TWO-PHASE OIL AND GAS SEPARATION

DIn oil and gas separator design, we mechanically separate from a hydrocarbon stream the liquid and gas components that exist at a specific temperature and pressure. DSeparators are classified as "two-phase" if they separate gas from the total liquid stream and "threephase" if they also separate the liquid stream into its crude oil and water components. DSeparators are designed in either vertical, or spherical configurations. horizontal,

Horizontal Separator

Vertical Separator

spherical Separator

PRINCIPLES OF SEPAEATION DThe fluid enters the separator and hits an inlet diverter causing a sudden change in momentum. The initial gross separation of liquid and vapor occurs at the inlet diverter. DThe force of gravity causes the liquid droplets to fall out of the gas stream to the bottom of the vessel where it is collected.( liquid collection section) DThe liquid collection section provides the retention time required to let entrained gas evolve out of the oil and rise to the vapor space. The liquid then leaves the vessel through the liquid dump valve. The liquid dump valve is regulated by a level controller.

DThe gas flows over the inlet diverter and then horizontally through the gravity settling section above the liquid. As the gas flows through this section, small drops of liquid that were entrained in the gas and not separated by the inlet diverter are separated out by gravity and fall to the gas liquid interface. SEPARATOR INTERNALS 1-Inlet Diverters There are two main types of inlet diverters are: i-Baffle plates ii-Centrifugal diverters DA baffle plate can be a spherical dish, flat plate, angle iron, cone, or just about anything that will accomplish a rapid change in direction and velocity of the fluids and thus disengage the gas and liquid.

DIVERTER BAFFLE

TANGENTIAL BAFFLE

DCentrifugal inlet diverters use centrifugal force to disengage the oil and gas. Centrifugal diverters work well in initial gas separation and help to prevent foaming in crudes. 2-Wave Breakers In long horizontal vessels it is necessary to install wave breakers, which are nothing more than vertical baffles spanning the gas-liquid interface and

perpendicular to the flow.

3-Mist Extractor Mist extractors can be made of wire mesh, vanes, centrifugal force devices, or packing. DWire mesh pads are made of finely woven mats of stainless steel wire wrapped into a tightly packed cylinder. The liquid droplets impinge on the matted wires and coalesce. DVane eliminators force the gas flow to be laminar between parallel plates that contain directional changes. In vane eliminators, droplets impinge on the plate surface where they coalesce and fall to a liquid collecting spot. They are routed to the liquid collection section of the vessel.

DCentrifugal mist eliminators that cause the liquid drops to be separated by centrifugal force. These can be more efficient than either wire mesh or vanes and are the least susceptible to plugging. However, they are not in common use in production operations because their removal efficiencies are sensitive to small changes in flow. In addition, they require relatively large pressure drops to create the

centrifugal force.

CENTRIFUGAL MIST ELIMINATORS

D Random packing is sometimes used for mist extraction. The packing acts as a coalesces.

THE ADVANTAGES OF EACH TYPE OF SEPARATOR: 1-VERTICAL SEPARATOR XLiquid level control not as critical. XWill handle large quantities of sand. XEasier to clean. XHas greater liquid surge capacity. XIs smaller plot area. 2-HORIZONTAL SEPARATOR XSuccessfully used in handling foaming crude. XCheaper than vertical separator.

XMore economical an efficient for processing large volumes of gas. XSmaller diameter for a given gas capacity. XMore flexible choice of nozzle arrangement. 3-SPHERICAL SEPARATOR XCheaper than either horizontal or vertical separator. XBetter clean out and bottom drain features than vertical type. XMore compact than other types

SEPARATOR DESIGN PROCEDURES FACTORS AFFECTING SEPARATION The following factors must be determined before separator design: Gas and liquid flow rates (minimum, average, and peak) Operating and design pressures and temperatures Surging or slugging tendencies of the feed streams Physical properties of the fluids such as density and compressibility Presence of impurities (paraffin, sand, scale, etc.) Foaming tendencies of the crude oil Corrosive tendencies of the liquids or gas

