Bicol University College of Engineering

Department of Chemical Engineering

ChE Design 1:
Pressure Vessel Design
Engr. Sandino Michael Angelo G. Aguilar, ChE
Email: sandinomichaelangelo.aguilar@bicol-u.edu.ph
Objectives
• To demonstrate an understanding of the importance of
pressure vessels in various industries.
• Explain different types of pressure vessel and their
applications.
• Discuss the factors that influence pressure vessel design.
• Explore different components of a pressure vessel, such as
heads, shells, nozzles, and supports.
• Teach techniques for optimizing pressure vessel designs for
cost-effectiveness. Discuss trade-offs between design
complexity, materials, and manufacturing costs.
What are Pressure Vessels?
A pressure vessel is considered as any closed vessel that is
capable of storing a pressurized fluid, either internal or external
pressure, regardless of their shape and dimensions.
ASME Code Definition
A vessel in which the pressure is obtained from an indirect
source or by the application of heat from an indirect source or a
direct source. The vessel proper terminates at (a) the first
circumferential joint for welded end connections; (b) the face of the
first flange in bolted flange connections; or (c) the first threaded joint
in threaded connections."
Pressure vessels include but are not limited to compressed gas
storage tanks (i.e., air, oxygen, nitrogen tanks, etc.), anhydrous
ammonia tanks, hydropneumatics tanks, autoclaves, hot water
storage tanks, chemical reactors, and refrigerant vessels, designed for
pressure greater than 15 psi (1.034 bar) and a volume greater than 5
cubic feet (0.142 m3) in volume or 3/2 cubic feet (0.042 m3) in
volume with a pressure greater than 600 psi (41.37 bar).
What are Vessels?
Vessels are used for the following:
• Vapor-Liquid Separation
• Liquid-Liquid Separation
• Buffer system/hold-up for downstream equipment as protection
• Containment Vertical Pressure Vessel

Horizontal Pressure Vessel 3-phase Separator Vessel

Vessels in Industries (GPSA Sec. 7)
1. Flash Tank – Vessel used to separate the gas evolved from liquid
flashed from a higher pressure to a lower pressure.
2. Scrubber or Knockout Drum – Vessel designed to handle streams with
a high gas-to-liquid ratio. The liquid is commonly entrained as mist in
the gas or is free-flowing along the pipe wall.
3. Three Phase Separator – a vessel used to separate gas and two
immiscible liquids of different densities (e.g. gas, water, and oil).
4. Slug Catcher – a separator design able to absorb sustained in-flow of
large liquid volumes at irregular intervals. Usually found on gas
gathering systems or other two-phase pipeline systems.
Note: Separator is used as another term for scrubbers, knockouts, line-drips and
decanters.
 Vessels in Industries

Knockout Drum (Vertical / Horizontal)

Flash Tanks (Vertical / Horizontal)

References:
1. https://www.alutal.com.br/en/industrias-e-aplicacoes/geracao-de-energia/tanques-flash
2. https://amarineblog.com/2020/11/25/what-is-knockout-drum/
Slug Catcher
3. https://enggcyclopedia.com/2012/02/slug-catcher/
FLOWSHEET SAMPLE

PFD (LP Steam Condensate Drum) P&ID (LP Steam Condensate Drum)
When to use Vertical or
Horizontal Vessel?
Condition VERTICAL TYPE HORIZONTAL TYPE
Compact Separators OK OK
Small Liquid Surge Drums OK -
Solids Removal with Liquid OK -
High Vapor Load OK -
High Liquid Load - OK
Three Phase (G/L/L) Separation - OK
Liquid-Liquid Separation - OK

High Liquid Degassing Residence Time - OK

Foaming Feeds - OK
Cost Higher Lower
Plot Area Consumption Low High
PARTS OF VESSELS

