Supersonic Gas Separation (3S Technology): A Strategic Opportunity for PDVSA at Amuay and Cardón

3S Technology opportunity case

Venezuela’s Paraguaná Refining Complex (CRP), which includes the Amuay and Cardón refineries, remains a cornerstone of the country’s energy system. These facilities have opportunity and capacity to process offshore crude while receiving significant volumes of associated gas and natural gas through dedicated pipelines. However, the current gas-handling configuration leaves valuable C3–C4 fractions unrecovered.

Paraguana Refining Complex 1 — Supersonic Gas Separation (3S Technology): A Strategic Opportunity for PDVSA at Amuay and Cardón 3

The implementation of a modern, compact and highly efficient solution — the 3S Supersonic Separation Unit — would offer PDVSA (Petróleos de Venezuela) a unique opportunity to recover these liquids and significantly improve refinery economics.

1. Current Gas Handling at CRP: Lost C3+ Value

After onshore processing, associated gas undergoes only basic condensate separation before being blended with mainland natural gas and routed to Amuay and Cardón. No fractionation or NGL recovery is performed, resulting in large volumes of propane, butane and heavier hydrocarbons remaining in the gas, unused and unmonetized.

Refinery	Gas Flow (MMSCFD)	Gas Flow (m³/h)	Annual Volume (million m³)
Amuay	49	55,125	481
Cardón	58	65,250	573

This means Venezuela is currently losing thousands of tons per year of valuable C3–C4 products due to the absence of an efficient separation technology at refinery inlet points.

2. 3S Supersonic Separation: A Modern and Reliable Solution

As documented in various technical materials by 3S-MOST, the 3S Supersonic Separator operates by:

Accelerating gas through a Laval nozzle into supersonic velocity
Inducing instant cooling and condensation of C3–C4 and water
Separating liquids through a cyclonic mechanism without moving parts
Operating as a compact, static, low-maintenance system

This makes it ideal for refineries like Amuay and Cardón, where reliability, footprint, and CAPEX discipline are critical factors.

Key Technical Advantages

High C3–C4 recovery even with variable inlet compositions
No rotating equipment — minimal maintenance
No chemical additives or regeneration systems
Compact skid-mounted configuration
Suitable for unattended or remote operation

3. Recovery Potential for Amuay and Cardón

Based on the engineering evaluation, installation of 3S units (3S SuperSonic Swirl Separator) at both refineries would unlock significant NGL recovery:

Location	Inlet Flow (MMSCFD)	Treated Flow (MMSCFD)	C3–C4 Recovery (kg/h)	C3–C4 Annual Recovery (tons/year)
Amuay	49	48.1	2,418	21,180
Cardón	58	56.9	2,862	25,071

Total C3–C4 recovery => approximately 46,000 tons per year …

… offering a strong return even under conservative pricing assumptions.

Installation of 3S-separation unit for C3-C4 -fractions extraction at each refinery: Amuay refinery gas, & Cardón refinery gas, — 3S-separation – basic block unit diagram

4. Cost Estimate

Given the recovery volumes, such systems featuring 3S Supersonic Separator would typically pay for themselves rapidly.

5. Strategic Impact for Venezuela (Amuay & Cardón)

Economic Benefits

Monetization of large C3–C4 volumes
Increased LPG availability
Improved refinery efficiency and stability

Operational Benefits

Cleaner and more predictable fuel gas for refinery operations
Reduced risk of liquids carryover
Lower stress on compressors and furnaces

National Benefits

Reduced flaring and emissions
Strengthening of domestic fuel supply chains
Modernization of a key national asset

Conclusion

The integration of 3S Supersonic Gas Separation at the Amuay and Cardón refineries offers a compelling opportunity for Petróleos de Venezuela (PDVSA) and for Venezuela’s energy sector. With high recovery efficiency, low maintenance requirements and a flexible financing structure, this technology represents an immediately actionable step toward restoring and enhancing national refining capability.

Total C3–C4 recovery => approximately 46,000 tons per year …

In a context where every recovered barrel and every recovered molecule counts, 3S technology stands out as a practical, efficient and high-impact investment for the Paraguaná Refining Complex.

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Supersonic Gas Separation – The Next-Generation Solution for Natural Gas Processing

General-about: Gas Separation

In today’s energy market, the demand for efficient, compact, and environmentally friendly gas-treatment technologies has never been higher. Traditional separation methods—based on absorption, adsorption, or cryogenic expansion—often require large equipment, chemicals, and high energy consumption.

The supersonic separator, also called a supersonic gas separator, is a breakthrough solution that changes this paradigm.
By combining the principles of supersonic expansion, rapid cooling, and centrifugal separation, this technology enables dehydration, hydrocarbon dew-point control, acid-gas removal, and NGL recovery in a single compact unit.

Among all current solutions, the 3S supersonic gas separator has emerged as one of the most advanced and widely commercialized systems.
At M-ost Ltd (3S-MOST), we are the official licensee and global manufacturer of 3S technology, providing complete turnkey solutions for NGL recovery, gas conditioning, and CO₂/H₂S extraction to customers worldwide.

