Natural Gas

Separators

Omar Mohammed Q.
University of Mosul

Collage of Petroleum Engineering and Mining

Petroleum Reservoir Engineering Department

By Under Graduated Third Stage

Omar Mohammed Qambar

Natural Gas Separators

Types, Classification,
Application, and Terminology

The author thanks Zainab H. for her overwork with the students to provide the best scientific material to
them.

No part of this article may be used or reproduced in any manner whatsoever without written permission of
the author except in the case of brief quotations embodied in critical articles and reviews. For information
attach with the author by Emil: [email protected]

This article was written by Omar M. Q. in June, 2020 after it was asked from Zainab Hazim to write on
this subject, for evaluate the students as a part of the degree of the final exam.

Omar Mohammed Q.
 Natural Gas Separators
Introduction
The separator is a device used to separate entrained gas from production liquids. Surface

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processing facilities (Figure 1) generally use gas separators to render the liquids safe for further
processing or disposal. Gas-separation equipment is also used in downhole applications, such as
the protection of pumping equipment against gas lock by separating and redirecting free gas at the
pump suction or inlet (Schlumberger Oil Field Glossary).
Separation of oil and gas is a critical field processing operation. As producing pressure is
increased and lighter condensates are produced, efficient separation has become more critical than
ever. Moreover, some of the new concepts in separation technology have been applied to
advantage on old lease producing oil at moderate or low pressures. As gas transmission lines raise
their standards, separation becomes a part of the overall field processing necessary to condition
the gas. Several technologies are available to remove liquids and solids from gases. However,
selecting gas/liquid separation technologies requires not only knowledge of the process
conditions, but a knowledge of the characteristics of the liquid contaminants. Selection should be
made based on the droplet size, concentration, and whether the liquid has waxing or fouling
tendencies (Brown et al., 1994).
Before evaluating specific technologies, it is important to understand the mechanisms used to
remove liquids and solids from gases. Three principles used to achieve physical separation of gas
and liquids or solids are momentum, gravity settling, and coalescing. Any separator may employ
one or more of these principles; however, the fluid phases must be immiscible and have different
densities for separation to occur. Momentum force is utilized by changing the direction of flow
and is usually employed for bulk separation of the fluid phases. The gravitational force is utilized
by reducing velocity so the liquid droplets can settle out in the space provided. Gravity segregation
is the main force that accomplishes the separation, which means the heaviest fluid settles to the
bottom and the lightest fluid rises to the top. However, very small droplets such as mist cannot be
separated practically by gravity. These droplets can be coalesced to form larger droplets that will
settle by gravity (Saeid Mokhatab et al,. 2006).
Raw natural gas after transmission through the field-gathering network must be processed
before it can be moved into long-distance pipeline systems for use by consumers. The objective
of gas processing is to separate natural gas, condensate, noncondensable, acid gases, and water
from a gas-producing well and condition these fluids for sale or disposal. The typical process
operation modules are shown in Figure 2 (Saeid Mokhatab et al,. 2006).
Separators are used in many other locations other than wellhead production batteries, such as
gasoline plants, upstream and downstream of compressors, and liquid traps in gas transmission
lines. They are also found on inlets to dehydration units, gas sweetening units, et cetera. At some
of these locations’ separators are referred to as knockouts, free liquid knockouts, and traps.
Sometimes these vessels are called scrubbers. Caution should be used when referring to a vessel
required for gas/liquid separation as a scrubber. Within the gas industry there is another type of
vessel often called a scrubber. This is one that is designed to handle a gas stream with only trace
amounts of free liquid present in the gas. They are not designed using the same criteria as is used

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 Natural Gas Separators
for gas/liquid separation where appreciable amounts of liquid are present or where liquid slugging
maybe encountered.

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In this article we will not discuss the separators design we will focus on the major separator

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types, benefits, out shape, and terminology.

Figure 1
Typical gas production process system (from William, et al,. 2010).

Figure 2
Simplified typical onshore treatment process (Saeid Mokhatab et al,. 2006).

Processing Objectives
If the natural gas is transportated by pipeline, the processing installation must be designed to meet
either transport or final specifications. Processing of a gas stream may have one of the following
three basic objectives (Odello, 1981; Rojey et al., 1997).
• To produce a sales gas stream that meets specifications of the type shown in Table 4-1.
These specifications are mainly intended to meet pipeline requirements and the needs of
industrial and domestic consumers.

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 Natural Gas Separators
• To maximize NGLs production by producing a lean gas stripped of most of the
hydrocarbons other than methane.
•

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To deliver a commercial gas. Such gas must be distinguished by a certain range of gross

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heating value lying.

Table 1
Natural Gas Specifications in the Salable Gas Stream (Goar and Arrington, 1978)

Characteristic Specification
Water content 4–7 lb/MMscf (max)
Hydrogen sulfide content 1/4 grain/100 scf (max)
Gross heating value 950 Btu/scf (min)
Hydrocarbon dew point 15◦F at 800 psig (max)
Mercaptan content 0.2 grain/100 scf (max)
Total sulfur content 1–5 grain/100 scf (max)
Carbon dioxide content 1–3 mole percent (max)
Oxygen content 0–0.4 mole percent (max)
Sand, dust, gums, and free liquid Commercially free.
Typical delivery temperature 120◦F
Typical delivery pressure 714.7 psia

Effect of Gas Type in Field Processing

The gas composition of the field is the most important issue in choosing a processing scheme.
In other words, depending on the type of reservoir and the composition of the produced gas, the
gas processing plant may contain extensive facilities for the processing of the associated
liquefiable hydrocarbons. Typically, associated gas is very rich in liquefiable hydrocarbons and
must undergo NGL and condensate recovery to meet hydrocarbon dew point or minimum heating
value requirements. The gas processing scheme will also be dictated by the format of the sales
contract and its specifications. The contract may be totally different for each customer depending
on the composition and amount of gas, plant recoveries, and the contractual preferences of the
customer (Bullin and Hall, 2000).