GPSA Fig. 7-7 Gas-Liquid Separators

VESSEL OPERATION
Vapor/Liquid separation is present within the vessel
through flashing.
1. Feed is entered through a distributor or inlet
diverter such that the momentum of the liquid
entrained in the vapor causes the largest
droplets to impinge and drop by gravity.
2. Gravity separation of small droplets as the
vapor flows through the disengagement height.
3. A mist eliminator is present to entrain small
liquid droplets that are carried by vapor so that
larger droplets are formed that will separate by
Liquid Droplet (V/L Separation)
gravity Reference: Fig. 7-2 GPSA
PRESSURE VESSEL COMMON CONTROLS
Pressure vessels are required to
be controlled for safe
operation:
a. Flow Control (FC) – Control
of material balance based
on flow in or out of the
vessel.
b. Pressure Control (PC) –
Regulate the operating
pressure of the vessel,
normally located along the
vapor stream.
PRESSURE VESSEL COMMON CONTROLS
Pressure vessels are required to
be controlled for safe
operation:
c. Level Control – Monitor the
liquid levels inside the
vessel.
d. Temperature Control –
required to control heat
input or removal within
setpoint.
VESSEL INTERNALS
1. Inlet Devices – provides appropriate flow distribution (G/L
separation), reduction of inlet momentum (ρv2), and prevention of
droplet shattering or re-entrainment of the bulk liquid phase.
Common:
• None
• Diverter Plate
• Half Pipe
• Vane-type
• Cyclonic
 No
Conditions Baffle Elbow Half Pipe Diffuser Cyclone
Distributor

Momentum Reduction Poor Good Good Good Good Good

Inlet Distributor Selection

Bulk Separation Good Poor Average Average Good Good

Prevent Re-entrainment Good Average Average Average Good Average

Substantial Liquid in Gas Poor Poor Poor Average Good Good

Prevent Liquid Shatter Good Poor Poor Average Good Good

Low Differential Pressure Good Good Good Good Good Average

Prevent Foam Creation Poor Poor Poor Poor Average Good

Gas Distribution Poor Average Average Poor Good Poor

Prevent Liquid Surge Entrainment Good Good Good Liquid Good Good

Three Phase Poor Average Average No Good Good

VESSEL INTERNALS
2. Mist Extractors / Demisters - device fitted
to vapor-liquid separator vessels to
enhance the removal of liquid droplets
entrained in a vapor stream.

Mesh Type (Fig. 7-10 GPSA) Vane Type (Fig. 7-15 GPSA)
VESSEL INTERNALS
3. Weir - controls the liquid level in the vessel. This helps minimize
unwanted surges within the unit that are deleterious to the efficiency
of the vessel.
VESSEL INTERNALS
4. Vortex Breaker - installed on the outlet nozzle of a new tank. used in
engineering to stop the formation of a vortex when a fluid (liquid or
gas) is drained from a vessel such as a tank or vapor-liquid separator.
LIQUID LEVELS and HOLDING TIME
• Liquid Level
Control Range – length b/w LLL
and HLL, vessel holding time
a. Low Liquid Level (LLL) – lowest
in operation
b. High Liquid Level (HLL) –
highest in operation
c. Normal Liquid Level (NLL) –
50% of the control range
Notes:
Measuring Range – measured by level A. w/o Emergency Trip B. w/ Emergency Trip
transmitters
Visible Range – measured by Level Gauges
LIQUID LEVELS and HOLDING TIME
• Liquid Level
Alarm Level – set levels for
cautions to operators for safety
operations
a. Low Alarm Level (LAL) – 10%
of the upper level of LLL
b. High Alarm Level (HAL) – 90%
of the upper level of LLL / 10%
lower than HLL
Notes:
Measuring Range – measured by level A. w/o Emergency Trip B. w/ Emergency Trip
transmitters
Visible Range – measured by Level Gauges
LIQUID LEVELS and HOLDING TIME
• Liquid Level
Protection Range – indicates
length between LLLL and HHLL
a. Low Low Liquid Level (LLLL) –
lowest cut for emergency
shutdown
b. High High Liquid Level (HHLL)
– highest cut for emergency
shutdown
Notes:
Measuring Range – measured by level A. w/o Emergency Trip B. w/ Emergency Trip
transmitters
Visible Range – measured by Level Gauges
LIQUID LEVELS and HOLDING TIME
• Holding Time / Retention Time
-Liquid hold-up volume in the vessel
(Q) divided by the draw-off rate (P)