1-Procedures for sizing horizontal separators For sizing a horizontal separator it is necessary to choose a vessel length and a diameter. This choice must satisfy the conditions: 1- For gas capacity : that allow the liquid drops to fall from the gas to the liquid volume. 2- For sufficient retention : to allow the liquid to reach equilibrium. Step 1: Tabulate the physical properties of the fluids to be separated

Step 2: Calculate values of, vessel internal diameter(d) and effective length (Le ) , that satisfy the gas capacity constraint. Step 3: Calculate values of, d and Le , that satisfy the retention time constraint. Step 4: Estimate vessel length (L) i- For gas capacity:

ii- For liquid capacity: Step 5: Calculate slenderness ratios (SR) select a size of reasonable diameter and length for (SR) on order of 3 to 4 are common Where: d= Vessel internal diameter, in Le= Effective length of the vessel where separation occurs, ft T = Operating temperature, 0R P = Operating pressure , psia Qg =Gas flow rate, MMscfd QL =Liquid flow rate , bpd dm =Liquid drop to be separated , micron CD = Drag coefficient tr =Desired retention time for the liquid, min rg = Density of gas , lb/ft3 rL = Density of liquid , lb/ft3

Example: Sizing a horizontal separator: Given: Gas flow rate =10 MMscfd Liquid flow rate =2000 bpd Operation pressure =1000 psia Operation temperature =600F Density of gas =3.71 lb/ft3 Density of liquid =51.5 lb/ft3 Oil viscosity = 0.013 cp Gas compressibility = 0.84 Liquid drop = 140 micron Retention time =3 min Drag coefficient =0.851 Find: Vessel length and diameter

Solution: 1-Calculate Le and d for gas capacity

2- Calculate Le and d for liquid capacity

3-Assume d, [ 24, 30, 36, 42 ] , and calculate Le for gas and liquid capacity. 4- Calculate L based on large value of Le 5- Calculate (SR)

d 24 30 36 42

Gas (Le) 1.66 1.33 1.11 0.95

Liquid (Le) 14.88 9.52 6.61 4.86

L 19.84 12.69 6.81 6.48

SR=12L/d 9.92 5.08 2.94 1.85

6-We choose L and d based on (SR): By interpolation :

SR L d 5.08 12.84 30 4 L d 2.94 6.81 36

i-For length:

ii-For diameter:

2-Procedures for sizing vertical separators In vertical separators: i- A minimum diameter must be maintained to allow liquid drops to separate turn the vertically moving gas. ii- The liquid retention time requirement specifies a combination of diameter and liquid volume height. iii- Any diameter greater than the minimum required for gas capacity can be chosen. Step 1: Tabulate the physical properties of the fluids to be separated.

Step 2: Calculate minimum diameter based on gas capacity .

Step 3: Assume diameter greater than the minimum diameter required for gas capacity . Step 4: Compute combinations of diameter (d) and height of the liquid volume (h) for variants assume diameter based on liquid capacity constrain.

Step 5: Compute length (L) .

Where: d is the minimum diameter for gas capacity . Step 6: Calculate slenderness ratios (SR) select a size of reasonable diameter and length for (SR) on order of 3 to 4 are common

Example: Sizing a vertical separator: Given: Gas flow rate =10 MMscfd At 0.6 specific gravity Liquid flow rate =2000 bpd At 40 API Operation pressure =1000 psia Operation temperature =600F Density of gas =3.71 lb/ft3 Density of liquid =51.5 lb/ft3 Oil viscosity = 0.013 cp Gas compressibility = 0.84 Liquid drop = 140 micron Retention time =3 min Drag coefficient =0.851 Find: Vessel length and diameter

Solution: Minimum diameter for gas capacity

2- Assume diameter [24 ,30, 36, 42 ] 3-Compute combinations of diameter (d) and height of the liquid volume (h)

