GAS C L E A N I N G

Laurance S. Reid
The University of Oklahoma
Norman, Oklahoma

Gas c l e a n i n g is one of the oldest p r o c e s s e s that c o n d i t i o n

natural gas for market. Also it is the most n e g l e c t e d and ignored
of the gas c o n d i t i o n i n g processes, but not w i t h o u t cause. No
m a n a g e m e n t g r o u p w i l l admit to s e l l i n g d i r t y gas. Like the itch,
no one admits the a f f l i c t i o n and to even d i s c u s s the p o s s i b i l i t y
is to be indelicate! It has s e e m e d r e a s o n a b l e to a s s u m e that if
dirt cannot be seen, then it does not e x i s t - - a c o m f o r t i n g a s s u m p -
tion which, u n f o r t u n a t e l y , is untrue.

Every o p e r a t i n g gas c o m p a n y has p i p e l i n e dirt p r o b l e m s and

these vary only in the d e g r e e of severity. Usually, they are c a l l e d
by other, more p a l a t a b l e names such as low t r a n s m i s s i o n e f f i c i e n c y ,
s c o r e d cylinders, o i l - p o i s o n e d adsorbent, e x c e s s i v e lube oil con-
sumption, poor m e a s u r e m e n t , e n t r a i n m e n t losses, et cetera.

Since the early days of the industry, gas scrubbers have been
used for the intended purpose of removing extraneous material from
gas. The term "scrubber" derives from the early belief that gas
needed to be washed with oil to be clean. Scrubbers have been
built in a variety of forms and their performance has ranged from
poor to acceptable. In an effort to distinguish between these and
the more recent devices that are truly capable of fine separations,
the latter are called "gas cleaners."

Gas cleaners have attained a reasonably advanced state of

development although significant improvements would be welcome at
this time. They are to be found in increasing numbers protecting
compressor stations, pipelines, town border stations, injection
wells and processing plants. But many older scrubbers, and some
newer ones, need to be rebuilt or replaced.

Pipeline Dirt

P i p e l i n e dirt is d e f i n e d here as all m a t t e r other than gas

in a gas mixture. It may c o m p r i s e solids, or liquids or both.
F i n e p a r t i c l e s of solid m a t t e r may be d i s p e r s e d in gas as a powder,
or they may be d i s p e r s e d in w a t e r or h y d r o c a r b o n liquid as a slurry.
Some s o l i d s that have been i d e n t i f i e d i n c l u d e f o r m a t i o n cuttings,
d r i l l i n g mud, d e s i c c a n t dust, c o n s t r u c t i o n dirt, sand, mill scale,
red iron oxides, iron c a r b o n a t e , iron sulfide, w e l d i n g slag,
e r o d e d steel cuttings, salt crystals, plug valve grease, et cetera.

L i q u i d s found in gas p i p e l i n e s include free water, h y d r o -

c a r b o n c o n d e n s a t e , crude oil, a b s o r p t i o n oil, glycol, amine s o l u t i o n s ,
l u b r i c a t i n g oil et cetera. These c o l l e c t in sags in the line and
are moved d o w n s t r e a m in slug flow by the gas as more liquid collects.
Slugs can be r e m o v e d w i t h r e l a t i v e ease in line drips or s c r u b b e r s
b e f o r e they travel far in p i p e l i n e s and g a t h e r i n g systems. Of g r e a t -
er c o n c e r n is the r e m o v a l of very finely d i s p e r s e d matter, k n o w n as
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" p a r t i c u l a t e matter", w h i c h is c a r r i e d by a f l o w i n g gas stream. Dis-

p e r s i o n s of liquid p a r t i c u l a t e s are o f t e n c a l l e d "aerosols,,

The c o n c e n t r a t i o n of p i p e l i n e dirt in a f l o w i n g gas s t r e a m

may be so small that it e s c a p e s notice. In w e l l - m a i n t a i n e d p i p e -
line systems, dirt may m o v e at a r a t e of two p o u n d s per m i l l i o n
s t a n d a r d cubic feet. So a m a j o r p i p e l i n e s y s t e m h a n d l i n g one
b i l l i o n cubic feet per day w o u l d move one ton of dirt. In s e v e r e
cases, the dirt c o n t e n t may r a n g e u p w a r d to 400 p o u n d s per m i l l i o n
c u b i c feet. Dirt m o v e m e n t is c o n t i n u o u s and its c o n c e n t r a t i o n
v a r i e s as s y s t e m loads change. Pipeline operating techniques often
i n c l u d e o n - s t r e a m " p i g g i n g " to m a i n t a i n m a x i m u m flow e f f i c i e n c y
and this is b a c k e d by a d e q u a t e s c r u b b e r c a p a c i t y at r e c e i v i n g ,
c o m p r e s s o r and b o r d e r stations. However, s u b s t a n t i a l q u a n t i t i e s
of v e r y s m a l l p a r t i c u l a t e s pass on t h r o u g h most of these d e v i c e s
to a c c u m u l a t e in d i s t r i b u t i o n s y s t e m s and c r e a t e one of the i n d u s -
try's most v e x i n g problems.

