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SOLIDS/LIQUIDS SEPARATION
Fred Mueller
President
ABSTRACT
Gas solids/liquids separation is the removal of entrained non-gas particles from multi-phase gas
streams in order to protect either stationary or rotating equipment from the harmful effects due
to non-gas particles entering those devices. Mechanical separation concepts require basic
understanding of particle formation, physics, size and motion.
INTRODUCTION
Particle Formation
Non gas particles are generated and entrained in the gas stream in the spray, annular or slug
flow regimes. Particle formation begins initially on the molecular level when particles of like
substances collide, therefore coalescing with one another.
Particle Physics
The forces imposed on particles in mechanical separators are gravity, drag and inertial forces.
The physical phenomena that generate these forces are dependent on particle size, shape,
velocity, and on the gas streams density and viscosity.
Particle Size
An index for the determination of particle size spectrum is the Reynolds number. The Reynolds
number provides a ratio between viscous and inertial forces acting on particle motion. Newtons,
Intermediate, and Stokes laws are used to describe the action by which mechanical separators
operate.
Particle Motion
Mechanical separators utilize the particle motion of impingement in the primary separation of
solids/liquids and gravity forces to carry off of separated solids/liquids.
Fundamentals of Gas Solids/Liquids Separation
Many process operations require the removal of entrained non-gas particles from multi-phase gas
streams. The removal of these non-gas particles is the process in itself (capture of a valuable
product) or the process of cleaning a gas stream in order to protect either stationary or rotating
equipment from the harmful effects due to non-gas particles entering those devices.
The removal of entrained non-gas particles from a multi-phase gas stream is a separation process
involving the removal of:
C POINT
LIQUID
Small liquid particles of like substances will join (a) Bubble (e) Slug
with one another upon collision in what is called
coalescence. The rate at which the particles with GAS GAS
GAS
no net movement will join together is dependent
on gas viscosity and temperature and the number (b) Plug (f) Semi-annular
of particles present. Higher temperatures, lower
viscosities, and flow stream agitation will provide GAS
GAS
higher coalescence rate. Liquid present within
the gas stream will flow in one of several flow (c) Stratified (g) Annular
regimes.
GAS
Figure 2 depicts the various flow regimes that
occur within multi-phase gas streams. The two
(d) Wavy (h) Spray
flow regimes that provide the lowest liquid to gas
weight ratio are annular and spray flow. Annular
flow is characterized by finite liquid amounts Figure 2
carried in suspension with significant amounts
along the pipe wall. Spray flow regime is characterized by particles in suspension in the gas with
negligible amounts of liquids on the pipe wall. Slug flow regime is often encountered in gas
streams with greater liquid to gas weight ratio than annular or spray regimes.
Liquid particles are generally idealized as being spherical in shape since this is the shape surface
tension forces impart. Liquid particles might have shapes other than this depending on other
forces such as gravity and drag. Solid particles are also idealized as being spherical, though
in reality have irregular shapes.
Black Powder
What is it? Black powder is a catch-all term that describes material that collects in gas pipe
lines and creates wear and reduced compressor efficiency, clogged instrumentation and
valves, and flow losses in long pipe lines. The material can be wet, with a tar-like appearance,
or dry and be a fine powder. Chemical analyses reveal it is any of several forms of iron sulfide
and iron oxide. Further, it can be mechanically mixed or chemically combined with any number
of contaminants, such as water, liquid hydrocarbons, salts, chlorides, sand or dirt. Some pipe
lines have black powder problems and others do not. It appears those lines closer to the gas
gathering end of the system have problems, while those at the distribution end, with relatively
small systems, do not. Black powder is found in both "dry" and "wet" lines. One parallel line
can have a problem while the other does not. No pipe line has been identified to date that
has been able to eliminate the problem once it starts.
The forces imposed on particles in
mechanical separators are gravity, drag
and inertial forces.
Gas Motion Particle Motion
Gravity forces act vertically downward.
Drag forces are resistive forces. Inertial Particle being propelled by gas, with the gas velocity
forces are a result of particle circular exceeding the particle velocity.
motion. Particle circular motion generates
The particle is said to drag behind the gas, and this
centripetal force; a force that is directed retarding (slippage) is caused by the drag force being slightly
towards the center of the circular motion. less than the gas impact force on the particle.