🔬 Scientific Basis of Supersonic Gas Separation

1️⃣ Supersonic Expansion and Non-Equilibrium Condensation

The core principle behind a supersonic separator is the rapid expansion of gas through a Laval (converging–diverging) nozzle.
As the gas accelerates to supersonic velocity, static pressure and temperature drop dramatically—sometimes to as low as −50 °C or below.
This sudden cooling induces non-equilibrium condensation of vapors such as water, CO₂, H₂S, and heavy hydrocarbons into fine liquid droplets.

This process happens within milliseconds, making it much faster than conventional chilling or absorption systems. It also avoids hydrate formation due to the extremely short residence time of the gas in the separator.

2️⃣ Swirl Flow and Centrifugal Separation

To separate the condensed droplets from the gas, a swirler or vortex generator imparts a strong rotational motion to the flow.
This creates powerful centrifugal forces—thousands of times greater than gravity—which drive condensed droplets outward toward the walls.
The purified gas moves through the centerline, while the liquid phase is extracted through dedicated drainage ports.

3S SuperSonic gas separator — SuperSonic gas Separator

3️⃣ Energy Efficiency and Compact Design

A diffuser section downstream of the separation zone recovers some of the lost pressure energy, increasing overall efficiency.
Because the system uses the gas’s own expansion energy—not external refrigeration or chemicals—it operates with very low power consumption.
This results in a compact, efficient, and low-maintenance solution ideal for both onshore and offshore gas-processing facilities.

⚙️ Components of a Supersonic Separator

Laval Nozzle – accelerates gas to supersonic velocity
Swirler (Vortex Generator) – induces strong centrifugal forces
Separation Section – condensation and liquid separation zone
Diffuser – recovers pressure and stabilizes outlet flow
Liquid Collection System – removes condensed phases efficiently

Together, these components perform the entire process—cooling, condensation, and separation—within a single, compact device.

🌍 Key Advantages of Supersonic Separation

✅ Compact and lightweight: Perfect for space-limited sites, including offshore platforms and skid-mounted applications.
✅ Chemical-free operation: No glycol, amine, or other chemicals needed for dehydration or acid-gas removal.
✅ Multi-functional process: Performs dehydration, NGL recovery, and CO₂/H₂S extraction in one unit.
✅ High reliability: No moving parts, minimal maintenance, and simple control.
✅ Fast response: The process is nearly instantaneous; no large inventories of gas or liquid.
✅ Environmentally friendly: Eliminates chemical waste and reduces greenhouse gas emissions.
✅ Cost-effective: Reduced CAPEX and OPEX compared to conventional technologies.

🧠 The 3S Supersonic Gas Separator – Patented & Proven

The 3S supersonic gas separator is a patented technology, recognized for its unique design and performance.
It is protected under international patent filings, including:

These patents cover the fundamental design and operation of the 3S supersonic separator, ensuring global protection and consistent quality.

At M-ost Ltd (3S-MOST), we are the official licensee and worldwide manufacturer of this patented technology.
Every 3S unit is custom-engineered to the client’s feed-gas composition, pressure, temperature, and target separation efficiency.

🏭 Industrial Applications

The 3S supersonic gas separator is versatile and applicable to a broad range of industrial gas processes:

🔹 Gas Conditioning & Enrichment

Removes water vapor and heavy hydrocarbons (C₂+, C₃+)
Controls gas dew-point to prevent hydrate formation
Improves pipeline gas quality and heating value

🔹 NGL Recovery

Extracts propane, butane, and heavier hydrocarbons (C₃+ fractions)
Reduces the need for bulky cryogenic systems
Ideal for onshore plants and offshore platforms

🔹 CO₂ / H₂S / Acid Gas Separation

Partially or completely removes acid gases from raw natural gas
Can operate standalone or as a pre-treatment before amine/membrane systems
Enables cleaner, specification-grade natural gas

🔹 LNG & Cryogenic Pre-Treatment

Reduces CO₂ and heavy hydrocarbon content before liquefaction
Improves LNG yield and plant efficiency
Integrates seamlessly into existing LNG pre-treatment trains

🔹 Offshore & Subsea Gas Processing

Compact, lightweight, and low-maintenance
Suitable for unmanned or subsea installations
Reduces space, weight, and operational risk

🧩 Why Choose 3S-MOST

Official 3S licensee and global manufacturer
Tailored engineering for specific gas compositions and process goals
Compact, modular units ready for plug-and-play installation
Proven track record in industrial and offshore environments
Global delivery, commissioning, and after-sales support
Dedicated inquiry forms for quick and accurate proposals

🟢 Inquiry Forms:

3S Separator General Inquiry
Gas Dew-pointing Inquiry
CO₂ Separation / Extraction Inquiry
C₂+, C₃+ Extraction Inquiry

🌐 The Future of Gas Processing is Supersonic

Supersonic gas separation combines advanced fluid dynamics with industrial practicality.
It offers an environmentally responsible and energy-efficient way to treat natural gas while meeting modern operational demands.

