Phase Separator for Mechanical Foam Breaking in Sour Gas
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Solution Overview
Problem
Small-scale field processing systems for desulfurization of raw natural gas face challenges due to the multiphase nature of the gas streams, leading to operational difficulties such as foam and emulsion formation, pump cavitation, and sensor degradation, which complicates the removal of hydrogen sulfide from sour gas.
Innovation Solution
An oxidation-reduction desulfurization system utilizing a phase separator within a pressure vessel, where the sour gas stream undergoes an oxidation-reduction reaction forming surface foam and a non-gaseous multi-phase mixture, with a primary stage phase separator designed to facilitate mechanical breaking of foam and emulsions through freefall, and a secondary stage phase separator for further separation of non-gaseous surge, managed by a controller to maintain optimal levels and flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oxidation-reduction reaction is used to remove hydrogen sulfide from sour gas, then desulfurization effectiveness is improved, but foam and emulsion formation occurs causing operational difficulties
Solution Approach 1:
The phase separator divides the reaction vessel into distinct zones: an upper gas outlet zone for sweet gas removal and a lower liquid outlet zone for foam/emulsion discharge. This spatial segmentation allows the oxidation-reduction reaction to proceed effectively while separating the harmful foam and emulsion phases from the gas stream, preventing operational difficulties.
Solution Approach 2:
The phase separator extracts and removes the harmful foam and emulsion phases from the reaction mixture by providing a dedicated liquid outlet at the bottom. This extraction prevents foam carryover into the gas stream and eliminates the need for additional foam control equipment, resolving the operational difficulties caused by foam formation.
2Ease of operation
If phase separator is designed with inlet inside pressure vessel, then mechanical breaking of foam and emulsion is achieved, but device complexity increases
Solution Approach 1:
The phase separator merges multiple functions into a single integrated component: it serves as both a separation chamber and a foam-breaking device. The inlet structure positioned inside the pressure vessel creates a freefall zone that mechanically breaks foam and emulsions while simultaneously separating phases, eliminating the need for separate foam breakers and reducing overall device complexity.
Solution Approach 2:
The phase separator inlet structure performs multiple functions: it introduces the sour gas stream into the reaction zone, creates a freefall path for mechanical foam breaking, provides phase separation between gas and liquid phases, and controls liquid discharge. This multi-functionality reduces the number of separate components needed, simplifying the overall system despite the enhanced operational capabilities.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Effectively separates sweet gas from sour gas streams, mechanically breaking foams and emulsions, and managing flow to prevent operational issues, enabling efficient desulfurization and recovery of sulfur and water, thus overcoming the complexities of multiphase processing.
Implementation Method 1
generating sweet gas from a sour gas stream via an oxidation-reduction reaction that results in formation of surface foam and a non-gaseous multi-phase mixture
Implementation Method 2
the surface foam and the separated non-gaseous multi-phase mixture flow into a partially gas-filled upper section of the primary stage phase separator and freefall to a lower level, thereby facilitating mechanical breaking of the foam and the emulsion
Data Source
AI summary
An oxidation-reduction desulfurization system includes a reactor vessel with sour gas inlet at the bottom and a gas outlet at the top. A primary stage phase separator includes a vertically-oriented pipe with an inlet located inside the reactor vessel. The ratio of the reactor vessel diameter to the pipe inlet diameter is in a range of 2:1 to 5:1. Surface foam and non-gaseous multi-phase mixture including emulsion flow into a partially gas-filled upper section of the vertically-oriented pipe and freefall to a lower level, thereby facilitating mechanical breaking of the foam and the emulsion. A secondary stage phase separator connected to the gas outlet separates non-gaseous surge from sweet gas. Valves and a controller automatically maintain target levels of the non-gaseous multi-phase mixture and non-gaseous surge.