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Drilling mud degasser

A degasser is a device used in the upstream oil industry to remove dissolved and entrained gases from a liquid. In drilling it is used to remove gasses from drilling fluid which could otherwise form bubbles.[1] In a produced water treatment plant it is part of the process to clean produced water prior to disposal.

Degasser

[edit]

For a small amount of entrained gas in a drilling fluid, the degasser can play a major role of removing small bubbles that a liquid film has enveloped and entrapped.[citation needed] In order for it to be released and break out the air and gas such as methane, H2S and CO2 from the mud to the surface, the drilling fluid must pass through a degassing technique, and it can be accomplished by the equipment called a degasser, which is also a major part of mud systems.[2]

Another function of a degasser in the oil industry is to remove dissolved gases from a produced water stream as part of the water clean up process prior to its disposal.[3]

Types of Degasser

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Vacuum Tank Degasser

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Vacuum Type is the most common form of degasser.[citation needed] It can be horizontal, vertical or round vessel.[citation needed] A vacuum action is created to pull in the gas cut mud. When the liquid enters the tank it will flow and be distributed to a layer of internal baffle plates designed for the mud to flow in thin laminar film and is exposed to a vacuum that forces the gas to escape and break out of the mud.[citation needed] The vacuum pump moves the escaping gas from the vessel discharging it to the rig's flare or environmental control system.[citation needed]

Atmospheric Degasser

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This type of degasser processes mud by accelerating fluid through a submerged pump impeller and impinging the fluid on a stationary baffles to maximize surface and thus enable escaping gas vent to atmosphere.[4]

Produced water Degasser

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A produced water degasser can be either a horizontal or vertical vessel.[5] It operates at a low pressure to maximise the amount of gas (eg methane, carbon dioxide) that is removed from the water stream.[6] It can be located immediately downstream of the production separators prior to low pressure water treatment system such as dissolved gas flotation. In this case the degasser may also act as a surge drum to ensure a steady flow of water to the treatment plant. Alternatively, it can be located downstream of produced water hydrocyclones.[3] In either case the degasser provides sufficient residence time to allow dissolved or entrained gases to be released from the produced water stream. From the degasser water is disposed of via a caisson into the sea, or for disposal elsewhere. The separated gas is routed from the degasser to a flare or vent system for safe disposal. The degasser can be provided with an oil collection device to remove accumulated oil from the surface of the produced water inside the degasser.[5] A degasser may accumulate solids (sand) in its base, facilities to remove solids may be installed.

See also

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Mud Gas Separator

Degassing

Notes

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[edit]
Revisions and contributorsEdit on WikipediaRead on Wikipedia

Degasser

View on Grokipedia
from Grokipedia
A degasser is a device or engineered to remove dissolved or entrained gases, such as oxygen, , , or , from liquids or solvents, thereby preventing issues like bubble formation, , , or interference in fluid systems. These systems typically operate by reducing , applying , or using semi-permeable membranes to facilitate gas extraction, ensuring the stability and efficiency of industrial and analytical processes. Degassers vary in design to suit specific needs, with common types including vacuum degassers, which lower pressure to expand and extract gas bubbles from fluids like drilling mud or HPLC solvents; centrifugal degassers, which use rotational force to separate gases based on density differences for higher-throughput applications; membrane degassers, employing gas-permeable barriers under vacuum or stripping gas to target dissolved oxygen and carbon dioxide; and chemical or ultrasonic degassers, which react with or agitate gases out of melts in metallurgy without mechanical vacuum. In practice, degassers are indispensable across multiple sectors: in , they reduce corrosive gases like oxygen to below 50 ppb in or from and operations, extending equipment life; in , particularly (HPLC), they eliminate air from mobile phases to maintain consistent flow rates, prevent pump failures, and ensure accurate peak detection; in and gas , they safely vent hazardous gases such as H₂S and CO₂ from to avoid blowouts; and in metal production, they minimize gas in alloys like aluminum to improve material quality.

