liquid liquid separation technology
DESCRIPTION
BrochureTRANSCRIPT
Liquid-Liquid Separation Technology
Sulzer Chemtech
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Introduction
2
Content Page
Introduction 2
ProductSummary 4
Mellaplate 6
FeedInletsandCalmingBaffles 9
DCCoalescer 10
DusecCoalescer 11
WashTankDistributor 14
TestingandNewDevelopments 15
In industrial process equipments liquid-liquidmixturesareproducedbyessentiallytwodifferentmechanisms.
a) Mixingofthephasesineitherpurpose-built equipment, mechanical mixers,staticmixerswherepressureenergyisappliedtoincreasethesurfacefreeen-ergyof thefluids toproducedroplets,or inshearflowof thefluidmixture inpipes.
b)Thecoolingofasaturatedliquidbelowthe solution point so that the solutephase condenses out of solution re-sultingintheformationofasecondliq-uidphase.Thistakesplacefrequentlyin storage tanks and in processesdownstreamofcondensersorcoolers
Whentwophasesareformed,thismixtureismostoften in the formofadispersion(droplets of one phase distributed in thesecondorcontinuousphase).Themixtureis thermodynamically unstable, meaningthatgiventime,thedropletswillseparateout to form two bulk liquid phases. Thistakes place by droplets coalescing bothwith “near neighbor” droplets (drop-drop
The Brownian force additionally acts onsmallerdropletsinafluid.Aneverydayex-ampleisseeninabeamofsunlightwheredustparticlesintheairareseento“shim-mer”,therandommotionbeingduetothebombardmentof thesmalldustparticlesby air molecules. The dust particles af-fectedinthiswayareinthesizerangeof0.1~2mm.Largerparticlesarenotaffect-edinthisway.Inasimilarmannersmallerliquid droplets in a liquid continuum areso affected and since the settling veloc-ityduetogravityofsuchdroplets isverylow, therandommotion impartedonthedropletsbyBrownianmotionturnsouttobeoftheorderofthesettlingvelocity.Thenetresult is thatdroplets in thisrangeofsizeswillnotsettleoutandthereforearenotamenabletogravitysettlingmethods.Such dispersions are called secondarydispersions.Technically theyarestill ther-modynamicallyunstablebutthekineticsofseparation by gravity only is so low thatformostpurposestheyappearstable.Se-condarydispersionscannotbeseparatedeffectively in gravity or primary separati-on equipment and require different tech-niquesforseparation.
coalescence)andwiththebulkphaseasthis forms and settles from the mixture(drop-interface coalescence). The kinet-ics,orrateatwhichtheseprocessestakeplace,determinetheselectionanddesignof equipment. The driving force promot-ingcoalescence isgravityand inagivensystemisproportionalto∆r · g,∆rbeingthedensitydifferencebetweenthetwoliq-uidphases.Thediameterofthedropletsisacriticalparameter. Indeterminingthesettling velocity in a liquid-liquid disper-sionthedropletsizecombinedwith∆r · gwilldefinethe“settling”forceonadroplet.This separation principle is governed bytheStokesLawwhichisdefinedas:
Where:
vd Settlingvelocityofadispersed droplet
Dr Densitydifferencebetweenthe twoliquidphases
d Dropsizediameter
mc Dynamicviscosityofcontinuous phase
g Gravitationalacceleration
g · |Dr| · d2
18 · mc
vd =
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Introduction
3
The simplest forms of equipment usedto separate dispersions are horizontal orvertical gravity settling tanks. The capac-ityofsuchvesselsdecreasesastherateofcoalescenceandseparationdecreases.Therefore, there will be circumstanceswhere the dimensions of such vesselsare uneconomical for some applicationsand methods to improve the separationkineticsneed tobeapplied.Thiscanbeachievedbyincreasingthedrivingforcetoacceleratethestepsinthemechanismofcoalescence.
