Systems, methods, and apparatus for processing crude oil

Abstract

The present disclosure relates to novel and advantageous systems, methods, and apparatuses for processing crude oil. In particular, the present disclosure relates to novel and advantageous systems, methods, and apparatuses for separating crude oil into components. More specifically, the present disclosure relates to novel and advantageous systems, methods, and apparatuses for separating crude oil into components of different densities.

Description

Technical Field

[0001] The present disclosure relates to novel and advantageous systems, methods and apparatus for processing crude oil. Specifically, the present disclosure relates to novel and advantageous systems, methods and apparatus for separating crude oil into components. More specifically, the present disclosure relates to novel and advantageous systems, methods and apparatus for separating crude oil into components of different densities. Background Art

[0002] The background description provided herein is for the purpose of generally presenting the context of the present disclosure. The work of the inventors presently mentioned within the scope described in this background section and aspects of the description that may not qualify as prior art at the time of filing are neither explicitly nor implicitly admitted to be prior art with respect to the present disclosure.

[0003] Crude oil is a finite resource. Crude oil can be processed to separate the various components into individually usable components, which is usually done using fractional distillation. Some of these components undergo cracking to help meet the demand for smaller molecules.

[0004] Fractional distillation uses fractionating columns to separate crude oil into simpler, more useful components. One such component is hydrocarbon molecules. Hydrocarbon molecules generally have similar boiling points and therefore can be separated together in fractional distillation.

[0005] Figure 1a A basic prior art fractionation tower 1 for separating crude oil into component parts is illustrated. As shown, the fractionation tower is hotter at its lower section 3 and cooler at its upper section 5. A plurality of conduits 7 are provided at levels of the fractionation tower 1 corresponding to the heights at which specific components can be removed.

[0006] During the fractional distillation of crude oil, the heated crude oil enters a fractionation column or tower, which is hot at the bottom and gradually cools toward the top. The vapors from the crude oil rise through the column. The vapors condense when they become cool enough (for the various components, this is at different temperatures based on their boiling points). Therefore, the liquid is drawn out of the column at different heights, usually corresponding to the temperature of the column dropping to a height below the corresponding boiling point. The shortest hydrocarbons with very low boiling points do not condense and leave the column in a gaseous state.

[0007] Figure 1b A schematic diagram of a prior art fractionation tower 1 is illustrated, showing crude oil components 9 and their uses. This process adopted in crude oil processing is a biochemical separation process in its raw material production stage, where the crude oil is exposed to soft physical effects in addition to chemical and associated thermodynamic processes. Purely mechanical processes are considered to be not strong enough because they cannot exceed the limits of stirring (which is gravity precipitation). Therefore, physical processes are considered to lead to inefficient circulation effects.

[0008] Centrifuged water and crude oil form a highly viscous non-Newtonian fluid mixture with a viscosity exceeding 0.8 Pa.sec or 0.8 kg / m.sec. This is significantly affected by the phenomenon of shear thickening, in which the shear stress rises exponentially with any velocity gradient effect. Current centrifugal methods for separating crude oil are insufficient to address non-Newtonian fluid mixtures and therefore have limited success. Cohesive forces between adjacent liquid layers and adhesive forces between the liquid and the machine fixed surface (which can be referred to as the liquid physical response) almost eliminate the useful decelerating centrifugal force that leads to failure of oil dehydration. Figure 1c The shear thickening phenomenon is illustrated.

[0009]

[0006] Therefore, there is a need in the art for a mechanical process for separating crude oil into its components that overcomes the challenges of shear thickening of non-Newtonian fluids. Summary of the invention

[0010] The following presents a brief summary of one or more embodiments of the present disclosure to provide a basic understanding of such embodiments. This summary is not an extensive overview of all conceived embodiments, and is neither intended to identify key or important elements of all embodiments nor to define the scope of any or all embodiments.

[0011] A device for processing crude oil is provided. The device includes a rotatable component and a drive that rotates the rotatable component. The rotatable component may include a rotatable container, a crude oil inlet, a crude oil processing chamber, a water outlet, and a crude oil outlet. The rotatable component may have an outer wall and may enclose a volume. The crude oil inlet may be configured to receive crude oil into the container. The crude oil processing chamber may be configured to accommodate a certain volume of crude oil and may be fluidly connected to the crude oil inlet. The water outlet may be fluidly connected to the crude oil processing chamber. The water outlet may be located near a radially outward region of the crude oil processing chamber and may be configured to guide water out of the crude oil processing chamber after the water has been separated from the crude oil. The crude oil outlet may be fluidly connected to the crude oil processing chamber, and the crude oil outlet is located at a radially inward position relative to the water outlet. The drive device may be configured to rotate the rotatable component around a rotation axis, wherein during operation of the device: the drive rotates the rotatable component around the rotation axis, and the crude oil in the crude oil processing chamber rotates with the rotatable component, thereby separating the crude oil into components of different densities, migrating water toward the water outlet, and migrating oil toward the oil outlet. The apparatus for processing crude oil may be configured to operate to continuously separate components of the crude oil.The apparatus for processing crude oil may also include a flywheel mechanically coupled to the rotatable component to facilitate continuous rotation of the rotatable component.

[0012] In some embodiments, the rotatable container is generally cylindrical in shape, and the crude processing chamber is generally annular in shape, and during operation, crude oil is separated into a radially outer annular water volume and a radially inner oil volume. In some embodiments, the axis of rotation is vertically oriented, and the rotatable assembly includes at least one solid discharge port, the at least one solid discharge port is located near the radially outward position of the rotatable container near the bottom end of the crude processing chamber, wherein the rotation of the rotatable assembly causes the solid particles suspended in the crude oil to migrate radially outward and gravity pulls the solid particles downward toward the at least one solid discharge port. The crude processing chamber may be located in the lower portion of the rotatable container, and the rotatable container may also include a water reservoir located above the crude processing chamber to receive water separated in the crude processing chamber, wherein the water outlet is connected to the inlet of the water reservoir by means of at least one conduit. The water reservoir may be annular in shape.

[0013] In some embodiments, water is pushed through at least one conduit due to the pressure exerted on the contents of the crude processing chamber. The water reservoir may include at least one water outlet located in a radially inward region of the rotatable container. The at least one water outlet of the water reservoir may be located radially outward relative to the crude oil outlet of the crude processing chamber. The rotatable container may also include a vertically arranged gas evacuation plenum located in a central region of the rotatable container so that the radially outward facing surface of the gas evacuation plenum forms the inner surface of the crude processing chamber, and the gas phase separated from the crude oil is transported upward through the vertically arranged gas plenum and out of the device.

[0014] The device for crude oil processing may also include an oil-gas mechanical seal, which is arranged at the upper end of the device, and the oil-gas mechanical seal has an internal chamber in fluid communication with the upper end of the vertically arranged gas evacuation plenum. The vertically arranged gas evacuation plenum guides the gas extracted from the crude oil into the chamber of the oil-gas mechanical seal, wherein the chamber of the oil-gas mechanical seal is connected to at least one gas outlet port to transport the gas out of the device. The chamber of the oil-gas mechanical seal may be defined by a peripheral wall, an upper wall and a lower wall. The upper wall and the lower wall of the oil-gas mechanical seal may each be defined by a liquid reservoir to solve the gas leakage from the chamber of the oil-gas mechanical seal. The liquid reservoir may include NaOH, wherein the gas is H2S, and wherein the liquid reservoir solves the gas leakage by reacting with the gas to produce Na2S. The oil-gas mechanical seal may be fixed relative to the rotating assembly. The oil-gas mechanical seal may receive the upper part of the rotating assembly therein, and the upper part includes the upper end of the vertically arranged gas evacuation plenum. The oil-gas mechanical seal may include a plurality of seals that seal on the upper end of a vertically disposed gas exhaust plenum. The oil-gas mechanical seal may include a plurality of seals that seal on the upper end of a vertically disposed gas exhaust plenum.

[0015] In some embodiments, at least one solid discharge port may be configured to direct a material slurry including solids into a filter to further separate the solids from a liquid component of the slurry. The filter may include an elongated outer container and an elongated porous inner container disposed within the elongated outer container, the elongated porous inner container having an electric auger disposed therein, the filter also having a slurry inlet for directing the slurry into the elongated inner container, a solids outlet mechanically connected to the elongated inner container, and a liquid outlet connected to the outer container, wherein the slurry inlet directs the slurry into the elongated inner container, wherein the auger propels the slurry toward the solids outlet, and further wherein the liquid is transported from the slurry and enters a chamber defined between the elongated outer container and the elongated porous inner container to separate the liquid from the solids in the slurry. The filter may be tilted at an angle so that the auger propels the solids upward as the solids are separated from the liquid of the slurry.

