SEPARATOR SIZING

INTRODUCTION
Separation of oil and gas is a critical field-processing operation.
Technically easier and less costly to process gas, crude oil, and produced water separately.
The water is often corrosive. It is important to remove water upfront to be able to use less costly materials of
construction at the downstream.

SEPARATOR TYPES
Wellhead separators are often classified by their geometrical configuration (vertical, horizontal, horizontal double
barrel, or spherical) and by their function (two-phase), or three phase (gas-oil-water) separation.

Peerless Tech Spec. Vane Separators, Dallas, TX

INTRODUCTION
A complete separator must have the following;
 A primary separation section remove bulk of the liquid from the gas
 Capacity that is sufficient to handle surges of the liquid from the line
 Sufficient dimensions to give enough time for liquid droplets to settle out from the gas phase
 A method for eliminating the turbulence so that proper settling may take place
 Proper back-pressure and liquid level control.

COMPONENTS OF SEPARATORS

Primary Separation Section: Liquid is collected and removed

from the inlet stream.

The momentum of the inlet stream is utilized to separate the

liquid via impacting it onto a baffle and changing the direction
of the motion abruptly

Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
COMPONENTS OF SEPARATORS
Secondary or Gravity Settling Section:
Velocity is reduced; liquid droplets can settle out by
gravity.
Internal baffling: inhibit foams, reduce turbulence,
and accelerate droplet removal.
Vanes: droplet collectors

Mist Extraction or Coalescence Section: Series of

vanes, a woven wire mesh pad, or a centrifugal
device, removes small droplets from the gas
stream.
Means of separation is impingement on a surface.
Small droplets impinge on a surface and coalesce
together.
Liquid carryover often meet a 0.1 gallon per MMscf
spec. Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
 COMPONENTS OF SEPARATORS
Liquid accumulator Section: Liquid separated from gas is collected. It has to provide 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

Process Controls: The separator pressure is typically regulated by a backpressure regulator in the exit gas line, or to
control pressure loss across the valve. The two phase separators have a liquid level controller to activate a dump
valve to maintain desired liquid level. Three phase separators have two liquid level controllers.

Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
VERTICAL SEPARATORS
Vertical separators are usually selected when the gas-liquid ratio is high or total gas volumes are low.

Peerless Tech Spec. Vane Separators, Dallas, TX

 HORIZONTAL SEPARATORS

Horizontal separators are most efficient when large volumes of total fluids and large amounts of dissolved gas are present
with the liquid

Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
 HORIZONTAL SEPARATORS
The length of horizontal separator has a greater effect on capacity than the height of a vertical type. The required length
depends on droplet size, gas velocity, droplet density, vessel diameter, and the degree of turbulence.

Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
 HORIZONTAL SEPARATORS
Single and Double Barrel Horizontal Separator: The double barrel separator consists of an upper separation section
and a lower liquid chamber. The single barrel type combines both into a single chamber. In single barrel type, the
diameter must be larger to compensate for the volume occupied by the liquid.

Peerless Tech Spec. Vane Separators, Dallas, TX

MIST EXTRACTOR

Mist eliminators are used to aid gravity settling by changing the momentum of the stream and also by impaction. To be
effective, a mist extractor must accomplish two basic functions

• Have a means to capture liquid

• Must be able to drain the captured liquid without allowing re-entrainment into the gas stream.

Vane with pockets, allow a higher gas throughput (capacity) per flow area due to the enhanced drainage, but are not
typically used in highly fouling service.

Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
MIST EXTRACTOR

Sulzer Chem Tech. Gas/Liquid Separation Technology

 MIST EXTRACTOR
Wire Mesh or Fibrious mist Eliminators

Mesh mist eliminators or pads are made by knitting wire, metal, or plastic into tightly packed layers, which are then
crimped and stacked to achieve the required pad thickness.

Koch - Glitsch, Inc. Mist Elimination, Liquid-Liquid Coalescing

MIST EXTRACTOR

Mesh pads remove liquid droplets by impingement of droplets

onto the wires, followed by coalescence into droplets large
enough to disengage from the bottom of the pad and drop
through the rising gas flow in the liquid holding part of the
separator.

Inertial impaction (Primary Mechanism): Droplets that have

sufficient momentum to break free of the gas streamline and
continue to move in a straight line until they impinge on a
target.
Direct interception (Secondary Mechanism): small particles that
managed to remain on the gas streamline, and are collected if
the droplet pass close enough to the target such that it touches
the target.

