209- Technical proposal for the vane separator dedicated to the dilution steam generation tank in the ethylene plant - NOVEL TECH

In previous technical posts, we discussed in detail separators such as steam generators and steam drums. The gas-liquid separators used or recommended for different process packages may vary, but generally there are several main types: conventional wire mesh demisters, conventional cyclone separators, conventional simple Snowflake vane separators, umbrella-type cyclone separators, and feather vane separators. Generally speaking, traditional wire mesh demisters have limited operating flexibility; during operation, “liquid slugging” and “flooding” are likely to occur, resulting in a significant decrease in separation efficiency ； Traditional cyclone separators are not suitable for fluctuating operating conditions, as this leads to poor separation stability and significant variations in separation efficiency ； The traditional simple Snowflake leaf separator essentially overcomes the main shortcomings of conventional wire mesh demisters and conventional cyclone separators; however, in high-pressure and ultra-high-pressure conditions, there is still a need to improve the separation efficiency ； The umbrella-type cyclone separator represents an improvement over the Chevron vane separator, achieved by combining deformation techniques with cyclone separation; it is primarily recommended for use in the process packages of EO/EG plants, that is, those for the production of ethylene oxide through ethylene oxidation and hydration, as well as in petrochemical ethylene glycol production projects ； The feather-leaf separator is a new type of separation technology device that combines momentum separation, coalescence separation, vector separation, and liquid film surface free energy capture separation techniques to operate together. It offers significant advantages over other separation technologies in terms of separation accuracy, depth of separation, operational flexibility, operating pressure drop, and maintenance costs. In particular, it excels at addressing the problematic issue of \"siphon short-circuiting\" – where substances that have already been separated are suddenly drawn back into the purified airflow due to siphonic effects, leading to secondary contamination and mixing – especially under complex and fluctuating operating conditions. As a result, it is often chosen for the technical upgrading and modification of various systems.

The attachment below shows excerpts from the documents regarding the umbrella-type cyclone separator used in the process package for the production of ethylene oxide (EO) and ethylene glycol (EG) via the oxidation-hydration of ethylene

This post was last edited by luoli519 on 2022-10-8 at 14:18. The umbrella-type cyclone separators used in the process package for the ethylene oxidation-hydration process to produce ethylene oxide (EO) and ethylene glycol (EG) are shown in the following pictures:

This post was last edited by luoli519 on 2023-3-23 at 13:57. In the ethylene plant process package mentioned in this technical post, the dilution steam generator 5100-V-1270 utilizes a feather separator. Please refer to the technical design documents provided by the owner’s design institute, as shown in the attached drawings:

This post was last edited by luoli519 on 2022-10-8 at 14:40. The process data for the dilution steam generator 5100-V-1270 provided by the owner’s design institute are as follows: 1. N2 flow at the top gas-phase outlet: Flow rate: 264,483 kg/h; OT: 182℃； OP: 0.942 MPaG; Molecular weight: 18.02 ； Gas density: 5.35 kg/m³; Gas phase viscosity: 0.015 cP ； Vapor compression factor: 0.928. 2. Upper waist gas-liquid mixture inlet N5AB stream: Flow rate: 1,308,543 kg/h; OT: 182.1℃ ； OP: 0.949 MPaG; wherein, gas flow rate: 261,709 kg/h; molecular weight: 18.02 ； Gas flow density: 5.39 kg/m3; gas phase viscosity: 0.015 cp ； Vapor compression factor: 0.928 ； Liquid flow rate: 1,046,834 kg/h; Molecular weight: 18.02 ； Air density: 884.81 kg/m³; Surface tension: 41.74 dyne/cm ； Vapor viscosity: 0.148 cp.

This post was last edited by luoli519 on 2022-10-8 at 14:49. 3. Liquid phase inlet N11 stream in the middle and lower waist area: Flow rate: 287,620 kg/h; OT: 148.9℃； OP: 0.949 MPaG; Molecular weight: 18.02 ； Density: 918.39 kg/m3; Surface tension: 49.17 dyne/cm ； Vapor viscosity: 0.183 cp. 4. Lower waist liquid phase inlet N12 stream: Flow rate: 29158 kg/h; OT: 174.8℃ ； OP: 0.942 MPaG; Molecular weight: 18.02 ； Density: 892.64 kg/m3; Surface tension: 43.4 dyne/cm ； Vapor viscosity: 0.154 cp. 5. Bottom liquid phase outlet stream N6: Flow rate: 1,308,543 kg/h; OT: 174.8℃ ； OP: 0.956 MPaG; Molecular weight: 18.02 ； Density: 892.65 kg/m³; Surface tension: 43.4 dyne/cm ； Vapor viscosity: 0.154 cp.

The technical requirements specified by the owner’s design institute for the vane separator are as follows: 1. Ensure complete separation of liquid droplets with sizes of 8–10 microns or larger, such that the residual amount in each million standard cubic feet of exhaust airflow does not exceed 0.1 gallon； 2. Under the design operating conditions, the pressure drop across the vane separator shall not exceed 7 kPa ； 3. The material is 304 stainless steel.

The dimensions of the aforementioned louvered separator dedicated to the dilution steam generator, as agreed upon by all parties, are as follows:

The main technical details of the vaned separator specifically designed for dilution steam generators, which were determined using Novel’s advanced dynamic separation technology along with its specialized calculation and configuration design system platform, are summarized as follows: 1. Separator model: NOVEL G50-3800-1.3/FV; 2. Design platform: Novel’s proprietary advanced dynamic separation technology calculation and configuration design system platform； III. Dimensions and material: ID 3800mm * T/T 10900mm ； Shell: Q345R + Internals: S30403 ； IV. Performance Parameters: 4.1 Design Pressure: 1.3 MPaG/FV ； 4.2 Design temperature: 220°C ； 4.3 Separation efficiency: 100% removal of liquid droplets with a size of 4.59 microns or larger, with no residual liquid in the outlet stream exceeding 0.1 GL/MMSCF ； 4.4 Rated total pressure drop: 1.58kPa ； 4.5 Operating noise level: 27.48db. V. Main core internal components: 5.1 Pre-distributed coalescing internal component set, model G50D3800/7; 5.2 Precision vaned separation internal component set, model G50-133-2000EDP; 5.3 Anti-siphon short-circuit liquid dropping internal component set, model G50LD7.

This post was last edited by luoli519 on 2022-10-28 at 14:20. The attached figure is one of the proof documents supporting the four core technologies of the special vane separator for dilution steam generators, prepared by NOVEL’s authoritative dynamic separation technology calculation and configuration design system platform: “Compilation of Numerical Data on Vane Separators”