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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
Mist Extractor
The mist extractor removes very fine droplets that did
not separate out from the gas stream in the gravity
settling section before it exists the separator. It
contains elements that provide a large surface area,
which helps to coalesce the small liquid droplets as
the gas, pass through it (API, 2008)
Separator Internals
According to the efficiency of gas/liquid separators
can be greatly enhanced through properly designed
vessel internals. This internals reduce the size and
weight of the vessel thereby lowering the overall cost.
During operation, vessel internals protects the
processing system from contamination. Similarly,
Figure 1: Droplets and bubbles settling and rising they reduce the cost of operation related to; chemical
paths in horizontal and vertical separators usage and downstream equipment (pump, compressor,
heat exchanger, etc.) breakdown and cavitation. Most
SECTIONS OF A SEPARATOR importantly, thewell-designed internals capture free
Separators are spilt into three different sections based liquid in the gas stream ensuring minimum valuable
on their design. These are; liquid hydrocarbon loss. The following are common
Inlet / Diverter Section vessel internals used in three-phase separators.
This is also known as the primary separation section. (Grave, et al., 2014)
It is where the initial bulk separation takes place.
Fluid entering the separator hits the inlet diverter and Inlet Diverters
thus undergoes a sudden change in momentum. This Inlet diverters are used in phase separators to
result in a sudden change in direction in horizontal redistribute the incoming fluid and create an even
separators or some form of centrifugal force in mass flux along the flow direction. In order to
vertical separators which causes separation of the gas enhance separation, it is essential to improve the flow
from the oil due to gravity forces. Oil has been denser distribution near the inlet nozzle. Due to this reason,
settle to the bottom of the separator while gas rise to more complicated inlet diverters have been developed
the top, the liquid flows to the gravity section. to absorb the momentum of the incoming stream and
Examples of inlet diverters used include diverter at the same time introduce pre – separation effect. (Lu
plates, cyclones, and vane distributors. Inlet diverters and Greene, 2009) Some examples of inlet diverters
are further explained in the vessel internal section of and their mode of operation is explained below;
this work.
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
platforms due to their compactness and ease of Another difference between two and three-phase
transportation. Spherical separators are less efficient separation is that, during three-phase separation, a
than horizontal or vertical separators because of their layer is usually formed between the oil and water
limited liquid settling section. They are difficult to continuous phases. This layer forms an emulsion
design and fabricate and hence are seldom used in which sometimes can make interface control difficult.
oilfield separation processes. (Francis et al., 1995) This case can be seen in all types of three-phase
separators be it vertical, horizontal or spherical. Due
(1) to this reason, it is important to understand how
emulsions are formed, its stability and treatment.
Emulsions have been reviewed but are not reported
(2) here due to page limitation
It is also important to point out that the weir in Factors to Consider when Sizing a Separator
horizontal three-phase separators is designed to
prevent the water phase from exiting through the oil The following factors should be considered when
outlet unlike in horizontal two-phase separators where sizing a three-phase separator.
weirs are installed to prevent basic sediments and - Operating Temperature: This determines the type of
water from exiting through the oil outlet during material to be used for the vessel. Three-phase
cleaning operations. separators should be constructed from expensive
material alloys to withstand the high operating
Separator Sizing temperature. High pressure signifies the vessel
Separator sizing requires the review of the different shell should be designed to support the high load.
factors to consider when designing a separator, these Similarly, the temperature was found to play a
factors tell the design engineer how to set the significant role in the corrosion of carbon steel in
separating conditions such as temperature and the presence of carbon dioxide and hydrogen
pressure, the type of configuration to use and other sulphide. The increase in temperature was found
important decisions to make when selecting the to increase the rate of corrosion in carbon steels,
appropriate separator for a given condition. Below is a where a maximum was recorded at 40o by Yameng
list of the most important factors to consider. et al., (2014), a gradual decrease was then
observed with increasing temperature. The
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
increase was attributed to increasing in hydrogen prevent liquid re-entrainment in the gas phase
ion concentration and diffusion enhancement of (Elhaj and Adli, 2014).