Koch-Glitsch, Inc. Mist Elimination, Liquid-Liquid Coalescing

PHASE SEPARATION THEORY

VERTICAL SEPARATORS: In the top section of a vertical separator the downward flow of any liquid drops is inherently
countercurrent to the rising vapor flow. In horizontal separators, the flows are crosscurrent; liquid drops fall downward as gas
flows horizontally.
PHASE SEPARATION THEORY

For vertical vessels, a dispersed liquid droplet will settle out when the vertical continuous phase velocity (gas phase
velocity for gas-liquid separation) is less than the terminal velocity of the droplet.
PHASE SEPARATION THEORY
DRAG COEFFICIENT
The drag coefficient is a function of the shape of the particle and the Reynolds number of the flowing fluid.

Manning, F. S. and Thompson, R.E. (1995). Oilfield Processing, Volume Two: Crude Oil, PenWell Corporation, Tulsa
 PHASE SEPARATION THEORY
HORIZONTAL SEPARATORS
In a horizontal separator, the drop’s downward velocity is perpendicular to the horizontal gas flow. The time, , for most
remote liquid droplet to fall through the entire gas phase is set equal to the theoretical residence time for gas flow through
the separator ,.

The fall time for the liquid droplet

Residence time for gas

When vertical velocity (fall velocity) is at terminal droplet

velocity
PHASE SEPARATION THEORY
EMPIRICAL METHODS
The terminal velocity calculations may neglect many real phenomena. Provides qualitative guidance
• Interaction between drops, variations in drop size, bulk phase (continuous phase) turbulence with eddies and
currents
• Shape distortion of the drops (they aren’t necessarily spherical).
• Presence of Mist Extractor
• Separator geometry, flow rates and fluid properties are also important factors.
Therefore, is determined most reliably by through pilot-testing in the field on the wellstream.
In the absence of field or pilot data, the following API (1989) recommendations are available;
 PHASE SEPARATION THEORY
EMPIRICAL METHODS

GPSA (1987) recommended adjustment of for high pressures for separators with mist eliminator.

• For pressures psig the is given as;

• For most vapors under vacuum

• For Glycol and Amine solutions, multiply by 0.6 - 0.8
• For Vertical vessels without demisters, divide by 2
• For compressor suction scrubbers, mole sieve scrubbers and expander inlet separators, multiply by 0.7-0.8.

GPSA (1987). Engineering Data Book, Vol I, Section-7, 10 th Edition, Gas Processors Suppliers Association, Tulsa, OK.
 PHASE SEPARATION THEORY
EMPIRICAL METHODS

Otto H. York Company suggested the following relations for values for separators with York Demister.
•
•
•
Pressure in above equations are in psig.

Otto H. York Company Inc. Mist Elimination in Gas Treatment Plants and Refineries. Engineering, Parsipanny, NJ.
PHASE SEPARATION THEORY
LIQUID-LIQUID SEPARATION

Gravity Settling Method: The flow of rising light droplets in the heavy liquid phase or settling heavy liquid droplets in the
light liquid phase is considered laminar and is governed by Stokes’ law;

Similarly, terminal velocity for the light liquid

droplets (oil drops) that are coming out of heavy
liquid phase
PHASE SEPARATION THEORY
LIQUID-LIQUID SEPARATION
Settling Time: the amount of time required for liquid droplets to settle out from the continuous phase (another liquid phase).

Residence Time: Residence time is defined as the amount of time a fluid remain within the settling compartment of the
separator
PHASE SEPARATION THEORY
LIQUID-LIQUID SEPARATION

For liquids to separate,

If not satisfied, then the liquid separation is controlling

Keep the disengagement depth constant and increase diameter
 PHASE SEPARATION THEORY
LIQUID-LIQUID SEPARATION
Settling is more readily accomplished in low
viscosity liquid .
Generally water de-oiling is much easier than
oil de-watering for heavier oils

GPSA (1987) Engineering Data Book, Vol I, Section-7, 10 th Edition, Gas Processors Suppliers Association, Tulsa, OK
PRESSURE VESSEL SPECIFICATIONS
VESSEL SHELL THICKNESS
The ASME BPV (American Society of Mechanical Engineers, Boiler and Pressure Vessel) code will be considered here. It is
the standard used in North America and most commonly referenced internationally.

is the design pressure (psig)

internal diameter of shell (in)
denotes maximum allowable stress (psi)
(in) is the corrosion allowance
is the joint efficiency

Design Pressure: It is typically either the operating pressure with 15 – 30 psi added to it or the operating pressure
+10%, whichever is greater.

Design Temperature, T (F): The strength of metals decreases with increasing temperature so the maximum allowable
stress will depend on the material temperature.
 PRESSURE VESSEL SPECIFICATIONS
VESSEL SHELL THICKNESS
Maximum allowable Stress, (psi): The maximum allowable stress values for ASME BPV Code Sec. VIII D.1 are given
in ASME BPV Code Sec II Part D Table 1A for ferrous metals and Table 1B for nonferrous metals .

