Liquid Liquid Separation Technology

Sulzer Chemtech

Liquid-Liquid Separation Technology 

Introduction

coalescence)andwiththebulkphaseas  The Brownian orce additionally acts on this orms and settles rom the mixture smallerdropletsinafuid.Aneverydayex(drop-interace coalescence). The kinet- ampleisseeninabeamosunlightwhere ics,orrateatwhichtheseprocessestake dustparticlesintheairareseento“shima) Mixingothephasesineitherpurpose- place,determinetheselectionanddesign mer”,therandommotionbeingduetothe built equipment, mechanical mixers, o equipment. The driving orce promot- bombardmentothesmalldustparticles staticmixerswherepressureenergyis ingcoalescenceisgravityandinagiven by air molecules. The dust particles aappliedtoincreasethesuracereeensystemisproportionalto∆r · g,∆rbeing ectedinthiswayareinthesizerangeo ergyothefuidstoproducedroplets, thedensitydierencebetweenthetwoliq- 0.1~2 mm.Largerparticlesarenotaectorinshearfowothefuidmixturein uidphases.Thediameterothedroplets edinthisway.Inasimilarmannersmaller pipes. isa criticalparameter.In determiningthe liquid droplets in a liquid continuum are settling velocity in a liquid-liquid disper- so aected and since the settlingvelocb)Thecoolingoasaturatedliquidbelow sionthedropletsizecombinedwith∆r · g ityduetogravityosuchdropletsisvery the solution point so that the solute phase condenses out o solution re- willdenethe“settling”orceonadroplet. low,therandommotionimpartedonthe sultingintheormationoasecondliq-  This separation principle is governed by dropletsbyBrownianmotionturnsoutto theStokesLawwhichisdenedas: beotheorderothesettlingvelocity.The uidphase.Thistakesplacerequently netresultisthatdropletsinthisrangeo in storage tanks and in processes 2 sizeswillnotsettleoutandthereoreare g · |Dr| · d downstreamocondensersorcoolers vd = notamenabletogravitysettlingmethods. 18 · mc Whentwophasesareormed,thismixture Such dispersions are called secondary ismostotenintheormoadispersion dispersions.TechnicallytheyarestilltherWhere: (dropletsoonephasedistributedinthe modynamicallyunstablebutthekineticso vd Settlingvelocityoadispersed secondorcontinuousphase).Themixture separation bygravityonlyis solow that droplet is thermodynamically unstable, meaning ormostpurposestheyappearstable.Sethatgiventime,thedropletswillseparate condarydispersionscannotbeseparated Dr Densitydierencebetweenthe outto ormtwo bulk liquid phases. This eectively in gravity or primary separatitwo liquid phases takes place by droplets coalescing both on equipment and require dierent techDropsizediameter with“nearneighbor”droplets(drop-drop d niquesorseparation. In industrial process equipments liquidliquidmixturesareproducedbyessentially twodierentmechanisms.

mc

Dynamicviscosityocontinuous phase

g  Gravitationalacceleration

Content

Page

Introduction

2

Product Summary

4

Mellaplate

6

Feed Inlets and Calming Bafes

9

DC Coalescer

10

Dusec Coalescer

11

Wash Tank Distributor

14

 TestingandNewDevelopments

15

2

Introduction

 The simplest orms o equipment used to separatedispersions arehorizontal or verticalgravitysettlingtanks.Thecapacityosuchvesselsdecreasesastherate ocoalescenceandseparationdecreases.  Thereore, there will be circumstances where the dimensions o such vessels are uneconomical or some applications and methods to improve the separation kineticsneedtobeapplied.Thiscanbe achievedbyincreasingthedrivingorceto acceleratethestepsinthemechanismo coalescence. Sulzer oers a range o equipment designed to accelerate the separation o either primary or secondary immiscible liquiddispersions.Coalescers-andtheir inherent benets - are today oten considered preerable to conventional gravity separators. Figure 1 gives a simple overviewo howprimary and secondary dispersionsareusuallyormedandwhich Sulzercoalescersaresuitabletoseparate thesedispersions.

