11

SEPARATION EQUIPMENT
The design of equipment for the separation of vapors and liquids is essential to almost all processes. The
design concepts of a simple separator may be extended to several other processes such as fractionation tow-
ers, two-phase flow, slug catcher design, desalters, etc. The purpose of this chapter is to review the principles
governing the basic separation process and set forth some criteria for use in the planning and operation of the
equipment involved.

The basic equipment for separating liquid from vapor uses both gravitational and centrifugal force.
The gravitational force is utilized by reducing velocity so the liquid can settle out in the space provided.
Centrifugal force is utilized by changing the direction of flow. A true separator, as defined herein, depends
on gravitational force to a substantial degree and has sufficient liquid retention time to allow for effective
vapor-liquid disengagement.

FABRICATION SPECIFICATIONS
Most process vessels are fabricated to applicable codes established by government agencies, profes-
sional and trade groups, and/or by individual companies. These codes allow specification of fabrication
standards in a convenient manner, provide legal protection and help ensure a safe environment for personnel.
By specifying acceptable code construction, a company demonstrates that it is operating in a prudent manner.

Current addresses for detailed information about some of the commonly used codes are:

ASME Pressure Vessel Code American Society of Mechanical Engineers, United Engineering Center
345 East 47th Street, New York, NY 10017 USA
Netherlands Regels Voor Toestellen onder Druk, Ministry of Social Affairs
Government Printing Office, Christoffel Plantijnstraat, The Hague, Netherlands
Germany A. D. Merkblatt Code published by Carl Heymanns Verlag KG
5 Cologne I, 18-22, West Gennany
Italy A.N.C.C. published by Casa Editrice Luigi DiG. Pirola, via Comelico 24
(P. 0. Box 3680), Milano, Italy (24688)
Sweden Published by Tryckkarlskommissionen IV A, P. 0. Box 5073
S-102 42, Stockholm, Sweden
United Kingdom BS 5500, British Standards Institutions, London, England

Japan Dai Isshu Atsuryoku Youki Kouzou Kikaku, Japan Boiler Association
5-35-4 Shiba Minato-ku, Tokyo, Japan
Also Japanese Standard Association, 4-1-24 Akasaka, Minato-ku, Tokyo, Japan

CHAPTER 11 63
 VAPOR-LIQUID SEPARATION EQUIPMENT

If too much liquid is carried into the separation section, the falling of the small droplets is hindered
and entrainment becomes more prevalent. This is one reason internal design is critical. Theory does not give
the designer sufficient tools, so design is best accomplished by actual test.

The mist extractor is designed to trap those droplets that have for any reason been carried beyond the
separation section proper. This subject will be explored more thoroughly in a later section.

Principles of Separation
Separation equipment employs one or more of the following mechanisms: (I) gravity settling, (2)
centrifugal force, (3) impingemen~ (4) electrostatic precipitation, (5) sonic precipitation, (6) filtration, (7)
adhesive separation, (8) adsorption, or (9) thermal.

The problem is amplified because particles of varying size and characteristics, both liquid and solid,
must be removed. Furthermore, size and cost of the equipment required are always practical factors.

Particle Size. This is normally defined by its diameter in microns, IJ.! = I X 10"6 meters. The particles
greater than 10 J.! may be separated by properly designed equipment. Those smaller, sometimes referred to as
particulates, represent a serious problem. Up until the present time at least, the use of settling, impingement
and centrifugal force have not been generally effective in handling these small particles. The other processes
as yet have not been generally used on high pressure gas because of several serious limitations.

There are several ways of describing the average particle diameter:

I. Diameter of a sphere having average volume:
113
3
D = [ :L(nD )]
P :Ln
2. Diameter of sphere having average area:

:L(nD2) 1/2
D =
P :Ln
3. Diameter of sphere having geometric mean diameter:

D p -- c-B

Where: B = L(n In D)/:Ln

Dp = average particle diameter
D = diameter of given size particle
n = number of particles of given size (dimensionless)
(D and Dp in consistent units)

The usual probability of particle sizes normally takes the form shown in Curve a, Figure I 1.3. Often
the curve will be skewed to the right or left as with Curve b, or several peaks may be encountered as with c.

Figure 11.4 gives examples of particle sizes for comparison purposes. The general break point be-
tween fog and mist is approximately 50 microns.

The determination of average particle size is relatively easy with solids, but no method yielding repro-
ducible data has yet been devised for liquids. This determination of particle size may be considered some-
what academic because size changes continually in an actual line - yet it is by necessity the logical starting
point in design.

Most particles have no electrical charges of any magnitude; therefore, if a charge is desired (electro-
static precipitation), this normally must be imposed by artificial means. For all practical purposes the parti-
cles may be considered inert.

CHAPTER 11 69
 SEPARATION EQUIPMENT

• NUMBER OF PARTICLES OF' SIZE SELECTED

• • • -..:.....t.!.__ __
" Talc Settl ng c~amber
Silica O i i -~'~_;I,_-===------­
lmpmgement separators

Particle slze, microns

Figure 11.3 Typical Particle Distribution Figure 11.4 Particle Size Examples(I I· I!

Although particles of widely varying absolute density are encountered, their bulk density is generally
not much greater than that of the gas. Consequently, separation by gravity is logically limited to particles of
relatively large size. It is only above 10 J.l that their higher density starts having an effect.

