TWO-PHASE OIL AND GAS SEPARATION

In oil and gas separator design, we mechanically

separate from a hydrocarbon stream the liquid and
gas components that exist at a specific temperature
and pressure.
Separators are classified as "two-phase" if they
separate gas from the total liquid stream and "three-
phase" if they also separate the liquid stream into its
crude oil and water components.
Separators are designed in either horizontal,
vertical, or spherical configurations.
Horizontal Separator
Vertical Separator
spherical Separator
PRINCIPLES OF SEPAEATION
The fluid enters the separator and hits an inlet
diverter causing a sudden change in momentum. The
initial gross separation of liquid and vapor occurs at
the inlet diverter.
The force of gravity causes the liquid droplets to fall
out of the gas stream to the bottom of the vessel
where it is collected.( liquid collection section)
The liquid collection section provides the retention
time required to let entrained gas evolve out of the oil
and rise to the vapor space. The liquid then leaves the
vessel through the liquid dump valve. The liquid
dump valve is regulated by a level controller.
The gas flows over the inlet diverter and then
horizontally through the gravity settling section above
the liquid. As the gas flows through this section,
small drops of liquid that were entrained in the gas
and not separated by the inlet diverter are separated
out by gravity and fall to the gas liquid interface.
SEPARATOR INTERNALS
1-Inlet Diverters
There are two main types of inlet diverters are:
i-Baffle plates
ii-Centrifugal diverters
A baffle plate can be a spherical dish, flat plate,
angle iron, cone, or just about anything that will
accomplish a rapid change in direction and velocity of
the fluids and thus disengage the gas and liquid.
 DIVERTER BAFFLE

TANGENTIAL BAFFLE
Centrifugal inlet diverters use centrifugal force to
disengage the oil and gas. Centrifugal diverters work
well in initial gas separation and help to prevent
foaming in crude’s.

2-Wave Breakers

In long horizontal vessels it is necessary to install

wave breakers, which are nothing more than vertical
baffles spanning the gas-liquid interface and
perpendicular to the flow.
3-Mist Extractor
Mist extractors can be made of wire mesh, vanes,
centrifugal force devices, or packing.
Wire mesh pads are made of finely woven mats of
stainless steel wire wrapped into a tightly packed
cylinder. The liquid droplets impinge on the matted
wires and coalesce.
Vane eliminators force the gas flow to be laminar
between parallel plates that contain directional
changes.
In vane eliminators, droplets impinge on the plate
surface where they coalesce and fall to a liquid
collecting spot. They are routed to the liquid
collection section of the vessel.
Centrifugal mist eliminators that cause the liquid
drops to be separated by centrifugal force. These can
be more efficient than either wire mesh or vanes and
are the least susceptible to plugging. However, they
are not in common use in production operations
because their removal efficiencies are sensitive to
small changes in flow. In addition, they require
relatively large pressure drops to create the
centrifugal force.
CENTRIFUGAL MIST ELIMINATORS
 Random packing is sometimes used for mist
extraction. The packing acts as a coalesces.
THE ADVANTAGES OF EACH TYPE OF SEPARATOR:

1-VERTICAL SEPARATOR
Liquid level control not as critical.
Will handle large quantities of sand.
Easier to clean.
Has greater liquid surge capacity.
Is smaller plot area.

2-HORIZONTAL SEPARATOR
Successfully used in handling foaming crude.
Cheaper than vertical separator.
More economical an efficient for processing
large volumes of gas.
Smaller diameter for a given gas capacity.
More flexible choice of nozzle arrangement.

3-SPHERICAL SEPARATOR
Cheaper than either horizontal or vertical
separator.
Better clean out and bottom drain features
than vertical type.
More compact than other types
SEPARATOR DESIGN PROCEDURES
FACTORS AFFECTING SEPARATION
The following factors must be determined before
separator design:
• Gas and liquid flow rates (minimum, average, and
peak)
• Operating and design pressures and temperatures
• Surging or slugging tendencies of the feed streams
• Physical properties of the fluids such as density and
compressibility
• Presence of impurities (paraffin, sand, scale, etc.)
• Foaming tendencies of the crude oil
• Corrosive tendencies of the liquids or gas
1-Procedures for sizing horizontal separators
For sizing a horizontal separator it is necessary to
choose a vessel length and a diameter. This choice
must satisfy the conditions:
1- For gas capacity : that allow the liquid drops to fall
from the gas to the liquid volume.
2- For sufficient retention : to allow the liquid to reach
equilibrium.
Step 1:
Tabulate the physical properties of the fluids to be
separated
Step 2:
Calculate values of, vessel internal diameter(d) and
effective length (Le ) , that satisfy the gas capacity
constraint.

