Simple CFD Paper
Simple CFD Paper
Separator
Abhijith Joshy, Adithya B, Anfal M A, Anirudh Nambiar
Abstract: The multiphase separators are usually the primary up to 80-90% of the cross-sectional area of the vessel
and largest technical devices inoil manufacturing platforms, (Smith, 1987). The configuration of the internal devices
furthermore this primary separation step is a key element in the
is a factor that determines the oil removal efficiency
oil and gas industries in the downstream equipment, together
with compressors, are absolutely dependent on the efficient which is related to the minimum required volume of the
performance of those multiphase separators. This project is separators (Mostafaiyan et al., 2014). Therefore, in order
concerned with CFD simulation of three phase oil-separator to enhance the separation efficiency, gravity separators
consisting of all the internal parts. The VOF model was used to are equipped with different types of internals (Han et al.,
simulate the phase behaviour and fluid flow patterns. The 2017; Kharoua et al., 2013, Simmons et al., 2004).
project also evaluated conventional separation design
methodologies using detailed CFD simulations, and The phase separation process is always accomplished in
adjustments in the design. This project studies various models
three zones, in spite of the variety of design
of the separator and the best optimized model has been
obtained. The CFD model consisted of the momentum, configurations proposed for multiphase separators. In the
continuity and standard k-𝜀turbulence equations. Assumptions first zone, that is the primary separation zone, an inlet
and effective model configurations were used to establish diverter is used so that an abrupt change in flow
design criteria for new or modified separators. These criteria direction and velocity causes the largest liquid droplets to
will be combined with an algorithmic design method used in
impinge on the diverter and then drop by gravity. The
industry to specify a realistic optimum separator design. This
allows you to lay down an effective most suitable separator, a bulk of the liquid phase is separated from the gas phase,
beneficial approach become settled for estimation of the droplet in this zone. The next zone is the secondary separation
sizes used to calculate sensible separation velocities for zone. In the secondary separation zone, the liquid
numerous oil refinery conditions. In difference with classic droplets settle outof the gas stream due to gravity and
design techniques, the conclusions of the CFD simulation
gravity separation of fine droplets occurs as the vapor
implied enhancement in design. In this extra settling time is
critical for droplets to penetrate through the interfaces. As a and liquid phases flow through the main section of the
result, this research project does display the advantages that separator at relatively low velocities. Because of gravity
CFD analyses can provide in optimizing the design of new and buoyancy, the liquid collection section in the bottom
separators and fixing troubles with present design. half of separator provides the retention time required for
Key words: CFD; Oil Separator; Coalescer; Baffles; VOF entrained gas bubbles or other liquid droplets to join their
corresponding phases. While small accumulated liquid
INTRODUCTION droplets are again separated by gravity, gas flows above
The simultaneous flow of oil, water, and gas is of the liquid phase. The final zone is the coalescing media
practical significance for the oil and gas industry. Crude zone. It is designed for mist elimination in which very
oil is actually produced with water in the form of a fine droplets that could not be separated in the gravity
mixture of water droplets in oil and it is important to settling zone are separated by passing the gas stream
remove water from the oil for economic and operational through a mist eliminator. Vanes, wire mesh pad, or
reasons. Various physical treatment methods including coalescing plates may be used in this zone, to provide
pH adjustment, centrifugation, and gravitational settling very fine droplets to coalesce and form larger droplets
have been employed (Zolfaghari et al., 2016) which can which can be separated out of gas stream by gravity. By
improve phase separation by helping, collision, changing the inlet device of the separator, the opening
migration, and subsequent coalescence of droplets area and position of the perforated plate, the