Opposite to centripetal force is centrifugal
force and is due to a forced turning of the Gas Rotation
gas stream, and acts at right angles to the
particle angular motion. Fd
Axis
determinant in the operation of cyclone Fg F
and impingement type separators. This
action is best described in a rectangular
vector coordinates as shown in figure 3.
Note:
The particle in motion, if not at the wall, Fc - Centrifugal
will accelerate radially to the wall, and in Fd - Drag
the process absorb some of the centrifugal Fg - Gravity
F - Total
force.
Forces acting on a particle due to circular acceleration
generates particle motion along vector F.
The particle drag forces act in the direction
of the particle motion. Drag forces are in
response to the viscous effects of the gas Figure 3
opposing the particle motion. Drag forces are composed of pressure differences and shearing
stresses on the surface of the particle.
Additionally, a buoyant force is present due to displacement of the gas by the particle. This force
is insignificant on particles greater than 0.1 microns. Particles 0.1 microns and smaller approach
molecular size where buoyant forces become considerable in relation to particle size and become
a factor in Brownian Movement. Brownian Movement is the motion exhibited by small particles
that move non-uniformly along the gas streamlines due to collisions with gas molecules (additional
information regarding Brownian Movement will follow) .
Significant complex particle motion (rectilinear and curvilinear) translation exists about the axis
of the particle. Pure particle motion about the rotational axis exists but is not as significant as
the complex particle motion translation.
On the particle boundary layer shear stresses of the gas stream are opposed by the surface
tension of the gas-liquid interface. The liquid particle system may change relative to the magnitude
of the shear stress and surface tension; such as in the instance of liquid particles may be
generated from sheet flow (stream of liquid) and large particles may be broken into smaller
particles if the shear stress is larger than the surface tension.
As previously established, the physics that govern separator operation are those which determine
the forces and stresses acting on particles in the gas stream. The physical phenomena that
generate drag forces are dependent on particle size, shape, velocity, and on the gas stream's
density and viscosity.
For small particles or low velocities, viscous forces are dominant. For larger particles and higher
velocities inertial forces are dominant. This dynamic ratio of inertial to viscous forces is a
dimensionless number referred to as the Reynolds Number abbreviated - Re. The Reynolds
Number provides a determination of which regime, inertial or viscous, is dominant. This dynamic
ratio is graphically depicted in Figure 4.
100,000
Symbols and Legend
Ap = Area of Particle Projected on Plane Normal to
direction of Flow or Motion, sq. ft.
10,000 C = Overall Drag Coefficient, Dimensionless
Dp = Diameter of Particle, ft.
u2/2)A p
Fluid, ft./sec.
= Fluid Viscosity, (lb.mass)/(ft.)(sec.)=Centiposis 1488
Drag Coefficient, C =
Spheres
10 Disks
Cylinders
1.0
0.1
0.0001 0.001 0.01 0.1 1.0 10 100 1,000 10,000 100,000 1,000,000
Dp u
Reynolds Number, NRe =
Drag Coefficients for Spheres, Disks, And Cylinders and Any Fluid. From Perry, R. H., Ed., Chemical Engineers Handbook, 7th. ed., 1997,
McGraw Hill Company, Inc.
Figure 4
Drag force on spherical particles 3 to 100 micron is directly proportional to velocity in low Reynold's
number region. The applicable physical law is Stokes' Law and at Re < 2.0 the flow is laminar
and streamlines are smooth, it is considered to be "creeping flow" around the spherical particle.
Particles less than 3 microns in the Re < 2.0 regime are subject to Brownian Movement and
Stokes' - Cunningham Law. See Figure 5.
Creeping Flow
When a particle falls under the influence of gravity it will accelerate until the frictional drag in the
fluid balances the gravitational forces. At this point it will continue to fall at a constant velocity.
This is the terminal velocity. For spherical particles between 3 and 100 microns and
0.0001 < Re < 2 the applicable physical law that applies is Stokes'. The formula is stated in
Figure 6.
ut = Terminal Settling Velocity of Particle Under Action
2 ( s- ) of Gravity, ft/sec.
ut = gL Dp gL = Local Acceleration due to Gravity,(ft.)/(sec.) (sec.)