[0016] In some embodiments, the apparatus for processing crude oil further comprises a suspended solids discharge valve, the suspended solids discharge valve being fluidically connected to at least one solids discharge port, the suspended solids discharge valve being at least partially located below the crude oil processing chamber. The suspended solids discharge valve may comprise a sampling disc defining at least one solids discharge conduit formed therein, the sampling disc being configured to rotate relative to the lower wall of the crude oil processing chamber. The lower wall of the crude oil processing chamber may define at least one opening passing therethrough, and the relative rotation of the sampling disc relative to the lower wall of the crude oil processing chamber aligns at least one opening in the lower wall of the crude oil processing chamber with at least one solids discharge conduit of the sampling disc for a predetermined period of time so that solids are transported from the crude oil processing chamber, through at least one opening in the lower wall of the crude oil processing chamber and into at least one solids discharge conduit of the sampling disc. The suspended solids discharge valve may further comprise a discharge ring comprising at least one radially outwardly directed discharge port, wherein solids are transported to the at least one radially outwardly directed discharge port by the sampling disc.

[0017] The sampling disc may be rotated relative to the lower wall of the crude oil processing chamber by a gear train driven by the second drive. The gear train may be a planetary gear train.

[0018] The rotating assembly can be configured to rotate at a first speed, and the sampling disk can be configured to rotate at a second speed different from the first speed to permit relative rotation of the sampling disk relative to the crude oil processing chamber. The first speed can be within about one percent of the second speed. The first speed and the second speed can differ between about one rpm and about ten rpm. The first speed can be between about 500 rpm and about 5000 rpm.

[0019] A method for purifying crude oil is provided. The method includes directing a flow of crude oil into a rotating chamber of a separation device, rotating the crude oil with the rotating chamber of the separation device to separate the crude oil into component parts, and causing the component parts to leave the separation device. Rotating the crude oil with the separation device causes the crude oil to be layered into a gaseous component, a purified oil component, a water component, and a solid component in a radial direction. The gaseous component is emptied through a gas exhaust pipe in a central area of ​​the separation device. The purified oil is caused to leave through an oil outlet port located radially outside the gas exhaust pipe. The water component is caused to leave through a water outlet port located radially outside relative to the oil outlet port. The method may also include continuously operating the separation device, and continuously introducing crude oil into the separation device and continuously emptying oil and water from the separation device.

[0020] The solid component can be discharged from the solid discharge port of the separation device. The solid component can be directed to a solid separation filter in the form of a slurry. The gaseous component can be directed to a fixed chamber of an oil-gas mechanical seal located at the upper end of the separation device, and the oil-gas mechanical seal includes a plurality of mechanical seals, and the plurality of mechanical seals can rotatably receive the upper end of the separation device. The oil-gas separation device may include a liquid reservoir located above and below the fixed chamber, wherein the gas leaking through the plurality of mechanical seals is intercepted and neutralized by the liquid reservoir. The gas leaking through the plurality of mechanical seals that can be intercepted by the liquid reservoir includes hydrogen sulfide.

[0021] An apparatus for neutralizing harmful gases is provided. The apparatus may include a container having a gas receiving chamber and a liquid filled reservoir. The gas receiving chamber may be coupled to a gas inlet and a gas outlet, the gas receiving chamber being configured to rotatably receive a rotating tubular conduit for directing a flow of gas. The liquid filled reservoir may be disposed above and below the gas receiving chamber to receive gas that leaks through a seal of the gas receiving chamber. The receiving chamber may include a plurality of cascade chambers separated by mechanical seals. Four cascade chambers separated by four mechanical seals may be provided.

[0022] An oil-gas mechanical seal is provided. The seal may be fixed and may include an internal chamber and a gas inlet port for allowing gas to enter the internal chamber. The internal chamber may be defined by a peripheral wall, an upper wall, and a lower wall. The gas inlet port may be in fluid communication with a gas evacuation collection chamber from a separator device, wherein the separator device has a gas outlet port to transport gas out of the device to the gas evacuation collection chamber. The upper wall and the lower wall may be defined by a liquid reservoir that addresses gas leakage from the chamber. In one embodiment, the gas is H2S, and the liquid reservoir is NaOH, and the liquid reservoir addresses gas leakage by reacting with the H2S to form Na2S.

[0023] Although multiple embodiments are disclosed, yet other embodiments of the present disclosure will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments of the present invention. As will be appreciated, the various embodiments of the present disclosure are capable of modification in various obvious aspects, all of which do not depart from the spirit and scope of the present disclosure. Therefore, the drawings and detailed description should be regarded as illustrative in nature and not restrictive. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter regarded as forming the various embodiments of the present disclosure, it is believed that the invention will be better understood from the following description taken in conjunction with the accompanying drawings, in which:

[0025] Figure 1a It is a prior art fractionation column used to separate crude oil into its component parts.

[0026] Figure 1b is a prior art fractionation column showing the components of crude oil and their uses.

[0027] Figure 1c The shear thickening phenomenon is illustrated.

[0028] Figure 2a A cross-sectional side view of a crude oil separator according to one embodiment is illustrated.

[0029] Figure 2b An example is given according to an embodiment Figure 2a Operational discharge nozzle design of crude oil separator.

[0030] Figure 2c Illustrated Figure 2a A cross-sectional perspective view of a crude oil separator.

[0031] Figure 2d A photograph illustrating the exterior of a crude oil separator according to one embodiment is illustrated.

[0032] Figure 3a The weight of the spinning liquid shell under the influence of α rad / s is illustrated.

[0033] Figure 3b A general separation profile of a rotatable container according to one embodiment is illustrated.

[0034] Figure 3c A rotatable container (comprising Figure 3b separation contour), liquid sensor, water outlet, crude oil outlet and gas outlet.

[0035] Figure 3dA rotatable container (comprising Figure 3b separation profile) and the specificity of water outlet, crude oil outlet and gas outlet.

[0036] Figure 4a A driving gear mechanism according to one embodiment is illustrated.

[0037] Figure 5 An air-oil mechanical seal according to one embodiment is illustrated.

[0038] Figure 6a A particle ejector according to one embodiment is illustrated.

[0039] Figure 6b A photograph of a particle ejector according to one embodiment is illustrated.

[0040] Figure 6c An isometric view of a cascade of rotating gears is illustrated according to one embodiment.

[0041] Figure 7 A slurry separator according to one embodiment is illustrated.

[0042] Figure 8a A process flow diagram according to one embodiment is illustrated.

[0043] Figure 8b The speed reduction under gravity separation and the speed reduction under centrifugal separation are illustrated.

[0044] Figure 8c The net effective driving separation force affecting the unwanted impurities according to the Archimedean principle is illustrated.

[0045] Figure 9a Illustrate the effect of a range of accelerations on water.

[0046] Figure 9b The influence of the acceleration range on the water droplet separation speed is illustrated respectively.

[0047] Fig.10a The effect of the acceleration range on sand is illustrated.

[0048] Fig.10b Illustrate the effect of a range of accelerations on marble and solid.

[0049] Fig.10c The effect of a range of accelerations on limestone is illustrated.

[0050] Fig.11 The sand separation velocity in cm / s is illustrated as a function of frequency, impurity radius and medium viscosity.

[0051] Fig.12Illustrate the effect of acceleration on metal.

[0052] Fig.13 The metal separation velocity in cm / s is illustrated as a function of frequency, impurity radius and medium viscosity.

[0053] Fig.14 A separation process using a crude oil separation system is illustrated.

[0054] Fig.15a The effect of the acceleration range on salt is illustrated.

[0055] Fig.15b The salt separation velocity in cm / s is illustrated as a function of frequency, impurity radius and medium viscosity.

[0056] Fig.16 Desludging, desalting and degassing profiles are illustrated.

[0057] Fig.17a The acceleration range for 1000 g effects is illustrated.

[0058] Fig.17b The effect of acceleration range in flash gas is illustrated.

[0059] Fig.18 The gas flash velocity in cm / s is illustrated as a function of frequency, bubble radius and medium viscosity.

[0060] Fig.19 A three-dimensional frequency performance graph is illustrated.

[0061] Fig. 20 The net effective driving separation force affecting the unwanted impurities is illustrated.

[0062] Fig.21 An efficient separation force in terms of gravity is illustrated.