(Xie et al., 2015). At the beginning of the separation performance of the separator can be improved
process, the three-phase separator is used for the (Kharoua et al., 2012a; Kharoua et al., 2012b; Lee et al.,
separation of oil, gas, and water in the petroleum 2008; Vilagines and Akhras, 2010).The single perforated
industry. In order to determine the capacity of plate installed in the separator was modeled as porous
subsequent equipment such as heat exchangers, liquid media of finite thickness with directional permeability,
extractors, and distillation columns,a proper sizing of the and the CFD results showed that the flow streamlines
oil separator is crucial (Laleh et al., 2012c). The three- developed quickly downstream of the perforated plate
phase oil separator has mainly two parts: a gas-liquid were short circuiting (Frankiewicz and Lee, 2002). It
section and an oil- water section. A large equipment is was recommended that the fluids could choose the path
used in the gravity settling approach for separation, which of least resistance for travelling of least resistance for
is not convenient, practical, and economical for offshore travellingand could anticipate the outlet zone. . As a result
conditions. The liquid level can vary from 0.20-0.27 m of this behaviour, the result was a significant loss in the
𝜕 𝜕 𝜕
(𝛼𝜌𝑣), +𝑢 (𝑎𝜌𝑣) + 𝑣 (𝛼𝜌𝑣)
𝜕𝑡 𝜕𝑥 𝜕𝑦
Porosity (𝜀P) 0.954 0.980 0.25 𝜕𝑃 𝜕 𝜕𝑣 𝜕 𝜕𝑣
= −𝛼 + 𝛼𝜌𝑔𝑦 + (𝛼𝜇 ) + (𝛼𝜇 )
𝜕𝑦 𝜕𝑥 𝜕𝑥 𝜕𝑦 𝜕𝑦
Porous
resistance 0 For the three-phase mixture, the momentum and
continuity equations were solved. The concentration
(1/𝑚2) 3.76*105 2.57*106
1 fields of dispersed phase were obtained by tracking their
( ) volume fractionand relative motions of the dispersed
Kx
phase were approximated by algebraic equations. It is
Porous 0 considered that, the Reynolds number of the liquid phase
at the inlet was up to 58,000. The flow in the separator
resistance(1/𝑚2) 0 2.57*106
1 also involved in significant
( ) turbulence under the operating conditions. The k-ε model
ky
was implemented to account for the turbulent effects. The
Inertial 0 0 turbulence model was applied to all the three phases.
The oil phase was set as the primary phase because
resistance (1/m) 1.03*104
(𝑐rx) it is the phase, with highest mass and volume fraction
among the three phases at the inlet. The gas and water
were the secondary phases ( or dispersed phases),
Inertial 0 0 which were assumed to form droplets or bubbles within
resistance (1/m) 1*106 the continuous phase. For the three-phase mixture, the
(𝑐ry) momentum and continuity equations were solved. The
Because of high flow velocity, a high density mesh was concentration fields of the dispersed phase were obtained
applied to one inlet and the three outlets. A perforated by tracking their volume fraction and the relative
plate with a thickness of 3 mm was used to concentrate the motions of the dispersed phase were approximated by
mesh on it. Owing to the porous media assumption, the algebraic equations. It is considered that, the Reynolds
fluid flows of the coalescer and the demister were not number of the liquid phase at the inlet was up to 58,000.
sensitive. At the interfaces of the gas and the liquid, a The flow in the separator also involved significant
relatively high mesh density was used. The domain of the turbulence under the operating conditions. The k-ε model
gas phase had a relatively low mesh density. To attain was implemented to account for the turbulent effects. The
skewness of 0, element size was made to 0.005 m. With turbulence model was applied to all the three phases. The
default size and angle with medium smoothing, capture oil phase was set as the primary because it is the phase,
curvature was applied. with highest mass and volume fraction among the three
phases at the inlet. The gasand water were the secondary
phases (or dispersed phases), which were assumed to form
Deflector shape
For studying the effect of deflector shape in separating
efficiency, two models were selected. One model was
designed using a curved plate deflector and the other
using a flat one. Both models had weir plate designated
(b)
in base geometry and consisted of single baffle. For
boththe models, CFD simulation was carried out applying
the same boundary conditions and operating parameters.
Contours of volume fraction of oil, air, and turbulent
kinetic energywere calculated
MODEL 1 (With flat deflector)
(c)
Number of baffles
(a) (a)
(b)
Figure 7. (a)Volume fraction of oil
(b)Velocity distribution
CONCLUSION
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