𝑄 (𝑚3 )
𝑡=
𝑚3
𝑃
ℎ𝑟
LIQUID LEVELS and HOLDING TIME
Reference: Monnery & Svrcek (1994) Multiphase Flow: Successfully Specify Three-Phase Separators
DIMENSIONS / SIZING
L/D ratio Criteria: L/D Values vs Vessel DP
• Vertical Separators – 2 to 4 range Vessel Design pressure Recommended
(barg) L/D
• Horizontal Type – 2.5 to 5 of L/D.
0 - 17 2.5
Note:
17-35 3-4
1. Dimensions shall be rounded up by >35 4-6
50mm, unless otherwise specified.
2. Fabrication dimensions must be
consulted to mechanical engineers.
DIMENSIONS / SIZING
Vessel Heads
1. (2:1) Semi-ellipsoidal head –
commonly selected in vessel
design.
2. Flat heads – commonly used for
vessel ID < 30 inches with lower
pressure rating.
3. For Design pressure exceeding 60
barg, use hemispherical over
semi-ellipsoidal.
DIMENSIONS / SIZING
Diameter
• Vessel Diameter is related to its vapor loading/capacity
upon separation.
• Critical parameter – vapor velocity

Forces Present:
𝐶𝐷
a. Drag Force: 𝐹𝑑𝑟𝑎𝑔 = 𝐴𝜌𝑉 𝑣 2
2
4
b. Gravity/Bouyant Force: 𝐹𝑔 = 𝑔 𝜌𝐿 − 𝜌𝑉 𝜋𝑅3
3
DIMENSIONS / SIZING
Diameter
Force Balance:
𝐹𝑑𝑟𝑎𝑔 = 𝐹𝐺
𝐶𝐷 2
4 3
𝐴𝜌𝑉 𝑣 = 𝑔 𝜌𝐿 − 𝜌𝑉 𝜋𝑅
2 3
𝝆𝑳 − 𝝆𝑽 𝟖𝒈𝑹
𝒗𝒂𝒍𝒍𝒐𝒘 = 𝑲 ; 𝑲=
𝝆𝑽 𝟑𝑪𝑫

𝟒𝑸𝑽
𝑫=
𝝅𝒗𝒂𝒍𝒍𝒐𝒘
DIMENSIONS / SIZING
Diameter
However, the actual calculation of diameter considers selected internals for the
vessel.
A. Vessel Vessel without Mesh/Demisters – The diameter of vessel is governed
by the terminal velocity for separation of liquid droplets (D > 150 um) by
gravity.
Terminal settling velocity (for spherical particles):
PHB 8th ed: Eq. 6-229.
𝟒𝒈𝑫𝑷 (𝝆𝑳 − 𝝆𝑽 )
𝒗𝑻 =
𝟑𝝆𝑪𝑫
CD values vs Re (8th ed PHB)
DIMENSIONS / SIZING
Diameter
A. Vessel Vessel without Mesh/Demistors.
Terminal Velocity Calculation (PHB 8th ed Eq. 6-232 to 6-234):
• Stoke’s Law (Laminar flow, Re < 0.1)
𝒈𝑫𝟐𝑷 (𝝆𝑳 − 𝝆𝑽 )
𝒗𝑻 =
𝟏𝟖𝝁
• Intermediate Regime (0.1 < Re < 1000)
𝟐𝟒
𝑪𝑫 = 𝟏 + 𝟎. 𝟏𝟒𝑹𝒆𝟎.𝟕
𝑹𝒆
• Newton’s Law (1000 < Re < 350,000, CD = 0.445)
𝒈𝑫𝑷 𝝆𝑳 − 𝝆𝑽
𝒗𝑻 = 𝟏. 𝟕𝟑
𝝆𝒗
DIMENSIONS / SIZING
Diameter
A. Vessel Vessel without Mesh/Demistors.
Terminal Velocity Calculation (Industry Approach):

