SECTION 7

Separators and Filters

PRINCIPLES OF SEPARATION
Three principles used to achieve physical separation of gas
and liquids or solids are momentum, gravity settling, and
coa-

lescing. Any separator may employ one or more of these principles, but the fluid phases must be "immiscible" and have
different densities for separation to occur.

FIG. 7-1
Nomenclature
A
Ap
C
C*

=
=
=
=

C
Di
Dp
Dv
Gm

=
=
=
=
=

g
Hl
J
K
KCR

=
=
=
=
=

L
Ll
M
Mp

=
=
=
=

area, ft
2
particle or droplet cross sectional area, ft
empirical constant for separator sizing, ft/hr
empirical constant for liquid-liquid separators,
2
(bbl cp)/(ft day)
drag coefficient of particle, dimensionless (Fig. 7-3)
separator inlet nozzle diameter, in.
droplet diameter, ft
inside diameter of vessel, ft
maximum allowable gas mass-velocity necessary
for particles of size Dp to drop or settle out of gas,
2
lb/(hr ft )
2
acceleration due to gravity, 32.2 ft/sec
width of liquid interface area, ft
gas momentum, lb/(ft sec2)
empirical constant for separator sizing, ft/sec
proportionality constant from Fig. 7-4 for use in
Eq 7-5, dimensionless
seam to seam length of vessel, ft
length of liquid interface area, ft
mass flow, lb/sec
mass of droplet or particle, lb

Filter Separators: A filter separator usually has two compartments. The first compartment contains filter-coalescing elements. As the gas flows through the elements, the
liquid particles coalesce into larger droplets and when the
droplets reach sufficient size, the gas flow causes them to
flow out of the filter elements into the center core. The
particles are then carried into the second compartment of
the vessel (containing a vane-type or knitted wire mesh
mist extractor) where the larger droplets are removed. A
lower barrel or boot may be used for surge or storage of the
removed liquid.
Flash Tank: A vessel used to separate the gas evolved from
liquid flashed from a higher pressure to a lower pressure.
Line Drip: Typically used in pipelines with very high gasto-liquid ratios to remove only free liquid from a gas
stream, and not necessarily all the liquid. Line drips provide a place for free liquids to separate and accumulate.
Liquid-Liquid Separators: Two immiscible liquid phases
can be separated using the same principles as for gas and
liquid separators. Liquid-liquid separators are fundamentally the same as gas-liquid separators except that they

Momentum

MW = molecular weight, lb/lb mole

P = system pressure, psia
2
Q = estimated gas flow capacity, MMscfd per ft of
filter area
3
QA = actual gas flow rate, ft /sec
R = gas constant, 10.73 (psia ft3)/(R lb mole)
Re = Reynolds number, dimensionless
Shl = specific gravity of heavy liquid, water = 1.0
S ll = specific gravity of light liquid, water = 1.0
T = system temperature, R
t = retention time, minutes
U = volume of settling section, bbl
Vt = critical or terminal gas velocity necessary for
particles of size Dp to drop or settle out of gas,
ft/sec
W = total liquid flow rate, bbl/day
Wcl = flow rate of light condensate liquid, bbl/day
Z = compressibility factor, dimensionless
Greek:
3
g = gas phase density, lb/ft
3
liquid phase density, droplet or particle, lb/ft
l
= viscosity of continuous phase, cp
must be designed for much lower velocities. Because the
difference in density between two liquids is less than between gas and liquid, separation is more difficult.
Scrubber or Knockout: A vessel designed to handle
streams with high gas-to-liquid ratios. The liquid is generally entrained as mist in the gas or is free-flowing along
the pipe wall. These vessels usually have a small liquid
collection section. The terms are often used interchangeably.
Separator: A vessel used to separate a mixed-phase stream
into gas and liquid phases that are "relatively" free of each
other. Other terms used are scrubbers, knockouts, linedrips, and decanters.
Slug Catcher: A particular separator design able to absorb
sustained in-flow of large liquid volumes at irregular intervals. Usually found on gas gathering systems or other twophase pipeline systems. A slug catcher may be a single
large vessel or a manifolded system of pipes.
Three Phase Separator: A vessel used to separate gas and
two immiscible liquids of different densities (e.g. gas,
water, and oil).
Fluid phases with different densities will have
different mo- mentum. If a two phase stream

changes direction sharply, greater momentum will not allow

the particles of the heavier phase to turn as rapidly as the
lighter fluid, so separation oc- curs. Momentum is usually
employed for bulk separation of the two phases in a stream.

FIG. 7-2
Forces on Liquid Droplet in Gas Stream
Drag Force of
Gas on Droplet

Gravity Settling
Liquid droplets will settle out of a gas phase if the gravitational force acting on the droplet is greater than the drag
force of the gas flowing around the droplet (see Fig. 7-2).
These forces can be described mathematically using the
terminal or free settling velocity.

2 g Mp
l

Liquid
Droplet
Dp

4 g Dp
l

Ap C

l
g

Eq 7-1

The drag coefficient has been found to be a function of the

shape of the particle and the Reynolds number of the flowing
gas. For the purpose of this equation particle shape is
consid- ered to be a solid, rigid sphere.