P i p e l i n e dirt p r o b l e m s are e a s y to i g n o r e b e c a u s e fine p a r t i -

c u l a t e m a t t e r cannot be seen w i t h the naked eye. Yet these m a t e r i -
als a r e the cause of s u c h d i f f i c u l t i e s as b r o k e n c o m p r e s s o r valves,
s c o r e d c y l i n d e r s and rods, low t r a n s m i s s i o n e f f i c i e n c y , poor
m e a s u r e m e n t , e r o s i o n of r e g u l a t o r s , fouled a p p l i a n c e c o n t r o l s and
p l u g g e d pilot lights. Unfortunately, no m e t h o d has been d e v e l o p e d
for a b s o l u t e m e a s u r e m e n t of the p a r t i c u l a t e c o n t e n t of a f l o w i n g
gas s t r e a m d e s p i t e s u s t a i n e d e f f o r t s by the A m e r i c a n Gas A s s o c i a t i o n ,
o p e r a t i n g c o m p a n i e s and m a n u f a c t u r e r s . E v a l u a t i o n of gas c l e a n e r
e f f e c t i v e n e s s d e p e n d s on o p e r a t i n g r e c o r d s and a v a r i e t y of r e l a t i v e
m e a s u r e m e n t m e t h o d s that have n e v e r b e e n s t a n d a r d i z e d and are sub-
ject to q u e s t i o n .

Particulate Size and the M i c r o n Scale

In o r d e r to g r a s p the p i p e l i n e dirt problem, a r e a l i s t i c con-

cept of the size of p a r t i c u l a t e s is n e c e s s a r y . H e r e the m i c r o n
s c a l e is useful. One inch equals 2 5 , 4 0 0 m i c r o n s and one m i l l i m e t e r
e q u a l s 1000 microns. R a r e l y is it p o s s i b l e for the h u m a n eye to
see a p a r t i c l e that is ten m i c r o n s in d i a m e t e r w i t h o u t u s i n g a good
m a g n i f y i n g g l a s s or m i c r o s c o p e (2)

An a v e r a g e s t r a n d of hair is a p p r o x i m a t e l y i00 m i c r o n s in
diameter. A No. 200 s i e v e m e s h w i l l pass a 7 4 - m i c r o n p a r t i c l e
w h i l e a No. 400 m e s h s i e v e w i l l pass one of 3 7 - m i c r o n a v e r a g e
diameter. W h i t e blood cells of h u m a n s a v e r a g e 25 m i c r o n s d i a m e t e r
w h i l e red b l o o d cells are s l i g h t l y less than eight m i c r o n s diameter.
P a r t i c u l a t e s l a r g e r than l0 m i c r o n s in d i a m e t e r are said to be
coarse. S m a l l e r sizes are c a l l e d "fine" p a r t i c u l a t e s .

Fine p a r t i c u l a t e s may a c c u m u l a t e in s u f f i c i e n t q u a n t i t y to be
s e e n as a c l o u d because, in a g g r e g a t e , they r e f l e c t light. Tobacco
s m o k e is a c o m m o n e x a m p l e of a d e n s e d i s p e r s i o n of p a r t i c u l a t e s
w h o s e d i a m e t e r s r a n g e from 0 . 2 5 to 1.0 microns.
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W i t h these c r i t e r i a in mind, it s h o u l d be noted t h a t the best

c o n t e m p o r a r y gas c l e a n e r s can r e m o v e v i r t u a l l y all p a r t i c u l a t e m a t t e r
of 4 - m i c r o n d i a m e t e r and larger. A e r o s o l s are more d i f f i c u l t to
r e m o v e than solids and some recent a d v a n c e s in d e m i s t i n g t e c h n i q u e s
have r e d u c e d the d i a m e t e r of p a r t i c u l a t e s r e m o v e d below 4 microns.
P a d - t y p e or c a r t r i d g e filters have c a p a b i l i t i e s in the o r d e r of 1.0
m i c r o n d i a m e t e r and larger w h e r e dirt l o a d i n g r e q u i r e m e n t s are small
and w h e r e no a e r o s o l s are p r e s e n t in the gas. W h i l e these figures
may s e e m impressive, recent s t u d i e s (4,6) on dust p r o b l e m s in dis-
t r i b u t i o n s y s t e m s i n d i c a t e that the size d i s t r i b u t i o n of the p a r t i -
c u l a t e m a t t e r r a n g e s from 0.5 to 2.0 m i c r o n s a v e r a g e diameter.
It follows that e f f e c t i v e r e m o v a l of p a r t i c u l a t e m a t t e r in this r a n g e
must be the goal of d e s i g n e r s and users of gas c l e a n i n g f a c i l i t i e s .