Step 3:
Calculate values of, d and Le , that satisfy the
retention time constraint.

Step 4:
Estimate vessel length (L)
i- For gas capacity:
ii- For liquid capacity:

Step 5:
Calculate slenderness ratios (SR)
“ select a size of reasonable diameter and length for (SR) on
order of 3 to 4 are common”
Where:
d= Vessel internal diameter, in
Le= Effective length of the vessel where separation occurs, ft
T = Operating temperature, 0R
P = Operating pressure , psia
Qg =Gas flow rate, MMscfd
QL =Liquid flow rate , bpd
dm =Liquid drop to be separated , micron
CD = Drag coefficient
tr =Desired retention time for the liquid, min
rg = Density of gas , lb/ft3
rL = Density of liquid , lb/ft3
Example:
Sizing a horizontal separator:
Given:
Gas flow rate =10 MMscfd
Liquid flow rate =2000 bpd
Operation pressure =1000 psia
Operation temperature =600F
Density of gas =3.71 lb/ft3
Density of liquid =51.5 lb/ft3
Oil viscosity = 0.013 cp
Gas compressibility = 0.84
Liquid drop = 140 micron
Retention time =3 min
Drag coefficient =0.851
Find:
Vessel length and diameter
Solution:
1-Calculate Le and d for gas capacity

2- Calculate Le and d for liquid capacity

3-Assume d, [ 24, 30, 36, 42 ] , and calculate Le for

gas and liquid capacity.

4- Calculate L based on large value of Le

5- Calculate (SR)
 d Gas (Le) Liquid (Le) L SR=12L/d
24 1.66 14.88 19.84 9.92
30 1.33 9.52 12.69 5.08
36 1.11 6.61 6.81 2.94
42 0.95 4.86 6.48 1.85

6-We choose L and d based on (SR):

By interpolation :

SR 5.08 4 2.94
L 12.84 L 6.81
d 30 d 36
i-For length:

ii-For diameter:
2-Procedures for sizing vertical separators
In vertical separators:
i- A minimum diameter must be maintained to allow
liquid drops to separate turn the vertically moving
gas.
ii- The liquid retention time requirement specifies a
combination of diameter and liquid volume height.
iii- Any diameter greater than the minimum required
for gas capacity can be chosen.
Step 1:
Tabulate the physical properties of the fluids to be
separated.
Step 2:
Calculate minimum diameter based on gas capacity .

Step 3:
Assume diameter greater than the minimum diameter
required for gas capacity .
Step 4:
Compute combinations of diameter (d) and height of
the liquid volume (h) for variant’s assume diameter
based on liquid capacity constrain.
Step 5:
Compute length (L) .

Where: d is the minimum diameter for gas capacity .

Step 6:
Calculate slenderness ratios (SR)
“ select a size of reasonable diameter and length for
(SR) on order of 3 to 4 are common”
Example:
Sizing a vertical separator:
Given:
Gas flow rate =10 MMscfd
At 0.6 specific gravity
Liquid flow rate =2000 bpd
At 40 API
Operation pressure =1000 psia
Operation temperature =600F
Density of gas =3.71 lb/ft3
Density of liquid =51.5 lb/ft3
Oil viscosity = 0.013 cp
Gas compressibility = 0.84
Liquid drop = 140 micron
Retention time =3 min
Drag coefficient =0.851
Find:
Vessel length and diameter
Solution:
Minimum diameter for gas capacity

2- Assume diameter [24 ,30, 36, 42 ]