Gravitational Force
on Droplet

Reynolds number is defined as:

1,488 Dp Vt
Re

Eq 7-2

In this form, a trial and error solution is required since

both
particle size, Dp, and terminal velocity, Vt, are involved.
To avoid trial and error, values of the drag coefficient are
pre- sented in Fig. 7-3 as a function of the product of drag
coeffi- cient, C , times the Reynolds number squared; this
technique eliminates velocity from the expression1. The
abscissa of
Fig. 7-3 is given by:

Gas Velocity

C Re

8
0.95

FIG. 7-3
13

DRAG COEFFICIENT,C

Drag Coefficient of Rigid Spheres

7-2

3
10

g
2

Dp

Eq 7-3

C (Re)2

Gravity Settling Limiting Conditions

As with other fluid flow phenomena, the drag coefficient
reaches a limiting value at high Reynolds numbers.

Newtons LawFor relatively larger particles (approximately 1000 microns and larger) the gravity settling is described by Newtons law (Fig. 7-4). The limiting drag
coefficient is 0.44 at Reynolds numbers above about 500. Substituting C = 0.44 in Eq 7-1 produces the Newtons law equation expressed as:
g Dp
Vt

1.74

Eq 7-4

An upper limit to Newtons law is where the droplet size is

so large that it requires a terminal velocity of such
magnitude that excessive turbulence is created. The
maximum droplet
which can settle out can be determined by:
2
Eq 7-5
0.33
Dp

KCR

For the Newtons law region, the upper limit to Reynolds

number is 200,000 and KCR = 18.13.

Stokes LawAt low Reynolds numbers (less than 2), a

linear relationship exists between drag coefficient and the
Reynolds number (corresponding to laminar flow). Stokes law
applies in this case and Eq 7-1 can be expressed as:
2

Vt

1,488 g Dp
18

Eq 7-6

The droplet diameter corresponding to a Reynolds number

of 2 can be found using a value of 0.0080 for KCR in Eq 7-5.
The lower limit for Stokes law applicability is a droplet diameter of approximately 3 microns. The upper limit is about
100 microns.
A summary of these equations is presented in Fig. 7-4.

Coalescing
Very small droplets such as fog or mist cannot be separated
practically by gravity. These droplets can be coalesced to
form larger droplets that will settle by gravity. Coalescing
devices in separators force gas to follow a tortuous path. The
momen- tum of the droplets causes them to collide with other
droplets or the coalescing device, forming larger droplets.
These larger droplets can then settle out of the gas phase by
gravity. Wire mesh screens, vane elements, and filter
cartridges are typical examples of coalescing devices.

SEPARATOR DESIGN AND

CONSTRUCTION
Separators are
usually characterized as vertical,
horizontal, or spherical. Horizontal separators can be single
or double bar- rel and can be equipped with sumps or boots.

Parts of a Separator

advantage of the inertial effects of centrifugal force or an

abrupt change of direction to separate the major portion of
the liquid from the gas stream.
The secondary or gravity section, B, is designed to utilize
the force of gravity to enhance separation of entrained droplets. It consists of a portion of the vessel through which the
gas moves
at a
relatively low velocity with little
turbulence. In some designs, straightening vanes are used to
reduce turbu- lence. The vanes also act as droplet collectors,
and reduce the distance a droplet must fall to be removed from
the gas stream.
The coalescing section, C, utilizes a coalescer or mist extractor which can consist of a series of vanes, a knitted wire mesh
pad, or cyclonic passages. This section removes the very
small droplets of liquid from the gas by impingement on a
surface
where they coalesce. A typical liquid carryover from the mist
extractor is less than 0.1 gallon per MMscf.
The sump or liquid collection section, D, acts as receiver for
all liquid removed from the gas in the primary, secondary, and
coalescing sections. Depending on requirements, the liquid
section should have a certain amount of surge volume, for degassing or slug catching, over a minimum liquid level necesRegardless of shape, separation vessels usually contain
four major sections, plus the necessary controls. These
sections are shown for horizontal and vertical vessels in Fig.
7-5. The pri- mary separation section, A, is used to separate
the main por- tion of free liquid in the inlet stream. It
contains the inlet nozzle which may be tangential, or a
diverter baffle to take

sary for controls to function properly. Degassing may

require
a horizontal separator with a shallow liquid level while emulsion separation may also require higher temperature, higher
liquid level, and/or the addition of a surfactant.

Separator Configurations
Factors to be considered for separator configuration selection include:
How well will extraneous material (e.g. sand, mud, corrosion products) be handled?
How much plot space will be required?
Will the separator be too tall for transport if skidded?
Is there enough interface surface for three-phase separation (e.g. gas/hydrocarbon/glycol liquid)?
Can heating coils or sand jets be incorporated if required?
How much surface area is available for degassing of
sepa- rated liquid?
Must surges in liquid flow be handled without large
changes in level?

7-4

Is large liquid retention volume necessary?

Vertical Separators
Vertical separators, Fig. 7-6, are usually selected when the
gas-liquid ratio is high or total gas volumes are low. In the
vertical separator, the fluids enter the vessel striking a
divert- ing baffle which initiates primary separation. Liquid
removed by the inlet baffle falls to the bottom of the vessel.
The gas moves upward, usually passing through a mist
extractor to remove suspended mist, and then the "dry" gas
flows out. Liq- uid removed by the mist extractor is coalesced
into larger drop- lets which then fall through the gas to the
liquid reservoir in the bottom. The ability to handle liquid
slugs is typically ob- tained by increasing height. Level
control is not critical and liquid level can fluctuate several
inches without affecting op- erating efficiency. Mist
extractors can significantly reduce the required diameter of
vertical separators.
As an example of a vertical separator, consider a
compressor suction scrubber. In this service the vertical
separator:
Does not need significant liquid retention volume.