The 3S supersonic gas separator, developed under international patents and commercialized globally by M-ost Ltd (3S-MOST), represents the next generation of separation technology—delivering superior performance, low maintenance, and compact design.

3S CE Certification 2 — Supersonic Gas Separation – The Next-Generation Solution for Natural Gas Processing 6

⚡ Get in Touch

Are you ready to bring supersonic efficiency to your gas processing operations?
Contact us today to discuss your project or request a customized 3S supersonic separator proposal.

🔗 Request a 3S Separator Proposal

✅ M-ost Ltd (3S-MOST) — official licensee, manufacturer, and global supplier of the 3S supersonic gas separator technology.
Compact. Efficient. Chemical-free. The future of gas processing is supersonic.

Debottlenecking Gas Processing Units: Doubling Capacity with 3S Technology

General-about: Gas Separation

In the evolving landscape of natural gas processing, operators are increasingly challenged to expand throughput without major capital investments in new infrastructure. 3S Technology Debottlenecking — the strategic enhancement of existing facilities — offers a practical and cost-effective solution.

The 3S Technology (Supersonic Separation System) represents a breakthrough in 3S Technology Debottlenecking for low-temperature separation (LTS) units and other gas processing facilities. By integrating a 3S separation module into an existing LTS train, operators can double gas processing capacity while maintaining stable product quality and minimizing energy consumption.

Principal Technological Scheme

Benefits of 3S Technology Debottlenecking

Understanding 3S Technology Debottlenecking

3S Technology Debottlenecking = Principal technological scheme for increasing the capacity of the LTS unit by 2 times using 3S separation technology — If the existing LTS unit is designed for the inlet gas flow rate Q at some P_in and P_out, the application of 3S-separation unit allows to increase the gas flow rate, for example, by 2 times.
The inlet gas flow with a flow rate of 2Q is divided into two equal streams, which are cooled in H1 and H2 respectively; Valve D is closed.
The cooled flow of 2Q and pressure P_in enters the 3S-separator, where it is divided again into 2 equal flows: purified gas and gas-liquid mixture, each of which has a flow rate Q and a pressure P_out.
Some design arrangements of the 3S-separator allows achieving such separation. The purified gas enters the H2 as a cooling agent. The gas-liquid stream is directed to a low-temperature separator S, where it is separated into a gas entering H1, and an unstable liquid.
The unit should also include: an inlet separator, a dehydration unit, and an outlet CS (if necessary).

How It Works

In a conventional LTS unit, gas enters a heat exchanger and is expanded across a Joule–Thomson valve to achieve partial condensation. The resulting gas–liquid mixture is separated in a low-temperature separator. However, capacity expansion is limited by the cooling duty and pressure drop constraints.

With the 3S debottlenecking configuration, the inlet gas flow is divided into two parallel streams, each cooled separately through existing and added heat exchangers (H2 if applicable). The cooled mixture then passes through the 3S separator, where supersonic flow induces high-efficiency phase separation of the gas–liquid stream.

In the Supersonic Gas Separation process, the gas is accelerated through a Laval nozzle, resulting in an adiabatic expansion and cooling that causes heavy hydrocarbons and water to condense. The centrifugal field generated inside the separator efficiently removes the condensed droplets before the gas is recompressed or directed downstream.

The process splits the flow into:

Purified gas, directed as a cooling medium through H2;
Gas–liquid mixture, sent to the existing LTS separator (S) for final separation.

This arrangement effectively doubles the processing throughput (from Q to 2Q) without major redesign or replacement of core process units.

Advantages of 3S Debottlenecking

2× Capacity Increase — Leverages existing LTS infrastructure with minimal footprint expansion.
Improved Efficiency — High-speed supersonic separation enhances phase disengagement and cooling performance.
Low Energy Demand — No moving parts or external refrigeration required.
Modular Integration — Compact 3S modules can be retrofitted into existing plant layouts.
Enhanced Reliability — Reduces hydrate formation risks and stabilizes downstream operations.

Applications Across the Gas Value Chain

3S debottlenecking solutions can be applied across Upstream, Midstream, and Downstream sectors:

Upstream: Expanding field-level gas treatment or flared gas recovery systems.
Midstream: Increasing plant throughput and preventing hydrate formation during gas conditioning.
Downstream: Ensuring steady, high-quality gas supply for petrochemical feedstock and refinery integration.

Additional Research and Knowledge Sources

Wikipedia: Supersonic Gas Separation — Overview of the principle and applications.
ResearchGate: Supersonic Gas Separation Technology – A Review — In-depth study of supersonic gas separation fundamentals and industrial implementation.
ScienceDirect Topic: Supersonic Separation — Academic references and applications in gas dehydration and hydrocarbon recovery.
OnePetro Library: Supersonic Gas Separation Papers — Peer-reviewed SPE papers on gas treatment and NGL recovery performance.

Conclusion

As the global energy market transitions toward efficiency and sustainability, 3S Technology provides a smart path forward for operators seeking to maximize the potential of existing gas processing assets. By combining compact design, low operational costs, and proven separation performance, 3S-based debottlenecking unlocks significant process capacity — without the cost and complexity of building anew.