Immiscible Dispersions Typically Formed

Deliberately By:

 Accidentally By:

LowShearProcessessuchas:

HighShear&ThermalProcessessuchas:

•SolventExtraction •MixerSettlers •SteamStripping •WashingProcesses •Counter-currentTowers

Creating Primary Dispersions:

•Coarsedropletdistribution •Predominantly>30µm •Separatereadilyundergravity

•Waxyeeds? •SolidsContent? •LowPressureDrop?

•CentriugalPumps •ChokeValves •CondensationoImmiscible Liquids •EntrainedDispersionrom PrimarySeparations •Sub-coolingoLiquidsin Storage

Creating Secondary  Dispersions:

•Finelydisperseddroplets •Typically1-30µm •Slowtoseparateundergravity •Appearanceotenhazy

Separated Using

 Yes

No

Separated Using

Separated Using

Mellaplate Coalescers

DC Coalescers

Dusec Coalescers

Dusec Plus Coalescers

Fig. 1: Overview about Formation of Dispersion and suitable Sulzer Coalescer Types

3

Product Summary

Type of Separator 

Materials

 Applications

Mellaplate TM

Stainlesssteels  Alloy625,825

Improvedseparationeciency.  Twophasesdisengagecontinuouslyalong theplateorsheets.Improvedfowstability. Reducedriskodropletre-entrainment.  Verysuitableinsystemssusceptibleto oulingwithincreasedplateangleand platespacing. Eciencymaintainedevenwithphase inversionodispersedliquid. Suitableoroperationwithagasphase.

DCCoalescer TM

 Theseareproducedby twodissimilarlaments knittedtogethertoorm themesh.Onelamentis ametallicwiremadeo  stainlesssteeloralloyC22, C276,400,625or800 andtheotherismadeo  PP,FEP,ETFE,PTFE, orglassbers

Improvedseparationeciency. Highercapacitiesallowde-bottlenecking oconventionalseparators. Largecostsavingsinpressurevessels. Eciencymaintainedevenwithphase inversionodispersedliquid. Highreevolumemeanssmaller pressuredrop.

Dusec TM DusecPlus TM

Incartridgeormwiththe liquidfowingromthe centerradiallyoutwards, theDusecandDusecPlus Coalescerconsistoaselectionobermaterials.

Fibertopologyandsuraceproperties combinedwithoptimizedlayer compositionsmeanhighereciency. Separationeciencydownto10ppm entrainmentoreedroplets. Higherloadingsandabsenceojetting romouterlayersmeanhigherpacking densities. Smallervesselsizemeanscapitalcost reduction. Pressuredropminimized. Quickperormancerecoveryollowing eedconditionchanges.

Shell Schoepentoeter TMand SchoepentoeterPlus TM InletDevice

Stainlesssteels,  Alloy625,825

 TheSchoepentoeteristhemostcommonlyusedvaneinletdeviceorintroducing gas/liquidmixturesintocolumns.  TheSchoepentoeterPlusisanadvanced eedinletvanedevicewithconsiderably increasedde-entrainmenteciency. Bothdevicessuppressandminimizethe turbulenceintheinletcompartmento  theseparator. Entryogasintotheliquidphaseislow.

GIRZCyclone InletDevice

Stainlesssteels,  Alloy625,825

 TheGIRZisusedasadeoamingcyclonic inletdevicetosuppressandbreakmany typesoprocessoams.Sometypical applicationsincludereewaterknockout drums,fashdrums,testseparators,2and 3-phaseproductionseparators.

0604 2507-4

4

Product Summary

Typical Operational Range

Characteristics

 Applicableorprimarydispersions. Dependingonthetypeused,Mellaplate coalescerscanoperateatseparation fuxesoupto100m3 /m2h.Compared toemptysettlersimproved“cut-o”diametersareachievedduetoshortersettling distancebetweenplates.