[0063] Fig. 22 The three-dimensional efficient centrifugal force with respect to gravity is illustrated.

[0064] Fig.23 The process of dehydrating crude oil is illustrated.

[0065] Fig.24 The sediment decomposition process is illustrated.

[0066] Fig.25 Operational case studies are illustrated. DETAILED DESCRIPTION

[0067] The present disclosure relates to novel and advantageous systems, methods and apparatus for processing crude oil. Specifically, the present disclosure relates to novel and advantageous systems, methods and apparatus for separating crude oil into components. More specifically, the present disclosure relates to novel and advantageous systems, methods and apparatus for separating crude oil into components of different densities.

[0068] Broadly speaking, the present disclosure relates to a crude oil purifier. The system, method, apparatus and device provide an effective primary purification process, which may include crude oil dehydration, sludge sediment decomposition, total suspended solids (TSS) separation, crude oil desalting, TSS washing and degassing. It should be understood that as used herein, crude oil includes oil, water, impurities, particulates, gas, etc.

[0069] The present disclosure uses the decelerating centrifugal force effect to play a role in different fields of separation technology. Centrifugal separators (also known as hydrocyclones, motor-driven hydrocyclones, and more generally rotatable assemblies) operate to perform a dehydration process on crude oil. The crude oil separator disclosed herein is capable of separating viscous fluids without shear thickening of non-Newtonian fluid mixtures and impurities.

[0070] The crude oil processor has many advantages over prior art crude oil processors. These include:

[0071] The TSS value can be significantly reduced, for example, to 35ppm;

[0072] ·The moisture percentage can be reduced to the lowest level;

[0073] The volume of separated suspended solids can be significantly reduced, for example, to a few microns;

[0074] · The separator can overcome all or most of the main medium viscosities. Raw materials and potential are usually unable to resist the high efficiency deceleration force;

[0075] The sludge settling structure is actually broken down and the resulting oil is lighter;

[0076] Efficiently desalt heavy crude oils so that the separated oil is usually desalted and the water required for desalting is minimized;

[0077] Degassing, making the separated oil ultra-desulfurized;

[0078] The separator has tunable performance efficiency;

[0079] Production capacity can be expanded while keeping power consumption within a selected range; usually a power-saving machine;

[0080] Can be self-cleaning and cartridge-free;

[0081] Can meet health, safety and environmental regulations;

[0082] · Includes periodic or selective pneumatically operated discharge systems, i.e., spin-on valves; and

[0083] The separator can be a liquid classifier with a liquid differentiation sensor.

[0084] In addition to simplifying the separation process, the crude oil processor or separator can also have the indirect positive technical results of oil dehydration. The water required for desalting is significantly reduced. The chemical catalysts required for processing are reduced. No heating of the oil-water blend is required for dehydration. The time of oil in the desalter is reduced, and the unit productivity is therefore increased. This has been shown to achieve a 30% increase in production capacity. Pipeline and fittings deterioration is minimized. Maintenance needs and periodic blockages are reduced due to the reduction of sludge sediment. After sludge elimination, the fixed environmental impact from the dumping area is controlled. Settled sludge in the main storage container is reduced.

[0085] Figure 2a A cross-sectional side view of a crude oil separator according to one embodiment is illustrated. Figure 2b An example is given according to an embodiment Figure 2a Operational discharge nozzle design of crude oil separator. Figure 2c Illustrated Figure 2a A cross-sectional perspective view of a crude oil separator. Figure 2d A photograph of the exterior of a crude oil separator according to one embodiment is illustrated. In various embodiments, the crude oil separator or a portion thereof may include food grade heat treated stainless steel so that the separator may be self cleaning.

[0086] As shown, the crude oil separator 50 includes a rotatable assembly 52, an oil-gas seal 54, and a particle ejector 56 (in Figure 2c5. The oil-gas seal 54 may be disposed above the rotatable assembly 52, and the particle ejector 56 may be disposed below the rotatable assembly 52. ​​The rotatable assembly 52 includes a centrifugal mechanism that can rotate continuously during operation. The rotatable assembly includes a rotatable container 58, a crude oil inlet 60, a crude oil processing chamber 62, one or more water outlets, and one or more crude oil outlets. The rotatable container 58 has an outer wall and surrounds the crude oil processing chamber 62. The crude oil inlet 60 receives crude oil into the container 58. The crude oil processing chamber 62 is configured to accommodate a certain volume of crude oil and is fluidly connected to the crude oil inlet 60. The water outlet 64 is fluidly connected to the crude oil processing chamber and is located near the radially outward region 68 of the crude oil processing chamber 62. The water outlet 64 is configured to guide water out of the crude oil processing chamber 62 after the water has been separated from the crude oil. The crude oil outlet 66 is fluidly connected to the crude oil processing chamber 62 and is located near the radially inward region 70 of the crude oil processing chamber 62. The crude oil outlet 66 is located at a radially inward position relative to the water outlet 64. The drive rotates the rotatable component 52 around the axis of rotation. The axis of rotation can be vertically oriented. During operation of the device, the drive rotates the rotatable component 52 around the axis of rotation. The crude oil in the crude oil processing chamber rotates with the rotatable component, thereby separating the crude oil into components of different densities. Water usually migrates outward and in the radially outward region 68, while oil usually migrates to the inside of the water and in the radially inward region 70. Therefore, water migrates toward the water outlet 64, and oil migrates toward the oil outlet 66. It should be noted that the terms water and brine are used interchangeably in this article.

[0087] The crude oil separator may be configured to operate to continuously separate components of the crude oil, and more specifically, to continuously separate components of the crude oil based on their densities.In some embodiments, a flywheel may be mechanically coupled to the rotatable component to facilitate continuous rotation of the rotatable component.

[0088] The rotatable container 58 may be generally cylindrical in shape, and the crude processing chamber 62 is generally annular in shape. During operation, the crude oil separates into a radially outer annular water volume 68 and a radially inner annular oil volume 70. There may be a natural separation barrier 72 between the annular water volume 68 and the annular oil volume 70. A sensor may be provided to measure the separation barrier and ensure that it is properly aligned to direct oil to the crude oil outlet 66 and water to the water outlet 64.

[0089] The rotatable assembly 52 may include at least one solids discharge port 74 located near a radially outward position of the rotatable container 58 near the bottom end of the crude oil processing chamber 62. Rotation of the rotatable assembly 52 may cause solid particles suspended in the crude oil to migrate radially outward, and gravity pulls the solid particles downward toward the at least one solids discharge port 74. The at least one solids discharge port 72 may be configured to direct the slurry of material including solids into a filter (see Figure 7 ) to further separate the solids from the liquid component of the slurry.

[0090] A suspended solids discharge valve 56 (also referred to as a particulate discharger) may be disposed in fluid communication with the at least one solids discharge port 74 , the suspended solids discharge valve 56 being at least partially located below the crude processing chamber 62 .

[0091] The crude processing chamber 62 may be located in a lower portion of the rotatable container 58. The rotatable container 58 may include a water reservoir 76 located above the crude processing chamber to receive water separated in the crude processing chamber. The water reservoir 76 may be annular in shape. The water outlet 64 may be connected to the inlet of the water reservoir by means of at least one conduit 78. Water may be pushed through the at least one conduit 78 due to the pressure exerted on the contents of the crude processing chamber 62. The water reservoir 76 may include at least one water outlet 80, and the at least one water outlet 80 of the water reservoir 76 may be located in a radially inward region of the rotatable container 58. The at least one water outlet of the water reservoir may be located radially outward relative to the crude oil outlet of the crude processing chamber.

[0092] The rotatable container 58 may include a vertically disposed gas exhaust plenum 82 located in a central region of the rotatable container. A radially outward facing surface 84 of the gas exhaust plenum 82 may form an inner surface of the crude oil processing chamber. The gas phase separated from the crude oil may be transported upward through the vertically disposed gas chamber 82 and out of the device.

[0093] The rotatable container 58 is tunable and eliminates or reduces the shear thickening phenomenon that causes non-Newtonian fluids. Figure 1c The reason for the failure of centrifugal separation in highly viscous fluids with a viscosity higher than that of water (viscosity can exceed 1.0 Pa.sec) is that water and crude oil are non-Newtonian fluid mixtures that are greatly affected by the phenomenon of shear thickening, where the shear stress rises exponentially with any velocity gradient effect. This stems from the inadequate design of the interaction between the fixed and dynamic parts of these machines. The liquid physical response (cohesion between adjacent liquid layers and adhesion between the liquid and the fixed surfaces of the machine) almost eliminates the useful decelerating centrifugal force. This is the main reason for the failure of oil dehydration when using motor-driven hydrocyclones or ordinary hydrocyclones. The disclosed rotatable container eliminates this failure.