Gravity Settling Laws and Particle Characteristics

Newtons Law
C

0.44

g Dp

1.74

Vt

Dp

KCR

KCR

18.13

KCR

0.334

KCR

0.025

Intermediate Law
C
Vt

18.5 Re
0.71

3.54g

Dp
g

1.14

0.29

0.6

l
0.43

0.71

Stokes Law
C

24 Re
2

Vt

1488 g Dp

18

13

FIG. 7-7
FIG. 7-5

FIG. 7-6

Gas-Liquid Separators

Example Vertical Separator with Wire Mesh Mist Extractor

HORIZONTAL
Gas Outlet

Two Phase
Inlet

C
B
D

Liquid
Outlet

VERTICAL

Mesh
Pad

C
Gas
Outlet

Two Phase
Inlet

A
B

Dimensions may be influenced by instrument connection

requirements.

D
A - Primary Separation
B - Gravity Settling
C - Coalescing
D - Liquid Collecting

Vortex
Breaker

For small diameter separators ( 48" ID.) with high L/G inlet flow
ratios this dimension should be increased by as much as 50%.
May use syphon type drain to:

Liquid
Outlet

The liquid level responds quickly to any liquid that entersthus tripping an alarm or shutdown.
The separator occupies a small amount of plot space.

Horizontal Separators
Horizontal separators are most efficient where large volumes of total fluids and large amounts of dissolved gas are
present with the liquid. The greater liquid surface area in
this configuration provides optimum conditions for releasing
en- trapped gas. In the horizontal separator, Fig. 7-7, the
liquid which has been separated from the gas moves along
the bot- tom of the vessel to the liquid outlet. The gas and
liquid occupy their proportionate shares of shell crosssection. Increased slug
capacity is obtained through
shortened retention time and increased liquid level. Fig. 7-7
also illustrates the separa- tion of two liquid phases (glycol
and hydrocarbon). The denser glycol settles to the bottom
and is withdrawn through the "boot." The glycol level is
controlled by a conventional level control instrument.
In a double barrel separator, the liquids fall through connecting flow pipes into the external liquid reservoir below.
Slightly smaller vessels may be possible with the double
barrel horizontal separator where surge capacity establishes
the size of the lower liquid collection chamber.

A. reduce vortex possibility

B. reduce external piping that requires heating (freeze protection)

As an example of a horizontal separator consider a rich

amine flash tank. In this service:
There is relatively large liquid surge volume leading to
longer retention time (this allows more complete release
of the dissolved gas and, if necessary, surge volume for
the circulating system).
There is more surface area per liquid volume to aid in
more complete degassing.
The horizontal configuration would handle a foaming
liq- uid better than a vertical.
The liquid level responds slowly to changes in liquid inventory.

Spherical Separators
These separators are occasionally used for high pressure
service where compact size is desired and liquid volumes are
small. Fig. 7-8 is a schematic for an example spherical separator. Factors considered for a spherical separator are:
compactness;
limited liquid surge capacity;
minimum steel for a given pressure.

Example Horizontal Three-Phase Separator with Wire Mesh Mist Extractor

GAS/HYDROCARBON/GLYCOL
3-PHASE INLET
INLET
INLET
BAFFLE
BAFFLE

GAS

MIST EXTRACTOR

LIQUID
LEVEL
DV
LC
LC
INTERFACE
LEVEL

VORTEX
BREAKER
LIQUID HYDROCARBON

BOOT
A

SECTION A-A/

OVER-FLOW
BAFFLE

GLYCOL

FIG. 7-8
3

Example Spherical Separator

GAS OUTLET
MIST
EXTRACTOR
SECTION
PRESSURE
GAUGE

INLET

SECONDARY
SEPARATION
SECTION

LIQUID
LEVEL
CONTROL

LIQUID
PRIMARY
SEPARATION
SECTION

DRAIN

COLLECTION
SECTION

CONTROL
VALVE

LIQUID OUTLET

Courtesy American Petroleum Institute

GAS-LIQUID SEPARATOR DESIGN

FIG. 7-9
Typical K & C Factors for Sizing Woven Wire Demisters

Specifying Separators
Separator designers need to know pressure, temperature,
flow rates, and physical properties of the streams as well as
the degree of separation required. It is also prudent to define
if these conditions all occur at the same time or if there are
only certain combinations that can exist at any time. If
known, the type and amount of liquid should also be given,
and whether it is mist, free liquid, or slugs.
For example, a compressor suction scrubber designed for
70-150 MMscfd gas at 400-600 psig and 65-105F would require the separator manufacturer to offer a unit sized for the
worst conditions, i.e., 150 MMscfd at 400 psig and 105F.
But the real throughput of the compressor varies from 150
MMscfd at 600 psig, 105F to 70 MMscfd at 400 psig, 65F.
Because the high volume only occurs at the high pressure, a
smaller sepa- rator is acceptable. Conversely, a pipeline
separator could be just the opposite because of winter to
summer flow changes.

Basic Design Equations

Horizontal
Vertical
Spherical
Wet Steam
Most vapors under vacuum
Salt & Caustic Evaporators
Adjustment of K & C Factor
for Pressure - % of design
value15
Atmospheric
150 psi
300 psi
600 psi
1150 psi

Separators without mist extractors are designed for gravity

settling using Eq 7-1. Values for the drag coefficient are
given in Fig. 7-3 for spherical droplet particles. Typically the
sizing is based upon removal of 150 micron diameter
droplets.