Sulzer offers a range of equipment de-signed to accelerate the separation ofeither primary or secondary immiscibleliquiddispersions.Coalescers -and theirinherent benefits - are today often con-sidered preferable to conventional grav-ity separators. Figure 1 gives a simpleoverview of how primary and secondarydispersionsareusuallyformedandwhichSulzercoalescersaresuitabletoseparatethesedispersions.
Immiscible Dispersions
Typically Formed
Deliberately By:
LowShearProcessessuchas:
•SolventExtraction•MixerSettlers•SteamStripping•WashingProcesses•Counter-currentTowers
Creating Primary Dispersions:
•Coarsedropletdistribution•Predominantly>30µm•Separatereadilyundergravity
•Waxyfeeds?•SolidsContent?•LowPressureDrop?
Accidentally By:
HighShear&ThermalProcess-essuchas:
•CentrifugalPumps•ChokeValves•CondensationofImmiscibleLiquids•EntrainedDispersionfromPrimarySeparations•Sub-coolingofLiquidsinStorage
Creating Secondary Dispersions:
•Finelydisperseddroplets•Typically1-30µm•Slowtoseparateundergravity•Appearanceoftenhazy
SeparatedUsing
MellaplateCoalescers
SeparatedUsing
DCCoalescers
DusecCoalescers
Dusec PlusCoalescers
Separated Using
Fig. 1: Overview about Formation of Dispersion and suitable Sulzer Coalescer Types
Yes No
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Type of Separator
MellaplateTM
DCCoalescerTM
DusecTM
DusecPlusTM
ShellSchoepentoeterTMandSchoepentoeterPlusTMInletDevice
GIRZCycloneInletDevice
Materials
StainlesssteelsAlloy625,825
Theseareproducedbytwodissimilarfilamentsknittedtogethertoformthemesh.OnefilamentisametallicwiremadeofstainlesssteeloralloyC22,C276,400,625or800andtheotherismadeofPP,FEP,ETFE,PTFE,orglassfibers
Incartridgeformwiththeliquidflowingfromthecenterradiallyoutwards,theDusecandDusecPlusCoalescerconsistofase-lectionoffibermaterials.
Stainlesssteels,Alloy625,825
Stainlesssteels,Alloy625,825
Applications
Improvedseparationefficiency.Twophasesdisengagecontinuouslyalongtheplateorsheets.Improvedflowstability.Reducedriskofdropletre-entrainment.Verysuitableinsystemssusceptibletofoulingwithincreasedplateangleandplatespacing.Efficiencymaintainedevenwithphaseinversionofdispersedliquid.Suitableforoperationwithagasphase.
Improvedseparationefficiency.Highercapacitiesallowde-bottleneckingofconventionalseparators.Largecostsavingsinpressurevessels.Efficiencymaintainedevenwithphaseinversionofdispersedliquid.Highfreevolumemeanssmallerpressuredrop.
Fibertopologyandsurfacepropertiescombinedwithoptimizedlayercompositionsmeanhigherefficiency.Separationefficiencydownto10ppmentrainmentoffreedroplets.Higherloadingsandabsenceofjettingfromouterlayersmeanhigherpackingdensities.Smallervesselsizemeanscapitalcostreduction.Pressuredropminimized.Quickperformancerecoveryfollowingfeedconditionchanges.
TheSchoepentoeteristhemostcommon-lyusedvaneinletdeviceforintroducinggas/liquidmixturesintocolumns.TheSchoepentoeterPlusisanadvancedfeedinletvanedevicewithconsiderablyincreasedde-entrainmentefficiency.Bothdevicessuppressandminimizetheturbulenceintheinletcompartmentoftheseparator.Entryofgasintotheliquidphaseislow.
TheGIRZisusedasadefoamingcyclonicinletdevicetosuppressandbreakmanytypesofprocessfoams.Sometypicalapplicationsincludefreewaterknockoutdrums,flashdrums,testseparators,2and3-phaseproductionseparators.
