbox:
Th8= 20s; whereas the theoretical= 20 s
hcal8= 300 mm
High liquid alarm (trip), LAHH=h8+h7+h6+h5+h4

LAHH
965
mm
High liquid level, LAH=h8+h7+h6+h5
LAH
865
mm
Normal oil level, NOL=h8+h7+h6
NOL
765
mm
Low liquid level, LAL=h8+h7
LAL
405
mm
Low liquid level alarm (trip), LALL=h8
LALL
300
mm
Baffle height
Baffle
765
mm
High liquid alarm (trip), LIH=hw1+hw2+hw3+hw4
LIH
615
mm
High liquid level, NIL=hw4+hw2+hw3
NIL
515
mm
Low liquid level, LIL=hw4+hw3
LIL
250
mm
Low liquid level alarm (trip), LILL=hw4
LILL
150
mm
Figure A.12 Explanation of Sections inside3-phase separator From Toolbox Sizing Simulation
14
TAN/TAN
FEED
h2
MINI
GAS
MINI
h1
LAHH-HLA
LAH-HLL
NLL-NOL
LAH-LLL
id
ILAH-IHL
INLL-INL
ILAL-ILL
ILALL-ILA
h
hw1
hw2
hw3
hw4
h3
h4
h5
h6
h7
LALL-LLA
WATER
AL
h
h8
OIL
C
Figure A.13 Drawing of 3-phase separator Design and Sections From Toolbox Sizing Simulation
Information:
h1
: height for gas area
h2
: horizontal length for a number of mm of carbon deposit
h3
: height between demister and liquid
h4
: height between LAHH and LAH
h5
: height between LAH and NOL
h6
: height between NOL and LAL
h7
: height between LAL and LALL
h8
: LALL (Low Liquid Level Alarm)
Oil Description
LAHH
: Liquid alarm high high-shut down
LAH
: Liquid alarm high-high level
NLL
: Normal liquid level
LAL
: Liquid alarm low-low level
LALL
: Liquid alarm low-low shut down
15
Water Description
ILAHH
: Interface liquid alarm high-high shut down
ILAH
: Interface liquid alarm high-high level
INLL
: Interface normal liquid level
ILAL
: Interface liquid alarm low-low level
LALL
: Interface liquid alarm low-low shut down
The water length/internal diameter ratio represented by WL/D is given by the

value below; as well as the ratio of water length/oil length; whereas if the value of
B/C is decreased will result in a decreased of vessel diameter.
Water_Length/Internal_diameter
Water length/Oil_length
WL_D
3.5
B_C
7.0
Figure A.14 Ratio of Water Length/Internal Diameter and Water length/Oil Length From Toolbox
Sizing Simulation
Results
Length
Water length
Oil length
Baffle
Internal Diameter
11440
10010
1430
765
2860
mm
mm
mm
mm
mm
Figure A.15 Results of The Calculation From Toolbox Sizing Simulation

A.2.
Centrifuge
A.2.1 Decanting Centrifuge Bivalent Salt

Function of this unit is to separate Solid material from liquid fluid. In this
case to separate Salt from Water and MEG mixture. The salt component are shown
below:
16
Comp
MEG
Water
Salt
Total
Mass flow (kg/h) Massa jenis (kg/m3)

Volume rate (m3/h)
18084.5
1113.2
16.24550844
33585.5
1000
33.5855
1126.202612
2245.332
0.501575095
52796.20261
50.33258354
Qf = volume rate salt+volume rate water +volume rate MEG
Comp
MEG
Water
Salt
Total
Mass flow (kg/h) Massa jenis (kg/m3) Volume rate (m3/h)

17903.655
1113.2
16.08305336
31906.225
1000
31.906225
767.5631631
1673.235
0.458730043
50577.44316
48.4480084
From feed data and specification ofdecanter centrifuge:
Feedrate=52796.20261kg/h
Feed solid = 2,1%
Radius of gyration (R) =425 mm=0.425 m
Radius of outlet centrifuge(Rs)=375 mm=0.375 m
G =300 times gravity
17
To calculate rotary speed of centrifuge we use G formula:
In the formula above, we can have , where are
From formula above we see that theres Vr variable. Vr is the velocity of rotary of
the machine. After we calculate Vrotary of decanter, we can calculate Power
needed for centrifuge
So the power needed to
A.2.2 Decanting Centrifuge Monovalent Salt