[0094] Using the crude oil separator described herein, the fluid inside the spinning cylinder moves at the same speed as the rotatable container. Therefore, there is no relative velocity between the fluid and the rotatable cylinder. Because the relative velocity gradient remains zero, there is zero shear stress. This keeps the non-Newtonian fluid rarefied and substantially prevents fluid thickening, which is the main failure point of centrifugal separation discussed above.

[0095] Figure 3aThe weight of the spinning liquid shell under the influence of α rad / s is illustrated. More specifically, Figure 3a The separation directions of water and solids are illustrated.

[0096] Figure 3b The general separation profile of a rotatable container according to one embodiment is illustrated. The rotatable container provides superior performance efficiency and minimum required residence time. An umbrella-shaped stainless steel filter may be provided, as shown in dashed lines, to reduce or eliminate relative slippage of the liquid layers. As shown, the extracted gas travels to the center of the rotatable container and is directed upward. Brine is directed to the outermost. Oil is directed between the gas and brine. Suspended solids fall out from the bottom. Figure 3b It is also illustrated how the commit time can be practically suppressed to minimize the dwell time to the prevailing practical limit to enable scaling up of the desired production capacity.

[0097] Figure 3c A rotatable container (comprising Figure 3b Separation profile), spin-on liquid sensor, water outlet, crude oil outlet and gas outlet. Separated brine leaves the brine outlet. Separated oil leaves the oil outlet. Gas leaves the gas outlet. Suspended solids leave near the bottom.

[0098] In order to provide relatively continuous oil-brine separation, and to substantially avoid oil-water mixing events, the spin-on sensors may be positioned at specific locations where the cylindrical shells that separate the oil and water undulate back and forth. Figure 3c A and B (shown as 6) in FIG. 6 show the relationship between the oil shell and the water shell. AB Indicates the relationship.

[0099] If R AB ≈0.0Ω, the oil outlet can be closed to brine. Therefore, additional oil can be injected for balancing or the oil outlet can be temporarily closed (e.g. for a filling type main outlet connection). If R AB ≈(open circuit), the brine outlet can be closed to oil. Therefore, additional brine can be injected for balancing or the brine outlet can be temporarily closed (e.g. for a filling type main outlet connection). The gas and sulfur flash mechanism is efficient, with the gas flash force from 0.8 g / cm 3 The bubble jumps to 8Kg / cm 3 , which ensures ultra-desulfurization of the oil sulfur to 0.01 wt%.

[0100] Figure 3d A rotatable container (comprising Figure 3b The separation profile) and the specificity of the water outlet, crude oil outlet and gas outlet. As shown in the figure, the outlet can be set as a combined connector for liquid and gas.

[0101] In order to separate crude oil, crude oil is pumped into a rotatable container through a crude oil inlet. The rotatable component is rotated by a drive. The crude oil rotates with the rotatable component and forms layers. Water is pushed outward, and oil is pushed inward. The water outlet guides the water out of the rotatable component. The crude oil outlet guides the crude oil out of the rotatable component. Solid particles (such as TSS slurry) migrate to the side of the rotatable container and slide downward, and are guided to a particle ejector for removal and processing. Natural gas, hydrogen sulfide (H2S) migrate to the center of the rotatable component and flow upward to the oil-gas seal. The oil-gas seal may include a gas plenum with a liquid buffer to neutralize H2S. The oil-gas seal may be fixed. The liquid buffer may include sodium hydroxide (NaOH), and NaOH may react with H2S to form sodium sulfide (Na2S). Typically, such an oil-gas seal may have any strong alkaline liquid or gas buffer to react with a strong acid to form, for example, salt and water. Thus, the oil-gas seal aids in cooling and prevents dangerous H2S leaks.

[0102] Therefore, a method for purifying crude oil is provided. The method includes directing a flow of crude oil into a rotating chamber of a separation device, and rotating the crude oil together with the rotating chamber of the separation device so that the crude oil is stratified into a gaseous component, a purified oil component, a water component, and a solid component in a radial direction. The method may also include exhausting the gaseous component through a gas exhaust pipe in a central area of ​​the separation device, exhausting the purified oil through an oil outlet port located radially outside the gas exhaust pipe, and exhausting the water component through a water outlet port located radially outside relative to the oil outlet port.

[0103] The method may also include continuously operating the separation device, continuously introducing crude oil into the separation device and continuously draining oil and water from the separation device. The solid component may be discharged from a solid drain port of the separation device. More specifically, the solid component may be directed to a solid separation filter in the form of a slurry.

[0104] The method may also include directing the gaseous component into a fixed chamber of an oil-gas mechanical seal located at an upper end of the separation device, the oil-gas mechanical seal including a plurality of mechanical seals that rotatably receive the upper end of the separation device. The oil-gas separation device may also include a liquid reservoir located above and below the fixed chamber, wherein gas leaking through the plurality of mechanical seals is intercepted and neutralized by the liquid reservoir. The gas leaking through the plurality of mechanical seals intercepted by the liquid reservoir may include hydrogen sulfide.

[0105] Figure 4a A drive gear mechanism according to one embodiment is illustrated. In this embodiment, a reduction planetary gear driven by the main drive motor is used to have a sampling disk speed of 2 rpm, with the gear drive shaft running at 70 rpm relative to the spinning drum.

[0106] Figure 5 An air-oil mechanical seal 54 according to one embodiment is illustrated. The air-oil mechanical seal 54 can be used to neutralize harmful gases. The air-oil mechanical seal may include a gas receiving chamber 100 and liquid-filled reservoirs 102, 104 disposed above and below the gas receiving chamber 100. The gas receiving chamber 100 may be coupled to a gas inlet and a gas outlet. The gas receiving chamber may be configured to rotatably receive a rotating tubular conduit 106 that guides a gas flow. The liquid-filled reservoirs 102, 104 disposed above and below the gas receiving chamber 100 may be configured to receive gas leaking through the seals 108, 110 of the gas receiving chamber. In some embodiments, the air-oil mechanical seal may include four cascade chambers 112, 102, 100, 104 separated by four mechanical seals 114, 108, 110, 116. The mechanical seals 114, 108, 110, 116 may be configured to withstand conditions ranging from a pH of 1 to 14, temperatures of -50°C to 300°C, and pressures up to 300 bar. In one embodiment, the mechanical seals 114, 108, 110, 116 are tungsten carbide seals.

[0107] The oil-gas mechanical seal 54 may be disposed at the upper end of the device and may have an internal chamber in fluid communication with the upper end of a vertically disposed gas evacuation collecting chamber. The vertically disposed gas evacuation collecting chamber guides the gas extracted from the crude oil into the gas receiving chamber of the oil-gas mechanical seal. The gas receiving chamber of the oil-gas mechanical seal is connected to at least one gas outlet port to transport the gas out of the device. The chamber of the oil-gas mechanical seal is defined by a peripheral wall, an upper wall, and a lower wall. The upper wall and the lower wall of the oil-gas mechanical seal may each be defined by a liquid reservoir (such as a sodium hydroxide (NaOH) solution) to resolve gas leakage from the chamber of the oil-gas mechanical seal. This may be, for example, by reacting with a gas hydrogen sulfide (H2S) leak to produce sodium sulfide (Na2S). In other embodiments, different liquids may be provided as liquid reservoirs, and different mechanisms (such as absorption of gas) may be used to resolve gas leakage.

[0108] The oil-gas mechanical seal may be fixed relative to the rotating assembly. The oil-gas mechanical seal may receive an upper portion of the rotating assembly therein, the upper portion including an upper end of a vertically disposed gas exhaust plenum. The oil-gas mechanical seal may include a plurality of seals that seal on the upper end of the vertically disposed gas exhaust plenum.

