Gas-liquid scrubber design: Theory, practice and experiences

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1 Gas-liquid scrubber design: Theory, practice and experiences Separation Technology. Tekna September Erik Solhem Statoil Classification: Internal

2 Presentation overview Basic theory. The K-value. Working principle of a scrubber Wire mesh pad, vane pack, cyclones Scrubber design and performance Historic trends in North Sea scrubber design. (From Norsok to today) Some scrubber case stories Success or failure Summary 2 Classification: Internal

3 The inside of a scrubber Cyclone demister section, remove the last droplets Mesh pads, coalesce and separate droplets, redistribute gas and liquid Gravity separator section, remove bulk of liquid by gravity separation Inlet section, distribute gas evenly into scrubber vessel, dampen inlet momentum NORSOK:Cyclone downcomer drain height utilization<50% from HH level 3 Classification: Internal Figure: courtesy of Cameron

4 Basic Theory: The K-value Most commonly used expression for sizing of gas scrubbers Developed by Souders and Brown in 1934 to size fractionation columns (droplet separation between trays by gravity) Known as Souders Brown value K-value C-factor Gas load factor (GLF) Figure: courtesy of FMC 4 Classification: Internal

5 Souders-Brown equation (K-value) u g Drag Gravity Keeping the K-value constant therefore means: About the same size of droplets will be separated by gravity. The use of K-value as a design parameter means that one has to reduce the gas velocity when pressure (and thereby gas density) is increased The K-value is an empirical scaling factor and measure of the vessel compactness 5 Classification: Internal

6 K-value vs droplet separated by gravity (cut size) At elevated pressures (> 10 bar) same K-value gives about same droplet cut size At low pressure; droplets must be larger to separate by gravity. 6 Classification: Internal

7 What droplet size do we have? Droplet size determined by inlet impulse. Droplet size in gas flow. The droplet Weber number But value of We? d max We g d u d 2 g Droplet size inlet pipe Droplet size range times dpmax At 60 bar and Norsok P-100 design inlet momentum; droplet range micron Compare with gravity cut size of 450 micron for K-value 0.1 m/s and 175 micron at K-value 0.05 m/s But who knows what droplets you have,and bulk liquid fraction after the inlet?? Need to capture and coalesce droplets to maximize size and separation by gravity (or inertial force) We: equals the ratio of the kinetic energy on impact to the surface energy, 7 Classification: Internal

8 Working principle of a scrubber gas In 1947 Otto York introduces the wire mesh demister, and established a company based on his idea and a1000$ loan. Demisting-section, droplet removal Droplet liquid separation Bulk liquid separation liquid Primary separation. Gas distribution The wire mesh demister typically allow K values up to about 0.11 m/s A 20-30% design margin is often used See GPSA 13 th ed. Vol 1 section 7 Performance is usually very good < 13 litre/millsm3 carry over 8 Classification: Internal

9 Flooding mesh scrubber movie. Statoil LP lab link 9 Classification: Internal

10 Mesh scrubber operating range Bürkholz, Armin Droplet Separation VCH-Verlag, Weinheim 1989, The mesh has limited capacity, with a sudden loss of performance. Capacity must be de-rated for high pressure /low surface tension. See GPSA handbook. High liquid load reduces gas capacity ( flooding+re-entrainment) For higher capacity, vane pack or cyclone demisters can be used. 10 Classification: Internal

11 High(er) capacity scrubbers. Vane Packs Vane pack scrubber: Horizontal gas flow typically perform better than vertical gas flow HFV Vane K-value: Norsok P-100= m/s. GPSA= m/s VFV vane K-value : Norsok P-100= m/s. GPSA = m/s Limits depend on fluid conditions. Higher K s in water/air. Vendors brochures may quote K-values in the range m/s Capacity limited by re-entrainment at higher pressure and low surface tension. Reduce load. Figures: Courtesy of Peerless Manufacturing Company (Left). Courtesy of Sulzer (Right) 11 Classification: Internal

12 High(er) capacity scrubbers. Cyclones Liquid and droplet separated by centrifugal force generated by the swirling flow Liquid extraction from slits in axial cyclone wall Cyclones arranged in box/ compartment that collect and drain liquid out Capacity depends on geometry,size. Re-entrainment limits gas capacity Reduce load per cyclone at high pressure, low surface tension Reverse flow Axial flow. Non-recycling Axial recyling Axial cyclone box Cyclone with secondary gas demisting Figures: Courtesy of Burgess Manning (Peerless subsidiary) / Cameron/ Sulzer. 12 Classification: Internal