Separation process
The process can be described as:
• Two phase separation, or
• Three phase separation
The phases referred to are oil, water and gas. In two phase separation, gas is removed from
total liquid (oil plus water). In three phase separation, however, in addition to the removal of gas
from liquids, the oil and water are separated from each other. Figure 3 shows the difference
between 2 and 3 phase separation.

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 Natural Gas Separators

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Figure 3
The Difference between 2 & 3 Phase Separation.

Nomenclature of Separating Pressure Vessels

Pressure vessels in the oilfield are used for separating well fluids produced from oil and gas
wells into the gaseous and liquid components. Vessels are separated into two groups by the
American Society of Metallurgical Engineering (ASME), the “governing” body of pressure vessel
standards and codes [7]. These are low-pressure, less than or equal to 125 psig, or high-pressure,
greater than 125 psig. Some of the more common types of vessels (from William, et al,. 2010)
used for separation in oil and gas production are:
• 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, line drips,
and descanters. The design of these vessels may be either low or high pressure.
• Scrubber or Gas Knockout—a vessel designed to handle streams of high gas/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 scrubber and
knockout are used interchangeably. Typically, these are high-pressure vessels.
• Three–Phase Separator—a vessel used to separate gas and two immiscible liquids of
different densities (e.g., gas, oil, and water). Typically, these vessels are low pressure but
can just as easily be designed for high pressures.
• Liquid-Liquid Separator or Free Water Knockout—two immiscible liquid phases can be
separated using the same principles as for gas and liquid separators. These vessels are
designed to operate at much lower
velocities and pressures than the gas-liquid separators; they are designed to take advantage
of the physical properties of the liquids, and in as much vertical vessels may be more
effective than horizontal.
• Filter Separator—These separators usually have two compartments. The first 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

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 Natural Gas Separators
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

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mesh mist extractor) where the larger droplets are removed. A lower barrel or boot may

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be used for surge or storage of the removed liquid.
• Line Drip—Typically used in pipelines with very high gas/liquid ratios to remove only
free liquid from the gas stream and not necessarily all the liquid from a gas stream. Line
drips provide a place for free liquids to separate and accumulate. Typically, these are high-
pressure vessels.
• Slug Catcher—A separator, which is designed to absorb sustained inflow of large liquid
volumes at irregular intervals. Usually found on gas gathering systems or other two-phase
pipeline systems. A slug catcher may be a single large vessel or a manifold system of pipes.
Typically, these are high-pressure vessels.
• Flash Tank (Chamber, Trap, or Vessel)—A conventional oil and gas separator operated
at low pressure, with the liquid from a higher-pressure separator being “flashed” into it.
This flash chamber is quite often the second or third stage of separation, with the liquid
being discharged from the flash chamber to storage.
• Expansion Vessel—A first-stage separator on a low-temperature or cold separation unit.
This vessel may be equipped with a heating core to melt hydrates, or a hydrate-preventative
liquid (such as glycol) may be injected into the well fluid just before expansion into this
vessel.
• Desanders—A high-pressure vessel that is installed on some gas wells to “catch” any sand
that is produced along with the gas. This sand may be from a frac job, or it may be from
the formation. The pressure drop at the desander allows the majority of this sand to drop
out at a controlled location rather than in the lines, at measurement points, or in production
equipment.

Gas–liquid separators in oil and gas processing

Gas–liquid separator types often used in oil and gas processes are:
• Conventional gas/liquid separators.
• Cyclones.
• Oil/gas separators.
• Flare knock-out drums.
• Filter separators.
Figure 4 shows a summary of different types of mechanical separators (in this article we will not
talk about liquid-liquid and solid-liquid separation).
❖ Separation principles
Gas–liquid separation processes most frequently employed in oil, gas, and petrochemical
(OGP) industries are based on either one or a combination of gravity settling, impingement, and
centrifugation principles. Some types of filtration are seldom employed in this field. Note that as
a general rule, mechanical separation occurs only when the phases are immiscible and/or have
different densities (Alireza Bahadori, et al,. 2014).

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 Natural Gas Separators

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Figure 4
Types of mechanical separators (Alireza Bahadori, et al,. 2014)

❖ Mechanical separation by momentum

Fluid phases with different densities will have different momentum. If a two-phase stream
changes direction sharply, greater momentum will not allow the particles of heavier phase to turn
as rapidly as the lighter fluid, so separation occurs. Momentum is usually employed for bulk
separation of the two phases in a stream (Alireza Bahadori, et al,. 2014).

Omar Mohammed Q.
 Natural Gas Separators
❖ Mechanical separation by gravity
Liquid droplets or solid particles will settle out of a gas phase if the gravitational force acting

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on the droplet or particle is greater than the drag force of the gas flowing around the droplet or

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particle. The same phenomenon happens for solid particles in liquid phase and immiscible spheres
of a liquid immersed in another liquid. Rising of a light bubble of liquid or gas in a liquid phase
also follows the same rules, i.e., results from the action of gravitational force (Alireza Bahadori, et
al,. 2014).

