Novel cyclone and structure optimization method

Abstract

The invention discloses a novel swirler and a structure optimization method, and relates to the technical field of oil exploitation, the swirler comprises a connecting cylinder and a guide wheel outer cylinder, a guide wheel and a turbine are coaxially arranged in the guide wheel outer cylinder, the middle of the turbine is fixedly connected with a main shaft, the guide wheel is composed of an inner ring and an outer ring, the outer side of the outer ring is fixedly connected with the guide wheel outer cylinder, and the guide wheel outer cylinder is fixedly connected with the main shaft. The inner ring is fixedly connected to the interior of the outer ring, and a plurality of curved-surface runners are annularly and uniformly distributed on the outer side of the outer ring and are U-shaped. The multi-stage guide wheel and turbine staggered distribution structure is adopted for the cyclone, a multi-stage fluid energy transfer path is formed, the curved surface flow channels are annularly and evenly distributed on the outer side of the guide wheel, the Bernoulli principle and the kinetic energy gradient optimization theory are combined, and the flow channel sectional area change, curvature radius adjustment and multi-stage contraction and expansion structure design are adopted, so that the multi-stage fluid energy transfer path is formed. And the fluid dynamic pressure energy is efficiently converted into turbine impact force. According to the design, kinetic energy gradient transmission is achieved through graded flow guide, and the coupling efficiency of axial lifting force and radial shearing force is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of oil extraction technology, and more specifically to a novel hydrocyclone and its structural optimization method. Background Technology

[0002] In the field of oil extraction, hydrocyclones, as the core equipment of hydraulic lift technology, replace the power output mode of traditional mechanical pumps or electric submersible pumps by converting fluid kinetic energy, and have shown unique advantages in water injection development oil fields, ecologically sensitive areas and blocks with weak power infrastructure.

[0003] However, current conventional hydrocyclones suffer from technical bottlenecks due to design flaws in their flow guiding structures. Firstly, insufficient matching between the flow channel geometry parameters and the multiphase flow field leads to turbulent separation and vortex dissipation when the fluid passes through, resulting in an ineffective pressure drop loss of up to 30%-45%.

[0004] Secondly, the traditional single-stage acceleration structure fails to achieve kinetic energy gradient transfer, resulting in insufficient coupling efficiency between axial lift and radial shear force, and the actual lifting efficiency is reduced by about 25%-40% compared with the theoretical value.

[0005] These problems not only increase system energy consumption by more than 30%, but also restrict large-scale application under complex reservoir conditions.

[0006] Therefore, it is necessary to propose a novel hydrocyclone and structural optimization method to solve the above problems. Summary of the Invention

[0007] (a) Technical problems to be solved The purpose of this invention is to address the problems of insufficient matching between the geometric parameters of the existing hydrocyclone channel and the multiphase flow field, which leads to turbulent separation and vortex dissipation during fluid flow, and the failure of traditional single-stage acceleration structures to achieve kinetic energy gradient transfer, resulting in insufficient coupling efficiency between axial lift and radial shear force. This invention provides a novel hydrocyclone and a structural optimization method.

[0008] (II) Technical Solution To achieve the above objectives, the present invention specifically adopts the following technical solution: A novel hydrocyclone includes a connecting cylinder and a guide wheel outer cylinder. A guide wheel and a turbine are coaxially arranged inside the guide wheel outer cylinder. A main shaft is coaxially fixedly connected to the center of the turbine. The guide wheel consists of an inner ring and an outer ring. The outer ring is fixedly connected to the outer cylinder, and the inner ring is fixedly connected to the inside of the outer ring. Multiple curved flow channels are evenly distributed in a ring on the outer side of the outer ring. The axial length of each curved flow channel is greater than the axial length of the inner ring. The curved flow channels are U-shaped and penetrate the outer ring, extending onto the surface of the inner ring.