13 Cyclone scrubber separation efficiency What efficiency is required to meet a spec of 13 litre/millsm3 at 80 bar? 99.95% separation = 13.6 litre/millsm3 Cyclone efficiency determined by load and fluid conditions 99.5% separation Gas load 0.25 vol% Inlet separation determined by vessel K value, liquid load and inlet conditions, inlet momentum.and design Do you need this performance? Can you measure this carry over? Can you see the effects of the carry over? 90% separation Maybe No, not directly Sometimes 13 Classification: Internal Figure: courtesy of Cameron

14 How much is 13 litre/millsm3 (0.1USG/mmscf) carry over? 0.03 mm/h=0.7 mm/d rainfall 2.3 mm/h=55 mm/d rainfall Typical scrubber feed liquid load Norsok 2001: Removed in Norsok 2010 Dresser Rand: OEM Specification for solvent injection in centrifugal compressors: < 3wt% and <25 micron droplets Dresser rand link 14 Classification: Internal

15 Effects of carry -over Compressor before After Many compressors can tolerate condensate carry-over!! Combination of water carry-over and CO2 can be very damaging Carry-over to TEG contactors can lead to operating problems Amine contactors can be especially sensitive to condensate carry-over. Carry-over can result in off-spec HC Dewpoint in export gas, while compressor is OK Carry-over may give contamination of compressor seal gas 15 Classification: Internal

16 Historic trends in Scrubber design. From a North Sea perspective K=0.05 m/s K=0.1 Individual Company Standards are too costly. Remove them. Vendor shall guaranty the performance. K=0.1 IBC Separation conference 2001: Almost all field developments last 5 years have undersized and malfunctioning scrubbers High Vane pack K- values. Reverse cyclones Axial cyclones In very small scrubbers K=0.35 K=0.15 Fit for purpose designs K=0.08 K=0.25 inline 1934 Souder Brown K-value 1947 Otto York mesh Mesh and vane pack 1988 Oil company standards SPE handbook 1993 NORSOK = NO company standards 2001 NORSOK= 5.3 Scrubber design Now Company Standards are too costly. Simplify or remove them 16 Classification: Internal

17 Case story A: NORSOK design All compressors eroded Cooler plugged 206bar High cyclone dp =liquid drain suction 82bar K-value=1.06 Vol% = 0.01 K-value=0.17 Vol% =2.6 Cyclones 23bar K-value=0.18 Vol% =1.6 Cyclones 5bar 30=>38 C K-value=0.25 Vol% =0.3 VFV Vane-K= 0.35 Solution: Modify scrubbers>inlet cyclones+ more cyclones, improved design Eliminate liquid knock out by change in operating temp. Reduce temp in previous stage,increase at problem stage Before : Compressor lasted 3 months. After: Running OK for 10years+ 1.4bar 30=>25 C 17 Classification: Internal

18 Case story B and C: Dehydration inlet scrubber 150% Capacity upgrade failed: Massive TEG losses well below new design rate 60bar High load TEG tower New internals tested OK Revamped scrubber K-value=0.2 Vol% =1, surf tension 5 dyn/cm Cyclones. NEW scrubber K-value=0.08 m/s Triple mesh 10 ton Scrubber revamped once before. Inlet cyclone gas blow by limits capacity. 30bar Inline separation upstream scrubber + New cyclonic inlet in scrubber 1998: K-value=0.34 Vol% =1.5 Inlet cyclone+cyclones Satisfactory operation Design K=0.42 Tested OK to K= Classification: Internal

19 Mesh scrubber performance at 60 bar Carry-over monitored by radioactive tracer test. Detection limit: >0.5% carry-over <99.5% separation. K-value based on water m/s : no detectable water carry-over K-value based on condensate K=0.113 m/s: 2.6% condensate carry-over No negative effects detected on downstream compressor o Low liquid load Figures: Courtesy of Tracerco and Linde 19 Classification: Internal

20 Things to remember about scrubbers The K-value is the typical scaling factor and measure of compactness The capacity of a mesh is limited to typical K=0.11 m/s due to flooding Use a 30% design margin for scrubbers. Define your design cases carefully. Limited debottlenecking options Higher vessel capacities can be achieved with vane pack and cyclones Smaller diameter, but taller vessels. Cyclone scrubber typically used for high capacities and high pressure But are also limited by re-entrainment at high pressure/low surface tension Overall scrubber performance is determined by inlet separation and K-value K-value range for cyclone scrubbers is m/s depending on liquid load and pressure. Ball park K-value is 0.15 m/s for cyclone scrubbers. Be aware of the pressure drop drainage limitation in high dp demistors (cyclones) DO NOT FORGET: GRAVITY ALWAYS WORK 20 Classification: Internal

21 Gas-liquid scrubber design: Theory, practice and experiences Erik Solheim Advisor gas production systems Statoil Upstream Process Technology Tel: Classification: Internal

22 22 Classification: Internal

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