MTT- ENGINEERING SOLUTIONS

Predicting Three-Phase Separator Performance Under Real FPSO Motion Conditions

Structured packing details.

Three-phase separation is not just about vessel diameter, retention time, or adding a coalescer pack. In a gas–oil–water separator, one of the most overlooked design details is the humble calming baffle. At first glance, it may look like a simple plate. In reality, it can make the difference between stable separation and poor interface control. A properly designed calming baffle helps: --> Suppress liquid motion after the inlet zone --> Reduce oil/water interface disturbance --> Prevent back-mixing between separated phases --> Protect the coalescing zone from turbulence --> Improve residence time effectiveness --> Stabilise the oil and water outlets Why Placement Matters? A baffle installed too close to the inlet may choke the flow or create high local velocities. Too far downstream, and turbulence may already have propagated into the settling section. Poorly positioned baffles can also create recirculation zones, short-circuiting, or unwanted re-entrainment of the dispersed phase. This is where CFD becomes a powerful design verification tool. CFD allows engineers to visualise what is otherwise hidden inside the vessel: --> Gas disengagement behaviour. --> Liquid velocity profiles. --> Dead zones. --> Back-mixing regions. --> Interface disturbance. --> Flow maldistribution through coalescers. --> Outlet vortexing risks. For three-phase separators, this is especially valuable because oil/water separation is highly sensitive to turbulence, residence time distribution, and internal geometry. At MTT Separation Technology, we support clients with separator design, internals selection, baffle arrangement, coalescer selection/configuration, and CFD-based design verification to help ensure the vessel performs as intended — not just on paper, but in operation. In separation design, the internals are not accessories they are critical to the performance of the vessel. #ThreePhaseSeparation #OilAndGas #ProcessEngineering #CFD #SeparatorDesign #ProducedWater #OilWaterSeparation #MechanicalDesign #MTTSeparationTechnology #ProcessSeparation

Plastic structured packing plays a critical role in many mass transfer applications where corrosion resistance, low pressure drop, and efficient gas-liquid contact are essential. Compared with random packing, structured packing provides an ordered flow path that improves liquid distribution and mass transfer efficiency while reducing pressure drop. When manufactured from materials such as PP, PVC, CPVC, or PVDF, it becomes an excellent solution for corrosive duties where metallic packing may be unsuitable or unnecessarily expensive. Key technical advantages of plastic structured packing include high surface area, low weight, good hydraulic performance, and strong chemical resistance in the right service. It is commonly used in scrubbers, absorbers, stripping towers, odour control units, water treatment systems, and chemical processing applications. Typical examples include caustic scrubbers, acid fume treatment towers, wastewater air stripping units, and other services where aggressive chemistry and low energy consumption are important design considerations. As always, correct selection depends on operating temperature, chemical compatibility, pressure drop limits, fouling tendency, and required separation efficiency. When properly selected and installed, plastic structured packing can deliver reliable performance and strong lifecycle value. At MTT, we help clients assess the right packing type, material, and internal configuration for each application. #StructuredPacking #PlasticStructuredPacking #MassTransfer #ScrubberDesign #PackedColumns #ProcessEngineering #ChemicalEngineering #WaterTreatment #SeparationTechnology #MTT

MTT Designed & Engineered Wedge Wire Reactor Outlet Baskets In high-performance reactor service, the outlet basket is not just a screen. It is a critical process and mechanical component — and at MTT, we design it that way. Why Wedge Wire? MTT reactor outlet baskets utilise profiled wedge wire construction rather than conventional woven mesh. This provides: ✔ Precise slot control (tight tolerance retention) ✔ High open area with lower ΔP ✔ Superior structural strength under differential pressure ✔ Reduced blinding due to V-shaped slot geometry ✔ Improved cleanability and longer service life In catalyst service, that geometry matters. The outward-facing V-profile prevents solids from lodging within the slot — a common failure mode with woven mesh. ⸻ Designed — Not Just Fabricated Every MTT wedge wire outlet basket is: • Hydraulically checked (velocity, ΔP, fouling margin) • Structurally verified for upset differential pressure • Rated for catalyst bed load and transient conditions • Designed for removability and maintainability • Matched to process temperature and metallurgy requirements We don’t treat outlet baskets as “ancillary internals”. We treat them as pressure-critical reactor components. ⸻ What We See in Brownfield Reactors Across refinery and petrochemical units, common issues include: • Undersized open area → Excess pressure drop • Screen rupture during start-up or blocked outlet events • Catalyst loss due to slot deformation • Inadequate support rings or weld detailing • No consideration of transient ρv² The result? Unplanned shutdowns. Catalyst loss. Downstream damage. ⸻ Engineered for Real Operating Conditions At MTT, we design wedge wire outlet baskets for: • Steady-state operation • Start-up surges • Partial blinding • Rapid depressurisation • Upset differential pressure Because reactors rarely operate in ideal conditions. ⸻ The Reality If your outlet basket fails, it’s not a minor internal issue. It’s a plant reliability event. That’s why we engineer them properly — with process and mechanical integrity considered together. If you’re reviewing reactor internals or upgrading a unit, happy to have a technical discussion. MTT – Engineered Separation & Reactor Internals. #ProcessEngineering #ReactorDesign #Refining #Petrochemical #WedgeWire #MTTProjects

