Process calculation of three-phase separators and separation packing

Depending on the medium and structure, different fillers are used; there are also cases where no filler is used at all

A three-phase separator generally has coalescing and defoaming packing; the coalescing packing is located in the pre-separation section, while the defoaming packing is located at the gas phase outlet section. Calculations can be carried out in accordance with API-related standards.

1. Selection of packing type: The choice of packing type depends on the requirements of the separation process, and the following aspects are generally considered: (1) High mass transfer efficiency – Generally, structured packings have a higher mass transfer efficiency than random packings. (2) High flux – While ensuring high mass transfer efficiency, packings with a high bubble point velocity or gas kinetic energy factor should be selected. (3) Low pressure drop across the packing layer. (4) Packings that are resistant to fouling and clogging, and that are easy to install, remove, and maintain. Metal packings can be made from various materials, and the main consideration when selecting them is corrosion resistance. Carbon steel packing is inexpensive and has good surface wetting properties; it should be given priority for use in systems that are non-corrosive or have low corrosivity ； Stainless steel packing has strong corrosion resistance and can generally withstand the corrosion of common substances other than Cl–. However, it is more expensive, and its surface wettability is poor; in certain special applications (such as vacuum distillation processes with extremely low spray densities), its surface must be treated to achieve good performance ； Packers made of materials such as titanium and special alloy steels are very expensive, and are generally used only in environments with extremely high corrosivity. Generally, metal fillers can be made into thin-walled structures; they have a high flow rate, low gas resistance, and excellent impact resistance, allowing them to be used under conditions of high temperature, high pressure, and high impact loads. As such, they are the most widely used.

For the process calculations mentioned by the original poster, reference can be made to Chapter 4 of Feng Shuchu’s book on oil and gas transportation and processing; page 254 there contains the calculation procedures for horizontal three-phase separators. There are also various design standards, such as CNOOC’s standards for oil and gas separator design and the API standards in the United States. Other reference materials include technical manuals on oil and gas transportation design in oil fields. I have been working on this project recently, and to determine the basic dimensions of the separators, I relied on these sources, primarily those related to oil and gas transportation and processing.

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Refer to the standards: domestically, SY/T 0515-2007 Standard for Separators; internationally, API SPEC 12J

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