Neorius | Advanced Refining and Chemical Technologies

High-Efficiency Vane-Type Separator

The high-efficiency vane-type separator is a gas–liquid separation solution with high efficiency, large processing capacity, and low operating and maintenance costs. It can be subdivided into the following types:

High-Efficiency Horizontal Separator

1. High-Efficiency Horizontal Separator with a Single Liquid Collection Section

Working Principle:

(A) The inlet feed conditioning device for the gas–liquid mixture reduces the kinetic energy of the incoming two-phase stream, while removing large liquid droplets and slug flow entrained in the gas.

(B) Large droplets and slug flow pass through the flow-straightening baffles into the liquid collection section.

(C) The gas stream, carrying smaller entrained droplets, flows into the high-efficiency separation vanes.

(D/E) The entrained liquid captured by the vanes is collected underneath and directed downward by gravity through drain pipes to the separator bottom, and is ultimately discharged.

(F/G) A properly designed liquid level control system ensures smooth liquid discharge from the separator bottom, while the liquid seal prevents gas carry-under into the drain pipes and short-circuiting of the flow.

Key Features & Benefits

High liquid handling capacity

High liquid separation efficiency

Extended liquid residence time

High operational flexibility for slug flow conditions

Suitable for foaming liquid service, resistant to plugging, no need for maintenance or replacement

The high-efficiency horizontal separator with a single liquid collection section can effectively remove entrained liquid droplets from the gas stream even under high gas flow conditions.

Technical Specifications

The high-efficiency horizontal separator with a single liquid collection section ensures 100% removal of droplets ≥8 μm. Under maximum design throughput, the total liquid carryover in outlet gas does not exceed 0.1 U.S. gallons per MMSCF (13.4 liters per million Nm³).

2. High-Efficiency Horizontal Dual Liquid Collection Chamber Separator

Working Principle:

(A) The inlet buffer device for the gas-liquid two-phase stream helps reduce the kinetic energy of the fluids entering the separator, while removing large entrained liquid droplets and slug flow.

(B) The primarily separated large liquid droplets and slug flow are directed into the secondary liquid collection chamber through the front downcomer.

(C) The gas carrying the remaining fine liquid droplets flows into the high-efficiency separation vanes located downstream.

(D) The liquid captured by the separation vanes is collected below the vanes and, under the action of gravity, is directed into the secondary liquid collection chamber through the rear downcomer.

(E) A properly designed liquid level control ensures that the liquid at the bottom of the secondary collection chamber is discharged smoothly from the separator.

Key Features & Benefits

High gas and liquid handling capacity

High liquid separation efficiency

Long liquid residence time

Strong adaptability to slug flow conditions

Effective for foaming liquids: the secondary collection chamber efficiently releases entrained gas bubbles, providing stable liquid conditions

Not prone to clogging, no maintenance or replacement required

The High-Efficiency Horizontal Dual Liquid Collection Chamber Separator can still effectively remove entrained liquid droplets from the gas stream even under extremely high gas flow rates. The secondary liquid collection chamber completely isolates the gas from the captured liquid, thereby eliminating re-entrainment caused by high-velocity gas. In addition, the secondary chamber functions as a settling and stabilizing zone, effectively releasing entrained gas bubbles from the liquid and ensuring stable liquid conditions.

Technical Specifications

Our High-Efficiency Horizontal Dual Liquid Collection Chamber Separator guarantees 100% removal of liquid droplets with diameters ≥ 8 microns. At maximum design throughput, the total liquid carryover in the outlet gas does not exceed 0.1 U.S. gallon per million standard cubic feet (13.4 liters per million standard cubic meters).

High-Efficiency Separation Vanes

Based on extensive industrial experience and comprehensive experimental test data, we are able to provide customers with targeted optimization designs for high-efficiency separation vanes and develop customized solutions according to special operating conditions specified by customers, in order to enhance separator performance.

Fixed or removable vane assemblies supported by welding or bolted connections

Vane backflushing system

Multi-stage vane combination system

A wide variety of vane types with flexible gas flow optimization distribution

Combination Structures of High-Efficiency Separation Vanes

High-efficiency separation vanes are typically designed in different combination structures to meet process performance requirements and vessel dimensional constraints. The unit combination structures of high-efficiency separation vanes generally include four basic forms: single-vane set, double-vane set, four-vane set, and eight-vane set. When process performance and vessel dimensions have specific requirements, high-efficiency separation vanes can also be designed in targeted combination structures to meet special customer demands.

Comparison of High-Efficiency Separation Vanes with Conventional Wire Mesh

Compared with conventional wire mesh, high-efficiency separation vanes offer significant techno-economic advantages.

The vessel dimensions required for designs utilizing high-efficiency separation vanes are typically reduced by at least 30–40% compared with conventional wire mesh designs, resulting in lower capital investment and reduced footprint.

High-efficiency separation vanes are formed by pressing smooth stainless steel plates, making them resistant to damage and clogging. Their daily operation, maintenance, and shutdown overhauls incur very low costs, while their service life far exceeds that of conventional wire mesh.