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LIQUID LEVEL
THREE GAS
PHASE IN OUT
60" ID
PHASE
OUT
16"
LIGHT
PHASE
INTERFACE OUT
LEVEL 30"
HEAVY
PHASE
12 Ft. Coalescer Vessel OUT
800-231-0077
14211 Industry Street • Houston, TX 77053 • TEL: 713-434-0934 • FAX: 713-433-6201
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LIQUID-LIQUID COALESCER DESIGN MANUAL
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Stokes Settling — Using Gravity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Basic Design Concepts — The Emulsion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Basic Design Concepts — Operating Principles of a Coalescer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Basis for Sizing and Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Intra-Media Stokes Settling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Direct Interception . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Gravity Separation Downstream of a Coalescer Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Coalescer Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Case Studies
• Case Study 1 - Oil-Water Separators - Environmental Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
• Case Study 2 - Gas Plants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
• Case Study 3 - Alkylation Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
• Case Study 4 - Oil/Water Separator on a Production Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
• Case Study 5 - Upgrading a Three-Phase Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
General References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Ranges of Application for Coalescing Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
ACS Oil / Water Separators utilize patented* technology to separate oily waste water.
Applications include oil spill clean up for marine, power plants, refineries, vehicle terminals, and
countless others. The separated water is purified for
1992 Vaaler Award direct sewer or ocean discharge. The oil is captured
for ACS Industries and recycled.
Oil-Water Separator
*US Patent Nos. 5,023,002 & 5,246,592
ACS Separations & Mass-Transfer Products • 14211 Industry Street • Houston, Texas 77053
TEL: 800-231-0077 • FAX: 713-433-6201 • WEB: www.acsseparations.com • EMAIL: separations@acsind.com
Introduction flowing and the opposing forces of buoyancy and vis-
cous drag balance (Figure 1), the droplet has achieved
Whether engineering a new coalescer vessel, or
debottlenecking an existing separator, full knowledge its Terminal Settling Velocity. This vertical velocity is
and understanding of the basic principles involved are constant because there are no net forces acting upon
required. Often overlooked are the capabilities of prop- the droplet. This mechanism of separating liquids by
erly selected and designed internals for the enhance- gravity is called Stokes Settling after the nineteenth
ment of simple gravity separation. This Liquid-Liquid century English researcher Sir George Stokes.
Coalescer Design Manual describes the use of various The equation he developed for the terminal settling
media and methods employed for decades to increase velocity is still used today:
plant productivity. Typical applications include:
• Removal of Bottlenecks in existing vt = 1.78 X 10-6 (∆S.G.) (d)2 / µ (1)
Decanters and Three Phase Separators.
vt = Terminal Settling Velocity, ft/s
• Reduction in New Vessel Sizes – Up to five
d = Droplet Diameter, microns
times relative to gravity settling alone.
∆S.G. = Specific Gravity Difference
• Improvements in Product Purity – Carry-over
between the Continuous
entrainment reduced to 1 ppm and less.
and Dispersed Phases
• Compliance with Environmental Regulations –
µ = Continuous Phase Viscosity, centipoise
Cost effective solutions to wastewater
treatment and oil spill cleanups.
When two liquids are immiscible, or non-soluble in The size of a gravity decanter is derived from 1) the
one another, they can form either an emulsion or a terminal settling velocity of a minimum sized droplet
colloidal suspension. In either of these mixtures, the and 2) the inertial force imparted to the droplet due to
dispersed liquid forms droplets in the continuous the velocity of the emulsion through the vessel. At
phase. In a suspension, the droplets are less than one these conditions, all droplets larger than a minimum
micron in diameter and the liquids cannot readily be will be removed at a quicker rate and hence need not
separated with the technologies described here. be considered. The minimum sized droplet must be
Fortunately, in the chemical and hydrocarbon process estimated if empirical data is not available. Typically
industries droplet sizes are typically greater than this the minimum droplet size is estimated to be between
and/or the purities required can be achieved without 75 to 300µm. For example, API Publication 421 uses
addressing the ultra-light colloidal component of the minimum sized droplets of 150µm for oil/water sys-
stream. tems in refineries. Note that in Stokes Settling the
vessel must be sized to ensure laminar or streamline
Stokes Settling – Using Gravity flow; turbulent flow causes remixing. An example of
Traditionally, gravity separators were used to handle this sizing method in a decanter is contained in Case
emulsions before the use of coalescing media became Study 2, see page 12.