❖ Mechanical separation by filtration

Filtration is the separation of a fluid-solid mixture involving passage of most of the fluid
through a porous barrier that retains most of the solid particulates contained in the mixture.
Filtration processes can be divided into three broad categories: cake filtration, depth filtration, and
surface filtration (Alireza Bahadori, et al,. 2014).
❖ General notes on separator piping
Piping to and from the separator must interfere as little as possible with the good working of
the separator. The following constraints should be observed:

1- There should be no valves, pipe expansions, or contractions within 10 pipe diameters of

the inlet nozzle.
2- There should be no bends within 10 pipe diameters of the inlet nozzle except the
following:
a. For knock-out drums and demisters, a bend in the feed pipe is permitted if this is
in a vertical plane through the axis of the feed nozzle.
b. For cyclones a bend in the feed pipe is permitted if this is in a horizontal plane
and the curvature is in the same direction as the cyclone vortex.
3- If desired, a pipe reducer may be used in the vapor line leading from the separator, but it
should be no nearer to the top of the vessel than twice the outlet pipe diameter.
If these conditions cannot be complied with, some loss of efficiency will result.
If a valve in the feed line near to the separator cannot be avoided, it should preferably be of
the gate or ball type fully open in normal operation. High pressure drops that cause flashing and
atomization should be avoided in the feed pipe. If a pressure-reducing valve in the feed pipe
cannot be avoided, it should be located as far upstream of the vessel as practicable (Alireza
Bahadori, et al,. 2014)

Conventional gas–liquid separators

Conventional gas–liquid separators are usually characterized as vertical, horizontal, or
spherical. Horizontal separators can be single or double barrel and can be equipped with sumps or
boots. They may be further classified as two-phase (gas–liquid) or three-phase (gas–liquid–
liquid). Horizontal separators can be single- or double-barrel and can be equipped with sumps or
boots.

Omar Mohammed Q.
 Natural Gas Separators
Regardless of shape, separation vessels usually contain four major sections plus the necessary
controls. These sections are shown for horizontal and vertical vessels in Figure 5.

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As shown in Figure 5, the inlet device (A) is used to reduce the momentum of the inlet flow

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stream, perform an initial bulk separation of the gas and liquid phases, and enhance gas flow
distribution. There are a variety of inlet devices available (Alireza Bahadori, et al,. 2014).

Figure 5
Gas-liquid separators (GPSA
2004)

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 Natural Gas Separators
The gas gravity separation section (B) is designed to utilize the force of gravity to separate
entrained liquid droplets from the gas phase, preconditioning the gas for final polishing by the

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mist extractor. It consists of a portion of the vessel through which the gas moves at a relatively

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low velocity with little turbulence. In some horizontal designs, straightening vanes are used to
reduce turbulence. The vanes also act as droplet coalescers, which reduces the horizontal length
required for droplet removal from the gas stream (GPSA 2004).
The liquid gravity separation section (C) acts as a receiver for all liquid removed from the gas
in the inlet, gas gravity, and mist extraction sections. In two-phase separation applications, the
liquid gravity separation section provides residence time for degassing the liquid. In three-phase
separation applications, the liquid gravity section also provides residence time to allow for
separation of water droplets from a lighter hydrocarbon liquid phase and vice versa. Depending
on the inlet flow characteristics, the liquid section should have a certain amount of surge
volume, or slug catching capacity, to smooth out the flow passed on to downstream equipment
or processes (GPSA 2004).
Efficient degassing may require a horizontal separator while emulsion separation may also
require higher temperature, use of electrostatic fields, and/or the addition of a demulsifier.
Coalescing packs are sometimes used to promote hydrocarbon liquid-water separation, though
they should not be used in applications that are prone to plugging, e.g., wax, sand (Alireza
Bahadori, et al,. 2014).
The mist extraction section (D) utilizes a mist extractor that can consist of a knitted wire
mesh pad, a series of vanes, or cyclone tubes. This section removes the very small droplets of
liquid from the gas by impingement on a surface where they coalesce into larger droplets or
liquid films, enabling separation from the gas phase. Quoted liquid carryover from the various
types of mist extraction devices are usually in the range of 0.01–0.13 m3/Mm3 (GPSA 2004).
❖ Vertical separators
Vertical separators (see Figures 6 and 7) are selected when the gas–liquid ratio is high. In
cases where there is a frequent fluctuation in inlet liquid flow or where revaporization or
remixing of fluids in the vessel should be prevented, vertical separators are preferred.

A vertical separator, shown in Figure 8, is usually selected when the gas–liquid ratio is high
or total gas volumes are low. In a vertical separator, the fluids enter the vessel through an inlet
device whose primary objectives are to achieve efficient bulk separation of liquid from the gas
and to improve flow distribution of both phases through the separator. Liquid removed by the
inlet device is directed to the bottom of the vessel (Alireza Bahadori, et al,. 2014).
The gas moves upward, usually passing through a mist extractor to remove any small
entrained liquid droplets, and then the vapor phase flows out of the vessel. Liquid removed by
the mist extractor is coalesced into larger droplets that then fall through the gas to the liquid
reservoir in the bottom (GSPA 2004).

The ability to handle liquid slugs is typically obtained by increasing vessel height to
accommodate additional surge volume. Level control is normally not highly critical, and liquid

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 Natural Gas Separators
level can fluctuate several inches without affecting the separation performance or capacity of the
vessel. Except for knockout drum applications, mist extractors are normally used to achieve a

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low liquid content in the separated gas in vessels of reasonable diameter (GSPA 2004).