corrosive species while the decrease was due to - Cost (capital and operating): The oil industry as
high transport resistance of corrosion film as the with all other industries aims to recover as much
temperature increase. (Jepson and Bhongale, 1996; oil at the cheapest cost possible. Therefore, the
Yameng et al., 2014) cost is a very important factor to consider when
- Physical properties of the fluid: Physical designing a separator. The cost is greatly affected
properties of the fluid such as density and by the shape and dimension of the separator and
viscosity are important factors to be considered equally the material used in fabricating the
when sizing a separator. Fluid with higher density separator.
difference and low viscosity will require less time
for the phases to separate as compared to lower Logical and Geometrical constraint: Separators have a
density and less viscous fluids. maximum size constraint due to handling and
- Gas and liquid flow rates: The phase’s flow rates transportation. These limits are set to ensure the
of the inlet stream are an important factor to equipment are easily manufactured and safely
consider when sizing a three-phase separator. transported to the necessary operation sites in the
Higher flow rates will result in lesser residence most economical manner. Below are some of the
time of the fluid in the vessel. Therefore, flows reported separator size constraints;
with high flowrates will require larger diameters to
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
Handling of foaming oil Vertical separators have a less The best separator to handle foaming Spherical vessels perform poorly
tendency to handle foaming oil oil is a horizontal separator with foaming oil
Liquid level control Liquid level control is not critical Its more critical to control liquid level Liquid level control is very
in horizontal separators critical
Maintenance & Difficult associated with height Horizontal vessels are much more Average to maintain
inspection hazards accessible
Installation Difficult to install due to height and Average and not as difficult as It’s the easiest to install among
needs stronger mounting base vertical separators the three configurations
Advantages Vertical separators save space uses Horizontal separators require less Spherical separators have the
their full diameter for gas flow at piping for field connections and can advantage of easy shipping and
the top and have less tendency for handle foaming crude as it reduces installation due to its compact
liquid re-vaporization into the gas turbulence and foaming. Also, space size.
phase. requirements can be minimized as
several separators can be stacked
together
Disadvantages Vertical separators require bigger Liquid level control is more critical in Spherical separators are
diameter separator for a given gas horizontal separators compared to expensive to build and very
capacity which results in high vertical separators and are more difficult to use especially for
capital and transportation cost. difficult to clean when wax, paraffin, three-phase separation due to
and sand are deposited at the bottom having very limited liquid settling
of the separator. section.
Rules for Selection Criteria Step 1: What is the purpose of the equipment?
Having understood the factors to consider when sizing Different types of separators are used for
a separator as well as the functions, advantages, and different purposes. The following table is
disadvantages of each separator configuration, the used as a guide to selecting the right
following criteria (questions) can be used when equipment for a purpose.
selecting a separator. These questions or rules are Step 2: What will be the application of the separator?
developed for the first time and will greatly ease the This could be low temperature separators,
process of selecting the appropriate separator. The test separators or production separators
rules are;
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
Step 3: What are the properties of the fluid? Are there Separation Theories
any impurities? Several models have been developed for the design
This is where the designer considers the and sizing of phase separators. These models were
temperature, pressure, density and viscosity built based on two separate underlying theories
of the stream. The droplet size to be removed namely droplet settling theory and retention time
or retention should also be considered in this theory. Both theories will be discussed in brief before
step reviewing the various models.
Step 4: How many phases will be separated?
This step is strongly dependant on the stream Droplet Settling Theory
properties. The separator could be a two or This theory is based on the premise that a droplet of
three-phase separating gas from liquid or liquid of given diameter/size will take a fixed finite
separate gas, oil, and water. time to settle a known distance in each continuous
Step 5: What is the composition of the well-stream? fluid. It is assumed that particles/droplets are spherical
All things being equal, a horizontal separator in shape and settle through a stagnant continuous
should be used for high to medium gas-oil phase due to gravity forces.
ratio streams whereas, a vertical separator In a gravity separator, entrained liquid tends to fall
should be used for streams with low gas-oil concurrent to the gas flow due to gravity. Each droplet
ratio and when sand, paraffin or wax are accelerates because of its negative buoyant force until
present. this force is equal to the droplet’s drag force.
