Flash Tank Calculation Report

BLOWDOWN FLASH TANK
PROCESS DESIGN REPORT
Client's Name: Galliford Try
Contractor's Name:
Project Title: Hull Biomass UK LLP 1
Location: Hull, United Kingdom
Job Number: MI-17085
HP Document No. MI-17085-PR-CR-001
Client Doc. No. HULL_06_REP_10_51705
Current Revision: 3 - Latest Issue
3 29/05/17 Latest Issue S.P. - -
2 12/04/17 Re-Issued for Approval S.P. D.L. -
1 01/02/17 Issued for Approval G.N. L.M. L.M.
0 18/01/17 Issued for Review G. N. L.M. L.M. / J.B.

Prepared By Checked By Approved By
Revision Date Description
Signatures
This document is issued by Harris Pye DMCC, Dubai UAE. The information contained in this document is the confidential property
of Harris Pye. It cannot be disclosed, copied or used for any purpose without written approval from Harris Pye. If you are not
authorised to possess this document, please destroy it immediately.
Client: Galliford Try Doc. No. MI-17085-PR-CR-001
Project: Hull Biomass UK LLP 1 Tag No. T-06-17023
Location: Hull, United Kingdom Job No. MI-17085
BLOWDOWN FLASH TANK Rev. Date Sheet
2 of 29___ _
PROCESS DESIGN REPORT 3 29/05/17
REVISION HISTORY
Rev. Date Description Comments / Revised parts
0 18/01/17 Issued for Review First revision
- Revision History sheet added

1 01/02/17 Issued for Approval - Continuous Blowdown inlet drum pressure changed to 49.3 bar(a)
and saturation.
Re-Issued for - Incorporated updated information on CBD line; Inlet nozzles &
2 12/04/17
Approval tank top portion dimensions
3 29/05/17 Latest Issue Revised Client Document number
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TABLE OF CONTENTS
Revision History 2
Contents 3
Design Input Data 4
Assumptions 5
Nozzles Sizing 6
N1/ N9 - CBD Inlet 6
N2 - Flash Steam Outlet 9
N3 - Liquid Outlet 9
N4-N5 - Level Instruments 10
N6 - Pressure Intrument 10
N7 - Vent 11
N8 - PRV 11
Vessel Sizing 13
Vessel Diameter for Gravity Separation 13
Wire Mesh Pad Mist Eliminator Sizing 14
Calculation of Vessel Height 15
References 17
Appendix- 18
Demister pad Datasheet 18
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Rev DESIGN INPUT DATA
Flash Tank Design

Units Value
Data
Operating Pressure [bar(a)] 3.51
Operating Temperature [°C] 139.0
Design Pressure [bar(a)] 5.0
Design Temperature [°C] 260.0
Liquid
Stream Description Units CBD [3] Two-Phase Inlet Flash Steam
Outlet/Liquor
2 Flow Rate [kg/h] 1,000 1,000 264.6 735.4
2 [kg/s] 0.278 0.278 0.074 0.204
2 Pressure [bar(a)] 49.79 3.52 3.51 3.51
2 Temperature [°C] 262.4 139.0 139.0 139.0
2 Enthalphy [kJ/kg] 1153.2 1153.2 2732.1 584.7
2 Quality [-] 0.000 0.265 1.000 0.000
2 Density [kg/m³] 777.8 7.20 1.9 927.1
2 Viscosity [cP] 0.100 0.198 (2) 0.014 0.198
2 Volumetric Flow [m³/s] 0.00036 0.0386 0.0384 0.00022
2 Specific Heat [kJ/kg K] 5.029 3.760 2.303 4.284
2 Thermal Conduct. [W/m K] 0.601 - 0.029 0.685
Notes:
(1) Flash Steam and liquid Outlet stream properties are calculated by heat and mass balance.
(2) Mixture viscosity approximated with saturated liquid viscosity.
2 (3) Pressure upstream of the CBD valve, including also the static head.
Physical Constants Symbol Unit Value

Acceleration of gravity g [m/s²] 9.81
Pi π [-] 3.14
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Rev ASSUMPTIONS
The following assumptions were made for the design of the blowdown flash tank:
1. The operating pressure in the flash tank is established by the downstream equipment, i.e. the deaerator. The pressure will be
the deaerator pressure plus the pressure drops of the flashed steam in the piping and vessel internals. In the following, a
0.01 bar pressure drop is assumed, to be verified after pipe routing and vessel sizing.
2. The vapor-liquid separation in the vessel is mainly achieved by gravity settling of the liquid droplets and by action of the
inlet device. A wire mesh mist eliminator is installed in the vessel to increase the separation efficiency.
3. For gravity settling, the momentum equation reduces to a balance of the gravity and drag forces at steady state. This allows
to calculate a terminal velocity, which is the superficial velocity around the liquid droplets under equilibrium conditions.
4. The typical droplet size for a flash vessel with two-phase flow inlet in similar applications is 150 micron (μm). The
blowdown flash vessel will be able to separate the liquid droplets larger than 150 μm by gravity. To achieve a higher
separation efficiency and to remove the smaller-sized droplets, a demister pad (wire mesh mist eliminator) will be used.
5. To determine the drag force, the C vs Reynolds curve is divided into three regions, corresponding to typical Re number
D
regions, where different physical laws are used to represent the CD vs Re curve (namely Stoke's, Intermediate and Newton's
Laws, respectively). This results in three different formulations of the terminal velocity, based on the Reynolds number and
thus depending on the fluid. In this work, the Intermediate Law will be used, representing the typical range encountered in
similar applications.
6. Liquid residence time in the vessel is taken as 2 min, based on level control considerations and on the surge volume to
accommodate transients in the inlet stream.
7. The vessel is vented at atmospheric pressure, with the assumption of closed flash steam output and open inlet.
2 8. The sizing calculations are done for Nozzle N1A,the same is applicable to N1B due to similar Process design parameters.
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Rev FLASH TANK NOZZLES SIZING

