A Dynamic Simulation Framework for Performance Analysis of a Three-Phase Separator
Abstract
The present study addresses the mathematical modeling and dynamic simulation of a three-phase gravitational separator. The overall goal was robust construction and modeling to optimize the reduction of water composition in crude oil emulsions. The presence of emulsified water severely impacts primary oil processing, decreasing the final quality of the product (increase in BS&W - Basic Sediment and Water), exponentially increasing operating costs (OPEX). For the construction of the model, the Python language was used, implementing mass balances and equations that describe the dynamics of phase separation. Correlations from the literature were incorporated for the calculation of fluid properties, such as density, and efficiency of the phases as a function of API gravity, and the classification of the oils used in the simulation scenarios themselves was validated. The results obtained show that the model was successful in describing the behavior of the system. Notably, the simulations demonstrated that oils with higher API gravity (lighter, with lower density) have faster and more efficient separation kinetics. This is because the lower viscosity of the oil (continuous phase) offers less resistance to the movement of water droplets, and the greater density difference between the phases intensifies the gravitational force, accelerating decantation. The behavior of the model compared to real scenarios can be correlated with the impact of the chemical composition, and the higher concentration of components such as asphaltenes and resins, natural emulsifiers present in oils, in heavy oils tend to form more rigid interfacial films, stabilizing the emulsion, making it difficult to coalescence. It is concluded that the simulated model obtained satisfactory accuracy, presenting results consistent with the theory and industrial practice in all the proposed scenarios, proving to be a valuable tool for the analysis and optimization of separation processes.
