Real Separators in HYSYS

Modeling Real Separators in HYSYS

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Real Separators in HYSYS

Introduction
The HYSYS Separator unit operation normally assumes perfect phase separation, but it can also be configured to model imperfect separation by using the HYSYS Real Separator capabilities. The real separator offers the user a number of advantages: Includes carryover so that your model matches your process mass balance or separator design specifications. Predicts the effect of exit devices on mitigating carryover. This workshop will introduce the user to the concepts needed to use these real separator features. The workshop will then step the user through a typical real separator application.

Workshop
The workshop will focus on using the HYSYS Real Separator capabilities to model imperfect separation in a 3-phase oil-water-gas separator. An exercise is included where a demister pad is added to the model as a secondary separation device to reduce liquid carryover into the gas. Additionally, a demonstration is given of the carryover feature in a dynamic model.

Learning Objectives
After completion of this module, you will be able to: Account for carryover in process design problems. Calculate carryover based on vessel geometry and inlet conditions using several basic correlations. Model an exit device to reduce carryover in the vapour product. Understand how carryover effects are accounted for in a dynamic model of a separator.

Prerequisites
Before starting this module you should be familiar with the HYSYS interface and be able to add and configure streams, operations, utilities, and case studies.

Real Separators in HYSYS

Modeling Separators
Real World Considerations
In real world separators, separation is not perfect: liquid can become entrained in the gas phase and each liquid phase may include entrained gas or entrained droplets of the other liquid phase. Recent years have seen increasing use of vessel internals (e.g., mesh pads, vane packs, weirs) to reduce the carryover of entrained liquids or gases.

Real Separators in HYSYS

Carryover Option
As with many other unit operations, HYSYS allows you to increase the fidelity of your separator model to account for non-ideal effects. HYSYS 3.2 introduces Real Separator capabilities like the carryover option. This option can be used to model imperfect separation in both steady state and dynamic simulation. Gas and liquid carryover can be specified or calculated (three different correlations are available for this purpose).

Vessel Internals
Internals used to reduce carryover can be included in your separator model with some of the provided carryover correlations. Internals used to reduce liquid carryover in the gas product are termed exit devices. Weirs are used to improve heavy liquid - light liquid separation in horizontal vessels.

Nozzle Calculations
Included with the carryover correlations are calculation methods for inlet and outlet nozzle pressure drop. Inlet and outlet devices can be included in these calculations. The user can also specify pressure drop if the carryover option is not in use.

Real Separators in HYSYS

Dynamic Models of Real Separators

The dynamic model of a separator must account for changing pressure and flow due to liquid levels, nozzle pressure drop, and heat effects. As such, vessel geometry, including internals and nozzle geometry, and heat loss parameters need to be specified. Modeling imperfect separation with the carryover option and a specifiable PV work term are also available. Level taps can also be set for monitoring the relative levels of the different liquid phases. All of these items can be set up via the Rating tab.

Limitations of the carryover option: As droplet distribution is not a stream property, this information is not passed onto the product streams. While droplet distribution is not passed on, product streams containing carryover will contain multiple phases with the phase flow rates equal to that predicted by the carryover calculations.

Specifying Carryover
The HYSYS separator allows the user to directly specify what fraction of each of the feed phases is entrained in the other phases. Product-based specifications are also allowed. This gives you a simple method to match your material balance to your design assumptions or your real world separator.

Calculating Carryover & Related Properties

There are also three sets of correlations available to calculate phase dispersion and carryover. A detailed description of each method is given in the next section. All three follow the same basic calculation sequence: 1. Calculate the initial phase dispersion based on the inlet feed. All three methods assume the dispersion follows a Rossin Rammler distribution. 2. Calculate the carryover after the primary separation (gravity settling) of each phase in every other phase; specifically: Light Liquid entrained in Gas Heavy Liquid entrained in Gas Gas entrained in Light Liquid Gas entrained in Heavy Liquid Light Liquid entrained in Heavy Liquid 3. Heavy Liquid entrained in Light Liquid Based on the exit dispersion from step 2, calculate the affect of any installed secondary separation device (e.g., demister pad or vanes) on the liquid carryover into the vapour product. (This is not applicable to the Generic correlations.)

