Separation processes

Lecture 7
Separator sizing I
Nazir mafakheri
Petroleum engineering
 Separator Sizing
The basic steps in separator design are listed below:

1. Estimate diameter and length on basis of liquid requirements.

Considerations of design include drop size removal, retention time,
coalescers (e.g., plate packs), surge volume, levels and alarms, and
motion.

2. Calculate the gas cross-sectional area and vessel length.

Considerations of design include drop size, removal, mist eliminator
requirements, and velocity requirements.

Lecture 7
 Separator Sizing
The basic steps in separator design are listed below:

3. Select vessel diameter and length to satisfy Steps 1 and 2.

4. Select inlet device and iterate.

Separators are typically sized by the droplet settling theory or
retention time for the liquid phase. For the gas phase, the
settling theory or requirements of the demister are used.

Lecture 7
 Separator Sizing
Settling Theory

 In gravity settling, the dispersed phase drops/bubbles will settle at a

velocity determined by equating the gravity force on the drop/bubble
with the drag force caused by its motion relative to the continuous
phase.
 In horizontal vessels, a simple ballistic model can be used to
determine a relationship between vessel length and diameter.
 In vertical vessels, settling theory results in a relation for the vessel
diameter.

Lecture 7
 Separator Sizing
Horizontal Separators
 Droplet settling theory, using a ballistic model, results in the
relationship For liquid drops in gas phase shown in below:

d = vessel internal diameter, in.; P = operating pressure, psia;

dm = drop diameter, μm; Z = gas compressibility;
hg = gas-phase space height, in.; ρl = liquid density, lbm/ft3;
Fg = fractional gas cross-sectional area; ρg = gas density, lbm/ft3;
Leff = effective length of the vessel where separation occurs, ft; Qg = gas flow rate, MMscf/D;
T = operating temperature, °R; CD = drag coefficient. (See
Appendix A for calculation.)

Lecture 7
 Separator Sizing
Horizontal Separators
 Droplet settling theory, using a ballistic model, results in the
relationship for bubbles or liquid drops in liquid phase shown in
below:

d = vessel internal diameter, in.; P = operating pressure, psia;

dm = bubble or drop diameter, μm; Z = gas compressibility;
hc = continuous liquid-phase space height, in.; ρd = dispersed liquid-phase density, lbm/ft3;
Fc = fractional continuous-phase cross-sectional area; Qc = continuous liquid-phase flow rate, B/D.;
Leff = effective length of the vessel ft; ρc = continuous liquid-phase density, lbm/ft3;
T = operating temperature, °R;
CD = drag coefficient. (See Appendix A for calculation.)

Lecture 7
 Separator Sizing
Horizontal Separators
 For low Reynolds number flow:

trc = continuous-phase retention time, minutes

μc = continuous-phase dynamic viscosity, cp
Δγ = specific gravity difference (heavy/light) of continuous and dispersed phases.

Lecture 7
 Separator Sizing
Vertical Vessels
 Settling theory results in the following relationship. For liquid drops
in gas phase:

For bubbles or liquid drops in liquid phase:

Lecture 7
 Separator Sizing
Vertical Vessels
Settling theory results in the following relationship. For bubbles or
liquid drops in liquid phase Assuming low Reynolds number flow:

Lecture 7
 Separator Sizing
Drop/Bubble Sizes
 If drop or bubble removal is being
used for sizing, consult following
Table for guidelines.
 Sizing the water phase by oil-drop
removal is usually not effective.
 The water effluent quality is more
likely dictated by the added
chemicals.
 Hence, the water-phase volume is
typically determined by a retention
time, based on experience.
Lecture 7
 Separator Sizing
Drop/Bubble Sizes
 The oil drops to be removed from
the gas stream also depend upon the
downstream equipment.
 Flare scrubbers are typically
designed for removal of drops that
are a few hundred microns in size
 Compressor scrubbers are typically
designed large enough so that a mist
extractor, which can remove 10- to
20-μm drops and smaller

Lecture 7
 Separator Sizing
Retention Time. Horizontal Vessels
The relationship of vessel diameter and length is given by

tro = oil retention time, minutes,

trw = water-retention time, minutes,
Qo = oil flow rate, B/D,
Qw = water flow rate, B/D,
Fl = fraction of vessel cross-sectional area filled by liquid.

