Specifying Separators
Basic parameters: temperature, pressure, flow rates, physical
properties of the fluids as well as degree of separation
Define time frame of separation occurrence
For known fluids, specify type and amount, also state ie. mist, free
liquid or sludge
Select worst case scenario and apply safety factors: safer to be
wrong on the right side
A compressor suction scrubber designed for 70-150 MMscfd gas at 400-600 psig
and 65-105 oF would require the separator manufacturer to offer a unit sized for the
worst conditions, ie. 150 MMscfd at 600 psig and 105 oF
pecifying Separators
Basic design equations for
separators with mist
extractors (vertical):
critical velocity (max)
Vt K
( l g )
( ft / sec)
correlation
by Sounders and Brown
Gm C
g ( l g ) (lb / hr. ft 2 )
Gm maximum allowable gas mass-velocity
necessary for particles of size D p to drop or
settle out of gas
K factor
(ft/sec)
C factor
(ft/hr)
Horizontal (w/vertical
pad)
0.4 50 0.5
1440 to
1800
Spherical
0.2 to 0.35
720 to
1260
0.18 to
0.36
648 to
1260
0.36
0.33
0.30
0.27
0.21
1260
1188
1080
972
756
Wet Steam
0.25
900
Most Vapor under vacuum
0.20
720
Salt and Caustic
Evaporators
0.15
540
Separator Type
Vertical or Horizontal
(w/horiz. Pad)
@atm pressure
@300 psig
@600 psig
@900 psig
@1500 psig
Note:
(1)
K = 0.35 @100 psig subtract 0.01 for every
100 psi above 100 psig
(2)
For glycol and amine solutions, multiply K by
0.6 0.8
(3)
Typically use one half of the above K or C
values for approximate sizing of vertical
separators without woven demisters
(4)
For compressor suction scrubbers and
expander inlet separators multiply K by 0.70.8
Specifying Separators
Horizontal separators with mist extractors are sized using
similar equations + additional factors for length, L.
Vt K
( l g ) L
10
g
0.56
Gm C g ( l g )
L
10
0.56
Gas capacity is calculated by subtracting the cross sectional
area occupied by the liquid from the vessel cross section
Ga
s
Common for horizontal separators to maintain its seam-seam
length to its diameter ratio of between 2:1 to 4:1
Specifying Separators
Important note:
The separator sizing equations given are used in the sizing of
the separation elements. It is common for the separation
elements to be placed in a larger vessel ie. For surging
purposes.
Specifying Separators
Mass flow rates:
In most instances it is convenient to use mass flow rate for
sizing purposes. When handling gas flows, the flow is given in
volume flow rate (MMSCFD)
M 3600Vtg
m 0.785Md 2 F
The fraction of the total area available for gas flow
can be found using the following table
h/D
h/D
0.0
5
0.98
1
0.3
0
0.74
8
0.1
0.94
8
0.3
5
0.68
8
0.4
0
0.62
6
0.4
5
0.56
4
0.5
0
0.5
0.5
0.43
0.1
5
0.90
6
0.2
0.85
8
h
0.2
5
0.80
4
Specifying Separators
Horizontal separators without mist extractors are dependent of gravity as
its sole mechanism for separation.
Important to set minimum droplet diameter to be removed
Typical range of droplet diameters 150 2000 microns
Vessel length can be calculated using,
4Qa
L
VtDv
Assuming the time taken for the gas to flow from inlet to outlet is the same as the time for the
liquid droplet of size Dm to fall from the to pof the vessel to the liquid surface
Example 1
A horizontal gravity separator ( without mist extractor) is required to
handle 60 MMscfd (39.8 Ib/s) of 0.75 specific gravity gas (MW =
21.72) at a pressure of 500 psig and a temperature of 100 F.
compressibility is 0.9, viscosity is 0.012 cp and liquid specific
gravity is 0.50. It is desired to remove all entrainment greater than
150 microns in diameter. No liquid surge is required.