Product Summary
0604 2507-4
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Typical Operational Range
Applicableforprimarydispersions.Dependingonthetypeused,Mellaplatecoalescerscanoperateatseparationfluxesofupto100m3/m2h.Comparedtoemptysettlersimproved“cut-off”diam-etersareachievedduetoshortersettlingdistancebetweenplates.
Applicableforprimarydispersions.Low”cut-off”diameters,thereforeextendedrangeofoperation.Thelowerlimitisatornearthetransitionregionfromprimarytosecondarydispersioni.e.,cut-offdropletsize~30-40µm.DependingontheDCCoalescertypeandapplication,highseparationfluxesofupto120m3/m2hcanbeachieved.
Applicableforsecondarydispersionswherethedropletsaresosmalltheydonotreadilywetasurfaceorsettleundergravity–typicaldropsizesareintherangeof1to30microns.Designedtoachievehighperformancewithminimumpressuredrop,theDusecPlusmodelprovidesahighcapacityalter-nativetoconventionalDuseccartridges.Thesmallerdiameterandincreasedpack-ingdensitymakeitsuitableformaximizingtheeffectiveareaofthecoalescermediainagivensizeofvessel.
Generallydesignedatdynamicpressures<8000Pa,butcanperformwellathighervalues.Istypicallyusedforfeedshavingagasvolumefractionof>70vol%.Suitableforinstallationinhorizontalorverticalseparators.Suitableforliquidslugs.
TheGIRZcyclonicinletdeviceutilizesthemomentumofthefeedstreaminletinor-dertogeneratehighg-forces.Defoamingisachievedasgasbubblesareseparatedfromtheliquidphasebythecentripetalforcesinthecyclonetubes.Gasisre-leasedfromthetopofthedeviceandthebottomopeningofthecyclonesissub-mergedbelowtheliquidintheseparatorinordertoavoidagas‘blowout’.
Characteristics
MellaplateWismadeupofasetofparallelplatesthatisfittedintoavesselintheseparationsectionsuchthattheplaneoftheplatesisarrangedintheaxialdirectionofthevessel.Theplatesarenormallyinclinedtotheaxisatanangleof45ºor60º.Theplatespacingisoftheorderof15to100mm.MellaplateM,MGandNaremadeupofstructuredcor-rugatedmetalorplasticsheets.Highpackingdensitymeansmoresheetsinagivenvesselvolume.
Manufacturedasaknittedwiremeshpacking.Canbeeasilycustomizedtosuitmostvesselshapesandsizes.DCCoalescersaresensitivetothepresenceofsolidsinthefeed.Typically,particlesizesbelow~50µmdonotcauseexcessiveblockage.
DusecandDusecPluscoalescersaresuppliedascar-tridges.Scopeofsupplyusuallyincludessupportsandmountingplatesuitablefordirectinstallationinavesselofeitherhorizontalorverticalorientation.Cartridgesareavailableforhighlyaggressivechemicalenvironmentsandhightemperatureapplications.
Constructedfrombanksofsweptvanes.Designsavail-ableforoperationinmostgas/liquidflowregimes.TheSchoepentoeterPlusisequippedwithsophisticatedcatchingrimstominimizeentrainment.
TheGIRZconsistsofanarrangementoftwoormorecyclonessymmetricallyarrangedoffacommon,central-lylocatedheader.Thedevicecanbeinstalledinverticalorhorizontalvessels.Ifrequired,mixingelementsatthecyclonegasoutletwillimprovethedistributiontothedownstreamdevice.