[0009] Optionally, the width of the outer ring is greater than the width of the inner ring, and the thickness of the outer ring is less than the width of the inner ring.

[0010] Optionally, the curved flow channel is U-shaped in general, including an inlet section, a deflection section, and an outlet section. The cross-sectional area of ​​the flow channel in the inlet section, deflection section, and outlet section generally changes from small to large and then back to small, wherein the maximum cross-sectional area of ​​the flow channel in the inlet section is smaller than the maximum cross-sectional area of ​​the flow channel in the outlet section.

[0011] Optionally, the cross-sectional area of ​​both the inlet and outlet sections gradually increases along the flow direction.

[0012] Optionally, the inlet section includes a first arc-shaped end and a first expansion section. The outer side of the first expansion section includes a first side and a second side. The angle between the second side and the inner side of the first expansion section is smaller than the angle between the first side and the inner side of the first expansion section.

[0013] Optionally, the outlet section includes a second expansion section and a second arc-shaped end.

[0014] Optionally, the cross-section of the flow channel of the deflection section generally exhibits a trend of increasing area followed by decreasing area, and both sides of the deflection section are arc-shaped.

[0015] A novel method for optimizing the structure of a hydrocyclone includes the following steps: Design various flow patterns for the guide wheel; Based on a comprehensive evaluation of the torque and pressure drop at the inlet and outlet of each flow channel, the selected flow channel pattern is determined.

[0016] Optionally, the torque of each flow channel and the pressure drop generated at the inlet and outlet are obtained by simulation calculation.

[0017] Optionally, the design method of the flow channel is the controlled variable method. First, it is determined that the flow area of ​​the flow channel is equal. The preliminary design is carried out by changing the cross-sectional area of ​​the flow channel, adjusting the radius of curvature, and using a multi-stage contraction and expansion structure. Then, the kinetic energy is converted into turbine impact force through Bernoulli's principle and kinetic energy gradient optimization to complete the final design.

[0018] (III) Beneficial Effects The beneficial effects of this invention are as follows: 1. This invention relates to a hydrocyclone employing a paired working system of guide wheels and turbines, arranged in a multi-stage spatial configuration. The guide wheels and turbines are staggered, with the guide wheels and turbines coaxially positioned inside the outer cylinder of the guide wheel, and the main shaft passing through the center of the guide wheel. This invention forms a multi-stage fluid energy transfer path. Curved flow channels are evenly distributed in a ring around the outer side of the guide wheel. Combining Bernoulli's principle and kinetic energy gradient optimization theory, through changes in the cross-sectional area of ​​the flow channels, adjustments to the radius of curvature, and a multi-stage contraction and expansion structure design, the fluid dynamic pressure energy is efficiently converted into turbine impact force. This design achieves kinetic energy gradient transfer through staged flow guidance, significantly improving the coupling efficiency of axial lift and radial shear force.

[0019] 2. The hydrocyclone structure optimization method provided by the present invention controls the pressure drop conversion rate between 1.11% and 1.36% by optimizing the geometric parameters of the guide wheel flow channel, thereby reducing ineffective pressure drop loss and improving energy conversion efficiency. The optimized hydrocyclone structure solves the problem of insufficient matching degree between the flow channel geometric parameters and the multiphase flow field, which leads to turbulent separation and vortex dissipation when the fluid passes through.

[0020] 3. This invention utilizes the ANSYS Fluent simulation model to simplify the modeling of the hydrocyclone. By simplifying complex structures such as four-stage guide wheels and turbines into a single-stage model, the interference of geometric details on the simulation is reduced, significantly improving computational efficiency. Through mesh generation, the ANSYS Fluent simulation employs a hexahedral honeycomb mesh, which is more efficient than traditional unstructured meshes. The boundaries between the fluid and solid domains are clearly defined, and the inlet and no-slip wall boundary conditions are uniformly set, eliminating boundary interference caused by multi-stage coupling, ensuring the reliability of simulation results, and facilitating targeted optimization. Attached Figure Description