𝟎. 𝟏𝟓𝟒 𝒈𝟎.𝟕𝟏 𝑫𝟏.𝟏𝟒

𝒑 𝝆𝑳 − 𝝆𝑮 𝟎.𝟕𝟏
𝒗𝑻 = ; 𝟐 ≤ 𝑹𝒆 < 𝟓𝟎𝟎
𝝆𝟎.𝟐𝟗
𝑮 𝝁𝟎.𝟒𝟑
𝑮

wherein; vt = terminal velocity (m/s)

Dp = droplet diameter (m), 150um = 150 x10-6 m
ρ = liquid or gas density (kg/m3)
𝜇 = viscosity (Pa-s)
Re = Reynold’s Number (-)
Note: Calculation is based on Intermediate region (2<Re<500) flow for simpler approach.
DIMENSIONS / SIZING
Diameter
B. Vessel with Mesh/Demisters – governed by max. allowable velocity of mist
eliminators for separation of liquid droplets (D < 150 um) by gravity.

Max Allowable Vapor Velocity (Souders-Brown Equation):

(PHB 8th ed Sec. 14, Eq. 14-226)
𝝆𝑳 − 𝝆𝑮
𝒗𝒎𝒂𝒙 = 𝒌
𝝆𝑮
wherein;
vmax - max allowable vapor velocity (m/s)
ρ - liquid or gas density (kg/m3)
k - SB constant (m/s), Refer to GPSA Engineering Data Book for values.
DIMENSIONS / SIZING Operating Pressure (bar) K (m/s)

Diameter OP ≤ 7 0.107
7 < OP ≤ 21 0.101
B. Vessel with Mesh/Demisters
21 < OP ≤ 42 0.092
• GPSA k values for horizontal mesh
42 < OP ≤ 63 0.083
pad
OP > 63 0.065
Note: If the mesh is a vane pack, the K
value is 3.3.
DIMENSIONS / SIZING
Diameter
• Diameter shall be calculated based on the above velocity criteria
𝟒𝑸𝒗
𝑫 ≥ 𝟏𝟎𝟎𝟎
𝝅 𝟑𝟔𝟎𝟎 𝒗
wherein;
D = drum diameter (mm)
Qv = vapor vol. flowrate (m3/hr)
v = vapor velocity (m/s)
DIMENSIONS / SIZING
Height Calculation
• Vessel Height is based on the liquid levels and
disengagement height for vapor space. H7
H6
Dimension Section GPSA Distance Criteria
200 mm min. H5
H1 BTL to LLLL (150 mm nozzle EL + 50mm min.
instrument EL)
H4
H2 LLLL to HHLL Retention Time requirement
HHLL to Feed Nozzle 300-600mm for diffuser or 0.25D for H3 HHLL
H3
Bottom other types (600 mm min.) HLL
H2
H4 Nozzle Diameter per nozzle sizing LLL

Disengagement 300-900 mm for diffuser or 0.5D for H1 LLLL

H5
Height other types
H6 Mist eliminator 100-150 mm
H7 Mist Eliminator to TTL 150mm min.
DIMENSIONS / SIZING
Nozzle Sizing
Recommended
• Feed Inlet Nozzle – sized based on the fluid Inlet Distributor
momentum (kg/m-s2)
momentum (𝜌𝑣 2 )
𝒇𝒍𝒖𝒊𝒅 𝒎𝒐𝒎𝒆𝒏𝒕𝒖𝒎 = 𝝆𝒎 𝒗𝟐𝒎 None 975 - 2250