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Figure 6
A vertical separator (Alireza Bahadori, et al,.
2014).

Figure 7
A vertical separator schematic
(Alireza Bahadori, et al,. 2014).

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 Natural Gas Separators

Figure 8

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Vertical separator with wire

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mesh mist extractor (GPSA
2004).

Typical vertical separator length over diameter (L/D) ratios are normally in the two to four
range. As an example of a vertical separator, consider a compressor suction scrubber (Alireza
Bahadori, et al,. 2014).
. In this service, the vertical separator:
• Does not need significant liquid retention volume
• Has a properly designed liquid level control loop that responds quickly to any liquid that
enters, thus avoiding tripping an alarm or shutdown
• Occupies a small amount of plot space

❖ Horizontal separators
Horizontal separators (see Figure 9) are used where large volumes of total fluids and large
amounts of dissolved gas are present with the liquid. They are also preferred where the vapor–
liquid ratio is small or where three-phase separation is required.
In cases where limitations exist in vessel size, a double barrel separator can be employed.
Horizontal separators are most efficient when large volumes of liquid are involved. They are
also generally preferred for three-phase separation applications. In a horizontal separator, shown
in Figure 10, the liquid that has been separated from the gas moves along the bottom of the vessel
to the liquid outlet (Alireza Bahadori, et al,. 2014).

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 Natural Gas Separators
As we maintained above there are two types of horizontal separators and these types are:
The gas and liquid occupy their proportionate shares of the shell cross-section. Increased slug

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capacity is obtained through shortened retention time and increased liquid level (GPSA 2004).
Figure 10 also illustrates the separation of two liquid phases (glycol and hydrocarbon). The

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denser glycol settles to the bottom and is withdrawn through the boot. The glycol level is
controlled by an interface level control instrument. Horizontal separators have certain advantages
with respect to gravity separation performance in that the liquid droplets or gas bubbles are moving
perpendicular to the bulk phase velocity, rather than directly against it as in vertical flow, which
makes separation easier.

Figure 9
Horizontal separator schematic (Alireza Bahadori, et al,. 2014).

Figure 10
Horizontal separator schematic (Alireza Bahadori, et al,. 2014).

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 Natural Gas Separators
1- Horizontal Single Tube
The horizontal separator (Figure 11) may be the best separator for the money. The horizontal

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separator has a much greater gas-liquid interface area consisting of a large, long, baffled gas-

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separation section that permits much higher gas velocities. This type of separator is easier to skid-
mount and service and requires less piping for field connections and a smaller diameter for a given
gas capacity. Several separators can be stacked easily into stage-separation assemblies,
minimizing space requirements (Chi U. Ikoku, et al,.1992).
In operation, gas flows horizontally and, at the same time, falls toward the liquid surface. The
gas flows in the baffle surfaces and forms a liquid film that is drained away to the liquid section
of the separator. The baffles need only be longer than the distance of liquid trajectory travel at the
design gas velocity. The liquid level control placement is more critical than in a vertical separator,
and surge space is somewhat limited. Horizontal separators are almost always used for high gas-
oil ratio well streams, for foaming well streams, or for liquid-from-liquid separation (Chi U. Ikoku,
et al,.1992).

Figure 11
Conventional horizontal separator (Courtesy Petroleum Extension Service,)
2- Horizontal Double Tube
A horizontal double-tube or double-barrel separator (Figure 12) has all the advantages of a normal
horizontal separator plus a much higher liquid capacity. Incoming free liquid is immediately
drained away from the upper section into the lower section. The upper section is filled with baffles,
and gas flow is straight through and at higher velocities (Chi U. Ikoku, et al,.1992).

Figure 12
Conventional horizontal double-barrel separator. (Courtesy Petroleum Extension Service.)

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 Natural Gas Separators
❖ Spherical separators

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These separators are used for high-pressure service where compact size is desired and liquid
volumes are small, (see Figures 13 and 14). Mist extractor can be installed in this type of separators

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(Alireza Bahadori, et al,. 2014).

Figure 13 Figure 14
A spherical separator schematic A spherical separator diagram (Chi U. Ikoku,
et al,.1992).
Spherical separators offer an inexpensive and compact vessel arrangement (Figure 15).
However, these types of vessels have a very limited surge space and liquid settling section. The
placement and action of the liquid level control in this type of vessel is very critical (Chi U. Ikoku,
et al,.1992).

Figure 15
Spherical low-pressure separator. (After Sivalls et al,. 1977)

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 Natural Gas Separators
Three-phase or oil-gas-water separation
Three-phase or oil-gas-water separation can be easily accomplished in any type of separator

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by installing either special internal baffling to construct a water leg or water siphon arrangement,

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or by using an interface liquid level control. A three-phase feature is difficult to install in a
spherical separator because of the limited internal space available, Figure 16 is a horizontal three-
phase separator (Chi U. Ikoku, et al,.1992).

Figure 16
Spherical low-pressure separator. (After Sivalls, C. R. et al,. 1977.)

With three-phase operation, two liquid level controls and two liquid dump valves are required.
Three-phase separators are used commonly for well testing and in instances where free water
readily separates from the oil or condensate.
From an evaluation of the advantages and disadvantages of the various types of separators, the
horizontal single-tube separator has emerged as the one that gives the most efficient operation for
initial investment cost for high-pressure gas-distillate wells with high gas-oil ratios. For high
liquid loadings, vertical separators should be considered (Chi U. Ikoku, et al,.1992).
Figures 17 to 18 illustrate schematics of some three-phase separators.