Step 6: Are there any restrictions such as space or Acceleration goes to zero at this point and the droplet
cost? reaches its terminal velocity. Separation or
entrainment is determined by this velocity. If the
Final step deals with restrictions such as cost and velocity is slightly less than the gas flowing velocity,
space. Horizontal separators are less then the droplet will be carried along with the gas. On
expensivehowever, occupies more space whereas the other hand, if the velocity slightly exceeds the gas
vertical separators are totally opposite when it comes flowing velocity, the droplet will settle and separate
to cost and space, out from the gas.
Based on these questions, the following block
diagram in Figure 3 could be used; Buoyant force is an upward force exerted by the fluid
which opposes the weight of the droplet, it depends on
the droplet volume and the densities of the droplet and
the continuous phase. The drag force is the resistance
force caused by the motion of the droplet through the
fluid, it depends on the droplet’s cross sectional area
and velocity relative to the gas, and the gas velocity
and density. The drag coefficient for spherical
droplets depends on the Reynolds number for flow
around the droplet.
(4)
(5)
(6)
(7)
(8)
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
Neither of these extreme situations is valid for gas – Mostafaiyan et al., (2014): Evolutionary
liquid separation problems and therefore the complete computational algorithm was developed for this
formula for drag coefficient as stated in equation (8) model with the aim based on optimisation of three-
should be used. phase separators to minimise volume. This
optimisation parameter was chosen to support the
Svrcek and Monnery (1993 and 1994): This model design engineer of offshore installations where space
was based on droplet settling theory. A detailed is at a premium. In this model, a well-defined
description on how to size a two and three-phase horizontal three-phase separator was used as a target
horizontal and vertical separators was explained by design. The separators length, diameter, water channel
Svrcek and Monnery (1993 and 1994). This model is length, surge and residence times were manipulated to
an iterative process. For proper separation in the meet the target design that has a minimum volume.
secondary section of the vessel, the allowable velocity New generation designs with minimum possible
must be calculated to determine the disengagement volumes were obtained through recombination and
area. By equating the drag force and the gravity force mutation of previous ones.
the terminal velocity is obtained as shown in equation
10. Vertical velocity is set to be 0.75 times the Retention Time Theory
calculated terminal velocity for the droplets to settle. The retention time theory basically requires a design
Equation 10 above can be rearranged to a Saunders – that gives the fluid sufficient residence time in the
Brown equation as in (12) vessel to separate. It generally requires experimental
data based on batch tests conducted in the laboratory
(11) to determine the time for a well-stream mixture to
separate into various components. If problems such as
(12) foaming and waxing occurs, retention time increase.
Similarly, it also increases as the viscosity or density
of the oil increases. Although batch tests are easy to
(13) perform, they tend to overestimate the time required
for separation to take place given field separators use
water wash and some mixing to accelerate
coalescence and settling of water droplets. Another
The vapour disengagement area is set by guidelines as weakness of this theory is that it restricts the separator
a minimum of 0.2 times the diameter and the length design unless a significant number of tests are
required for holdup and surge, liquid / liquid and gas / conducted. In practice, to achieve maximum accuracy
liquid separation is calculated. The settling velocity the tests need to be conducted on the actual fluid at
and settling times are then calculated. The actual separator operating conditions with similar oil and
residence times are calculated and compared with the water pad thickness (Arnold and Koszela, 1990;
required settling times. In cases where the residence Grodal and Realff, 1999).
times are less than the required settling time, then the
diameter is increased or for a given diameter, the Arnold and Stewart (1986): This model is
length is increased. commonly used in sizing three-phase separators.
Based on this model, the retention time for water
The minimum length for vapour / liquid separation removal from oil and that of oil removal from water
(Lmin) is compared with the sum of the minimum needs to be specified. The dimensions of the separator
length required for holdup and surge and the length to can then be determined from equation 14.
