University of Technology

chemical Engineering
Department

Branch:-Refinery.
Study:-morning.
Stage:- Third.
Year:-25/1/2021.

Design Equipment
(Vertical separator)
By:
1-‫ﻣﺮﯾﻢ ﺟﺎﺳﻢ‬
2-‫ﻣﻨﺘﻈﺮ ﻗﺎﺳﻢ‬

 Introduction:-
*separator:-
-A cylindrical or spherical vessel used to separate oil, gas and water from the total
fluid stream produced by a well. Separators can be either horizontal or vertical.
Separators can be classified into two-phase and three-phase separators (commonly
called free-water knockout). The two-phase type deals only with oil and gas, while
the three-phase type handles oil, water and gas. Additionally, separators can be
categorized according to their operating pressure. Low-pressure units handle
pressures of 10 to 180 psi [69 to 1241 kPa]. Medium-pressure separators operate
from 230 to 700 psi [1586 to 4826 kPa]. High-pressure units handle pressures of 975
to 1500 psi [6722 to 10,342 kPa]. Gravity segregation is the main force that
accomplishes the separation, which means the heaviest fluid settles to the bottom and
the lightest fluid rises to the top. Additionally, inside the vessel, the degree of
separation between gas and liquid will depend on the separator operating pressure,
the residence time of the fluid mixture and the type of flow of the fluid. Turbulent
flow allows more bubbles to escape than laminar flow.

vertical separator:-
-A vertical separator is a vessel for the bulk removal of liquids or solids by gravity.
Operators prefer to utilize vertical separators over other separators when the well
streams have large liquid to gas ratios, constant flow, and small liquid surge
characteristics (high gas/ low liquid). Vertical separators are also preferred when well
streams have sizable quantities of sand, mud, or other related substances as well as
process flow streams, which are characterized by large instantaneous volumes of
liquid or slugs. Lastly, when there are horizontal space limitations, but little or no
vertical height limitations (i.e. offshore platform), vertical separators would be a
good, space-saving option.
These separators may go by many names like oil-water separator, three-phase
separator, two-phase separators, but functionality is all relatively the same. With these
reasons it is important to have properly functioning parts because without them it is
just a pressure vessel.

Gas-Liquid separator:-
-vapor–liquid separator is a device used in industrial applications to separate a vapor–
liquid mixture into its constituent phases. It can be a vertical or horizontal vessel, and
can act as a 2-phase or 3-phase separator.
A typical vapor–liquid separator including commonly a de-entrainment pad and
sometimes an inlet distributor.
A vapor–liquid separator may also be referred to as a flash drum, breakpot, knock-out
drum or knock-out pot, compressor suction drum, suction scrubber or compressor
inlet drum, or vent scrubber. When used to remove suspended water droplets from
streams of air, it is often called a demister.
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 Benefits of Vertical Separators:-

-Oil and gas separators are pressure vessels designed to separate gas and liquid
components, which emerge from an oil well. These are commonly used in processing
stations, and can also be found on offshore platforms. Depending on their
configurations, most separators are classified as vertical or horizontal.

The Difference between the Two Separators:-

-The difference between vertical and horizontal separators is the fluid ratios that they
work with. Vertical separators are designed to support intermittent oil and gas flow
streams. Horizontal separators are designed to support high flow and continuous oil
and gas streams. Unless you are in an area where oil is at an abundance, many oil and
gas companies prefer to use vertical separators in their applications.

Three Basic Benefits of Vertical Separators

-The design and function of vertical separators gives them a variety of advantages,
making them extremely beneficial for oil and gas applications.

• Separation Procedure: When the incoming stream enters the separator, it is

spun around within the machine. This spinning action causes the liquid to stay
together along the machine’s walls, rather than allowing gravity to pull it to the
bottom of the separator. The spinning action not only supports the separation
process, but also prevents the liquid from entering the gas stream. For this
reason, vertical separators are useful when dealing with large liquid slugs from
wells.
• Liquid Level Control: Vertical separators have the capability to control the
level of the liquids within its chambers. They are able to perform this due to
their shape. Any change in the liquid volume is very small, and does not affect
the overall liquid level in the chamber. Furthermore, the level flow will not
affect the gas flow or its mist content. Hence, vertical separators are ideal for
wells with fluctuating streams.
• Easy Maintenance: By design, vertical separators do not require a lot of floor
space in terms of installation and use. They are easy to clean, hence can be
used to separate crude or sandy oils. They are also capable of handling wax,
and paraffin without any chance of blockage. Vertical separators are known to
have fewer incidents of re-entrainment compared to other types of separators.

 parts go to a vertical separator:-

1.Liquid Level Controllers - Liquid level controllers maintain a desired level in a
vessel. The displacer floats in the process fluid and as the fluid level passes to the
high-level set point. The liquid level controller pilot sends signals to the dump valve
to open. As the level decreases and reaches the low-level set point the pilot stops send
supply gas to the dump.

2.Dump Valves - A dump valve is opened by

controller to drain the liquids from a vessel.

3.Gauge Valve Sets - These valves are used

when replacing a broken sight glass to isolate
process fluid.

