Production Engineering II

Two Phase Separation Process

 Course Learning Outcomes (CLO)
1. Differentiate between various types of offshore
structure.

2. Analyze the HSE requirement for oil and gas fields

operation.

3. Propose the suitable processes and treatment

equipment to manage produced oil, gas and water.

4. Perform standard engineering calculations for the

design of separator, storage tanks and pipelines.
 Lecture Outcomes

At the end of this lecture, students should be able to :

 Understand the two phase separation theory.

 Identify the data required to calculate settlement velocity

 Perform settlement velocity calculation

 Overview
In designing a separator to handle a produced stream,
the aim is to purchase the separators with minimum
size that can provide the separation condition with no
or minimal process problem

Separation conditions:
Separation problems:
Enough gas capacity Lss • Liquid re-
Enough liquid capacity
entrainment
Settlement of droplets
• Mist extractor over
greater than specific size
flooding
Efficient separation at
• Gas bowby
given retention time ID
 Separation Theory
i. Liquid Droplet Settling

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 (or negative buoyant

force) on the droplet equals the drag force exerted on the
droplet due to its movement through the continuous gas
phase.
Separation Theory
 Separation Theory
i. Liquid Droplet Settling

The drag force and buoyant forcen on a droplet is

determined using the following equations:

( )
2
𝜌𝑔 𝑉𝑡
𝐹 𝐷 =𝐶 𝐷 𝐴 𝑑
2𝑔

)( )
2
𝐹 𝐷 =𝐶 𝐷 ( 𝜋
4
𝐷𝑚
2 𝜌𝑔 𝑉 𝑡
2𝑔 (1) (2)

Where, FD = drag force, lb, CD = drag coefficient, dimensionless, Ad = cross

sectional area of droplet, ft2, Dm = oil droplet diameter, ft , 𝜌𝑔 = density of
continuous (gas) phase, lb/ft3
Vt = settling velocity of the oil droplet, ft/s , g = gravitational constant, 32.17
ft/s2 , V = volume of spherical oil droplet, ft3 , 𝜌𝑜 = density of oil, lb/ft3
 Separation Theory
The terminal velocity is the velocity at the balance
between buoyant force and the drag force. i.e:
𝐹 𝐷 =𝐹 𝐵

)( )(
2
𝐶𝐷 ( 𝜋
4
𝐷𝑚
2 𝜌𝑔𝑉 𝑡
2𝑔
=
𝜋
6
3
)
𝐷 𝑚 ( 𝜌𝑜 − 𝜌𝑔 ) FD

FB

24
𝑉𝑡 = 𝑔
3 𝜌𝑔 (
𝜌𝑜 − 𝜌 𝑔
)( )
𝐷𝑚
𝐶𝐷 (3)

Taking the particle diameter unit as micron, the above

equation can be reduced for the settling velocity as:

[( )( )]
1/ 2
𝜌𝑜 − 𝜌 𝑔 𝑑𝑚
𝑉 𝑡 =0 . 01186 (4)
𝜌𝑔 𝐶𝐷
 Separation Theory
 The CD is a function of Reynolds number. For low Reynolds‟s number flow, i.e. NRe < 1,
24
𝐶 𝐷= (5)
𝑁 𝑅𝑒
 Unfortunately, Stokes‟ Law (creeping flow) doesn’t govern for production facilities design.
Hence the following drag coefficient formula can be used for practical application:

24 3
𝐶 𝐷= + + 0 . 34 (6)
𝑁𝑅𝑒 √ 𝑁𝑅𝑒

 Here, Reynolds’ number,

𝜌 𝑔 𝑑𝑚 𝑉 𝑇
𝑁 𝑅𝑒=0 . 0049
𝜇𝑔 (7)

Where 𝜌𝑔 = density of gas, lb/ft3

dm = oil droplet diameter, μm
Vt = terminal velocity, ft/s
𝜇𝑔 = viscosity of gas, cP
 Separation Theory