[0109] The suspended solids discharge valve (also referred to as a particulate discharger) may be arranged to be in fluid communication with a solid discharge port or a crude oil separation system. The suspended solids discharge valve may be at least partially located below the crude processing chamber of the rotatable assembly. The suspended solids discharge valve may include a sampling disc defining at least one solids discharge conduit formed therein, the sampling disc being configured to rotate relative to the lower wall of the crude processing chamber. The lower wall of the crude processing chamber may define at least one opening passing through it. The relative rotation of the sampling disc relative to the lower wall of the crude processing chamber aligns at least one opening in the lower wall of the crude processing chamber with at least one solids discharge conduit of the sampling disc for a predetermined period of time so that solids are transported from the crude processing chamber, through at least one opening in the lower wall of the crude processing chamber and into at least one solids discharge conduit of the sampling disc. This may be configured as a normally closed / normally open discharge system. When the solids are discharged, the contents inside the container are not exposed to the external atmosphere. When at least one opening in the lower wall of the crude processing chamber is aligned with at least one solids discharge conduit of the sampling disc, the solids pass through. As they rotate away from each other, they get rid of the solids while being isolated from the contents of the container.

[0110] The sampling disc is rotated relative to the lower wall of the crude oil processing chamber by a gear train driven by a second drive. The gear train may be, for example, a planetary gear train. Figure 6c An isometric view of cascading rotating gears in a center disk of a particle ejector is illustrated according to one embodiment.

[0111] The rotating assembly may be configured to rotate at a first speed, and the sampling disc may be configured to rotate at a second speed different from the first speed to allow relative rotation of the sampling disc relative to the crude oil processing chamber. In some embodiments, the first speed is within about one percent of the second speed. In some embodiments, the first speed and the second speed differ between about one rev / min and about ten rev / min. In some embodiments, the first speed is between about 500 rev / min and about 5000 rev / min.

[0112] The suspended solids discharge valve may further include a discharge ring including at least one radially outward outward discharge port, wherein solids are transported by the sampling disc to the at least one radially outward outward discharge port.

[0113] Figure 6a and Figure 6b A specific embodiment of a suspended solids discharge valve 56 or a particle discharger according to one embodiment is illustrated. Return to Reference Figure 2c, the particle ejector 56 may be disposed below the rotatable container 58. The particle ejector may include a suspended solids ejection spinning system. In some embodiments, the particle ejector 56 may include a spinning valve ejection system. In the illustrated embodiment, three layers or discs 120, 122, and 124 are stacked together to form a spinning cylinder with a flange. The lower disc 120 may have a peripheral lip or rim 126 for receiving the center disc and include the ejection ring discussed above. The upper disc 124 receives the suspended solids and may seal the center disc within the lower disc. The upper disc may include the sampling disc described above. The center disc 122 may include Figure 6c Gear train 128 is shown.

[0114] A central crude oil inlet 130 may be disposed in the upper disk 124 and is in fluid communication with the solid discharge port of the rotating assembly. A plurality of TSS slurry outlet holes 132 are provided through each of the three disks 120, 122, 124. In the upper disk 124, the outlet holes 132 may be positioned between the crude oil inlet 130 and the periphery. In the center disk 122, the outlet holes 132 may be substantially near the periphery. In the lower disk 120, the outlet holes 132 may pass through the rim 126. Generally speaking, when the disks 120, 122, and / or 124 are aligned so that the outlet holes are aligned, solids are pushed through the upper disk 124 into the center disk 122, through the center disk 122 to the lower disk 124, and out of the outlet holes 132 of the lower disk 120. The solid discharge mechanism works directly on the cylinder wall for pushing solids to the rim to be discharged through the outlet holes.

[0115] The particle separator keeps the media exposed by the spinning closed. For the closed cylindrical sample, a buffer valve with a sampling mechanism is provided. A 25 mm diameter and 20 mm thickness were used to perform the case study, where (6 holes * 6 outlets * 2 net revolutions / minute * sample volume) = 707 ml slurry / minute. This produced 1400 grams of suspended sand. Assuming 300 ppm in crude oil, the disclosed system has a discharge capacity that can cover approximately 4.7 barrels / minute = 6720 barrels / day.

[0116] Figure 7 A slurry separator or filter 150 according to one embodiment is illustrated. As shown, the slurry separator 150 includes a slurry mixture inlet 152, a brine separation screen 154, a brine outlet 156, and a total suspended solids outlet 158. The slurry filter 150 can be directly or indirectly coupled to where solids are discharged from a solid discharge valve. This can be, for example, an outlet along a slurry mixture path outside the separation system such as a blowdown pipe.

[0117] As discussed above, the solid discharge port may be provided as part of the suspended solid discharge valve 56 and configured to direct the material slurry including solids into the filter 150 to further separate the solids from the liquid component of the slurry. The filter may include an elongated outer container 151 and an elongated porous inner container 153 disposed within the elongated outer container 151. The elongated porous inner container 151 may include a brine separation net 154. The elongated porous inner container 151 may have an electric auger 155 disposed therein. As previously described, the filter 150 may have a slurry inlet 152 for directing the slurry into the elongated inner container 153, a solid outlet 158 ​​in mechanical communication with the elongated inner container 153, and a liquid outlet 156 in communication with the outer container 151. The slurry inlet 152 directs the slurry into the elongated inner container 153, wherein the auger 155 propels the slurry toward the solid outlet 158. Liquid is transported from the slurry and into chamber 157 defined between elongated outer container 151 and elongated porous inner container 153 to separate the liquid from the solids in the slurry. The filter may be tilted at an angle so that the auger 155 propels the solids upward as they separate from the liquid of the slurry.

[0118] Figure 8a A system and process flow diagram according to one embodiment is illustrated. Figure 8a In the system shown, three separators S1 200, S2 202 and S3 204 are provided. The fluid is sent to the degasser flash drum 206. This extracts most of the gas content and sends it along pipeline 208. The fluid is sent to the body water separator 200. The body water separator 200 can be a three-phase separator. At this stage, the gas separated in the body water separator is sent along pipeline 210 to merge with the gas from the flash drum 206. The fluid is separated into oil and water, wherein the water is sent to the second separator 202 and the oil is sent to the oil processing vessel 212. The second separator 202 separates any remaining oil and sends it to the oil processing vessel 212. The second separator 202 sends the separated water, which is substantially free of gas and oil, to a water tank 214. The sediment from the second separator 202 is sent along pipeline 216. The oil is sent to the third separator 204, where any remaining gas, water and sediment are extracted. The sediment is sent out along pipeline 218 to merge with the sediment from the second separator 202. The oil is sent to oil tank 220. Therefore, at the end of the process, there are four main products: oil (in oil tank 220), water (in water tank 214), gas (optionally in a storage tank (not shown)) and solids (optionally in a storage tank (not shown)). The disclosed separation system solves problems that are not solved by currently used oil processing technology. The separation system minimizes power and water consumption and increases crude oil production capacity.

[0119] Various performance characteristics and the principles behind such characteristics will now be discussed. Archimedes' principle is a fundamental physical law of fluid mechanics and is referenced when discussing the performance of the disclosed system. Archimedes' principle states that the upward buoyant force exerted on a body immersed in a fluid (whether completely or partially) is equal to the weight of the fluid displaced by the body. More specifically:

[0120] The net or combined force affecting any unwanted impurity = (impurity density / cm 3 -Carrying fluid density / cm 3 )*Deceleration acceleration.

[0121] It is expected that the numerical results are severely exaggerated and are quadratically related to the operating frequency. Figure 8b The speed reduction under gravity separation and the speed reduction under centrifugal separation are exemplified. More specifically, Figure 8b The difference in efficiency between separation using a gravity process and separation using a centrifugal process is illustrated. Figure 8c The net effective driving separation force affecting the unwanted impurities according to the Archimedean principle is illustrated.

[0122] Dehydration. The separation system is a highly efficient heavy crude oil dehydrator. Note: Kg weight means 1kg*9.81=9.81 Newtons. The net precipitation effective force affecting one cubic centimeter of water (Archimedes principle) under gravity is:

[0123] From 0.2 g weight / cm 3 Water = (0.001962N) is accelerated to:

[0124] 1.0.2kg weight / cm 3 of water (at 1000 gravity) until:

[0125] 2.0.3kg weight / cm 3 of water (at 1500 gravity) until:

[0126] 3.0.6kg weight / cm 3 of water (at 3000 gravity) until:

[0127] 4.1.0kg weight / cm 3 of water (under 5000 gravity effect).

[0128] Thus, even in the foam state, any moisture percentage can be reduced to a minimum. Figure 9a and Figure 9b The effects of the acceleration range on the water and water droplet separation speeds are illustrated respectively.

[0129] Total suspended solids (TSS). Typically, any value of TSS can be reduced to, for example, 35 ppm. Using crude oil separation systems and equipment, the net settling effective force (Archimedes principle) affecting one cubic centimeter of sand under gravity is:

[0130] From 1.2 g weight / cm 3 Sand = (0.011772N) accelerated to:

[0131] 1.1.2kg weight / cm 3 of sand (under 1000 gravity effect).