Sizing of the nozzles is an iterative procedure, starting with an assumed diameter and configuration, checking that the fluid
velocity in the line and in the nozzle does not exceed the maximum allowable velocity, usually established by erosion
limits. In addition, the nozzle size is usually taken as the feed line size.
2 1. Blowdown Flash Tank Inlet Nozzle (N1 / N9)
2 The feed inlet to the separator is, in general, a 2-phase mixture, due to the flashing of the fluid in the blowdown
line,downstream to the blowdown valve.The following is a summary of the conditions of the inlet continuous blowdown
stream to the flash tank.
Units Two-Phase Inlet to Vessel (1) Design Condition (3)

- Max Norm Min Vapor Liquid
2 Flow Rate min [kg/h] 1,100 1,000 500 291.1 808.9
[kg/s] 0.306 0.278 0.139 0.081 0.225
Pressure p [bar(a)] 3.52 3.52 3.52 3.51 3.51
Temperature T [°C] 139.0 139.0 139.0 139.0 139.0
Enthalphy h [kJ/kg] 1,153 1,153 1,153 2732.1 584.7
Quality x [-] 0.265 0.265 0.265 1 0
Density ρ [kg/m³] 7.2 7.2 7.2 1.91 927.1
Viscosity μ [cP] 0.198 (2) 0.198 (2) 0.198 (2) 0.014 0.198
Volumetric Flow Q [m³/s] 0.0424 0.0386 0.0193 0.0423 0.00024
Notes:
(1) Two-Phase mixture after blowdown valve, in the blowdown line.
(2) Mixture viscosity approximated with saturated liquid viscosity.
(3) Design condition taken as the Max flow condition. The flash pressure in this case was assumed equal to the Normal
case.
Determination of the flow regime in the inlet line
Since the inlet to the vessel is a multiphase fluid, the determination of the flow regime in the inlet line is very important for
the inlet nozzle sizing and for the efficient separation of the two components. Normally, the inlet nozzle of a flash vessel is
sized for Annular or Spray flow. Other flow regimes, such as Slug, Plug and Froth are not recommended.
The existing blowdown line data from the boiler to the Flash Tank is summarized below.
Description Unit Existing Line Data Recalculated Nozzle
2 Line Number - - 01-15-BB-AS1-067 06-50-BB-6CS-H26A/B
2 Line Material - - A 335 P1 A 335 P1
Nozzle Material - - A 106 Gr.B A 106 Gr.B
Nominal Diameter DN - 15 50
Outside Diameter OD mm 21.3 60.3
Schedule Sch. - 80 80
Thickness t mm 3.7 5.5
Inside Diameter ID mm 13.9 49.3
Flow Area A m² 0.00015 0.00191
Flow Velocity v m/s 281.0 22.3 OK
A preliminary calculation of the velocity in the existing line shows that for the two-phase mixture, the velocity is
unrealistic. Therefore, the line has to be resized to avoid such high velocities.
The maximum velocity in a two-phase line is usually established by the erosional limit, which can be calculated according
to:
𝑉_𝑒𝑟=(100 ∙0.3048)/√(𝜌_𝑚 ) (100) (0.3048)
= = 45.5 m/s [Ref.5]
(7.2) (0.0624)
Taking this as a base, the new line size has been calculated iteratively, and the flow regime in the new line was determined,
using a flow map from the literature [Ref.1]. To use this map, some flow parameters must be calculated, and used as input
to the chart axes. The insersection point gives the flow regime in the pipe with sufficient accuracy for practical applications.
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PROCESS DESIGN
Taking this as a base, the new line size has been calculated REPORT
iteratively, and the flow regime in2 the new line 11 of 29 _____
was determined,
29/05/17
using a flow map from the literature [Ref.1]. To use this map, some flow parameters must be calculated, and used as input
to the chart axes. The insersection point gives the flow regime in the pipe with sufficient accuracy for practical applications.
σ = Fluid surface tension = 0.050 N/m

Gl = Liquid mass velocity = 117.95 kg/m² s
Gv = Vapor mass velocity = 42.44 kg/m² s = 8.69 lbm/ft² s
𝜆 = 〖 (𝜌_𝑣^′ 𝜌_𝑙^′ ) 〗 ^0.5=[(𝜌_𝑣/1.2)
(𝜌_𝑙/1,000)]^0.5 = 1.22
𝜓 = 0.073/𝜎 [((𝜇_𝑙∕0.001))/ 〖 (𝜌_𝑙∕1000) 〗
^2 ]^(1/3) = 8.94
𝑋 = (𝐺_𝑙 𝜆 𝜓)/𝐺_𝑣
= 30.2
𝑌 = 𝐺_𝑣/𝜆
= 7.15 lbm/ft² s
The flow pattern in the inlet piping
is annular, as recommended for
similar applications.
Although, there is some intrinsic