Fundamentals

Definition and Purpose

A degasser is specialized equipment that removes dissolved or entrained gases—such as oxygen, , , or —from liquids, primarily , fluids, or molten metals, to address issues including , , and reduced operational efficiency. In , it targets gases that promote scaling or degradation in systems like boilers. For operations, it eliminates gas intrusions in mud to maintain fluid integrity. In , it extracts from molten alloys to avoid defects in castings. The core purpose of a degasser is to enhance liquid stability, boost process , ensure by reducing risks from hazardous or explosive gases, and meet stringent quality standards across industrial applications. For example, in , it lowers dissolved oxygen to as low as 50 ppb (with further reduction possible using chemical ), preventing and extending equipment lifespan in high-pressure systems. In oil and gas drilling, it mitigates hazards by stabilizing hydrostatic pressure in gas-cut fluids. In molten metal processing, it improves material properties by minimizing gas-related . Degassers achieve this through a general process that creates environmental conditions—such as lowered , increased , or agitation—to reduce gas , enabling the gases to evolve from the liquid phase and be safely vented. This approach yields key benefits, including the prevention of formation in muds, viscosity reduction in processed fluids, and protection of equipment from damage caused by entrained gases. Overall, these devices support reliable industrial operations by maintaining fluid performance and safety.

Historical Development

Early efforts to remove dissolved gases from water date back to ancient practices like boiling, but systematic degassing for industrial purposes began in the late 19th and early 20th centuries with the development of deaerators for boiler feedwater to prevent corrosion. In metallurgy, research into hydrogen's effects on steel brittleness originated in the 1870s, with initial vacuum degassing experiments in the 1940s addressing gas inclusions in alloys. A major milestone was the introduction of the Dortmund-Hörder (DH) process in the late 1950s (around 1956) by Dortmund-Hörder Hütte Union in , which enabled large-scale vacuum degassing of molten in ladles to remove and , improving quality for automotive and structural applications. The Ruhrstahl-Heraeus (RH) process followed in the late 1950s, patented in 1957, using circulation through snorkels in a for efficient degassing and , developed by Ruhrstahl AG and AG. In the oil and gas industry, while basic degassers appeared in the 1920s, advanced vacuum degassers gained prominence in the 1950s-1960s to handle gas-cut during deeper . Centrifugal degassers became more integrated in oilfield operations by the for high-throughput gas separation. Membrane degassers emerged in the 1980s- for precise applications like . By the 2000s, and integration advanced degassing in and plastics processing. Since the 1990s, ultrasonic has been researched for non-contact removal in and alloys. Emerging trends as of 2025 include advanced electrochemical and plasma-based methods for battery production and sustainable processes.

Operating Principles

Vacuum Degassing

Vacuum operates on the principle that the of gases in decreases as is reduced, as governed by . This law states that the concentration of a dissolved gas in a liquid is proportional to the of the gas above the liquid, expressed through the Henry's law constant kH=PCk_H = \frac{P}{C}, where PP is the partial pressure of the gas and CC is the concentration of the dissolved gas. By applying a , typically in the range of 0.1 to 0.5 , the partial pressure is lowered, driving dissolved gases out of solution and forming bubbles that can be removed. This pressure reduction also lowers the of the liquid, facilitating the and escape of gas bubbles without excessive heating. The process begins with the entering a sealed chamber, where a establishes the low-pressure environment. Inside the chamber, the is exposed to the , often through distribution mechanisms that promote gas release; gases are then drawn toward the , sometimes aided by defoamers to manage formation and prevent liquid carryover. The degassed subsequently exits the chamber, while extracted gases are safely vented through a separate outlet to avoid re-entrainment or hazards. This stepwise operation ensures controlled gas liberation while maintaining liquid flow continuity. Key components of a vacuum degassing system include the , which generates and sustains the reduced pressure; the degassing tank or chamber, serving as the sealed enclosure; and spray baffles or nozzles that distribute the liquid into thin films or droplets to maximize surface area for efficient gas and release. These elements work synergistically to enhance contact between the liquid and the , accelerating the desorption process. Efficiency in vacuum degassing can reach up to 99% removal for gases like oxygen, with up to 85-90% removal for species like (H₂S) and (CO₂), which have favorable characteristics under reduced . Factors such as , typically maintained between 20°C and 60°C, further improve outcomes by increasing gas rates while countering any temperature-dependent increases for certain gases. This method's high efficacy stems from the direct manipulation of to exploit thermodynamic equilibria, outperforming ambient-pressure techniques in precision gas removal.