[0132] until:

[0133] 2.1.8kg weight / cm 3 of sand (under 1500 gravity effect).

[0134] until:

[0135] 3.3.6kg weight / cm 3 of sand (under 3000 gravity effect).

[0136] until:

[0137] 4.6.0kg weight / cm 3 of sand (under 5000 gravity effect).

[0138] Fig.10a The effect of the acceleration range on sand is illustrated. Fig.10b Illustrate the effect of a range of accelerations on marble and solid. Fig.10c The effect of a range of accelerations on limestone is illustrated. Fig.11 The sand separation velocity in cm / s is illustrated as a function of frequency, impurity radius and medium viscosity.

[0139] TSS separation. Suspended solid density between 2 and 8 g / cm 3 The crude oil separation system, apparatus and method achieve efficient extraction of any solid particles from its packing medium regardless of its volume, thereby leaving it at the discharge outlet regardless of the flow rate of the blend and the pressure difference between the layers.

[0140] TSS Washing: Accumulated solids within crude separation systems and equipment can be washed during the separation process.

[0141] Suspended Solids (SS) Volume. Generally speaking, any value of the separated SS volume can be reduced to a few microns. Using crude oil separation systems and equipment, the effective force (Archimedes principle) affecting the net precipitation of one cubic centimeter of metal particles under gravity is:

[0142] From 7.2 g / cm 3 The metal pellet = (0.070632N) is accelerated to:

[0143] 1.7.2kg weight / cm 3 of metal particles (under 1000 gravity effect).

[0144] until:

[0145] 2.10.8kg weight / cm 3 of metal particles (under 1500 gravity effect).

[0146] until:

[0147] 3.21.6kg weight / cm 3 of metal particles (under 3000 gravity effect).

[0148] until:

[0149] 4.36.0kg weight / cm 3 of metal particles (under the effect of 5000 gravity).

[0150] Fig.12 Illustrate the effect of acceleration on metal. Fig.13 The metal separation velocity in cm / s is illustrated as a function of frequency, impurity radius and medium viscosity.

[0151] Medium viscosity. Crude oil separation systems and equipment can overcome any major medium viscosity. Raw materials and potential cannot withstand efficient deceleration forces.

[0152] Sludge settling. Using crude oil separation systems and equipment, any sludge settling is broken down. As a result, the oil is lighter. Fig.14 A separation process using a crude oil separation system according to embodiments disclosed herein is illustrated.

[0153] Desalting. Crude oil separation systems and equipment are highly efficient heavy crude oil desalters that minimize the amount of water required for desalting. Using crude oil separation systems and equipment, the effective forces (Archimedes principle) affecting the net precipitation of one cubic centimeter of salt under gravity are:

[0154] From 0.8 g weight / cm 3 of salt = (0.00785N) to accelerate to:

[0155] 1.0.8kg weight / cm3 of salt (under 1000 gravity effect).

[0156] until:

[0157] 2.1.2kg weight / cm 3 of salt (under 1500 gravity effect).

[0158] until:

[0159] 3.2.4kg weight / cm 3 of salt (under 3000 gravity effect).

[0160] until:

[0161] 4.4.0kg weight / cm 3 of salt (under 5000 gravity effect).

[0162] Fig.15a The effect of the acceleration range on salt is illustrated. Fig.15b The salt separation velocity in cm / s is illustrated as a function of frequency, impurity radius and medium viscosity.

[0163] Oil desalination. The weight of suspended salt particles can be magnified 3000 to 5000 times. This disperses the salt aggregates through the viscous fluid directly to the separation equipment and the main discharge outlet of the system. Fig.16 Desludging, desalting and degassing profiles are illustrated.

[0164] Degassing. Crude oil separation systems and equipment are highly efficient degassers. The inner separation shell of the crude oil contains bubbles of unwanted associated gas extracted from the oil sediment as released. The separated oil contains almost no gas. Therefore, the net floating and flashing effective forces (Archimedes principle) affecting one cubic centimeter of gas under gravity and traditional degassing operating conditions are:

[0165] From **(0.001-0.80)g weight / cm 3 Gas = -0.79g weight = -(0.00775N) accelerated to:

[0166] 1.(0.799kg weight / cm 3 of gas) flash force (under 1000 gravity effect).

[0167] until:

[0168] 2.(1.1985kg weight / cm 3 of gas) flash force (under 1500 gravity effect).

[0169] until:

[0170] 3.(2.397kg weight / cm3 of gas) flash force (under 3000 gravity effect).

[0171] until:

[0172] 4.(3.995kg weight / cm 3 Gas) flash force (under 5000 gravity effect).

[0173] **The bubbles will be displaced forcefully by the oil at a net pressure (in kg weight) of (0.00079*centrifugal acceleration / 9.81).

[0174] Thus, the oil from the crude oil separation system and equipment is nearly desulfurized and contains no acid gases such as hydrogen sulfide. Fig.17a The acceleration range for 1000 g effects is illustrated. Fig.17b The effect of acceleration range in flash gas is illustrated. Fig.18 The gas flash velocity in cm / s is illustrated as a function of frequency, bubble radius and medium viscosity.

[0175] Tunable Performance. Crude oil separation systems and equipment have tunable performance efficiency. Fig.19 A three-dimensional frequency performance graph is illustrated. More specifically, Fig.19 The net effective numerical force driving the separation that affects the unwanted impurities is illustrated. Fig. 20 The net effective driving separation force affecting the unwanted impurities is illustrated. Fig.21 The efficient separation force in terms of gravity is illustrated. More specifically, Fig.21 Two variable efficient separation forces in terms of gravity are illustrated. Fig. 22 The three-dimensional efficient centrifugal force in terms of gravity is illustrated. More specifically, Fig. 22 Two variable three-dimensional efficient centrifugal forces with respect to gravity are illustrated.

[0176] Production capacity. Using the crude oil separation system and method, production capacity can be expanded while keeping power consumption within a desired permissible range. This results in reduced power consumption.

[0177] Purification Stages. The purification stages that can be achieved using the crude oil separation system and method include: submission profile, dewatering, sludge sediment decomposition, TSS separation, oil desalting, TSS washing and degassing.

[0178] Dehydration. The crude oil blend is exposed to an acceleration effect equivalent to about 3000 to 5000 times the force of gravity; the relative weight difference exceeds 600 to 1000 grams per gram of water, which is the effective sedimentation force of oil and water. This thrust overcomes the raw material potential and even any high cohesion between the blend layers, allowing very small water droplets to penetrate any high viscosity fluid. Fig.23The process of dehydrating crude oil is illustrated.

[0179] Sludge sediment decomposition. Using crude oil separation systems and equipment, a rotational acceleration equivalent to 3000 to 5000 times the acceleration of gravity creates a relative weight difference between oil and most suspended solids, which can typically exceed (3.6 to 6.0) Kg for sand and 21.6 Kg to 36.0 Kg for a certain amount of metal per gram of oil. This process results in forced sediment decomposition in opposite directions. This force, which is divided into two opposing forces, pushes solids to the outside and pushes heavy oil or petroleum to the center. Fig.24 The sediment decomposition process is illustrated.

[0180] Indirect positive technical results of crude oil separation and dehydration include:

[0181] The output oil is substantially desalted.

[0182] Less water required for the desalination process.

[0183] Less chemical catalyst required.

[0184] No need to heat the oil-water mixture for dehydration.

[0185] • The oil residence time in the desalter is reduced and the productivity is thereby increased.

[0186] ·Deterioration of pipes and fittings is minimized.

[0187] • Most maintenance needs and periodic blockages are minimized due to the virtually absence of sludge sedimentation.

[0188] · After sludge removal, control of fixed environmental impacts originating from dumping areas.

[0189] Less settled sludge in storage vessels.

[0190] It should be understood that the systems, devices, apparatuses and / or methods and / or their components can be applied to fields other than crude oil separation. For example, one or more can be used for industrial water treatment that is typically contaminated with oil and grease. One or more can be used in degrease traps to serve as primary integrated residential or regional degrease traps before overflowing into sanitary networks. One or more can be used to separate water from the fluid produced in oil extraction pipelines. One or more can be used to separate suspended solids from sewage and industrial water.

[0191] Crude oil separation systems, equipment and methods utilize physics and fluid mechanics in oil purification technology. This will be explained below. For the purpose of this discussion, the following definitions are used:

[0192] Liquid travel: Initially the net vertical distance between the internal inlet and outlet. (referred to as (h2-h1)).