Learn more about 3S modular solutions for gas processing, conditioning, and NGL recovery at 3S-MOST.eu.

Modular NGL Recovery & Gas Conditioning / Enrichment for Smarter Midstream Operations

General-about: Gas Separation

In today’s upstream and midstream gas landscape, operators face increasing pressure to monetize every hydrocarbon, reduce emissions, and keep CAPEX and OPEX under control. 3S Technology delivers a modular approach to NGL recovery, gas conditioning, and enrichment, combining advanced separation principles with plug-and-play scalability for fast, low-maintenance deployment.

Why NGL Recovery Matters

Recovering natural gas liquids (NGLs) such as ethane, propane, butanes, and heavier hydrocarbons has become a key profitability lever for gas producers. NGL extraction not only enhances product value but also contributes to emission reduction and resource optimization.

A recent technical review highlights that efficient NGL recovery is essential for both economic and environmental performance across the gas value chain (An Overview of Natural Gas Liquids Recovery and Fractionation Processes – 2023).

Further research demonstrates that replacing traditional Joule–Thomson valves with supersonic separators can significantly improve NGL recovery, underscoring the impact of modern compact systems (Nature Scientific Reports – 2022).

Key Takeaways

NGL recovery adds significant margin beyond methane sales.
Recovery efficiency directly impacts downstream fuel and power yields.
Modular plants enable deployment in satellite or flare-gas recovery settings.
Supersonic and modular systems can outperform traditional expansion methods in flexibility and uptime.

Keywords: NGL recovery, C3+ extraction, supersonic separator, modular skid, midstream optimization, natural gas liquids, flare gas monetization, process intensification

Gas Conditioning & Enrichment

Conditioning and enrichment ensure gas streams meet pipeline and process specifications — controlling hydrocarbon dew point, removing water, and enriching targeted components like C₂/C₃ to maximize plant throughput.

Academic work underscores the value of combining dew-point control, NGL removal, and enrichment to manage feed variability and boost recovery efficiency (Natural Gas Quality Enhancement: A Review of Conventional and Novel Treatment Technologies – 2016).

Professional studies from Siemens Energy demonstrate how modular fuel-gas conditioning systems reduce project schedules, simplify logistics, and improve lifecycle economics (Fuel Gas Conditioning System Modularization and Optimization – 2019).

Applications

Pre-pipeline gas conditioning (dew-point and NGL removal)
Gas enrichment to relieve cryogenic or fractionation bottlenecks
Brownfield and satellite fields where full cryogenic units are uneconomic
Capacity boost at existing GPPs or LNG feed conditioning

Keywords: gas conditioning, dew point control, enrichment module, C2/C3 recovery, pipeline specification, modular gas treatment, midstream skid installation

Why a Modular Approach Makes the Difference

Compared to conventional turboexpanders or chillers, modular systems like 3S Technology deliver:

Shorter project timelines (often measured in months rather than years)
Lower CAPEX and OPEX (compact designs, fewer moving parts)
High flow tolerance (±15% per unit; scale by adding/removing parallel units)
Minimal downtime (streamlined maintenance)
Attractive payback (driven by liquids uplift and emissions reduction)

These traits align with current best practices for process intensification and distributed gas recovery (overview of NGL recovery and fractionation processes).

3S-MOST Applications

Associated & flare-gas recovery — monetize waste streams while reducing emissions.
Satellite or stranded fields — deploy compact skids without extensive civil works.
Plant debottlenecking — use enrichment to raise throughput on existing assets.
Peak-load balancing — scale modularly with flow changes.

External References (Technical)

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3S Separator Technology – Supersonic Debottlenecking for Gas Processes

General-about: Gas Separation

3S Separator Technology: Supersonic Debottlenecking for Gas Processes

The 3S Supersonic Separator is a static device that accelerates gas through a convergent–divergent (Laval) nozzle, inducing rapid cooling and condensation. A swirl generator creates high centrifugal forces that throw droplets to the wall, while a diffuser recovers part of the pressure and directs a liquid slip stream to a knock-out vessel. This single, motionless unit delivers pre-condensation, dehydration, and pressure-savvy separation in milliseconds — ideal for debottlenecking existing plants.

Where 3S Unlocks Capacity

Upstream of cold boxes / J-T stages – pre-remove condensables and water to cut refrigeration duty and reduce recycle gas.
Hybrid with turbo-expanders – 3S handles bulk condensation; the expander polishes to ultra-low dew points and higher NGL recovery.
Replace or downsize chemical trains – fewer rotating assets and no solvent regeneration for many duties.
Brownfield revamps – compact skid modules add throughput without major civil works.

Hybrid flow scheme with 3S separator upstream of turbo-expander showing gas and liquid paths — **Figure 1.** Hybrid Flow Scheme — *3S Separator Upstream of Turbo-Expander*.
The blue gas path passes through a pre-cooler and 3S unit before expansion; orange shows the liquid slip stream
leading to knock-out and stabilization.

Debottlenecking Impact

In pilot and field tests, 3S modules consistently delivered higher C₃₊ recovery than J-T valves at the same Δp, while lowering chiller load and recycle.
This translates into more sales gas, deeper hydrocarbon dew point (HCDP), and room in the pressure budget for downstream equipment.