Real Separators in HYSYS

Correlation Details
Three different correlation models are provided: Generic, Horizontal Vessel and ProSeparatorTM. Generic Correlations The generic correlations should be used when your only criterion for separation is specifying a critical droplet size. Inlet phase dispersion is calculated using a generic method that ignores vessel geometry the user specifies inlet splits and Rossin Rammler parameters and these are used to calculate the inlet dispersion. Carryover is calculated by assuming that all droplets smaller than a user-specified critical droplet size are carried over. Horizontal Vessel Correlations The Horizontal Vessel correlations are designed with the horizontal 3-phase Separator in mind. Inlet phase dispersion is calculated using inlet device efficiency (rather than specified splits) and user-supplied Rossin Rammler parameters. Primary separation is calculated based on settling velocities rather than critical drop size. Each phase has a residence time in the vessel. A droplet will be carried over if it does not travel far enough (back to its parent bulk phase) in the time allowed. ProSeparator Correlations The ProSeparator correlations are rigorous but are limited to calculating liquid carryover into gas. Both light liquid and heavy liquid entrainment are calculated, so 3-phase Separators are also supported, but no carryover calculations are done for the liquid phases. Inlet phase dispersion is calculated based on inlet flow conditions and inlet pipe size. (ProSeparator calculates its own Rossin Rammler parameters using this information.) Primary separation is based on critical droplet size; however, the critical droplet size is not user-specified but calculated using gas velocity through the vessel. Exit Devices & Other Calculations Secondary separations accomplished by exit devices (e.g., demisting pad) can be calculated by specifying a critical drop size (Horizontal Vessel) or through the use of device specific correlations (ProSeparator). Inlet flow regime, Nozzle Pressure Drop, Exit Device Sizing can also be calculated using one of the various Horizontal Vessel correlations. Rossin Rammler Parameters Rossin Rammler distributions are defined by: F = exp(-d/dm)x) Where: F = fraction of droplets larger than d dm is related to d95 x = RR index d95 = 95% of droplets are smaller than this diameter for the specified dispersion RR Index = exponent used in the RR equation (also known as the spread parameter)

Real Separators in HYSYS

Using Sub-calculations If desired, the user can use a different correlation for each of the calculation steps. In this case, a correlation is specified for each sub-calculation, rather than specifying an overall correlation. Only those parts of the correlation that apply to the particular sub-calculation will be used.

Sub-calculations will not used in this workshop.

Example If the Generic correlation is used for the Inlet device and ProSeparator is used for primary L-L and G-L separation calculations, then the usersupplied data for the generic inlet calculations (i.e., inlet split and Rossin Rammler parameters) will be used to generate the inlet droplet dispersion. The ProSeparation primary separation calculations will then be performed using this inlet dispersion. As ProSeparator correlations will not be used to calculate the inlet conditions, any ProSeparator inlet setup data is ignored. Likewise, any critical droplet sizes entered in the Generic correlation will be ignored as the ProSeparator is being used for the primary separation calculations.

Real Separators in HYSYS

Process Overview

Real Separators in HYSYS

Workshop
Process Description
In this workshop, a 3-phase Separator is used to separate an oil/water/gas mixture. Entrained liquids in the gas product have been identified as a potential process issue. The HYSYS Real Separator will be used to account for liquid entrainment in the model. Carryover of liquids can be troublesome, especially if the gas is then passed through a turbine/compressor where liquid droplets can cause major damage to the internals of the machine. We will determine if a demisting pad is appropriate to prevent carryover and how to size it appropriately. The separator considered in this workshop is based on the LP Separator used in the two-stage compression module of the Turbo Expander plant constructed in the Process Modeling Using HYSYS course. You will begin building the case by creating a copy of the existing separator. This means that while experimenting with the parameters of the separator, the rest of the Turbo Expander plant (recycles, adjust, etc.) does not have to solve each time. An exercise later will be to incorporate the rigorous separator into the full model.

Build an Ideal Separator

Dont worry if you have not built the Turbo Expander plant case. The file ADV6_AdvancedRecyc les_Soln.hsc contains this case.

1. 2. 3. 4. 5. 6. 7. 8.

Open the two-stage compression case of Turbo Expander plant case. Create a material stream called To LP Sep Clone. Double-click on the To LP Sep Clone stream. The stream property view appears. Click on the Define from Other Stream button. In the Available Streams list, select To LP Sep. In the Copy Stream Conditions group, check all the available conditions and click OK. Create a stream called Water, and specify its temperature and pressure to be the same as To LP Sep Clone with a flowrate of 4000 kg/h. Add a Mixer and provide the following information: Enter MIX-100 To LP Sep Clone Water Feed Set Outlet to Lowest Inlet

In this cell Connections Name Inlets Outlet Parameters Automatic Pressure Assignment

Real Separators in HYSYS

9.

Add a 3-phase Separator and specify it with the following information: Enter V-101 Feed Vapour LLiquid HLiquid

In this cell Connections Name Inlets Vapour Light Liquid Heavy Liquid

10. Open the separator unit operation and select the Worksheet tab. What is the vapour fraction and molar flow of the product stream? Vapour ______________________

Light Liquid ______________________ Heavy Liquid ______________________

Add Carryover Effects

Let us say that we know (from a plant mass balance or as a design assumption) that approximately 800 kg/h of liquid is entrained in the vapour stream. How do we specify this in our model and ensure an accurate mass balance? 1. Select the Rating tab. Click on the C.Over Setup page to bring up the carryover models, and choose Product Basis as the active model. 2. Enter the entrainment data. Select Specification By: Flow and choose Basis = Mass. Enter 800 kg/h for Light liquid in gas.

3.

Examine the product streams and the C.Over Results page and compare to the ideal separation case.