Product Summary
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Mellaplate
6
Sulzer MellaplateTM Type W
Thistypeofcoalescerconsistsofacombi-nationofinclinedparallelplates,withfixedspacing,so thatdropletsettlingdistanceisreducedsignificantlyandthisenhancesthe coalescence process. The inclinedarrangement of plates allows the liquidphases to disengage diagonally towardsthe liquid interface. The flow is normallykeptinthelaminarregionforbettersepa-ration performance. The inclination andthe spacing between the plates is deter-
SulzeroffersMellaplateTMcoalescers,whichenhancetheseparationprocessbyallowingthereducingthedropletsettlingdistance,thusaidingthecoalescenceofthedroplets.
SulzerMellaplatecoalescersareavail-ableinfourdifferenttypes:
Construction Form
Relative Capacity 1)
Typical droplet cut-off size
Pressure drop
Solids Handling
Remarks
Mellaplate W
Flatparallelplates
1
≥ 50µm
Negligible
Highfoulingresistance
Mellaplate MG
Structuredcorrugatedflatplates
1.5
≥ 100µm
0.5–4mbar
Goodtohighfoulingresistance
Mellaplate M
Structuredcorrugatedmetalsheets
1.5
≥ 50µm
1–10mbar
Moderatetogoodfoulingresistance
Alsousedaswaveandfoambreakerelements
Mellaplate N
Structuredcorrugatedplasticsheets
1.5
≥ 50µm
1.5–15mbar
Moderatetogoodfoulingresistance
Moresuitedforde-oilingduetotheplasticsurface
Table A 1)ValuesarerelativetoMellaplateWtype
mined by the application, the nature ofcontaminantspresent in themixtureandthedegreeofseparationneeded.Typically,the angle is either 45 or 60° with platespacing from15 to100mm.Due to thehigh fouling resistance, the Mellaplate W(Fig.2) is, forexample,used incrudeoilproduction separators. It is also ideal forretrofittinganexistinggravitysettlertoop-erateatahigherthroughputandimprovetheseparationperformance.
From the construction aspect, the Mel-laplateWcanbemadeinmodularframearrangementorboxes(Fig.3).Alternative-ly,itcanalsobeconstructedinonepiece(Fig. 4) for vessels with access throughthe body flange. Experienced engineersatSulzercanassistyouindesigningthisseparator to ensure trouble-free installa-tionandoperation.
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Mellaplate
Fig. 2a: Sulzer Mellaplate W
Fig. 2b: Sulzer Mellaplate W
Fig. 3: Frame and Box Arrangement
Fig. 4: One Piece Sulzer Mellaplate W
Framearrangement Boxarrangement
0611 2505-4
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Mellaplate
TheSulzerMellaplateCoalescer typesW,M, MG and N can be used flexibly in ei-therhorizontalorverticalvessels.Atypicalsketch of a 3-phase separator is shown
SulzerMellachevronmisteliminator
SulzerMellaplateMwaveandfoambreaker
ShellSchoepentoeterinletdevice
Calmingbaffleplate
SulzerMellaplateWcoalescer
Weir
Sulzer MellaplateTM Type M, MG and N
This type of coalescer is made of struc-tured corrugated metal or plastic sheets(Fig. 5). Various universities and oil com-panieshavetestedMellaplateM,MGandNtypesinoil/waterseparatorsalsoundermoving conditions. Sulzer supplied thefirstMellaplatein1988fortheHuttonTen-sionLegPlatform(TLP)inUK.Sincethenhundreds of oil/water separators havebeenequippedwithvariousMellaplateM,MGandNstyles.Somehavebeenusedaswavebreakersordampersinoil/waterseparatorsonTLPsandFPSOs(FloatingProductionStorageandOffloading).
Fig. 5: Sulzer Mellaplate - M
Vessel Arrangement with Sulzer MellaplateTM Coalescer
Fig. 6: Horizontal 3-phase separator
below(Fig.6)whichshowstheSulzerMel-laplateWascoalescerandtheMellaplateMaswavebreakingdevice.
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Inlet Devices
Feed Inlets
For two phase liquid/liquid separators orthreephaseseparators,itisimportantthattheflowinthevesselisequalized.
