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