A Comparison Study between Steady-State and Dynamic Operation Models on the HTPS Performance

Abstract:

Given the importance of enhance the performance of oil separators in production field, this research study the separation process through simulations based on a real field data, WQ-2 south of Iraq-Basra. By implementing both dynamic and steady-state approaches in Aspen HYSYS V.14, the optimization was carried out for each approach for comparison. Results from the steady-state simulation revealed limited improvement, with closely converging iterations and changes applied to only one variable at a time. In contrast, the dynamic simulation given more realistic and favorable results, as manual adjustments were applied in a real-time response to the actual field dynamics range and conditions. The result shows that the maximum OVFR=15050 m3/h and CO=0.1999099 at T= 60 °C and P= 15 barg for static model, while the OVFR=1580.9 m3/h, CO=0.0093 at P=14 barg, T=76 °C where the operation time 120 min for dynamic. Compared to the static approach, the dynamic approach was efficient to reach better performance when the selected parameters were optimized and that led to a substantial improvement in the separation efficiency. Therefore, the dynamic simulation could be considered a mandatory approach when the overall separator efficiency need to be enhanced.

You might also be interested in these eBooks

Info:

Periodical:

Engineering Chemistry (Volume 13)

Pages:

105-118

Citation:

Online since:

February 2026

Export:

Share:

Citation:

* - Corresponding Author

[1] Manning, F.S. and R.E. Thompson, Oilfield processing of petroleum. 1991.

Google Scholar

[2] Arnold, K. and M. Stewart, Surface production operations, Volume 2:: Design of gas-handling systems and facilities. Vol. 2. 1999: Elsevier.

Google Scholar

[3] Mokhatab, S., W.A. Poe, and J. Speight, Handbook of natural gas transmission and processing. Gulf Professional Publishing. 2012.

Google Scholar

[4] Stewart, M. and K. Arnold, Gas-liquid and Liquid-liquid Separators. 2008: Gulf Professional Publishing.

Google Scholar

[5] Ahmed, T., N. Makwashi, and M. Hameed, A review of gravity three-phase separators. Journal of Emerging Trends in Engineering and Applied Sciences, 2017. 8(3): pp.143-153.

Google Scholar

[6] Ahmed, T., et al., Design and capital cost optimisation of three-phase gravity separators. Heliyon, 2020. 6(6).

Google Scholar

[7] (DEng, D.D.H., Gas Processing. 2024.

Google Scholar

[8] Famisa, R.B., HYSYS Modelling of a Horizontal Three-Phase Subsea Separator. 2016, NTNU.

Google Scholar

[9] Arnold, K.E. and P.J. Koszela, Droplet-settling vs. retention-time theories for sizing Oil/Water separator. SPE Production Engineering, 1990. 5(01): pp.59-64.

DOI: 10.2118/16640-pa

Google Scholar

[10] de Souza Sampaio, N.A., et al., effect of pressure and temperature on the retention time of crude oil inside the three-phase separator using the response surface methodology. revista de Gestão Social e Ambiental, 2025. 19(5): pp.1-14.

DOI: 10.24857/rgsa.v19n5-033

Google Scholar

[11] Zhang, T., C. Li, and S. Sun, Effect of temperature on oil–water separations using membranes in horizontal separators. Membranes, 2022. 12(2): p.232.

DOI: 10.3390/membranes12020232

Google Scholar

[12] Al-Mhanna, N.M., Simulation of high pressure separator used in crude oil processing. Processes, 2018. 6(11): p.219.

DOI: 10.3390/pr6110219

Google Scholar

[13] Hasan, A.F. and G.M. Farman, Optimization of Separator Size and Operating Pressure for Three-phase Separators in the West Qurna1 Oil Field. Iraqi Journal of Chemical and Petroleum Engineering, 2024. 25(1): pp.103-110.

DOI: 10.31699/ijcpe.2024.1.10

Google Scholar

[14] Bahadori, A., H.B. Vuthaluru, and S. Mokhatab, Optimizing separator pressures in the multistage crude oil production unit. Asia‐pacific Journal of Chemical Engineering, 2008. 3(4): pp.380-386.

DOI: 10.1002/apj.159

Google Scholar

[15] Bymaster, A., et al. High pressure gas-liquid separation: an experimental study on separator performance of natural gas streams at elevated pressures. in Offshore Technology Conference. 2011. OTC.

DOI: 10.4043/21781-ms

Google Scholar

[16] Sulaiman, F.A., et al., Mitigating Liquid Carry-Over and Foaming in a Gas Processing Plant through the Installation of Vertical Scrubbers. Petroleum Chemistry, 2024. 64(1): pp.62-74.

DOI: 10.1134/s0965544124020178

Google Scholar

[17] Shaban, H.I., A study of foaming and carry-over problems in oil and gas separators. Gas separation & purification, 1995. 9(2): pp.81-86.

DOI: 10.1016/0950-4214(95)93944-f

Google Scholar

[18] Choi, M. Prediction of separator performance under changing field conditions. in SPE Annual Technical Conference and Exhibition? 1990. SPE.

DOI: 10.2118/20703-ms

Google Scholar

[19] Sulaiman, F.A., H. Sidiq, and R. Kader, Liquid carry-over control using three-phase horizontal smart separators in Khor Mor gas-condensate processing plant. Journal of Petroleum Exploration and Production Technology, 2024. 14(8): pp.2413-2435.

DOI: 10.1007/s13202-024-01817-4

Google Scholar

[20] Farman, G.M., Determining Optimum Oil Separator Size and Optimum Operating Pressure. Iraqi Journal of Chemical and Petroleum Engineering, 2022. 23(2).