Mechanisms of Separation

P i p e l i n e dirt is s e p a r a t e d from f l o w i n g gas s t r e a m s by s e v e r a l

m e c h a n i s m s w h i c h i n c l u d e g r a v i t a t i o n a l settling, c e n t r i f u g i n g ,
impingement, and d i f f u s i o n (1, 10). Gravitational settling assists
in the r e m o v a l of large p a r t i c l e s of p i p e l i n e dirt and it is a u g m e n t e d
to a c o n s i d e r a b l e d e g r e e by a p p l i c a t i o n of c e n t r i f u g a l force and cen-
t r i f u g a t i o n plays a s i g n i f i c a n t role in c a u s i n g fine p a r t i c u l a t e s to
impinge on c o l l e c t i o n targets s u c h as fine fibres, w i r e s and aerosols.
W a r n e r and S c a u z i l l o (9) have s h o w n that d i f f u s i o n plays a s i g n i f i c a n t
role in the r e m o v a l of a e r o s o l s c l a s s i f i e d as fine p a r t i c u l a t e s .
I o n i z a t i o n t e c h n i q u e s have not been a p p l i e d to n a t u r a l gas c l e a n i n g
b e c a u s e of s a f e t y c o n s i d e r a t i o n s . Sonics have been e m p l o y e d to
c o a l e s c e p a r t i c u l a t e m a t t e r in l a b o r a t o r y s t u d i e s but no i n s t a n c e is
k n o w n w h e r e this t e c h n i q u e has been applied to c l e a n i n g p i p e l i n e gas.

In a d d i t i o n to the m e c h a n i s m s listed above, f i l t r a t i o n is a

p r i n c i p a l m e c h a n i s m for r e m o v i n g solid p a r t i c u l a t e s . However, f i l t e r -
ing d e v i c e s are not e f f e c t i v e for r e m o v a l of aerosols.

Contemporary Gas Cleaning Equipment

C o n t e m p o r a r y gas c l e a n e r s may be c l a s s i f i e d into five basic types:

gas-liquid s e p a r a t o r s , c o a l e s c e r - s e p a r a t o r s , o i l - b a t h s c r u b b e r s ,
c e n t r i f u g a l s c r u b b e r s and dust filters. All types may a s s u m e the
p h y s i c a l form of a v e r t i c a l c y l i n d r i c a l vessel, a h o r i z o n t a l c y l i n -
d r i c a l v e s s e l or a s p h e r e as d i c t a t e d by the a p p l i c a t i o n and by
the d e s i g n d e t a i l s of the internals. The b e t t e r v e r s i o n s of all
types e m p l o y a p r i m a r y s e p a r a t i o n s e c t i o n to r e m o v e the bulk of
the c o a r s e p a r t i c u l a t e s and m i n i m i z e the dirt l o a d i n g on the fine
s e p a r a t i o n s t a g e in w h a t e v e r form it may appear.

Basic differences in these five types are to be found in their

fine separation stages. In gas-liquid separators, fine separation
is effected by means of a highly efficient mist eliminator. In
some forms, this mist eliminator may a l s o f u n c t i o n as a filter of
sorts for solid particulates which, if allowed to accumulate in
excessive a m o u n t s , may p l u g t h e e l e m e n t , make its primary function
ineffective and, ultimately, result in its destruction.
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In coalescer-separators, fine s e p a r a t i o n is a c c o m p l i s h e d by
p a s s i n g the gas t h r o u g h a h i g h - d e n s i t y fibre mass at a v e l o c i t y
s u f f i c i e n t to impinge the fine a e r o s o l on the fibres to f o r m
larger d r o p l e t s w h i c h are b l o w n off the d o w n s t r e a m side of the
coalescer. L a r g e r d i a m e t e r p a r t i c l e s can be caught more e f f e c t i v e l y
by the mist e l i m i n a t o r set d o w n s t r e a m from the c o a l e s c e r element.
The c o a l e s c e r may be e i t h e r a fibrous pad or a r e p l a c e a b l e car-
tridge. Most pads are r e m o v a b l e and can be c l e a n e d and r e t u r n e d
to service. C a r t r i d g e s can be b a c k - f l o w e d three or four times
prior to r e p l a c e m e n t . W h e r e solid p a r t i c u l a t e m a t t e r is present,
e i t h e r dry or in s l u r r y form, the c o a l e s c e r f u n c t i o n s as a f i l t e r
to r e m o v e this m a t e r i a l but, u n l e s s removed, it w i l l plug the
fibrous mass, i n c r e a s e the p r e s s u r e d i f f e r e n t i a l across it and,
u l t i m a t e l y , r e s u l t in its d e s t r u c t i o n . A r e c e n t d e v e l o p m e n t is the
use of a b l o t t i n g s t a g e b e t w e e n c o a l e s c e r and mist e l i m i n a t o r to
u n l o a d the l a t t e r and i n c r e a s e its e f f e c t i v e n e s s (7).