Eq 7-7

Gm

Eq 7-8

Note that if both sides of Eq 7-7 are multiplied by gas density, it is identical to Eq 7-8 when:
C

3600 K

Eq 7-9

Some typical values of the separator sizing factors, K and

C, are given in Fig.7-9. Separators are sized using these
equa- tions to calculate vessel cross-sectional areas that
allow gas velocities at or below the gas velocities calculated
by Eq 7-7 or
7-8.
Horizontal separators greater than 10 ft. in length with mist
extractors are sized using Eqs 7-10 and 7-113. Horizontal
separators less than 10 ft. in length should use Eqs 7-7 and
7-8. In horizontal separators, the gas drag force does not directly oppose the gravitational settling force. The true
droplet
velocity is assumed to be the vector sum of the vertical
termi- nal velocity and the horizontal gas velocity. Hence,
the mini- mum length of the vessel is calculated by
assuming the time
for the gas to flow from the inlet to the outlet is the same as
the time for the droplet to fall from the top of the vessel to the
surface of the liquid. In calculating the gas capacity of horizontal separators, the cross-sectional area of that portion of
the vessel occupied by liquid (at maximum level) is
subtracted from
the total vessel cross-sectional area.

0.40 to 0.50
0.18 to 0.35
0.20 to 0.35
0.25
0.20
0.15

1440 to 1800
650 to 1260
720 to 1260
900
720
540

100
90
85
80
75

Typically use one-half of the above K or C values for

approximate sizing of vertical separators without wire
demisters
For compressor suction scrubbers and expander inlet
separators multiply K by 0.7 - 0.8

Vt

Gm

L
g

0.56

Eq 7-10

10

and the correlation developed by Souders and Brown2 to relate

vessel diameter to the velocity of rising vapors which will not
entrain sufficient liquid to cause excessive carryover:

C Factor
ft hr

For glycol and amine solutions, multiply K by 0.6 - 0.8

Most vertical separators that employ mist extractors are

sized using equations that are derived from Eq 7-1. The two
most common are the critical velocity equation:
Vt

K Factor
ft sec

Separator Type

10

0.56

Eq 7-11

Separators can be any length, but the ratio of seam-to-seam

length to the diameter of the vessel, L/Dv, is usually in the range of 2:1 to 4:1.

Frequently separators without mist extractors are sized

us- ing Eq 7-7 and 7-8 with a constant (K or C) of typically
one-half of that used for vessels with mist extractors.
Although com- bining the drag coefficient and other physical
properties into an empirical constant is unsound, it can be
justified since:
Selection of the droplet diameter (separation efficiency)
is arbitrary. Even if the diameter can be selected on a
rational basis, little information is available on the
mass distribution above and below the selected size.
Liquid droplets are not rigid spherical particles in dilute
concentration (unhindered settling).
Note: A number of the "separator" sizing equations given
only size the separation element (mist extractor, Eqs 7-7, 78,

7-8

7-10, 7-11, and vane separator, Eq 7-13): these equations do

not directly size the actual separator containment vessel.
Thus, for example, a 24 in. diameter wire mesh mist extractor might be installed in a 36 in. diameter vessel because the
liquid surge requirements dictated a larger vessel.

Separators without Mist Extractors

This is typically a horizontal vessel which utilizes gravity
as the sole mechanism for separating the liquid and gas
phases. Gas and liquid enter through the inlet nozzle and
are slowed to a velocity such that the liquid droplets can
fall out of the gas phase. The dry gas passes into the outlet
nozzle and the liquid is drained from the lower section of the
vessel.

Diameter, ft.
3.5
4.0
4.5
5.0

To design a separator without a mist extractor, the

minimum size diameter droplet to be removed must be set.
Typically this diameter is in the range of 150 to 2,000
microns (one micron is 10-4 cm or 0.00003937 inch).
The length of vessel required can then be calculated by assuming that the time for the gas to flow from inlet to outlet
is the same as the time for the liquid droplet of size Dp to
fall from the top of the vessel to the liquid surface. Eq 7-12
then relates the length of the separator to its diameter as a
function of this settling velocity
(assuming no liquid
retention):
4 QA
L
Eq 7-12
Vt Dv
If the separator is to be additionally used for liquid storage,
this must also be considered in sizing the vessel.
extractor) is required to handle 60 MMscfd of 0.75 specific
gravity gas (MW = 21.72) at a pressure of 500 psig and a temperature of 100F. Compressibility is 0.9, viscosity is 0.012 cp,
and liquid specific gravity is 0.50. It is desired to remove all
entrainment greater than 150 microns in diameter. No
liquid surge is required.
Gas density,

P MW
RTZ

514.7

10.73

2.07 lb ft

21.72
0.90

560

3
3

Liquid density,

0.5 62.4

31.2 lb ft
39.8 lb sec

Mass flow,

60 10 21.72
379 24 3600

150
Particle diameter,

0.00003937

Dp

0.000492 ft

12

From Eq 7-3,
C Re

0.95

108

0.95

10

3
g Dp
2

2.07

0.000492

0.012

31.2

2.07

4738
From Fig. 7-3, Drag coefficient, C = 1.40

Terminal velocity,

4 g Dp

Vt

4 32.2

0.212
Gas flow,

QA

M
g

Assume a diameter, Dv = 3.5 ft

Vessel length,

4 QA
Vt DV

l
C

0.000492 29.13
3 2.07 1.40
0.46 ft sec

39.80
2.07

19.2 ft sec
15.2 ft

Length, ft.
15.2
13.3
11.8
10.6

Usually vessels up through 24 in. diameter have nominal

pipe dimensions while larger vessels are rolled from plate
with
6 in. internal increments in diameter.
Example 7-2What size vertical separator without mist extractor is required to meet the conditions used in Example 7-1?
QA
19.2
41.7 ft2
Vt
0.46
Dv = 7.29 ft minimum; use 90 inch ID
A

