Gas Separation

Process

1
 Origin of hydrocarbon
 The most widely accepted theory says that fossil fuels
are formed when organic matter (such as the remains of
a plant or animal) is compressed under the earth, at
high temperatures, for a very long time.
 How hydrocarbon Formed
In most areas, a thick liquid called oil formed
first, but in deeper, hot regions underground, the
natural gas was formed. Over time, some of
this oil and natural gas began working its way
upward through the earth’s crust until they ran
into rock formations called “cap rocks” that are
dense enough to prevent them from seeping to
the surface. It is from under these cap rocks
that most oil and natural gas is produced today.
1. Natural gas

Natural gas is a fossil fuel.

Like oil and coal,

Natural gas is a combustible

mixture of hydrocarbon
gases. While natural gas is
formed primarily of A Methane
methane, it can also include molecule, CH4
ethane, propane, butane and
pentane 4
 What is it?
It is of particular interest to us because:

 when burned it gives off a great deal of energy

 is one of the cheapest forms of energy
 Unlike other fossil fuels, natural gas is the
cleanest burning and emits lower levels of
potentially harmful byproducts into the air.
1. Natural gas

Currently, natural gas supplies one-fourth of the energy needed to

efficiently run the world's homes, businesses, vehicles, industries and
power plants.

Main applications are:

Power plants
Raw material for industry
Domestic and industrial
heating systems
NG vehicles

6
 Chemical Composition
of Natural Gas
Component Sample Analysis Range
(mole %) (mole %)
Methane 94.9 85.0 - 98.0
Ethane 2.5 1.0 - 5.1
Propane 0.2 0.1 - 1.5
iso - Butane 0.03 0.01 - 0.3
normal - Butane 0.03 0.01 - 0.3
iso - Pentane 0.01 trace - 0.14
normal - Pentane 0.01 trace - 0.04
Hexanes plus 0.01 trace - 0.06
Nitrogen 1.6 1.3 - 5.6
Carbon Dioxide 0.7 0.1 - 1.0
Oxygen 0.02 0.01 - 0.1
Hydrogen trace trace - 0.02
Specific Gravity 0.585 0.57 - 0.62
 Methane Sales gas Local consumption
NATURAL GAS

&gas export
Ethane/Propane Petrochemicals Polyethylene &
polypropylene
Propane Commercial
propane Export
Propane/Butane
LPG
Local consumption
Pentane (+)
Condensate Middle
distillates
Tc,
Ra

9
FUNDAMENTALS
OF ROCK
PROPERTIES
 POROSITY

The porosity of a rock

is a measure of the
storage capacity (pore
volume) that is capable
of holding fluids.
 the porosity is the ratio of the pore volume to
the total volume (bulk volume). This important
rock property is determined mathematically by
the following generalized relationship:

 Porosity Φ = pore volume/ bulk volume

 PERMEABILITY
 Permeability is a property of the
porous medium that measures the
capacity and ability of the
formation to allow fluids
movement through pores.

 The rock permeability, k, is a very
important rock property because it
controls the directional movement
and the flow rate of the reservoir
fluids in the formation.
Reservoir Rock
Characteristics
 Introduction
 A reservoir trap is a combination of
physical conditions that will cause
hydrocarbon liquids and/or gases and water
to accumulate in porous and permeable
rock and prevent them from escaping either
laterally or vertically
Oil and Gas trapping
 Natural gas reservoir

Oil and associated gas

reservoir

Natural gas
components

17
17
:Typical Composition of Natural Gas

Water
Impurities CO2,H2S, Hg
Nitrogen
LNG
Methane

Ethane

NGL’s Propane

Butane LPG
C5 +
18
18
Natural Gas Properties

19
 Natural Gas Phase Behavior
 The natural gas phase behavior diagram is a plot of pressure vs temperature that
determines whether the natural gas stream at a given pressure and temperature
consists of a single gas phase or two phases: gas and liquid.