[0021] Figure 1 This is a three-dimensional schematic diagram of the hydrocyclone structure of the present invention; Figure 2 This is a cross-sectional schematic diagram of the hydrocyclone structure of the present invention; Figure 3 This is a three-dimensional schematic diagram of the connecting cylinder structure of the present invention; Figure 4 This is a three-dimensional schematic diagram of the guide wheel structure No. 0 of the present invention; Figure 5 This is a schematic diagram of the outer contour of the curved flow channel structure of the No. 1 guide wheel of the present invention; Figure 6 This is a diagram showing the convergence iteration count of the 0th guide wheel in this invention. Figure 7 This is a diagram showing the number of torque iterations for guide wheel 0 in this invention. Figure 8 This is a static pressure cloud diagram of guide wheel No. 0 of the present invention; Figure 9 This is a dynamic pressure cloud diagram of the No. 0 guide wheel of the present invention; Figure 10 This is a schematic diagram of the flow channel pattern of guide wheels 1-6 of the present invention; Figure 11 This is a partial mesh division diagram of the No. 1 guide wheel of the present invention; Figure 12 This is a diagram showing the convergence iteration count of the first guide wheel of the present invention; Figure 13 This is a diagram showing the number of iterations for the first guide wheel of the present invention; Figure 14 This is a static pressure cloud diagram of the No. 1 guide wheel of the present invention; Figure 15 This is a dynamic pressure cloud diagram of the No. 1 guide wheel of the present invention; Figure 16 This is a partial mesh division diagram of the No. 2 guide wheel of the present invention; Figure 17 This is a diagram showing the convergence iteration count of the second guide wheel of the present invention; Figure 18 This is a diagram showing the number of torque iterations for the No. 2 guide wheel of the present invention; Figure 19 This is a static pressure cloud diagram of the No. 2 guide wheel of the present invention; Figure 20 This is a dynamic pressure cloud diagram of the No. 2 guide wheel of the present invention; Figure 21 This is a partial mesh division diagram of the No. 3 guide wheel of the present invention; Figure 22 This is a diagram showing the convergence iteration count of the third guide wheel in this invention. Figure 23 This is a diagram showing the number of torque iterations for guide wheel #3 of this invention; Figure 24 This is a static pressure cloud diagram of the No. 3 guide wheel of the present invention; Figure 25 This is a dynamic pressure cloud diagram of the No. 3 guide wheel of the present invention; Figure 26 This is a partial mesh division diagram of the No. 4 guide wheel of the present invention; Figure 27 This is a diagram showing the convergence iteration count of the fourth guide wheel in this invention. Figure 28 This is a diagram showing the number of torque iterations for guide wheel No. 4 of the present invention; Figure 29 This is a static pressure cloud diagram of the No. 4 guide wheel of the present invention; Figure 30 This is a dynamic pressure cloud diagram of the No. 4 guide wheel of the present invention; Figure 31 This is a partial mesh division diagram of the No. 5 guide wheel of the present invention; Figure 32 This is a diagram showing the convergence iteration count of the fifth guide wheel in this invention. Figure 33This is a diagram showing the number of torque iterations for guide wheel No. 5 of the present invention; Figure 34 This is a static pressure cloud diagram of the No. 5 guide wheel of the present invention; Figure 35 This is a dynamic pressure cloud diagram of the No. 5 guide wheel of the present invention; Figure 36 This is a partial mesh division diagram of the guide wheel No. 6 of the present invention; Figure 37 This is a diagram showing the convergence iteration count of the guide wheel No. 6 in this invention; Figure 38 This is a diagram showing the number of torque iterations for guide wheel No. 6 of the present invention; Figure 39 This is a static pressure cloud diagram of the No. 6 guide wheel of the present invention; Figure 40 This is a dynamic pressure cloud diagram of the No. 6 guide wheel of the present invention.