Stokes flow Turbulent flow

Field unit Field unit

SI unit SI unit
 Procedure for calculating settling velocity

Step 1: Assume laminar flow and calculate Vt1

Step 2: use Vt1 to calculate Re
Step 3: use Re to calculate CD for non-laminar
flow
Step 4: calculate Vt2 using the general equation
Step 5: if the absolute difference of Vt1 and Vt2
is within the allowable error stop, otherwise
go to step 2 and iterate
Procedure for calculating settling velocity and drag
coefficient-method 1
start
0 .5
 ( l   g )d m 
Calculate Vt assuming Stokes flow Vt  0.0204  
(Vt_assumed))   g 
Vd g t m
Use vt calculated above to calculate Re Re  0.0049
 g
24 3
Calculate CD at turbulent flow CD  
Re Re0.5
 0.34
0.5
 ( l   g ) d m 
Calculate V (Vt_calc) Vt  0.0119  
  g C D 
No
Check
V t _ assumed
V t _ calc.  e
Yes

Vt=Vt_calc

End
Procedure for calculating settling velocity and drag
coefficient-method 2
start

Assume a value of CD (CD_assumed)

0.5
 ( l   g ) d m 
Calculate Vt Vt  0.0119  
  g C D 
Calculate Reynolds number Vd
g t m
Re  0.0049
 g

24 3
Calculate CD (CD_calc) CD  
Re Re0.5
 0.34

No
Check
C D _ assumed
 C D _ calc.  e
Yes

CD=CD_calc

End
 Separation Theory
Example 1

Determine drag coefficient using the following operating conditions:

- Gas specific gravity: 0.6

- Oil gravity: 35 oAPI
- Operating pressure: 1000 psia
- Operating temperature: 60 oF
- Gas compressibility: 0.84
- Viscosity of gas: 0.013 cP
- Diameter of oil droplet: 100 μm
 Separation Theory
Tabulate the Values

Iteration CD Vt NRe CD % error Remarks

Step
1.
2.
3.
4.
5.
6.
7.
8. Convergence
 Separation Theory
Tabulate the Values

Iteration CD Vt NRe CD % error Remarks

Step
1. 0.3400 0.7419 103.7142 0.8660 154.7013
2. 0.8660 0.4649 64.9864 1.0815 24.8811
3. 1.0815 0.4160 58.1533 1.1461 5.9782
4. 1.1461 0.4041 56.4893 1.1640 1.5626
5. 1.1640 0.4010 56.0530 1.1689 0.4173
6. 1.1689 0.4001 55.9364 1.1702 0.1120
7. 1.1702 0.3999 55.9051 1.1705 0.0301
8. 1.1705 0.3999 55.8967 1.1706 0.0081 Convergence
 Separation Theory
ii. Droplet Size
 The purpose of the gravity settling section is to condition the gas for final polishing by the
mist extractor.

 In the designing phase of a separator, the liquid droplet sized to be removed must be
selected.

 From field experience, if 140 micron sized droplets are removed, the mist extractor will
not be flooded and is able to removed droplets of sized between 10 to 140 micron
diameters.

 The design calculation for separators in this module is based on 140 micron sized
droplets removal.
 Separation Theory
iii. Liquid Retention Time

 The average time a molecule of liquid is retained in the vessel is termed as “retention
time”.

 Sufficient retention time would ensure that the liquid and gas reach equilibrium at
separator pressure.

 The retention time is represented by the volume of the liquid storage in the separator
divided by the liquid flow rate.

 In normal operations a retention time of 30s to 3 mins is sufficient for separation

operations. However, retention times of 4 times the normal amount is required in cases
where foaming crude is present.
 Separation Theory
iii. Liquid Retention Time (con’t)

 The table below illustrates the typical retention times required for two phase separators
from field data.
 Separation Theory
iv. Liquid Re-Entrainment

 Caused by high gas velocity at the gas-liquid interface in a separator.

 The momentum which is transferred from the gas to the liquid causes waves and ripples
in the liquid which results in droplets being broken away from the liquid phase.

 The general rule of thumb to minimize the liquid re-entrainment is to limit the slenderness
ratio to a maximum of 4 or 5 for half full horizontal separators.

 Is more prominent for high pressure separators sized on gas-capacity constraints and
also for applications with higher oil viscosities (<30oAPI)
Separation Theory
 Summary
1. Two forces, namely drag force and negative buoyancy
force, act on a liquid particle during its flow from inlet
diverter to mist extractor
2. At the balance of drag force and negative buoyancy
force, the droplet settles down to the liquid collection
section with a velocity termed “terminal velocity”
3. Settlement velocity can be calculated using liquid and
gas densities and droplets diameter.
4. All liquid droplets with size greater the assumed size
(normally 100-140 microns) should settle down before
reaching the mist extractor to avoid over-flooding.
5. The stream inlet velocity should be managed to avoid
liquid re-entrainment.
 THANK YOU
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