FIGURE 1 commonplace. In this
equipment, differences in In order to settle fine droplets and ensure laminar flow,
Forces on a light droplet densities of the two liquids large vessels and long residence times are required.
dispersed in a heavy liquid cause droplets to rise or It may take five, ten, and or even thirty minutes to
Bouyant Force fall by their buoyancy. The make a separation, depending on the physical prop-
greater the difference in erties of the stream. With the capacity intensification
densities, the easier the forced on modern refineries and chemical plants and
Inertial Force
separation becomes. achieved with advanced mass transfer internals, cat-
d
Rising (or falling) droplets alysts, and heat exchanger designs, operators find
are slowed by frictional that their separators only have half or a third of the
forces from viscous effects time originally anticipated. This results in hazy, off
of the opposing liquid. spec products or intermediates that cause problems
Viscous Drag
Force When the stream is not in downstream equipment.
Operating Principles of a Coalescer depend on Intra-Media Stokes Settling confine the dis-
Liquid-Liquid Coalescers are used to accelerate the tance a droplet can rise or fall between parallel plates
merging of many droplets to form a lesser number of or crimps of packing sheets (Figure 5). This is com-
droplets, but with a greater diameter. This increases pared to simple gravity separators in which the travel-
the buoyant forces in the Stokes Law equation. Settling
of the larger droplets downstream of the coalescer FIGURE 5
element then requires considerably less residence OIL DROPLETS RISING TO A COLLECTION SURFACE
time. Coalescers exhibit a three-step method of opera-
L
tion as depicted in Figure 3.
FIGURE 3 h
THREE STEPS IN COALESCING
Submicron droplets
flow around target Several captured droplets
coalesce, forming larger ing distance is equal to the entire height of the pool of
Droplets strike drops...
target and adhere
liquid present in the separator. This effect is also seen
...which trickle down in knitted wire mesh, but their high void fractions mean
and fall, becoming
separated the surface is very discontinuous.
Meshes, co-knits of wire and yarns; and wire and glass
wools all depend primarily on Direct Interception
where a multiplicity of fine wires or filaments collect
fine droplets as they travel in the laminar flow stream-
lines around them (Figure 6). As can be see in Figure
4, in general they can capture smaller droplets than
1) Collection of Individual Droplets those that depend on enhanced Stokes Settling. A
2) Combining of Several Small Droplets into Larger Ones general rule with Direct Interception is that the size of
3) Rise/Fall of the Enlarged Droplets by Gravity the target should be close to the average sized droplet
in the dispersion. Finer coalescing media allow for the
Wire/Polymer O 94-98% 21-35 micron Coalescers work better in laminar flow for sev-
Co-Knits
eral reasons. First, as mentioned above,
Wire/FG Co-Knits, H 92-96% 8 - 10 micron High/High droplets will stay in the streamlines around a
Glass Mat
wire or fiber target. Second, high fluid velocities
Table 2 overcome surface tension forces and strip
Step 2 – Droplet Coalescence droplets out of the coalescer medium. This results in re-
The second step is to combine, aggregate, or coa- entrainment in co-current flow and prevents droplets
lesce captured droplets. Increasing the tendency for from rising/sinking in counter-current flow. Lastly, slow-
droplets to adhere to a medium, increases the proba- er velocities result in greater residence time in the
bility that subsequent droplets will have the opportuni- media and therefore more time for droplet-to-target
ty to strike and coalesce with those that already have impact, droplet-to-droplet collisions, and Intra-Media
Stokes Settling.
Axis of Corrugation
9b Axis of Corrugation
Stokes-Pak™ with
Horizontal Sheets
h 1/2"
Axis of Corrugation
Stokes-Pak ™
9c
Stokes-Pak™ with
make more efficient use of a vessel volume than a Vertical Sheets
straight PPI (Parallel Plate Interceptor) since more
metal is used and the specific surface area is greater.
