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# 2004 Institution of Chemical Engineers
Trans IChemE, Part A, October 2004
Chemical Engineering Research and Design, 82(A10): 13831390
ithin primary crude oil separators used by the oil industries, the residence time distribution of both organic and aqueous phases has been obtained for the purpose of
flow diagnostics. This paper describes the application of the Alternative Path
Model developed by Simmons et al. (2002) to give a quantitative description of the hydrodynamics and mixing within several field separators. Parameters developed from the model are
used to describe the degree of mixing within the vessels. The model shows that vessel performance is affected by the internal configuration (flow smoothing baffles and separation
plates) and the primary separation duty (gas liquid or oil water). The presence of baffling
is shown to reduce the turbulence within the flow for oil water separation, but less so for
gas oil separation, which had the overall effect of increasing mixing levels, perhaps due to
the buoyancy of the fast rising gas bubbles. The presence of secondary peaks on some of
the measured residence time distributions indicates the presence of secondary flows within
the main body of the separators. This was most noticeable when the differential velocity
between the oil and water phases was high.
Keywords: multiphase flow; liquid liquid mixing; residence time distribution; crude oil water
separators; gravity settling.
INTRODUCTION
Gravity separation of the mixture of fluids produced from
petroleum reservoirs is used to achieve a primary split
between the gas, oil, and water phases. This operation is
necessary since it is the usual practice to separate the
phases before pumping to downstream process facilities.
This is done in order to remove the water phase and also
to prevent operational difficulties, such as the presence of
slug flow in the pipelines, which may occur. Since the
volume flow rates of the fluids produced are very large,
the separation process is usually performed in a train of
horizontal cylindrical vessels.
Recent trends in the design of offshore platforms and fluid
separation equipment are aimed at reducing costs by saving
on space and weight, which creates considerable motivation
for the development of methods to improve separation efficiency. To achieve this, it is necessary to accelerate the
separation process. The major factors controlling the separation of the phases are the settling and coalescence of drops
Correspondence to: Dr M.J.H. Simmons, Department of Chemical Engineering, University of Birmingham, Edgbaston, Birmingham, B1S 2TT, UK.
E-mail: m.j.simmons@bham.ac.uk
1383
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SIMMONS et al.
Trans IChemE, Part A, Chemical Engineering Research and Design, 2004, 82(A10): 13831390
c(t)
c(t) dt
(1)
Hence
1
E(t) 1
(2)
c(t) dt
m
Q
tE(t) dt
(4)
c(t)
c(t) dt
(5)
Using
we obtain
1
MRT 01
0
tc(t) dt
c(t) dt
(7)
E(t) 1
VA
Q
(3)
MRT
1385
(6)
MRT
V=Q
V
MRTA VA =Q VA
(8)
MATHEMATICAL MODEL
Alternative Path Model (APM)
The APM is based on splitting the flow behaviour in the
vessels into a series of zones and includes two alternative
paths for the fluid to travel that have different time constants. Possible velocity profiles in the vessel and flow
zones are shown in Figure 3a. In the formulation of the
APM, the presence of the rag layer (the layer between
the two liquid phases containing one phase dispersed in
the other) is neglected. When systems are described in
this way, the model can be derived mathematically by
using transfer functions from Laplace Domain descriptions (Levenspiel, 1999; Luyben, 1990). A block diagram
of the APM is given in Figure 3b.
The APM has six adjustable parameters for each phase:
. time constant in inlet mixing (CSTR) zone, t1;
. time constant of a stirred tank in each series, t2, t3;
Trans IChemE, Part A, Chemical Engineering Research and Design, 2004, 82(A10): 13831390
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SIMMONS et al.
Table 1. Mean residence time and APM data for the field separators
MILNE POINT
3.6
6.8
1.575
0.914
0.40
1.575
0.939
0.40
1.473
0.863
0.40
1.473
0.863
0.40
1.575
0.977
0.40
1.575
0.813
0.40
ORGANIC PHASE
Volumetric flow (m3/s)
Mean velocity (m/s)
MRT (s) from RTD equation (6)
MRTA (s) from equation (7)
Dimensionless volume, VD (2)
Sec. peak no., F (2)
0.073
0.032
680
753
0.90
1.35
0.076
0.035
621
698
0.89
1.56
0.074
0.036
668
675
0.99
0.96
0.070
0.034
622
714
0.87
1.46
0.074
0.036
854
678
1.25
0.16
0.070
0.027
730
894
0.82
0.51
AQUEOUS PHASE
Volumetric flow (m3/s)
Mean velocity (m/s)
MRT (s) from RTD equation (6)
MRTA (s) from equation (7)
Dimensionless volume, VD (2)
Sec. peak no., F (2)
Fractional mixed volume, D (2)
0.033
0.023
1585
1050
1.51
0.48
0.30
0.033
0.022
1632
1108
1.47
0.38
0.23
0.033
0.026
1152
932
1.24
0.15
0.26
0.037
0.029
1343
831
1.61
0.26
0.27
0.037
0.023
1359
1068
1.27
0.04
0.40
0.032
0.028
1421
845
1.68
0.00
0.40
10
11
KINNEIL
Vessel diameter (m)