Towler, G. and Sinnott, R. (2013). Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, Second Edition, Elsevier
 PRESSURE VESSEL SPECIFICATIONS
VESSEL SHELL THICKNESS
Joint Efficiency, E:
The strength of welded joint will depend on the type of joint and quality of welding.

Towler, G. and Sinnott, R. (2013). Chemical Engineering Design: Principles, Practice and Economics of Plant and Process Design, Second Edition, Elsevier
PRESSURE VESSEL SPECIFICATIONS
HEAD TYPES
The major types of heads are Ellipsoidal, Torispherical and Hemispherical. They are collectively referred to as domed heads

Torispherical heads (dished heads)

• Most commonly used
• Can be used up to 15 bar pressure. At higher pressure its cost should be compared with ellipsoidal

Hemispherical head is the strongest shape, capable of resisting about twice the pressure of torispherical head of the same
thickness.
• Can be used for high pressures
• Costlier than shallow torispherical head
PRESSURE VESSEL SPECIFICATIONS
Head Thicknesses for Different Head Types
Ellipsoidal Heads (2:1): Most standard ellipsoidal heads are manufactured with a major and minor axis ratio of 2:1. For
this ratio, the following equation ca be used to calculate the minimum thickness required by ASME BPV Code Sec. VIII D.1
Part UG-32

Torispherical Heads: A torispherical shape is formed from a part of a torus and part of a sphere. The shape is close to
that of an ellipse but is easier and cheaper to fabricate. The ASME Code gives the design equation

Hemispherical Heads: In the ASME BPV Code Sec. VIII D.1, the equation specified is the same for a spherical shell
PROMAX SEPARATOR SIZING TOOL
PROMAX SEPARATOR SIZING TOOL

Vessel Type
PROMAX SEPARATOR SIZING TOOL
Vapor-Liquid Droplet Diameter

Vapor-Liquid
PROMAX SEPARATOR SIZING TOOL
Terminal Velocity in Vapor

Terminal Velocity in Light Liquid

Liquid-Liquid Droplet Diameter

Liquid-Liquid C*
PROMAX SEPARATOR SIZING TOOL

Light Liquid Holdup Time

Light Liquid Holdup Volume

Light Liquid Holdup Depth

PROMAX SEPARATOR SIZING TOOL
PROMAX SEPARATOR SIZING TOOL

Light Liquid Surge Time /Volume /Depth Light Liquid Low Level Shutdown Depth
PROMAX SEPARATOR SIZING TOOL
Heavy Liquid Holdup Time / Volume / Depth
PROMAX SEPARATOR SIZING TOOL
Heavy Liquid Surge Time Heavy Liquid Surge Volume Heavy Liquid Surge Depth Heavy Liquid Low Level Shutdown Depth
PROMAX SEPARATOR SIZING TOOL
PROMAX SEPARATOR SIZING TOOL

Demister Pad Thickness

Demister Pad Overhead Clearance

PROMAX SEPARATOR SIZING TOOL
Minimum Vapor Disengagement Depth Vapor Disengagement Depth
PROMAX SEPARATOR SIZING TOOL

Feed Nozzle Diameter

Vapor Nozzle Diameter

Light Liquid Nozzle Diameter

Heavy Liquid Nozzle Diameter

PROMAX SEPARATOR SIZING TOOL Type of Separator
Residence Time
(minutes)
Light Liquid Residence Time: Hydrocarbon/Water
Above 35° API Hydrocarbon 3-5

Below 35° API Hydrocarbon

100+° F 5 - 10
80+° F 10 - 20
60+° F 20 - 30
Ethylene Glycol/Hydrocarbon (Cold
20 - 60
Separators)
Amine/Hydrocarbon 20 - 30
Coalescer, Hydrocarbon/Water
Separators
100° F and Above 5 - 10
80° F 10 - 20
60° F 20 - 30
Caustic/Propane 30 - 45
Caustic/Heavy Gasoline 30 - 90
PROMAX SEPARATOR SIZING TOOL
Residence Time
Type of Separator
(minutes)
Heavy Liquid Residence Time
Hydrocarbon/Water
Above 35° API Hydrocarbon 3-5
Below 35° API Hydrocarbon
100+° F 5 - 10
80+° F 10 - 20
60+° F 20 - 30
Ethylene Glycol/Hydrocarbon (Cold
20 - 60
Separators)
Amine/Hydrocarbon 20 - 30
Coalescer, Hydrocarbon/Water
Separators
100° F and Above 5 - 10
80° F 10 - 20
60° F 20 - 30
Caustic/Propane 30 - 45
Caustic/Heavy Gasoline 30 - 90
PROMAX SEPARATOR SIZING TOOL

Vessel Inside Diameter Shell Length Total Vessel Length

PROMAX SEPARATOR SIZING TOOL
Light Liquid Settling Depth Heavy Liquid Settling Depth Settling Compartment Length
PROMAX SEPARATOR SIZING TOOL