Natco presentation about produced waterFull description
Another reference material for pollution designer.
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study for heavy crude oil desalting with different delsalter technology.
Design av demistere for
eparas ons e no og , Presenter: Dag Kvamsdal
Overview toda s
resentation
• Typi Typica call sepa separa rati tion on per perfo form rman ance ce req requi uire reme ment nt of of demisters • • Test Testin ing g of of dem demis iste ters rs in labo labora rato tory ry • What What will will affe affect ct the the dem demis iste terr per perfo form rman ance ce • Natc Natco o Nor Norwa way y foc focus us for for new new deve develo lopm pmen entt of of demisters and scrubber internals
Demisters in a
rocess s stem
Primary Separators Gas scrubbers Contactor towers
Demisters used in scrubbers and separators xamp es Vanepack
Demisting c yclones
Separators
Single stage scrubber
Two types of demisters discussed Axial flow cyclones and vane packs
Suited for low-mid ressure a lication and low gas loading
Axial flow cyclones Suited for high pressure demisting
Process conditions Operating temperature Gas actual flow rate Gas actual d ensity Gas actual viscosit Hydrocarbon liquid flow rate Oil actual density Hydrocarbon surf ace tension Oil actual viscosity Water flow rate Water actual densit y Water actual viscosit y Liquid fraction
Efficiency limitations for scrubbers Operational envelope LCO<0.1 gal/MMSCF
The scrubbers using inlet vanes will have a limitation around k=0.15 m/s to 0.20 m/s due to the rapid increase in liquid to
.
> 0.1 gal/MMSCF
.
o i t c a r f e m 1.0 % l o v d i u q i L 0.5 %
Increasing Pressure
< 0.1 gal/MMSCF 0.0 %
k‐value m s
Options for demister testing The Natco axial flow cyclone has been tested at the following labs
r wa er a ora ory Functional testing of a full axial flow cyclone box
Test pressure 1-5 barg
a co a ora ory Testing of individual demisters and demister sections
ea
u
a ora ory
For instance StatoilHydro Klab.
Model fluids and possibility to run gas 3
Real fluids, Full size test sections and up to 150 bar
Testing high pressure demisters Real world vs laboratory conditions
Real world 10
1
Gas density [kg/m3] 100
Real world
ur ace ens on
10
1
100
Demisters -
-
-
r wa er Natco Norway Laboratory
Scrubbers
Diameter [m]
gm
Separation efficiency for a demister Differences from lab to real conditions axial flow cyclones
Test data
100.0 % 99.5 % 99.0 % 98.5 % y c n e i c i f f E
separation efficiency, nothing to learn!
98.0 % 97.5 % Real fluids
.
Model fluids
96.5 %
Air water
96.0 % 95.5 % 50 %
70 %
90 %
Flow [‐]
110 %
Model fluids gives reduced efficiency and it is possible to evaluate the eometr Real fluids gives considerably lower efficiency
Flow mechanisms in a demister
Droplet break up
Droplet transportation
Wall interaction
CFD challen e for demister e ui ment •
Why cannot CFD replace testing all together •
Limited computer capacity allows sets an upper limitation of the length scales that can be resolved
•
CFD can only resolve the length < 1000 nodes in 3 dimension total nodes 10003 = 109
The challenge of CFD; it is all about scales
Turbulence
Droplets 10-6
10-5
Len th m 10-4 CFD resol ved
10-3
10-2
10-1 CFD resol ved
10-0
CFD ability to capture the flow field RANS calculations Time averaged solution that in many ways do not visualize the real flow pattern in the vanepack
LES calculations Able to calculate the main flow structures and the general flow pattern qualitative correct Calculation 15 000 ours us ng 7 000 000 cells
Multiphase flow Including; droplet break up, coalescence and wall film model
Flow in a vane ack as filmed in the laborator
as
ens y
gm
Flow in the vane ack slow motion
Gas density 60 kg/m3
Efficiency vane pack As tested in the Natco laboratory 100 %
Vane pack efficiency
98 % 97 %
y c n e i c i f f E
96 %
. gas densities up to 60 kg/m3
95 % 94 % 93 %
Increasing density
.
92 % 91 % 90 %
K‐value [m/s] 100 % 98 % 96 % y c n e i c i f f e n o i t a r a p e S
94 %
Vane pack
92 %
Cyclones
Vane ack efficienc compared to axial flow cyclones
90 % 88 %
The axial flow cyclones can handle considerably higher flow without loss of performance
86 % 84 %
80 %
K‐value [m/s]
Develo ment of scrubber internals
– New generation of axial flow cyclones • Should achive 10 times or more better performance than the existing axial flow cyclones • mpor an or one s age n ne so u ons as we as pressure scrubbers
g
– • Should give 99% or better efficiency for a k-value in the . .
Next generation axial flow cyclones Operational envelope LCO<0.1 gal/MMSCF
Improved axial flow cyclones where the efficiency is improved with a factor of 10 compared with The maximum k value to achieve 0.1 gal/MMSCF will be as shown 2.0 %
> 0.1 gal/MMSCF o 1.5 % i t c a r f e m 1.0 % l o v d i u q 0.5 % i L
Increasing Pressure
< 0.1 gal/MMSCF 0.0 %
k‐value [m/s]
Design of Gas Scrubbers Inlet devices
Inlet Vane Diffuser
Inlet Cyclone Distributor
Swirl Inlet
Statoil’s SPINLET
Efficienc
for new t
Key for further scrubber development is to manage to remove 99% or more of the droplet in ~ .