[0022] Reference numerals: 1. Connecting cylinder; 2. Outer cylinder of guide wheel; 3. Guide wheel; 4. Turbine; 5. Main shaft; 6. Water inlet channel; 7. Inner ring; 8. Outer ring; 9. Curved flow channel; 10. Outer bottom edge; 11. Second outer side edge; 12. Second top edge; 13. Second inner side edge; 14. Inner bottom edge; 15. First inner side edge; 16. First top edge; 17. First outer side edge. Detailed Implementation

[0023] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0024] Please see Figure 1 , Figure 2 , Figure 3 , Figure 5 and Figure 10This application discloses a novel hydrocyclone, including a connecting cylinder 1 and a guide wheel outer cylinder 2. The connecting cylinder 1 has eight water inlet channels 6 evenly distributed inside, and the connecting cylinder 1 is connected to the guide wheel outer cylinder 2 through the water inlet channels 6. The guide wheel outer cylinder 2 has a guide wheel 3 and a turbine 4 coaxially arranged inside, with the guide wheel 3 and turbine 4 arranged in pairs. In this embodiment, the guide wheel 3 is a four-stage guide wheel, and the turbine 4 is a four-stage turbine, with the guide wheel 3 and turbine 4 staggered to form a multi-stage fluid energy transfer path. A main shaft 5 is coaxially fixedly connected to the center of the turbine 4, and the main shaft 5 passes through the axis of the guide wheel 3. The guide wheel 3 consists of an inner ring 7 and an outer ring 8. The outer ring 8 is fixedly connected to the outer cylinder 2 on its outer side, and the inner ring 7 is fixedly connected to the inside of the outer ring 8. The width of the outer ring 8 is greater than the width of the inner ring 7, and the thickness of the outer ring 8 is less than the thickness of the inner ring 7. The hydrocyclone described in this invention is suitable for water-injection oilfields, ecologically sensitive areas, and areas with weak power infrastructure, and replaces traditional mechanical or electric lifting devices by using hydraulic energy.

[0025] Multiple curved flow channels 9 are evenly distributed on the outer ring of the outer ring 8, and the curved flow channels 9 penetrate the outer ring 8 and are formed on the surface of the inner ring 7. The length of the curved flow channels 9 in the axial direction is greater than the length of the inner ring 7 in the axial direction, and the curved flow channels 9 are U-shaped.

[0026] The curved flow channel 9 includes an inlet section, a deflection section, and an outlet section. The cross-sectional areas of the inlet, deflection, and outlet sections generally exhibit a trend of increasing and then decreasing area, with the maximum cross-sectional area of ​​the inlet section being smaller than that of the outlet section. The cross-sectional areas of both the inlet and outlet sections gradually increase along the flow direction. The inlet section includes a first arc-shaped end and a first expansion section. The outer side of the first expansion section includes a first side and a second side. The angle between the second side and the inner side of the first expansion section is smaller than the angle between the first side and the inner side of the first expansion section. The first and second side together form the first outer side 17. The outlet section includes a second expansion section and a second arc-shaped end.

[0027] The first arc-shaped end is enclosed by the first top edge 16; that is, the end space corresponding to the first top edge 16 is the first arc-shaped end. The first expansion segment connects to the first arc-shaped end and is enclosed by the first outer side 17 and the first inner side 15; that is, the space corresponding to the first outer side 17 and the first inner side 15 is the first expansion segment. The deflection segment connects to the first expansion segment and is enclosed by the outer bottom edge 10 and the inner bottom edge 14; that is, the space corresponding to the outer bottom edge 10 and the inner bottom edge 14 is the deflection segment. The second expansion segment connects to the deflection segment and is enclosed by the second inner side edge 13 and the second outer side edge 11; that is, the space corresponding to the second inner side edge 13 and the second outer side edge 11 is the second expansion segment. The second arc-shaped end connects to the second expansion segment and is enclosed by the second top edge 12; that is, the space corresponding to the second top edge 12 is the second arc-shaped end.