ρm – mean fluid density of the feed (kg/m3) Diffuser 6000 - 9000

𝒎𝑮 + 𝒎𝑳
𝝆𝒎 = Half pipe or
𝑸𝑮 + 𝑸𝑳 1500 - 3750
elbow
m – mass flowrate (kg/s)
Baffle or other
Q – volume flowrate (m3/s) 1500 - 3750
types
vm – velocity of fluid (m/s)
𝑸𝑮 + 𝑸𝑳 Optional criteria: Vapor velocity to 9 – 18
𝒗𝒎 = 𝝅
𝑫𝟐 m/s or below erosional velocity
𝟒
D – nozzle diameter (m)
DIMENSIONS / SIZING
Nozzle Sizing
• Gas Outlet Nozzle – sized based on the fluid momentum (𝜌𝑣 2 )
𝝆𝑽 𝒗𝟐𝑽 ≤ 𝟒𝟓𝟎𝟎 𝑷𝒂

ρV – gas density of outlet stream (kg/m3)

m – mass flowrate (kg/s)
Q – volume flowrate (m3/s)
vV – velocity of fluid (m/s)
𝑸𝑽
𝒗𝑽 = 𝝅
𝑫𝟐
𝟒
D – nozzle diameter (m)
DIMENSIONS / SIZING
Nozzle Sizing
• Liquid Outlet Nozzle – sized based on the liquid velocity

𝒗 = 𝟐~𝟐. 𝟓 𝒎/𝒔

𝑄𝐺
vL – velocity of liquid (m/s) 𝑣𝑚 = 𝜋 2
𝐷
4
D – nozzle diameter (m)

Note: To be updated based on recommended line sizing criteria.

DIMENSIONS / SIZING
Auxiliary Nozzles
• Minimum connection size for vent and drain nozzles are as follows:
Full Vessel Volume (m3) Drain Vent
< 17 2” 2”
17 – 200 3” 3”
200 – 400 3” 4”
400 - 700 4” 6”
> 700 6” 8”

• Instrument connection (i.e. LG or LT), steam and purge out nozzle

size is 2”
DIMENSIONS / SIZING
Vortex Breakers
• All vessel designs must be equipped with a vortex breaker at the
liquid outlet nozzle

Manholes – minimum manhole size for maintenance are as follows:

Vessel ID (mm) Nozzle Size
≤ 750 10” (handhole)
750 < ID ≤ 900 18”
900 < ID ≤ 1500 20”
ID > 1500 24”
MATHEMATICAL EQUATION
(SUPPLEMENTARY)
• Volume for each head
𝐤 = 𝒅/𝑫
𝝅
𝑽𝒕𝒐𝒕𝒂𝒍 = 𝒌𝑫𝟑
𝟔
𝑽𝑯 𝑯 𝟐 𝑯
= 𝟑−𝟐
𝑽𝒕𝒐𝒕𝒂𝒍 𝑫 𝑫
wherein:
d – head depth (m)
D – vessel diameter (m)
k = 0.25 for 2:1 ellipsoidal head
k = 0.19 for dish type head
k = 0.5 for spherical head
H – segment height Note: Above calculation is based only for vessel
head, include volume at cylindrical part for the
VH – segment volume
overall volume of vessel and liquid.
Vtotal – total volume of head
EQUIPMENT COST
• A preliminary estimate for Vessel cost can
Pressure Vessels a b n Remarks
Vertical, CS -400 230 0.6 S: 150-69,200 kg
be done based on shell mass (kg). Refer to Horizontal, CS -2,500 200 0.6 S: 250-69,200 kg

the correlation below. Vertical, SS304 -10,000 600 0.6 S: 90-124,200 kg

Horizontal, SS304 -15,000 560 0.6 S: 170-117,000 kg

𝑪𝒗𝒆𝒔𝒔𝒆𝒍 = 𝒂 + 𝒃𝑺𝒏
Density
Metal Type
Wherein; (kg/m3)
Mild Steel 7900
C = equipment cost ($US) , US Gulf Coast Basis (Jan2006)
Low alloy Steel 7900
a,b,n = constants, Refer to table below. Cast Iron 7200