O i l - b a t h s c r u b b e r s are one of the o l d e s t forms s t i l l in use.

They are d e s i g n e d to c l e a n gas by i m p i n g i n g s o l i d p a r t i c u l a t e s on
w e t t e d s u r f a c e s or on a e r o s o l s w h o s e a v e r a g e d i a m e t e r s are o n l y
s l i g h t l y larger. The o b j e c t i v e here is to make a s l u r r y f r o m the
solids, to r e j e c t these by s e t t l i n g and to r e t u r n the liquid to
the c o n t a e t zone for r e c i r c u l a t i o n . S i n c e most s c r u b b e r s of this
type are s e l f - e n e r g i z e d and are c i r c u l a t e d i n t e r n a l l y , the oil
e m p l o y e d r a r e l y has o p p o r t u n i t y to s e t t l e its dirt. Comprehensive
tegts on s c r u b b e r s of this type have r e v e a l e d that c l e a n oil must
be used if c l e a n gas is to be p r o d u c e d (3). This is done best by
an e x t e r n a l c i r c u l a t i n g s y s t e m w h i c h p r o v i d e s s p a c e and time for
s e t t l i n g , f o l l o w e d by f u l l - s t r e a m f i l t r a t i o n of the liquid prior
to its r e t u r n to the scrubber. An e f f e c t i v e o i l - b a t h s c r u b b e r
must have a h i g h l y e f f i c i e n t mist e l i m i n a t o r c a p a b l e of r e j e c t i n g
d r o p l e t s w h i c h c o n t a i n s o l i d p a r t i c u l a t e s as nuclei. Because
high liquid l o a d i n g is i n h e r e n t in the d e s i g n of these units, m i s t
e l i m i n a t o r s are s e l f - w a s h i n g w h e r e clean oil is used but they
must be s u b s t a n t i a l in area to a c c o m m o d a t e these loadings.

C e n t r i f u g a l s c r u b b e r s e m p l o y m u l t i p l e c y c l o n e s in p a r a l l e l
to r e m o v e e i t h e r s o l i d or liquid p a r t i c u l a t e s as small as four
m i c r o n s d i a m e t e r u n d e r r a t e d c o n d i t i o n s of o p e r a t i o n (3). Gen-
e r a l l y k n o w n as " A e r o t e c " tubes, these are r e l a t i v e l y s m a l l and
of s t a n d a r d size w h i c h can be s e m i - m a s s produced. Each c o m p r i s e s
two c o n c e n t r i c tubes. The top of the annulus is c l o s e d but gas
e n t e r s the u p p e r a n n u l u s via t a n g e n t i a l inlets and flows c e n t r i f u -
g a l l y downward in the annulus at high velocity. P a r t i c u l a t e s are
e x p e l l e d from the lower end via a c o n e n o z z l e w h i l e the c a r r i e r
gas turns 180 d e g r e e s and rises t h r o u g h the inner tube to d i s c h a r g e
from its u p p e r end. The v e s s e l must be d i v i d e d into t h r e e c o m p a r t -
ments by two d i a p h r a g m s . D i r t y gas enters the c e n t e r compartment,
p a s s e s t h r o u g h m u l t i p l e c y c l o n e s set in parallel, d i s c h a r g e s its
dirt into the lower c o m p a r t m e n t and the c l e a n gas p a s s e s t h r o u g h
the inner tubes to the u p p e r c o m p a r t m e n t en route to the v e s s e l
outlet. W i t h i n the c a p a c i t y r a n g e of the tubes, e f f i c i e n c y a p p e a r s
to be l i m i t e d by r e - e n t r a i n m e n t of p a r t i c u l a t e s s m a l l e r than four
m i c r o n s diameter. This d e v i c e f u n c t i o n s best w h e r e gas flow is
c o n s t a n t at d e s i g n capacity. At h i g h e r rates, p r e s s u r e drop is
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excessive. At lower rates, e f f i c i e n c y d e c l i n e s rapidly. Units

d e s i g n e d for r e m o v a l of s o l i d m a t t e r do not f u n c t i o n w e l l on a e r o -
sols and v i c e versa, b e c a u s e of d e n s i t y d i f f e r e n c e s of the p a r t i c u -
late phases.

