Separator Design-1

PRACTICAL GUIDELINES TO TWO PHASE HORIZONTAL

SEPARATOR DESIGN

Prepared By: Baber Rafique

Process Engineer
www.linkedin.com/in/baberrafique
baberrafique@gmail.com
 Separator Design Theory

This section describes the general guidelines & rules of thumb are presented for separator
design that may applicable in most of cases however operating experience & good
engineering evaluations are required for optimum design.

Types of Separators Based on

Fluid Phases

2-Phase Separator 3-Phase Separator

Gas & Liquid Phases Gas & 2 Liquid Phases
Gas/oil or Gas/water Gas/oil/water

Types of Separators Based

on Orientaions

Horizontal Vertical
Irrespective of numbers of fluid present or orientation of vessel, separation is governed by
three phenomena.

i. Momentum shift that is carried out by deflector plate separates the bulk of liquid
volume
ii. Gravity settling by force of gravity separates 100-500 micron droplets
iii. Coalescence by demister pad separates 10-100 micron droplets.

In the gravity settling section of a separator, liquid droplets are removed using the force of
gravity. Liquid droplets, contained in the gas, settle at a terminal or “settling” velocity. At
this velocity, the force of gravity on the droplet or “negative buoyant force” equals the drag
force exerted on the droplet due to its movement through the continuous gas phase. The
drag force on a droplet may be determined from the following equation:

𝑉𝑡2
FD = CD Ad ρ Eq-1
2𝑔
FD = drag force, lbf (N),

CD = drag coefficient,

Ad = cross-sectional area of the droplet, ft2 (m2),

ρ = density of the continuous phase, lb/ft3 (kg/m3),

Vt = terminal (settling velocity) of the droplet, ft/s (m/s),

g = gravitational constant, 32.2 lbmft/lbf s2 (m/s2).

Drag coefficient is calculated based on the Reynolds number. Fighure-1 below represents
the equation of CD. As in practically it’s rare that stream line flow exists. Thus

24 3
CD = + 1/2 + 0.34 Eq-2
𝑅𝑒 𝑅𝑒
 Figure 1:Coefficient of drag for varying magnitudes of the Reynolds number

And terminal velocity is given by eq 3a or 3b depending upon units used.

1/2
𝜌𝑙 − 𝜌𝑔 𝑑𝑚
𝑉𝑡 = 0.0119 Eq-3a (Field Units)
𝜌𝑔 𝐶𝐷

1/2
𝜌𝑙 − 𝜌𝑔 𝑑𝑚
𝑉𝑡 = 0.0036 Eq-3b (SI Units)
𝜌𝑔 𝐶𝐷

ρl = density of liquid, lb/ft3(kg/m3),ρg = density of the gas at the temperature and pressure
in the separator, lb/ft3(kg/m3).
Eq-3 & 2 are solved iteratively to find the value of CD.

Solve eq-3 using initial guess of CD as 0.34, then calculate Re using eq-4

𝜌𝑔 𝑑𝑚 𝑉𝑡
𝑅𝑒 = 0.0049 Eq-4
𝜇
Then using eq-2 recalculates the CD. Compared both CD if doesn’t match guess new one and
repeat.

Gravity settling section is usually designed for 140 micron droplets this will reduce the load
on mist extractor.
In order to ensure that gas & liquid in separator attain the equilibrium some suitable
retention time must be selected. Exact retention time depends upon the PVT of t fluids.
However, for most of application 30 s to 3 min have been found sufficient.

Liquid re-entrainment could over flood the mist eliminator by a margin and is caused by
high gas velocity. In order to minimize the liquid re entrainment slenderness ratio
(length/dia) of 3 to 5 is recommended for half filled separator.

In the absence of laboratory data table-1 can be used as guideline.

Retention Time for Two-Phase Separators

°API Gravity Retention Time (Minutes)

35+ 0.5 to 1
30. 2
25. 3
20+ 4+
1. If foam exists, increase above retention time by a factor of 2 to 4.
2. If high CO2 exists, use a minimum of 5-minute retention time.
Table-1

Steps to Design Two Phase Horizontal Separator 50% Liquid Volume

While designing a separator flow conditions, variations in flow, properties of fluid should be
considered.

When sizing a horizontal separator, it is necessary to choose a seam-to- seam vessel length
and a diameter that satisfy following two conditions;

i. Gas capacity that allows the liquid droplets to dropout from gas phase
ii. Liquid retention time to attain the equilibrium.