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 Natural Gas Separators

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Figure 17
Three-phase horizontal separator with coalescer plates (from William, et al,. 2010).

Figure 18
Three-phase vertical separator
(from William, et al,. 2010).

Conventional gas–liquid
separators Selection
There are no simple rules for separator selection. Sometimes, both configurations should be
evaluated to decide which is more economical. The relative merits and common applications of
vertical and horizontal separators are summarized by Manning and Thompson (1995).
a. Horizontal Separators
Horizontal separators are used most commonly in the following conditions:
• Large volumes of gas and/or liquids.
• High-to-medium gas/oil ratio (GOR) streams.
• Foaming crudes.
• Three-phase separation.

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 Natural Gas Separators
Advantages and disadvantages of these separators are as follow:
Advantages:

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• Require smaller diameter for similar gas capacity as compared to vertical vessels.
• No counterflow (gas flow does not oppose drainage of mist extractor).

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• Large liquid surface area for foam dispersion generally reduces turbulence.
• Larger surge volume capacity
Disadvantages:
• Only part of shell available for passage of gas.
• Occupies more space unless “stack” mounted.
• Liquid level control is more critical.
• More difficult to clean produced sand, mud, wax, paraffin, etc.
b. Vertical Separators
These separators are used in the following conditions.
• Small flow rates of gas and/or liquids.
• Very high GOR streams or when the total gas volumes are low.
• Plot space is limited.
• Ease of level control is desired.
Advantages and disadvantages of these separators are as follow:
Advantages
• Liquid level control is not so critical.
• Have good bottom-drain and clean-out facilities.
• Can handle more sand, mud, paraffin, and wax without plugging.
• Less tendency for reentrainment.
• Has full diameter for gas flow at top and oil flow at bottom.
• Occupies smaller plot area.
Disadvantages
• Require larger diameter for a given gas capacity, therefore, most competitive for very low GOR
or very high GOR or scrubber applications.
• Not recommended when there is a large slug potential.
• More difficult to reach and service top-mounted instruments and safety devices.
c. Spherical separators
Advantages and disadvantages of these separators are as follow:
Advantages
• Offer an inexpensive and compact vessel arrangement (Chi U. Ikoku, et al,.1992).
• Mist extractor can be installed in this type of separators (Alireza Bahadori, et al,. 2014).
• They may be very efficient from a pressure containment standpoint (Ampuero J. F. I., Castro A.
J. C. et al,. 2017)
Disadvantages
• They have limited liquid surge capacity (Ampuero J. F. I., Castro A. J. C. et al,. 2017)
• They exhibit fabrication difficulties (Ampuero J. F. I., Castro A. J. C. et al,. 2017)

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 Natural Gas Separators
• A three-phase feature is difficult to install in a spherical separator (Chi U. Ikoku, et
al,.1992).

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Separators comparison

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from all presented above we can summarize it in a simple comparison (Table 2).
Table 2
Summary of phase separator (from Ahmed T. et al,. 2017).

Function Vertical Horizontal Spherical

Usage Vertical separators are used
This configuration is used for Spherical separators are small
when the gas-oil ratio is low,
streams with high to medium leases operating at moderate pres-
when sand, paraffin or wax are
gas-oil ratio and for flow sure they are used for low or inter-
present and when ease of level
streams with large volume of mediate gas-oil ratio
control is desired gas and /or liquids
Cost Expensive to build Less expensive compared to They are the most expensive to
other configurations build
Cleaning Easier to clean than horizontal Most difficult to clean because Much easier to clean than the other
vessels sludge have longer length to set- configurations
tle
Gas / Liquid Handle streams with large liq- Handle streams with large gas Poor gas/liquid capacity
Capacity uid capacity capacity
Surge Space Good surge space Limited surge space Least surge space
Separation Less efficient Best Least efficient
efficiency
Handling of Vertical separators have a less The best separator to handle Spherical vessels perform poorly
foaming oil tendency to handle foaming foaming oil is a horizontal sepa- with foaming oil
oil rator
Liquid level Liquid level control is not crit- Its more critical to control liquid Liquid level control is very
control ical level in horizontal separators critical
Maintenance Difficult associated with Horizontal vessels are much Average to maintain
& height hazards more accessible
inspection
Installation Difficult to install due to Average and not as difficult as It’s the easiest to install among the
height and needs stronger vertical separators three configurations
mounting base
Advantages Vertical separators save space Horizontal separators require Spherical separators have the ad-
uses their full diameter for gas less piping for field connections vantage of easy shipping and in-
flow at the top and have less and can handle foaming crude as stallation due to its compact size.
tendency for liquid re-vapori- it reduces turbulence and foam-
zation into the gas phase. ing. Also, space requirements
can be minimized as several sep-
arators can be stacked together
Disadvantages Vertical separators require Liquid level control is more crit- Spherical separators are expensive
bigger diameter separator for a ical in horizontal separators to build and very difficult to use
given gas capacity which re- compared to vertical separators especially for three-phase separa-
sults in high capital and trans- and are more difficult to clean tion due to having very limited liq-
portation cost. when wax, paraffin, and sand. uid settling section.
are deposited at the bottom of
the separator.