Function of this unit is to separate Solid material from liquid fluid. In this case to
separate Salt from Water and MEG mixture. The salt component are shown
below:
Comp
MEG
Water
Salt
Total
Mass flow (kg/h) Massajenis (kg/m3)

Volume rate (m3/h)
17903.655
1113.2
16.08305336
31906.225
1000
31.906225
767.5631631
1673.235
0.458730043
50577.44316
48.4480084
18
Qf = volume rate salt+volume rate water +volume rate MEG
Comp
MEG
Water
Salt
Total
Mass flow (kg/h)

9838.92
1234.464995
145.6232606
11219.00826
Massa jenis (kg/m3)

1113.2
1000
1275
Volume rate (m3/h)

8.838411786
1.234464995
0.114214322
10.1870911
From feed data and specification of decanter centrifuge:
Feedrate =
Feed solid = 1,517%
Radius of gyration (R) = 425 mm=0.425 m
Radius of outlet centrifuge(Rs) = 375 mm=0.375 m
G = 300 times gravity
kg/h
To calculate rotary speed of centrifuge we use G formula:
19
In the formula above, we can have , where are
From formula above we see that theres Vr variable. Vr is the velocity of rotary of
the machine. After we calculate Vrotary of decanter, we can calculate power
needed for centrifuge
So the power needed to
A.3
Flash Separator
Purpose
: A place to separate the light component such as

water from rich MEG.
Kind of Vessel
: Flash drum
Construction Material
: Stainless Steel 316L
For this tank, the material used is Stainless steel SA-240 grade 316L.
Stainless steel is used because large impurities such as salt and liquid
hydrocarbon, contained in this vessel. These impurities will scrape vessel wall.
Stainless steel is stronger than carbon steel for facing impurities. So, in order to
avoid serious corrosion and damage in the tank for a long term, stainless steel is
used. Type of head that chose is Torispherical Dished Head. This type is chosen
because our operating pressure is atmosperic (below 10 atm). It also takes little
cost and the design is simple.
20
Operating Condition
Hold Up Time
= 4 minutes
Temperature
= 131.31 oC
Mixing Feed Density
= 864.8 kg/m3
Liq. Product Density
= 1007 kg/m3
Mass Flow Liq. Product
= 51670kg/h
Std. Ideal Liq. Volume Flow
= 50.15m3/h
Mass Flow Vap. Product
= 37890 kg/h
Vapor Product Density
= 634.3 kg/m3
Std. Ideal Vap. Volume Flow
= 37.47 m3/h = 2.5 m3/4 minutes
A. Vessel Dimension
From HYSYS simulation, we get some data that is used for sizing:
Liquid Volume Flow
= 0.476 m3/4 minutes
Vapor Volume Flow
= 2.867 m3/4 minutes
Volume for Vapor + Volume for Liquid
= Flash Drum Volume
Height to diameter ratio of vessel (Ht : D
=4:1
Based on Towler, Chemical Engineering Design page 603, steps to calculate

vessel sizing shown below:
Settling TimeVelocity
(
Which
because demister pad is used in the flash tank
So calculated can be done

(
21
Vessel Diameter
Vessel Height
Since the H/D ratio used for this flash separator is 4, so the height of the
flash separator is
Liquid Depth
Liquid depth (
Which
is calculated as shown below
is retention time. Based on GPSA Engineering Book (1987), it
stated that retention time required for flash drum is 3 to 5 minutes. So,
the liquid depth is
Design Pressure
Safety factor for the pressure is 15 % and our flash separator is operated
in atmospheric pressure so the design pressure is
(
Vessel Wall Thickness

