1 - Classification: Open

Gas/liquid separation
Course: TPG 4140 Natural Gas
Date: 18.10.2010
Bernt Henning Rusten, Statoil R&D Centre Trondheim
Gas/liquid separation
2 - Classification: Open
Content

Where and when is separation required

Gas/liquid separation theory

Why gas/liquid separation research

Laboratory facilities

Gas/liquid separators and internals
3 - Classification: Open
Why is gas/liquid separation a big issue?
This is easy!
Some wind
from the side
Some wind
from below
4 - Classification: Open
Why is gas/liquid separation a big issue?
It is challenging
at real operating
conditions!
5 - Classification: Open
Introduction to gas/liquid separation
Animation
6 - Classification: Open
Natural gas transport network
NCS

Gas is processed offshore. Separation of gas, oil and
water. Conditioning of Water, CO
2

and H
2

S if present.

Rich gas is transported to the onshore terminal in dense
phase in pipelines up to 830 km length.

New pipelines considered for further increase in natural
gas production from Norwegian Continental Shelf

Gas/liquid separation is of great importance for all
processes in the oil and gas industry to operate
satisfactorily

Protect process equipment (compressors,
pumps and heat exchangers)

Fulfil product specifications

Essential in future subsea processing
Source: www.gassco.no
7 - Classification: Open
Troll A on its way offshore
Gas to Europe
Kollsnes
Production capacities:
Troll A 120 MSm/d
Kvitebjrn 21 MSm/d
Kollsnes 144 MSm/d
Kvitebjrn
8 - Classification: Open
Separation in Gas processing train
Testseparator
1st stage separator
2
nd
stage
scrubber
1
st
stage
scrubber
Glycol
contactor
3
rd
stage
scrubber
Rich gas (RG)
0
10
20
30
40
50
60
70
80
90
100
110
120
-20 -10 0 10 20 30
Temperature [C]
P
r
e
s
s
u
r
e

[
b
a
r
a
]
Calculated dew point curve 2nd stage scrubber outlet
Operating point 2nd stage scrubber
EOS = SRK
Rich Gas Cricondenbar
Norne
9 - Classification: Open
Gas dynamic pressure (often called momentum)

gas

v
gas liq
gas
gas
U GLF

Basic definitions
Primary

separation

inlet

device;
here

inlet

vane
Demisting; removal

of

remaining

liquid;
here

Axial

Flow

Cyclones

(AFC)
Mesh

Pad

for
coalescing/demisting
Gas Load Factor, GLF (often called K-value)
Liquid

fraction
Separation

efficiency
- each

internal
- total
Liquid

entrainment

liquid

not separated

in scrubber
-carry-over
-re-entrainment

(liquid

separated

but

teared

up again

into

the

gas)
gas volume
liquid volume
feed liquid scrubber
scrubber in separated liquid
10 - Classification: Open
Souders-Brown equation

(Gas Load Factor (GLF), K-value)

The GLF assumes constant

Droplet diameter (varies with pressure and interfacial
tension)

Drag coefficient C
d
(varies with pressure because of
different flow regime)
d
GLF
F
d

= G
d
11 - Classification: Open
Important parameters for gas/liquid separation

Interfacial tension decisive for:

Droplet diameter

Liquid behaviour

Re-entrainment (droplets separated into
a film ripped back up into droplets)

Gas and liquid density

Gas and liquid viscosity

Gas and liquid loading

Flow pattern (CFD modelling used,
Computational fluid dynamics)
12 - Classification: Open
Why is there a need for gas/liquid separation research?
Before 2000, Before 2000, no internal research activity was established, but many no internal research activity was established, but many
problems were identified in operational units. problems were identified in operational units.
What was wrong?
Vendor design and understanding were based on model fluid data
(air/water).
Separation technology performing well with model fluids collapsed when
implemented in field at real fluid properties.
More compact technology was used.
New fields with higher pressures started to produce; more difficult
separation.
Need for fundamental understanding of phenomena occurring
and equipment limitations.
13 - Classification: Open
K-lab large scale test facility K-lab, Krst
In operation since 2004
Pressure; 1

148 bara
Fluids; hydrocarbon gas and liquid or model liquid
Test section ID 840 mm, height approx. 6 m
Low pressure test rig Research Centre, Trondheim
In operation since 2001
Pressure; 1.8

7 bara
Fluids; air with Exxsol D-60 and/or water/glycol
Test section ID 400 mm, height 4 m
High pressure test rig Research Centre, Trondheim
In operation since 2003
Pressure; 1

100 bara
Fluids; hydrocarbon gas and liquid or Nitrogen with Exxsol D-60
Test section ID 150 & 250 mm, height 4 m
Offshore and onshore production facilities
Test facilities for gas/liquid separation
Multiphase Flow loop Hrya, Porsgrunn
14 - Classification: Open
Separators

Horizontal separators

Liquid dominated service

Oil/water separation

Better for slug handling

GLF 0.122

0.152 m/s

for L/D = 5*

Vertical separators

Gas dominated service (scrubber)