Lecture 7
 Separator Sizing
Retention Time. Vertical Vessels
Similarly for vertical vessels, the relationship of vessel diameter and
liquid pad heights is given by:

ho = oil pad height, in

hw = water pad height, in

Lecture 7
 Separator Sizing
Demister Sizing.
As discussed previously, many types of demisters are limited by a
maximum velocity given by
Kd = demister capacity factor, ft/sec and depends upon the demister type;
Vm = maximum velocity, ft/sec;
ρL = liquid density, lbm/ft3;
ρg = gas density, lbm/ft3

For horizontal vessels, the required demister area (Ad) is given by:

Lecture 7
 Separator Sizing
Demister Sizing.

For vertical and horizontal vessels, The vessel diameter is then obtained as

Lecture 7
 Separator Sizing
Demister Sizing.

 For demisters (horizontal or vertical vessels) sealed in a gas box, in

addition to the demister area, some height must be maintained
between the bottom of the demister and the highest liquid level for
the demister to drain.

 A pressure drop exists across the demister. If the liquid level is too
high, the demister will not drain, and liquid siphoning can occur. A
small hole is sometimes drilled into the drainpipe as a siphon breaker.

Lecture 7
 Separator Sizing
Demister Sizing.
When using settling theory or
demister sizing in horizontal
vessels, one should also consider
the gas velocity for re-
entrainment.
Too high of a gas velocity will
result in liquid re-entrainment
from the liquid surface, which
may flood the demister and
cause carryover. Typical gas
velocities for re-entrainment are
shown in.

Lecture 7
 Separator Sizing
Seam-to-Seam Length. Horizontal Vessels.
The seam-to-seam length, Lss, of the vessel should be determined from the geometry
once a diameter and effective length have been determined. Length must be allotted for
inlet devices, gas demisters, and coalescers. For screening purposes, the following
approximations can be used:

Lecture 7
 Separator Sizing
Seam-to-Seam Length. Vertical Vessels.
The seam-to-seam length of the vessel should be determined from the geometry, once a
diameter and height of liquid volume are known. Allowance must be made for the inlet
nozzle, space above the liquid level, gas separation section, mist extractor, and for any
space below the water outlet as shown in next slide . For screening purposes, the
following approximations can be used, where d is the vessel diameter).

Lecture 7
 Separator Sizing
Seam-to-Seam Length. Vertical
Vessels.

The ratio of height to diameter is

typically in the 3 to 5 range for
two-phase separators. For three-
phase separators, the ratio is in the
1.5 to 3 range.

Lecture 7
 Separator Sizing
Nozzle Sizing.
 Nozzles are generally sized by
momentum or velocities.
 This Table gives guidelines that can be
used for sizing nozzles, where
 ρm is the bulk density
 Vm the bulk velocity.
 In addition, the API RP14E4 on erosion
velocity should be included. This
relationship is also given by an inlet
momentum criterion as ρmVm 2 = C 2
 The value of C can also vary with pipe
material, solids loading, and service

Lecture 7
 Separator Sizing
Example1: Design Vertical Two-Phase Separator With a Mesh Pad Demister. Given Values:

Gas rate 10 MMscf / D

Gas-specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Oil rate 2,000 B / D
Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60°F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
Liquid-retention time 1 minute
Inlet nozzle 4 in.