Any turbulence or disturbances such asflowvariations,surgesorexternalmotionmaysignificantlycompromisethesepara-tionefficiency.Separatorsinanupstreamoil and gas environment are particularlyexposed to such problems. Sulzer inletdevices help to significantly improve theflowdistributionacrossthevesselwithoutcausingdropletstoshatter.
Fig. 8b: Calming baffle boxes in front of a Mellaplate W
Fig. 8a: Calming baffle plate
Fig. 7: CFD prediction of axial velocity distribu-tion after the second baffle of a two calming baffle arrangement
Calming Baffles
Sulzer recommends using the calmingbaffle in all liquid/liquid andgas/liquid/liq-uidseparators,eitheroperatedassimplegravity settler or equipped with SulzerMellaplateorDCCoalescer.Thesebafflesareprovidedwithuniformholeswhichareoptimized to achieve good flow distribu-tion and minimize any turbulence in theliquid phases towards the coalescer in-ternals. Depending on the type of appli-cations,twocalmingbafflesmaybeused.
Fora3-phaseseparator,dependingon thecharacteristicand inletmomentumof thefeedmixture,differenttypesofinletsaresuitable:
Elbowpipe
Halfopenpipe
ShellSchoe-pentoeterTM
vanetypeinlet
SulzerGIRZcyclonicinlet
Suitabilityforlargegasvol.
fraction
–
+
+++
+++
InletMomentum
–
+
++
+++
Defoaming
–
–
+
+++
Degassing
–
–
++
+++
RelativeCostofDevice
$
$$
$$$
$$$$
Table B
0.115 m/s
0.102
0.090
0.077
0.064
0.051
0.038
0.026
0.013
0-000
CDE = 15
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DC Coalescer
Sulzer DC CoalescerTM
TheSulzerDCCoalescerTechnologyprovidessignificantlylowersettling times forprimarydispersionswithdroplets as small as30microns.
Whilethedropletspassthroughthecoalescer,theygrowinsizethrough a continuous process of coalescing and draining. Thefastersettlingvelocityofcoalesceddroplets leadstominimizedvesseldimensionsasopposedtogravityseparationalone.
Thecoalescerusesacombinationoftwomaterialswithdifferentsurfacefreeenergy–typicallymetalandplastic–toenhancethedropletcoalescenceofbothphases(Figure9).
Theco-knittedSulzerDCCoalesceroutperformssinglemediumalternativesprovidinganimproveddrainingatthejunctionpointsof the twodissimilarmaterials. (TableC).Theseparationperfor-manceismaintainedregardlessofwhichphaseisdispersed.
TheSulzerDCCoalescercanbeinstalledbothverticallyandho-rizontally. Shape and fixing method can be customized for thevesselorhousingintowhichitwillbeinstalled.Abroadvarietyofmaterialsandknittingtypesofferatailor-madesolutionwhereverefficientliquid-liquidseparationisrequired.
Key Benefits
• Debottleneckingofexistingsettlers
•Reducedsizeof2-and3-phaseseparators
•Improvedphaseseparationefficiency
•Low“cut-off”diametersprovideextended rangeofoperation.Thelowerlimitisatornearthetransitionregionfromprimarytosecondarydispersionsi.e.,cut-offdropletdiameter~30-40µm.