MellaplateWismadeupoasetoparallelplatesthat isttedintoavesselintheseparationsectionsuchthat theplaneotheplatesisarrangedintheaxialdirection othevessel.Theplatesarenormallyinclinedtotheaxis atanangleo45ºor60º.Theplatespacingisothe ordero15to100mm. MellaplateM,MGandNaremadeupostructuredcorrugatedmetalorplasticsheets. Highpackingdensitymeansmoresheetsinagiven vesselvolume.

 Applicableorprimarydispersions. Low”cut-o”diameters,thereore extendedrangeooperation.Thelower limitisatornearthetransitionregion romprimarytosecondarydispersioni.e., cut-odropletsize~30-40µm. DependingontheDCCoalescertype andapplication,highseparationfuxeso upto120m3 /m2hcanbeachieved.

Manuacturedasaknittedwiremeshpacking. Canbeeasilycustomizedtosuitmostvesselshapes andsizes. DCCoalescersaresensitivetothepresenceosolidsin theeed.Typically,particlesizesbelow~50µmdonot causeexcessiveblockage.

 Applicableorsecondarydispersions wherethedropletsaresosmalltheydo notreadilywetasuraceorsettleunder gravity–typicaldropsizesareinthe rangeo1to30microns. Designedtoachievehighperormance withminimumpressuredrop,theDusec PlusmodelprovidesahighcapacityalternativetoconventionalDuseccartridges.  Thesmallerdiameterandincreasedpackingdensitymakeitsuitableormaximizing theeectiveareaothecoalescermediain agivensizeovessel.

DusecandDusecPluscoalescersaresuppliedascartridges.Scopeosupplyusuallyincludessupportsand mountingplatesuitableordirectinstallationinavessel oeitherhorizontalorverticalorientation.Cartridgesare availableorhighlyaggressivechemicalenvironments andhightemperatureapplications.

Generallydesignedatdynamicpressures <8000Pa,butcanperormwellathigher values. Istypicallyusedoreedshavingagas volumeractiono>70vol%. Suitableorinstallationinhorizontalor verticalseparators. Suitableorliquidslugs.

Constructedrombanksosweptvanes.Designsavailableoroperationinmostgas/liquidfowregimes.  TheSchoepentoeterPlusisequippedwithsophisticated catchingrimstominimizeentrainment.

 TheGIRZcyclonicinletdeviceutilizesthe momentumotheeedstreaminletinordertogeneratehighg-orces.Deoaming isachievedasgasbubblesareseparated romtheliquidphasebythecentripetal orcesinthecyclonetubes.Gasisreleasedromthetopothedeviceandthe bottomopeningothecyclonesissubmergedbelowtheliquidintheseparatorin ordertoavoidagas‘blowout’.

 TheGIRZconsistsoanarrangementotwoormore cyclonessymmetricallyarrangedoacommon,centrallylocatedheader.Thedevicecanbeinstalledinvertical orhorizontalvessels.Irequired,mixingelementsatthe cyclonegasoutletwillimprovethedistributiontothe downstreamdevice.

5

Mellaplate

SulzeroersMellaplate TMcoalescers,whichenhancetheseparationprocessbyallowingthereducingthedropletsettlingdistance,thus aidingthecoalescenceothedroplets.