uncertainty in the actual flow
pattern, but this method was
considered acceptable for the scopes
of this work.
Therfore, the chosen line and nozzle
size are adequate.
Figure 1 - Determination of the flow
regime in the inlet piping [Ref.1].
Nozzle sizing
To size the nozzle, a maximum (conservative) value for the kinetic energy per unit volume (ρv²) is usually specified, and
the nozzle diameter calculated iteratively based on this value.
The maximum value of (ρv²) is very dependent on the type of inlet device (if any) mounted on the nozzle, which usually
decrease the momentum of the inlet fluid to values not dangerous from the point of view of corrosion or liquid entrainment.
(ρv²) ≤ 3,500 kg/m s² considering an inlet baffle only.
If inlet devices, such as slotted distributors or inlet vanes are used, higher values of the (ρv²) can be accepted.
Check of (ρv²) value with chosen nozzle diameter.
(ρv²) = (7.2) (22.3)² = 3,574 kg/m s² Increase the nozzle size
Sizing of Inlet baffle
b
Given the low inlet mixture velocity with the selected nozzle size, no inlet device is required. a
However, an inlet baffle is installed to deflect the entering flow and promote an initial
Dv
separation of the two phases.
Typical dimensions for the inlet baffle/diverter are:
a ≥ max {2 D ; D + 50} ≥ 120.65 mm say 150 mm a
b ≥ 100 ≥ 100 mm say 120 mm
c ≥ max {2 D ; D + 60} ≥ 120.65 mm say 150 mm c
Figure 2 - Sketch of inlet baffle.
Calculation of Pressure Drop in Inlet Nozzle.

An estimate of the pressure drop in the inlet nozzle can be obtained using the Lockhart and Marinelli correlation. To apply
the method, the pressure drops per unit length in the selected line are calculated considering each phase as present alone in
the piping section considered. Then, the Lockhart and Martinelli parameter is calculated as follows:
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BLOWDOWN FLASH Rev. Date Sheet
An estimate of the pressure drop in the inlet nozzle can be obtainedTANK
using the Lockhart and Marinelli correlation. To apply
PROCESS
the method, the pressure drops per unit DESIGN
length in the REPORT
selected line are calculated considering each as present alone12inof 29 _____
2 phase 29/05/17
the piping section considered. Then, the Lockhart and Martinelli parameter is calculated as follows:
𝑋=[(∆𝑃/𝐿)_𝐿/(∆𝑃/𝐿)_𝐺 ]^(1/2)
Total 2 -Phase max flow rate = 1,100 kg/h

Liquid Flow rate = 808.9 kg/h
Vapor Flow rate = 291.1 kg/h
Nozzle length lN = 150.0 mm
Nozzle OD = 60.3 mm
Nozzle Thickness = 5.5 mm
Nozzle ID = 49.3 mm
Nozzle flow area = 0.0019 m²
Absolute pipe roughness (CS) = 0.0457 mm
Relative Pipe Roughness = 0.00093
Liquid pressure drop
Liquid mass flux GL = 117.9 kg/m² s
GL D (117.9) (0.0493)
Liquid Reynolds Number = = = 29,320 Turbulent
μ 1.98E-4
Friction factor (using Zigrang and Sylvester correlation)
Z&S Factor A = -3.102
Friction factor fL = 0.0259
𝑓_𝐿 1/𝐷 (𝐺_𝐿^2)/ 〖 2𝜌 〗 _𝐿
Pressure drop per meter = (Δp/L) L = = 3.95 Pa/m
Vapor Pressure Drop
Vapor mass flux GG = 42.4 kg/m² s
GL D (42.4) (0.0493)
Vapor Reynolds Number = = = 10,550 Turbulent
μ 1.98E-4
Friction factor (using Zigrang and Sylvester correlation)
Z&S Factor A = = -2.859
Friction factor = fG = 0.0321
𝑓_𝐺 1/𝐷 (𝐺_𝐺^2)/ 〖 2𝜌 〗 _𝐺
Pressure drop per meter = (Δp/L) G = = 0.63 Pa/m
Calculation of Lockhart and Martinelli parameters
X = = 2.50
Following the recommendation in Ref.2, a value of X double will be used fo rthe annular and spray flow patterns.
X' = 5.00
= 5.10
4.6 〖 (𝑋^′) 〗 ^(−1.78)+12.5 〖 (𝑋^′) 〗 ^(−0.68)+0.65
YL 1+20/((𝑋^′))+1/
= 〖 (𝑋^′) 〗 ^2 = 5.04
YG = 〖 (𝑋^′) 〗 ^2 𝑌_𝐿 = 30.1

The resulting pressure drop per unit length is then:
(Δp/L) 2-ph = YL (Δp/L) L = = 20.1 Pa/m
(Δp/L) 2-ph = YG (Δp/L) G = = 19.0 Pa/m
The frictional pressure drop in the inlet nozzle length, is then:

Δpfrict = lN (Δp/L) L = = 3.02 Pa
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The entrance loss, with the assumption of incompressible flow (Δp≤10% Pin),and A1/A2 → 0 is given by:
(𝑉_1^2)/2 (1−𝐴_1/𝐴_2 )^2
Δpentr = = 248.21 Pa
Finally, the pressure drop due to the change in direction of the fluid due to the baffle plate would need to be estimated.
However, since the calculation of the pressure drop of a 2-phase fluid changing direction is an involved and iterative
calculation, this loss will be conservatevely estimated as 1.5 times the entrance loss.
Thus:
Δpbp = 1.5 Δpentr = 372.31 Pa
Δptotal = Δpfrict+Δpentr+Δpbp = 623.5 Pa = 0.0062 bar
2. Flash Steam Outlet Nozzle (N2)
The data on the existing flash steam line to the deaerator is shown in the table below. A preliminary calculation of the
velocity in this line shows that for the LP Flash Steam, the velocity is low compared to the usual velocities for steam (≈ 15 -
20 m/s). Therefore, a new line size was assumed and the velocity recalculated (see Table below).
Description Unit Existing Line Recalculated Line
2 Line Number - - 01-100-STM-CS1-029 06-50-STM-1CS-H28
Material - - A 106 Gr.B A 106 Gr.B
Nominal Diameter DN - 100 50
Outside Diameter OD mm 101.6 60.3
Schedule Sch. - 80 40
Thickness t mm 8.1 3.9
Inside Diameter ID mm 85.4 52.5
Flow Area A m² 0.0057 0.0022
2 Flow Velocity v m/s 7.4 19.5 OK
The nozzle size will be as per the recalculated line size. Also in this case, a check for the (ρv²) shall be made. However, for
gas/vapor outlet nozzles, this parameter can be higher, due to the single phase fluid and the relatively low erosion risk.
Check of (ρv²) value with chosen nozzle diameter.
(ρv²) = (1.9) (19.5)² = 729 kg/m s² ≤ 5,400 kg/m s² Nozzle Size is Acceptable
2 In addition, a check for sonic velocity has to be made, since the fluid in the nozzle is in the vapor phase, but for saturated
steam this velocity is usually very high (>400 m/s, for LP Steam), so the selected nozzle is acceptable.
3. Liquid Outlet Nozzle (N3)
To size the oultet liquid/liquor line, a nozzle size (and line size) is assumed and the fluid velocity is checked. The criteria
for liquid outlet nozzles is usually based on the fluid velocity, as follows:
0.6 m/s ≤ v ≤ 1.2 m/s
Description Unit Outlet Liq./Liquor Line
2 Line Number - - 06-20-BB-1CS-H27
Material - - A 106 Gr.B
Nominal Diameter DN - 20
Outside Diameter OD mm 26.7
Schedule Sch. - 80
Thickness t mm 3.9
Inside Diameter ID mm 18.8
Flow Area A m² 0.0003
2 Flow Velocity v m/s 0.9 Nozzle Size is Acceptable
Sizing of Vortex Breaker
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The vortex breaker sizing is based on rules of thumb, and a minimum fluid height above the device has to be maintained.
Minimum fluid height above vortex breaker = 150 mm
438.2 mm
Vortex Breaker height = 1.5 ODn = 40.0 mm
Vortex Breaker width = 2.5 ODn = 66.7 mm
Actual fluid height above vortex breaker = 403 mm OK LWL
250 mm 66.7 mm
403 mm
193 mm
40 mm
Figure 3 - Arrangement of Vortex Breaker.
OD = 26.7 mm
4. Instrumentation and Safety Nozzles
4.1 Level Instrument Nozzles (N4 - N5)

The following table summarizes the main data for the Level Instrument Nozzles [Ref.7].
Description Units Instrument Nozzles Data
Instrument Tag No. - LIT-06-17302 LE-06-17301
Instrument Type - Level Transmitter Level Gauge
Control Range mm 650 -
Visible Range mm - 700
Nozzle Material - A 106 Gr.B A 106 Gr.B
Number of Nozzles - 2 2
Nozzle Size NPS 3/4 3/4
DN 20 20
Nozzle Schedule Sch. 80 80
Nozzle Outside Diameter mm 26.7 26.7
2 Distance between nozzle CL mm 650 650
3/4" 3/4"
HHWL
Control Range
HWL
Level Transm.
Level Gauge
650
NWL
650
650
LWL
LLWL
3/4"
BTL 75
3/4"
Figure 4 - Schematic representation of Level Instruments Arrangement.
4.2 Pressure Instrument Nozzle (N6)

The following table summarizes the main data for the Pressure Instrument Nozzle [Ref.7].
Description Units Nozzle Data
Instrument Tag No. PIT-06-17401
Instrument Type Pressure Transmitter
Nozzle Nominal Size NPS 1
DN 25
Nozzle Schedule Sch. 80
Nozzle Outside Diameter mm 33.4
4.3 Vent Nozzle (N7)

In order to size the vent nozzle, a design case was considered where the flash steam line is closed and the CBD inlet nozzle
is kept open. This means that the steam flashing in the vessel at the venting pressure, has to be vented through the vent
nozzle. To calculate the amount of flash steam to vent in the design condition, the pressure drop in the vent piping has to be
estimated and added to the atmospheric pressure. For 649383605.xlsx
preliminary calculations, the pressure drop in the vent line is
estimated, subject to update after pipe routing.
PROCESS DESIGNwhere
In order to size the vent nozzle, a design case was considered REPORT
the flash steam line is closed
2 and the 15 of 29 _____
CBD inlet nozzle
29/05/17
is kept open. This means that the steam flashing in the vessel at the venting pressure, has to be vented through the vent
nozzle. To calculate the amount of flash steam to vent in the design condition, the pressure drop in the vent piping has to be
estimated and added to the atmospheric pressure. For preliminary calculations, the pressure drop in the vent line is
estimated, subject to update after pipe routing.
2 Δpvent, assumed = 0.02 bar

pv = patm + Δpvent = 1.033 bar(a)
The amount of flash steam at this pressure would then be obtained, as before, by flashing of the incoming Continuous
Blowdown to the pressure of the vessel during venting. The following table gives the thermophysical properties of the inlet
CBD and the flash steam under venting conditions. With the calculated flash steam, the vent nozzle can be sized,
maintaining a fluid velocity ≤ 50 m/s.
Description Units Inlet CBD Flash Steam

