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Page 1: Liquid Liquid Separation Technology

Liquid-Liquid Separation Technology

Sulzer Chemtech

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Page 2: Liquid Liquid Separation Technology

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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