SulzerMellaplate coalescersareavailableinourdierent types:

Mellaplate W

Mellaplate MG

Mellaplate M

Mellaplate N

Construction Form

Flatparallelplates

Structuredcorrugated fatplates

Structuredcorrugated metalsheets

Structuredcorrugated plasticsheets

Relative Capacity 1)

1

1.5

1.5

1.5

Typical droplet cut-off size

≥

Pressure drop

Negligible

0.5–4mbar

1–10mbar

1.5–15mbar

Solids Handling

Highouling resistance

Goodtohighouling resistance

Moderatetogood oulingresistance

Moderatetogood oulingresistance

 Alsousedaswaveand oambreakerelements

Moresuitedor de-oilingduetothe plasticsurace

50µm

≥

100µm

Remarks

Table A

≥

50µm

≥

50µm

1)ValuesarerelativetoMellaplateWtype

Sulzer Mellaplate TM Type W  Thistypeocoalescerconsistsoacombinationoinclinedparallelplates,withxed spacing,sothatdropletsettlingdistance isreducedsignicantlyandthisenhances the coalescence process. The inclined arrangement o plates allows the liquid phases to disengage diagonally towards the liquid interace. The fow is normally keptinthelaminarregionorbetterseparation perormance. The inclination and the spacing between the plates is deter-

6

mined by the application, the nature o contaminantspresentinthemixtureand thedegreeoseparationneeded.Typically, the angle is either 45 or 60° with plate spacingrom15to100mm.Duetothe highoulingresistance,theMellaplateW (Fig.2)is,orexample,usedincrudeoil productionseparators.Itisalsoidealor retrottinganexistinggravitysettlertooperateatahigherthroughputandimprove theseparationperormance.

From the construction aspect, the MellaplateWcanbemadeinmodularrame arrangementorboxes(Fig.3).Alternatively,itcanalsobeconstructedinonepiece (Fig. 4) or vessels with access through the body fange. Experienced engineers atSulzercanassistyouindesigningthis separator to ensure trouble-ree installationandoperation.

Mellaplate

Fig. 2a: Sulzer Mellaplate W 

0611 2505-4

Fig. 2b: Sulzer Mellaplate W 

Framearrangement

Boxarrangement

Fig. 4: One Piece Sulzer Mellaplate W 

Fig. 3: Frame and Box Arrangement 

7

Mellaplate

Sulzer MellaplateTM Type M, MG and N  This type o coalescer is made o structured corrugated metal or plastic sheets (Fig. 5). Variousuniversities and oil companieshavetestedMellaplateM,MGand Ntypesinoil/waterseparatorsalsounder moving conditions. Sulzer supplied the rstMellaplatein1988ortheHuttonTensionLegPlatorm(TLP)inUK.Sincethen hundreds o oil/water separators have beenequippedwithvariousMellaplateM, MGandNstyles.Somehavebeenused aswavebreakersordampersinoil/water separatorsonTLPsandFPSOs(Floating ProductionStorageandOfoading). Fig. 5: Sulzer Mellaplate - M 

 Vessel Arrangement with Sulzer MellaplateTM Coalescer  TheSulzer MellaplateCoalescer typesW, M,MGandNcanbeusedfexiblyineitherhorizontalorverticalvessels.Atypical sketch o a 3-phase separatoris shown

below(Fig.6)whichshowstheSulzerMellaplateWascoalescerandtheMellaplate Maswavebreakingdevice.

SulzerMellachevron misteliminator

SulzerMellaplateM waveandoambreaker

ShellSchoepentoeter inletdevice

Weir

SulzerMellaplateW coalescer Calmingbafeplate

Fig. 6: Horizontal 3-phase separator 

8

Inlet Devices

Feed Inlets Fortwo phase liquid/liquidseparators or threephaseseparators,itisimportantthat thefowinthevesselisequalized.  Any turbulence or disturbances such as fowvariations,surgesorexternalmotion maysignicantlycompromisetheseparationeciency.Separatorsinanupstream oil and gas environment are particularly exposed to such problems. Sulzer inlet devices help to signicantly improve the fowdistributionacrossthevesselwithout causingdropletstoshatter.