4.Sight Glass - A sight glass is a transparent

glass tube that allows you to see the process
fluid level inside a vessel.

5.Temperature Gauges - Temperature gauges

are designed to show process temperature.

6. Thermowell - Thermowells are designed to

block the process fluid and to be a connection
port for temperature gauges.

7.Pressure Gauges - Pressure Gauges are

designed to show process pressure.

8.Vent Caps - Vent caps are used to protect the

PSV from rainwater. This vent cap also has a
whistle vent integrated for low amounts of
pressure relieving that is usually not noticeable.

9.Pressure Safety Valves -The pressure safety

valve will open if process pressure exceeds the
factory set pressure. The PSV ensures the safety
of the equipment.

 Application:-
Separators are perfect for separation tasks in which a high degree of selectivity is
required or in which the separation of the finest particles is important. They are also
used for separating solid/liquid mixtures having only a small difference in density.
Disk stack separators have many applications that can be found in the most diverse
branches of industry, for example:
• In the food and beverage sector
• In the grease and oil processing industry
• In the chemical, pharmaceutical, and biotechnology industries
• In the petroleum industry and energy production
• In environmental protection

Separators are mainly used for three different separation processes:

• As a clarifier for clarifying liquids. Clarification is the separation of finely

distributed solid particles from a liquid. The separator is used for mixtures with
a low solids content. If the mixture to be clarified contains a large quantity of
solids, a decanter is a better choice. The clarification of turbidity from fruit
juice is a typical example application for a separator.
• As a purifier/separator for separating liquids. This separates a liquid with a
lower density from a liquid with a higher density. An example of this use is the
separation of water from mineral oil. Solids can be separated out of such a
mixture at the same time.
• For concentrating liquids. This involves the concentration of a light liquid from
a heavy liquid. One example is the extraction of essential oil from water using
the separator. The simultaneous separation of solids is possible.

The technology of separating water from gas and vice versa is extensively used by
several industrial sectors for multiple applications, some of which are mentioned
below.
• Oil refineries
• Petrochemical and chemical plants
• Compressor systems
• Natural-gas processing plants
• Flare stacks
• Combined cycle power plants
• Refrigeration systems
• Gas pipelines
• Soil vapor extraction
• Paper mills
• Steam condensate flash drums
• Geothermal power plants
• Air conditioning
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 Calculations:-
A-
ρL − ρv
1-ut = 0.07
ρv
878.346 − 6.125
ut = 0.07 = 0.84m /sec
6.125
us = 0.84 × 0.15 = 0.126m /sec
mv
2-Vapour volumetric flow rate =
ρv
6500
= = 0.3m 3 /sec
6.125 × 3600

4 × Vv
3-Dv =
π × us
4 × 0.3
Dv = = 1.74m. Take it 1.75m
π × 0.126
mL
4-Liquid volumetric flow rate =
ρL
9000
= 3 × 10−3m 3 /sec
878.346 × 3600

5-Allow a minimum of 10 min hold up

Volume held in vessel= 3 × 10−3 × 600sec = 1.8m 3
1.8
Liquid depth required hv = = 0.75m
π × 1.752 /4
B-
1- Design pressure = operating pressure × 1.1

12 × 1.1 = 13.2bar 1.32N/mm 2

2-Design Temperature = operating Temperature +15

35+15=50 C o

Welded efficiency =0.9

3-From table (13.2) Typical design stress for plate (carbon steel)

Temperature design between 0 to 50

The stress is 135N/mm 2

 pi × Di
4-Thickness for plate T =
2SE − 1.2pi
1.32 × 1750
T= = 9.5mm
2 × 135 × 0.9 − 1.2 × 1.32
Thickness of the plate + c
9.5+2=11.5mm

When C= Corrosion allowance=2

5- Thickness for head

pi × Di
T=
2SE − 0.2pi
1.32 × 1750
T= = 9.5mm
2 × 135 × 0.9 − 0.2 × 1.32

Thickness of the head + C

9.5+2=11.5mm

6- The nozzles
For into gas-liquid and out gas
Q
A=
u
0.3m /sec
A= = 0.02m 2
15m /sec
pi
A= × D2
4
A
D=
π /4
0.02
D= = 0.16m. 160mm thickness of the Diameter from pipe schedule is.
π /4
(7.11mm)

Nozzle of liquid out

3 × 10−3m 3 /sec
A= = 3 × 10−3m 2
1m /sec
A
D=
π /4
3 × 10−3
D= = 0.06m. 60mm thickness of the Diameter from pipe schedule is.
π /4
(3.91mm)
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 Reference:-
•chemical engineering design (volume 6) Table(13.2)
page 812 ,815 & 825

• https://www.pdfdrive.com/search?q=Gas-
Liquid+And+Liquid-
Liquid+Separators&pagecount=&pubyear=&searchin=
&em=

• https://petrowiki.spe.org/Oil_and_gas_separators

• https://croftsupply.com/search.php?
search_query=SeparAtor

• https://en.m.wikipedia.org/wiki/
Separator_(oil_production)

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