[0028] The optimized design concept of the curved flow channel 9 of the guide wheel is based on the change of the flow channel cross-sectional area, the adjustment of the radius of curvature and the multi-stage contraction and expansion structure; through Bernoulli's principle and kinetic energy gradient optimization, the kinetic energy is converted into turbine impact force.

[0029] The hydrocyclone of this invention employs a four-stage staggered distribution structure of guide wheels and turbines. Inside the outer cylinder 2 of the guide wheels, guide wheels 3 and turbines 4 are coaxially arranged, with a main shaft 5 passing through the center of guide wheel 3, forming a multi-stage fluid energy transfer path. Seven curved flow channels are evenly distributed in a ring on the outer side of the guide wheels. Combining Bernoulli's principle and kinetic energy gradient optimization theory, through changes in the cross-sectional area of ​​the flow channels, adjustments to the radius of curvature, and a multi-stage contraction and expansion structure design, the fluid dynamic pressure energy is efficiently converted into turbine impact force. This design achieves kinetic energy gradient transfer through staged flow guidance, significantly improving the coupling efficiency of axial lift and radial shear force.

[0030] The curved flow channel used in this invention has a torque of 1936N. Its pressure drop is 21.63 MPa, and the pressure drop conversion rate is only 1.11%. The lowest pressure drop conversion rate under the same operating conditions means that less energy consumption can achieve the same lifting effect. By reducing the cross-sectional area of ​​the inlet channel and smoothing the transition, the pressure drop loss is reduced by 15%-20%; the cross-sectional area of ​​the outlet channel is gradually expanded, further enhancing the ability of fluid kinetic energy to drive the rotation of the next-stage turbine.

[0031] This hydrocyclone is particularly suitable for water-injection oilfields, ecologically sensitive areas, and blocks with weak power infrastructure. Its hydraulic drive eliminates the need for mechanical or electric submersible pumps, significantly reducing equipment maintenance costs and environmental pollution risks. For example, in remote oilfields with limited power, the hydrocyclone can achieve continuous operation through natural water flow.

[0032] On the other hand, please see Figure 4-40 This application discloses a novel method for optimizing the structure of a hydrocyclone, including... S1: The hydrocyclone is simplified through simulation model to obtain the first-stage turbine, first-stage guide wheel and main shaft. The fluid domain in the first-stage turbine, first-stage guide wheel and main shaft is extracted and meshed.

[0033] In one specific implementation, the simulation model is the ANSYS Fluent simulation model. The steps for simplifying the structure of the hydrocyclone using the ANSYS Fluent simulation model are as follows: S11: Simplified Model: The structure of the multi-stage hydrocyclone is simplified to a single-stage turbine, a single-stage guide wheel, and a main shaft. This implementation uses a four-stage hydrocyclone structure.

[0034] S12: Extracting the fluid domain: Set the first-stage turbine, first-stage guide wheel and main shaft as solid domains, and the remaining gaps as fluid domains; S13: Mesh generation: Mesh the solid domain and the extracted fluid domain. The minimum unit size of the mesh is 0.5 mm, and the mesh adopts a hexahedral honeycomb mesh. S14: Loading has completed mesh generation. The interface between the fluid domain and the solid domain is identified as the boundary, including the inlet boundary, outlet boundary, and no-slip wall boundary.

[0035] A simplified model of the hydrocyclone was developed using ANSYS Fluent simulation. By reducing the complex structure, including the four-stage guide wheel and turbine, to a single-stage model, the interference of geometric details on the simulation was minimized, significantly improving computational efficiency. Through mesh generation, a hexahedral honeycomb mesh (minimum element size of 0.5 mm) was used in the ANSYS Fluent simulation, which is more efficient than traditional unstructured meshes. The interaction between the fluid and solid domains of different guide wheels was accurately simulated. After separating the solid domain (first-stage turbine, first-stage guide wheel, and main shaft) from the fluid domain, the boundaries between the fluid and solid domains were clearly defined. Unified inlet and no-slip wall boundary conditions were set to eliminate boundary interference caused by multi-stage coupling, ensuring the reliability of simulation results and facilitating targeted optimization. This method not only reduced experimental costs but also enabled quantitative analysis of the dynamic characteristics of the flow field, providing a scientific basis for optimizing the flow pattern of the guide wheel.