Separators With Wire Mesh Mist Extractors

Wire mesh pads are frequently used as entrainment separators for the removal of very small liquid droplets and,
there- fore, a higher overall percentage removal of liquid.
Removal
of droplets down to 10 microns or smaller may be possible
with these pads. The pad is generally horizontal with the gas
and
entrained liquid passing vertically upward. Performance is
adversely affected if the pad is tilted more than 30 degrees
from the horizontal4. Liquid droplets impinge on the mesh
pad, coalesce, and fall downward through the rising gas
stream. Wire mesh pads are efficient only when the gas
stream velocity is low enough that re-entrainment of the
coalesced droplets does not occur. Figs. 7-10 and 7-11
illustrate a typical wire mesh installation in vertical and
horizontal vessels.
Eqs 7-7 and 7-10 define the maximum gas velocity as a
func- tion of the gas density and the liquid density. A value
for K can be found from Fig. 7-9. Firmly secure the top and
bottom of the pad so that it is not dislodged by high gas
flows, such as when a pressure relief valve lifts.
In plants where fouling or hydrate formation is possible or
expected, mesh pads are typically not used. In these services
vane or centrifugal type separators are generally more appropriate. Most installations will use a six inch thick pad with 9
to 12 lb/ft3 bulk density. Minimum recommended pad thickness is four inches4. Manufacturers should be contacted for
specific designs.
Wire meshispads
caninbeFig.
used
in horizontal
vessels.
A typical
installation
shown
7-11.
The preferred
orientation
of
the mesh pad is in the horizontal plane. When installed in a
vertical orientation, the pad is reported to be less efficient.
Problems have been encountered where liquid flow through
the pad to the sump is impaired due to dirt or sludge accumulation causing a higher liquid level on one side, providing the
serious potential of the pad being dislodged from its mounting
brackets making it useless, or forcing parts of it into the
outlet
pipe. The retaining frame must be designed to hold the mist
pad in place during emergency blowdown or other periods of
anticipated high vapor velocity.
4 19.2
0.46 3.5

The pressure drop across a wire

applicati
mesh pad is sufficiently low
ons. The
(usually less than an inch of water)
effect of
to be considered negligible for most
the
Other reasonable solutions are as follows:

pressure drop becomes significant only in the design of

vacuum services and for equip- ment where the prime mover
is a blower or a fan. Manufacturers should be contacted for specific information.

FIG. 7-10
Example Minimum Clearance Mesh Type Mist Eliminators

Nod

VAPOR OUT

Cm

Nod
MIST EXTRACTOR

Cm

45

45

TOP VAPOR OUTLET

VAPOR OUT
SUPPORT
RING

SIDE VAPOR OUTLET

WHERE:

MINIMUM EXTRACTOR CLEARANCE, Cm:

Cm = 0.707 X or

Mod

SUPPORT
RING

Mod = MIST EXTRACTOR OUTSIDE DIAMETER

Nod = NOZZLE OUTSIDE DIAMETER

Nod

FIG. 7-11
Horizontal Separator with Knitted Wire Mesh Pad Mist Extractor and Lower Liquid Barrel

PLAN

Inlet
Distributor

Alternate
Vapor Outlet

Knitted Wire
Mesh Pad

Vapor
Outlet

Two Phase Inlet

Liquid
Outlet

ELEVATION

Example 7-3 What size vertical separator equipped with a

wire mesh mist extractor is required for the conditions used
in Examples 7-1 and 7-2?
K

0.28 ft sec (from Fig. 7-9 for 500 psig)

Vt

0.28

QA
Vt

Dv

31.2

2.07
2.07

19.2
1.05

FIG. 7-12
Example Vertical Separator with Vane Type Mist Extractor

1.05 ft sec

18.3 ft

Inlet
Diverter

Vane Type

4.82 ft minimum ; use 60 in. ID vessel

Mist Extractor

Separators with Vane Type Mist Extractors

Vanes differ from wire mesh in that they do not drain the
separated liquid back through the rising gas stream. Rather,
the liquid can be routed into a downcomer, which carries the
fluid directly to the liquid reservoir. A vertical separator
with a typical vane mist extractor is shown in Fig. 7-12.
The vanes remove fluid from the gas stream by directing
the flow through a torturous path. A cross-section of a typical
vane unit is shown in Fig. 7-13. The liquid droplets, being
heavier than the gas, are subjected to inertial forces which
throw them against the walls of the vane. This fluid is then
drained by gravity from the vane elements into
a
downcomer.

Vapor
Outlet
Dv
Two-phase
Inlet
Downcomer

Vane type separators generally are considered to achieve

the same separation performance as wire mesh, with the
added advantage that they do not readily plug and can
often
be housed in
smaller vessels. As vane type
separators depend upon inertial forces for performance,
turndown can sometimes be a problem.
Vane type separator designs are proprietary and are not
eas- ily designed with standard equations. Manufacturers of
vane type separators should be consulted for detailed
designs of their specific
equipment. However, a gas
momentum equa- tion5 can
be used to estimate the
approximate face area of a vane type mist extractor similar
to that illustrated in Fig.
7-13.
J

gV t

20 lb ft

sec

Liquid Outlet

Eq 7-13

where gas velocity, Vt, is the velocity through the

extractor cross-section.

