Separation Process

◼ Separator is a pressure vessel designed to divide

a combined liquid–gas system into individual
components that are relatively free of each other
for subsequent processing.
Phase separation of the production stream is usually
performed as soon as is conveniently possible
because:

*It is technically easier and less costly to process the gas,

crude oil, and produced water phases separately.

*The produced water is often corrosive. Therefore, removing

the water reduces corrosion damage.
CLASSIFICATION OF OIL AND
GAS SEPARATORS
Why we should use it?
Downstream equipment cannot handle gas–liquid mixtures

• Pumps require gas-free liquid

•Compressor and dehydration equipment require liquid-free gas

• Product specification set limits on impurities

•Measurement devices for gases or liquids are highly inaccurate when another
phase is present.
Factors Affecting Separation

1. gas and liquid flow rates (minimum, average, and

peak)

2. operating and design pressures and temperatures

3. physical properties of the fluids such as density

4. presence of impurities (paraffin, sand, scale, etc.)

❑ SEPARATORS have two main types :
Common Components
◼ Primary Separation Section

◼ Secondary or Gravity Settling Section.

◼ Mist Extraction or Coalescence Section.

◼ Liquid Accumulator Section

Separator internal

Install especial parts increase the separation

efficiency
Primary Separation Section
INLET DIVERTER
Fluid enters the separator and hits
an inlet diverter, causing a sudden
change in momentum.

Exploit the momentum of the inlet

stream either by change of
direction (as in horizontal
separators) thus separating most
of the incoming liquid.
Secondary or Gravity Settling Section.

◼ Gas velocity and turbulence is

reduced so that entrained liquid
drops can settle out by gravity.

◼ Internal baffling is often used to

dissipate foams, further reduce
turbulence, and accelerate drop
removal.
•The liquid collection section
provides the retention time required
to let entrained gas evolve out of
the oil and rise to the vapor space
and reach a state of equilibrium
 b-Mist Extractor (Coalescence section )

•a small diameter drops that are not easily separated in the

gravity settling section. Before the gas leaves the vessel
it passes through a coalescing section or mist extractor
that removes very small droplets of liquid in one final
separation before the gas leaves the vessel.
Coalescing packs afford an effective
means of separating and removing liquid
mist from a stream of natural gas.

The packs use a combination of

impingement, change of direction, change
of velocity, and coalescence to separate
and to remove liquid mist from gas.

These packs provide a large surface area

for collection and coalescence of the liquid
mist .
- It just mesh screen installed
at gas outlet to remove liquid
droplet escaping with gas
stream

- remove liquid droplets 10–

40 micron and larger
Shapes of Mist Extractor

Vane-type mist extractors are

less efficient in removing very
small droplets than other Vane-type
impaction types such as wire-
mesh
Liquid Accumulator Section

◼ Provides sufficient capacity to handle surges in

liquid flow

◼ Adequate retention time is necessary to allow for

removal of any gas breaking out of solution

◼ and, in three-phase separators, for separation of

free water and oil.
vortex breaker

A vortex breaker
located over the
liquid outlet nozzle
(s) to avoid gas
outlet with liquid
stream
Inlet weir

To Assure there is
no contamination
happened between
the two liquid
Three Phase Separator (Spillover Weir)
 Advantage of Horizontal Gas Separators

1. Liquid quantity with feed stream is high

2. Installations where vertical height limitations indicate the
use of a horizontal vessel.
3. Separating foaming crude oil where the larger liquid/gas
contact area of the horizontal vessel .
Disadvantage of horizontal separator

1. Area limitation
2. High expensive
3. Solid particles
removing problems
 Advantage of vertical Gas Separators

1. Where economics favors the

vertical separator.
2. Installations with horizontal
space limitations but with little or
no vertical height limitations
3. High efficiency in solid removal
Disadvantage of horizontal separator

❑Limited with low liquid

quantity in feed stream

❑ If the size of the liquid

droplet is too small, it will
be carried up and out with
the vapor.
1. In the gravity settling section of a horizontal vessel, the
liquid droplets fall perpendicularly to the gas flow and
thus are more easily settled out of the gas continuous
phase because it provides more area for the bubbles to
escape
horizontal vessels are most economical for normal oil–
water separation, particularly where there may be
problems with emulsions, foam, or high gas–liquid ratios.

Vertical vessels work most effectively in low gas–oil ratio

(GOR) applications and where solids production is
anticipated.
 Classification by Function

◼ Two-phase , (vapor-liquid) .

➢ Three-phase (gas-oil-water) .
 Classification by Operating Pressure

◼ Low-pressure separators usually operate at

pressures ranging from 10 to 20 up to 180 to 225
psi.

◼ Medium-pressure separators usually operate at

pressures ranging from 230 to 250 up to 600 to 700
psi.

◼ High-pressure separators generally operate in the

wide pressure range from 750 to 1,500 psi.
 Classification by Application

◼ Test Separator
◼ A test separator is used to separate and to meter the well fluids.
◼ They can be permanently installed or portable (skid or trailer mounted).

◼ Production Separator
◼ A production separator is used to separate the produced well fluid from a
well, group of wells

◼ Low-Temperature Separator.
◼ The temperature reduction is obtained by the Joule-Thompson effect of
expanding well fluid as it flows through the pressure-reducing choke or valve
into the separator.

◼ Liquids thus recovered require stabilization to prevent excessive evaporation

in the storage tanks.
 Summary for the Function of Separator
Internals
Internal Device Purpose of Device or Situation
where Device should not be used
1- Mist Pad a- remove liquid mist from gas.
b- break oil-water emulsion.

c- not used where hydrate, wax, or dirt may be

present.
2- Deflector Plate a- separate liquid from gas.
b- used in all services.
3- Coalescing a- remove liquid mist from gas.
Plate b- separate oil from water.
c- not used where hydrate, corrosion, wax or dirt
present.
 Summary for the Function of Separator
Internals
4- Straightening Vanes a- remove liquid mist from gas.
b- separate oil from water.
c- not used where hydrate, corrosion, wax or dirt
present.
5- Filter Elements a- remove solid particles from gas or liquid.

b- separate oil from water.

c- remove mist from gas.
d- not used where wax or hydrate may be present.
6- Coalescing Materials a- separate oil from water.
b- not used where wax may be present.
 Summary for the Function of Separator
Internals
7- Centrifugal a- separate gas from liquid.
Devices b- not used where wax or dirt may be present.
c- not used with intermittent gas flow.
8- Horizontal a- usually used in large gas-liquid vessels where waves
Baffles occur.
9- Vortex Breakers a- should be used on all liquid outlet nozzles in gas-liquid
separators
b- are not needed if vessel is full of liquid
10- Float Shield a- should be used when internal level control float is used.
11- Water Jets and a- used only when solids may be present.
Sand Cones