Corrosion factor (C)
: 0.042 in/year
(Chuse&Eber,
1954)
Allowable working stress (S)
: 12650 lb.m2
(Brownell&Young, 1979)
Joint efficiency (E)
: 0.85
Equiptment age (A) plant
: 10 tahun
22
P R
(C A)
SE 0.6 P
(
Where :
Vessel wall thickness sillinder part (in)
Design pressure (psi)
Inside vessel radius (in)
Allowable stress
Fabrication efficiency
so
(
So the standar cyllinder thickness is = 46.4/100 in
Head Sizing
Data for calculating thicness and height of head from Brownel Process
Equipment Design page 89, that is
Inside radius corner (icr) = 2.5

Straight flange (sf) = 1.875
Thickness of head will be
(
Head Height
From Brownell, there is some equation to calculate height of head:
( )
23
Total Height of Vessel

Total height of vessel will be
A.4
Air Cooler
For sizing the air cooler, Hudson software is used to calculate the size for
the Air Cooler Heat Exchanger (ACHE). Air cooler in this system is used to
condense steam from top product of flash separator and decrease the temperature,
so the water can be disposed to sea safely. The Air temperature is 30oC and used
to cool the steam from 131.28oC to 31oC. Figure below shown the input data of
the program that is needed to calculate this ACHE. Heat duty is gotten from hysys
simulation.
24
Figure A.16. Input Summary ACHE Simulator

25
By using this program, the calculation for ACHE can be done and shown in
the figures below.
Figure A.17. Result Summary

26
Figure A.18 Result Summary 2

A.5.
Heat Exchanger
A.5.`1 Heat Exhanger E-1800

A procedure for designing Heat Exchanger E-101 will be described as
follows by calculated using TOTAL Toolbox Shell & Tube Heat Exchanger
Sizing Tool and Aspen HYSYS Simulation:
27
Figure A.19 TOTAL Toolbox Sizing Simulation

1.
1st step & 2nd step; Determine fluid specification

The first step consists in defining how many linear zones are require for heat
exchanger calculation (from 1-5). If there is a phase change, more than one zone
will be required and the exchanger will be provided with one shell only. In order
to design an exchanger with several zone and several shells in the series the user
shall design each zone separately.
Then the flow configuration shall be chosen. The calculation, the
verification, and the graph are updated accordingly. For a heat exchanger with one
pass tube side, the counter current and cocurrent mode can be choses. For a heat
exchanger with two or more pass tube side, the flow configuration is called
multipasses and is considered as counter-current.
In order to complete the definition of the inputs of calculation, the user can
fill the green boxes; inlet and outlet temperature of both fluids, heat duty, and
overall heat transfer coefficient.
Operation condition such as flow rates, terminal temperatures, heat duty and
physical properties are obtained from Aspen Plus simulation.
28
Figure A.20 Result in Aspen Plus Simulation

Figure A.21 Process Condition input in Toolbox

Figure A.22 Heat Exchange with multipasses tube side and minimum number of shell
29
2. 3rd step & 4th step; the LMTD and the temperature correction factor F
Figure A.23 Result in Total Toolbox Simulation

Based on theory, Choose the simple combination of shell and tube passes or
number of shells in series that will have a value of F above 0.8 or so. The
correction factor calculation following:
where
Ti
= Temperature input on tubeside
To
= Temperature output on tubeside
Ti
= Temperature input on shellside
To
= Temperature output on shellside
Figure A.24 Correction Factor for 1 Pass-Shellside and Mutiple of Two Passes-Tubeside
(Source : Wallas, 1990)
30
LMTD (log mean temperature difference), calculated for determine the

differences of mean temperature between hot fluid and cold fluid along heat
exchanger. LMTD can be calculated with this following equation:
(
(
(
(
where
T1 = hot fluid temperature, in
T2 = hot fluid temperature, out
t1 = cold fluid temperature, in
t2 = cold fluid temperature, out
The overall heat transfer coefficient can be assumed according to fluid type
used in heat exchanger. For this heat exchanger, we assume between 172192kcal/(h.m2.oC) for Gas (1-7abs) heat exchanger. Assume U = 190
kcal/(h.m2.oC).
Heat transfer area can be calculate with the following equation:
31
2.
5th step & 6th step Determine type, tube size and tube configuration