Atmospheric and Centrifugal Degassing

Atmospheric degassing operates at standard (1 atm) and relies on gravity, spraying, or bubbling to promote natural of gases from liquids, with mechanical agitation increasing the gas-liquid for enhanced separation. In this method, the liquid is typically sprayed into a tower or agitated to expose it to air, allowing dissolved or entrained gases such as oxygen, , or hydrocarbons to escape without the need for reduced . The process for atmospheric degassing involves directing the liquid to flow over trays, packing material, or impact plates within a column, where it forms thin films or droplets that maximize surface exposure. Countercurrent is often introduced to strip gases through , with the degassed liquid collected at the bottom and vented gases exiting the top. This approach is particularly suited for handling large volumes of fluids in applications like or initial gas removal in drilling mud, where simplicity and ambient operation are prioritized over deep gas extraction. Centrifugal degassing employs rotating impellers or vessels to generate centrifugal forces several hundred times , which separate lighter gas bubbles from the denser phase by amplifying effects. The gas bubbles migrate toward the center of and rise to the surface for venting, while the liquid is directed outward and exits separately. This mechanical separation is effective for entrained gases in viscous fluids like drilling muds, without requiring vacuum systems. In the centrifugal process, the or is pumped into a spinning vessel, where it is spread into a thin, turbulent layer against the walls by the impeller's action. Gas bubbles, being less dense, move inward along the axis and upward to a collection zone for safe discharge, with efficiency directly linked to the rotational and . The treated is then returned to the , maintaining density and preventing issues like pump . Compared to vacuum degassing, atmospheric and centrifugal methods consume less energy and support higher-volume flows, making them ideal for preliminary treatment, though they are less effective for deeply dissolved gases that require lower pressures for release. Vacuum methods generally offer superior efficiency for such challenging separations, as detailed in the Vacuum Degassing section.

Types of Degassers

Vacuum Tank Degassers

Vacuum tank degassers are typically designed as enclosed cylindrical or rectangular vessels equipped with internal baffles or spray nozzles to facilitate the exposure of to vacuum conditions for gas removal. These tanks are constructed from corrosion-resistant materials, such as with protective coatings or , to withstand harsh operational environments involving abrasive and chemically aggressive . The internal components, including stacked plates with weir designs and deep corrugations, promote and thin-film distribution of the , enhancing gas bubble release. Configurations vary based on application needs, with horizontal tanks favored for handling viscous drilling muds due to their extended surface area for fluid spreading via full-length baffles, while vertical tanks offer a compact suitable for treatment by leveraging for separation. Round vessels are commonly used for general-purpose in oilfield operations. Tank capacities generally range from 500 to 2000 gallons, accommodating flow rates of 500 to 1200 gallons per minute (gpm), depending on the model and specifications. In operation, gas-contaminated fluid is drawn into the tank by a generated by a liquid ring pump, where reduced causes entrained gases to evolve and separate from the liquid. The gases are then vented through a dedicated separator and safely discharged, while the degassed fluid is returned to the system via the pump. This process applies degassing principles to achieve high removal rates, with efficiencies reaching 94-99% for gases like in multi-stage setups. Unique features include integrated safety valves for pressure relief to prevent over-vacuum conditions and foam breakers to manage frothing in high-gas-cut fluids, ensuring operational safety and continuity. Maintenance involves routine oil changes every 500-1000 operating hours to maintain and integrity, along with periodic tank inspections for , welds, and baffle integrity to prevent leaks or structural failures.

Atmospheric Degassers

Atmospheric degassers consist of open-top towers or spray chambers, typically ranging from 10 to 30 feet in height, engineered for efficient gas removal in large-volume applications with minimal in open systems. These structures incorporate packing media, such as Raschig rings, to maximize the surface area for gas-liquid contact without requiring vacuum equipment. During operation, liquid is distributed and sprayed downward over the packing while air circulates upward, stripping dissolved gases through ; this countercurrent flow is particularly effective for CO2 removal in processes. Air movement can rely on natural or be assisted by fans, enabling capacities of 1000 to 5000 gallons per minute depending on tower dimensions and flow rates. These degassers provide lower capital and operational costs relative to vacuum-based alternatives, though they demand a larger installation footprint due to their open design. Removal efficiencies reach 80-95% for volatile gases like CO2, influenced by factors such as inlet and packing depth. Variants include columns, which facilitate stepwise gas-liquid interaction, and venturi , which introduce enhanced agitation for improved in certain configurations. Safety features are essential, particularly explosion-proof venting systems to manage flammable gases such as H2S during operations. The underlying atmospheric principles of countercurrent stripping are covered in the operating principles section.