2 Flow Rate min [kg/h] 1,100 357.0
[kg/s] 0.306 0.099
Pressure p [bar(a)] 3.5 1.033
Temperature T [°C] 139.0 100.5
Enthalphy h [kJ/kg] 1,153.2 1153.2
Quality x [-] 0.265 0.325
Density ρ [kg/m³] 7.20 1.87
ρfs [kg/m³] - 0.61
Viscosity μ [cP] 0.198 0.280
Volumetric Flow Q [m³/s] 0.0424 0.163
The following table summarizes the main data for the Vent Nozzle sizing.
Description Unit Vent Line

Equipment Tag Number - - T-06-17026
Vent Valve Tag No. - - V-06-17019
Nominal Diameter DN - 80
Outside Diameter OD mm 88.9
Schedule Sch. - 40
Thickness t mm 5.5
Inside Diameter ID mm 77.9
Flow Area A m² 0.0048
2 Flow Velocity v m/s 34.2 OK
4.4 PRV Nozzle (N8)

In order to determine the Pressure Relief Valve (PRV) nozzle size, the preliminary sizing of the valve has to be undertaken.
In the following, preliminary sizing calculations, as per Ref.9 will be presented. For further information, see Ref.8 for the
final PRV datasheets.
In the table below, the design data for the pressure relief valve sizing is given.
Description Symb. Unit Value

2 Relieving capacity W kg/h 320.2
Vessel Design pressure pd bar(a) 5
Vessel MAWP MAWP bar(a) 5
2 PRV Set Pressure Pset bar(a) 5
Allowable overpressure Po,% % 10%
2 Relieving pressure P1 bar(a) 5.5
Downstream Pressure - bar(a) 1.013
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2 Backpressure - bar(a) 1.013
Relieving Temperature (sat.) T1 °C 155.5
K 428.6
To size the valve for vapor relief, a preliminary check for critical flow (or chocked flow) has to be made and the critical
pressure calculated as follows. If the downstream pressure is less than or equal to the critical pressure, critical flow will be
established in the valve.
2 𝑝_𝑐𝑟=𝑃_1 [2/(𝑘+1)]^(𝑘∕(𝑘−1) ) 2 1.135/(1.135-1)
= 5.5 = 3.18 bar(a) Critical Flow
1.135+ 1
where:
Pcr = Critical Pressure
P1 = Relief Pressure
k = 1.135 for dry saturated steam
The required effective discharge area of the pressure relief valve for vapor service is calculated according to the following
formula, from API 520-1.
2 𝐴=(190.4 𝑊)/(𝑃_1 𝐾_𝑑 𝐾_𝑏 𝐾_𝑐 𝐾_𝑁 𝐾_𝑆𝐻 ) 190.4 (320.2)

= = = 126.32 mm²
550 (0.9 · 0.975) ·1 · 1 · 1 · 1
= 0.1958 in²
where:
Kd = Effective coefficient of discharge for preliminary sizing = 0.9 · 0.975
Kb = Capacity correction factor due to backpressure = 1
Kc = Combination correction factor, in case of installation with rupture disk = 1
KN = Correction factor for Napier equation = 1
KSH = Superhated steam correction factor = 1
2 Therefore, an E orifice, as per API 576, with a discharge area of 0.196 in², or 143 mm² is adequate.
The following table summarizes the PRV Nozzle and Valve data.
Description Unit PRV Nozzle Data
2 Equipment Tag Number - - T-06-17026
PRV Valve Tag No. - - PRV-06-17082
2 Valve Discharge Area Chosen A mm² 198.1
2 Valve Orifice Designation - - 1½F2
2 Nozzle Nominal Diameter DN - 40
2 Nozzle Outside Diameter OD mm 48.3
Nozzle Schedule Sch. - 80
2 Nozzle Thickness t mm 5.1
2 Nozzle Inside Diameter ID mm 38.1
4.5 Summary of nozzle sizes

Nozzle No. Description Nozzle Size and Schedule
N1/ N9 CBD Inlet DN50 Sch.80
N2 Flash Steam Outlet DN50 Sch.40
N3 Liquid Outlet DN20 Sch.80
N4 Level Gauge DN20 Sch.80
N5 Level Transmitter DN20 Sch.80
N6 Pressure Transmitter DN25 Sch.80
N7 Vent DN80 Sch.40
N8 Pressure Relief Valve DN40 Sch.80
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PROCESS DESIGN REPORT 2 29/05/17 18 of 29_ ____
Rev FLASH TANK VESSEL SIZING

The procedure to size the Flash Vessel is similar to that of sizing any gas (or vapor)/liquid separator. In fact, the inlet CBD
stream consists in a liquid-vapor mixture, and the two phases are separated in the vessel.
The main parameter to size the vessel is the inside diameter. In general, the final value of the vessel diameter shall be such
that the requirements for gravity separation of the liquid droplets, wire mesh pad (demister) and liquid holdup are satisfied.
1. Vessel Diameter for Gravity Separation.
The blowdown flash vessel will be able to separate the liquid droplets larger than 150 μm by gravity. So,
Dp = 150 μm = 1.5E-04 m
The terminal velocity, according to the Intermediate Law assumption is:

𝑢_𝑡=0.154 (𝑔^0.71 𝐷_𝑝^1.14
(𝜌_𝑙−𝜌_𝑔 )^0.71)/(𝜌_𝑔^0.29 𝜇_𝑔^0.43 )
where:
ρl = Saturated liquid density = 927.1 kg/m³
ρg = Saturated flash steam density = 1.9 kg/m³
μg = Flash steam viscosity = 1.4E-05 kg/m s (= cP/1000)
Substituting,
(
0.154) (5.06) (4.37E-05) (127.65)
ut = = 0.446 m/s
(1.207) (0.008083)
2 Check for Intermediate Law assumption validity : (2 < Re < 500)
𝑅𝑒=(𝑢_𝑡 𝐷_𝑝 (0.446) (0.00015) (1.9)

𝜌_𝑔)/𝜇_𝑔 = = 9.40 OK
0.000014
An alternative method to calculate the terminal velocity makes use of the following general formula:
𝑢_𝑡=1.15√(( 〖 𝜌〗 _𝑔 𝐷_𝑝
( 〖𝜌 _𝑙−𝜌 〗 _𝑔))/( 〖 𝜌〗 _𝑔 𝐶_𝐷 ))
Since CD is dependent on Re, and thus on the terminal velocity, an iterative approach would be required. However, using a
the following correlation, together with Figure 1, the terminal velocity is eliminated and the drag coefficient can be directly
calculated.
(1.30E+07) (1.9) (3.38E-12) (925)

〖𝐶 _𝐷 𝑅𝑒 〗 ^2=( 〖 0.13 ∙ 〖 10 〗 ^8 𝜌 〗 _𝑔 = = 419.1
𝐷_𝑝^3 ( 〖𝜌 _𝑙−𝜌 〗 _𝑔))/(𝜇_𝑔^2 ) 0.000185
Figure 5 - Drag Coefficient determination from CD(Re)² [Ref.3].
649383605.xlsx

(9.81) (0.00015) (925.1)
CD ≈ 4.0 Hence, the terminal velocity: ut = 1.15 = 0.485 m/s
(1.9) (4)
The difference between the two values of the terminal velocity calculated with the two above methods is ≈ 8.82 %, hence
acceptable.
Taking the lower value of the two terminal velocities calculated above (conservative), the required vessel diameter can be
calculated, with the vapor velocity being less than the terminal velocity, to avoid entrainment:
𝐷/1000≥√(4/𝜋∙𝑄_𝑎/𝑢_𝑡 )
(4) (0.0423)
= = 0.347 m
(3.14) (0.446)
where:
D = Minimum Inside Diameter of the flash tank vessel = 347 mm
ut = Terminal velocity for liquid droplets = 0.446 m/s
Qa = Flash steam max volumetric flow rate = 0.0384 m³/s
2. Wire Mesh Pad Mist Eliminator Sizing
To size the mist eliminator, a simplified and more empirical approach is employed, due to the complexity in expressing the
mesh pad separation performance in simple mathematical terms.
Similarly to the above, a critical velocity is calculated, using the following formula:
𝑉_𝑐=𝐹 𝐾√((𝜌_𝑙−𝜌_𝑔)/𝜌_𝑔 )
where:
2
K = Sizing factor or velocity constant (0.055 - 0.110 for vertical drums) = 0.085
F = Design margin to account for surging and uncertainties in data = 0.85
Typical values for K are in the range of 0.055 - 0.110 m/s for vertical separation drums with demister pad (for flash tank
applications, a value of 0.076 is employed). In the case of a flash drum with wet steam the K value can be taken as:
925.1
K = 0.076 m/s Vc = (0.076) (0.85) = 1.42 m/s
and 1.9
The minimum required wire mesh pad diameter is then obtained:
𝐷_𝑤𝑚/1000≥√(4/𝜋∙𝑄_𝑎/𝑉_𝑐 )
(4) (0.0423)
= = 0.195 m say 200 mm
(3.14) (1.42)
where:
Dwm = Minimum Required Diameter of the Wire mesh pad = 200.0 mm
Vc = Critical velocity = 1.421 m/s
Qa = Flash steam volumetric flow rate (max) = 0.0423 m³/s
The vessel drum inside diameter shall be larger than the required pad diameter, to allow for proper installation.
Dves ≥ Dwm + 100 = 200 + 100 = 300.0 mm

Thus, the required vessel diameter to satisfy both design criteria above, shall be:
Dves ≥ max{D ; Dv} = max {347 ; 300} = 347 mm say IDves = 438.2 mm
(Assuming an 18 in NPS Pipe, Sch. STD) ODves = 457.2 mm
649383605.xlsx

2 The wire mesh pad outside diameter, chosen from commercially available sizes: ODwm = 323.9 mm
Minimum size of wire mesh pad bottom ring supports = 107.15 mm say 120 mm (on each side)
Calculated vapor velocity with the chosen diameter = 0.28 m/s ≤ ut = 0.45 m/s → OK
Mesh Pad Thickness

The recommended thickness of the mesh pad for this application is 150 mm, with a typical pressure drop of less than 25
mmWC.
Therefore, selected wire mesh pad thickness is: twm = 150 mm
Check for vapor velocity through the wire mesh pad to be:
uwm 0.51
0.30 ≤ = = 0.3612 ≤ 1.1 OK
Vc 1.42
3. Calculation of Vessel Height
2 The vessel height is usually calculated as a function of the vessel diameter. In fact, an optimal H/D ratio usually exists, that
minimizes the cost of the vessel. Typically the H/D ratio for similar vessels ecountered in practice varies in the range 3.0 -
5.0, depending on the operating pressure.
The total height of the cilindrical part of the vessel can be expressed as:
Hh
Ht = HT-T + 2 Hh = H1 + H2 + H3 + twm + H4 + 2 Hh H4
twm
where:
H3
H1 = Height from bottom TL to HHWL, depending on liquid holdup time (see 3.1)
H2 = Height from HHWL to inlet nozzle CL
H3 = Vapor space disengaging height H2
HHW
twm = Wire mesh pad thickness L
HWL
H4 = Height from top of wire mesh pad to top TL LWL H1
2 Hh = Height (depth) of one vessel head. = 193 mm LLW

L
(Assuming a ASME B16.9 pipe cap will be used) Hh
Figure 6 - Flash Vessel.