3-Compute combinations of diameter (d) and height of
the liquid volume (h)
Tr (min) d (in) h (in) L=(h+76)/12 (ft) SR=12L/d

3 24 86.80 13.57 6.79

30 55.56 10.96 4.38
36 38.60 9.55 3.18
42 28.35 8.69 2.48

4- Choose:
Diameter=36 in
Length=9.55=10 ft
THREE-PHASE OIL AND GAS SEPARATION
Three – phase separator are designed as either
horizontal or vertical pressure vessels
1-Horizontal Separator
PRINCIPLES OF SEPAEATION
Fluid enters the separator and hits an inlet diverter.
This sudden change in momentum does the initial
gross separation of liquid and vapor .
The inlet diverter contains a down comer that
directs the liquid flow below the oil/water interface.
This forces the inlet mixture of oil and water to mix
with the water continuous phase in the bottom of the
vessel and rise through the oil/water interface. This
process is called "water-washing," and it promotes
the coalescence of water droplets which are entrained
in the oil continuous phase.
The liquid collecting section of the vessel provides
sufficient time so that the oil and emulsion form a
layer or "oil pad" at the top. The free water settles to
the bottom.
The weir maintains the oil level and the level
controller maintains the water level. The level of the
oil downstream of the weir is controlled by a level
controller that operates the oil valve.
An interface level controller senses the height of the
oil/water interface. The controller sends a signal to
the water pump valve thus allowing the correct
amount of water to leave the vessel so that the
oil/water interface is maintained at the design height.
The gas flows horizontally and out through a mist extractor to
a pressure control valve that maintains constant vessel
pressure. The level of the gas/oil interface can vary from half the
diameter to 75% of the diameter depending on the relative
importance of liquid/gas separation.
Alternate configuration known as a "bucket and weir" design.
This design eliminates the need for a liquid interface controller.

Both the oil and water flow over weirs where level control is
accomplished by a simple displacer float. The oil overflows the
oil weir into an oil bucket where its level is controlled by a level
controller that operates the oil valve.
The water flows under the oil bucket and then over a water weir.
The level downstream of this weir is controlled by a level
controller that operates the water dump valve.
HORIZONTAL SEPARATOR [bucket and weir
design]
It is critical to the operation of the vessel that the
water weir height be sufficiently below the oil weir
height so that the oil pad thickness provides
sufficient oil retention time.
If the water weir is too low and the difference in
specific gravity is not as great as anticipated, then the
oil pad could grow in thickness to a point where oil
will be swept under the oil box and out the water
outlet. Normally, either the oil or the water weir is
made adjustable so that changes in oil/water specific
gravities or flow rates can be accommodated.
To obtain a desired oil pad height, the water weir
should be set a distance below the oil weir, which is
calculated by:
Setting the pressure at point A

Where:
Dh = distance below the oil weir, in.
h0 = desired oil pad height, in.
r0 = oil density, lb/ft3
rw = water density, lb/ft3
However, in heavy oil applications or where large
amounts of emulsion or paraffin are anticipated it may
be difficult to sense interface level. In such a case
bucket and weir control is recommended.

Vertical
Separator
Flow enters the vessel through the side as in the
horizontal separator, the inlet diverter separates the
bulk of the gas.
A down comer is required to transmit the liquid
through the oil-gas interface . A chimney is needed to
equalize gas pressure between the lower section and
the gas section.
The spreader or down comer outlet is located at the
oil-water interface. From this point as the oil rises any
free water trapped within the oil phase separates out.
The water droplets flow countercurrent to the oil.
Similarly, the water flows downward and oil droplets
trapped in the water phase tend to rise countercurrent
to the water flow.
SEPARATOR DESIGN PROCEDURES
1-Horizontal Separators
For sizing a horizontal three-phase separator it is
necessary to specify a vessel diameter and a seam-to-
seam vessel length.
The gas capacity and retention time considerations
establish certain acceptable combinations of diameter
and length.
The need to settle 500-micron water droplets from
the oil establishes a maximum diameter.
Step1:
Select oil retention time (tr)0 and water retention time
(tr)w
Step2:
Calculate maximum oil pad thickness. (ho)max , allow
the water droplets to settle out time (tr)0 .