Fora 3-phaseseparator,dependingon thecharacteristicandinletmomentum othe eedmixture,dierenttypesoinletsaresuitable: Suitabilityor Inlet largegasvol. Momentum raction

Deoaming

Degassing

Relative Costo  Device

Elbowpipe

–

–

–

–

$

Halopenpipe

+

+

–

–

$$

ShellSchoepentoeter TM vanetypeinlet

+++

++

+

++

$$$

SulzerGIRZ cyclonicinlet

+++

+++

+++

+++

$$$$

Table B

Calming Bafes Sulzer recommends using the calming bafeinallliquid/liquidandgas/liquid/liquidseparators,eitheroperatedassimple gravity settler or equipped with Sulzer MellaplateorDCCoalescer.Thesebafes areprovidedwithuniormholeswhichare optimized to achieve good fow distribution and minimize any turbulence in the liquid phases towards the coalescer internals. Depending on the type o applications,twocalmingbafesmaybeused. Fig. 8a: Calming bafe plate

0.115 m/s 0.102 0.090 0.077 0.064 0.051 0.038 0.026 0.013 0-000

CDE = 15 Fig. 7: CFD prediction of axial velocity distribution after the second bafe of a two calming  bafe arrangement 

Fig. 8b: Calming bafe boxes in front of a Mellaplate W 

9

DC Coalescer 

Sulzer DC Coalescer TM  TheSulzerDCCoalescerTechnologyprovidessignicantlylower settlingtimesorprimarydispersionswithdropletsassmallas 30microns.

Metallament highsuracereeenergy

Whilethedropletspassthroughthecoalescer,theygrowinsize througha continuous process o coalescing anddraining. The astersettlingvelocityocoalesceddropletsleadsto minimized vesseldimensionsasopposedtogravityseparationalone.

Coalesceddroplets atjunctionotwo dissimilarmaterials

 Thecoalescerusesacombinationo twomaterialswithdierent suracereeenergy–typicallymetalandplastic–toenhancethe dropletcoalescenceobothphases(Figure9).  Theco-knittedSulzer DCCoalesceroutperorms singlemedium alternativesprovidinganimproveddrainingatthejunctionpoints othe twodissimilarmaterials.(TableC).The separation perormanceismaintainedregardlessowhichphaseisdispersed.  TheSulzerDC Coalescercanbeinstalledbothvertically andhorizontally. Shape andxing method canbe customized orthe vesselorhousingintowhichitwillbeinstalled.Abroadvarietyo materialsandknittingtypesoeratailor-madesolutionwherever ecientliquid-liquidseparationisrequired.

Plasticlament lowsuracereeenergy Fig. 9: Preferential Wetting & Junction Effect 

Packing

Dispersedphase

StainlessSteel

Kerosene

0.10

Water

1.00

Kerosene

1.10

Water

0.05

Kerosene

1.45

Water

1.45

Polypropylene

Key Benets

• Debottleneckingoexistingsettlers •Reducedsizeo2-and3-phaseseparators •Improvedphaseseparationeciency •Low“cut-o”diametersprovideextendedrangeooperation.  Thelowerlimitisatornearthetransitionregionromprimaryto secondarydispersionsi.e.,cut-odropletdiameter~30-40µm.

Sulzer DCCoalescer StainlessSteel/  Polypropylene

RelativeFlux1)

1)whereentrainmentexceedslimit

Table C: Comparison of conventional and Sulzer DC Coalescer 

•Depending on the DC Coalescer type and application, high separationfuxesoupto120m3 /m2harepossible(Figure10) •Applicableorprimarydispersions •Equalperormanceregardlessowhichphaseisdispersed Typical applications of Sulzer DC Coalescer

•Separationodispersionollowingwaterwashingstages •Entrainmentreductionoeitherphaseorliquid-liquidextraction columnsasLPGAmineTreaters,HydrogenPeroxideExtraction ColumnsandCausticWashers • Separation o dispersions ormed by condensation ollowing azeotropicdistillationasinButanol/WaterDistillation •Separationoliquidsollowingsteamstripping Fig. 11: Sulzer DC Coalescer    y   c   n   eDC    i   c        f    E   n   o    i    t   a   r   a   p   e    S