[0193] ·A1 = main inlet cross-sectional area.

[0194] A2 = main internal outlet area.

[0195] · P1 = Main interior entrance.

[0196] ·P2 = Main internal exit.

[0197] ·ρ = blend density.

[0198] G = 9.8 m / s 2 . (acceleration due to gravity)

[0199] ·(P1+ρgh1+1 / 2gv1 2 =p2+ρgh2+(1 / 2gv2 2 )),therefore

[0200] P2=p1+ρg(h1-h2)+(1 / 2g(v1 2 -v2 2 )). Unit: kg / ms 2 .

[0201] Assume (h1-h2) = 1m, where the flow rate is 200 barrels / day

[0202] (ie: 2.3 liters / second, 2-inch nozzle, so v1 = 1.17 m / s, v2 = 0.0029 m / s).

[0203] P2=P1+(1000*9.81+1 / 2*9.81((1.17)2-(0.0029) 2 )) / (101,300)atm=(P1+9816.71 / 101,300atm)=P1+0.0969atm.

[0204] The increase obtained is almost negligible and will not deviate from the impurities of the separation method used.

[0205] Using the disclosed separation systems, methods and processes, the following performance parameters are achieved.

[0206] Radial separation velocity: affects the radial separation velocity of the centrifugal separator. oil The net or resulting sedimentation force of a particle of diameter dp in a viscous oil of density is its original weight, which is related to the oil carrying force according to Archimedean principle and the force of its movement. and when velocity is constant with respect to time rather than position: therefore The potential is the opposite.

[0207]

[0208] Duration:

[0209]

[0210] productivity:

[0211]

[0212] Machine Equivalence:

[0213]

[0214] ∑=Effective separation area*Centrifugal separation factor (m2)

[0215]

[0216] The total pressure due to centrifugal force (see Figure 3a and Figure 2b ):

[0217]

[0218]

[0219] based on Figure 3a , once the two chambers C1 and C2 (see Figure 2b ) become equal, establishing discharge stability in the interconnected container system.

[0220] therefore:

[0221]

[0222] R2 (Oil discharge radius): can be derived from the inlet or feed pipe diameter (usually 6 inches) and the gas chamber void. (It is usually 20cm)

[0223] R (equilibrium radius): derives the chamber volume governed by the pre-assigned residence times of both water and oil. The factor A can be as follows:

[0224] For the volume water separated from crude oil emulsion A, A = 1 / 3,

[0225]

[0226] A = 1 / 2, Water res =A*(60 / k)=(5-7.5)sec. (conventional crude oil).

[0227] A=0.65, Water res =A*(60 / k)=(4.5-5.5)sec. (conventional crude oil).

[0228] For wastewater treatment, A = 20. (pretreatment product).

[0229] For crude oil treatment, A = 1 / 8. (pre-treatment product).

[0230] Oil-water depletion region stability: As mentioned above, the cylindrical shell separates oil and water. The stability of the shell is evaluated in order to drain the two liquids at a rate appropriate to their percentages, i.e., an equilibrium process. Shell volume = 2πhRdr, Shell mass = 2πhρRdr, Shell weight = 2πhρω 2 R 2 dr. Note: The change between water and oil produces 0.2g / cm 3 Case Study: Body Water Separator Running at 1800 rpm:

[0231] That is: (water content = 50%) t res =20sec. A=1 / 3, R out =50cm, R2 (oil discharge) = 20cm, h = 300cm, dr = 1mm.,

[0232] Therefore, (shell weight change = 2πhρω2R2dr) Newtons.

[0233] will be: (2π*3*200*(188) 2 *(.44) 2 *0.001)=25796N=2629.5Kg.

[0234] This change will produce a thrust of 2.68 tons targeting stability. If this is the case, a physical analysis is performed; if the separated oil chamber tends to shift 1mm towards the separated water; then the total force of 2682Kg pushes the oil inwards, and if the water shifts 1mm towards the oil, the same force (2682Kg) pushes the water forward. (Each mm displacement of the depletion area produces a force of 2682Kg. This will push the depletion line back. Therefore, a completely stable configuration is obtained.

[0235] Fig.25 An operational case study (radius of the discharge nozzle) is illustrated. By adopting the drop velocity equation:

[0236] Separation speed v and centrifugal acceleration α = (R*(2πf) 2 ), which is directly related to the centrifugal acceleration and the operating frequency in a square relationship. (μ represents viscosity in Pa·sec, ρ represents density, and α represents 2 This illustrates the efficiency of the desalination process.

[0237] Note that acting on α (centrifugal acceleration) is better than acting on temperature to soften or reduce μ (viscosity). The next two equations provide an explanation as to why acting on centrifugal acceleration is more effective at reducing viscosity than acting on temperature.

[0238] By rewriting the above equation, we get:

[0239]

[0240] This shows that, using the disclosed separation system, tuning alpha is more efficient, faster, easier, more practical, more economical, and is quadratically related to the separation speed. In addition, increasing the temperature is much slower, more expensive, and is linearly related to the separation speed.

[0241] As used herein, the term "substantially" or "generally" refers to the complete or almost complete scope or degree of an action, characteristic, property, state, structure, project or result. For example, an object that is "substantially" or "generally" closed will mean that the object is completely or almost completely closed. The allowable accuracy of the deviation relative to absolute integrity may depend on the specific circumstances in some cases. However, in general, the proximity of completion will be to have the same overall result as having obtained absolute and complete completion. When used in a negative sense to refer to the complete or almost complete lack of an action, characteristic, property, state, structure, project or result, the use of "substantially" or "generally" is equally applicable. For example, an element, combination, embodiment or composition that "substantially does not contain" or "generally does not contain" an element can actually still include such an element, as long as the element has no significant effect overall.

[0242] To assist the Patent Office and any reader of any patent issuing in this application in interpreting the appended claims, applicants wish to note that they do not intend for any of the appended claims or claim elements to invoke the provisions of 35 U.S.C. §112(f) unless the words "method for" or "step for" are expressly used in a particular claim.

[0243] Additionally, as used herein, the phrase “at least one of [X] and [Y]” (where X and Y are different components that may be included in an embodiment of the present disclosure) means that the embodiment may include component X but not component Y, the embodiment may include component Y but not component X, or the embodiment may include both component X and component Y. Similarly, the phrase, when used with respect to three or more components, such as “at least one of [X], [Y], and [Z],” means that the embodiment may include any one of the three or more components, any combination or subcombination of any of these components, or all of these components.

[0244] In the foregoing description, various embodiments of the present disclosure have been given for the purpose of illustration and description. The embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. In view of the above teachings, obvious modifications or variations are possible. Different embodiments have been selected and described in order to provide the best illustration of the principles of the present disclosure and its practical application and to enable those of ordinary skill in the art to utilize various embodiments with various modifications as suitable for the specific purpose contemplated. All such modifications and variations are within the scope of the present disclosure as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equally entitled.

Claims

1. A device for processing crude oil, comprising: A rotatable component, the rotatable component comprising: a rotatable container having an outer wall and enclosing a volume; a crude oil inlet, the crude oil inlet being used to receive crude oil into the container; a crude oil processing chamber, the crude oil processing chamber containing a certain volume of crude oil, the crude oil processing chamber being in fluid communication with the crude oil inlet; a water outlet in fluid communication with the crude processing chamber, the water outlet being located adjacent a radially outward region of the crude processing chamber, the water outlet being configured to direct the water out of the crude processing chamber after the water has been separated from the crude; and a crude oil outlet in fluid communication with the crude processing chamber, the crude oil outlet being located radially inwardly relative to the water outlet; and a drive for rotating the rotatable component about an axis of rotation, wherein during operation of the device: The drive rotates the rotatable component about the rotation axis; and causing the crude oil in the crude oil processing chamber to rotate together with the rotatable component, Thereby, the crude oil is separated into components of different densities, water is caused to migrate toward the water outlet and oil is caused to migrate toward the oil outlet.

2. The apparatus of claim 1, wherein the apparatus is configured to operate to continuously separate components of crude oil.

3. The apparatus of claim 1, wherein the rotatable container is generally cylindrical in shape and the crude processing chamber is generally annular in shape, and further wherein, During operation, the crude oil separates into a radially outer annular water volume and a radially inner oil volume.

4. An apparatus according to claim 1, wherein the rotation axis is vertically oriented, and further wherein the rotatable component includes at least one solid discharge port, the at least one solid discharge port being located near a radially outward position of the rotatable container near the bottom end of the crude oil processing chamber, wherein rotation of the rotatable component causes solid particles suspended in the crude oil to migrate radially outward and gravity pulls the solid particles downward toward the at least one solid discharge port.

