16-Nov-14

Natural Gas Processing and Liquefaction

Phase Separation
CO 2

Sulfur Sulfur Acid

Recovery Unit Gas

Raw Gas Inlet Gas Acid Gas

Phase Separation
Compression Treating

Condensate to
Solids Water LNG
Stabilization Units LNG Plant

Natural Gas Liquids Nitrogen

Dehydration
Recovery Rejection
Water Nitrogen

Helium Outlet Gas Gas to

Recovery Compression Pipeline
Helium
C2
Field Operation Natural Gas Liquids Sweetening C3
Gas Processing Plant Operation Fractionation Units C4s
Not Available in all Gas Processing Plants C5+
Receive from Different Gas Processing Plants

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Natural Gas Processing and Liquefaction

Phase Separation
Introduction (1)
Several technologies are available to remove liquids and solids from gases. However,
selecting gas/liquid separation technologies requires not only knowledge of the process
conditions, but a knowledge of the characteristics of the liquid contaminants. Selection
should be made based on the droplet size, concentration, and whether the liquid has
waxing or fouling tendencies
Three principles used to achieve physical separation of gas and liquids or solids are
momentum, gravity settling, and coalescing. Any separator may employ one or more of
these principles; however, the fluid phases must be immiscible and have different
densities for separation to occur.
Momentum force is utilized by changing the direction of flow and is usually employed
for bulk separation of the fluid phases. The gravitational force is utilized by reducing
velocity so the liquid droplets can settle out in the space provided. Gravity segregation is
the main force that accomplishes the separation, which means the heaviest fluid settles
to the bottom and the lightest fluid rises to the top. However, very small droplets such as
mist cannot be separated practically by gravity. These droplets can be coalesced to form
larger droplets that will settle by gravity.

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Natural Gas Processing and Liquefaction

Phase Separation
Introduction (2)

Technology Droplet Size Removed

Gravity Separator Down to 300 μm
Centrifugal Separator Down to 8-10 μm
Mist Eliminator Pad Down to 10 μm
Vane Separator Down to 10 μm
High Efficiency Liquid/gas Coalescer Down to 0.1 μm

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Natural Gas Processing and Liquefaction

Phase Separation
Gravity Separators - Introduction
Separators are
Gravity separators are pressure vessels that separate a mixed-phase sometimes called
stream into gas and liquid phases that are relatively free of each “scrubbers” when
other. In a gravity separator, gravitational forces control separation, gas rate / Liquid rate
and the efficiency of the gas/liquid separation is increased by is very high
lowering the gas velocity. Because of the large vessel size required
to achieve settling, gravity separators are rarely designed to remove
droplets smaller than 250 μm.

Geometric Operating
Function
Configuration Pressure
• Vertical • Two-phase (separates gas • Low pressure
• Horizontal from total liquid) (10-180 psi)
• Three-phase (separate the gas • Medium pressure
and also separates the liquid (230-700 psi)
phases (e.g., oil and water) • High pressure
(975-1500 psi)

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Natural Gas Processing and Liquefaction

Phase Separation
Gravity Separators – General Description
Gravity separators normally have the A gravity-settling section providing
following components adequate retention time so that proper
 A primary gas/liquid separation settling may take place.
section with an inlet diverter to remove  A mist extractor at the gas outlet to
the bulk of the liquid from the gas. capture entrained droplets or those too
small to settle by gravity.
 Proper pressure and liquid-level
A typical scheme
of a vertical 3-
controls.
phase separator

A typical scheme of a horizontal 3-

phase separator

Oil→H.C. liquid
Oil→H.C. liquid for for non-
non-associated gas associated gas
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Natural Gas Processing and Liquefaction