Tr (min) 3

d (in) 24 30 36 42

h (in) 86.80 55.56 38.60 28.35

L=(h+76)/12 (ft) 13.57 10.96 9.55 8.69

SR=12L/d 6.79 4.38 3.18 2.48

4- Choose: Diameter=36 in Length=9.55=10 ft

THREE-PHASE OIL AND GAS SEPARATION Three phase separator are designed as either horizontal or vertical pressure vessels 1-Horizontal Separator

PRINCIPLES OF SEPAEATION Fluid enters the separator and hits an inlet diverter. This sudden change in momentum does the initial gross separation of liquid and vapor . The inlet diverter contains a down comer that directs the liquid flow below the oil/water interface. This forces the inlet mixture of oil and water to mix with the water continuous phase in the bottom of the vessel and rise through the oil/water interface. This process is called "water-washing," and it promotes the coalescence of water droplets which are entrained in the oil continuous phase.

The liquid collecting section of the vessel provides sufficient time so that the oil and emulsion form a layer or "oil pad" at the top. The free water settles to the bottom. The weir maintains the oil level and the level controller maintains the water level. The level of the oil downstream of the weir is controlled by a level controller that operates the oil valve. An interface level controller senses the height of the oil/water interface. The controller sends a signal to the water pump valve thus allowing the correct amount of water to leave the vessel so that the oil/water interface is maintained at the design height.

The gas flows horizontally and out through a mist extractor to a pressure control valve that maintains constant vessel pressure. The level of the gas/oil interface can vary from half the diameter to 75% of the diameter depending on the relative importance of liquid/gas separation. Alternate configuration known as a "bucket and weir" design. This design eliminates the need for a liquid interface controller. Both the oil and water flow over weirs where level control is accomplished by a simple displacer float. The oil overflows the oil weir into an oil bucket where its level is controlled by a level controller that operates the oil valve. The water flows under the oil bucket and then over a water weir. The level downstream of this weir is controlled by a level controller that operates the water dump valve.

HORIZONTAL SEPARATOR [bucket and weir design]

It is critical to the operation of the vessel that the water weir height be sufficiently below the oil weir height so that the oil pad thickness provides sufficient oil retention time. If the water weir is too low and the difference in specific gravity is not as great as anticipated, then the oil pad could grow in thickness to a point where oil will be swept under the oil box and out the water outlet. Normally, either the oil or the water weir is made adjustable so that changes in oil/water specific gravities or flow rates can be accommodated.

To obtain a desired oil pad height, the water weir should be set a distance below the oil weir, which is calculated by:

Setting the pressure at point A

Where: Dh = distance below the oil weir, in. h0 = desired oil pad height, in. r0 = oil density, lb/ft3 rw = water density, lb/ft3

However, in heavy oil applications or where large amounts of emulsion or paraffin are anticipated it may be difficult to sense interface level. In such a case bucket and weir control is recommended.

Vertical Separator

Flow enters the vessel through the side as in the horizontal separator, the inlet diverter separates the bulk of the gas. A down comer is required to transmit the liquid through the oil-gas interface . A chimney is needed to equalize gas pressure between the lower section and the gas section. The spreader or down comer outlet is located at the oil-water interface. From this point as the oil rises any free water trapped within the oil phase separates out. The water droplets flow countercurrent to the oil. Similarly, the water flows downward and oil droplets trapped in the water phase tend to rise countercurrent to the water flow.

SEPARATOR DESIGN PROCEDURES 1-Horizontal Separators For sizing a horizontal three-phase separator it is necessary to specify a vessel diameter and a seam-toseam vessel length. The gas capacity and retention time considerations establish certain acceptable combinations of diameter and length. The need to settle 500-micron water droplets from the oil establishes a maximum diameter. Step1: Select oil retention time (tr)0 and water retention time (tr)w

Step2: Calculate maximum oil pad thickness. (ho)max , allow the water droplets to settle out time (tr)0 .

