1st Stage Separator A first stage separator is shown in figure 2.

Regardless of shape, separation vessels usually contain four major sections plus the necessary controls. The inlet device is used to reduce the momentum of the inlet flow stream, perform an initial bulk separation of the gas and liquid phases, and enhance gas flow distribution. The gas gravity separation section is designed to utilize the force of gravity to separate entrained liquid droplets from the gas phase, preconditioning the gas for final polishing by the mist extractor. It consists of a portion of the vessel through which the gas moves at a relatively low velocity with little turbulence. In some horizontal designs, straightening vanes are used to reduce turbulence. The vanes also act as droplet coalescers, which reduces the horizontal length required for droplet removal from the gas stream.

Fig 2: 1st stage separator (vertical)

The liquid gravity separation section acts as a receiver for all liquid removed from the gas in the inlet, gas gravity, and mist extraction sections. In two-phase separation applications, the liquid gravity separation section provides residence time for degassing the liquid. The mist extraction section utilizes a mist extractor that can consist of a knitted wire mesh pad, a series of vanes, or cyclone tubes. This section removes the very small droplets of liquid from the gas by impingement on a surface where they coalesce into larger droplets or liquid films, enabling separation from the gas phase. Contactor After the 1st stage separator, natural gas flows upward to the contactor. For equal distribution in the contactor, for example a chimney tray is used. A chimney tray is installed between the scrubber and the contacting sections to collect the wet glycol and to provide a liquid volume for level control. It also acts as a gas distributor for the upward flowing wet gas. The dehydration section is filled with structured packing. The upward flowing gas stream is in intimate contact with the down flowing lean glycol, so that the water vapour in the gas stream is absorbed by the glycol. A liquid distributor is installed at the top of the packed section to ensure an even distribution of the glycol flow through the structured packing. The glycol, a highly hygroscopic liquid, moves downward through the structured packing and absorbs the water vapour from the rising gas stream, thus reducing the water content of the gas stream to the required specification exit dew point. The water-rich glycol is collected at the bottom of the structured packing on the chimney tray, and is subsequently discharged under level control to the regeneration unit to be regenerated. The gas leaves the contactor via the top after passing through a mist eliminator in the top of the contactor to remove any entrained glycol.
Fig 3: Contactor + structured packing

Reflux Coil and Pre-Flash Exchanger Rich glycol from the contactor flows via the still column reflux coil and the pre-flash lean/rich glycol heat exchanger to the flash vessel. A cross-connection line with globe valve is installed, bypassing the reflux cooler, to regulate the glycol stream through the reflux coil and thus the top temperature in the still column. The glycol is heated in the reflux coil by the hot vapour leaving the reboiler and simultaneously the hot vapour insides the still column is cooled and partially condensed to minimise glycol losses.

Flash Vessel As the glycol flows down over the structured packing in the contactor, hydrocarbons are dissolved in the glycol. Separation of these dissolved gaseous and liquid hydrocarbons from the rich glycol takes place in a three phase glycol / gas separator: the flash vessel. A horizontal flash vessel is shown in figure 4. The TEG enters the vessel through an inlet device whose primary objectives are to achieve efficient bulk separation of liquid from the gas. The liquid that has been separated from the gas moves along the bottom of the vessel to the liquid outlet. The gas and liquid occupy their proportionate shares of the shell cross-section. Increased slug capacity is obtained through shortened retention time and increased liquid level. The glycol level is controlled by an interface level control instrument. Horizontal separators have certain advantages with respect to gravity separation performance in that the liquid droplets or gas bubbles are moving upright to the bulk phase velocity, rather than directly against it as in vertical flow, which makes separation easier. In a double-barrel separator, the liquids fall through connecting flow pipes into the external liquid reservoir below. Slightly smaller vessels may be possible with the double-barrel horizontal separator, where surge capacity establishes the size of the lower liquid collection chamber.

Fig 4: front- and side view of a flash vessel

Glycol Filters and Activated Carbon Filter The glycol outlet flow from the flash drum is filtered to remove any debris and suspended substances. Two 100% glycol particulate filters A and B (one operating, one stand-by) for particulate removal (5 microns and larger) are installed. Each filter is provided with a local mounted pressure differential indicator to monitor the pressure drop and as such the fouling. A slipstream of approximately 25% flows subsequently through the activated carbon filter to remove heavy hydrocarbons, which were not separated by gravity in the flash vessel. Rich/lean Glycol Heat Exchanger Rich glycol from the filters passes through the cold side of the rich/lean glycol heat exchanger and is preheated prior to being discharged into the reboiler via a feed pipe in the packed section of the still column. Regenerated lean glycol from the reboiler (or stripping column) is cooled through the hot side of the rich/lean glycol exchanger and the hot side of the pre-flash lean/rich glycol exchanger.

Glycol Reboiler and Still Column The reboiler, still column and reflux coil are assembled as one composite unit, the still column with internal reflux coil mounted on top of the reboiler. The still column is packed with stainless steel pall rings to distribute the rich glycol stream as it passes downwards to the reboiler. Boiling glycol in the reboiler below releases water vapour, which rises through the still column and contact downward flowing rich glycol. Water vapour is discharged to a low pressure flare through a discharge pipe at the top of the unit. The reflux coil serves to cool and partially condense the rising vapour so as to reduce glycol carry-over in the exiting water vapour and to indirectly preheat the incoming glycol from the gas dehydration process. In cases requiring lower gas dew points, the use of stripping gas achieves higher glycol purity. The stripping gas is passed over the lean glycol from the reboiler in a counter-current contactor. The stripping gas provides a final stage of glycol dehydration by absorbing an amount of water. Glycol Surge Drum Regenerated glycol from the reboiler flows over a fixed weir, or standpipe, into the surge drum via the stripping gas column (not always) and the lean/rich glycol heat exchangers, driven by the static head of the elevated reboiler. The liquid level in the surge drum is monitored by a level gauge, which provides visual level indication. A level transmitter is installed to provide an alarm at low level and will stop the TEG circulation pumps. Glycol make-up to the system is done manually or automatically, from drums or glycol storage tank. Glycol Circulation Pumps Two identical, electric driven circulation pumps draw lean glycol from the surge drum and discharge to the contactor column. The pumps are positive displacement type and each for a capacity of 100%. One is operating; the other is installed as stand-by. Individual pump discharge lines incorporate pulsation dampers, to reduce the pulsing effects. Pressure safety relief valves prevent overpressure in pump and piping by relieving back into surge drum. Chemical Injections Pumps and Chemical Storage Tanks Chemical dosing pumps and tanks are installed to inject anti-foam and pH control agents. The pumps are electric driven and are equipped with manual stroke adjustment. The chemicals are injected in the suction line of the circulation pumps, to promote mixing with the glycol. Continuation After al these units, the lean glycol will pass a cooler (air cooled or water cooled). The glycol is then recirculated to the contactor.