Separators with Centrifugal Elements

There are several types of centrifugal separators which
serve to separate solids as well as liquids from a gas stream.
These devices are proprietary and cannot be readily sized
without detailed knowledge of the characteristics of the specific internals. The manufacturer of such devices should be
consulted for assistance in sizing these types of separators.
Use care in selecting a unit as some styles are not suitable in
some applications. A typical centrifugal separator is shown in
Fig. 7-14. The main advantage of a centrifugal separator over
a filter (or filter separator) is that much less maintenance is
involved. Disadvantages of centrifugal separators are:
some designs do not handle slugs well,
efficiency is not as good as other types of separators,
pressure drop tends to be higher than vane or clean
knitted mesh mist extractors, and

FIG. 7-13
Cross Section of Example Vane Element Mist Extractor
Showing Corrugated Plates with Liquid Drainage Traps

Gas
Flow

Drainage
t
h

ey

have a narrow operating flow range for highest efficiency.

Traps

Assembly
Bolts

FIG. 7-14
Example Vertical Separator with Centrifugal Elements
VAPOR OUTLET

INLET
CLEAN OUT/
INSPECTION

LIQUID
OUTLET
Courtesy Peerless Manufacturing Co.

Filter Separators
General This type of separator has a higher separation
efficiency than the centrifugal separator, but it uses filter elements, which must periodically be replaced. An example filter
separator is shown in Fig. 7-15. Gas enters the inlet nozzle
and passes through the filter section where solid particles are
filtered from the gas stream and
liquid particles are
coalesced into larger droplets. These droplets pass through
the tube and are entrained into the second section of the
separator, where a final mist extraction element removes
these coalesced drop- lets from the gas stream.
The design of filter separators is proprietary and a manufacturer should be consulted for specific size and recommendations. The body size of a horizontal filter separator for a
typical application can be estimated by using 1.3 for the value
of K in Eq 7-7. This provides an approximate body diameter
for a unit designed to remove water (other variables such as
viscosity and surface tension enter into the actual size determination). Units designed for water will be smaller than
units sized to remove light hydrocarbons.
Example 7-4 A filter separator is required to handle a flow
of 60 MMscfd at conditions presented in Example 7-1. Estimate the diameter of a filter separator.
31.2
Vt

A
Dv

1.3

QA

Vt
2.2 ft

2.07
4.88 ft sec

2.07
19.2
4.88

3.93 ft

26.9 in. minimum

Use 30 inch ID separator.

In many cases the vessel size will be determined by the filtration section rather than the mist extraction section.
The

filter cartridges coalesce the liquid mist into droplets which

can be easily removed by the mist extractor section. A design
consideration commonly overlooked is the velocity out of
these filter tubes into the mist extraction section. If the
velocity is too high, the droplets will be sheared back into a
fine mist that will pass through the extractor element. A
maximum allow- able velocity for gas exiting the filter tube
attachment pipe can be estimated using the momentum Eq
7-13 with a value of
1250 for J. Light hydrocarbon liquids or low pressure gas
should be limited to even less than this value. No published
data can be cited since this information is proprietary with
each filter separator manufacturer.

Design The most common and efficient agglomerator is

composed of a tubular fiber glass filter pack which is capable
of holding the liquid particles through submicron sizes. Gas
flows into the top of the filter pack, passes through the elements and then travels out through the tubes. Small, dry
solid particles are retained in the filter elements and the
liquid coa- lesces
to form larger particles. Liquid
agglomerated in the fil- ter pack is then removed by a mist
extractor located near the gas outlet.
The approximate filter surface area for gas filters can be
estimated from Fig. 7-16. The figure is based on applications
such as molecular sieve dehydrator outlet gas filters. For
dirty gas service the estimated area should be increased by a
factor of two or three.
The efficiency of a filter separator largely depends on the
proper design of the filter pack, i.e., a minimum pressure
drop while retaining an acceptable extraction efficiency. A
pressure drop of approximately 1-2 psi is normal in a clean
filter sepa- rator. If excessive solid particles are present, it
may be neces- sary to clean or replace the filters at regular
intervals when a pressure drop in excess of 10 psi is
observed. However, as a rule, 25 psi is recommended as a
maximum as the cartridge units might otherwise collapse.
Removal of the filter pack is easily achieved by using a
quick-opening closure.
Various guarantees are available from filter separator
manufacturers such as one for 100 percent removal of liquid
droplets 8 microns and larger and 99.5 percent removal of
par- ticles in the 0.5-8 micron range. However, guarantees
for the performance of separators and filters are very difficult
to ver- ify in the field.
While most dry solid particles about ten microns and larger
are removable, the removal efficiency is about 99 percent for
particles below approximately ten microns.
For heavy liquid loads, or where free liquids are contained
in the inlet stream, a horizontal filter separator with a liquid
sump, which collects and dumps the inlet free-liquids separately from coalesced liquids, is often preferred.

LIQUID-LIQUID SEPARATOR DESIGN

Liquid-liquid separation may be divided into two broad
cate- gories of operation. The first is defined as "gravity
separation" where the two immiscible liquid phases separate
within the
vessel by the differences in density of the liquids. Sufficient
retention time must be provided in the separator to allow for
the gravity separation to take place. The second category is
defined as "coalescing separation." This is where small particles of one liquid phase must be separated or removed from a
large quantity of another liquid phase. Different types of internal construction of separators must be provided for each
type of liquid-liquid separation. The following principles of
de-

