Liquid carry-over control using three-phase horizontal smart separators in Khor Mor gas-condensate processing plant

Liquid carry-over phenomenon, where liquid droplets escape with gas, is a prevalent operational challenge in gas–liquid separators. Liquid carry-over leads to foaming issue and performance reduction within separator downstream absorption processes. In order to ascertain whether liquid carry-over is inducing foaming within the gas sweetening process’s absorption tower at Iraq’s Khor Mor gas-condensate processing plant, this study initiated an evaluation of the liquid droplet size distribution in the gas product and gas/liquid separation efficiency of upstream Alpha, Bravo #1, Bravo #2, and Charlee separators that feed into the aforementioned tower by using the Horizontal Vessel and ProSeparator correlations in Aspen HYSYS v.11 software. The study revealed that Alpha and Bravo #2 experienced liquid carry-over issues. In response to these challenges, an innovative smart separator design, referred to as an adjustable separator, was proposed, employing the Arnold-Stewart semi-empirical procedure. This design allows for easy adjustment to accommodate changes in feed composition and operational conditions, mitigating the liquid carry-over problem. The smart design demonstrated a significant increase in gas/liquid separation efficiency for Alpha separator, improving by 31.11% under current conditions and 77.65% under future conditions. Similarly, under both current and future conditions, the smart design of Bravo #2 separator yielded an enhancement of 21.31% and 28.23%, respectively. These results suggest that the smart design can be considered an optimal solution for controlling liquid carry-over. This innovation not only maintains high gas/liquid separation efficiency but also prevents foaming, offering a robust solution for ensuring sustained operational performance and productivity in gas–liquid separation processes.