Numerical Simulation of Oil-Water Separation

Process in Disc Separator

Zhiguo Zhao
1

1. University of Science and Technology Beijing, Beijing,
100083, china
E-mail:lnzzg98@163.com
Boqiang Shi
2
2. University of Science and Technology Beijing, Beijing,
100083, china
E-mail: shiboqiangustb@163.com


AbstractUsing Numerical Methods to research disc separator
inner flow field is an important method to optimize the design.
This article based on VOF model, N-S equations and RNG k-
model, solved with the SIMPLE algorithm, simulated separator
oil-water separation process respectively with initial state filled
with water, oil and oil-water mixture this three different
initialization conditions by using flunet software. The numerical
simulation results show that the initial condition has little effect
on the oil-water separation, and eventually a stable layer
interface can be formed and purification rate can reach at 98%.
There is strong turbulence near the inlet and wastewater outlet,
while flow is relatively stable between the discs gaps and near the
oil outlet, basically in a laminar flow state. The research results
laid a foundation of separator design and optimization and also
can reduce the time and cost required for experiments.
Keywords- Disc Separator; the oil-water Separation Process;
Numerical Simulation
I. INTRODUCTION
Dish-style separator (the separator) is one of the most
widely used sedimentation-type centrifuge [1], for separating
on difficult materials, mainly used for mining vehicles,
hydraulic equipment, steel rolling equipment and mining
machinery and equipment to remove moisture and mechanical
impurities in lubrication Oil, in order to reduce equipment wear
and prolong the life of machinery and equipment. The research
shows that there are many factors which influence the
separation performance of separator [2]. Due to experimental
conditions, a simple means to optimize the experimental study
of these parameters is not only cycle-long but also expensive,
which cannot meet the engineering needs. With the CFD
simulation technology becoming matured [3], numerical
simulation is increasingly becoming an important method of
the oil-water separation process. In the existing literature, the
paper about the strength calculation of the drum separator and
studies of optimal design is primary [4-5], but about movement
analysis of oil-water separation flow field in separator is only a
little, so there are practical value in this paper.
II. GOVERNING EQUATION AND COMPUTING METHOD
A. Governing Equation
Continuity equation:
0
m
m
u
x

(1)
Momentum equation
2
m m
n m
n m n n
u u p
u F
x x x x


= +

(2)
In which, is fluid density, p is pressure, is fluid dynamic
viscosity, , ( , 1, 2, 3)
m n
u u m n = is fluid velocity component,
, ( , 1, 2, 3)
m n
x x m n = is rectangular coordinates system, and
m
F is quality force [6].
B. Computing method
Using VOF model in oil-water separation, the separation
machine has strong turbulence in high-speed rotation. While
using RNG k- turbulence model in the calculation, the method
has better stability, economy and accuracy. As oil-water
mixture cannot be compressed, and the turbulence exists inside
the separation machine, also the internal pressure is changing
distributed, so that governing equation use three-dimensional
of unsteady incompressible Reynolds-averaged NS equations,
which was solved by using SIMPLE method [7].
III. PHYSICAL MODEL AND INITIAL CONDITION
A. Physical model
It is all the symmetry structure of axis in the drum
separator. In order to simplify the calculation model, modeling
of the rotation axis is defined by two-dimensional model
instead of three-dimensional structure to solve in the gambit
software. In Fig.1, two-dimensional model of the separation
Drum and disc was shown. The left blue is the rotation axis
(symmetry), green is the fluid inlet, upper red is outlet, and
inside light green area is the fluid. The fluid under the
centrifugal force is through the disc to both sides.
Computation models basic parameters are as follows:
drum diameter is 150 mm, height is 95 mm, inlet diameter is
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978-1-4244-9171-1/11/$26.00 2011 IEEE
10 mm, disc has 52 pieces, thickness is 0.4 mm and disc gap is
0.5 mm.

Fig.1 the two-dimensional model of separator drum and disc
B. Boundary conditions
As the separators rated capacity per hour is a constant, so
the son-speeds at x, y direction was chose at 2.5 m/s. Outlet
conditions have a tremendous influence on the simulation
results, and fluid is allowed to free in outflow outlet without
any qualification, which is the most realistic boundary
conditions, so this paper choose outflow outlet, set the moving
grid wall, and choose the 800rsd/s speed.
At the inlet boundary of flow field, it needs to define
turbulence parameter of flow field [8]