9201 SS/PTFE(M) DC 9201 SS/PP DC 9233 SS/PTFE(M) DC 9233 SS/PP DC 9230 SS/PTFE(M) DC 9230 SS/PP

0 Fig. 10: Performance chart of Sulzer DC Coalescers

10

Flux [m3 /m2h]

DC 9236 SS/PTFE(M) DC 9236 SS/PP 120

Dusec Coalescer 

DusecTM and Dusec PlusTM Cartridge Coalescer Insecondarydispersions,thedropletsaresosmallthattheydonotreadilywetasurace  Another big advantage these coalescers orsettleundergravity.Typicaldropsizesareintherangeo1to30microns.Incartridge oer isthattheyperormequallywellinormwiththeliquidfowingromthecentreradiallyoutwards,thecoalescingprocessis dependent which phase is dispersed. improvedastheliquidencountersa fowresistance.Dueto adhesiveorces,theinter- Dusec cartridge coalescers can be inscepteddropletsclingontothebersuraceatselectivepointswhereclustersormuntil talled in bothhorizontal andverticalvescoalescencetakesplaceandthedropletgrows.Viscousdragorcesincreaseuntilthey sels(Fig.13). exceedtheadhesionorces,causingthedropletstoseparateromtheberandmove  A selection o high specic surace area urtherintothecoalescerberbed,wheretheprocessisrepeated.Finallythedroplets reachprimarydispersionsize>60microns.ThisistheworkingprincipleoSulzerDu- bermaterials,arrangedin aspecicpattern in the cartridge, ensure high eciseccartridgecoalescers(Fig.12).Animportantadvantageisthattheouterlayerothe encycoalescenceodropletsinabroad cartridgeisothesamecompositeconstructionastheSulzerDCCoalescer,whichaccelerates separation andavoidsjetting &entrainment.Normallyno dropletsleavethe spectrum o applications. Depending on thearrangement& constructionolayers outersuraceanddrainagetakesplacewithintheDCCoalescerslayer.Inprincipalthe in the cartridge, theSulzer Dusec coaledistancebetweenthecartridgescantheoreticallybezero.Inpractice,however,aminiscers have been classied into dierent mumpracticalspaceisnecessarytoallowthecartridgestobeeasilyinstalledontothe types (Table D). Qualied engineers at platewithinthevessel. Sulzer can provide advice on coalescer design including specication o vessel dimensions, main process and interace controlconnections,andthenumberand typeoDuseccartridges.Thecartridges 1. 2. areavailableindierentlengtho500mm, Dropletscaptured Dropletscoalescence 1000mmand1500mm. onlaments begins

 Acceleratedseparationwithoutdroplet break-upattheoutlet otheSulzerDusec andDusecPlus cartridges

Cartridgedesignsare available or many applications including aggressive chemicalenvironments,asorhydrogenperoxideandorhightemperatureduties.

Jetting&entrainment attheoutletoconventionalcartridges

3. Largerdroplets capturedormed bycoalescence

4. Ultimately,dragorce oliquidstreampulls dropletsromlaments

Fig. 12: Schematic representation of droplet coalescence in a Sulzer Dusec Coalescer 

11

Dusec Coalescer 

N2

Key Benets

N1

•Fiber topology and surace properties combinedwith optimizedlayer compositionsmeanhighereciency •Higher loadings andabsenceo jetting rom outer layers mean higher packing densities.

N2

•Works equally well independent which phaseisdispersed •Pressuredropminimized •Separationdownto10ppmreeentrainmentpossible •Suitableorinteracialtensions >2dyne/cm N3

•Quick perormance recovery ollowing eedconditionchanges

N1

N3 Fig. 13a: Heavy phase dispersed 

Fig. 13b: Light phase dispersed 

Legend:

N2

N1:Feed N2:Lightphaseoutlet N3:Heavyphaseoutlet N1

N3 Fig 13c: Heavy phase dispersed (horizontal layout). A dome is used if the light phase is dispersed.