5. An apparatus according to claim 4, wherein the crude oil processing chamber is located in the lower part of the rotatable container, and further wherein the rotatable container also includes a water storage layer located above the crude oil processing chamber to receive water separated in the crude oil processing chamber, wherein the water outlet is connected to the inlet of the water storage layer by means of at least one conduit.

6. The device according to claim 5, wherein the water storage layer is annular in shape.

7. An apparatus according to claim 5, wherein water is propelled through the at least one conduit due to pressure exerted on the contents of the crude oil processing chamber, and further wherein the water storage layer includes at least one water outlet, wherein the at least one water outlet of the water storage layer is located in a radially inward region of the rotatable container.

8. The apparatus of claim 7, wherein the at least one water outlet of the water reservoir is located radially outward relative to the crude oil outlet of the crude oil processing chamber.

9. An apparatus according to claim 8, wherein the rotatable container further comprises a vertically disposed gas evacuation collecting chamber, wherein the vertically disposed gas evacuation collecting chamber is located in a central region of the rotatable container, wherein a radially outward facing surface of the gas evacuation collecting chamber forms an inner surface of the crude oil processing chamber, and further wherein the gas phase separated from the crude oil is transported upward through the vertically disposed gas evacuation collecting chamber and leaves the apparatus.

10. The apparatus of claim 1 further comprising a flywheel mechanically coupled to the rotatable component to facilitate continued rotation of the rotatable component.

11. The apparatus of claim 4, wherein the at least one solids discharge port directs a slurry of material including solids into a filter to further separate the solids from a liquid component of the slurry.

12. An apparatus according to claim 11, wherein the filter comprises an elongated outer container and an elongated porous inner container disposed within the elongated outer container, the elongated porous inner container having an electric screw conveyor disposed therein, the filter also having a slurry inlet for directing slurry into the elongated inner container, a solid outlet mechanically connected to the elongated inner container, and a liquid outlet connected to the outer container, wherein the slurry inlet directs slurry into the elongated inner container, wherein the screw conveyor propels the slurry toward the solid outlet, and further wherein liquid is transported from the slurry and enters a chamber defined between the elongated outer container and the elongated porous inner container to separate the liquid from the solids in the slurry.

13. The apparatus of claim 12, wherein the filter is inclined at an angle to cause the auger to propel the solids upward as they separate from the liquid of the slurry.

14. The apparatus of claim 4, further comprising a suspended solids discharge valve in fluid communication with the at least one solids discharge port, the suspended solids discharge valve being at least partially located below the crude processing chamber.

15. The device according to claim 14, wherein: The suspended solids discharge valve includes a sampling disc defining at least one solids discharge conduit formed therein, the sampling disc being configured to rotate relative to a lower wall of the crude processing chamber; and The lower wall of the crude processing chamber defines at least one opening therethrough, and relative rotation of the sampling plate with respect to the lower wall of the crude processing chamber causes the at least one opening in the lower wall of the crude processing chamber to align with the at least one solids drainage conduit of the sampling plate for a predetermined period of time to allow solids to be transported from the crude processing chamber, through the at least one opening in the lower wall of the crude processing chamber, and into the at least one solids drainage conduit of the sampling plate.

16. The apparatus of claim 15, wherein the sampling disk is rotated relative to the lower wall of the crude processing chamber by a gear train driven by a second drive.

17. The apparatus of claim 16, wherein the rotating assembly is configured to rotate at a first speed and the sampling disc is configured to rotate at a second speed different from the first speed so as to permit relative rotation of the sampling disc with respect to the crude processing chamber.

18. The apparatus of claim 16, wherein the first speed is within about one percent of the second speed.

19. The apparatus of claim 18, wherein the first speed and the second speed differ by between about one revolution per minute and about ten revolutions per minute.

20. The device of claim 19, wherein the first speed is between about 500 rpm and about 5000 rpm.

21. The apparatus of claim 16, wherein the gear train is a planetary gear train.

22. The apparatus of claim 15, wherein the suspended solids discharge valve further comprises a discharge ring including at least one radially outward outward discharge port, wherein solids are transported by the sampling disk to the at least one radially outward outward discharge port.

23. The device of claim 9, further comprising an oil-gas mechanical seal disposed at an upper end of the device, the oil-gas mechanical seal having an internal chamber in fluid communication with an upper end of the vertically disposed gas exhaust plenum.

24. The device of claim 23, wherein the vertically disposed gas evacuation plenum directs gas extracted from crude oil into a chamber of the oil-gas mechanical seal, wherein the chamber of the oil-gas mechanical seal is coupled to at least one gas outlet port to transport gas out of the device.

25. The apparatus of claim 24, wherein the chamber of the oil-gas mechanical seal is defined by a peripheral wall, an upper wall, and a lower wall.

26. The apparatus of claim 25, wherein the upper wall and the lower wall of the oil-gas mechanical seal are each defined by a liquid reservoir to address gas leakage from the chamber of the oil-gas mechanical seal.

27. The apparatus of claim 26, wherein the reservoir comprises NaOH, wherein the gas is H2S, and wherein the reservoir resolves gas leaks by reacting with the gas to produce Na2S.

28. The apparatus of claim 23, wherein the oil-gas mechanical seal is fixed relative to the rotating assembly.

29. The apparatus of claim 28, wherein the oil-gas mechanical seal receives an upper portion of the rotating assembly therein, the upper portion including the upper end of the vertically disposed gas exhaust plenum.

30. The apparatus of claim 29, wherein the oil-gas mechanical seal comprises a plurality of seals that seal against the upper end of the vertically disposed gas evacuation plenum.

31. A method for purifying crude oil, comprising: directing the crude oil stream into a rotating chamber of a separation device; causing the crude oil to rotate together with the rotating chamber of the separation device so that the crude oil is stratified into a gaseous component, a purified oil component, a water component, and a solid component in a radial direction; exhausting the gaseous components through a gas exhaust pipe in a central region of the separation device; allowing the purified oil to exit through an oil outlet port located radially outwardly of the gas vent pipe; and The water component is caused to exit through a water outlet port located radially outwardly relative to the oil outlet port.

32. The method of claim 31 further comprising continuously operating the separation device and continuously introducing crude oil into the separation device and continuously draining oil and water from the separation device.

33. The method of claim 31 further comprising discharging the solid component through a solids discharge port of the separation device.

34. The method of claim 33, further comprising directing the solid component in the form of a slurry to a solid separation filter.

35. The method of claim 31 further comprising directing the gaseous component into a fixed chamber of an oil-gas mechanical seal located at an upper end of the separation device, the oil-gas mechanical seal comprising a plurality of mechanical seals capable of rotatably receiving the upper end of the separation device.

36. The method of claim 35, wherein the oil-gas separation device further comprises liquid reservoirs located above and below the fixed chamber, wherein gas leaking through the plurality of mechanical seals is intercepted and neutralized by the liquid reservoirs.

37. The method of claim 36, wherein the gas that is intercepted by the reservoir and leaks past the plurality of mechanical seals comprises hydrogen sulfide.

38. An apparatus for neutralizing harmful gases, comprising a container having: a gas receiving chamber coupled to the gas inlet and the gas outlet, the gas receiving chamber being configurable to rotatably receive a rotating tubular conduit directing a flow of gas; and Liquid filled reservoirs are disposed above and below the gas receiving chamber to receive gas that leaks past the seal of the gas receiving chamber.

39. The apparatus of claim 37, wherein the gas receiving chamber comprises a plurality of cascade chambers separated by mechanical seals.

40. Apparatus according to claim 38, wherein four cascade chambers are provided separated by four mechanical seals.

41. An oil-gas mechanical seal, the seal comprising: an interior chamber defined by a peripheral wall, an upper wall, and a lower wall; a gas inlet port for admitting gas into the interior chamber, wherein the gas inlet port is in fluid communication with a gas evacuation plenum from a separator device, and wherein the separator device has a gas outlet port for transporting gas out of the device to the gas evacuation plenum; wherein the upper wall and the lower wall are defined by a liquid reservoir layer, the liquid reservoir layer accounting for gas leakage from the chamber; and The seal is stationary.

42. The oil-gas mechanical seal of claim 40, wherein the gas is H2S, wherein the reservoir is NaOH, and wherein the reservoir resolves gas leaks by reacting with the H2S to form Na2S.

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