Tube size chosen based on available manufacturer size. Standard exchanger

tube diameters are 0.75 or 1 in. OD. The smaller diameter eligible because it
produce dense heat exchanger, so that the cost will be cheaper. Tube thickness
chosen for keep the internal pressure and give enough of corrosion allowance.
We choose 0.75 in (19.5mm). OD for this heat exchanger and tube length
will be chosen by assumption.The configuration of tube usually consists of
triangular, rotated square and square configuration. Triangular configuration gives
higher heat transfer rates than square configuration so that triangular configuration
chosen.
Figure A.26 Tube configuration

32
There are several following consideration for fluid placement in shell and
tube:
a. Corrosion : the more corrosive fluid should be fixed to tubeside for decreasing
material costs.
b. Fouling : the fluid that have higher fouling should be fixed to tubeside for keep
the fluid velocity. High velocity can reduce fouling.
c. Fluid temperature : if the high fluid needs special material alloy, so that the
fluid must be placed in tube side for reduce overall costs.
d. Operation pressure : the higher flow pressure should be placed in tube. Because
of the small diameter, tube is able to keep high pressure.
e. Viscosity : if the fluid flow is turbulent, higher viscosity fluid should be fixed
to shell for acquiring the greater heat transfer coefficient.
The number of tubes ascertainable by calculate each tube area first. And
then we can calculate the number of tubes from the following equation:
Tube length is normally chosen between 8, 12, 16, or 20 ft. But, we assume
the tube length is 5.5 m is because this equipment would be installed on modular
platform. More length tube will decrease shell diameter, so that the exchanger
costs is cheaper.
With assuming the length of tubes = 5.5m, tube area is acquired,
3.
Drawn of Heat Exchanger Design E-101 by HRTI Xchanger Design

Simulator;
fill the boxes; inlet and outlet temperature of both fluids, heat duty, and overall
heat transfer coefficient as seen as figure below;
33
Figure A. 27 Input Summary in HTRI Xchanger Simulation

Figure A.28 Input Geometry in HRTI Xchanger Simulation

34
Figure A.29 Input Process in HTRI Xchanger Simulation

Figure A.30 Result of Drawing HE in HTRI Xchanger Simulation

35
Figure A.31 Drawing HE 3D Model in HTRI Xchanger Simulation

Figure A.32.Tube Layout in HTRI Xchanger Simulation

36
A.5.2 Heat Exchanger E-1860

A procedure for designing Heat Exchanger E-102 will be described as
follows by calculated using TOTAL Toolbox Shell & Tube Heat Exchanger
Sizing Tool and Aspen HYSYS Simulation:
Figure A.33 TOTAL Toolbox Sizing Simulation

1.
1st step & 2nd step; Determine fluid specification

The first step consists in defining how many linear zones are require for heat
exchanger calculation (from 1-5). If there is a phase change, more than one zone
will be required and the exchanger will be provided with one shell only. In order
to design an exchanger with several zone and several shells in the series the user
shall design each zone separately.
Then the flow configuration shall be chosen. The calculation, the
verification, and the graph are updated accordingly. For a heat exchanger with one
pass tube side, the counter current and cocurrent mode can be choses. For a heat
exchanger with two or more pass tube side, the flow configuration is called
multipasses and is considered as counter-current.
37
fill the green boxes; inlet and outlet temperature of both fluids, heat duty, and
overall heat transfer coefficient.
Operation condition such as flow rates, terminal temperatures, heat duty and
physical
properties
are
obtained
from
Aspen
Plus
simulation.
Figure A.34 Result in Aspen Plus Simulation

Figure A.35 Process Condition input in Toolbox

38
Figure A.36 Heat Exchange with multipasses tube side and minimum number of shell
2.
3rd step & 4th step; the LMTD and the temperature correction factor F

