Separator Function

Process streams often contain multiple phases requiring separation before downstream processing. Operational separators provide gravity-based phase disengagement. Gas rises to top outlet. Heavier liquid settles to bottom. Intermediate-density liquid collects at controlled interface. Simple reliable technology used throughout process industries.

Vessel Configuration

Horizontal or vertical design depending on application. Horizontal works better for high gas-to-liquid ratios and foaming service. Vertical suits high liquid volumes and space constraints. Three-phase separators handle gas plus two immiscible liquids like oil and water. Two-phase units separate gas-liquid or liquid-liquid only.

Operating Conditions

Pressure ranges from atmospheric to 1500 psig based on process requirements. Temperature typically -20°C to 200°C. Size depends on flow rates - from small 12-inch diameter units handling a few GPM to large 10-foot diameter vessels processing thousands of barrels daily.

Internal Design

Inlet diverter breaks momentum preventing re-entrainment. Spreader plates distribute flow across vessel cross-section. Vane packs or mesh pads capture droplets above 10 microns. Weirs control liquid levels. Coalescing plates enhance liquid-liquid separation. Design matches specific separation duty.

Material Selection

Carbon steel suits hydrocarbon service at moderate conditions. Stainless steel handles corrosive streams or water service. Special alloys for sour gas with H₂S. Internal components resist erosion and corrosion. Coatings protect against specific chemicals or process conditions.

Applications

Production separators at wellheads and tank batteries, compressor knockout drums, reactor effluent separation, distillation reflux drums, storage tank vapor-liquid separation, glycol contactor inlet scrubbing, and countless other process applications requiring phase separation.

Level Control

Interface level instruments maintain oil-water boundary in three-phase service. Liquid level controls regulate drawoff maintaining inventory. Pressure control manages gas space conditions. Temperature monitoring tracks process state. Controllers integrate with facility automation systems.

Separation Efficiency

Gravity separation plus internals achieve 95-99% phase removal. Remaining trace opposite-phase acceptable for most applications. Further polishing uses coalescers, filters, or specialty equipment if needed. Operational separators handle bulk separation economically.

Performance Factors

Retention time allows gravity separation - typically 1-5 minutes for gas-liquid, 5-30 minutes for liquid-liquid depending on density difference and viscosity. Proper velocity prevents re-entrainment. Temperature affects viscosity and density differences influencing separation.

Maintenance

Periodic inspection through manholes checks internals for fouling, corrosion, or damage. Cleaning removes accumulated solids or emulsions. Relief valve testing maintains safety systems. Simple robust design minimizes downtime.

Construction Standards

Design per ASME Section VIII for pressure vessels or API 650 for atmospheric tanks. Materials and construction suit operating conditions. Relief protection per API 520/521. Complete documentation with process datasheets, mechanical drawings, and material certifications.

ERGIL operational separators provide reliable phase separation across diverse process applications in oil, gas, chemical, and refining operations.