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Development of scrubber internals
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Design av demistere for høytrykksanvendelsehøytrykksanvendelse
S j t k l i 2009Separasjonsteknologi 2009
September 30 2009September 30, 2009Presenter: Dag Kvamsdal
Overview todays presentationOverview todays presentation
• Quick overview of demisters• Quick overview of demisters• Typical separation performance requirement of
demisters• Operational envelope for scrubbers today• Operational envelope for scrubbers today• Testing of demisters in laboratory• What will affect the demister performance• Status on CFD calculations• Status on CFD calculations• Natco Norway focus for new development of
demisters and scrubber internals
Demisters in a process systemDemisters in a process system
Primary Separators
Gas scrubbers
Contactor towers
Demisters used in scrubbers and separatorsE lExamples
Vanepack
Demisting cyclones
Separators
Demisting cyclonesDemisting cyclones
ScrubberSingle stage scrubber
Two types of demisters discussedAxial flow cyclones and vane packs
Vane packVane pack
Suited for low-mid pressure application p essu e app ca oand low gas loading
Axial flow cyclones
Suited for high pressure demisting
Separation efficiency scrubberUsing Natco Norway correlationsg y
eff
[%]
Sep
Efficiency demister
0 % 20 % 40 % 60 % 80 % 100 % 120 %
Relative flow rate
li id
gasgasuk
ρρρ−
=
ep e
ff [%
]
gasliquid ρρ
Se
Efficiency bulk separation vesselK-value [m/s]
Required separation efficencyExample; Achieve 0.1 gal/MMSCF
Demister section
Process conditions Year 2011Operating pressure [bara] 25 1
Example case
section99.73 %
Operating pressure [bara] 25.1Operating temperature [ºC] 105Gas actual flow rate [Am³/h] 25263Gas actual density [kg/m³] 22.5Gas actual viscosity [cP] 0.01
I l t ti
y [ ]Hydrocarbon liquid flow rate [Am³/h] 22.71Oil actual density [kg/m³] 881Hydrocarbon surface tension [N/m] 0.021Oil actual viscosity [cP] 13.0200
Inlet section and vessel combined88.97 %
Water flow rate [Am³/h] 0.0Water actual density [kg/m³] 991.5Water actual viscosity [cP] 0.6Liquid fraction [vol%] 0.09 %
Overall efficiency: 99.97 %
Efficiency limitations for scrubbersOperational 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
the demister section from the bulk section of the vessel
2 0 %
the demister section from the bulk section of the vessel
1 5 %
2.0 %
n
> 0.1 gal/MMSCF
1.0 %
1.5 %
ume fraction
0.5 %Liqu
id volu
Increasing Pressure
0.0 %k‐value [m/s]
< 0.1 gal/MMSCF
k value [m/s]
Options for demister testingThe Natco axial flow cyclone has been tested at the following labs
Ai t l b t N t L b t R l fl id l b tAir water laboratory
Functional testing of a
Natco Laboratory
Testing of individual
Real fluid laboratory
For instance StatoilHydro K-full axial flow cyclone box
demisters and demister sections
lab.
Real fluids, Full size test
Test pressure 1-5 bargModel fluids and possibility to run gas densities of 60 kg/m3
,sections and up to 150 bar
densities of 60 kg/m
Testing high pressure demistersReal world vs laboratory conditions
1 10 100
Real world Gas density [kg/m3]
Real world S rface tension [kg/m3]1 10 100
Surface tension [kg/m3]
10-3 10-110-2 100 101
ScrubbersDemisters Diameter [m]10-3 10-110-2 100 101
Ai tAir water
Natco Norway Laboratoryy y
Separation efficiency for a demisterDifferences from lab to real conditions axial flow cyclones
99.0 %
99.5 %
100.0 % Test data
Test data from air water gives 100%
97.0 %
97.5 %
98.0 %
98.5 %
Efficiency
Real fluids
Test data from air water gives 100% separation efficiency, nothing to learn!
95.5 %
96.0 %
96.5 %
97.0 %Model fluids
Air waterModel fluids gives reduced efficiency and it is possible to evaluate the geometry
50 % 70 % 90 % 110 %
Flow [‐]
g y
Real fluids gives considerably lower efficiency
Flow mechanisms in a demisterAffecting the separation Affecting the separation
Droplet break up
Droplet transportation
Wall interaction
Collisions / Coalescence
CFD challenge for demister equipmentg q p
• 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
Equipment
The challenge of CFD; it is all about scales
Equipment
TurbulenceDroplets Length [m]
10-6 10-410-5 10-3 10-2 10-1 10-0
CFD resolvedCFD resolvedCFD resolvedCFD resolved
g [ ]
CFD ability to capture the flow field
RANS calculations
Time averaged solution that in many ways do y ynot 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 CPU h iCPU hours using 7 000 000 cells
Multiphase flowIncluding; droplet break up, coalescence and wall film model
Flow in a vanepack as filmed in the laboratoryp y
G d it 60 k / 3Gas density 60 kg/m3
Flow in the vanepack slow motionFlow in the vanepack slow motion
Gas density 60 kg/m3
Efficiency vane packAs tested in the Natco laboratory
99 %
100 %
Vane pack efficiency
High efficiency for k < 0 1 m/s for all96 %
97 %
98 %
99 %
ncy
High efficiency for k < 0.1 m/s for all gas densities up to 60 kg/m3
Falls below 99% when k>0 15 m/s92 %
93 %
94 %
95 %
Efficie
Increasing density
Falls below 99% when k>0.15 m/s90 %
91 %
K‐value [m/s]
Vane pack efficiency 96 %
98 %
100 %
Vane pack efficiency compared to axial flow
cyclones90 %
92 %
94 %
ion efficiency Vane pack
Cyclones
The axial flow cyclones can handle considerably higher flow without loss
of performance82 %
84 %
86 %
88 %
Separat
80 %
82 %
K‐value [m/s]
Development of scrubber internalsDevelopment of scrubber internals
• Under development• Under development– New generation of axial flow cyclones
• Should achive 10 times or more better performance than the existing axial flow cyclonesI t t f t i li l ti ll hi h• Important for one stage inline solutions as well as high pressure scrubbers
New scrubber inlet section– New scrubber inlet section• Should give 99% or better efficiency for a k-value in the
vessel of 0 25 m/svessel of 0.25 m/s.
Next generation axial flow cyclonesOperational envelope LCO<0.1 gal/MMSCF
Improved axial flow cyclones where the efficiency is improved with a factor of 10 compared with
existing cyclonesexisting cyclonesThe maximum k value to achieve 0.1 gal/MMSCF
will be as shown
2.0 %
n
> 0.1 gal/MMSCF
1.0 %
1.5 %
ume fraction
0.5 %
Liqu
id volu
Increasing Pressure
0.0 %k‐value [m/s]
< 0.1 gal/MMSCF
Design of Gas ScrubbersInlet devices
g
Inlet Vane Diffuser Swirl InletInlet Cyclone Distributor Statoil’s SPINLET
Efficiency for new type inletEfficiency for new type inlet
Key for further scrubber development is to manage to remove 99% or more of the droplet in
the vessel before demister up to k 0 25the vessel before demister up to k ~ 0.25
1.5 %
2.0 %
n
> 0.1 gal/MMSCF
1.0 %
1.5 %
lume fraction
0.5 %Liqu
id vol
Increasing Pressure
0.0 %k‐value [m/s]
< 0.1 gal/MMSCF