DOI: 10.31699/ijcpe.2022.2.6

Google Scholar

[21] Kotb, M., G. Abdelalim, and S. Abdall, Optimization of Oil-Gas Separation in the Production Stations at Abo-Sannan Field: Case Study. Improved Oil and Gas Recovery, 2024. 8.

DOI: 10.14800/iogr.1263

Google Scholar

[22] Li, Z., Y. Li, and G. Wei, Optimization of Control Loops and Operating Parameters for Three-Phase Separators Used in Oilfield Central Processing Facilities. Fluid Dynamics & Materials Processing, 2023. 19(3).

DOI: 10.32604/fdmp.2022.020633

Google Scholar

[23] GROUP-6-Separation-Operations, 7 Separation Operations.

Google Scholar

[24] Nath, S.R., Separation Train Design and Optimaztion in Offshore Oil and Gas Production Facilities. 2022, ACS Publications.

Google Scholar

[25] Qaroot, Y.F., Simulation of three-phase separator performance. 2013, The Petroleum Institute (United Arab Emirates).

Google Scholar

[26] Edwin, M., S. Abdulsalam, and I. Muhammad, Process simulation and optimization of crude oil stabilization scheme using Aspen-HYSYS Software. International Journal of Recent Trends in Engineering & Research, 2017. 3(5): pp.324-334.

DOI: 10.23883/ijrter.2017.3230.miiuw

Google Scholar

[27] dos Santos Lemos, I. and L. de Sousa Santos, Analysis of multi-objective optimization applied to the simulation of a natural gas separation plant. Gas Science and Engineering, 2024. 128: p.205360.

DOI: 10.1016/j.jgsce.2024.205360

Google Scholar

[28] Jonach, T., et al., Modeling and Simulation of 3-Phase Separators in the Oil and Gas Industry with Emphasis on Water Quality. Chemical Engineering Transactions, 2022. 94: pp.1009-1014.

Google Scholar

[29] Carvalho, A., D. Galindo, and J. Marinho, Modeling and simulation of a horizontal three-phase separator: influence of physicochemical properties of oil. Brazilian Journal of Petroleum and Gas, 2021. 14(4).

DOI: 10.5419/bjpg2020-0016

Google Scholar

[30] Joshy, A., A. MA, and A. Nambiar. CFD Analysis and Optimization of Three Phase Oil Separator. in Proceedings of the International Conference on Systems, Energy and Environment. 2022.

Google Scholar

[31] Pourahmadi Laleh, A., W.Y. Svrcek, and W. Monnery, Computational fluid dynamics-based study of an oilfield separator--Part I: a realistic simulation. Oil and Gas Facilities, 2012. 1(06): pp.57-68.

DOI: 10.2118/161212-pa

Google Scholar

[32] Lu, Y., J. Greene, and M. Agrawal. CFD characterization of liquid carryover in Gas/Liquid separator with droplet coalescence due to vessel internals. in SPE Annual Technical Conference and Exhibition? 2009. SPE.

DOI: 10.2118/124205-ms

Google Scholar

[33] AspenHYSYS:ProcessSimulationSoftware.Availableonline:(accessed on 7 February 2023). 2023-2025.

Google Scholar

[34] Gmehling, J., et al., Chemical thermodynamics for process simulation. 2019: John Wiley & Sons.

Google Scholar

[35] Gutierrez, J.P., et al., Thermodynamic Properties for the Simulation of Crude Oil Primary Refining. 2014.

Google Scholar

[36] Peng, D.-Y. and D.B. Robinson, A new two-constant equation of state. Industrial & Engineering Chemistry Fundamentals, 1976. 15(1): pp.59-64.

DOI: 10.1021/i160057a011

Google Scholar

[37] Elsharkawy, A.M. Predicting the properties of sour gases and condensates: equations of state and empirical correlations. in SPE International Oil Conference and Exhibition in Mexico. 2002. SPE.

DOI: 10.2118/74369-ms

Google Scholar

[38] Naji, H., Conventional and rapid flash calculations for the soave-redlich-kwong and peng-robinson equations of state. Emirates Journal for Engineering Research, 2008. 13(3): pp.81-91.

Google Scholar

[39] Wei, Y.S. and R.J. Sadus, Equations of state for the calculation of fluid‐phase equilibria. AIChE journal, 2000. 46(1): pp.169-196.

DOI: 10.1002/aic.690460119

Google Scholar

[40] McCain Jr, W.D., Properties of petroleum fluids. 1973.

Google Scholar

[41] Ahmed, T., Equations of state and PVT analysis. 2013: Elsevier.

Google Scholar

[42] Vilagines, R.D. and A.R. Akhras. Three-phase flows simulation for improving design of gravity separation vessels. in SPE Annual Technical Conference and Exhibition? 2010. SPE.

DOI: 10.2118/134090-ms

Google Scholar

[43] Kim, I.H., et al., Simulation-based optimization of multistage separation process in offshore oil and gas production facilities. Industrial & Engineering Chemistry Research, 2014. 53(21): pp.8810-8820.

DOI: 10.1021/ie500403a

Google Scholar

[44] Cui, Y., et al., Investigation of Influence of High Pressure on the Design of Deep-Water Horizontal Separator and Droplet Evolution. Processes, 2024. 12(12): p.2619.

DOI: 10.3390/pr12122619

Google Scholar

[45] Arnold, B.F. and P. Stahlecker, Linear regression analysis using the relative squared error. Linear algebra and its applications, 2002. 354(1-3): pp.3-20.

DOI: 10.1016/s0024-3795(01)00572-9

Google Scholar