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 Natural Gas Separators
Centrifugal gas–liquid separators
In centrifugal or cyclone separators, centrifugal forces act on droplet at forces several times

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greater than gravity as it enters a cylindrical separator. This centrifugal force can range from 5

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times gravity in large, low-velocity units to 2000 times gravity in small, high-pressure units.
Generally, centrifugal separators are used for removing droplets greater than 100 μm in diameter,
and a properly sized centrifugal separator can have a reasonable removal efficiency of droplet
sizes as low as 10 μm (Saeid Mokhatab et al,. 2006).
Alireza Bahadori, et al,. 2014 maintained that centrifugal separators utilize centrifugal action
for the separation of materials of different densities and phases. They are built in stationary and
rotary types. Various modifications of stationary units are used more than any other kind.
Centrifugal separators are generally divided into three types:
1. Stationary vane separators.
2. Cyclone separators.
3. Inertial centrifugal separators.
The efficiency of each of three types can be estimated using Table 3. Because of wide usage
of cyclone separators for separation of liquid entrainment from gas streams, this type is
discussed in the following sections.
Table 3
The Efficiency of Each Centrifugal Separators (Alireza Bahadori, et al,. 2014).

Type Efficiency Range

99% or higher of entering liquid. Residual

High velocity stationary vanes
entrainment 1 mg/kg (ppm) or less.
70e85% for 10 mm, 99% for 40 mm, and

Cyclone separator larger. For high entrainment, efficiency

increases with concentration.
Rotary 98% for agglomerating particles.

• Cyclone separators
The cyclone type unit is well recognized and accepted in a wide variety of applications from
steam condensate to dusts from kilns. In this unit, the carrier gas and suspended particles enter
tangentially or volutely into a cylindrical or conical body section of the unit, then spiral downward,
forcing the heavier suspended matter against the walls (Alireza Bahadori, et al,. 2014).
Solids tend to slide down the wall while liquid particles wet the wall, form a running film,
and are removed at the bottom.

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• Multi-cyclone separators
This type of centrifugal separator is a high-efficiency one, which is claimed by manufacturers

20
to be capable of removing almost all liquid droplets of 5 mm diameter and larger. This type can
also be used in gas–solid separation services (Alireza Bahadori, et al,. 2014).

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• Specification sheet
The following points should be considered when preparing a spec. sheet (or process data
sheet) for a cyclone separator in liquid entrainment separation service.
1- Application: (service application of unit should be described if possible).
2- Fluid stream.
3- Fluid composition (vol%).
4- Entrained particles:
a. Size range (micrometers or mesh).
b. Size percentage distribution.
c. True relative density (specific gravity) of particle, referred to water ¼ 1.0.
d. Source of entrainment, (boiling liquid, etc.).
e. Composition.
5- Operating conditions, (minimum, maximum, and normal):
a. Gas flow rate.
b. Entrained flow rate.
c. Temperature, (oC).
d. Pressure, (kPa).
e. Moisture content.
f. Dew point, (oC).
6- Installation altitude:
a. Normal barometer, (mm Hg).
7- Nature of entrained liquid:
a. Description, (oily, corrosive, etc.).
b. Surface tension at operating conditions.
c. Viscosity at operating conditions.
8- Insulation required and reason.
9- Construction features:
a. Storage required for collected liquid, (h).
b. Preliminary size of the inlet connection: (mm).
10- Special conditions (if any).

Flare knock-out drums

Flare knock-out (KO) drums are one type of gas–liquid separators that are used specifically for
separation of liquids carried with gas streams flowing to the flares in OGP plants.
The main difference between flare KO drums and other conventional gas/liquid separators lies
in the size of the droplets to be separated; i.e. separation of 300, 600 mm droplets fulfills the
requirements of flare gas disengagement. Therefore, usage of mist eliminating device is not
usually necessary in flare KO drums, except for cases where the results of calculations lead to an

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abnormally large drum size. In such cases, application of vane-type or multicyclone separators
may help avoid employing an extremely large drum (Alireza Bahadori, et al,. 2014).

21
Gas–liquid Filter Separators

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Gas–liquid filter separator (usually called gas filter separator) is used in separation of liquid and
solid particles from a gas stream. A gas filter separator has a higher separation efficiency than the
centrifugal separator, but it uses filter elements that must periodically be replaced. Gas filter
separators cannot handle more than small quantities of liquid (greater than 30–170 l/1000 Standard
m3) (Alireza Bahadori, et al,. 2014).
This type of separator is usually made horizontal with a lower liquid barrel (see Figure 19),
but a vertical type, especially when saving space is important, is offered by manufacturers
(see Figure 20) (Alireza Bahadori, et al,. 2014).
Filter separators are combination units which incorporate the features of a dry gas filter with
filter elements in conjunction with the features of a liquid-gas separation unit. They are used
primarily ahead of processing equipment where it is desirable to remove any solid foreign particle
elements as well as liquid from the gas stream. They are used ahead of compressors, dry desiccant
processing equipment, and gas processing equipment where contamination of a liquid circulated
in the system would be undesirable (Sivalls, C. R. et al,. 2009 a).
✓ Applications
Typical applications of gas filter separators are as follows (from Alireza Bahadori, et al,. 2014).:
• Compressor stations to protect compressors from free liquid and prevent cylinder wear
from solids.
• Metering and pressure reduction stations at city gates: to remove liquid hydrocarbons,
water, sand, and pipe scale.
• Protection of desiccant beds and collection of dust carryover from beds.
• Gas storage systems: to prevent injection or withdrawal of solids, dust, and small amounts
of liquids.
• Fuel lines to power plants and engines. Note: This type of separator shall not be used on a
stream carrying wax or a congealing liquid, otherwise filter elements will plug.