It can be shown from Equation 1 for Vt that the volume
of media necessary to remove virtually all droplets h
1/2"
equal to a minimum, typically 30-60 microns, is given
by:
Direct Interception
SOLIDS Direct Interception occurs when a droplet follows a
DRAIN
streamline around a target but collides with it because
SOLIDS
DRAIN
the approach distance is less than half its diameter,
d/2 (Figure 6). The formulas for Direct Interception in
mesh, co-knits, wire and glass wools are given below.
they both have sheets in the horizontal. STOKES- Given first is a formula for the collection of a droplet on
PAKTM with vertical sheets, on the other hand, retains a single target. Following that is a formula which,
fewer solids than the horizontal sheet version and so based on this factor, calculates the depth of the coa-
is often required in fouling situations. In this case, lescer element necessary to achieve a desired overall
there is some loss in coalescer efficiency due to the collection efficiency at a selected minimum droplet
longer distance a droplet could travel (see Figure 9 b size.
and c). The entire CPI unit can also be put on a 45˚ to
60˚ angle in order to retard fouling. However, this (4)
requires much more support structure and an addi-
tional 40 to 100% of coalescer volume since droplet
trajectory is lengthened (Figure 10).
η
the coalescer design volume over the theoretical in
order to compensate for the effects of bypass and D =Collection Efficiency of a Single
back mixing. With knowledge of the cross-sectional Target by Direct Interception
area of a fully flooded coalescer vessel or the lower
segment available in a horizontal 3-phase separator, E =Effective Length Multiplier
the required depth can easily be calculated from Vc.
ACS Plate-PakTM and Stokes-PakTM both come in units α =Volume Fraction of Fibers or Wires
which are 8" (203 mm) deep as a standard, but custom
depths are also available. d =Droplet Diameter, inches
Once the final coalescer length is selected the minimum
droplet size that can be collected at 99.9% efficiency K =Kuwabara’s Hydrodynamic Factor
-0.5 ln α -0.25 α2 + α -0.75
Impeller Polyester
12.5 Co-Knit 24/0.00095 0.021 .07
Mixers Interceptor-PakTM
FIGURE 12
Mixing Wire
22.0 Wool 50/.002 0.028 .40
Valves
Interceptor-PakTM
Extraction Knitted
79.0 Mesh 152/.006 0.014 .60
Columns Interceptor-PakTM
Table 3
Vertical Coalescers
Coalescer
Heavy
Horizontal Coalescers Stream
In
FIGIRE 14 A
Trays,
3-Phase Horizontal Coalescer Vessel Packing
Mixed or Agitated
Vapor Internals
Phase Plate-Pak™ Outlet
Inlet Inlet Device Mist Eliminator
FIGIRE 14 E
FIGIRE 14 B
Vertical Decanter with Coalescer
2-Phase Horizontal Coalescer Vessel
Emulsion In Wedge Light Product
LC Light
Stream
Out
Coalescer
Liquid Coalescing Heavy
Distributor Medium Product
FIGIRE 14 C
Emulsion
2-Phase Horizontal Coalescer Vessel with Boot In
Emulsion In Light Product
Coalescing Heavy
LC
Medium Dispersed
Phase
1.083 (1+(4.5/8.9))
were installed on each quick-response vessel. ACS was
awarded the prestigious Vaaler Award and two US = 0.00305
patents (Nos. 5,023,002 and 5,246,592) in developing
the coalescers for this application. L = π (.00035") (1-.027)ln (1-.999)
Typical conditions are – removing 25 gpm of oil with a -4(0.00305) 0.027
specific gravity of 0.85, and a viscosity of 12,000 centis-
tokes from 500 gpm of water with 3% salinity, a specific = 22.4"
gravity of 1.02, and a viscosity of 1 centistoke. The over- For safety each stage was supplied with a
all dimensions of the OWS for the MSRC are 8’ square 24" thick fiberglass co-knit element.
by 25’ long at a full of water weight of 25,000 lbs.
FIGURE 15
CPI media, such as ACS Plate-PaKTM which in this
case had 3/4" plate spacing to accommodate the high- ADVANCED OIL/WATER SEPARATOR
ly viscous oil, is known to be able to remove 99+% of
all droplets down to about 100 microns. Oil
Putting these factors into equation 2 yields –
FIGURE 16
GAS PLANT WITH JOULES-THOMPSON DEW POINT CONTROL
Compressor
Gas Product to Pipeline
70˚F 25˚F Hydrocarbon Vapor
Gas-Gas
Exchanger
90˚F @1150 PSIG
Feed From
Gas Field
Flash Tank
J-T Valve Steam
Lean
Glycol
COLD SEPARATOR
WITH COALESCER Reboiler
AT 250 PSIG
Condensate
LC
Rich
Rich Glycol Glycol
diately in order to make a clean break between the two 1.251 (1+(15/21))
immiscible phases and lower the free acid concentra-
tion in the hydrocarbon to less than 15 ppm. The first Putting this value in equation 6 gives
coalescer stage in the horizontal section, used to
remove the bulk of the acid, is a vertical Stokes-Pak™ L = π (.00083") (1-.019)ln (1-.999)
element, which is preceded by a 20% open perforated -4(0.0163) 0.019
plate liquid distributor. The second stage is a horizon-
tal ACS Interceptor-Pak™ with Teflon® Multi-Filament = 14.3"
Co-Knit. The inlet section of the large diameter vertical
section removes the fine acid droplets and allows Thus a 15" depth of a 15’ diameter Alloy 20/Teflon
them to drain counter-current to the ascending contin- Multi-Filament Interceptor-Pak™ Coalescer was
uous hydrocarbon stream. chosen for the second stage element.