18 Dp = Diameter of Spherical Particle, ft.
= Fluid Density, lb.mass/cu.ft.
= Fluid Viscosity, (lb.mass)/(ft.)(sec.)
Figure 6
The following examples illustrate the extremes in particle sizes and velocities in relation to the
Reynolds Number:
Particles with a Reynolds Number of 1.7
An 80 micron particle in air at 70 F and 14.7 PSIA with a density of 100 lbs / cu. ft. has terminal
velocity of 62 FPM. While a 1 micron particle in air at 70 F and 14.7 PSIA with a density of 100
lbs / cu. ft. has terminal velocity of 5,0000 FPM.
A10 micron particle in air at 70 F and 14.7 PSIA with a density of 100 lbs / cu. ft. has terminal
velocity of 0.96 FPM. While a particle less than 1 micron (1.9 X 10-3 to be exact) in air at 70 F
and 14.7 PSIA with a density of 100 lbs / cu. ft. has terminal velocity of 5,0000 FPM.
Particle Size
Particle size is commonly defined by its diameter in micrometers, more commonly called microns.
For proper separator design, particle size analysis is important for correct equipment selection.
A convenient index for determination of particle size spectrum is the Reynolds number. These
dimensionless numbers provide a measure of the ratio between viscous forces and inertial forces.
Three equations are generally used to describe the action of mechanical separation, each being
limited to definite particle spectrum. These equations have the following ranges of particle
spectrum when applied to water droplets in air at atmospheric conditions:
Below 3 micron particle size, Stokes-Cunningham Law applies. Below 0.1 micron, Brownian
Movement becomes dominant. Brownian Movement is a random motion of particles caused by
collisions with gas molecules. Particles within Brownian Movement range approach molecular
size. Newtons and the Intermediate Law equations are generally applied to knock out drums
and gravity settling separators. Whereas Stokes and Cunninghams Law equations apply to
centrifugal, impingement, and filtering type separators.
Determination of particle size in a system is relatively easy with solids. However, with liquids it
is not. Liquids are in continuous change of state, subsequently particle size of liquids will vary
depending upon the source and nature of the operation generating the particular particles.
For the applicable physical law for particles in relation to the Reynolds Number see Table 1.
Characteristics Of Dispersed Particles
Gravity Settling of Spheres in Still Fluid
Commercial
Particle General Common Methods Equipment for Spheres of Spheres of
Diameter Classification of Measuring Unit Density Any Density
Particle Size
Collection or
in Air in Any Fluid Critical Particle Diameter
Removal of Laws of Settling
Particles from Diameter, Reynolds
Above Which Law Will Not
Microns
a Gas Microns Number Apply
NRe
100,000 100,000
200,000 1
2
5 Newtons Law 3
Dp,crit = Kcr
C = 0.44 gL ( s- )
1 in. gL Dp ( s - )
2 ut =1.74
10,000 1 cm. 10,000
1 in. Kcr =2,360 for Newtons Law
5 4
2
500
1,000 1,000 Intermediate Law Kcr = 43.5 for
Gravity Settling Chambers
0.71 1.14
( s ) 0.7
Impingement Separators
0.153 gL Dp
Sieving
ut =
Rain
2 0.29 0.43
5 -1
C = 24 NRe
Elutriation
Sedimentation
2
2 gL Dp ( s- )
ut = = uts
Air Filters
18
10 10
Dust
Fog
Packed Beds
5
Permeability*
Scrubbers
Microscope
0.0001
Stokes - Cunningham Law The Cunningham Correction on Stokes
Cloth Collectors
The Value Kme has Experimentally been shown to lie between 1.3 and
Electrical Precipitators
Centrifuge
Ultrasonics
0.1 0.1
Brownian Movement Brownian Movement is a Random
Ultramicroscope*
x= 2
2 3 N Dp Particles under 3 Microns Diameter
and Becomes Entirely Predominant
100A for Particles Under 0.1 Micron
0.01 0.01
5
Molecules
Large
0.001 0.001
* Furnishes Average Particle Diameter, but no Size Distribution Nomenclature: (Any Self-Consistant System of Units may be Employed; English Units are given by
x Size Distribution may be Obtained by Special Calibration way of Example.)
