Inertial-filtering separation of gas condensate systems

Інерційно-фільтруюча сепарація газоконденсатних системKeywords
Energy and Energy Efficiency Tech mining and mineral processing

There are no scientifically based forecasts of gas-liquid flows separation and it is one of the reasons why designed separation devices and their technological regimes are often inefficient. So this project aim is to develop theoretical foundations of inertial-filtering separation processing when using many components mixtures. Scientific forecast of two phase flows behavior is pursued on the basis of mathematical and virtual modeling of hydrodynamic processing which take place in the inertial filtering separation sections of gas separating and mass changing equipment. Mathematical modeling should be carried out on the basis of classical fluid and gas mechanics and technical hydromechanics. Physical experiments will be conducted through experimental research of separation equipment stand models. At the stage of computer modeling the methods of computational fluid dynamics and movable cellular automata or discrete element method will be applied. They will help in choosing the best geometric configuration of the separation equipment and technological regime parameters of separation without making physical model and so one can go directly to research and manufacture of industrial design. Theoretical relationships can be developed using differential methods of mathematical analysis and integral calculus
The basis of this project is a developed physical model of high dispersion drop liquid in the natural gas flow, which taking in account quality parameters of natural gas helps to evaluate the distribution density of dispersed condensate droplets and water vapor.
After studding the high dispersion drop fluid formation mechanisms which take place in the natural gas flow, one got the formula for determination the average (critical) drop size of the dispersion phase, formed due to reduction and coagulation. Existing disadvantages of present separators were revealed after long time research work analyzing the separation processes of micro droplet moisture in gas environment. Promising ways of gas separation flow organization were thoroughly studied and so they combine the best advantages of inertial and filtering separation.

Innovative aspect and main advantages:
To capture fog (0,3-10 microns) and spray it is offered to combine inertial separation sections with grate (to capture particles larger than 5 microns) and fibrous filtering sections (for trapping particles smaller than 5 microns) working in self-cleaning mode and lower filtration rate. A distinctive feature of these sections capturing liquid particles is their coalescence after touching with filter elements and the formation of large liquid film or big droplets. Application spheres of gas depuration apparatus with filter elements expands rapidly due to the use of new synthetic polymer, glass and metal fibers, porous plastics and metal-ceramics.
Choice of the fog or spray catcher type, working on the mechanism of filtration, depends on the dispersion composition and concentration of suspended particles and the liquid phase, the presence of solid particles in the fog, the necessary efficiency and allowable pressure drop at the facility.
New designs of inertial-filtering devices will be worked out on the basis of theoretical analysis of established physical and mathematical models of gas flow movement and using computer modeling.
Summing up the results of experimental model and designed separation devices research one will get hydraulic and separation features of the gas separation and mass changing equipment inertial filtering separation sections. On the basis of hydraudynamic research one will develop the methodic for inertial filtering separators calculation. It will help to determine separation parameters and major geometrical sizes of separation units.
New separation ways and new designs of inertial filtering separation sections of gas and mass exchanging equipment will be proposed and protected by patents of Ukraine. They will help considerably raise the separation level. Obtained scientific results will be implemented into processing on the Ukrainian industrial oil gas enterprises.

Problem solved:
In industrial processes gas-liquid separation of mixtures at gas processing plants and compressor stations gravitational separation of solids, liquid drops and film from the gas stream is only used in combination with other methods of separation. Therefore it is more appropriate to direct the accompanying gas and oil flow energy for the separation of the drop fluid and solid impurities using inertial separation mechanism of
curvilinear and swirling flows. The effectiveness of inertial separators at the level of gravitational, and in most cases is much higher thanks to the transition from gravitational sedimentation speeds 0.05-0.2 m / s to inertial speeds of 5-20 m / s. It is essential that direct contact of the gas stream and droplets or film captured fluid, the use of additional design features, creating reverse currents swirl, along with improved conditions for separation and removal of trapped fluid, destroy the structure of liquid film and causes spray withdrawal, the intensity of which is determined by the gas flow rate. These enhancements are also resisting forces. So hydraulic resistance increases and it becomes impossible to achieve high degree purification degree; capturing ability decreases, gas separator efficiency and productive capacity become much lower.
In addition, the purification of gases from condensed particles ( due to their high dispersion, which often varies over time (with temperature and pressure)) becomes more complex problem than catching fog formed by mechanical processes.
Gases purification degree in these types of devices can be increased, and separation – intensified by coagulation of dispersed phase particles in the process of droplets merging when contacting with each other, which greatly facilitates their subsequent sedimentation. Coagulation can occur under the influence of hydrodynamic, electric, gravitational forces or can be caused by elastic acoustic vibrations and ultrasonic sound frequencies that overlap the Brownian motion of particles, and by condensing them into water vapor (gas supersaturation as a result of its rapid cooling immediately before cleaning, or during the process of purification).
Therefore, the main idea is to equip separation sections of gas separation and mass change devices with effective input nodes, acting as preliminary separators of liquids and capturing solids with coagulators of fine aerosol and high-efficient centrifugal, inertial and filtering separation elements.

Development status:
Prototype with favorable lab results

Potential customers, markets:
It is recommended for using in chemical, oil and gas, oil and chemical, metallurgical industries