Dust filters employ either fibrous cartridges or pads in

pressure cases fitted with by-passes and quick-opening closures to
facilitate rapid change of the filter elements. These are made of
various materials such as molded fibre glass, felt, cellulose, fine
wire and a wide variety of fine-stranded synthetic fibres, all
reinforced by wire or by resin impregnation to minimize compaction
and resultant pressure differential increase. In cylindrical car-
tridge form, radial flow is from outside to inside in most petroleum
industry applications in order to present maximum filter cake area,
maximum dirt-loading capacity and maximum resistance to rupture due
to excessive pressure differential. In service, particulates pene-
trate the fibrous mass until they lodge and form the base of the
filter cake that builds on the surface of the element. When flow
is reversed to remove the filter cake and reduce pressure drop, the
s u c c e s s of this o p e r a t i o n d e p e n d s on r e m o v a l of the p a r t i c u l a t e s
that p e n e t r a t e d the fibres. E f f e c t i v e n e s s d e c l i n e s w i t h each s u c c e s s i v e
b a c k - f l o w o p e r a t i o n u n t i l the f i l t e r e l e m e n t no l o n g e r r e s p o n d s and
must be r e p l a c e d . If s o l i d s are f i l t e r e d from a slurry, they are
m o r e d i f f i c u l t to r e m o v e by b a c k - f l o w i n g so the u s e f u l life of
f i l t e r m e d i a is r e d u c e d w h e r e a e r o s o l s are e n c o u n t e r e d . The e c o n o m i c
f e a s i b i l i t y of dust f i l t e r s d e p e n d s on the d i r t c o n c e n t r a t i o n of the
gas and the dirt l o a d i n g c a p a c i t y of the f i l t e r elements. Applica-
tions are l i m i t e d by the cost of f i l t e r r e p l a c e m e n t s and the labor
r e q u i r e d to c h a n g e them. H i g h dirt l o a d i n g s may d i c t a t e use of s o m e
o t h e r type of gas c l e a n e r such as an o i l - b a t h s c r u b b e r .

Some of the a b s o l u t e f i l t e r p a p e r s d e v e l o p e d for the A t o m i c

E n e r g y C o m m i s s i o n have been used s u c c e s s f u l l y in f i l t e r c a r t r i d g e s
for s e r v i c e w h e r e s o l i d s l o a d i n g is v e r y light.

Mist Eliminators

Mist e l i m i n a t o r s are e s s e n t i a l to all gas cleaners, e x c e p t dust

filters, and they must be s e l e c t e d and s i z e d w i t h care. Also, they
are used to c l e a n gas from a b s o r b e r s and to m i n i m i z e a b s o r b e n t loss
in g a s o l i n e plants, d e h y d r a t o r s and v a r i o u s gas t r e a t i n g plants.

The v a n e type m i s t e l i m i n a t o r is p e r h a p s the o l d e s t d e v i c e

s t i l l used by the i n d u s t r y s i n c e it has b e e n a v a i l a b l e in v a r i o u s
forms for m o r e than t h i r t y years. Gas p a s s e s t h r o u g h this e l e m e n t in
a horizontal direction. E n c l o s e d at the top, b o t t o m and sides, the
gas flows t h r o u g h m u l t i p l e , narrow, v e r t i c a l l y - d i s p o s e d channels,
e a c h f i t t e d w i t h a s e r i e s of a l t e r n a t i n g v e r t i c a l vanes w h i c h p r o j e c t
o u t w a r d i n t o e a c h channel. Gas flows a g a i n s t the edge of t h e s e
c h a n n e l s and the b a f f l i n g e f f e c t c a u s e s flow to be r e v e r s e d to pass
a r o u n d the edge. The c e n t r i f u g a l force g e n e r a t e d c a u s e s the a e r o s o l
p a r t i c u l a t e s to i m p i n g e on the w e t t e d s u r f a c e s of the vanes. These
f o r m liquid films w h i c h d r a i n by g r a v i t y into a s e a l e d c a t c h b a s i n
6C

at the b o t t o m of the e l e m e n t w h e n c e it drains to the liquid r e s e r v o i r

p r o v i d e d in the vessel. This d e v i c e can be m a s s - p r o d u c e d in a v a r i e t y
of u n i q u e forms. It is r e l a t i v e l y inexpensive, and it has large
c a p a c i t y per unit v o l u m e of shell space occupied. It h a n d l e s high
liquid l o a d i n g s quite well at p r e s s u r e d i f f e r e n t i a l s of i0 inches
of w a t e r or less.