 The phase behavior for natural gas with a given composition is typically displayed
on a phase diagram, an example of which is shown in Figure 1-1.

 The left-hand side of the curve is the bubble point line and divides the single phase
liquid region from the two-phase gas–liquid region.

 The right-hand side of the curve is the dew point line and divides the two-phase gas–
liquid region and the single-phase gas region.

20
 uid
Retrograde region
liq
X
Y
A
it

Vap
or
=
p
o
w
i
zy
n
/t
zW
:y

z
w y

21
 Definitions
1-Phase Diagram
A record of the effects of temperature, pressure and composition on the kinds and
numbers of phases that can exist in equilibrium with each other.

2-Bubble Point
The point at which the first infinitesimally small vapour bubble appears in a liquid
system. The bubble point curve on a phase diagram represents 0% vapour.

3-Dew Point
The point at which the first infinitesimally small droplet of condensation forms in a
gaseous system. The dew point curve on a phase diagram represents 0%
liquid.

4-Phase Envelope
The area on a pressure-temperature phase diagram for a mixture enclosed by the
bubble and dew point curves. This area represents the set of conditions for the
mixture were vapour and liquid phases co-exist in equilibrium.

5-Cricondenbar (Pmax)
The maximum pressure at which vapour and liquid can co-exist in equilibrium.

22
 Definitions
6-Cricondentherm (Tmax)
The maximum temperature at which vapour and liquid can co-exist in equilibrium.

7-Critical Pressure
The vapour pressure at critical temp.

8-Critical Temperature
The temp. above which all the mixture cannot be liquid

9-Quality Lines
Lines through the two-phase region showing a constant percentage of liquid and
vapour.

10-Retrograde
The name given to phase behaviour above the critical temperature and pressure
were vapour and liquid phases coexist and the amount of vaporisation or
condensation changes with pressure and temperature in the opposite
direction to normal behaviour. (e.g:condensation of liquids by occur by
lowering pressure or increasing temperature)

23
 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.
 SEPARATOR

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
 Separator size
 Operating pressure
 Operating temperature
 Fluid Composition
 Residence Time
 Separator Internals
 Surface Area of Gas-Oil Interface
 presence of impurities (paraffin, sand, scale,
etc.)
 gas and liquid flow rates (average and peak) 27
CLASSIFICATION OF OIL AND
GAS SEPARATORS
 SEPARATOR

 SEPARATORS have two main types :

1. HORIZONTAL 2. VERTICAL SEPARATOES

SEPARATORS

2. SPHERICAL
SEPARATORS
Common Components
 Primary Separation Section

 Secondary or Gravity Settling Section.

 Mist Extraction or Coalescence Section.

 Liquid Accumulator Section

 SEPARATOR
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
(depending on
internals)
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
 SEPARATOR

Disadvantage of Vertical 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.
 SEPARATOR
SELECTION CONSIDRATIONS

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
 SEPARATOR

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
 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
Purpose of Device or Situation Internal Device
where Device should not be used
a- remove liquid mist from gas. 1- Mist Pad
b- break oil-water emulsion.

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

present.
a- separate liquid from gas. 2- Deflector Plate
b- used in all services.
a- remove liquid mist from gas. 3- Coalescing
b- separate oil from water. Plate

c- not used where hydrate, corrosion, wax or dirt

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

b- separate oil from water.

c- remove mist from gas.
d- not used where wax or hydrate may be present.
a- separate oil from water. 6- Coalescing Materials
b- not used where wax may be present.
 Summary for the Function of Separator
Internals
a- separate gas from liquid. 7- Centrifugal
b- not used where wax or dirt may be present. Devices

c- not used with intermittent gas flow.

a- usually used in large gas-liquid vessels where waves 8- Horizontal

occur. Baffles
a- should be used on all liquid outlet nozzles in gas-liquid 9- Vortex Breakers
separators
b- are not needed if vessel is full of liquid
a- should be used when internal level control float is 10- Float Shield
used.
a- used only when solids may be present. 11- Water Jets and
Sand Cones