Bar chart comparing C3+ recovery percentage for J-T valve and 3S separator at 30, 50, 70 bar — **Figure 2.** Comparative C₃₊ Recovery — 3S vs J-T at Identical Pressure Drops.
Supersonic separation delivers up to **40% higher recovery** and alleviates bottlenecks in refrigeration and expansion stages.

Why 3S Debottlenecks

Process intensification: cooling, condensation, separation, and pressure recovery occur in one static device.
Energy-smart: converts part of differential pressure to deep cooling, then recovers pressure in the diffuser.
Reliability: no moving parts, no chemicals; ideal for remote/offshore and unattended operation.
CFD-aided design: geometry and swirl are tuned to place shocks stably, maximize droplet capture, and minimize entrainment.

Typical Outcomes in Revamps

Reduced refrigeration duty in cold boxes; fewer anti-hydrate measures.
Lower recycle gas and compressor power for the same product specs.
Deeper HCDP and water dew point; improved NGL yield.
Skid modularity to add capacity with minimal plot space.

Note: Actual gains depend on gas composition, inlet conditions, target specs, and allowable pressure drop.
3S is commonly applied as an upstream pre-treat step in a hybrid train to maximize efficiency.

INDUSTRY APPLICATIONS:

3S Technology│industry-applications

General-about: Gas Separation

INDUSTRY APPLICATIONS

3S Supersonic Separation modules are applicable across the gas value chain — from upstream wellhead conditioning to downstream petrochemical feedstock preparation.

UPSTREAM

Gas Processing Unit

Gas Treatment

✔️ Recovery of C3⁺ from raw gas streams.

Flared Gas Recovery

✔️ Recovery of C3⁺ from flared gas (>5 MMSCFD).

Fuel Gas Recovery

✔️ Recovery of C3⁺ from fuel gas used in compressors or generators.

MIDSTREAM

Gas Plant

Gas Conditioning

✔️ Preventing hydrate formation and corrosion during transportation.

Residual C3⁺ Recovery

✔️ Recovery of C3⁺ from fuel gas used in compressors or generators.

Debottlenecking

✔️ Increasing gas plant capacity with 3S separation units.

DOWNSTREAM

Gas-to-Chemical

Gas Treatment

✔️ Conditioning natural gas for refinery and petrochemical feedstock.

C3⁺ Recovery

✔️ Recovery of C3⁺ from refinery off-gas.

Flared Gas Recovery

✔️ Recovery of C3⁺ from flared streams.

Detailed Information to consider │ 3S — Process Flow :

3S Separator Technology — A Supersonic Shift in Gas Conditioning

General-about: Gas Separation

Supersonic Gas Separation

The 3S (Supersonic Separation) separator is a compact, no-moving-parts device that uses controlled expansion, swirl, and pressure recovery to condense and remove water, heavy hydrocarbons, and acid gases — while preserving valuable line pressure. This article renders key content and data from an on-site (research) technical project and integrates insights from recent 3S-MOST publications.

Why Supersonic Separation?

Conventional gas-conditioning methods (Joule–Thomson valves, turbo-expanders, refrigeration, solvent systems) each trade simplicity, efficiency, footprint, and maintenance. The 3S approach harnesses the thermodynamics of rapid expansion and the fluid mechanics of high-intensity swirl to do three things at once: cool the gas, condense target species, and separate droplets — all inside a static device.

In short: convert part of the available pressure into deep, controllable cooling; create strong centrifugal fields to throw condensed droplets to the wall; and recover pressure in a diffuser so downstream equipment sees a healthy delivery pressure.

Design & Working Principle of the 3S Separator

Feed gas receives angular momentum from a swirling part (swirling vanes). Entering a convergent–divergent (Laval) nozzle, the gas accelerates to supersonic speed. The rapid drop in static temperature creates supersaturation, nucleation, and droplet growth. Centrifugal forces drive droplets to the wall; the diffuser recovers part of the pressure while a liquid slip stream is routed to a downstream separator and dry gas continues to the consumer. 3s-most.eu

Mach number: tuned so “target” components (water, C₂⁺, CO₂/H₂S) pass into liquid phase.
Swirl intensity: balances efficiency with pressure drop and stability.
Pressure recovery: diffuser restores part of lost pressure — outperforming simple throttles.

Process Flow Schemes

3S modules are strategically integrated upstream of cold boxes or Joule–Thomson (J-T) stages to pre-condense and remove heavy hydrocarbons, water, and other condensables before deep chilling. This lightens the thermal load on downstream refrigeration systems, reduces recycle gas volume, and improves overall process stability.

In more advanced process schemes, hybrid layouts combine 3S separators with turbo-expanders, creating a synergistic effect: the supersonic stage handles bulk condensation at minimal energy cost, while the expander polishes the stream to achieve ultra-low hydrocarbon dew points (HCDP) and enhanced NGL recovery. This configuration not only debottlenecks existing trains, but also simplifies process complexity, enabling smaller, more modular gas-conditioning units.