Fig. 14: Sulzer Dusec with mounting plate

12

Fig. 15: Sulzer Dusec

Dusec Coalescer 

Resin bonded Type

Max. Design Temperature pH IPPlikelytobeattacked use  IEpoxyresinlikelytobeattacked use 

Mechanically sealed

1/RB

2/RB

3/RB

4/RB

5/RB

1/MS

2/MS

3/MS

4/MS

5/MS

80 <10

80 <10

90 <10

80 <10

80 <14

80 <10

80 <10

150 <10

80 <10

80 <14



















 Applications

Reining applications  Amineextraction LPG Processing Gas condensate Metal extraction Seawater Produced water Hydrogen peroxide  Aromaticsolvents Phaseratio:>5vol% dispersed phase  Availablecartridgelength Outer cartridge diameter Max.permissiblepressure dropbeorecartridgeshave to be replaced

Yes Yes Yes Yes Yes No No No No

Yes Yes Yes Yes Yes Yes Yes No No

Yes Yes Yes Yes Yes No Yes No No

Yes Yes Yes Yes Yes No No No No

Yes Yes Yes Yes Yes No No No No

Yes Yes Yes Yes Yes No No No No

Yes Yes Yes Yes Yes Yes Yes No No

Yes Yes Yes Yes Yes No Yes Yes Yes

Yes Yes Yes Yes Yes No No Yes Yes

Yes Yes Yes Yes Yes No No No No

No

No

No

Yes

No

No

No

No

Yes

No

500, 1000 and 1500 mm Dusec/Dusec Plus 230/156 mm

0.75 - 1 bar

500,1000and1500mm Dusec/Dusec Plus 230/156 mm

0.75 - 1 bar

Table D: Dusec and Dusec Plus Type Selection Table

Dusec PlusTM Coalescers Designed to achieve high perormance with minimum pressure drop, the Sulzer Dusec Plus model provides a high capacity alternative to conventional Dusec cartridges. The smaller diameter and increasedpackingdensitymakeitsuitable or applications where it is necessary to maximizetheeectiveareaothecoalescermediainagivensizeovessel.

Key benets

Service & Supply 

• AllthebenetsoaDuseccoalescer

Sulzeroersafexibleandcomprehensive servicewhichincludesthedesignor the complete vessel (including the various nozzle elevations, sizing) andproduction oadditionalinternalssuchasweirsand supports,orthemountingplateorSulzer DusecandDusecPluscoalescers.

• Higheciencyatminimalpressuredrop • Increasedpackingdensity • Maximizedeectiveareaothecoalescermediainagivensizeovessel.

13

Wash Tank Distributor 

Researchco-operation between Sulzer and Totalhas led to a newphase inversiontechnology where water-in-oil dispersions areconverted to oil-in-water. ‘Double emulsions’ canbe createdwhereverysmalldropletsowaterarecarriedinoil droplets whicharethemselvesdispersedwithinacontinuouswaterphase -knownasa‘waterleg’.Waterdroplets,alongwithsaltsandother contaminants,canberemovedromtheoilbycontactingtheoil dropletswiththecontinuouswaterphase.TheSulzerWashTank DistributorVROL(Fig.16)isusedatthebottomothewaterleg and has been developed tocreateoptimaldroplets ooil and removessolids,evenwhensubjectedtomotion. InconjunctionwithTotal,thetechnologyisbeingappliedinwash anddesaltingtanksinthehullsoFPSOvesselsorremovingentrainedwater,saltsandcontaminantsromcrudeoil.Thedistributor system substantially improves the separation perormance andconcentrationso<0.5%vol.BS&W(basicsedimentand water)intheoiloutletcanbeobtained. Fig. 16a: Wash Tank with Sulzer Distributor 

Fig. 16b: Sulzer Wash Tank Distributor 

Fig. 17: Sulzer Wash Tank Test Rig

Forthedevelopmentootherinnovativewashseparatorprocesses,smallandlargescaletestrigs(Fig.17)havebeendeveloped whichenableustoinvestigatedetailedcoalescencephenomena aswellasthewholeseparationprocess.CFDisusedtosimulate thewashtankprocessparticularlytakingintoaccountthemotion othetank.