C = Overall drag Coefficient, Dimensionless NRe = Reynolds Number, Dimensionless =Dp E/
Dp = Diameter of Spherical Particle, ft. R = Gas Constant, 1,546(ft-lb.Force)(lb. mole)(F)
From Kinetic Theory of Gases: Dp crit = Critical Particle Diameter Above Which Law will t = Time, sec
Not Apply, ft. T = Absolute Gas Temperature. F abs., or R
gc = Conversion Factor, 32.17(lb.mass/lb.Force)/ ut = Terminal Settling Velocity of Particle Under Action
m =3 / (ft./sec.) of Gravity, ft/sec.
gL = Local Acceleration due to Gravity,(ft.)/(sec.) (sec.) uts = Terminal Settling Velocity of Particle as Calculated
= 8gc RT / M Kcr = Proportionality Factor, Dimensionless from Stokes Law, ft./sec.
Km = Stokes-Cunningham Correction Factor = Mean Molecular Speed, ft./sec.
Dimensionless x = Average Linear Amplitude of Displacement of
Kme = Proportionality Factor, Dimensionless Particle in Time t, ft.
M = Molecular Weight, lb./mole = Fluid Density, lb.mass/cu.ft.
N = Number of Gas Molecules in a mole, s = True Density of Particle, lb.mass/cu.ft.
2.76 x 10 26 Molecules/lb mole. = Fluid Viscosity, (lb.mass)/(ft.)(sec.)
m = Mean Free Path of Gas Molecules, ft.
Characteristics of dispersed particles. Perry, J. H., Ed., Chemical Engineers Handbook, 3rd. ed., 1950, McGraw Hill company, Inc.
Table 1
Particle Motion
Mechanical separators utilize particle motion in two ways:
wPrimary separation of solids/liquids
wCarry off of separated solids/liquids
All separators have more that one generative force providing particle separation, however, they
are typically classified by the dominant separation process - gravity settling, impingement,
centrifugal action, coalescing, or filtering.
All mechanical separators rely on the principle of impingement. Impingement is the action of
particles colliding with other particles and/or surfaces.
All mechanical separators use gravity force to assist in the carry off of separated solids/liquids.
This force is normally considered the maximum agent available for carry off in mechanical type
separators with the exception of cyclone type separators.
There are four basic concepts of mechanical separation:
Mechanical separators are limited in carry off capabilities of separated solids/liquids due to re-
entrainment and creeping flow. Re-entrainment is due to drag force pulling solid/liquid off surfaces
to form globs/droplets which are re-injected into the gas stream. Re-entrainment (carry over)
can occur in all types of separators, and in the case of cyclone types is due to an intense inner
vortex creating a velocity field to pull solids/liquids out of the drain sump area and re-inject the
separated particulate into the gas steam.
Both re-entrainment and creeping flow can be eliminated by correct sizing techniques and product
design, that control the velocity in relation to the fluid density, viscosity, through the separating
element.
The basic information regarding particle formation, physics, motion and limitations have been
presented. The following information details the four concepts of mechanical separation.
Impingement Separator
An impingement separator is in the category of separators that
Centrifugal Separator
provide targets for the particulate to be intercepted. The wire mesh
separator and vane type separator are two of the most commonly
used impingement separators.
The wire mesh separator consists of wire knitted into a pad having
a number of unaligned isometrical openings. It has 97% to 99%
free voids and collects the particles primarily by impingement. The
principal of operation of a wire mesh pad is change of direction.
The gas flowing through the pad is forced to change direction a
number of times. Centrifugal action is to a minimum. Impingement,
therefore, is the primary separation mechanism. A liquid particle
striking the metal surfaces of a mesh pad, flows downward where
adjacent wires provide capillary space. At this point, liquid collects
and continues to flow downward. Surface tension tends to hold
this drop on the lower base of the pad until they are large enough
for the downward force of gravity to exceed that of the upward gas
velocity and surface tension.
LLC
In a mesh pad separator the impingement efficiency falls off rapidly
at low velocities because the droplets will tend to drift between
the wires. At high velocities, the element tends to flood. Liquid
cannot flow downward against the increased upward gas velocity
force and therefore accumulates. As the voids become full of liquid,
a portion is re-entrained and discharges with the outlet gas.
Filter Separator
Filter separators are designed to provide optimum
performance in mechanical separation, and are used
in separating aerosols and solid particles.