Liquid Holdup time
The liquid holdup time in the vessel was selected considering the requirements for uniform flow on the downstream
heat exchanger and thus provide a dampening effect for any possible oscillation in the inlet stream that may affect the
downstream equipment.
The liquid residence time (or holdup time) was selected as 2 min from HWL to LWL.
tmin = Minimum required liquid residence time in vessel = 2 min

Ql = Liquid outlet volumetric flow rate (max) = 0.0145 m³/min
Av = Vessel Cross-sectional area = 0.151 m²
Water Levels h [mm] V [m³] t [min]

HHWL - HWL 100 0.01508 1.04 650 HHWL
HWL - NWL 150 0.02262 1.56 550 HWL
OK
NWL - LWL 150 0.02262 1.56
NWL
LWL - LLWL 100 0.01508 1.04 400
LWL
649383605.xlsx

400
LLWL - BTL 150 0.02262 1.56 LWL
250
LLWL
BTL - Empty 193.0 0.01867 1.28 150 BTL
Total 843.0 0.11668 8.02
193.0
Therefore, the distance between the bottom tangent line (BTL) and the
HHWL, is:
Figure 7 - Liquid Levels in vessel.
H1 = 650 mm
and the holdup time in the level control range (HWL - LWL) is equal to 3.11 min.
Minimum distance of nozzle from HHWL
In order to avoid entrainment of liquid in the vapor stream, a minimum distance from the nozzle centerline to the
HHWL (High High Water Level) must be respected. This distance is usually taken as:
H2 = max {0.3 D ; 12"+0.5 ODn ; 350} = 350 mm

Vapor space disengaging height
The distance between the centerline of the inlet nozzle and the bottom supports of the Wire mesh pad is usually taken as:
H3 = max {0.5 D ; 900 ; 36" + 0.5 ODn} = 944.56 mm say 950 mm
Top Clearance above wire mesh pad
The clearance from the top of the Wire mesh pad to the outlet nozzle is
established based on the Figure [Ref.3].
NOD = Outlet Nozzle Outside Diameter = 60.3 mm

Dwm = Wire Mesh Pad Outside Diameter = 323.9 mm
Cm = Min Clearance = (NOD + Dwm)/2 = 131.8 mm
2 Assumed Clearance = 295.0 mm
2 Hdepth = ASME B16.9 pipe cap inside height = 193.0 mm
f = Head Straight Flange length = 0.0 mm
2 Hh = Total Head depth = 193.0 mm Figure 8 - Minimum Clearance above
2 H4 = Cm - Hh - f = 102.0 mm Demister [Ref.3].
DN 50
In summary, the set levels, considering fabrication allowances, are:
H1 = 650 mm ± 40 mm
193 mm
H2 = 350 mm ± 40 mm
H3 = 950 mm ± 40 mm 102 mm
twm = 150 mm ± 40 mm
H4 = 102.0 mm ± 40 mm 300 mm
Hh = 193.0 mm ± 40 mm
438.2 mm
HT-T = 2,202 mm => 2200 mm ± 40 mm 950 mm
Ht = HT-T + 2 Hh = 2,586 mm ± 40 mm 120 mm DN 50
HT-T
Check for: 3 ≤ ≤ 5 DN 50 150 mm
ODves
350 mm
HT-T HHWL
= 4.8 OK
649383605.xlsx
Rev FLASH TANK VESSEL

HHWL
SIZING
= 4.8 OK
ODves
HWL
600 mm
LWL
LLWL
193 mm
`
Figure 9 - Summary of Flash Vessel Dimensions.

DN 20
649383605.xlsx
]
23 of 29_____
INSULATION THICKNESS
Calculate the insulation thickness for PP (?), using the EN 12241 standard.
649383605.xlsx 03/08/2023
24 of 29_____
]
649383605.xlsx 03/08/2023
PROCESS DESIGN REPORT 25 of 29
2 29/05/17
Rev REFERENCES
[1] Green, D.W.; Perry, R.H. - Perry's Chemical Engineering Handbook, 8th Ed. (2008).
[2] Ludwig, E.E. - Applied Process Design Vol. 1, 3rd Ed. (1999).
[3] GPSA Engineering Data Book, Vol. I & II, 12th Ed. (2004).
[4] Towler, G.; Sinnott, R. - Chemical Engineering Design (2008).
[5] API 14E - Recommended Practice for Design and Installation of Offshore Production Platforms and Piping Systems,
5th Ed. (1991)
[6] EN ISO 4126 Safety Devices for Protection Against Excessive Pressure.
2 [7] Drawing No. HULL_01_DWG_19_70017_C - Blowdown System P&ID
2 [8] HP Document No. MI-17085-PS-SP-001_5 - Pressure Relief Valves Datasheets
[9] API 520-1, Sizing, Selection and Installation of Pressure Relieving Devices
PROCESS DESIGN REPORT 26 of 29
2 29/05/17
27 of 29
APPENDIX
Demister Pad Datasheet
649383605.xlsx
28 of 29
649383605.xlsx
Flash Steam NOTES
2
to Deaerator [1] Assumption of cold boiler
draining.
Intermittent Blowdown 7
Sootblower Condensate 8
Note [1] Hot Make-up