FIG. 7-15
Example Horizontal Filter-Separator

sign for liquid-liquid separation apply equally for horizontal

or vertical type separators. Horizontal vessels have some advantage over vertical ones for liquid-liquid separation, due to
the larger interface area available in the horizontal style,
and the shorter distance particles must travel to coalesce.
There are two factors which may prevent two liquid phases
from separating due to differences in specific gravity:
If droplet particles are so small they may be suspended
by Brownian movement. This is defined as a random motion which is greater than directed movement due to
gravity for particles less than 0.1 micron in diameter.
The droplets may carry electric charges due to dissolved
ions, and these charges can cause the droplets to repel
each other rather than coalesce into larger particles and
settle by gravity.
Effects due to Brownian movement are usually small and
proper chemical treatment will usually neutralize any
electric charges. Then settling becomes a function of gravity
and vis- cosity in accordance with Stokes law. The settling
velocity of spheres through a fluid is directly proportional to
the differ- ence in densities of the sphere and the fluid, and
inversely
proportional to the viscosity of the fluid and the square of the
diameter of the sphere (droplet), Eq 7-6. The liquid-liquid
separation capacity of separators may be determined8 from
Eqs 7-14 and 7-15 which were derived from Eq 7-6. Values of
C* are found in Fig. 7-17.

Vertical Vessels:
W cl

Shl

Sll

0.785 D v

Eq 7-14

Horizontal Vessels:
W cl

Shl

Sll Ll Hl

Eq 7-15

Since the droplet size of one liquid phase dispersed in another is usually unknown, it is simpler to size liquid-liquid
separation based on retention time of the liquid within the
separator vessel. For gravity separation of two liquid phases,
a large retention or quiet settling section is required in the
vessel. Good separation requires sufficient time to obtain an
equilibrium condition between the two liquid phases at the
temperature and pressure of separation. The liquid capacity
of a separator or the settling volume required can be determined10 from Eq 7-16 using the retention time give in Fig.
7-18.

W t

1440

Eq 7-16

The following example shows how to size a liquid-liquid

separator.

FIG. 7-16
Approximate Gas Filter Capacity

FIG. 7-17

Using the alternate method of design based on retention

time as shown in Eq 7-16 would give:

Values of C* Used in Eq 7-14, 7-15

U
Droplet Diameter,
Emulsion
Characteristic
Microns
Free liquids Loose
200
emulsion Moderate
150
emulsion
100
Tight emulsion
60

Constant9
C*
1100
619
275
99

FIG. 7-18
Typical Retention Times for Liquid/Liquid Separation
Retention
Time

Type of Separation

W t

1440

From Fig. 7-18, use 3 minutes retention time.

U
U

650 3
1440
1.35 42

1.35 bbl
56.7 gal

Assuming a 20" OD, 1480 psig working pressure, a vessel

would be made from 1.031" wall seamless pipe which holds
13.1 gal/ft. The small volume held in the bottom head can be
discounted in this size vessel. The shell height required for
the retention volume required would be:
Shell height

U
Vol ft

56.7
13.1

4.3 ft

Hydrocarbon/Water Separators
Above 35 API Hydrocarbon
Below 35 API Hydrocarbon
100F and above
80F
60F
Ethylene Glycol/Hydrocarbon Separators
(Cold Separators)11 14
Amine/Hydrocarbon Separators

3 to 5 min.
5 to 10 min.
10 to 20 min.
20 to 30 min.
20 to 60 min.
20 to 30 min.

11
11

Coalescers, Hydrocarbon/Water Separators

100F and above
80F
60F
Caustic/Propane
Caustic/Heavy Gasoline

5 to 10
10 to 20
20 to 30
30 to 45
30 to 90

min.
min.
min.
min.
min.

Example 7-5 Determine the size of a vertical separator to

handle 600 bpd of 55 API condensate and 50 bpd of produced
water. Assume the water particle size is 200 microns. Other
operating conditions are as follows:
Operating temperature = 80F
Operating pressure = 1000 psig
Water specific gravity = 1.01
Condensate viscosity = 0.55 cp @ 80F
Condensate specific gravity for 55 API = 0.76
From Eq 7-14
Wc l

Shl

Sll

0.785

Dv

From Fig. 7-17 for free liquids with water particle diameter =
200 microns, C* = 1100.

600 bbl d ay

1100

1.01

0.76 0.785

0.55

600
Dv

392.5

1.53 ft2

Dv

This would require a 20" OD x 10 separator to give sufficient surge room above the liquid settling section for any vapor-liquid separation.
Another parameter that should be checked when
separating amine or glycol from liquid hydrocarbons is the
interface area between the two liquid layers. This area
should be sized so the glycol or amine flow across the
interface does not exceed ap- proximately 2000 gallons per
day per square foot.
The above example indicates that a relatively small separator would be required for liquid-liquid separation. It should
be remembered that the separator must also be designed for
the vapor capacity to be handled. In most cases of high
vapor-liq- uid loadings that are encountered in gas processing
equipment design, the vapor capacity required will dictate a
much larger vessel than would be required for the liquid
load only. The properly designed vessel has to be able to
handle both the va- por and liquid loads. Therefore, one or
the other will control the size of the vessel used.

PARTICULATE REMOVALFILTRATION
Filtration, in the strictest sense, applies only to the separation of solid particles from a fluid by passage through a porous
medium. However, in the gas processing industry, filtration
commonly refers to the removal of solids and liquids from a
gas stream.
The most commonly used pressure filter in the gas processing industry is the cartridge filter. Cartridge filters are constructed of either a self-supporting filter medium or a filter
medium attached to a support core. Depending on the application, a number of filter elements is fitted into a filter
vessel. Flow is normally from the outside, through the filter
element,
and out through a common discharge. When pores in the filter
medium become blocked, or as the filter cake is developed,
the higher differential pressure across the elements indicates
that
the filter elements must be cleaned or replaced.
Cartridge filters are commonly used to remove solid contaminants from amines, glycols, and lube oils. Other uses include the filtration of solids and liquids from hydrocarbon
vapors and the filtration of solids from air intakes of engines
and turbine combustion chambers.