3S Separator Technology — A Supersonic Shift in Gas Conditioning 11

Detailed Information to consider │ 3S — Process Flow :

On-Site Technical Research: Data Comparison and Key Findings

Table 1. Comparative Characteristics of LTS Block — Field (1)

Parameter	With 3S Separator	Without 3S Separator
Pressure in primary separator (MPa abs)	12.0	12.0
Gas temperature at heat-exchanger inlet (°C)	7	7
Pressure at 3S-block outlet (MPa abs)	7.6	7.6
Gas flow at separator 10C-1 outlet (m³/h)	10,300	10,300
Hydrocarbon dew point at outlet (°C, 75 atm)	Below −40	−21.4
Water dew point at outlet (°C, 75 atm)	Below −25	−25.2
Gas pressure at outlet (MPa abs)	7.5	7.5
C₅⁺ components in sales gas (g/m³)	< 4	8
Droplet liquid in sales gas (g/m³)	Absent	1.5

Table 2. Comparative Characteristics of LTS Block — Field (2)

Parameter	With 3S Separator	Without 3S Separator
Pressure in primary separator (MPa abs)	10.0	10.0
Gas temperature at heat-exchanger inlet (°C)	7	7
Pressure at 3S-block outlet (MPa abs)	7.6	7.6
Gas flow at separator 10C-1 outlet (m³/h)	10,300	10,300
Hydrocarbon dew point at outlet (°C, 75 atm)	Below −30	−15
Water dew point at outlet (°C, 75 atm)	Below −25	−25
Gas pressure at outlet (MPa abs)	6.6	6.6
C₅⁺ components in sales gas (g/m³)	< 4	9
Droplet liquid in sales gas (g/m³)	0.6	1.3

Source: Adapted from a technical article ‘Low temperature 3S separator’, 2020 — by 3S-MOST for publication on www.3s-most.eu

Key Benefits of 3S Technology

Static design: No moving parts — low maintenance, high reliability.
Compact footprint: Ideal for offshore, FPSO, modular or brownfield retrofits.
Pressure-smart: Recovers part of expansion loss; more efficient than pure throttling.
Energy savings: Cuts refrigeration load and compressor power.
Extended field life: Reduces backpressure; delays compressor installations.

Applications

Plant Debottlenecking

Integrate a 3S stage upstream of JT or cold-box units to reduce refrigeration demand and reach tighter dew point specs — boosting throughput and efficiency.

Hybrid with JT & Turbo-Expanders

Combining 3S with existing expanders merges their strengths: throttling simplicity with expander-like cooling depth.

Inlet Air Cooling for Turbines

Adapted 3S designs can remove moisture from intake air, increasing gas turbine performance (and potentially preventing icing or corrosion).

Design Considerations

Mach number and nozzle geometry must match gas composition.
Swirl intensity and diffuser design affect efficiency and recovery.
CFD-aided optimization of nozzle shocks and boundary layers is critical for off-design stability.
Residence time is milliseconds; nucleation and droplet growth must occur within the nozzle–diffuser length.
Pressure budget planning is essential to maintain delivery specs.

Conclusion

The 3S Separator introduces a new era in gas conditioning: compact, reliable, and pressure-efficient. Data from the technical paper and on-site project confirms measurable improvements in compressor power, refrigerant use, and hydrocarbon dew point. Coupled with 3S’s latest designs, it stands as a next-generation technology for both onshore and offshore gas projects.

Further Reading:

3S Separator Technology: A Breakthrough in Supersonic Gas Separation

General-about: Gas Separation

3S Separator Technology: A Breakthrough in Supersonic Gas Separation

Overview of the 3S Separator

The 3S Separator (SuperSonic Separation) is a revolutionary technology for natural gas and process gas treatment, offering an innovative, highly efficient, and compact solution for gas-liquid and gas-solid separation. Built upon the principle of supersonic expansion, the 3S Separator utilizes advanced fluid dynamics to create extreme thermodynamic conditions, achieving condensation and separation in a single, continuous, and energy-efficient process.

The 3S system offers a new paradigm in gas conditioning, dehydration, and hydrocarbon dew point control, enabling significant operational and economic advantages over conventional technologies such as Joule-Thomson (JT) valves, glycol dehydration, and mechanical separation.

How It Works: The Supersonic Separation Principle

3S separator - working principle — 3S Separator Technology: A Breakthrough in Supersonic Gas Separation 15

The 3S Separator operates through a multi-step process:

Acceleration and Expansion: The gas enters a Laval nozzle where it is accelerated to supersonic speeds. This expansion causes a rapid drop in temperature and pressure.
Condensation: Due to the extreme cooling, heavier hydrocarbons, water, and other condensable components form droplets.
Swirling and Separation: A swirl element imparts a high centrifugal force, driving droplets and solid particles to the walls, separating them from the gas stream.
Recompression and Recovery: The lean gas is recompressed, and the separated liquids and solids are extracted downstream.

This sequence occurs in a matter of milliseconds, without moving parts, resulting in highly reliable and low-maintenance operation.

