New design and optimization of an industrial three-phase boot separator using the coupled CFD-RSM models

The optimum design of three-phase separators can pose a significant challenge to petroleum industries. In this study, the design of an industrial three-phase boot separator was optimized. For this aim, the response surface methodology (RSM) was coupled with computational fluid dynamics (CFD) method. Inlet diverter angle, baffle place, and the presence, and absence of the mist extractor were the parameters considered in this study. The interactions between these parameters were also investigated. A coupled VOF-DPM model (with a 12.9% error relative to the industrial data) was opted to calculate the response (liquid entrainment at the gas outlet) in the presence and absence of the mist extractor at different inlet diverter angles (0°–60°), and baffle places (0–10 m). A new mathematical model with a 2.02% error relative to the CFD results was introduced by using the RSM method. This model was used for estimating the optimal design, without the need to perform the CFD simulations with substantial computational time. Results showed that the optimum condition was achieved in the presence of the mist extractor at the angle of 26° and baffle place of 5 m. At the optimum design, the response decreased by 57.05% compared to the current condition of the separator. This result confirmed the superior performance of the new design compared to the old one.