Phase Separation
Gravity Separators – Horizontal Separator (1)
The fluid enters the separator and hits an inlet
diverter. This sudden change in momentum generates
the initial bulk separation of liquid and gas.
The inlet diverter contains a downcomer that directs
the liquid flow below the oil/water interface. This
forces the inlet mixture of oil and water to mix with
Oil→H.C. liquid
the water continuous phase in the bottom of the for non-
vessel and rise through the oil/water interface. This associated gas
process is called “water washing” and promotes the coalescence of water droplets that are
entrained in the oil continuous phase.
The inlet diverter assures that little gas is carried with the liquid, and the water wash
assures that the liquid does not fall on top of the gas/oil or oil/water interface, mixing the
liquid retained in the vessel and making control of the oil/water interface difficult.
The liquid-collecting section of the vessel provides sufficient time so that the oil and
emulsion form a layer or at the top. The free water settles to the bottom. The produced
water flows from a nozzle in the vessel located upstream of the oil weir. An interface level
controller senses the height of the oil/water interface. The controller sends a signal to the
water dump valve, thus allowing the correct amount of water to leave the vessel so that
the oil/water interface is maintained at the design
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Natural Gas Processing and Liquefaction

Phase Separation
Gravity Separators – Horizontal Separator (2)
The gas flows horizontally and outs through a mist
extractor (normally known as a demisting device) to
a pressure control valve that maintains constant
vessel pressure.
The level of the gas/oil interface can vary from half
the diameter to 75% of the diameter depending on
Oil→H.C. liquid
the relative importance of liquid/gas separation and for non-
what purpose the separator has. However, the most associated gas
common configuration is half full.

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Natural Gas Processing and Liquefaction

Phase Separation
Gravity Separators – Vertical Separator
Vertical separator is similar to horizontal one as
the flow enters the vessel through the side and the
inlet diverter separates the bulk of the gas.
The gas moves upward, usually passing through a
mist extractor to remove suspended mist, and then
the dry gas flows out.
A downcomer is required to transmit the liquid
collected through the oil–gas interface so as not to
disturb the oil-skimming action taking place. A
spreader is located at the downcomer outlet (at the
oil–water interface). As the oil rises, any free water
trapped within the oil phase separates out.
A chimney is needed to equalize gas pressure Oil→H.C. liquid
between the lower section and the gas section. for non-
associated gas

In the vertical separator, level control is not critical as in horizontal separators. The
liquid level can fluctuate several inches without affecting operating efficiency. However, it
can affect the pressure drop for the downcomer pipe (from the demister), therefore
affecting demisting device drainage.
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Natural Gas Processing and Liquefaction

Phase Separation
Gravity Separators – Separator Selection (1)
There are no simple rules for separator selection. Sometimes, both configurations
should be evaluated to decide which is more economical.
Horizontal Separator
Horizontal separators are used most commonly in the following conditions.
Large volumes of gas and/or liquids.
High-to-medium gas/liquids ratio streams.
Foaming oil crude (in case of associated gas)
Advantages
Require smaller diameter for similar gas capacity as compared to vertical vessels.
No counter-flow (gas flow does not oppose drainage of mist extractor).
Large liquid surface area for foam dispersion generally reduces turbulence.
Larger surge volume capacity (can accommodate sudden changes in feed).
Disadvantages
Only part of shell available for passage of gas.
Occupies more space unless “stack” mounted.
Liquid level control is more critical.
More difficult to clean produced sand, mud, wax, paraffin, etc.

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Natural Gas Processing and Liquefaction

Phase Separation
Gravity Separators – Separator Selection (2)
Vertical Separator
These separators are used in the following conditions.
Small flow rates of gas and/or liquids.
Very high gas/liquids ratio streams or when the total gas volumes are low.
Plot space is limited.
Ease of level control is desired.
Advantages
Liquid level control is not so critical.
Can handle more sand, mud, paraffin, and wax without plugging.
 Less tendency for re-entrainment.
Has full diameter for gas flow at top and liquid flow at bottom.
Occupies smaller plot area.
Disadvantages
Require larger diameter for a given gas capacity, therefore, most competitive for
very low gas/liquids ratio or very high gas/liquids ratio (scrubber applications).
Not recommended when there is a large slug potential.
More difficult to reach and service top-mounted instruments and safety devices.

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