Note:
1 micron = 0.00003937 in
MMscfd = 1000000 ft3/day
Example 1
Solution
Gas Density g = P (MW) / RTZ
= (514.7)(21.72) / ( 10.73)(560)(0.90)
= 2.07 Ib/ft3
Liquid Density
l
= 0.5 (62.4)
= 31.2 Ib/ft3
Mass flow rate
m = 60 x 106 ( 21.72) / ( 379)(24)(3600)
= 39.8 Ib/sec
Particle Diameter Dp = (150)(0.00003937) / (12)
= 0.000492 ft
CRe2 = (0.95)x108 gDp3 (l-g) / 2
= 4738
4 gDp ( l g )
Drag Coefficient, C
= 1.40
Vt
g 3C '
Terminal Velocity =
= 0.46 ft/sec
Gas Flow rate
= m/g
= 19.2 ft3/sec
Example 1
Solution
Assume a diameter, Dv
= 3.5 ft
Vessel Length,
= 4Qa / Vt Dv
= (4)(19.2)/(3.14)(0.46)(3.5)
= 15.2 ft
Varying diameters, appropriate lengths =
Diameter, ft
Length, ft
3.5
15.2
13.3
4.5
11.8
10.6
Example 2
What size vertical separator without mist extractor is required to meet
the conditions in example 1
Solution
Area
= Q / Vt
= 19.2/0.46
= 41.7 ft2
Dv
= 7.29 ft (minimum)
= 90 ID selected
Separators with Wire Mesh Mist Extractors
Frequently used as entrainment separators for the removal of very
small liquid droplets ( less then 10 microns)
Horizontally located and perpendicular to gas flow
Should be within 0-30o flat
Sizing is conducted using the previous terminal velocity equations
for horizontal and vertical vessels ( K value also obtained from
same table)
Separators with Wire Mesh Mist Extractors
Separators with Wire Mesh Mist Extractors
Example 3
What size of vertical separator equipped with a wire mesh mist
extractor is required for conditions used in the previous examples
From table for K values: K = 0.31 ft/sec
Vt 0.31
(31.2 2.07)
2.07
Vt 1.16
A
A
Q
Vt
19.2
1.16
ft
sec
Separators with Wire Mesh Mist Extractors
Dv 4.59 ft
A = 16.5 ft2
Vessel ID = 60 in
Separators with Vane Type Mist Extractors
No draining back through rising gas stream
A downcomer is used to routes
liquid out to drain
Inertia forces liquid droplets
against the vane walls
Offer similar separation performance to wire mesh with the added
advantage of higher resistance to plugging and cane be easily
installed in smaller vessels
The dependence on inertial forces can be a disadvantage at
reduced production rates
Retention Time in Separators
Liquid retention time
Retention time is average time a liquid molecule is
retained in vessel
To ensure liquid and gas reach equilibrium so that gas
molecule can evolve from liquid phase
Retention time = Volume of liquid storage in vessel
Liquid flow rate
Usually 1 to 3 minutes
Retention Time in Separators
Oil/water retention time
Need certain amount of oil storage so that oil reaches
equilibrium, entrained gas liberated, and free water
coalesced to fall into water storage
Need certain amount of water storage for entrained
large droplets of oil have time to coalesce and rise to
oil-water interface
Retention time 3 30 minutes
Separators with Centrifugal Elements
Separation of solids and liquids from a gas stream
Advantage over filter separators is lesser maintenance
The disadvantage include :
Lower efficiency compared to other
separator designs
Higher pressure drops compared to mist
extractors
Narrow operating flow range to achieve
higher efficiencies
Filter Separators
Higher separation efficiency compared to centrifugal separator
Periodic replacement of filter can be seen as a disadvantage
Solid particles are filtered out and the liquid phase is separated
through coalecing small droplets
Body size estimates for a horizontal filter separator uses a K value
of 1.3
Units designed for water will be smaller than units sized to remove
light hydrocarbons
Filter Separators
Separators with Centrifugal Elements
Example 4
A filter separator is required to handle a flow of 60 MMscfd at the similar
conditions found in previous examples. Estimate the diameter of a filter
separator
Vt 1.3
(31.2 2.07)
2.07
and
A = QA/Vt = 19.2/4.88
= 3.93 ft2
Dv
= 2.2 ft
= 26.9 in. min.