facilitate liquid – liquid separation (L = L1+L2). If L is (14)
less than Lmin, then L is set equal to Lmin, if L is This model restricts the slenderness ratio which is the
much less than Lmin, then the vapour space height is ratio of the seam to seam length to the internal
increased and the calculation should be repeated. If L diameter of the separator to be within the range of 3 to
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
5. Although slenderness ratios outside this range can changes as the height of the liquid volume changes. In
be used, the design needs to be checked to avoid re- their work, Arnold and Koszela reviewed two
entrainment. different sizing charts published by Parkersburg
(1950) and Black, Sivalls and Brynson (1959). They
Settling and Retention Time Theory found out that settling theory “provides a more
Several models are designed to incorporate both consistent scaling technique to describe oil capacities”
settling and retention time theories in sizing a three- than the retention time. Similarly, their work
phase separator. The models are designed in such a concluded that the dimensions of a separator that is
way that the droplet settling theory is used for the sized using the settling theory will be greatly
separation of the gas from the liquid (i.e. settling of dependant on the temperature (that is viscosity) of the
liquid droplets from the gas phase and rising of gas oil.
bubbles from the liquid) while the retention time
theory is used for the separation of the light liquid Deficiencies in Three – Phase Separators
from the heavy liquid. When both theories are used to The models used in the design of three phase
size a vessel, dimensions (diameter and length) from separators in the oil and gas industries today have
both theories are obtained and compared and the several deficiencies. These models do not provide the
governing theory is chosen from the two. The models oil percentage output from the separator, do not
restrict the slenderness ratio to a value of 3 to 5 to provide adequate information of the separator such as
avoid re – entrainment. the various liquid level heights, rely on arbitrary table
look ups for constants that are not clearly defined and
Arnold and Stewart (1998): This model was based more importantly do not consider the economics of
on a horizontal separator 50% full of liquid. The first the separator.
step uses Settling theory to determine the maximum
diameter of the vessel, achieved from obtaining the Therefore, there is the need to develop a robust model
maximum oil pad thickness. The first part of the that will provide all the necessary information the
separation termed “Gas Capacity Constraint” was extant models are lacking. The model should be able
developed by setting the gas retention time equal to to link the design of the separator to the economic
that required for a droplet size of 100 – micron to costs associated with its construction and operation,
settle to the liquid interface. Based on this, equation provide accurate separator dimensions with
15 was developed; transparent calculations that do not rely on arbitrary
table look ups and also provide the composition of the
(15) outlet stream.
Retention time is used for the separation of oil from The model should be to provide separator dimensions
water. The model developed the following equation, that will be able to cope with the changing field
which is used to determine acceptable combinations properties and produce outputs that falls within the
of the vessel diameter and length. new environmental and political policies thereby
(16) enhancing productivity and profitability to the oil and
Combinations of diameter and length that satisfy eq. gas companies.
15 and 16 are determined and the governing equation
is chosen from the results. Seam to seam length and CONCLUSION
L/D ratio are then determined. In conclusion, this paper gives a general overview of
mechanical devices used for the separation of
Comparison between Settling Theory and produced stream into gas, oil and water, known as
Retention Time Theory three-phase separators. The different sections,
Arnold and Koszela, (1987) did a comparison internalsas well as classification of the separators have
between droplet settling and retention time theories in also been presented. The review also looked at
sizing an oil/water separator. They stated that when separator sizing stating the factors affecting separator
sizing a separator, it is important to know which of sizing.
the two theories govern the design since the two
design theories will give different dimensions for both Separator geometry comparison table and rules for
vertical and horizontal vessels. In horizontal vessels separator selection criteria were developed to ease the
for example, settling theory states that for a given difficulties encountered when selecting a particular
flow condition, the product of diameter and length is separator for a given process.
equal to a constant whereas the retention time states
that the product of diameter squared and length is a Droplet settling, Iterative and computational fluid
constant. A similar difference can be seen with dynamics, Retention time theory and sometimes a
vertical vessels. Here, the settling theory states that combination of these theories have been used to size
the diameter of a vessel is independent of the liquid three phase separators. The theories were found to
height while retention time states that the diameter produce promising models.
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Journal of Emerging Trends in Engineering and Applied Sciences (JETEAS) 8(3):143-153 (ISSN: 2141-7016)
A Comparison between droplet settling and retention Mostafaiyan, M., Saeb, M. R., Alorizi, A. E., &
time theory showed that the two theories were found Farahani, M. (2014). Application of
to produce different separator dimensions and hence it evolutionary computational approach in design
is important to know which of the two govern the of horizontal three-phase gravity
separation in models designed by both theories. separators. Journal of Petroleum Science and
Engineering, 119, 28-35.
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