•Depending on the DC Coalescer type and application, highseparationfluxesofupto120m3/m2harepossible(Figure10)
•Applicableforprimarydispersions
•Equalperformanceregardlessofwhichphaseisdispersed
Typical applications of Sulzer DC Coalescer
•Separationofdispersionfollowingwaterwashingstages
•Entrainmentreductionofeitherphaseforliquid-liquidextractioncolumnsasLPGAmineTreaters,HydrogenPeroxideExtractionColumnsandCausticWashers
• Separation of dispersions formed by condensation followingazeotropicdistillationasinButanol/WaterDistillation
•Separationofliquidsfollowingsteamstripping
Metalfilamenthighsurfacefreeenergy
Coalesceddropletsatjunctionoftwodissimilarmaterials
Plasticfilamentlowsurfacefreeenergy
Fig. 9: Preferential Wetting & Junction Effect
Fig. 10: Performance chart of Sulzer DC Coalescers
Packing
StainlessSteel
Polypropylene
SulzerDCCoalescerStainlessSteel/Polypropylene
Dispersedphase
Kerosene
Water
Kerosene
Water
Kerosene
Water
RelativeFlux1)
0.10
1.00
1.10
0.05
1.45
1.45
Table C: Comparison of conventional and Sulzer DC Coalescer
DC 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 DC 9236 SS/PTFE(M) DC 9236 SS/PP
0 Flux [m3/m2h] 120
Sep
arat
ion
Effi
cien
cy
Fig. 11: Sulzer DC Coalescer
1)whereentrainmentexceedslimit
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Dusec Coalescer
DusecTM and Dusec PlusTM Cartridge Coalescer
Insecondarydispersions,thedropletsaresosmallthattheydonotreadilywetasurfaceorsettleundergravity.Typicaldropsizesareintherangeof1to30microns.Incartridgeformwiththeliquidflowingfromthecentreradiallyoutwards,thecoalescingprocessisimprovedasthe liquidencountersaflowresistance.Duetoadhesiveforces,the inter-cepteddropletsclingontothefibersurfaceatselectivepointswhereclustersformuntilcoalescencetakesplaceandthedropletgrows.Viscousdragforcesincreaseuntiltheyexceedtheadhesionforces,causingthedropletstoseparatefromthefiberandmovefurtherintothecoalescerfiberbed,wheretheprocessisrepeated.Finallythedropletsreachprimarydispersionsize>60microns.This is theworkingprincipleofSulzerDu-seccartridgecoalescers(Fig.12).AnimportantadvantageisthattheouterlayerofthecartridgeisofthesamecompositeconstructionastheSulzerDCCoalescer,whichac-celeratesseparationandavoids jetting&entrainment.Normallynodroplets leave theoutersurfaceanddrainagetakesplacewithintheDCCoalescerslayer.Inprincipalthedistancebetweenthecartridgescantheoreticallybezero.Inpractice,however,amini-mumpracticalspaceisnecessarytoallowthecartridgestobeeasilyinstalledontotheplatewithinthevessel.
Another big advantage these coalescersoffer is that they perform equally well in-dependent which phase is dispersed.Dusec cartridge coalescers can be ins-talled in both horizontal and vertical ves-sels(Fig.13).
A selection of high specific surface areafibermaterials,arrangedinaspecificpat-tern in the cartridge, ensure high effici-encycoalescenceofdroplets inabroadspectrum of applications. Depending onthearrangement&constructionof layersin the cartridge, the Sulzer Dusec coale-scers have been classified into differenttypes (Table D). Qualified engineers atSulzer can provide advice on coalescerdesign including specification of vesseldimensions, main process and interfacecontrolconnections,andthenumberandtypeofDuseccartridges. The cartridgesareavailableindifferentlengthof500mm,1000mmand1500mm.
Cartridge designs are available for manyapplications including aggressive chemi-calenvironments,asforhydrogenperoxi-deandforhightemperatureduties.
Fig. 12: Schematic representation of droplet coalescence in a Sulzer Dusec Coalescer
Acceleratedsepara-tionwithoutdropletbreak-upattheoutletoftheSulzerDusecandDusecPluscartridges
Jetting&entrainmentattheoutletofcon-ventionalcartridges
1.Dropletscapturedonfilaments
2.Dropletscoalescencebegins
3.Largerdropletscapturedformedbycoalescence
4.Ultimately,dragforceofliquidstreampullsdropletsfromfilaments
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Dusec Coalescer
Fig. 13a: Heavy phase dispersed Fig. 13b: Light phase dispersed
Fig 13c: Heavy phase dispersed (horizontal layout). A dome is used if the light phase is dispersed.