Centrifugal Degassers

Centrifugal degassers are compact cylindrical units equipped with internal rotors or impellers, typically featuring diameters ranging from 2 to 4 feet, designed for efficient gas separation in fluids. These devices are often mounted on skids to facilitate mobility and rapid deployment in field operations, such as oil and gas sites. The robust construction, including corrosion-resistant materials, allows them to handle various fluid viscosities and weights without preprocessing. In operation, drilling fluid enters the unit tangentially through a large inlet, where an internal rotates to generate and create a vortex within the vessel. The impeller typically spins at speeds of 300 to 400 RPM. Gas bubbles migrate to the center, coalesce, and are vented from the top via a blower or pressurizing unit, while the degassed liquid exits from the bottom outlet; these units can process flow rates of 800 to 1400 gallons per minute (gpm). Key features include self-priming capability, enabling operation without external priming pumps, and high effectiveness in removing entrained air from gas-cut fluids to prevent fluctuations. Power consumption generally ranges from 25 to 30 horsepower for the main motor, plus 1.5 to 2.2 horsepower for the blower, making them energy-efficient for continuous use. Advantages of centrifugal degassers include the absence of vacuum seals, which significantly reduces requirements compared to systems, and overall operational simplicity with low downtime. They achieve 85-95% efficiency in removing free gas, providing a reliable alternative for high-throughput applications. However, centrifugal degassers are less effective at removing dissolved gases than vacuum types, as they primarily target entrained or free gas through mechanical separation rather than reduction. This limitation can result in residual dissolved gas content in treated fluids, potentially requiring supplementary methods for complete .

Membrane Degassers

Membrane degassers utilize semi-permeable hollow-fiber membranes to separate dissolved gases from liquids, often under vacuum or with a stripping gas on the non-liquid side. These compact units are commonly made from materials like polypropylene or fluoropolymers, suitable for applications requiring precise control of gas levels, such as in high-performance liquid chromatography (HPLC) and water treatment. In operation, liquid flows through the lumen of the fibers while a (typically 20-100 mbar) or sweeps the shell side, creating a gradient that drives gas across the . This process efficiently removes gases like oxygen and , with units handling flow rates from 1 mL/min for lab-scale to 1000 gpm for industrial use, achieving removal efficiencies up to 99% for O₂ under optimal conditions. Advantages include low energy use, no chemical additives, and minimal liquid carryover, though they require periodic membrane replacement every 1-3 years depending on . Safety features often include leak detectors for integrity.

Other Types

Chemical degassers involve adding , such as or , to react with and bind dissolved gases like oxygen in , preventing without mechanical separation. Ultrasonic degassers use high-frequency sound waves (20-40 kHz) to agitate and cavitate liquids, dislodging entrained and dissolved gases, particularly in metallurgical melts like aluminum to reduce . These methods are targeted for specific environments where or mechanical systems are impractical.

Applications

Oil and Gas Industry

In the oil and gas industry, degassers play a critical role in drilling operations by removing invasive gases from drilling mud, thereby restoring its density and preventing well kicks that could lead to blowouts. These devices are essential for maintaining hydrostatic balance in the wellbore, as entrained gases reduce mud weight and compromise pressure control. Vacuum tank degassers are the standard choice, typically positioned immediately after shale shakers in the solids control system to process gas-cut mud efficiently before recirculation. During treatment, atmospheric or centrifugal degassers are employed to strip dissolved hydrocarbons and (H₂S) from the water separated during production, ensuring compliance with environmental regulations such as the U.S. EPA's effluent limitations for and grease, which set a monthly average of 29 mg/L and a daily maximum of mg/L for offshore discharges. These units facilitate safe reinjection or discharge by reducing contaminant levels, with centrifugal models particularly suited for high-volume flows in field processing. Specific examples include the use of centrifugal degassers on offshore rigs, where they handle high-volume flows to manage gas-contaminated fluids under demanding conditions. Integration of degassers with overall mud circulation systems enhances by minimizing gas-related interruptions, often reducing non-productive time through proactive gas removal. Challenges in degasser operations arise when handling containing H₂S concentrations up to 1,000 ppm, which poses risks to equipment and health hazards to personnel; protocols incorporate remote monitoring systems for real-time gas detection and automated shutdowns to mitigate exposure.