Lecture 7
 Separator Sizing
Example1: Design Vertical Two-Phase Separator With a Mesh Pad Demister. Given Values:
Gas rate 10 MMscf / D
Gas-specific gravity 0.6
Step 1. Calculate the required mesh-pad area Gas z-factor 0.84
Gas density 3.7 lbm / ft3
with this equation. This mesh area will result in a
Oil rate 2,000 B / D
vessel internal diameter of 15 in. Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60°F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
Step 2. Calculate the height for liquid retention Liquid-retention time 1 minute
Inlet nozzle 4 in.
time with below equation. ho = 74 in.

Lecture 7
 Separator Sizing
Example 1: Vertical Two-Phase Separator With a Mesh Pad Demister. Given Values:
Gas rate 10 MMscf / D
Gas-specific gravity 0.6
Step 3. Gas z-factor 0.84
Compute seam-to-seam length with below Gas density 3.7 lbm / ft3
Oil rate 2,000 B / D
equation. The Leff /D (D = d/12) is 9.2 and is Oil density 50 lbm / ft3
larger than the typical 3 to 5 range. Therefore, Operating pressure 1,000 psia
Operating temperature 60°F
the internal diameter must be increased to reduce Mesh pad K-factor 0.35 ft / sec
the Leff /D ratio. Mesh pad thickness 6 in.
Liquid-retention time 1 minute
Inlet nozzle 4 in.

Lecture 7
Separator Sizing

Lecture 7
 Separator Sizing
Example 1: Vertical Two-Phase Separator With a Mesh Pad Demister. Given Values:
Gas rate 10 MMscf / D
Step 3. Gas-specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
This table shows Leff /D for three different Oil rate 2,000 B / D
vessel IDs. Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60°F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
Liquid-retention time 1 minute
Inlet nozzle 4 in.

Lecture 7
 Separator Sizing
Example 1: Vertical Two-Phase Separator With a Mesh Pad Demister. Given Values:
Step 3. Gas rate 10 MMscf / D
Gas-specific gravity 0.6
ID vessel has the appropriate Leff /D ratio. The Gas z-factor 0.84
selected vessel would then be 24 in. × 8 ft SS tall Gas density 3.7 lbm / ft3
(after rounding up the height). Oil rate 2,000 B / D
Oil density 50 lbm / ft3
For two-phase separators, the ratio is in the 3 to Operating pressure 1,000 psia
5 range. Operating temperature 60°F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
Liquid-retention time 1 minute
Inlet nozzle 4 in.

Lecture 7
 Separator Sizing
Example 1: Vertical Two-Phase Separator With a Mesh Pad Demister. Given Values:
Gas rate 10 MMscf / D
Step 4. Gas-specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
The mesh pad can be installed in two ways, if Oil rate 2,000 B / D
the 1.15 ft2 is to be maintained. One, a full Oil density 50 lbm / ft3
Operating pressure 1,000 psia
diameter mesh pad can be installed with a Operating temperature 60°F
blanking annular plate on top. Two, a cylindrical Mesh pad K-factor 0.35 ft / sec
box with a 15-in. diameter can be installed Mesh pad thickness 6 in.
Liquid-retention time 1 minute
around the gas outlet.c Inlet nozzle 4 in.

Lecture 7
 Separator Sizing
Example 2: Horizontal Two-Phase Separator. Size a horizontal separator to remove 100 μm drops in the
gas phase.
Gas rate 10 MMscf / D
Gas-specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Gas viscosity 0.012 cp
Oil rate 2,000 B / D
Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 °F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
Liquid retention time 1 minute
Inlet nozzle 4 in.
Vessel fill 50 %
(Therefore, Fg = 0.5 and hg = 0.5d.)

Lecture 7
 Separator Sizing
Example 2: Horizontal Two-Phase Separator. Size a horizontal separator to remove 100 μm drops in the
gas phase.
Gas rate 10 MMscf / D
Step 1. Calculate vessel diameter and length with this Eq for gas capacity. Gas-specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Gas viscosity 0.012 cp
Oil rate 2,000 B / D
Assume hg = 0.5d so that Fg = 0.5. Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 °F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
From Appendix A, using a gas viscosity of 0.012 cp, CD = 1.42. Liquid retention time 1 minute
Inlet nozzle 4 in.
Vessel fill 50 %
(Therefore, Fg = 0.5 and hg = 0.5d.)