Dv

1.24 ft

Using a manufacturers standard size vessel might result

in specifying a 20" OD separator.

Two other types of pressure filters which also have applications in the gas processing industry include the edge and
pre- coat filter. Edge filters consist of nested metallic
discs,

enclosed in a pressure cylinder, which are exposed to liquid

flow. The spacing between the metal discs determines the
sol- ids retention. Some edge filters feature a self-cleaning
design in which the discs rotate against stationary cleaning
blades. Applications for edge filters include lube oil and
diesel fuel filtration as well as treating solvent.
Precoat filters find use in the gas processing industry; however, they are complicated and require considerable
attention. Most frequent use is in larger amine plants
where frequent replacement of cartridge elements is
considerably more expen- sive than the additional attention
required by precoat filters.
The precoat filter consists of a coarse filter medium over
which a coating has been deposited. In many applications, the
coating is one of the various grades of diatomaceous earth
which is mixed in a slurry and deposited on the filter
medium. During operation additional coating material is
often added continuously to the liquid feed. When the
pressure drop across the filter reaches a specified maximum,
the filter is taken off- line and back-washed to remove the
spent coating and accu- mulated solids. Applications for
precoat filters include water treatment for waterflood
facilities as well as amine filtration to reduce foaming.
Typical designs for amine plants use 12 gpm flow per square foot of filter surface area. Sizes range
upward from 10-20 percent of full stream rates7.

8.

Sivalls, C. R., Technical Bulletin No. 133, Sivalls, Inc., 1979,

Odessa, Texas.

9. American Petroleum Institute, Manual on Disposal of Refinery

Wastes, Vol. 1, 6th ed., 1959, p. 18-20, and private industry data.
10.

Sivalls, C. R., "Fundamentals of Oil & Gas Separation," Proceedings Gas Conditioning Conference, 1977, University of Oklahoma, p. P-1 to P-31.

11.

Sivalls, C. R., Technical Bulletin No. 142, Sivalls, Inc., 1980,

Odessa, Texas.

12.

Perry, Robert H., Editor, Chemical Engineers Handbook, 3rd

Edi- tion, McGraw-Hill Book Company, 1950, p. 1019.

13.

API, RP 521, "Guide for Pressure Relieving and Depressuring

Systems," Second Edition, Sept. 1982, p. 52.

14.

Pearce, R. L., and Arnold, J. L., "Glycol-Hydrocarbon

Separation
Variables,"
Proceedings
Gas
Conditioning
Conference, University of Oklahoma, 1964.

15.

Fabian, P., Cusack, R., Hennessey, P., Neuman, M.,

"Demystify- ing the Selection of Mist Eliminators, Part I,"
Chemical Engineer- ing, Nov. 1993.

BIBLIOGRAPHY
1. Schweitzer, Phillip A., Handbook of Separation Techniques for
Chemical Engineers, McGraw-Hill, 1979.
2.

Perry, John H., Editor, Chemical Engineers Handbook,

Third Edition, Section 15, Dust and Mist Collection by C. E.
Lapple, McGraw-Hill, New York, 1950, p. 1013-1050.

3.

Groft, B. C., Holder, W. A., and Granic, E. D., Jr., Well Design
Drilling and Production, Prentice-Hall Inc., Englewood
Cliffs, N.J., 1962, p. 467.

4.

Perry, Dunham, Jr., "What You Should Know About Filters,"

Hy- drocarbon Processing, V. 45, No. 4, April 1966, p. 145-148.

REFERENCES
1.

Perry, Robert H., Editor, Chemical Engineers Handbook, 5th

Edi- tion, McGraw-Hill Book Company, 1973, Chapter 5, p. 564.

2.

Souders, Mott, Jr., and Brown, George G., "Design of

Fractionat- ing ColumnsEntrainment and Capacity,"
Industrial and Engi- neering Chemistry, V. 26, No. 1, January
1934, p. 98.

5. Dickey, G. D., Filtration, Reinhold Publishing Corporation, New

York, 1981.

3. American Petroleum Institute, Spec. 12J: Oil and Gas Separators, 5th Ed., January 1982.

6. Gerunda, Arthur, "How To Size Liquid-Vapor Separators,"

Chemical Engineering, V. 91, No. 7, May 4, 1981, p. 81-84.

4.

Reid, Laurance S., "Sizing Vapor Liquid Separators,"

Proceedings Gas Conditioning Conference, University of
Oklahoma, 1980, p. J-1 to J-13.

5. Product Bulletin 24000-4-2, Peerless Manufacturing Company,

Dallas, Texas.
6. Sarma, Hiren, "How to Size Gas Scrubbers," Hydrocarbon Processing, V. 60, No. 9, September 1981, p. 251-255.
7. Paper presented by W. L. Scheirman "Diethanol Amine Solution
Filtering and Reclaiming in Gas
Treating Plants,"
Proceedings Gas Conditioning Conference, 1973, University of
Oklahoma.

7. Ludwig, Ernest E., "Applied Process Design for Chemical and

Petrochemical Plants," Gulf Publishing Co., Houston, Texas,
1964, V. 1, p. 126-159.
8. York, Otto H., "Performance of Wire Mesh Demisters," Chemical
Engineering Progress, V. 50, No. 8, Aug. 1954, p. 421-424.
9.

York, Otto H., and Poppele, E. W., "Wire Mesh Mist

Eliminators," Chemical Engineering Progress, V. 59, No. 6,
June 1963, p. 4550.