Deployment of Internal Liquid-Liquid Separation Technology to Mitigate Condensate Stabilization Salt Fouling Challenge

Abstract This abstract describes the approach taken in a Gas Condensate Stabilization facility to enhance water separation from gas condensate. This was done by installing a liquid-liquid separation technology that was retrofitted inside an existing three-phase separator. This resulted in eliminating a chronical salt fouling challenge in the Condensate Stabilizer Column Reboilers, which was caused by the carryover of the high-salinity water to the Condensate Stabilizer Column due to the inadequate gravity-separation in the existing three-phase separator. The principle of this proven liquid-liquid separation technology depends on two process stages; a turbulence isolation plate stage that quiescence the liquid flow; and a parallel-plates pack that coalesces small water droplet to form larger droplets which are then separated from the gas condensate by means of gravity. The whole set-up utilizes a self-supporting system that allow for installation inside the existing three-phase separator without any hot work (welding) to the vessel. The deployment of this technology resulted in achieving high quality gas condensate product, where the free water content dropped by 75%. In addition, it resulted in significant reduction in the capital and operating cost associated with a conventional standalone liquid-liquid coalescer vessel. Furthermore, the enhanced water separation eliminated the chronical salt fouling challenge faced in the Condensate Stabilizer Column Reboilers, thus improving the equipment integrity and availability. Finally, the improved product specifications resulted in smoother operation in the downstream processing facility and pipelines, ensuring a more reliable gas condensate supply network.