Lecture 7
 Separator Sizing
Example 2: Horizontal Two-Phase Separator. Size a horizontal separator to remove 100 μm drops in the
gas phase.

Step 1. Calculate vessel diameter and length with this Eq for gas capacity.
Note:
DRAG COEFFICIENT
Whenever relative motion exists between a particle and a surrounding
fluid, the fluid will exert a drag upon the particle. In steady flow, the
drag force on the particle is

FD = drag force
CD = drag coefficient
AP = projected particle area in direction of motion
r = density of surrounding fluid
u = relative velocity between particle and fluid

Lecture 7
 Separator Sizing
Example 2: Horizontal Two-Phase Separator. Size a horizontal separator to remove 100 μm drops in the
gas phase.

Step 1. Calculate vessel diameter and length with this Eq for gas capacity.

Lecture 7
 Separator Sizing
Example 2: Horizontal Two-Phase Separator. Size a horizontal separator to remove 100 μm drops in the
gas phase.
Gas rate 10 MMscf / D
Step 1. Calculate vessel diameter and length with this Eq for gas capacity. Gas-specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Gas viscosity 0.012 cp
Oil rate 2,000 B / D
Assume hg = 0.5d so that Fg = 0.5. Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 °F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
From Appendix A, using a gas viscosity of 0.012 cp, CD = 1.42. Liquid retention time 1 minute
Inlet nozzle 4 in.
Vessel fill 50 %
(Therefore, Fg = 0.5 and hg = 0.5d.)

Lecture 7
 Separator Sizing
Example 2: Horizontal Two-Phase Separator. Size a horizontal separator to remove 100 μm drops in the
gas phase.
Gas rate 10 MMscf / D
Step 1. Calculate vessel diameter and length with this Eq for gas capacity. Gas-specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Gas viscosity 0.012 cp
Oil rate 2,000 B / D
Step 2. Calculate Leff and Lss = Leff + d/12 for different values of d. Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Step 3. Calculate the vessel diameter and length for liquid retention time Operating temperature 60 °F
with this Eq. Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
Liquid retention time 1 minute
Inlet nozzle 4 in.
Vessel fill 50 %
(Therefore, Fg = 0.5 and hg = 0.5d.)

Lecture 7
 Separator Sizing
Example 2: Horizontal Two-Phase Separator. Size a horizontal separator to remove 100 μm drops in the
gas phase.
Gas rate 10 MMscf / D
Step 5. A comparison of these two table shows that the liquid capacity is the Gas-specific gravity 0.6
dominant parameter. Hence, a 24-in. × 6.6-ft vessel is sufficient, as it has a Gas z-factor 0.84
slenderness ratio within the typical 3 to 5 range. This size should be rounded Gas density 3.7 lbm / ft3
up to 24 in. × 7 ft. Gas viscosity 0.012 cp
Oil rate 2,000 B / D
Oil density 50 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 °F
Mesh pad K-factor 0.35 ft / sec
Mesh pad thickness 6 in.
Liquid retention time 1 minute
Inlet nozzle 4 in.
Vessel fill 50 %
(Therefore, Fg = 0.5 and hg = 0.5d.)