It has some s e r i o u s d i s a d v a n t a g e s . R a r e l y is it c a p a b l e of
r e m o v i n g a e r o s o l s w h o s e d i a m e t e r s are less than 40 m i c r o n s , so it
cannot be c o n s i d e r e d e f f e c t i v e in truly fine s e p a r a t i o n s , even
w h e n used w i t h a c o a l e s c e r d e s i g n e d to p r o d u c e d r o p l e t s large e n o u g h
to be caught by the vanes. Drop size d e c r e a s e s a p p r e c i a b l y w i t h flow
rate both above and b e l o w the c o a l e s c e r d e s i g n rate w h e r e size
r e a c h e s a m a x i m u m so that such a unit w o u l d be q u i t e i n f l e x i b l e .
S e v e r a l i n s t a n c e s are k n o w n w h e r e v a n e - t y p e mist e l i m i n a t o r s , l o c a t e d
in s u c t i o n s c r u b b e r s on r e c i p r o c a t i n g c o m p r e s s o r s , have b r o k e n up
as the result of d e s t r u c t i v e a c o u s t i c a l p u l s a t i o n c a u s i n g s e r i o u s
d a m a g e to c o m p r e s s o r cylinders.

F i b r o u s pads c o m p r i s i n g a k n i t t e d and c r i m p e d m e s h m a d e f r o m a
w i d e v a r i e t y of m a t e r i a l s are g e n e r a l l y r e c o g n i z e d as the most
e f f e c t i v e form of mist e l i m i n a t o r d e v e l o p e d to date. A v a i l a b l e in
c a r b o n and s t a i n l e s s steels, as well as n u m e r o u s o t h e r c o r r o s i o n
r e s i s t a n t metals, f i b r e g l a s s and m a n y s y n t h e t i c yarns in v a r i o u s
m i x t u r e s , these are k n i t t e d in a v a r i e t y of p a t t e r n s and the m e s h is
c r i m p e d b e f o r e f o r m i n g into pads of v a r i a b l e density, t h i c k n e s s and
shape. T h i c k n e s s may r a n g e from 4 to 36 inches. Pads m a y be r o l l e d
in c i r c u l a r form to fit v e r t i c a l c y l i n d r i c a l vessels, or m a d e into
pads of o t h e r g e o m e t r i c shapes, all fitted w i t h top and b o t t o m grids
to p r o v i d e s u p p o r t and means for firm a t t a c h m e n t . D e n s i t y varies,
as desired, from 3 to 40 pounds per cubic foot (5). Free volume
ranges from 90 to 99.4~. S u r f a c e area ranges from 50 to 600 s q u a r e
feet per cubic foot. W i r e d i a m e t e r ranges from 0.003" to 0.011".
W i r e is u s e d to r e i n f o r c e glass and s y n t h e t i c fibre m a s s e s of m u c h
finer s t r a n d d i a m e t e r s to p r e v e n t e x c e s s i v e c o m p a c t i o n .

C a p a c i t y of fibrous m e s h pads can be c a l c u l a t e d from a s p e c i a l

form of p a c k e d c o l u m n f l o o d i n g e q u a t i o n (5) to d e t e r m i n e a v e r a g e
f r e e - s p a c e v e l o c i t y at f l o w i n g conditions. This is d i v i d e d into
flow rate at f l o w i n g c o n d i t i o n s to c o m p u t e the s u r f a c e area required.
E f f e c t i v e p e r f o r m a n c e r a n g e is from 30 to 110% of the rated c a p a c i t y
(5). For u l t r a - f i n e s e p a r a t i o n s , this r e l a t i o n s h i p must be r e f i n e d
to take d i f f u s i o n a l forces into account (9).