Step3: Calculate the fraction of the vessel cross sectional area occupied by the water phase.

Step4: Calculate maximum diameter for oil pad thickness constraint

Step5: Calculate combination of d and Le for d less than dmax that satisfy the oil and water retention time constraint Step6: Estimate vessel length

Step7: Calculate slenderness ratios (SR)=(12L/d) select a size of reasonable diameter and length for (SR) on order of 3 to 5 are common

Example: Sizing a Horizontal Three-Phase Separator Given: Gas flow rate =5 MMscfd Oil flow rate =5000 bpd Water flow rate =3000 bpd Operation pressure =100 psia Operation temperature =900F Oil =300API Specific gravity =1.07 (water phase) Oil viscosity = 0.013 cp Oil Retention time =10 min Water Retention time =10 min Find: Vessel length and diameter

Solution: 1-Calculate difference in specific gravities

2- Calculate maximum oil pad thickness

3-Calculate maximum diameter for oil pad thickness constraint

4- Calculate combination of d and Le

d(in) 60 70 80 90 100

Le(ft) 31.56 23.18 17.75 14.02 11.36

L=(4/3Le) (ft) 42.07 30.91 23.67 18.70 15.15

(12L/d) 8.42 5.30 3.55 2.49 1.82

5- Possible choices [ 80 in x 24 ft]

2-Vertical Separators BA minimum diameter must be maintained to assure adequate gas capacity. BThe height of the three phase separator is determined from retention time consideration. Step 1: Calculate minimum diameter from requirement for water droplets to fall through oil layer. Use 500micron droplets if no other information is available.

Step 2: Calculate minimum diameter from requirement for oil droplets to fall through gas. Use 100-micron droplets if no other information is available.
Step 3: Choose the larger of the two as minimum diameter Step 4: DSelect oil retention time (tr)0 and water retention time (tr)w DEstimate the height of oil pad (h0) and height from water outlet to interface (hw) for various diameter (d)

Step 5: Estimate the vessel length (L)

Step 6: Select a size of reasonable diameter and length. Slenderness ratios (12 L/d) on the order of 1.5 to 3 are common. Where: Qw= Water flow rate ,bpd Q0= Oil flow rate ,bpd m = Viscosity , cp DS.G.= Difference in specific gravities dm= Liquid drop to be separated , microns.

T= Operating temperature, 0R Z= Gas compressibility Qg= Gas flow rate, MMscfd CD= Drag coefficient P=Operating pressure, psia rg=Density of gas ,lb/ft3 rl=Density of liquid,lb/ft3 h0= Height of oil pad, in hw= Height from water outlet to interface, in (tr)0= Oil retention time, min (tr)w= Water retention time, min d= Vessel diameter , in L= vessel length, ft

Example: Sizing a Vertical Three-Phase Separator Given: Gas flow rate =5 MMscfd Oil flow rate =5000 bpd Water flow rate =3000 bpd Operation pressure =100 psia Operation temperature =900F Oil =300API Gas specific gravity =0.6 Specific gravity of water =1.07 Oil viscosity = 10 cp Oil Retention time =10 min Water Retention time =10 min Gas compressibility = 0.84 Drag coefficient =0.89 Find: Vessel length and diameter

Solution: 1. Calculate liquid and gas densities.

2- Calculate difference in specific gravities.

3- Calculate minimum diameter to satisfy gas capacity constraint.

4- Calculate minimum diameter for water droplet settling.

5-Estimate the height of oil pad (h0) and height from water outlet to interface (hw)

6. Compute combinations of d, and h0 + hw for diameters greater than minimum diameter

d (in) 84 90 96 102 h0 + hw (in) 94.5 82.3 72.3 64.1 L (ft) 18.2 17.7 17.4 17.2 SR=12L/d 2.6 2.4 2.2 2.0

7- Choose a reasonable size: A 90-in. X 18-ft or a 96-in. X 17-ft size would be a reasonable choice.