:
Turbulence intensity:
2 2 2
' ' '
avg
u v w
I
u
+ +
=
(3)
In which,
2
' u ,
2
' v and
2
' w is the velocity pulsation of
fluid , , X Y Z directional and
avg
u is fluid average velocity.
The flow has low inlet velocity in this model, and flow
along the pipeline with little turbulence, so the intensity of
turbulence at inlet is at 1% as calculating.
Turbulence kinetic energy in entrance is:
( )
2
3
2
avg
k u I = (4)
In which,
2 2
avg x y
u v v = +
.
Turbulent dissipation rate at inlet is:
3 2
3 4
0.07
k
C
L

= (5)
In which, C

is empirical constant of turbulence, which value

approximate 0.09, and
L
is inlet pipeline diameter, which
value is 10 mm.
IV. RESULT AND ANALYSIS
Using three different states to initialize the model, the
volume fraction of water at the inlet were about 10%. Oil is
shown in red, and water is shown in blue.
1) While the initial state is that the drum was filled with
water, the initial flow field is shown in Fig.2. At this time
separator just started and oil-water flowed from the two inlets
into the drum. It can simulate the movement locus of the oil
flowing through enough time. The simulation step is 0.002s.
They are shown in Fig.3, Fig.4 and Fig.5.

Fig.2 Oil content volume fraction in water initialization

Fig.3 Oil content volume fraction in water initialization

Fig.4 Oil content volume fraction before water stationary initialization

Fig.5 Oil content volume fraction while water initialization is stable state
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Fig.3 shows oil-water distribution when the time is at 27s,
in which, oil slowly gathered at outlet after filled the entire
fluid chamber. Fig.4 and Fig.5 are allocation plan of fluid with
running 42s and 78s. Fig.4 can be seen as fluid verge to the
stable state. Due to different densities of oil and water, water
was borne by the larger centrifugal force, so the gradual move
outward and oil accumulation inside formed a stable sub-
interface. Fig.5 shows that fluid has been stabilized, the oil
outlet is filling with the oil, and the water outlet is mainly
water, mixed with a small amount of oil.
2) When the drum is filled with the oil in initial state, the
trajectory of water and the final distribution of the flow field
are shown in Fig.6 and Fig.7:

Fig.6 Movement locus of water in original state filled with oil

Fig.7 Steady flow in original state filled with oil
Fig.6 shows the water does not fill the container as the
oil, but along a certain path, directly flow to outer of drum
and flow out of the exit. At the beginning water flowed
slowly, so there will be hoarding water in the drum, until the
final minutes to form a stable interface.
3) While the initial state is that the drum is filled with a
mixture, which flows into the drum through only one inlet,
and waters content is 10%, the final state and initial
distribution of oil-water are shown in Fig.8 and Fig.9.

Fig.8 Oil-water allocation plan of mixture in the initial state

Fig.9 Steady state of mixture in the initial state
In the mixture initial state, the oil and water was gradually
separated to both sides, and finally formed a stable interface,
without apparent movement trajectories.
For the flow field within the drum, there was turbulence in
the entrance; the Reynolds number of disc gap is generally
less than 100, in which laminar flow is basic; the shape and
flow path of oil outlet are formulaic, so as to relatively stable
flow; high flow rate is at outlet, and flow path is rapidly
narrowing, in which there are greater turbulence. As its
shown in Fig.10, fluid motion is stable in the disc, and
turbulences in different degrees exist in others.

Fig.10 Fluid flow locus at sometime
Through the analysis of three cases, we can see that: the
initial conditions have little effect on the final result; the final
state is basically as the same; oil and water are layered to form
a stable interface; and the mixture initial conditions reach the
steady state firstly which just can be close to reality. Reached
steady state, oil and water were separated basically; the
percentage of oil outlet is nearly 98%, mixed with a small
amount of the oil near the outlet, mainly composed of water,
indicating that the oil-water separator is good.
V. CONCLUSION
1) The two-phase flow of oil-water separation on the
separator was simulated by using VOF model, RNG k-
turbulence model and SIMPLE arithmetic, and the oil-water
separation process in the drum was shown.
2) The simulation results show that the results of initial
conditions had little effect on the oil-water separation, a stable
layer interface was eventually formed, and purification rate
can reach at 98%. This design has the same effect with
expected, indicating that Fluent can be applied to the virtual
disc separator development, and can save experimental cost
and less development time.
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3) From the analysis of movement locus of oil and water, at
the waste water outlet and near the inlet there is strong
turbulence, while at the disc clearance and near the oil outlet
flow is relatively stable, basically in a laminar flow state. In
order to reduce turbulence phenomenon near the inlet and
outlet, the fillet should be done at the outer of baffle and inlet
pipe of separator.
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