🔗More => 3S separator operating principle

Key Features of the 3S Separator

Feature	Description
No Moving Parts	Ensures high reliability and minimal maintenance.
Compact Design	Up to 70% smaller and lighter than traditional systems.
Energy Efficient	Utilizes pressure drop instead of external power for operation.
Modular and Scalable	Easily integrated into various system sizes and configurations.
Instantaneous Response	Separation occurs in milliseconds, enabling real-time process adjustments.

Typical Applications

Common Uses

Natural Gas Processing
Pipeline Gas Conditioning
Hydrocarbon Dew Point Control
Gas Dehydration
CO2 and H2S Removal (with upstream cooling and sorbents)
NGL (Natural Gas Liquids) Recovery

Process Flow Example – 3S Separator

The following schematic outlines a typical 3S Separation Unit:

Typical 3S-Separation Unit (Process Flow Scheme)

Feed gas is pre-cooled (if needed).
The gas passes through the Laval nozzle and swirling chamber.
Condensates are removed via a cyclonic separation zone.
Clean, dry, and conditioned gas exits the system.

This layout can be adapted for upstream, midstream, and downstream operations depending on the customer’s process requirements.

🔗More => Standard Process Flow Scheme 3S separator

Benefits of the 3S Technology

Benefit	Impact
Enhanced Gas Quality	Delivers pipeline-spec or sales-grade gas without additional treatment.
Lower Operational Costs	No chemical reagents, heaters, or compressors needed downstream.
Increased Liquid Recovery	High efficiency in NGL and condensate separation.
Environmental Compliance	Reduced emissions and zero venting possible.
Fast ROI	Lower CAPEX and OPEX with short payback periods.
Minimal Footprint	Ideal for offshore platforms, FPSOs, and remote installations.

Comparing Technologies

Technology Comparison

Technology	3S Separator	JT Valve	Glycol Dehydration	Mechanical Separator
Moving Parts	No	No	Yes	Yes
Footprint	Small	Medium	Large	Medium
Energy Requirement	Low	Medium	High	Medium
Separation Efficiency	High	Medium	High (dehydration)	Low
Liquid Recovery	High	Medium	Low	Low
Environmental Impact	Low	Medium	High (chemicals)	Medium

Why Choose 3S Technology?

The 3S Separator is a proven and field-tested solution designed for modern energy systems. Whether your goal is to maximize liquid recovery, meet pipeline specs, reduce operating costs, or increase process efficiency, the 3S system provides a powerful alternative to legacy technologies.

With multiple units successfully operating in harsh environments and across diverse applications, the 3S solution is ready to meet the challenges of the evolving energy landscape.

More => 3S separator & 3S technology projects world wide

Contact and Integration Support

3S offers comprehensive engineering support, from feasibility studies to full integration into existing or new gas processing systems.

To learn more about how the 3S Separator can enhance your operations, contact our team or visit:

For more information on how the 3S Separator can improve your operations, get in touch with our team or visit:

🔗 www.3s-most.eu
🔗3S Separator – Inquiry Form

Process Flow Scheme – 3S Separator

General-about: Gas Separation

The inlet gas is divided into two streams: one is cooled at the [HE-1] Heat Exchanger, and the other at the [HE-2] Heat Exchanger.

To achieve efficient liquid extraction in the [3S-separator], the inlet gas is chilled to approximately minus –70°C to minus –90°C.

The cooled gas streams are combined and sent to the [3S-separator], where they are split into two outputs: a treated gas stream and a rich gas-liquid stream (comprising 15-30% of the inlet gas volume). This rich stream is directed to the [S1] low-temperature separator.

Gas from the [S1] separator is mixed with treated gas from the [3S-separator] and sent to [HE-1], where it is reheated by the cooling inlet gas. This results in the final NGL plant sales gas, primarily consisting of methane with a small amount of ethane.

The unstable liquid from [S1] is throttled and sent to [HE-2], where it cools part of the inlet gas by partially evaporating (acting as an evaporator).

After passing through [HE-2], the rich gas-liquid mixture, or “ethane-enriched condensate,” is processed in a conventional low-temperature separation (LTS) unit.

Key benefits of this process include efficient heat recovery, enhanced liquid extraction, and optimized gas processing with minimal energy consumption.

Numerical analysis – Low Temperature Separation

Inlet Air Cooling for Gas Turbine using 3S-Separator

General-about: Gas Separation

The Need for Inlet Air Cooling in Gas Turbine Power Plants in Hot and Humid Environments, and the Application of 3S Separators

Gas turbine power plants are widely used for electricity generation due to their efficiency and reliability. However, they are highly sensitive to ambient conditions, particularly temperature and humidity. In hot and humid environments, gas turbines face significant operational challenges, especially because hot air is less dense, reducing the power output and increasing the compressor work required. This leads to a decrease in efficiency, especially when ambient temperatures exceed 40°C. (The effects are particularly pronounced in hot regions, where ambient temperatures can exceed 40°C, leading to power output reductions of up to 30%.) Therefore, cooling the air before it enters the turbine’s compressor is critical for improving performance in these conditions.

