Abstract
This article presents a comprehensive study on the development and optimization of a multi-channel Laval nozzle-based sand separator designed for natural gas streams under high-pressure conditions (up to 5.0 MPa). A comprehensive study on the design and optimization of a sand separator has been presented, taking into account changes in flow parameters under conditions where the high-pressure (up to 5.0 MPa) gas flow rate decreases from 5 million m³/day to 0.5 million m³/day, and an adaptive system with three inlet pipes has been proposed. Calculations show that when the Mach number is maintained within the range of 1.1–1.25, the separation efficiency remains within the range of 90–95%. The study includes hydrodynamic modeling, flow regime analysis, and a parametric evaluation of nozzle dimensions to ensure stable supersonic separation at various gas flow velocities. A hybrid operational concept featuring three inlet lines and variable nozzle combinations is proposed enabling flexible operation from maximum to minimum flow conditions. Computational modeling and correlations confirm the technical feasibility of the design for enhancing sand capture efficiency under high-density conditions. CFD modeling has been presented at a conceptual level in this work and has been substantiated for future verification. Keywords: natural gas separation; sand trap; supersonic flow; high-pressure gas; flow optimization; computational modeling.