Key Benefits
• Fiber topology and surface propertiescombined with optimized layer compo-sitionsmeanhigherefficiency
•Higher loadings and absence of jettingfrom outer layers mean higher packingdensities.
•Works equally well independent whichphaseisdispersed
•Pressuredropminimized
•Separationdownto10ppmfreeentrain-mentpossible
•Suitableforinterfacialtensions >2dyne/cm
•Quick performance recovery followingfeedconditionchanges
N2
N3
N2
N1
N1
N3
N2
N3
N1
Legend:
N1:Feed
N2:Lightphaseoutlet
N3:Heavyphaseoutlet
Fig. 14: Sulzer Dusec with mounting plate Fig. 15: Sulzer Dusec
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Dusec Coalescer
Table D: Dusec and Dusec Plus Type Selection Table
Dusec PlusTM Coalescers
Designed to achieve high performancewith minimum pressure drop, the SulzerDusec Plus model provides a high ca-pacity alternative to conventional Duseccartridges. The smaller diameter and in-creasedpackingdensitymake itsuitablefor applications where it is necessary tomaximizetheeffectiveareaofthecoalesc-ermediainagivensizeofvessel.
Resin bonded Mechanically sealedType 1/RB 2/RB 3/RB 4/RB 5/RB 1/MS 2/MS 3/MS 4/MS 5/MSMax.DesignTemperature 80 80 90 80 80 80 80 150 80 80pH <10 <10 <10 <10 <14 <10 <10 <10 <10 <14IfPPlikelytobeattackeduse
IfEpoxyresinlikelytobeattackeduse
ApplicationsRefiningapplications Yes Yes Yes Yes Yes Yes Yes Yes Yes YesAmineextraction Yes Yes Yes Yes Yes Yes Yes Yes Yes YesLPGProcessing Yes Yes Yes Yes Yes Yes Yes Yes Yes YesGascondensate Yes Yes Yes Yes Yes Yes Yes Yes Yes YesMetalextraction Yes Yes Yes Yes Yes Yes Yes Yes Yes YesSeawater No Yes No No No No Yes No No NoProducedwater No Yes Yes No No No Yes Yes No NoHydrogenperoxide No No No No No No No Yes Yes NoAromaticsolvents No No No No No No No Yes Yes No Phaseratio:>5vol%dispersedphase No No No Yes No No No No Yes No
Availablecartridgelength 500,1000and1500mm 500,1000and1500mmOutercartridgediameter Dusec/DusecPlus230/156mm Dusec/DusecPlus230/156mmMax.permissiblepressuredropbeforecartridgeshavetobereplaced 0.75-1bar 0.75-1bar
Key benefits
• AllthebenefitsofaDuseccoalescer
• Highefficiencyatminimalpressuredrop
• Increasedpackingdensity
• Maximizedeffectiveareaofthecoalesc-ermediainagivensizeofvessel.
Service & Supply
Sulzeroffersaflexibleandcomprehensiveservicewhichincludesthedesignforthecomplete vessel (including the variousnozzle elevations, sizing) and productionof additional internals suchasweirsandsupports,orthemountingplateforSulzerDusecandDusecPluscoalescers.
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Research co-operation between Sulzer and Total has led to anew phase inversion technology where water-in-oil dispersionsare converted to oil-in-water. ‘Double emulsions’ can be creat-edwhereverysmalldropletsofwaterarecarriedinoildropletswhicharethemselvesdispersedwithinacontinuouswaterphase
-knownasa‘waterleg’.Waterdroplets,alongwithsaltsandothercontaminants,canberemovedfromtheoilbycontactingtheoildropletswiththecontinuouswaterphase.TheSulzerWashTankDistributorVROL(Fig.16)isusedatthebottomofthewaterlegand has been developed to create optimal droplets of oil andremovessolids,evenwhensubjectedtomotion.