Both conditions i & ii are governed by two different equations and discussed below.

i. Gas Capacity Constraints

1/2
𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
𝑑𝐿𝑒𝑓𝑓 = 420 Eq-5a (Field Units)
𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚

1/2
𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
𝑑𝐿𝑒𝑓𝑓 = 34.5 Eq-5b (SI Units)
𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚

d = vessel internal diameter, in. (mm),

Leff = effective length of the vessel where separation occurs, ft. (m).

T = operating temperature, °R(°K),

Qg = gas flow rate, MMscfd. (scmh),

P = operating pressure, psia. (kPa),

Z = gas compressibility,

CD = drag coefficient,
dm = liquid droplet to be separated (micron),

ρg = density of gas, lb/ft3(kg/m3),

ρl = density of liquid, lb/ft39kg/m3).

ii. Liquid Retention Time

𝑡 𝑟 𝑄𝑙
𝑑 2 𝐿𝑒𝑓𝑓 = Eq-6a (Field Units)
0.7

𝑑 2 𝐿𝑒𝑓𝑓 = 42441 𝑡𝑟 𝑄𝑙 Eq-6b (Field Units)

tr = desired retention time for the liquid, min,

Ql = liquid flow rate, bpd (m3/hr).

Eq 5 & 6 gives the effective length required as per both constraints i & ii.

Out of both the constraints the one having highest d 2Leff value will govern the separator size.

Seam to Seam Length (S/S)

Whatever constraint govern the separator size the S/S length includes

S/S Length = Inlet Section + Effective Length + Mist eliminator Section

As depicted in figure-3

Figure 2: Horizontal Separator

S/S length can be calculated using following equation

For gas capacity constraint dominated

𝑑
𝐿𝑠𝑠 = 𝐿𝑒𝑓𝑓 + Eq-7a (Field Units)
12
𝑑
𝐿𝑠𝑠 = 𝐿𝑒𝑓𝑓 + Eq-7b (SI Units)
1000
For liquid capacity constraint dominated

4
𝐿𝑠𝑠 = 𝐿𝑒𝑓𝑓 Eq-8
3
Note Eq. 5 & 6 could be solved for combinations of diameter & lengths. However, L/D ratio
is recommended to be 3 to 5.

Steps to Design Horizontal Two Phase Separator Other Than 50 % Liquid

Volume
In oil & gas majority of separators are designed for 50% liquid volume however, in some
special case it could be designed from different volume percent depending upon
requirements.

In case of different volume percentage, a new design constant is multiplied given by eq-9

1−𝛽
= 𝑑𝑒𝑠𝑖𝑔𝑛 𝑐𝑜𝑛𝑠𝑡𝑎𝑛𝑡 Eq-9
1−𝛼
α & β are area & diameter coefficient depicted by figure-4.

Figure 3: Coefficient of Design Constant

For gas capacity constraints

1/2
1−𝛽 𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
𝑑𝐿𝑒𝑓𝑓 = 420 Eq-10a (Field Units)
1−𝛼 𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚

1/2
1−𝛽 𝑇𝑍𝑄𝑔 𝜌𝑔 𝐶𝐷
𝑑𝐿𝑒𝑓𝑓 = 34.5 Eq-10b (SI Units)
1−𝛼 𝑃 𝜌𝑙 − 𝜌𝑔 𝑑𝑚
Figure 4:Design Constant for gas capacity constraints (Field Units)
 Figure 5:Design Constant for gas capacity constraints (SI Units)

Liquid Capacity Constraint

𝑡𝑟 𝑄𝑙
𝑑2 𝐿𝑒𝑓𝑓 = Eq-11a (Field Units)
1.4𝛼
 21221 𝑡𝑟 𝑄𝑙
𝑑2 𝐿𝑒𝑓𝑓 = Eq-11b (SI Units)
𝛼

Figure 6: Design constant for liquid capacity constraints Field Units

 Figure 7: Design constant for liquid capacity constraints SI Units

Lss calculations will be same for both cases as of 50% liquid filled separator.
References:
1-GPSA Engineering Data Book
2-API SPEC 12J, specification for Oil and Gas Separators
3-Arnold K, Stewart M, Surface Production Operations, Design of Oil-
Handling Systems and Facilities (3rd Edition)
4-https://petrowiki.spe.org/Separator_sizing