[0036] S2: Input the mesh into the simulation model to obtain the convergence iteration number diagram, torque iteration number diagram, static pressure and dynamic pressure cloud diagram of the designed guide wheel, and perform simulation verification of the fluid domain and solid domain of the hydrocyclone. In one specific implementation, the simulation model is the ANSYS Fluent simulation model. The Realizable k-ε turbulence model in the ANSYS Fluent simulation model is used to simulate and verify the fluid and solid domains of the hydrocyclone. The specific steps are as follows: S21: Simulation Test: Input the mesh into the Realizable k-ε turbulence model. The mathematical model of the transport equation for turbulent kinetic energy k is as follows: ; Among them, all Both represent partial derivatives. Corresponding time derivative, Derivatives of corresponding spatial coordinates For fluid density, Turbulent kinetic energy characterizes the energy intensity of turbulent fluctuation velocities. This indicates the turbulent kinetic energy generation term (shear force drives turbulent energy generation). Indicates the first Each coordinate direction Indicates the first Velocity components in each coordinate direction (e.g.) =1,2,3), Eddy viscosity, derived from k and ε, directly affects Reynolds stress. The modulus of the strain rate tensor. Turbulent kinetic energy dissipation rate represents the rate at which turbulent kinetic energy is converted into heat energy, reflecting the viscous dissipation effect of small-scale eddies. This represents the diffusion term.

[0037] Dissipation rate The mathematical model for the transport equation is as follows: ; in, As a dynamic adjustment factor, It is a fixed constant (default value is 1.9). Molecular viscosity (unit: m) 2 / s).

[0038] S22: Numerical Calculation: Set the inlet boundary as a velocity boundary condition, for example, velocity v = 20 m / s, direction along the axial direction, injection medium is water, density is 998 kg / m³. 3 , viscosity 0.001Pa The first-stage turbine, first-stage guide wheel, and main shaft region are defined as non-slip wall boundaries, and the outlet boundary is a pressure boundary condition. The ANSYS Fluent simulation model is used to perform numerical iteration and simulation calculations on the designed guide wheel, and the convergence iteration number diagram, torque iteration number diagram, static pressure and dynamic pressure cloud diagram of the designed guide wheel are obtained.

[0039] S23: Result Analysis: Calculate the torque generated when the hydrocyclone mass outlet reaches steady state. Based on the dynamic pressure contour map, and according to the dynamic pressure formula... To verify the accuracy of the simulation model, the calculated operating pressure is compared with the theoretical value to determine if they are on the same order of magnitude. It is a negative pressure value. Let be the fluid density and v be the fluid velocity. Determine if the error between the dynamic pressure and the theoretical value exceeds a threshold. If it does, return to S13 to increase the number of mesh divisions, decrease the minimum mesh element size, and re-perform the simulation.

[0040] The Realizable k-ε turbulence model outputs convergence iteration count plots, torque iteration curves, and static and dynamic pressure contour maps, visually revealing the flow field distribution. For example, the torque of guide wheel 0 at steady state is 138 Nm, which matches the theoretical value, proving the model's effectiveness. The static and dynamic pressure contour maps reveal vortex dissipation regions, such as the 30%-45% ineffective pressure drop loss in traditional cyclones, guiding structural improvements. The convergence iteration count reflects the model's stability; for example, flow pattern 0 requires multiple iterations to reach steady state, providing a basis for adjusting mesh density or boundary conditions.