Lecture 7
 Separator Sizing
Example 3: Vertical Three-Phase Separator. Given Values. The given values for Example are listed next:
Gas rate 5 MMscf / D
Gas specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Oil rate 5,000 B / D
Oil density 50 lbm / ft3
Oil viscosity 10 cp
Water rate 3,000 B / D
Water density 66.8 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 ° F
Liquid-retention time 10 minutes each phase
Inlet nozzle 12 in.
Drop removal from gas 100 μm

Lecture 7
 Separator Sizing
Example 3: Vertical Three-Phase Separator. Given Values. The given values for Example are listed next:
Gas rate 5 MMscf / D
Step 1. Calculate vessel diameter based on gas capacity from Gas specific gravity 0.6
this equation : Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Oil rate 5,000 B / D
Oil density 50 lbm / ft3
Oil viscosity 10 cp
Water rate 3,000 B / D
Water density 66.8 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 ° F
Liquid-retention time 10 minutes each phase
Inlet nozzle 12 in.
Drop removal from gas 100 μm

Lecture 7
 Separator Sizing
Example 3: Vertical Three-Phase Separator. Given Values. The given values for Example are listed next:
Gas rate 5 MMscf / D
Step 2. Calculate the vessel diameter based on water drop Gas specific gravity 0.6
removal from this equation for a 500- μm drop. Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Oil rate 5,000 B / D
Oil density 50 lbm / ft3
Oil viscosity 10 cp
Water rate 3,000 B / D
Water density 66.8 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 ° F
At this point, we know that the water-drop removal is the
Liquid-retention time 10 minutes each phase
dominant sizing parameter in comparison
Inlet nozzle 12 in.
to the gas capacity.
Drop removal from gas 100 μm

Lecture 7
 Separator Sizing
Example 3: Vertical Three-Phase Separator. Given Values. The given values for Example are listed next:
Gas rate 5 MMscf / D
Gas specific gravity 0.6
Step 3. Calculate liquid levels for retention time based on Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Oil rate 5,000 B / D
Oil density 50 lbm / ft3
Oil viscosity 10 cp
Water rate 3,000 B / D
Water density 66.8 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 ° F
Liquid-retention time 10 minutes each phase
Inlet nozzle 12 in.
Drop removal from gas 100 μm

Lecture 7
 Separator Sizing
Example 3: Vertical Three-Phase Separator. Given Values. The given values for Example are listed next:
Gas rate 5 MMscf / D
Gas specific gravity 0.6
Step 4. Calculate vessel seam to seam length from
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Oil rate 5,000 B / D
Oil density 50 lbm / ft3
Oil viscosity 10 cp
Water rate 3,000 B / D
Water density 66.8 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 ° F
Liquid-retention time 10 minutes each phase
Inlet nozzle 12 in.
Drop removal from gas 100 μm

Lecture 7
 Separator Sizing
Example 3: Vertical Three-Phase Separator. Given Values. The given values for Example are listed next:
Gas rate 5 MMscf / D
Step 4. Calculate vessel seam to seam length from Gas specific gravity 0.6
Gas z-factor 0.84
Gas density 3.7 lbm / ft3
Oil rate 5,000 B / D
Oil density 50 lbm / ft3
Oil viscosity 10 cp
Water rate 3,000 B / D
Water density 66.8 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 ° F
Liquid-retention time 10 minutes each phase
Inlet nozzle 12 in.
Drop removal from gas 100 μm

Lecture 7
 Separator Sizing
Example 3: Vertical Three-Phase Separator. Given Values. The given values for Example are listed next:
Gas rate 5 MMscf / D
Step 5. Gas specific gravity 0.6
• For three-phase separators, the ratio is in the 1.5 to 3 range. Gas z-factor 0.84
• Select a vessel size that satisfies gas capacity, water-drop Gas density 3.7 lbm / ft3
removal, and liquid-retention time requirements. Oil rate 5,000 B / D
• An 84-in. × 13.4-ft separator satisfies the requirements, so Oil density 50 lbm / ft3
you would round up to an 84-in. × 13.5-ft vessel. Oil viscosity 10 cp
• Similarly, a 90-in. × 12.5-ft separator would also be Water rate 3,000 B / D
satisfactory. Water density 66.8 lbm / ft3
Operating pressure 1,000 psia
Operating temperature 60 ° F
Liquid-retention time 10 minutes each phase
Inlet nozzle 12 in.
Drop removal from gas 100 μm

Lecture 7