Challenges in Hot and Humid Environments

High Temperatures: In hot climates, such as deserts or tropical regions, the reduced air density decreases oxygen content for combustion, leading to reduced turbine output and increased energy consumption by the compressor. Power output can drop by up to 30% in these conditions.
Humidity: In tropical regions or areas with high humidity, the presence of water vapor reduces combustion efficiency, as the water vapor displaces oxygen in the air.

Traditional Inlet Air Cooling Solutions

Several cooling methods are commonly used to address these challenges:

Evaporative Cooling: Cools the inlet air by evaporating water, which works well in dry climates but is less effective in humid environments.
Chiller Systems: Use mechanical refrigeration to cool the air but are energy-intensive and costly.
Fogging Systems: Spray water droplets into the intake air, cooling it as the water evaporates. This method is cost-effective but less efficient in very humid conditions.
Thermal Energy Storage (TES): Uses chilled water or ice stored during off-peak hours to cool the air during peak demand, but requires significant infrastructure investment.

The 3S Separator as a Cooling Solution

An innovative and highly efficient approach to cooling inlet air for gas turbines is the 3S (Supersonic Swirling Separator) technology. Originally developed for the oil and gas sector to separate gas mixtures, the 3S separator operates by accelerating gases through a convergent-divergent Laval nozzle, causing rapid cooling and condensation of gas-phase components. The cooling effect generated by this process makes it an ideal candidate for use in gas turbine inlet air cooling.

Application of 3S Separators for Inlet Air Cooling

In this application, the 3S separator can be integrated into a cooling system that uses free energy from various sources to power a refrigeration cycle. The proposed system utilizes hot flue gases from the turbine exhaust to generate the required cooling for the turbine’s inlet air.

*Inlet Air Cooling for Gas Turbine using 3S-Separator*

Proposed 3S Separator-Based Cooling System Using Hot Flue Gases

The system operates as follows:

Heat Exchanger (HE2): Hot flue gases from the gas turbine heat water in a heat exchanger. The pressurized water is then transformed into a vapor-liquid mixture.
3S Separator: The vapor-liquid mixture enters the 3S separator, where the liquid phase is separated from the vapor. The supersonic swirling flow enhances the separation, allowing the vapor fraction to power a turbine connected to a compressor.
Turbine (T) and Compressor (C): The turbine, driven by the vapor from the 3S separator, powers the compressor, which operates a refrigeration cycle (closed circuit) using a refrigerant such as freon or propane.
Heat Exchanger (HE1): In this heat exchanger, the cooled refrigerant absorbs heat from the inlet air, reducing its temperature before it enters the gas turbine’s compressor.
Water Recirculation: The separated water is recirculated to the pump (if applicable), ensuring continuous operation.

This configuration takes advantage of the waste heat generated by the turbine itself, thus reducing the need for external energy inputs and enhancing the overall efficiency of the cooling process.

Alternative Source: Free Energy from Pressure Drop in Gas Distribution Pipelines

Apart from utilizing the waste heat from hot flue gases, the 3S separator can also harness free energy from pressure drops in nearby gas distribution pipelines. In many cases, natural gas pipelines experience significant pressure reductions as gas is transported to lower-pressure distribution networks. This energy can be recovered and used to power the refrigeration system for cooling the gas turbine’s inlet air.

Advantages of 3S Separator-Based Cooling Systems

Energy Efficiency: By using waste heat from flue gases or free energy from pressure drops, the 3S separator significantly reduces the need for external energy inputs, improving the overall energy efficiency of the cooling process.
Environmentally Friendly: The system leverages renewable energy sources (waste heat or pipeline pressure drops), reducing the carbon footprint of the gas turbine plant.
Cost-Effectiveness: The 3S separator-based system eliminates the need for large, energy-intensive chillers, offering a compact and cost-efficient solution.
Flexibility: The system can be adapted to various refrigerants and environmental conditions, making it suitable for a wide range of climates and regulatory requirements.

Local Specificities for Application

Desert and Arid Regions (e.g., Middle East, North Africa): In areas with high ambient temperatures, the 3S separator system can utilize the excess heat from flue gases to cool the turbine inlet air. The system’s ability to operate efficiently in high temperatures makes it ideal for these regions.
Tropical and Humid Regions (e.g., Southeast Asia, Brazil): In hot and humid environments, the 3S separator can cool and dehumidify the air before it enters the turbine, improving performance in conditions where both temperature and humidity negatively impact gas turbine efficiency.
Regions with Developed Gas Infrastructure (e.g., U.S., Europe): Where high-pressure gas distribution pipelines are available, the 3S separator can harness the free energy from pressure drops in the pipelines, providing an additional energy-efficient cooling option.

Conclusion

The 3S separator presents an innovative solution for cooling gas turbine inlet air in hot and humid environments. By utilizing free energy from either hot flue gases or pressure drops in nearby gas pipelines, the system offers a flexible, energy-efficient, and cost-effective alternative to traditional cooling methods. As gas turbines continue to play a critical role in global power generation, especially in regions with extreme temperatures, the adoption of 3S technology for inlet air cooling can help ensure more reliable and efficient power generation.