Process conditions were 2480 GPM of alkylate that
had a specific gravity of 0.59 and a viscosity of 0.21 cp FIGURE 17
was mixed with 110 GPM of acid (2/1 ratio of recycle
to fresh) that had a specific gravity of 1.85 and a vis- COALESCER IN ALKYLATION UNITS
cosity of 25 cp. The mix valve is reported to create an HYDROCARBON OUT
average droplet size of approximately 400 microns for
the washing, but also generates a significant amount
of fine droplets. Stokes-Pak™ with horizontal sheets
and 1/2" crimps was chosen to remove 99+% of all STAGE 2
Teflon Multifilament Co-Knit
droplets down to about 35 microns. The volume of
15"
180" T/T
Vc = 219 * 2590 * 0.5 * .21 = 38.6 cubic feet
HC/
72" I.D.
FIGURE 19
General References: Holmes, T. L., AIChE Mugele, R. A., and Evans, H. D., ACS Industries presents the
Symposium Series, Industrial and Engineering information in this publication in
American Petroleum Institute 77, 211, pp. 40-47, 1981. Chemistry, 43, 6, 1951. good faith, believing it to be accu-
Publication 421, rate. However, nothing herein is to
Design and Operations of Oil- be construed as either an express
Lee, K. W. and Liu, B.Y.H., Paragon Engineering or implied guarantee or warranty
Water Separators, API Journal of the Air Pollution Services, Produced Water
Refining Department, regarding the performance, mer-
Control Association, 30, 6, Theory and Equipment chantability, fitness, application,
Washington, DC, 1990. 4/80. Description, Houston, TX. suitability, nor any other aspect of
the products and services of ACS
Gas Processors Suppliers Monnery, W.D. and Svrcek, Perry’s Chemical Engineer’s Industries, LP. No information
Association, Engineering Data W.Y., Chemical Engineering Handbook, 6th Edition, contained in this bulletin consti-
Book, Volume 1, 11th Edition, tutes an invitation to infringe any
Progress, pp. 29-40, 9/94. McGraw-Hill, New York, NY, patent, whether now issued or
Tulsa, OK, 1998. 1984. issued hereafter. All descriptions
Lieberman, N. P., and specifications are subject to
Hoffmann-La Roche Standard Troubleshooting Process Reist, P.C., Aerosol Science change without notice. Stokes-
Design Practice for Decanters Operations, and Technology, 2nd Edition, PakTM, Interceptor-Pak and Plate-
(Liquid-Liquid Settlers), Nutley, 3rd Edition, PennWell Books, McGraw-Hill, New York, NY, PakTM are trademarks of ACS
NJ, 11/84. Industries, LP. Teflon is a regis-
Tulsa, OK, 1991. 1993. tered trademark of E. I. Dupont de
Nemours.
Engineered Excellence!
Quick Replacement
Grass Root and Revamp Projects
MIST ELIMINATORS • ACS is the industry leader with 50+
years of experience engineering and fabricating mist elimination
products. Your only source for MisterMesh® mesh pads,
MultiPocket™ vanes and AccuFlow™ inlet distributors. ACS
offers the quickest replacements of virtually any mesh or
chevron mist eliminators with short lead time - stocked
inventory from polypropylene to Hastelloy!
and caged valve trays, and of course bubble cap, sieve, baffle
and rain deck trays. ACS offers the FRI tested high efficiency
SEMV® floating and fixed valves. ACS also offers other
non-proprietary replacement tray hardware for a variety
of trays available in the market.
24 7
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ACS Separations & Mass-Transfer Products 14211 Industry Street • Houston • Texas 77053
TEL: 800-231-0077 or 713-434-0934 • FAX: 713-433-6201 • WEB: www.acsseparations.com • EMAIL: separations@acsind.com