Fig. 16c: Sulzer Wash Tank Distributor 

14

Testing and New Developments

Our liquid phase separation testing acilities (Fig. 18) are available or the developmentoinnovativeequipment,andor investigatingspeciccustomerproblems. In-house development o an automatic dropletsizeanalysissystemallowsstate otheartmeasurementodropsizedistribution(Fig.19),eveninveryhighconcentrationdispersions. Mobiletestrigsareavailableorthecustomertotestintheactualprocess.

Fig. 18a: Test rig for Sulzer Mellaplate and DC Coalescer 

Fig. 19: Drop size analysis Fig. 18b: Sulzer Dusec test rig for customer  tests on site

Recent Sulzer Product Developments on the subject Flow Assurance and Phase Inversion Static mixers rom Sulzer (Fig. 20) are used or ecientmixing oone ormore phases.Whenthemixerisusedtocreate dispersions, Sulzer static mixers achieve well-dened droplet size distributions compared to other equipment such as chokevalves.

 ThespecialSulzerINVERTOMIX™(patent pending)canbeusedtoobtainphaseinversionromoil-in-watertowater-in-oilor viceversa.Thisprovidesgoodcontrolo phasecontinuityandis oparticularinterestor phase separation in heavy crudeoil-water systems as well as fow assuranceinpipelines.

0697 2720

Fig. 20: Sulzer static mixer 

Sulzer Static Mixer

Oil Sulzer INVERTOMIX TM

Water

Bypass

Water addition

15

Headquarters

North and South America

SulzerChemtechLtd P.O.Box65 8404Winterthur,Switzerland Phone +41522625028 Fax +41522620182 [email protected] www.sulzer.com

SulzerChemtechUSA,Inc. 1SulzerWay  Tulsa,OK74107,USA  Phone +19184466672 Fax +1 918446 5321

SulzerChemtechLtd,amemberotheSulzerCorporation,withheadquartersinWinterthur,Switzerland,isactiveintheeldoprocessengineering andemployssome3500personsworldwide. SulzerChemtechisrepresentedinallimportantindustrialcountriesand setsstandardsintheeldomasstranserandstaticmixingwithitsadvancedandeconomicalsolutions.

 Asia, Pacic

SulzerChemtechPte.Ltd. 10BenoiSector 629845Singapore Phone +6565155500 Fax +656862 7563

 Theactivityprogramcomprises: • Processcomponentssuchasractionation trays,structuredand randompackings,liquidandgasdistributors,gas-liquidseparators,and internalsorseparationcolumns • Engineeringservicesorseparationandreactiontechnologysuchas conceptualprocessdesign,easibilitiesstudies,plantoptimizationsincludingprocessvalidationinthetestcenter • Recovery o virtually  any solv ents used bythe pharmaceuticaland chemicalindustry,ordicultseparationsrequiringthecombinationo specialtechnologies,suchasthinlm/short-pathevaporation,distillationunderhighvacuum,liquid-liquidextraction,membranetechnology orcrystallization. • Complete separation process plants, in particular modular plants (skids) • Advanced polymerization technology orthe production oPLA and EPS • Tower eld services perorming tray and packing install ation, tower maintenance,welding,andplantturnaroundprojects • Mixingandreactiontechnologywithstaticmixers • Cartridge-based metering, mixing anddispensing systems, anddisposablemixersorreactivemulti-componentmaterial

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22.16.06.40-IX.12-10-PrintedinSwitzerland

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