Gas/liquid separation

GLF 0.10

0.30 m/s

depending on internals
used and operating conditions
Tordis SSBI (Subsea separation Boosting and Injection)
*Campbell J.M; Gas conditioning and processing Volume 2, ISBN 0-9703449-1-0
15 - Classification: Open
Static Inline separators

Statoil inline technology

Static swirl element

Separation chamber

Bulk separation

Advantages

Small footprint

Installed as a part of the piping system

Low installation cost compared to conventional
solution

Ideal for debottlenecking
16 - Classification: Open
Scrubber inlet design

Technologies

Inlet

vane

Inlet

cyclones

Spinlet

Inlet

tangential baffle

Purpose

Flow

distribution

(inlet

vane)

High

liquid

separation

efficiency

(Spinlet, inlet

cyclones

and inlet

tangential
baffle)
Inlet vane
Spinlet
Inlet Cyclones
Inlet tangential baffle
17 - Classification: Open
Primary separation efficiency
-

Separation efficiency decreases with increased pressure
-

K-value is not a correct way to scale
Figure is taken from: Austrheim, T. Experimental Characterization of High-Pressure Natural Gas Scrubbers,
University of Bergen 2006, ISBN 82-308-0248-3, Ph.D Thesis.
Constant liquid load at 0.2 vol%
18 - Classification: Open
Meshpad
-

Coalescence of small droplets

Structures

Layered

Rolled

Random

Material

Metals: SS, alumina, copper,
titanium

Polymers: PP, PE,co-knit

(multifilament glas fibers)

Porosity,

Wire-dimension, d
wire
19 - Classification: Open
GLF [m/s]
P
r
e
s
s
u
r
e
d
r
o
p
[
P
a
/
m
]
Dry mesh
Operated

mesh
E
f
f
i
c
i
e
n
c
y
[
%
]
100
Demisting

efficiency
Flooding-point behaviour
Flooding-

point
20 - Classification: Open
Operational characteristics
GLF [m/s]
P
r
e
s
s
u
r
e
d
r
o
p
[
P
a
/
m
]
E
f
f
i
c
i
e
n
c
y
[
%
]
100
Demister:

High
primary
separation
efficiency

Capture
small droplets
(2-10
microns)
Pre-conditioner:

Lower primary
separation efficiency

Act as an
agglomerator,
coalesces smaller
droplets to larger ones

Conditions the
secondary demister
elements, i.e

vanes or
cyclones
21 - Classification: Open
Demisting
-

Final polishing of the gas flow

Technologies

Axial

flow

cyclone

Vane pack

Filters

Purpose

Separate remaining

liquid
) (
) (
gas liq
drain
drain gas liq
g
P
h
gh P

Drainage margin:
Vane pack
Axial flow cyclone
Filter
22 - Classification: Open
Demisting

-

Final polishing of the gas flow
Double pocket vane pack
Axial flow cyclone
- Based on high centrifugal force
- Liquid deposits on wall and drains through slits
- GLF ~ 1 m/s
- Vertical and horizontal flow vane pack
- Based on change in flow direction
- Liquid deposits on wall and drains through slits
- GLF (vertical flow) ~ 0.12 m/s*
- GLF (horizontal flow) ~ 0.20 0.30 m/s*
Slits for liquid drainage
*Campbell J.M; Gas conditioning and processing Volume 2, ISBN 0-9703449-1-0
23 - Classification: Open
Droplet separation with cyclone technology
Grade efficiency:
Separation efficiency for a given particle size
Cut size d
50

:
Particle diameter with 50% separation efficiency
G
r
a
d
e

e
f
f
i
c
i
e
n
c
y
Calculated for a Verlaan cyclone at 92 bar pressure, GLF
vessel
=0.15 m/s
Figures are taken from: Austrheim, T. Experimental Characterization of High-Pressure Natural Gas Scrubbers,
University of Bergen 2006, ISBN 82-308-0248-3, Ph.D Thesis.
GLF
vessel
=0.15 m/s
24 - Classification: Open
Droplet separation with cyclone technology
70
75
80
85
90
95
100
0 1 2 3 4 5 6 7
Superficial Gas Velocity [m/s]
E
f
f
i
c
i
e
n
c
y

[
%
]
20 bar N2/Exxsol
50 bar N2/Exxsol
92 bar N2/Exxsol
20 bar Natural gas
50 bar Natural gas
92 bar Natural gas
-

Separation efficiency decreases with increased velocity and centrifugal force
-

Re-entrainment of separated liquid is critical
Figure is taken from: Austrheim, T. Experimental Characterization of High-Pressure Natural Gas Scrubbers,
University of Bergen 2006, ISBN 82-308-0248-3, Ph.D Thesis.
Constant cyclone liquid load
25 - Classification: Open
Separation efficiency is a balance between conflicting
mechanisms
Testing at real operating conditions shows that re-entrainment is the dominant mechanism
Experimental facilities with real fluid systems at high pressure is crucial to get the correct answers
26 - Classification: Open
Summary
Efficient gas/liquid separation is
essential in the oil and gas
value chain.
If it does not work