Adaptive Renovation of Centrifugal Separators: A Computational–Experimental Methodology for Optimizing Gas-Dynamic Regimes without Capital Expenditure

Ilnar Iakhin

Citation: Ilnar Iakhin, "Adaptive Renovation of Centrifugal Separators: A Computational–Experimental Methodology for Optimizing Gas-Dynamic Regimes without Capital Expenditure", Universal Library of Innovative Research and Studies, Volume 02, Issue 04.

Copyright: This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

Abstract

The methodology proposes an approach to the adaptive renovation of centrifugal multicyclone separators during declining production, without capital expenditure or hot work. The problem is demonstrated to be relevant, driven by the mismatch between gas-dynamic regimes and apparatus geometry, the growth of liquid carryover, and the risk of catastrophic failure of compressor equipment. The objective of the study is to develop and verify a computational–experimental procedure for selecting the active separation area by selectively plugging part of the centrifugal elements to maintain the operating point within the zone of maximum efficiency. The scientific novelty lies in introducing the efficiency triangle concept (velocity–pressure–design), using modified similarity correlations to determine critical velocities, and combining isokinetic probing with algorithmic tray configuration, implemented as a Python module. It is shown that application of the methodology makes it possible to restore the regulatory level of carry-over (<5 mg/m³), extend the service life of separation equipment, and reduce total costs by eliminating the need for separator replacement, with the intervention cost being less than 1 % of the price of a new separator. The methodology is intended for engineering and technical personnel at gas production and gas processing enterprises, as well as for design and service organizations involved in modernizing integrated gas treatment units.


Keywords: Adaptive Renovation, Multicyclone Separator, Centrifugal Separation, Gas-Dynamic Optimization, Critical Velocities.

Download doi https://doi.org/10.70315/uloap.ulirs.2025.0204019