Based on theory, Choose the simple combination of shell and tube passes or
number of shells in series that will have a value of F above 0.8 or so. The
correction factor calculation following:
39
where
Ti
= Temperature input on tubeside
To
= Temperature output on tubeside
Ti
= Temperature input on shellside
To
= Temperature output on shellside
Figure A.38. Correction Factor for 1 Pass-Shellside and Mutiple of Two Passes-Tubeside
(Source : Wallas, 1990)
LMTD (log mean temperature difference), calculated for determine the

differences of mean temperature between hot fluid and cold fluid along heat
exchanger. LMTD can be calculated with this following equation:
(
(
(
(
where
T1 = hot fluid temperature, in
T2 = hot fluid temperature, out
t1 = cold fluid temperature, in
t2 = cold fluid temperature, out
The overall heat transfer coefficient can be assumed according to fluid type
used in heat exchanger. For this heat exchanger, we assume between 172192kcal/(h.m2.oC) for Gas (1-7abs) heat exchanger. Assume U = 190
kcal/(h.m2.oC).
40
Table A.1. Typical Overall Heat Transfer Coefficients
(Source: GPSA Engineering Data Book)
Heat transfer area can be calculate with the following equation:
3.
5th step & 6th step Determine type, tube size and tube configuration
Figure A.39. Result in Total Toolbox Simulation

Tube size chosen based on available manufacturer size. Standard exchanger

tube diameters are 0.75 or 1 in. OD. The smaller diameter eligible because it
produce dense heat exchanger, so that the cost will be cheaper. Tube thickness
chosen for keep the internal pressure and give enough of corrosion allowance.
We choose 0.75 in (19.5mm). OD for this heat exchanger and tube length
will be chosen by assumption.
41
The configuration of tube usually consists of triangular, rotated square and

square configuration. Triangular configuration gives higher heat transfer rates
than square configuration so that triangular configuration chosen.
Figure A.40 Tube configuration

There are several following consideration for fluid placement in shell and
tube:
a. Corrosion : the more corrosive fluid should be fixed to tubeside for decreasing
material costs.
b. Fouling : the fluid that have higher fouling should be fixed to tubeside for keep
the fluid velocity. High velocity can reduce fouling.
c. Fluid temperature : if the high fluid needs special material alloy, so that the
fluid must be placed in tube side for reduce overall costs.
d. Operation pressure : the higher flow pressure should be placed in tube. Because
of the small diameter, tube is able to keep high pressure.
e. Viscosity : if the fluid flow is turbulent, higher viscosity fluid should be fixed
to shell for acquiring the greater heat transfer coefficient.
The number of tubes ascertainable by calculate each tube area first. And
then we can calculate the number of tubes from the following equation:
Tube length is normally chosen between 8, 12, 16, or 20 ft. But, we assume
the tube length is 5.5 m is because this equipment would be installed on modular
platform. More length tube will decrease shell diameter, so that the exchanger
costs is cheaper.
42
With assuming the length of tubes = 5.5m, tube area is acquired,
4.
Drawn of Heat Exchanger Design E-101 by HRTI Xchanger Design

Simulator;
fill the boxes; inlet and outlet temperature of both fluids, heat duty, and overall
heat transfer coefficient as seen as figure below;
Figure A.41 Input Summary in HTRI Xchanger Simulation

43
Figure A.42 Input Geometry in HTRI Xchanger Simulation

Figure A.43.Input Process in HTRI Xchanger Simulation

44
Figure A.44 Result of Drawing HE in HTRI Xchanger Simulation

Figure A.45.Drawing HE 3D Model in HTRI Xchanger Simulation

45
Figure A.46 Tube Layout in HTRI Xchanger Simulation

A.6
Pump
Pump is a device used to move fluids or sometimes slurries by mechanical
action. Pumps can be classified into two general types:

1. Dynamic pumps, such as centrifugal pumps.
2.
Positive displacement pumps, such as reciprocating and diaphragm

pumps.
Pump selection is made on the flow rate and head required, together with
other process considerations, such as corrosion or the presence of solids in the

fluid. The chart shown in Figure 5.6 can be used to determine the type of pump
required for a particular head and flow rate. This figure is based on one published
by Doolin (1977).
To size a pump, firstly things that must be defined:
1. The flow rate of liquid the pump is required to deliver
2. The total differential head the pump must generate to deliver the required
flow rate
3. Other key considerations for pump sizing are the net positive suction head
available (NPSH) and the power required to drive the pump
46
In this MEG regeneration and Reclamation system, we use reciprocating

pumps, the advantages of reciprocating pumps in general over centrifugal pumps
may be summarized as follows:
1. They can be designed for higher heads than centrifugal pumps.
2. They are not subject to air binding, and the suction may be under a
pressure less than atmospheric without necessitating special devices for
priming.
3. They are more flexible in operation than centrifugal pumps.
4. They operate at nearly constant efficiency over a wide range of flow rates
A.5.1 Reciprocating Pump