[0041] Based on the dynamic pressure formula, the simulation accuracy is inversely calculated. When the error between the calculated value and the theoretical value exceeds a threshold, mesh refinement (reducing element size) and model correction are automatically triggered to ensure that the result error is reduced. This closed-loop verification mechanism improves the simulation accuracy of the design flow pattern.

[0042] S3: Design various flow patterns for the guide wheel; perform simulation verification for each flow pattern; calculate the torque, pressure drop at the inlet and outlet, and pressure drop conversion rate of various guide wheels, and generate a comparison table.

[0043] The design method for the flow channel is the controlled variable method. By ensuring that the flow area of ​​the curved flow channel is equal, and by changing the cross-sectional area of ​​the flow channel, adjusting the radius of curvature, and using a multi-stage contraction and expansion structure, as well as by optimizing the Bernoulli principle and kinetic energy gradient, the kinetic energy is converted into turbine impact force.

[0044] In a specific implementation, the basic model design is first carried out, namely the structure of guide wheel No. 0. The flow pattern of guide wheel No. 0 is as follows: Figure 4 As shown, its curved flow channel is U-shaped, and its unfolded diagram is centrally symmetrically designed, including an inlet section, a deflection section, and an outlet section. The flow channel cross-sections of the inlet section, deflection section, and outlet section generally show a trend of increasing area followed by decreasing area. The flow channel cross-sections of the inlet section and outlet section gradually increase along the flow direction. The flow channel cross-section of the deflection section generally shows a trend of increasing area followed by decreasing area, and both sides of the deflection section are arc-shaped.

[0045] The preliminary design of guide wheel 0 follows the steps outlined above, simplifying the structure, extracting the fluid domain, and meshing the data. The simulation model is then input, and basic parameters are set: the inlet boundary is a velocity boundary condition, for example, velocity v = 20 m / s, axial direction; the injected medium is water with a density of 998 kg / m³. 3 , viscosity 0.001Pa The first-stage turbine, first-stage guide wheel, and main shaft region are defined as no-slip wall boundaries, and the outlet boundary is a pressure boundary condition. The convergence iteration count diagram, torque iteration count diagram, and static and dynamic pressure contour maps of guide wheel 0 are obtained, as follows: Figure 6 , Figure 7 , Figure 8 and Figure 9 As shown, simulations were performed to verify the fluid and solid domains of the hydrocyclone. When the hydrocyclone's mass outlet reaches steady state, the calculated torque is 138 N. m. Analysis of the convergence iteration count, torque iteration curve, and static and dynamic pressure cloud diagrams shows that it meets the existing engineering design requirements.

[0046] Then, optimization design was carried out based on the controlled variable method. Subsequently, six types of guide wheels were designed, including guide wheel 1, guide wheel 2, guide wheel 3, guide wheel 4, guide wheel 5, and guide wheel 6. Figure 10As shown. Due to the structural complexity of the four-stage model, it is simplified to a single-stage turbine-guide wheel equivalent model. Transient flow field simulation is performed using ANSYS Fluent to obtain the torque of different guide wheels, the pressure drop at the inlet and outlet, and the pressure drop conversion rate.

[0047] S31: Numerical simulation of guide wheel No. 1: Based on the flow pattern of guide wheel No. 0, the flow pattern of guide wheel No. 1 reduces the cross-sectional area of ​​the inlet section, so that the fluid can smoothly transition through the intermediate turning section, reducing pressure drop loss; the cross-sectional area of ​​the outlet section is gradually expanded, the fluid velocity is increased, the kinetic energy is increased, and the next stage turbine is driven to rotate.

[0048] Based on the No. 1 guide wheel, a fluid domain and solid domain separation model was performed using unstructured mesh generation. Simulation verification was conducted using a Realizable k-ε turbulence model. Under the condition of an inlet flow velocity v = 20 m / s injected water, the ANSYS Fluent simulation model was used to obtain the convergence iteration number diagram, torque iteration number diagram, and static and dynamic pressure contour maps of the No. 1 guide wheel at the guide wheel, turbine, and main shaft. Figure 11 , 12 13, 14, and 15. The torque generated at the hydrocyclone mass outlet when it reaches steady state is 1936 N. m.