The filter separator uses cylindrical coalescing elements for particle conditioning. The design
of these elements is the most important component in the design of a filter separator. The first
step in the design of the elements is an analysis of the liquid particle size and concentration in
the gas stream.
There are three mechanisms of particle collection to be considered in the design of filter elements
for mist elimination. These are inertial impaction, diffusion, and direct interception.
IMPINGEMENT
Inertial impaction (impingement) is the
aerodynamic behavior of a particle within the
fibrous media of the filter. If the particle has
sufficient inertia and low enough surface drag
AIR FLOW
characteristics, it will be attracted and held to
fiber in the media due to Van Der Waals Force. PATH OF PARTICLE FIBER
PARTICLE
FIBER
PA
PAT H O
F
identical. But since the motion is totally random,
the transfer of particles across any surface
near a fiber will be proportional to the
concentration on opposite sides of that surface.
It can be shown that there is a net transfer of
particles across a surface and that this transfer
is in the direction of the fiber surface itself.
The rate at which such transfer takes place is
proportional to a diffusion coefficient.
STRAINING
A third mechanism is that of direct interception
(straining). A particle of large enough size,
relative to the size of the fiber will be collected FIBER
even if it has no mass and can follow gas AIR FLOW
flow path. For this reason fiber diameter and PATH OF PARTICLE
PARTICLE
density are a major consideration in the design
of filter elements.
The combined properties of inertial impaction
(impingement), diffusion and direct interception
(straining) enable us to state qualitatively, at least,
how aerosol (suspended particles in gases) filtration
will be effected. The graph depicts the effect which, E
would result if aerodynamic collection alone were T
operative and if Brownian diffusion alone were
operative. The top curve depicts the sum of these
two effects. E
I
EFFICIENCY
E A
It is apparent that the Brownian diffusion curve falls D
toward zero for particles approaching molecular size
(an aerosol filter does not filter out gases). In addition,
it is not at all unusual for filter efficiency to drop
somewhat toward zero for large particles because
of their poor retention after capture by some filter
media. The mere transport of particles to the fiber PARTICLE SIZE OR VELOCITY
surface is not sufficient of itself to ensure their ED -DIFFUSION EFFICIENCY
collection. They also have to remain on the fiber EI -IMPACTION EFFICIENCY
surface. ET
A
-TOTAL EFFICIENCY
-POINT OF MINIMUM EFFICIENCY
Blow-off is the term referring to the process of re-entrainment of the liquid collected by the fibrous
pad in the gas flowing from the pad. It is effected by several factors - inlet aerosol concentration,
gas flow velocity, viscosities and densities of the gas and liquid, pad surface area and porosity
and interfacial and surface tension forces.
The ideal operating conditions of an agglomerator filter, is at a velocity just beyond the initial
blow-off velocity. At this condition more of the smaller droplets entering the pad would be impacted
because of the higher velocity and the droplets leaving the pad are at its larger size. At higher
velocities more droplets will be impacted but the blow-off droplets will be smaller in size.
A very important use of the blow-off characteristics of fibrous mat type eliminator element is that
of particle agglomeration. Fiberglass or similar materials with fine fibers can be used to collect
the very small aerosol particles at aerosol velocity which will produce blow-off drainage of the
collected liquid from the pad. The larger droplets can then be collected by another mechanical
separator such as vane, wire mesh or a centrifugal unit.
Hydrocarbon Gas Viscosity
0.10
0.09
3000
0.08
2000
0.07 1000
0.06
0.05
0.04
0.03 750
Pressure, psia
0.02
1500
0.015
Viscosity - Centipoises
.0125 500
0.01
0.009
0.008
0.007
0.006
14.7
.6 .7 .8 .9 1.0
0.005
Sp. gr
0.004
0.003
0.002
Petroleum Fluid Flow Systems, O.W. Boyd, 1st ed., 1983, Campbell Petroleum Series
Separation Handbook, E. J. Halter, 1st ed., 1966, Burgess Manning Company
Applied Process Design, Ernest E. Ludwig, Volume 1, 3rd ed., Gulf Publishing Company
Engineering Data Book, Gas Processors Suppliers Association, Volumes 1 and 2, 11th ed., 1998, Gas Processors
Suppliers Association.
200-059