Select a 30 ID separator
Liquid-Liquid Separators
Divided into 2 broad separation categories: gravity and coalescing
Horizontal and vertical separators share the same principles of
separation; horizontal separators have the advantage of a larger
surface area
2 factors affecting gravity separation in the liquid phase:
extra fine particles with random movement
electric charge from dissolved ions (repelling instead of
coalescing)
Separator sizing is based on Stokes Law
Liquid-Liquid Separators
Vertical vessels
Wcl C *
(0.785) Dv 2
Wcl flowrate of light condensate liquid (bbl/day)
Shl specific gravity of heavy liquid
Sll specific gravity of light liquid
Horizontal vessels
( Shl Sll )
Wcl C *
( Shl Sll )
(0.785) LlHl
Ll - length of liquid interface area, ft
Hl width of liquid interface area, ft
For unknown droplet sizes liquid-liquid separator sizing can be
done through retention time,
W (t )
U
1440
U volume of settling section, bbl
W total liquid flow rate, bbl/day
Liquid-Liquid Separators
Values of C*
Emulsion
Charactersitics
Droplet
diameter
(microns)
C*
Free liquids
200
1100
Loose emulsion
150
619
Moderate
emulsion
100
275
Tight emulsion
60
99
Liquid-Liquid Separators
Typical retention time for liquid-liquid separation
Type of Separation
Hydrocarbon/water Separators
Above 35o API HC
Below 35o API HC
100oF and above
80oF
60oF
Retention time
(min)
3-5
5-10
10-20
20-30
Ethylene Glycol/HC separators
20-60
Amine/HC separators
20-30
Coalescers, HC/Water
separators
100oF and above
80oF
60oF
5-10
10-20
20-30
Caustic/Propane
30-40
Caustic/Heavy Gasoline
30-90
Separators with Centrifugal Elements
Example 5
Determine the size of a vertical separator to handle 600 bpd of 55 o API condensate
and 50 bpd of produced water. Assume the water particle size is 200 microns.
Other operating conditions are as follows:
Operating temperature = 80 F
Operating pressure = 1000 psig
Water specific gravity = 1.01
Condensate viscosity = 0.55 cp @ 80 F
Condensate specific gravity for 55 o API = 0.76
( Shl Sll )
Wcl C
(0.785) Dv 2
For 200 microns, C* = 1100
Separators with Centrifugal Elements
Example 5
(1.01 0.76)
600bbl / day 1100
(0.785) Dv 2
0.55
Dv 1.24 ft
Using manufacturers std size vessels might result in specifying a 20 OD
separator
Separators: Construction Aspects
Fabrication specifications:
governed by specific codes and standards
ASME pressure vessel code ( the most widely used: Div 1 and 2)
BS/EC
JIS
DIN
Separators: Construction Aspects
Vessel Shell Thickness
as specified by ASME VIII, Div 1 (sect UT-27)
PRi
t
SE 0.6 P
PRo
t
SE 0.4 P
Spheres:
PRi
t
SE 0.2 P
t
Ri
Ro
P
S
E
thickness
internal radius of shell (exc. Corrosion allowance)
external radius of shell
working pressure
maximum allowable stress
joint efficiency
Double Welded Butt Joint
Fully radiographed 1.0
Spot radiographed 0.85
No radiographed
0.70
Single Welded Butt
Fully radiographed
Spot radiographed
No radiographed
Joint
0.9
0.80
0.65
Separators: Construction Aspects
Weight and Deck Area calculations
Wb 15dt
Wb
d
t
- mass per unit length (Ibm/ft)
- internal diameter, in
- wall thickness (inc. corrosion allowance), in
The weight of the internals (Wi) may be estimated from the following table:
For skidded equipment the following factors have been
found satisfactory for preliminary estimates:
Piping, W p 40% of W v
Electrical and Instumentation, W e 8% of W v
Skid Steel, W s 10% of W v
Wskid = W v+ W p + W e + W s
Separators: Construction Aspects
The total weight of the vessel can now be estimated using:
W v = W bL + W I + W N
Separators: Instrumentation and Controls
Split range level control
Level control with for pumping
Separators: Instrumentation and Controls
Liquid residence time and control