Many mist eliminator designs are essentially redistributors of the particle distribution curve. An ordi-
nary horizontal separator might have the particle distributions throughout its length as shown in Figure 11.5.

0 INLET ¢'PRIMARY ~ INLET

TO VANE

" '"
0 FROM
OUTLET
VANE

~ OUTLET
FROM VESSEL

30
"
Figure 11.5 Example of Particle Distribution in Separator

70 VOLUME 2: THE EQUIPMENT MODULES

 VAPOR-LIQUID SEPARATION EQUIPMENT

The distribution depends on internal design, the character of the fluids involved aud the equipment
immediately upstream. Taking a large pressure drop across a valve, particularly with high gas-oil ratio con-
densates, can atomize the liquid and cause small particle sizes. What all of this means is that a given separa-
tor's performance depends, to some degree, on the system within which it is placed.
A. An inlet particle distribution that is skewed and with several distinct particle sizes enters the
vessel as shown in (I).
B. The stream hits the inlet momentum device where bulk liquid (particles larger than 500 mi-
crons) are removed.
C. The distribution shown in (2) enters the primary separation area where gravity effectively
separates all particles 150 microns and larger.
D. The inlet to the vane mist eliminator should have been changed to the distribution in (3). At
this point the "vane" type mist eliminator through inertial force, centrifugal force, and reduc-
tion of turbulence, coalesces the small droplets into larger droplets. Some of these droplets
would be large enough to fall to the liquid by paths provided in the vane section. A signifi-
cant number of large droplets would pass through the vane as shown in (4).
E. The outlet from the vane would enter the secondary separation section where gravity would
again separate all those particles larger than 150 microns.
F. This new particle distribution would enter the mist eliminator where an action similar to Step
D would occur so that the final outlet from the vessel would have a distribution of particles
30 microns and less.
There are several points to be made about the above description. Many vendors would claim that they
remove all the particles down to 10 microns. This is not commercially viable in an entrainment type separa-
tor. In oil and gas production, most separators are sized to remove liquid droplets larger than about 150 ~m
by gravity settling. Smaller droplets must coalesce to form larger droplets (Dp > 150 ~m) which may be
separated by gravity. Mist extractors are commonly used to provide coalescence. Under ideal conditions, a
100 mm [4 inch] thick wire mesh demister pad will allow 30-40% of the droplets larger than 20 lm to pass
through, although the efficiency rises to near I 00% for droplets larger than 60-70 Jlm. As you can see,
separation efficiency is dependent on particle size distribution.

Experience has indicated that minimum particle size is related to inlet velocity, number of restrictions
and amount of pressure drop in the inlet piping. These facts give inlet nozzle guidelines as discussed later,
but the vendor usually has no control over the inlet piping. Therefore, although performance guarantees are
nice to have, the ultimate responsibility for a system is with the design engineer and not the vendor. Numer-
ous mechanical details will enhance the operation of vessels and should be looked for in the purchase of
equipment. These will be discussed briefly later.

Gravity Separation
The terminal velocity of a particle falling through a fluid by the pull of gravity is

(11.5)

Where: g = gravitational acceleration

Dp = particle diameter
Pp = particle density
Pf = fluid density
Jl = fluid viscosity

CHAPTER 11 71
 SEPARATOR SIZING

The severity of the foaming problem is exacerbated by the design of the control system ahead of the
separator when a substantial pressure loss is involved. When it is known that the liquid tends to foam. this
should be considered.

Use of Mass Flow Rate

Oftentimes it is more convenient to use mass flow rate for sizing purposes. The mass velocity (w), in
mass per unit area per hour is related to linear velocity by the equation

w = 3600 v p8

If this relationship is substituted into Equation 11.10 the result is

(11.12)

2 (11.13)
Also, m = 0.785 w d F
Metric English
mass velocity lbmlh ft 2
w =
lbmlh
m = mass flow
v linear velocity ft/s
gas density (actual) lbm/ft3
Pg =
liquid density lbm/ft3
PL =
separator I.D. ft
d =
F = fraction of area available to gas
K, = gas sizing constant

Combining Equations 11.12 and 11.13 enables one to solve diameter

0.5
0.0188
(F~s J
d = ---'----""=
0.25
(11.14)
[(PL- Pg)(Pgll

The value of "m" is related to volume rate of flow as follows:

3
Metric (qsc at l5°C and 100 kPa, std m /day):

m = 0.050 (std m3/day)(yof gas)

(11.15)
3
or m = 0.001 73 (std m /day)(MW gas)

English (qsc at 60°F and 14.7 psia, std cu ft/day):

m = 0.0032 (scf/day)(y of gas)

(11.16)
or m = 0.000 ll(scf/day)(MW gas)

In the sizing of vertical vapor-liquid vessels like absorbers and fractionators, it is customary to use
values of Ks = 0.043-0.067 m/s [0.14-0.22 ft/s]. This is designed to give a rather efficient vapor-liquid
separation over a short distance of a few feet. This is consistent with short separator experience.

Separator carryover is the origin of a host of operating problems. This is a good vessel with which to
adopt a conservative posture. It is relatively inexpensive.

CHAPTER 11 75