Vessel L/d (2)
Gasoil int. ht (m)
3.05
4.03
ORGANIC PHASE
Volumetric flow (m3/s)
Mean velocity (m/s)
MRT (s) from RTD equation (6)
MRTA (s) from equation (7)
Dimensionless volume, VD (2)
Sec. peak no., F (2)
Fractional mixed vol., D (2)
1.53
1.53
1.53
1.53
1.53
0.14
0.038
300
322
0.93
0.00
0.805
0.23
0.063
198
172
1.15
0.00
0.727
0.19
0.052
240
237
1.01
0.05
0.835
0.26
0.071
130
154
0.84
0.24
0.742
0.17
0.046
269
223
1.21
0.32
0.862
MAGNUS
12
ULA
13
14
15
2.64
2.8
1.19
0.87
3
3.3
1.15
0.675
1.15
0.695
3.3
3.0
1.90
0.87
ORGANIC PHASE
Volumetric flow (m3/s)
Mean velocity (m/s)
MRT (s) from RTD equation (6)
MRTA (s) from equation (7)
Dimensionless volume, VD (2)
Sec. peak no., F (2)
0.107
0.082
191
121
1.58
0.03
0.109
0.087
191
113
1.69
0.05
0.123
0.037
162
265
0.61
2.82
0.033
0.040
173
184
0.94
0.81
AQUEOUS PHASE
Volumetric flow (m3/s)
Mean velocity (m/s)
MRT (s) from RTD equation (6)
MRTA (s) from equation (7)
Dimensionless volume VD(2)
Sec. peak no., F (2)
Fractional mixed vol., D (2)
0.064
0.053
194
184
1.05
0.02
0.58
0.062
0.050
191
198
0.96
0.05
0.61
0.143
0.079
284
124
2.30
0.63
0.47
0.060
0.038
178
193
0.92
0.46
0.70
(1 f )t1N1 t=t1
e
(1 f )
(t 1 t2 )N
N
X
t1Ni ti1
et=t2
N1i i1
(
t
t
)
t
(i
1)!
1
2
2
i1
N
X
f t1N1 t=t1
t1Ni ti1
e
f
N1i i1
(t1 t3 )N
t3 (i 1)!
i1 (t1 t3 )
(10)
G(t)
Trans IChemE, Part A, Chemical Engineering Research and Design, 2004, 82(A10): 13831390
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The parameters in the model were fitted to the experimentally determined exit age distributions, E(t), using the Simplex method. A full description of the application of the
Simplex method to this problem is given by Komonibo
(2002). A fixed value of N 50 was used for both paths,
(11)
(12)
(13)
The total size of the inlet mixing zone, Vmix can be estimated similarly.
Vmix Qo t1o Qw t1w
Figure 3. (a) Possible flow zones within separator; (b) block diagram of Alternative Path Model (APM).
Trans IChemE, Part A, Chemical Engineering Research and Design, 2004, 82(A10): 13831390
(14)
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SIMMONS et al.
The Fractional Mixed Volume, D, is defined as the fractional amount of the vessel active volume occupied by turbulent mixing at the inlet, that is,
D
Vmix
Vtotal
(15)
lmix
l
(16)
Trans IChemE, Part A, Chemical Engineering Research and Design, 2004, 82(A10): 13831390
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Figure 5. Comparison of exit age distributions with APM for Expt. 12,
Magnus vessel: (a) organic phase; (b) aqueous phase.
Figure 6. Comparison of exit age distributions with APM for Expt. 14, Ula
vessel: (a) organic phase; (b) aqueous phase.
Trans IChemE, Part A, Chemical Engineering Research and Design, 2004, 82(A10): 13831390
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SIMMONS et al.
Greek symbols
t
time constant, s
Subscripts
o
w
organic phase
aqueous phase
REFERENCES
considerable mixing in the liquid phase despite internal baffling. This could be due to the rapid rise of bubbles of gas in
the oil, driven by buoyancy effects arising from large density differences between the gas and oil phases since this
vessel is used primarily for gas oil separation.
CONCLUSIONS
The alternative path model (APM) has been applied to
obtain parameters describing the hydrodynamics and separation performance of field separators from residence time
distribution (RTD) data. The model was fitted to the experimental exit age distributions using the Simplex method
and good agreement was obtained. For one of the vessels
used, the secondary peak number, F (an indication of the
presence of dead zones and re-circulatory effects) was
found to generally increase with increasing differential velocity between the organic and aqueous phases. Values of
fractional mixed volume, D, are lowest for vessels containing baffles at the inlet and down the body of the vessel to
smooth the flow and lower turbulence. A long vessel, that
is, high L/d, is advantageous. The effect of the baffles is
reduced for gas oil separation, perhaps due to the presence
of rapidly rising disengaging gas bubbles, which act to
increase the local turbulence.
NOMENCLATURE
c
d
D
E
f
F
L
lmix
m
MRT
MRTA
N
Q
t
V
VA
VD
concentration, kg m23
vessel diameter, m
fractional mixed volume
exit age distribution
flow fraction through each path
secondary peak number
vessel length, m
length of mixing zone, m
mass of injected tracer, kg
measured mean residence time, s
mean residence time (volume/volume flowrate), s
number of stirred tanks in each path
volume flowrate, m3 s21
time, s
phase volume, m3
phase volume based on interface height measurements, m3
dimensionless volume
ACKNOWLEDGEMENTS
M.J.H. Simmons would like to acknowledge funding by the School
of Chemical, Environmental and Mining Engineering, University of
Nottingham, and BP Exploration
The manuscript was received 10 November 2003, and accepted for
publication after revision 14 July 2004.
Trans IChemE, Part A, Chemical Engineering Research and Design, 2004, 82(A10): 13831390