Water Treatment

In water treatment, degassers play a crucial role in removing dissolved gases to enhance , prevent in distribution systems, and ensure suitability for end-use applications such as feed or potable supply. The primary gases targeted are oxygen, which is reduced to levels below 10 (ppb) for to minimize oxidative , and , which is removed to neutralize and avoid acidification that could lead to scaling or material degradation. Common methods include degassers, which use hydrophobic hollow fiber membranes under or sweep gas to selectively extract gases without direct contact, and packed tower degassers, which facilitate gas-liquid separation through countercurrent flow in structured packing media. Degassers are typically integrated post-filtration in municipal plants to address residual dissolved gases after initial clarification and softening stages, ensuring the water meets distribution requirements. In high-purity applications, such as deaerators for industrial systems, towers or atmospheric towers are employed to precondition feedwater, often achieving near-complete gas removal while preheating the liquid to improve overall process efficiency. Notable examples include tray-type degassers in power plants, where steam scrubbing across perforated trays reduces dissolved oxygen by over 99% from typical inlet levels of 8-10 mg/L to below 10 ppb, protecting tubes from pitting. Membrane contactors offer a compact, chemical-free alternative for , enabling up to 95% extraction in demineralized water systems without the need for large stripping towers or additives. The benefits of degassing extend equipment lifespan by significantly lowering rates through minimized oxygen-driven oxidation. This also supports compliance with guidelines for drinking water quality by mitigating gas-induced issues like taste alterations or indirect health risks from byproducts, though no specific limits exist for dissolved oxygen or . Emerging technologies, such as ultrasonic degassing for small-scale systems, utilize high-frequency sound waves to generate cavitation bubbles that collapse and release dissolved gases, achieving up to 90% efficiency in removing oxygen and other volatiles from low-volume water streams like laboratory or point-of-use applications.

Metallurgy and Other Industries

In metallurgy, vacuum degassing plays a critical role in refining molten steel by removing dissolved gases such as hydrogen and nitrogen, which can otherwise compromise material properties. The Ruhrstahl-Heraeus (RH) process, a prominent vacuum degassing method, involves circulating molten steel from a ladle into a vacuum vessel equipped with snorkels, where it is exposed to reduced pressures of 1-10 mbar at temperatures between 1500°C and 1600°C. This treatment reduces hydrogen content to below 1 ppm and lowers nitrogen levels, enhancing steel ductility and preventing issues like cracking or blistering. Argon gas is injected through the snorkels to stir the melt, promoting gas evolution and homogenization while minimizing oxidation. Developed in the 1960s, the RH process has become a standard for producing high-quality alloys used in automotive and aerospace applications. Beyond gas removal, degassing in production significantly reduces non-metallic inclusions, leading to cleaner with improved mechanical ; studies indicate reductions in inclusion content by up to 50% through extended treatment times and optimized stirring. In plastics , degassers integrated into single-screw extruders remove volatile organic compounds (VOCs) from molten polymers at temperatures of 200-300°C, preventing defects like bubbles or odors in the final product. -assisted systems ensure efficient VOC stripping, particularly in processes where contaminants from post-consumer plastics are prevalent. In the beverage industry, batch vacuum degassers deoxygenate fruit juices and other liquids by applying vacuum to release dissolved oxygen, thereby inhibiting oxidation, preserving color, and reducing foam formation during packaging. This process extends by minimizing microbial growth and enzymatic , with applications in producing clear, stable juices. Similarly, in (HPLC), inline degassers remove dissolved gases from mobile phases to prevent bubble formation, which could disrupt flow and baseline stability in analytical separations. Across laboratories in and plastics, ultrasonic methods offer precise control for small-volume samples, using high-frequency vibrations to nucleate and expel gases without introducing contaminants. These techniques are particularly valuable for experimental alloys or formulations where conventional systems may be impractical.

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