Real Separators in HYSYS

What is the vapour fraction of the vapour product stream? ______________ What is the rate of liquid carryover (kgmole/h)? ________________________

Using the Carryover Correlations

As an alternative to specifying the carryover, we can use correlations to predict the carryover: 1. Return to the C.Over Setup page and change the model selection to Correlation Based. For steps 2 4 select the appropriate radio button. 2. Correlation Setup (radio button): a) Select Overall Correlation and choose the ProSeparator correlation. b) Click the View Correlation button to enter inlet and separation parameters. In this case, the Inlet setup page can be left as is. The ProSeparator correlations will calculate the inlet dispersion without the need for further information. Since we do not have an exit device, we need to set this for the ProSeparator correlation: select the Vap. Exit Device page; select Mesh Pad; enter thickness = 0.0. Close the View Correlation window. 3. Dimensions Setup (radio button): Enter the vessel dimensions as length 8.0 m, diameter 3.0 m, light liquid level 1.5 m.

The Setup and Results views will be different depending on which correlation is used. Refer to page 5 for a detailed description of each correlation and its required parameters.

Vessel dimensions can also be entered on the Sizing page of the Rating tab. Data on these two pages is linked.

4.

DP / Nozzle Setup (radio button): Enter the following values for nozzle location (this is the horizontal or radial distance from the feed location): Feed 0.0 m, Vapour 6.0 m. Keep the default values for nozzle diameter and height.

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Real Separators in HYSYS

Analyze the Results

There are several pages where useful results are displayed: a) Open the Worksheet tab. What is the vapour fraction in the Vapour stream? ___________

b) Open the Rating tab and select the C.Over Results page. To view the carryover details, click the View Dispersion Results button. You should see results similar to this:

We need to eliminate all droplets larger than 50 microns (0.05 mm). Do we need an exit device to do secondary separation? _____ Open the Rating tab and select the C.Over Setup page. Click the View Correlation button and open the Results tab.
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Real Separators in HYSYS

Adding a Secondary Separation Device

1. 2. 3. Open the Rating tab and select the C.Over Setup page. Click the View Correlation button and open the Setup tab. Select the Vap. Exit Device page; select Mesh Pad and enter a thickness of 150.0 mm. What effect does this have on the carryover? __________________

Exercise 1
It is expected that the inlet hydrocarbon flow to the separator may vary by up to 25%. Anticipating that the separator may not be able to handle this increased flow, the engineer decides to model the new conditions in the separator and design a demister pad to remove the larger droplets. 1. Increase the flowrate of the To LP Sep Clone stream by 25%. 2. Select the C.Over Results page, then click the View Dispersion Results button. What is the Total Carryover with no mesh? With 150mm of mesh? _______________________________________________________ What is the removal efficiency of 50 micron droplets? ________________________________________________________ Based on this predicted dispersion, the engineer decides to install a thicker mesh pad. How would you suggest the engineer use HYSYS to determine the correct thickness? Perform the analysis yourself; how thick should the mesh pad be? _______________________________________________________ Now what is the vapour fraction of the Vapour product stream? ________________________________________________________

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Real Separators in HYSYS

Exercise 2
Connect the real separator into the two-stage compression loop to replace the ideal separator that is currently in use. Keep the Water feed stream connected. Is the real separator still capable of stopping 50 micron drops reaching the compressor suction?

Carryover in Dynamic Models

Please open sample case Dynamic Real Separator.hsc. This case is based on the one you have been working on, but dynamic specifications, controllers and strip charts have been added as needed. Specifically, the following changes were made to the model: 1. Valves were added to all boundary streams (e.g. Feed0 and VLV-100 were connected to the Feed stream). 2. Pressure-flow specifications were set on all boundary streams (you will find these specifications on the Dynamics tab of each boundary stream, e.g. Feed0 has a pressure specification of 30.05 kPa). 3. Dynamic specifications were set on the separator: All dynamic specifications used in this example or the separator were already entered on the Rating tab. a. Sizing & carry over data were left the same. b. Heat loss left at none c. Level taps and PV Work term options were not used Strip charts were created for 2 sets of variables (open the databook tabs titled Variables to see the list of variables and Stripcharts to view the strip chart configurations): The Vessel Conditions strip chart tracks vessel pressure, temperature, and liquid level. The Carry Over strip chart monitors liquid phase flow out of the vapour nozzle, as well as inlet flow rate to the vessel. Finally controllers were added to the alternate sample case called Controlled Dynamic Real Separator.hsc.

4.

5.

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Real Separators in HYSYS

Demonstration
1. 2. 3. 4. 5. Open Dynamic Real Separator.hsc. Click on the strip charts to bring them to the foreground. Click the Dynamic Mode button. Start the Integrator. When the liquid carryover flow achieves a steady value, stop the integrator. Change the position of VLV-100 to 25% open. Re-start the integrator. When the liquid carryover flow achieves a steady value stop the integrator. Change the position of VLV-100 to 75% open. Re-start the integrator. When the liquid carryover flow achieves a steady value stop the integrator. Is the mesh pad thick enough to account for all process conditions? _________________________________________________________________ A thick pad creates more pressure drop; are there other mitigations to consider?________________________________________________________ 7. Open Controlled Dynamic Real Separator.hsc; repeat the same exercise. What effect does controlling the liquid level have? ________________________________________________________________

6.

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