Why Vortex and Centrifugal Separators Save Money
Conventional separators use Stoke’s Law, K Factors, and “” based lowering annular and particle velocities to allow heaving liquid particles out of lighter gas streams. In contrast, vortex or cyclonic separation thrives off high velocities to induce tornadoes and g-forces to drive liquids out of the gas stream onto the wall of the internals. The tornado has a low-pressure internal core that holds the gas while the liquids travel out of the drains within the particular vessel configuration. The use of fixed internals with no filter or wire mesh internals, allows for no maintenance and continuous operation at a steady pressure drop. These factors combine to drive vessel size down from these other technologies, driving significant vessel and installation savings.
History
Vortex or cyclonic separation was originally developed to handle sediment in water and other low-pressure fluids to separate fine particles that would otherwise negatively impact treatment facilities and equipment. As it was developed, it was found to be cost effective in a wide variety of applications. The first gas scrubbers were developed in 1972, and first vortex cluster was installed for ConocoPhillips at their refinery in Dubai, U.A.E, in order to stop foaming in a gas / oil separator.
The patented technologies became mainstream, its ability to quickly process gas vs residence time in standard vessels, became a popular solution for operators worldwide.
Applications
So, what are the best applications of vortex separators? Originally designed for separating lube oil out of gas lines, vortex principles and technology have a wide variety of applications within the oil and gas industry.
Vortex Tube
Typically, applications are identified when they include any combination of high gas to liquid ratios, scrubbing applications similar to filter separators and coalescers, and large operational ranges. While there are specific cases for bulk liquid and gas separation using vortex at mid-level efficiency, it is more likely to be used in cases where high efficiency fluid separation is needed. For example, if hydrocarbons are being transported via pipeline to a processing plant, and liquids are to be separated from gases, a high efficiency vortex separation system is preferential to protect sensitive filtration and compression equipment downstream. The vortex systems offered by Taylor Forge Engineered Systems reach efficiencies of 99.9% of solids ≥ 0.3 microns and 99.9% of free liquids ≥ 1-3 microns.
Vortex Cluster
Developed originally to combat foaming in process streams, the cluster design is adept at handling liquid and gas dominant streams at high flow rates. Perfect for slugging applications and surges, the cluster helps create a calm liquid interface reducing residence time and foaming compared to conventional separators. Utilizing the large cluster internals, these units are also capable of handling paraffins, waxes, and other solids that may arrive in the process stream. Offered in retrofit and new applications, a cluster design will save significant money over empty slug or inlet vessels with wire mesh or vane, while also achieving higher levels of separation, lower pressure drops, and less maintenance. The vortex systems offered by Taylor Forge Engineered Systems reach efficiencies of 99.9% of solids ≥ 0.3 microns and 99.9% of free liquids ≥ 1-10 microns.
