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Real - Separator - Guide - Hysys PDF
Real - Separator - Guide - Hysys PDF
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Real Separator
1 Introduction
The HYSYS Separator unit operation normally assumes perfect phase
separation, but it can also be configured to model imperfect separation by
using the HYSYS Real Separator capabilities. The real separator offers the user a
number of advantages:
• Includes carry over so that your model matches your process mass
balance or separator design specifications.
• Predicts the effect of feed phase dispersion, feed conditions, vessel
geometry, and inlet/exit devices on carry over.
This document will introduce the concepts needed to use these real separator
features. An example is included to demonstrate a typical real separator
application.
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Real Separator
Vessel Internals
Internals used to reduce carry over can be included in your separator model
with some of the provided carry over correlations. Internals used to reduce the
amount of phase dispersion entering the vessel are termed “inlet devices”.
Internals used to reduce liquid carry over into the outlet gas product are termed
“exit devices”. “Weirs” are used to improve heavy liquid - light liquid separation
in horizontal vessels.
Nozzle Calculations
Included with the carry over correlations are calculation methods for inlet and
outlet nozzle pressure drop. Inlet and outlet devices can be included in these
calculations. The user can also specify pressure drop if the carry-over option is
not in use.
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Real Separator
There are two checkboxes at the bottom of the Feed Basis page. Checking the
Carry over to zero flow streams checkbox will ensure the specified carry over is
added to the product stream even if it has no flow. Checking the Use PH flash
for product streams checkbox will switch the HYSYS flash for the product
streams from PT to PH; it is only needed if the user encounters flash
inconsistencies with the PT flash. These two checkboxes are also available in
the Product Basis and Correlation Based models.
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Real Separator
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Real Separator
Water/Oil
PrimaryLiquid/
LiquidSeparation
GasdistributioninOil GasdistributioninOil
Gas/Oil
Diameter vsflow Diameter vs flow
Note: Only those parts of the correlation in use that apply to the particular
sub-calculation will be used.
Example: If the Generic correlation is used for the Inlet device and ProSeparator
is used for primary L-L and G-L separation calculations, then the user-supplied
data for the generic inlet calculations (i.e., inlet split and Rossin-Rammler
parameters) will be used to generate the inlet droplet distribution. The
ProSeparation primary separation calculations will then be performed using
these inlet distributions. As ProSeparator correlations will not be used to
calculate the inlet conditions, any ProSeparator inlet setup data is ignored.
Likewise, any critical droplet sizes entered in the Generic correlation will be
ignored as the ProSeparator is being used for the primary separation
calculations.
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Real Separator
3 Correlation Details
There are three sets of correlations available to calculate carry over: Generic,
Horizontal Vessel, and ProSeparator. After you have selected the type of
correlation, you can click on the View Correlation button to view its
parameters.
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Real Separator
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Real Separator
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Real Separator
Aspentech’s The complete topic of particle size analysis has been discussed by Allen (1981),
Process Manuals and this work is an excellent starting point to explore the subject in greater
provide a great depth than can be provided in this overview. A recent summary of the range of
overview on particle
analysis; more
most modern techniques available for the characterisation of particles in
information and liquids has been given by Svarovsky (1990).
further references
can be found there.
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Real Separator
F = exp(-d/dm)x) (1)
Where:
F = fraction of droplets larger than d
dm is related to d95
x = RR index
d95 = 95% of droplets are smaller than this diameter for the specified dispersion
RR Index = exponent used in the RR equation (also known as the “spread
parameter”)
ln(F) = (-d/dm)x
or
ln (ln(1/F)) = B + x ln(d) (2)
Where:
B = constant = ln (1/dm)
Therefore plotting ln(ln(1/F) against ln(d) can be used to calculate the R-R
parameters. Should such a plot not yield a straight line, it would follow that the
particle distribution cannot be adequately described by the Rossin-Rammler
function.
For more information on particle size analysis and particle size distributions
please refer to the Aspentech Process Manuals.
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Real Separator
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Real Separator
5 Tutorial Examples
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Real Separator
Process Overview
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Real Separator
Workshop
Process Description
In this workshop, a 3-phase Separator is used to separate an oil/water/gas
mixture. Entrained liquids in the gas product have been identified as a potential
process issue. The HYSYS Real Separator will be used to account for liquid
entrainment in the model.
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Real Separator
5. Open the separator unit operation and select the Worksheet tab.
What is the vapour fraction and molar flow of the product stream?
Vapour ______________________
Light Liquid ______________________
Heavy Liquid ______________________
3. Examine the product streams and the C.Over Results page and compare to
the ideal separation case.
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Real Separator
4. DP / Nozzle Setup (radio button): Enter the following values for nozzle
location (this is the horizontal or radial distance from the feed location):
Feed 0.0 m, Vapour 6.0 m. Keep the default values for nozzle diameter and
height.
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Real Separator
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Real Separator
b) Open the Rating tab and select the C.Over Results page. To view the
carryover details, click the View Dispersion Results button. You should
see results similar to this:
Open the Rating tab and select the C.Over Setup page. Click the View
Correlation button and open the Results tab.
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Real Separator
Exercise 1
It is expected that the inlet hydrocarbon flow to the separator may vary by up to
25%. Anticipating that the separator may not be able to handle this increased
flow, the engineer decides to model the new conditions in the separator and
design a demister pad to remove the larger droplets.
1. Increase the flowrate of the To LP Sep Clone stream by 25%.
2. Select the C.Over Results page, then click the View Dispersion Results
button.
Perform the analysis yourself; how thick should the mesh pad be?
_______________________________________________________
Now what is the vapour fraction of the Vapour product stream?
________________________________________________________
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Real Separator
Exercise 2
Connect the real separator into the two-stage compression loop to replace the
ideal separator that is currently in use. Keep the Water feed stream connected.
Is the real separator still capable of stopping 50 micron drops reaching the
compressor suction?
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Real Separator
Demonstration
1. Open Dynamic Real Separator.hsc.
2. Click on the strip charts to bring them to the foreground.
3. Click the Dynamic Mode button.
4. Start the Integrator. When the liquid carryover flow achieves a steady value,
stop the integrator.
5. Change the position of VLV-100 to 25% open. Re-start the integrator. When
the liquid carryover flow achieves a steady value stop the integrator.
6. Change the position of VLV-100 to 75% open. Re-start the integrator. When
the liquid carryover flow achieves a steady value stop the integrator.
Is the mesh pad thick enough to account for all process conditions?
_________________________________________________________________
A thick pad creates more pressure drop; are there other mitigations to
consider?________________________________________________________
6 Reference
Horizontal Vessel:
GPSA, Vol 1, 10th Ed., January 1990.
Separation Mechanism of Liquid-Liquid Dispersions in a deep-layer Gravity
Settler, E. Barnea and J Mizrahi, Trans. Instn. Chem. Engrs, 1975, Vol 53.
Droplet size spectra generated in turbulent pipe flow of dilute liquid-liquid
dispersions, A J Karabelas, AIChE, 1978, vol. 24, No. 2, pages 170-181.
ProSeparator Model:
Society of Petroleum Engineers papers:
SPE36647 – Separator Design and Operation: Tools for Transferring "Best
Practise"
SPE21506 – Proseparator – a novel separator/scrubber design program
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Real Separator
Rossin-Rammler Distributions:
Aspen Process Manuals – Mini Manual 1: Gas & Particle Properties; Part 8 –
Particle Size
General References:
Aspen Process Manuals – Gas Cleaning Manual:
Vol 1 – Introduction
Vol 2 – Demisting
Vol 10 – Applied Technology
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