✓ Efficiency
The efficiency of a filter separator largely depends on the proper design of the filter pack, i.e.
a minimum pressure drops while retaining an acceptable extraction efficiency. Regarding the
filtration capability, various guarantees are available from filter separator manufacturers, among
them, ability of a filter to remove 100% of 8 mm and larger liquid droplets or solid particles,
99.5% of 3 mm and larger, and 98% of droplets (or particles) larger than 1 mm is recommended
to be specified (Alireza Bahadori, et al,. 2014).
However, note that guarantees for the performance of separators and filters are very difficult
to verify in the field.

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Page

Figure 19
Sketch of horizontal gas filter separator (after Sivalls, C. R. et al,. 2009 a).

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Figure 20
Sketch of vertical gas filter separator (after Sivalls, C. R. et al,. 2009 a).

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✓ Specification sheet
In addition to the information necessary for a demister gas–liquid separator, the following data

24
should also be written in the specification sheet of a gas filter separator:

Page
1- Fluid filtered.
2- Molecular mass of gas and liquid density, in kg/m3.
3- Gas flow rate, (range at expected pressures), in m3/day.
4- Turn-down requirements.
5- Temperature range, in C.
6- Normal liquid rate, in m3/day.
7- Expected liquid slug size.
8- Expected solid content.
9- Other contaminants.

Twister Supersonic Separators

Saeid Mokhatab et al,. 2006 pointed that the Twister supersonic separator is a unique
combination of known physical processes, combining expansion, cyclonic gas/liquid separation,
and recompression process steps in a compact, tubular device to condense and separate water and
heavy hydrocarbons from natural gas. Condensation and separation at supersonic velocity are key
to achieving step-change reductions in both capital and operating costs. The residence time inside
the Twister supersonic separator is only milliseconds, allowing hydrates no time to form and
avoiding the requirement for hydrate inhibition chemicals. Elimination of the associated chemical
regeneration systems avoids harmful benzene, toluene, and xylene emissions to the environment
or the expense of chemical recovery systems. The simplicity and reliability of a static device, with
no rotating parts, which operates without chemicals, ensure a simple facility with a high
availability suitable for unmanned operation in harsh and/or offshore environments. In addition,
the compact and low weight Twister system design enables debottlenecking of existing space and
weight-constrained platforms. The first commercial application at the Shell-operated B11
platform offshore Malaysia proves the technical and commercial maturity of a Twister supersonic
separator, which is a major milestone toward the industry acceptance of this innovative technology
(Brouwer et al., 2004). However, the feasibility and benefits of this technology must be studied
for a specific gas development. More information about the system design of the Twister
supersonic separator is discussed in greater detail by Okimoto and Brouwer (2002) and Brouwer
and Epsom (2003).

Low Temperature Gas Separation Units

Low temperature gas separation equipment (Figure 21) is specifically designed to increase the
recovery of liquid distillate from high-pressure gas condensate wells, over that which could be
expected by conventional separation methods. Each well stream must be examined with regards
to the analysis of the stream composition, as well as operating characteristics of the well, such as

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flowing pressures and temperatures, to determine if it would be economically feasible to install a
low temperature gas separation unit. low temperature gas separation units are each custom

25
designed to meet the specific well stream characteristics and operating conditions. In looking at
the feasibility of installing a low temperature gas separation unit, the operator should also consider

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the type of liquid storage equipment available, or to be installed, as well as the transportation costs
of the recovered liquid product (Sivalls, C. R. et al,. 2009 b).

• Process Application
It is well known that lowering the operating temperature of a separator will increase the liquid
recovery. When the pressure is reduced on a high-pressure gas condensate stream by use of a
pressure-reducing choke, there is also an accompanying decrease in the fluid temperature. This is
what is known as the Joule-Thompson, or throttling effect, which is an irreversible adiabatic
process where the heat content of the gas remains the same across the choke, but the pressure and
temperature of the gas stream is reduced. It is also well known that a reduction of gas stream
temperature will bring about the problem of hydrate formation in the lines and equipment. This
occurrence and the handling of hydrates and gas streams are discussed more completely in other
technical publications. However, in brief, the hydrates are solid particles and masses formed in
gas streams consisting of water and liquid hydrocarbons. These hydrates will form at specific
conditions of temperature and pressure for each gas stream which is generally above 32° F for
most high-pressure gas streams. The low temperature effect is used to advantage in low
temperature units to increase the liquid recovery. The lower the operating temperature of the
separator, the higher the liquid recovery will be. However, the maximum flowing pressure from
the well at a given flow rate and the transmission line pressure will limit the maximum amount of
pressure drop available across the choke. Enthalpy curves on natural gas can be used to determine
the temperature drop that can be expected based on the available pressure drop. In general, at least
2500 to 3000 psi pressure drop should be available from wellhead flowing pressure to pipeline
pressure before a low temperature separation unit will pay out in increased liquid recovery. The
lowest operating temperature recommended for low temperature units is usually around –20° F.
Carbon steel embrittlement occurs below this temperature and high alloy steels for lower
temperatures are usually not economical for most oilfield installations. Generally, low temperature
separation units are operated in the range of 0° F to 20° F. The liquid recovered from the high-
pressure separator on low temperature units should be passed through at least one low pressure
separator to help in stabilizing the liquid product before it is put in storage tanks. Since this cold
liquid will contain many light hydrocarbons, severe agitation and flashing will occur if it is put
directly into a stock tank (Sivalls, C. R. et al,. 2009 b).

