Final Liquid Removal

After first-stage separation and intercooling, trace liquids may remain or form from temperature variations. Second-stage inlet separator catches these residual liquids providing clean dry gas to final compression preventing damage and maintaining efficiency.

Separator Configuration

Vertical vessel immediately before second-stage suction nozzle. Compact design with inlet from intercooler, mist eliminator, gas outlet to compressor, liquid sump with level control, and high-level shutdown. Mounted close to compressor minimizing piping where liquids could accumulate.

Operating Pressure

Matches second-stage suction pressure typically 150-500 psig after intercooling. Lower pressure drop maintains compression efficiency. Design accommodates interstage pressure with appropriate safety factors.

Liquid Sources

Residual condensate from incomplete first-stage removal. Additional condensation from ambient temperature changes. Carryover from upset conditions. Minimal liquid volume but critical to remove preventing second-stage damage.

Material Selection

Stainless steel handles syngas components and condensate corrosion. Compact construction reduces weight and cost. Mist eliminator materials withstand operating conditions. Design resists thermal cycling during load variations.

Safety Integration

High-level switches directly interlock with compressor emergency shutdown. Redundant level instruments ensure protection. Fast valve closure prevents liquid ingestion. Safety systems meet compressor manufacturer requirements and facility standards.

Separation Efficiency

Removes free liquids and droplets ensuring dry gas to second stage. Wire mesh captures fine mist. Combined efficiency 99%+ protects compression equipment. Low pressure drop typically under 0.5 psi preserves suction conditions.

Applications

Multi-stage syngas compression in gasification facilities, steam reformer syngas handling, Fischer-Tropsch synthesis gas compression, ammonia and methanol plant feed compression, and any two-stage or multi-stage syngas compression system.

Liquid Drainage

Level-activated automatic drains remove accumulated condensate. Drain frequency depends on liquid rates typically intermittent. Collected liquids route to process wastewater treatment coordinating with other syngas condensate streams.

Maintenance Access

Simple design enables quick inspection during turnarounds. Mist eliminator replacement if fouling occurs. Minimal maintenance requirements support continuous operation. Easy access for cleaning if tar deposits develop.

Construction Standards

Design per ASME Section VIII for operating pressure. Shutdown logic per safety instrumented system requirements. Materials for syngas service. Complete documentation with interlocking diagrams and safety systems.

ERGIL second-stage inlet separators provide final liquid protection ensuring reliable syngas compression in chemical synthesis facilities.