InconjunctionwithTotal,thetechnologyisbeingappliedinwashanddesaltingtanksinthehullsofFPSOvesselsforremovingen-trainedwater,saltsandcontaminantsfromcrudeoil.Thedistribu-tor system substantially improves the separation performanceandconcentrationsof<0.5%vol.BS&W (basic sedimentandwater)intheoiloutletcanbeobtained.
Forthedevelopmentofotherinnovativewashseparatorprocess-es,smallandlargescaletestrigs(Fig.17)havebeendevelopedwhichenableustoinvestigatedetailedcoalescencephenomenaaswellasthewholeseparationprocess.CFDisusedtosimulatethewashtankprocessparticularlytakingintoaccountthemotionofthetank.
14
Wash Tank Distributor
Fig. 16a: Wash Tank with Sulzer Distributor
Fig. 16b: Sulzer Wash Tank Distributor
Fig. 16c: Sulzer Wash Tank Distributor
Fig. 17: Sulzer Wash Tank Test Rig
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Our liquid phase separation testing faci-lities (Fig. 18) are available for the deve-lopmentof innovativeequipment,andforinvestigatingspecificcustomerproblems.In-house development of an automaticdroplet sizeanalysis systemallowsstateoftheartmeasurementofdropsizedistri-bution(Fig.19),eveninveryhighconcen-trationdispersions.
Mobile test rigsareavailable for thecus-tomertotestintheactualprocess.
Testing and New Developments
Oil
Water Bypass Wateraddition
Sulzer INVERTOMIXTM
Sulzer Static Mixer
Fig. 18a: Test rig for Sulzer Mellaplate and DC Coalescer
Fig. 18b: Sulzer Dusec test rig for customer tests on site
Fig. 19: Drop size analysis
Static mixers from Sulzer (Fig. 20) areused for efficient mixing of one or morephases.Whenthemixerisusedtocreatedispersions, Sulzer static mixers achievewell-defined droplet size distributionscompared to other equipment such aschokevalves.
ThespecialSulzerINVERTOMIX™(patentpending)canbeusedtoobtainphasein-versionfromoil-in-watertowater-in-oilorviceversa.Thisprovidesgoodcontrolofphasecontinuityand isofparticular inter-est for phase separation in heavy crude-oil-water systems as well as flow assur-anceinpipelines.
0697 2720
Fig. 20: Sulzer static mixer
Recent Sulzer Product Developments on the subject Flow Assurance and Phase Inversion
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www.sulzer.comPlease check for your local contact
Sulzer Chemtech Ltd, a member of the Sulzer Corporation, with headquarters in Winterthur, Switzerland, is active in the field of process engineering and employs some 4000 persons worldwide.
Sulzer Chemtech is represented in all important industrial countries andsets standards in the field of mass transfer and static mixing with its advanced and economical solutions.
The activity program comprises:
• Process components such as fractionation trays, structured and random packings, liquid and gas distributors, gas-liquid separators, and internals for separation columns
• Engineering services for separation and reaction technology such as conceptual process design, feasibilities studies, plant optimizations including process validation in the test center
• Recovery of virtually any solvents used by the pharmaceutical and chemical industry, or difficult separations requiring the combination of special technologies, such as thin film/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 for the production of PLA and EPS
• Tower field services performing tray and packing installation, tower maintenance, welding, and plant turnaround projects
• Mixing and reaction technology with static mixers
• Cartridge-based metering, mixing and dispensing systems, and disposable mixers for reactive multi-component material
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Legal Notice: The information contained in this publication is believed to be accurate and reliable, but is not to be construed as implying any warranty or guarantee of performance. Sulzer Chemtech waives any liability and indemnity for effects resulting from its application. 22.16.06.40 - X.13 - 10
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