The f u n c t i o n of the fibrous pad is to p r o v i d e targets w h o s e

d i a m e t e r s a p p r o a c h t h o s e of the p a r t i c u l a t e s w h i c h must i m p i n g e
the fibres. W h e n i m p i n g e m e n t occurs, the r e s u l t i n g film flows
d o w n w a r d to o t h e r fibre c o n t a c t p o i n t s w h e r e other droplets have
drained, f o r m i n g larger d r o p l e t s m o r e r e a d i l y i n f l u e n c e d by g r a v i -
t a t i o n a l forces. A s i n g l e fibrous pad is b o t h c o a l e s c e r and mist
eliminator. C o n s i d e r a b l e q u a n t i t i e s of liquid c o l l e c t and are held
in the lower layers of the pad to assist in the c o a l e s c i n g of aero-
sols c a r r i e d into the pad from below. Excess liquid falls from the
 7C

b o t t o m of the pad. The u p p e r p o r t i o n of the pad is q u i t e devoid of

liquid a c c u m u l a t i o n s and it f u n c t i o n s as the mist e l i m i n a t o r . For
r e m o v a l of free water, h y d r o c a r b o n c o n d e n s a t e s and light crude oil
mists, a 6 - i n c h pad t h i c k n e s s will p r o v i d e e x c e l l e n t mist e x t r a c t i o n .
For glycols, amines and o r g a n i c t r e a t i n g s o l u t i o n s , g r e a t e r thick-
ness and s p e c i a l m a t e r i a l s are required, s o m e t i m e s using two or m o r e
pads of d i f f e r e n t m a t e r i a l s . In c e r t a i n i n s t a n c e s it may be d e s i r -
able to s e p a r a t e two pads so that the first can f u n c t i o n as c o a l e s c e r
w h i l e the s e c o n d c o m p r i s e s the mist e l i m i n a t o r . As a r u l e - o f - t h u m b ,
the c o a l e s c e r pad w o u l d have half the area, or twice the f r e e - s p a c e
velocity, of the mist e l i m i n a t o r pad.

C o n f i g u r a t i o n of a fibrous pad is very i m p o r t a n t if e f f e c t i v e

p e r f o r m a n c e is to be achieved. It must be i n s t a l l e d in h o r i z o n t a l
p o s i t i o n w i t h gas flow u p w a r d t h r o u g h the mesh. Only in s p e c i a l i z e d
a p p l i c a t i o n s and w i t h the a p p r o v a l of the m e s h s u p p l i e r s h o u l d a
mist e l i m i n a t i n g pad be i n s t a l l e d in any o t h e r p o s i t i o n . Numerous
a p p l i c a t i o n s are k n o w n w h e r e fibrous pads are i n s t a l l e d in a v e r t i c a l
p l a n e w i t h gas f l o w i n g normal to the pad in a h o r i z o n t a l d i r e c t i o n .
U n l e s s this pad w e r e u n u s u a l l y thick, ( d e t e r m i n e d from v e s s e l dia-
meter, liquid l o a d i n g and p h y s i c a l p r o p e r t i e s of the liquid) it will
f u n c t i o n s o l e l y as a c o a l e s c e r that p a s s e s larger d r o p l e t s of liquid
t h r o u g h w i t h the gas. In general, d e s i g n s e m p l o y i n g this c o n f i g u r a -
tion are i n c a p a b l e of fine s e p a r a t i o n .

E x p e r i e n c e has s h o w n that s i n g l e f i b r o u s m i s t e l i m i n a t o r pads

that are p r o p e r l y d e s i g n e d and applied are c a p a b l e of a f f e c t i n g
r e m o v a l of 4 to 6 m i c r o n aerosols. M u l t i p l e pad i n s t a l l a t i o n s ,
p a r t i c u l a r l y those w i t h a b l o t t i n g s t a g e b e t w e e n c o a l e s c e r s and mist
e l i m i n a t o r s , are c a p a b l e of 1 to 3 m i c r o n p e r f o r m a n c e .

Test Methods and P e r f o r m a n c e Evaluation

I n a b i l i t y to o b t a i n a n a b s o l u t e m e a s u r e m e n t of the p i p e l i n e
dirt c o n t e n t of a f l o w i n g gas s t r e a m is h i n d e r i n g the d e v e l o p m e n t of
m o r e e f f e c t i v e gas c l e a n e r s and the e v a l u a t i o n of e x i s t i n g f a c i l i t i e s .
M a n y m e t h o d s have been proposed. Some have been d e v e l o p e d to a
c e r t a i n d e g r e e of u s e f u l n e s s i n c l u d i n g g r a v i m e t r i c methods, s l i d e
s a m p l i n g and counting, and v a r i o u s p h o t o m e t r i c and l i g h t - s c a t t e r i n g
techniques. The g r e a t e s t o b s t a c l e is the a b i l i t y to a n a l y z e a
total flow s t r e a m and m e a s u r e its p a r t i c u l a t e c o n t e n t u n d e r f l o w i n g
c o n d i t i o n s , or to o b t a i n a true s a m p l e of that s t r e a m and its con-
tents. It is s i g n i f i c a n t that the AGA P i p e l i n e R e s e a r c h C o m m i t t e e
s u s p e n d e d r e s e a r c h on gas c l e a n i n g about five years ago p e n d i n g
s o l u t i o n of this problem. The s o l u t i o n still pends.