MTT process upgrade – measurable yield improvement MTT recently completed a process improvement project focused on recovering lost yield from an underperforming process. The client’s historical performance had plateaued at an average recovery of ~80% across multiple batches. Rather than upsizing equipment, MTT implemented a targeted process upgrade using our specialist knowledge and equipment, supported by operating-condition optimization. Results achieved: • Recovery yield target: >85% • Achieved recovery: – 89.53% (Case 1) – 99.95% (Case 2) • Consistent improvement over historical average The improvement was driven by enhanced mass-transfer efficiency, improved hydraulic performance, and better phase separation, delivering a step-change in recovery without significant CAPEX. -> Higher yield -> Reduced losses -> Improved process robustness This project reinforces a key MTT principle: Well-designed equipment and sound process engineering knowledge often unlock more value to plant operators. If your process is “meeting expectations” but not exceeding them, there may still be meaningful upside available. #MTTEngineeringSolutions #ProcessEngineering #YieldImprovement #SeparationTechnology #ProcessOptimisation #MassTransfer #EngineeringThatDelivers

After several years of focused research, engineering trials, and full-scale validation, we’re proud to introduce the MTT AC Cyclone—a new generation of cyclone technology designed to deliver superior droplet removal performance with a significantly lower pressure drop than legacy designs on the market. What sets the MTT AC Cyclone apart? 🔹 Enhanced Separation Efficiency – Engineered aerodynamic geometry allows for high-performance droplet removal across a wide range of operating conditions. 🔹 Lower Pressure Drop – Optimized internal flow paths reduce energy losses, meaning improved operational efficiency and lower lifecycle cost. 🔹 Greater Operating Flexibility – Stable performance across broad turndown ratios, making it suitable for variable-load applications without sacrificing separation quality. 🔹 Versatile Implementation – Whether you’re designing a new build or upgrading an existing system, the MTT AC Cyclone is built for seamless integration and retrofit compatibility. This post has been a long time in the making, grounded in rigorous CFD modeling, pilot testing, and real-world field validation. The result: a cyclone solution that moves the industry forward in efficiency, reliability, and performance. We are immensely proud of the team, the partners, and the perseverance that made this possible. If you’re interested in improving separation efficiency or exploring retrofit options, let’s connect.

From Concept to Engineered Solution. At MTT we transform concepts into engineered, build-ready solutions that deliver certainty, performance, and value for our clients. Whether it starts as a simple process challenge, or a client’s desired outcome our team takes it through a disciplined, engineering-driven pathway: 1. Concept Development Understanding the problem, defining constraints, and mapping out the technical objectives. 2. Feasibility & Process Design Process modelling, equipment selection, and preliminary sizing using proven engineering principles and industry standards. 3. Detailed Mechanical & Layout Design 3D modelling, nozzle orientation, structural requirements, internal arrangement, operability and maintainability considerations. 4. Performance Prediction & Verification Droplet size modelling, CFD where required, hydraulic design, and separation performance estimates to give clients confidence before we even commence fabrication. 5. Deliverables That Drive Decisions GA & detailed drawings, datasheets, design reports, specifications, and fabrication-ready documentation — all aligned with client requirements and project standards. At MTT, we bridge the gap between ideas and engineered outcomes. We’re fast, practical, and deeply focused on delivering solutions that work — in the field, not just on paper. If you're exploring options to optimise, upgrade, or develop new process equipment, we’d love to help turn your concept into a fully engineered solution. #Engineering #ProcessDesign #OilAndGas #MTT #EngineeredSolutions #SeparationTechnology #DesignEngineering #Innovation