Step3:
Calculate the fraction of the vessel cross sectional
area occupied by the water phase.

Step4:
Calculate maximum diameter for oil pad thickness
constraint
Step5:
Calculate combination of d and Le for d less than
dmax that satisfy the oil and water retention time
constraint

Step6:
Estimate vessel length

Step7:
Calculate slenderness ratios (SR)=(12L/d)
“ select a size of reasonable diameter and length for
(SR) on order of 3 to 5 are common”
Example:
Sizing a Horizontal Three-Phase Separator
Given:
Gas flow rate =5 MMscfd
Oil flow rate =5000 bpd
Water flow rate =3000 bpd
Operation pressure =100 psia
Operation temperature =900F
Oil =300API
Specific gravity =1.07
(water phase)
Oil viscosity = 0.013 cp
Oil Retention time =10 min
Water Retention time =10 min
Find:
Vessel length and diameter
Solution:
1-Calculate difference in specific gravities

2- Calculate maximum oil pad thickness

3-Calculate maximum diameter for oil pad thickness

constraint
4- Calculate combination of d and Le
 d(in) Le(ft) L=(4/3Le) (ft) (12L/d)
60 31.56 42.07 8.42
70 23.18 30.91 5.30
80 17.75 23.67 3.55
90 14.02 18.70 2.49
100 11.36 15.15 1.82

5- Possible choices
[ 80 in x 24 ft]
2-Vertical Separators
A minimum diameter must be maintained to assure
adequate gas capacity.
The height of the three phase separator is
determined from retention time consideration.
Step 1:
Calculate minimum diameter from requirement for
water droplets to fall through oil layer. Use 500-
micron droplets if no other information is available.
Step 2:
Calculate minimum diameter from requirement for oil
droplets to fall through gas. Use 100-micron droplets if
no other information is available.

Step 3:
Choose the larger of the two as minimum diameter
Step 4:
Select oil retention time (tr)0 and water retention time
(tr)w
Estimate the height of oil pad (h0) and height from
water outlet to interface (hw) for various diameter (d)
Step 5:
Estimate the vessel length (L)

Step 6:
Select a size of reasonable diameter and length. Slenderness
ratios (12 L/d) on the order of 1.5 to 3 are common.
Where:
Qw= Water flow rate ,bpd
Q0= Oil flow rate ,bpd
m = Viscosity , cp
DS.G.= Difference in specific gravities
dm= Liquid drop to be separated , microns.
T= Operating temperature, 0R
Z= Gas compressibility
Qg= Gas flow rate, MMscfd
CD= Drag coefficient
P=Operating pressure, psia
rg=Density of gas ,lb/ft3
rl=Density of liquid,lb/ft3
h0= Height of oil pad, in
hw= Height from water outlet to interface, in
(tr)0= Oil retention time, min
(tr)w= Water retention time, min
d= Vessel diameter , in
L= vessel length, ft
Example:
Sizing a Vertical Three-Phase Separator
Given:
Gas flow rate =5 MMscfd
Oil flow rate =5000 bpd
Water flow rate =3000 bpd
Operation pressure =100 psia
Operation temperature =900F
Oil =300API
Gas specific gravity =0.6
Specific gravity of water =1.07
Oil viscosity = 10 cp
Oil Retention time =10 min
Water Retention time =10 min
Gas compressibility = 0.84
Drag coefficient =0.89
Find:
Vessel length and diameter
Solution:
1. Calculate liquid and gas densities.
2- Calculate difference in specific gravities.

3- Calculate minimum diameter to satisfy gas capacity

constraint.
4- Calculate minimum diameter for water droplet
settling.

5-Estimate the height of oil pad (h0) and height from

water outlet to interface (hw)
 6. Compute combinations of d, and h0 + hw for
diameters greater than minimum diameter

d (in) h0 + hw (in) L (ft) SR=12L/d

84 94.5 18.2 2.6
90 82.3 17.7 2.4
96 72.3 17.4 2.2
102 64.1 17.2 2.0

7- Choose a reasonable size:

A 90-in. X 18-ft or a 96-in. X 17-ft size would be a
reasonable choice.