S = shell mass (kg) ; 𝑆 = 𝜋𝐷𝐿𝑡𝜌𝑚𝑒𝑡𝑎𝑙 Stainless Steel (18Cr,8Ni) 8000

Nickel (>99% Ni) 8900
D = vessel diameter (m) Copper 8800
L = vessel length (TL-TL) (m) Brass 8900

t = wall thickness (m) Aluminum (>99%) 8600

Dural 2700
ρmetal = metal density (kg/m3) Lead 11300
Titanium 4500
PRESSURE VESSEL SIZING STEPS
1. Perform material balance around the vessel. Include properties per
fluid stream.
2. Select appropriate vessel orientation.
3. Select proper Inlet Device and Mist Extractor requirement.
4. Calculate Vessel diameter based on vapor loading and velocity
requirement.
5. Determine min. height requirement. Check L/D ratio
6. Select and size auxiliary nozzles.
7. Check dimensions and optimize.
8. Determine cost based on optimized dimension.
9. Sketch and prepare Process Data sheet (Final output)
 T
V PRESSURE VESSEL
SAMPLE SKETCH

F MH

LG1 HLL
LT1

LLL
LG2 LT2
BTL

D
L
SAMPLE VESSEL PROCESS DATA SHEET

Sample PDS
Sample Problem:
Vertical Knock-out Drum Sizing
Design a simple vertical knock-out drum based on the following process
conditions:
Vapor flow rate = 45,400 kg/hr
vapor density = 37.2 kg/m3
vapor viscosity = 0.01 cP
Liquid Flow rate = 28,000 kg/hr
liquid density = 464 kg/m3
Droplet diameter > 150 micrometer
Holding time of liquid from LLL to HLL = 3 min.
Activity #2:
Vertical Vessel Design Calculation
Case Scenario: You are a Design/Applications engineer who will be presenting a
calculation tool for a vertical vessel design with and without demisters to various
clients as your service. A sample case study will be used as an example for your
tutorial/user manual to possible clients.
Outputs:
• Vertical Vessel Design for (1) With Demister (2) Without Demister
• User Manual
• Process Datasheet for Vessel with Demister

Deadlines:
Technical Outputs: September X, 2023, 5pm
Technical Presentation: October X, 2023
Activity #2:
Vertical Vessel Design Calculation
Case Study:
A process fluid at 3000 kmol/hr is split into a flash drum before entering
a deethanizer column. The feed is a mixture of 40 mol% ethane, 40%
propane, and the rest as butane at operating conditions of 0oC and 2
barg pressure. Find the overall mass and component balances around
the separator.

Note:
1. Use DWSIM as your simulator to verify your manual calculation results
and also for the fluid properties required for vessel design.
2. Include results in your preparation of the USER Manual for your calc
tools!
REFERENCES:
• Srivastava, A. (2020). Process Design Engineering Manual: Part III.
• Towler, G., & Sinnott, R. (2008). Chemical Engineering Design:
Principles, Practice and Economics of Plant and Process Design.
Elsevier Inc.
• Perry, Robert. (2008). Chemical Engineering Handbook, 8th edition.
NY. McGraw Hill Companies
• Gas Processors Suppliers Association (GPSA) – Engineering Data Book
• Educational Institute for Equipment and Process Design – Sizing of
Vertical Vessel
• BN-EG-UE109 Guide for Vessel Sizing
Bicol University College of Engineering
Department of Chemical Engineering

ChE Design 1:
Pressure Vessel Design
Engr. Sandino Michael Angelo G. Aguilar, ChE
Email: sandinomichaelangelo.aguilar@bicol-u.edu.ph