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Figure 21
Schematic flow diagram low temperature separation unit (Sivalls, C. R. et al,. 2009 b)

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 Natural Gas Separators

Vertical Gas Scrubbers

27
Where only small or trace amounts of free liquid are known to be present in a gas stream,
vertical gas scrubbers may be designed and sized using the gas capacity of the mist eliminator

Page
only (Figure 22). This will result in a considerably smaller vessel for a given gas flow rate. Or, a
given size vessel will handle considerably more gas than it would under conventional vertical
separator sizing procedures. The vessel would be equipped with a conventional liquid level control
and liquid discharge valve and, of course, would have a settling section in the bottom of the vessel
for accumulating liquid drained out of the mist eliminator. However, surge room would be limited
and there would be no settling section for separation of the liquid and gas by gravity. The major
function of the vessel is to house the mist eliminator section which would remove entrained liquid
mist from the gas stream strictly due to the action of the mist eliminator. This type of vessel might
be used ahead of compressors where other separation equipment has already removed all of the
free liquids, or downstream of process vessels where only entrained liquids or slight amounts of
mist carryovers would be expected in the gas stream (Sivalls, C. R. et al,. 2009 c).

• Construction
A vertical gas scrubber would normally be constructed identically to a small two-phase vertical
gas separator. It would have a tangential inlet diverter, a liquid level control and discharge valve,
and full diameter wire mesh mist eliminator in the top of the vessel. Other usual separator devices
would be furnished such as a safety head, pressure relief valve, level gauge, etc. Normally, these
vessels would be built in only 5’ to 7 ½’ heights, depending on the diameter of the vessel. These
would not be equipped for three phase operation, since there would be not enough surge room for
a conventional settling section in the bottom of the vessel for proper separation of free water and
distillate. See Table 2 for typical specifications of standard size vertical gas scrubbers. Normally,
the gas scrubbers would have larger inlet and outlet gas connections than would conventional
separators of the same physical size, because these vessels would be handling considerably more
volumes of gas than would a conventional separator (Sivalls, C. R. et al,. 2009 c).

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Page

Figure 22
Vertical Gas Scrubbers (Sivalls, C. R. et al,. 2009 c).

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References
Alireza Bahadori, et al,. 2014. Natural Gas Processing Technology and Engineering Design.

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Ahmed T., Makwashi N., and M. Hameed, et al,. 2017. A Review of Gravity Three-Phase
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Ampuero J. F. I. and Castro A. J. C. et al,. 2017. Design of oil-gas separators from hydrocarbon
stream. National University of engineering, course: production I (pp-414).

Brouwer, J.M., Bakker, G., Verschoof, H-J., and Epsom, H.D., “Supersonic Gas Conditioning:
First Commercial Offshore Experience,” Paper presented at 83rd Annual GPA Convention,
New Orleans, LA (March 14–17, 2004).

Brouwer, J.M., and Epsom, H.D., “Twister Supersonic Gas Conditioning for Unmanned
Platforms and Subsea Gas Processing,” SPE 83977. Paper presented at Offshore Europe
Conference, Aberdeen, UK (Sept. 2–5, 2003).

Brown, R.L., Malbrel, C., and Wines, T.H., “Recent Developments in Liquid/Gas Separation
Technology.” Paper presented at the 44th Laurance Reid Gas Conditioning Conference,
Norman, OK (Feb. 28, 1994).

Bullin, K.A., and Hall, K.R., “Optimization of Natural Gas Processing Plants Including Business
Aspects.” Paper presented at the 79th GPA Annual Convention, Atlanta, GA (2000).

Chi U. Ikoku, et al,.1992. Natural Gas Production Engineering. KRIEGER Publishing company
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Courtesy Petroleum Extension Service.

Gas processors and suppliers (GPSA) engineering data book. 12th ed. 2004. Tulsa (OK, USA).

Goar, B. G., and Arrington, T. O., Processing sour Gas. 1. Guidelines for handling sour gas. Oil
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Manning, F.S., Thompson, R.E., “Oil Field Processing, Vol. 2: Crude Oil.” Pennwell Publishing
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Odello, R., Systematic method aids choice of field gas treatment. Oil Gas J. 79(6), 103–109 (Feb.
1981).

Okimoto, F.T., and Brouwer, J.M., Supersonic gas conditioning. World Oil. 223(8), (2002).

Rojey, A., Jaffret, C., Cornot-Gandolph, S., Durand, B., Jullin, S., and Valais, M., “Natural Gas
Production, Processing, Transport.” Editions Technip, Paris, France (1997).

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 Natural Gas Separators
Saeid Mokhatab, William A. Poe, and James G. Speight et al,. 2006. Hand Book of Natural Gas
Transmission and Processing. Elsevier Inc.

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Sivalls, C. R. et al,. 1977. Fundamental of Oil and Gas Separation. Proceeding of the gas
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Sivalls, C. R. et al,. 2009 a. Oil and Gas Separation Design Manual. ODESSA, TEXAS 79760.
SECTION 300, TECHNICAL BULLETIN, No. 162, Rev. 3.

Sivalls, C. R. et al,. 2009 b. Oil and Gas Separation Design Manual. ODESSA, TEXAS 79760.
SECTION 300, TECHNICAL BULLETIN, No. 163, Rev. 3.

Sivalls, C. R. et al,. 2009 c. Oil and Gas Separation Design Manual. ODESSA, TEXAS 79760.
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William C. Lyons, et al,. 2010. Working Guide to Petroleum and Natural Gas Production
Engineering. Elsevier Inc.

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