Meanwhile, a number of operating and manufacturing companies

are proceeding to develop evaluation programs for gas cleaners.
Currently, most of these are concerned with solids removal because
these techniques are simpler (8). Evaluation programs for aerosol
removal are being developed by the author. The o b j e c t i v e is to
devise interim test methods for evaluating gas cleaner performance
and to make purchasing and application more effective.
8C

Conclusions

In summary, it is urged that operating company management rec-

o g n i z e that gas cleaning problems exist. The only variable is to
be found in the degree of severity which may reflect the quality of
operation.

Distribution companies deserve clean gas now and in the future

but their problems today may have come to them twenty or more years
ago. Elimination of pipeline dirt, be it liquid or solid, will
continue to be an integral part of their operations but better gas
cleaning practices now will abate this problem in the future.

An acceptable, uniform m e t h o d for absolute measurement of the

dirt content of flowing gas streams is one of the industry's most
pressing needs. Efforts to achieve this objective deserve full
support of the industry.

Operating companies should evaluate the effectiveness of their

gas cleaners by tabulating operating records that reflect valve
breakage, packing failures, rod and cylinder scoring on recipro-
cating compressors; burned blade tips on gas turbine drives, loss of
efficiency on adsorption driers and quick-cycle hydrocarbon recovery
units due to lube oil contamination, frequency and severity of crude
oil contamination and salt accumulation in gasoline plants and gas
treating systems, loss of transmission efficiency due to accumulation
of lube oil and other pipeline dirt deposits in pipelines, absorp-
tion oil and lube oil consumption, frequency and nature of erosion
in regulator settings, frequency and nature of measurement problems
caused by pipeline dirt, and the frequency and nature of pipeline
dirt problems encountered in distribution systems. Analysis of
these data will provide many answers concerning the effectiveness of
existing gas cleaners.

Before buying a gas cleaner, study the application w i t h great

care and make a special effort to give the designer the best design
parameters available. These data will provide sound design and
adequate performance at a reasonable cost.

Remember that, to date, there is no single gas cleaner design

that is best for all applications. Recommendations and quotations
should be studied and evaluated with care so that quality of per-
formance is considered as well as price.

W i t h equipment costs rising and deliveries uncertain, give

thought to rebuilding older, inefficient gas scrubbers w i t h new,
efficient internals and realize appreciable savings in delivery
time and cost. In some cases, no piping changes will be required
so that additional savings can be realized.

Finally, it seems safe to predict that if the gas industry

develops more interest in gas cleaning and demands better facil-
ities, these will be forthcoming.
 9c

BIBLIOGRAPHY

. Chemical Engineer's Handbook, 3rd Ed., p. 1013, McGraw-

Hill Book Company, Inc., New York (1950).

. Fuel Contamination Information Manual, Navaer 00-801-74,

U. S. Navy ( 1 9 5 7 ) .

. Gas Cleaner Performance Tests, AGA Project NFX-12 (1959).

4. Lembcke, R. E., Proceedings of the Gas Conditioning Con-

ference, p. IA, University of Oklahoma Extension Divi-
sion, Norman, Oklahoma (1964).

. Matthews, W. D. and York, O. H., Proceedings of the Gas

Conditioning Conference, p. IF, University of Oklahoma
Extension Division, Norman, Oklahoma (1963).

. Perry, D., Jr., Analysis of Particulate Matter in Fluids

and Gases, University of Oklahoma Gas Compressor
Engines Seminar, Norman, Oklahoma (October 21, 1960).

. Reid, L. S., U. S. Patent Application Ser. No. 377,273

(pending).

. Ritter, Gerry, Proceedings of the Gas Conditioning Con-

ference, p. IE, University of Oklahoma Extension
Division, Norman, Oklahoma (1965).

. W a r n e r , B. J . and S c a u z i l l o , F r a n k , P r o c e e d i n g s o f t h e Gas
C o n d i t i o n i n g C o n f e r e n c e , p. 1G, U n i v e r s i t y of
Oklahoma E x t e n s i o n D i v i s i o n , Norman, Oklahoma ( 1 9 6 3 ) .
i0. Worley, M. S. and Laurence, L. L., Oil & Gas Separation
Is a Science, AIME (SPE) TF 504, presented at the
November i0, 1956 meeting of Venezuela Chapter of
AIME in Caracas, Venezuela.