Reprocating pump is a pump that can make a change the value of pressure
from suction pressure to discharge pressure. This pump could change the flow rate
of reactant.
Step Calculation of Reciprocating Pump Design:
1. Pump suction pressure
(
DP1 = Pressure drop from suction equipment to pump suction connection

V = Liquid velocity at suction connection (m/s)
H1 = Suction side static head at minimum liquid level (m)
(
If inside diameter of suction connection, D in inches, Q in m3/hr
(
If inside diameter D in mm (millimeter)
When velocity (V) is low or to be neglected, PS become
(
2. Pump discharge pressure
(
47
DP2 = Pressure drop from discharge connection to discharge equipment

(kg/cm2)
H2 = Discharge side static head at maximum level or end pipe (m)
3. Pump Differential Pressure
4. Pump Total Head

(
5. Net Positive Suction Head Available

(
NPSHA should be greater than NPSHR
6. Liquid Horse Power (LHP)
(
7. Pump Brake Horse Power (BHP)
(
(
Where Tc is torque factor 1.05 for N>100 RPM and 1.08 for N<100 RPM,
is volumetric efficiency
is pump mechanical efficiency (0.88),
variator efficiency (for varible speed metering pump, (0.80-0.85),
is speed
is
reducing gear efficiency (0.93-0.95). volumetric efficiency:
Water at above 1cP,
= 0.92 0.96
Water at below 1 cP
= 0.94 0.98
Viscous slurry
= 0.90-0.95
If there is any slurry sediment = 0.85-0.90
48

Appendix A: A.1. Three Phase Separator

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Appendix A: A.1. Three Phase Separator

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1

Three Phase Separator

Gas mass flowrate

Figure A.3 Gas Mass Flow From ASPEN HYSYS

Figure A.4 Mass Density of Gas From ASPEN HYSYS

Figure A.5 Water Mass Flow From ASPEN HYSYS

Figure A.6 Water Mass Density From ASPEN HYSYS

Figure A.7 Mass Flow of Oil From ASPEN HYSYS

Figure A.8 Mass Density of Oil From ASPEN HYSYS

Critical velocity of liquid in gas

Hor. Length : for (150) or no (100) mm

Where: QV = the gas volumetric flow rate at operating condition

the gas density at operating condition

Where: QL = the oil volumetric flow rate at operating condition

the oil density at operating condition

Where: QW= the volumetric flow rate at operating condition

the water density at operating condition

Where: VC = the critical velocity of liquid in gas

Where: Vg = the horizontal gas velocity

Step 6.Determining the vapor area (AV) calculated by the toolbox:

Where: AV = vapor area in gas section

Hold-up time between LIH and NIL

Height between NIL and bottom

Height between LIH and NIL

Hold-up time between NIL and LIL

Height between NIL and LIL

Height between LIL and LILL

Whereas the value of the theoritical corresponding volume is 7.22 m3

Whereas the theoretical corresponding volume is 1.13 m3

Separation residence time

Height between NOL and NIL

Hold-up time between LAHH and

Height between LAHHand LAH

Hold-up time between LAH and

Height between LAH and NOL

Hold-up time between NOL and LAL

Height between NOL and LAL

Hold-up time between LAL and

Height between LAL and LALL

Hold-up time (enough to close valve)

Mini 150 mm for bottom LT, 300 for 300

(Source : Authors Documentation)

High liquid alarm (trip), LAHH=h8+h7+h6+h5+h4

: height for gas area

: horizontal length for a number of mm of carbon deposit

: height between demister and liquid

: height between LAHH and LAH

: height between LAH and NOL

: height between NOL and LAL

: height between LAL and LALL

: LALL (Low Liquid Level Alarm)

: Liquid alarm high high-shut down

: Liquid alarm high-high level

: Normal liquid level

: Liquid alarm low-low level

: Liquid alarm low-low shut down

: Interface liquid alarm high-high shut down

: Interface liquid alarm high-high level