Boiler Drains 9 to Deaerator
Deaerator Overflow & 10 HOLDS

Drains
11 Vent Steam
Flash
Tank
Continuous Blowdown 1 T-06-
17026
6
Atmospheric
Blowdown Tank
T-06-17081
3 4
Make-up Water KEY
LCV
Preheater 12 Water
HE-06-17083 Saturated Steam
Make-up Water from Condensate
5
Treatment Plant To Drain System Intermittent Cond.
TCV
Foul Water
STREAM 1 2 3 4 5 6 7 8 9 10 11 12
Continuous Flash Tank Cold Hot Intermittent Sootblower Deaerator Blowdown
Description Flash Steam Cold Liquor Boiler Drains Vent Steam
Blowdown Liquor Make-up Make-up Blowdown Condensate Overflow Tank Outlet
Flow [kg/h] 1,000 264.6 735.4 735.4
Temperature [°C] 139.0 139.0 139.0 20
Pressure [bar(a)] 3.5 3.5 3.5 4
Density [kg/m³] 7.2 1.9 927.1 998.3
Volume Flow [ m³/h] 138.9 138.3 0.79
STREAM 13 14 0 08/03/23 Issued For Review GN LM

Rev Date Description Drawn Checked Approved
Description
Job No. Client: Site: HULL, UNITED
GALLIFORD TRY
Flow [kg/h] MI-17085 KINGDOM
Temperature [°C] Title:
Pressure [bar(a)]
BLOWDOWN SYSTEM PROCESS FLOW
Density [kg/m³]
DIAGRAM
Volume Flow [ m³/h]
Doc. No. Size: A4

MI-17085-PR-PF-001
Sheet: 01 of 01

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BLOWDOWN FLASH TANK

PROCESS DESIGN REPORT

Client's Name: Galliford Try

Project Title: Hull Biomass UK LLP 1

Location: Hull, United Kingdom

Job Number: MI-17085

HP Document No. MI-17085-PR-CR-001

Client Doc. No. HULL_06_REP_10_51705

Current Revision: 3 - Latest Issue

3 29/05/17 Latest Issue S.P. - -

2 12/04/17 Re-Issued for Approval S.P. D.L. -

1 01/02/17 Issued for Approval G.N. L.M. L.M.

0 18/01/17 Issued for Review G. N. L.M. L.M. / J.B.

Rev. Date Description Comments / Revised parts

0 18/01/17 Issued for Review First revision

- Revision History sheet added

3 29/05/17 Latest Issue Revised Client Document number

Client: Galliford Try Doc. No. MI-17085-PR-CR-001

Client: Galliford Try Doc. No. MI-17085-PR-CR-001

Flash Tank Design

Physical Constants Symbol Unit Value

Client: Galliford Try Doc. No. MI-17085-PR-CR-001

Rev FLASH TANK NOZZLES SIZING

Units Two-Phase Inlet to Vessel (1) Design Condition (3)

Determination of the flow regime in the inlet line

σ = Fluid surface tension = 0.050 N/m

Although, there is some intrinsic

Figure 2 - Sketch of inlet baffle.

Calculation of Pressure Drop in Inlet Nozzle.

Total 2 -Phase max flow rate = 1,100 kg/h

YG = 〖 (𝑋^′) 〗 ^2 𝑌_𝐿 = 30.1

(Δp/L) 2-ph = YG (Δp/L) G = = 19.0 Pa/m

The frictional pressure drop in the inlet nozzle length, is then:

3. Liquid Outlet Nozzle (N3)

Sizing of Vortex Breaker

4. Instrumentation and Safety Nozzles

4.1 Level Instrument Nozzles (N4 - N5)

4.2 Pressure Instrument Nozzle (N6)

4.3 Vent Nozzle (N7)

2 Δpvent, assumed = 0.02 bar

Description Units Inlet CBD Flash Steam

Description Unit Vent Line

4.4 PRV Nozzle (N8)

Description Symb. Unit Value

2 𝐴=(190.4 𝑊)/(𝑃_1 𝐾_𝑑 𝐾_𝑏 𝐾_𝑐 𝐾_𝑁 𝐾_𝑆𝐻 ) 190.4 (320.2)

4.5 Summary of nozzle sizes

Rev FLASH TANK VESSEL SIZING

The terminal velocity, according to the Intermediate Law assumption is:

𝑅𝑒=(𝑢_𝑡 𝐷_𝑝 (0.446) (0.00015) (1.9)

(1.30E+07) (1.9) (3.38E-12) (925)

Figure 5 - Drag Coefficient determination from CD(Re)² [Ref.3].

Rev FLASH TANK VESSEL SIZING

2. Wire Mesh Pad Mist Eliminator Sizing

Dves ≥ Dwm + 100 = 200 + 100 = 300.0 mm

(Assuming an 18 in NPS Pipe, Sch. STD) ODves = 457.2 mm

Rev FLASH TANK VESSEL SIZING

Mesh Pad Thickness

3. Calculation of Vessel Height