Flash Drum Designer 2.0

A complete overhaul: preliminary flash drum sizing from Aspen outlet data, with a proper Windows desktop app.

Flash Drum Designer v2.0

Major rewrite of the original tool. v2.0 is a preliminary mechanical sizing app for horizontal and vertical knockout drums — not a process simulator. Run your case in Aspen Plus (or similar), pull the FLASH2 outlet vapor and liquid mass flows and densities, and get drum diameter and length/height plus a PDF report.

If you used the old release: this version is a full ground-up overhaul — new GUI, GPSA K-factor workflow, PDF export, and clearer sizing logic throughout.

Download & run

1. Download FlashDrumDesigner.exe below.
2. Double-click to launch — no Python install required.
3. Enter outlet stream data from your simulation (or click Load Example).
4. Click Calculate. A PDF sizing report is saved automatically in the same folder as the EXE.

What’s new in v2.0

• Native Windows desktop GUI (PySide6) with a Windows 10–style layout
• GPSA K-factor lookup with pressure presets, custom pressure, and applicability rules (at / below / above selected pressure)
• Live K-factor preview showing effective K, table value, and source
• Load Example — propane / n-butane NGL depropanizer reflux drum case (17.2 bar g)
• Horizontal and vertical drum orientation
• SI and US customary units (kg/s, kg/m³, bar g / lb/hr, lb/ft³, psig)
• Service corrections — standard, glycol/amine, compressor suction
• Demister / no-demister K-factor adjustment
• Automatic PDF export when using the EXE — inputs, results, and 50% liquid-level schematic
• Command-line interface still available for scripting and batch runs

Sizing basis

• Souders-Brown vapor disengagement
• Liquid holdup from user-specified residence time
• Fixed 50% liquid level (half-full) design assumption
• Configurable L/D or H/D ratio and vapor area margin (default 20%)

Typical workflow

Simulate in Aspen → copy outlet vapor/liquid flows and densities → size the drum here → use results for preliminary mechanical design.

What this tool does not do

• Flash calculations, heat balances, or phase equilibrium
• Replace Aspen, HYSYS, or any process simulator
• Nozzle sizing, internals design, or full mechanical packages

Verify all results against your project standards before construction.

For developers

Source, CLI usage, and build instructions: README

Flash Drum Sizer 1.0

Flash Drum Designer v1.0

Takes mass flowrates and densities of in/outputs from process simulation software (e.g FLASH2 from Aspen Plus) and spits out design parameters, namely length and diameter of the flash drum.

Works for both horizontal and vertical drums. You may need to look up K-values for your specific use case, as listed K-values are intended for vertical drums with demister meshes. For many cases, K=0.107 as a conservative estimate for horizontal drums is fine too.