[0049] S32: Numerical simulation of guide wheel No. 2: The flow pattern of guide wheel No. 2 adopts a streamlined curved surface design. The flow channel cross-sections of the inlet section, the deflection section and the outlet section are generally arc-shaped. When the fluid flows over the surface, it achieves a smooth transition, effectively suppressing the generation of eddies, reducing the pressure drop to 11.34MPa and the drag coefficient to 18%.

[0050] Based on the No. 2 guide wheel, a fluid domain and solid domain separation model was performed using unstructured mesh generation. Simulation verification was conducted using a Realizable k-ε turbulence model. Under the condition of an inlet flow velocity v = 20 m / s injected water, the ANSYS Fluent simulation model was used to obtain the convergence iteration number diagram, torque iteration number diagram, and static and dynamic pressure contour maps of the No. 2 guide wheel at the guide wheel, turbine, and main shaft. Figure 15 , 16 17, 18, and 19. The torque generated at the hydrocyclone mass outlet when it reaches steady state is 992 N. m.

[0051] S33: Numerical simulation of guide impeller No. 3: The flow pattern of guide impeller No. 3 has a large inlet section cross-sectional area, and the cross-sectional area of ​​the flow channel deflection section gradually shrinks to 60% of the original cross-sectional area, which accelerates the fluid; the outlet section cross-sectional area recovers to 80% of the original cross-sectional area, and the flow velocity is slightly reduced to 22 m / s. Based on Bernoulli's principle, this design optimizes the kinetic energy gradient to convert the fluid dynamic pressure energy into turbine impact force, reducing the pressure drop by 18%-22% and increasing the turbine output torque.

[0052] Based on the No. 3 guide wheel, a fluid domain and solid domain separation model was performed using unstructured mesh generation. Simulation verification was conducted using a Realizable k-ε turbulence model. Under the condition of an inlet flow velocity v = 20 m / s injected water, the ANSYS Fluent simulation model was used to obtain the convergence iteration number diagram, torque iteration number diagram, and static and dynamic pressure contour maps of the No. 3 guide wheel at the guide wheel, turbine, and main shaft. Figure 21 , 22 23, 24, and 25. The torque generated when the hydrocyclone mass outlet reaches steady state is 131 N. m.

[0053] S34: Numerical simulation of guide wheel No. 4: The flow pattern of guide wheel No. 4 is based on the structural parameters of the flow patterns of guide wheels No. 0 and No. 1 (constant flow area). Geometric optimization is performed on the inlet section, and the radius of curvature of the inlet section is reduced by 2mm.

[0054] Based on the No. 4 guide wheel, a fluid domain and solid domain separation model was performed using unstructured mesh generation. Simulation verification was conducted using a Realizable k-ε turbulence model. Under the condition of an inlet flow velocity v = 20 m / s injected water, the ANSYS Fluent simulation model was used to obtain the convergence iteration number diagram, torque iteration number diagram, and static and dynamic pressure contour maps of the No. 4 guide wheel at the guide wheel, turbine, and main shaft. Figure 26 , 27 28, 29, and 30. The torque generated when the hydrocyclone mass outlet reaches steady state is 488 N. m.

[0055] S35: Numerical simulation of guide wheel No. 5: The flow pattern of guide wheel No. 5 adopts a double curvature flow channel design, with a curvature radius of 10mm at the inlet section and a curvature radius of 6mm at the outlet section, and the overall cross-sectional area of ​​the flow channel is constant.

[0056] Based on the No. 5 guide wheel, a fluid domain and solid domain separation model was performed using unstructured mesh generation. Simulation verification was conducted using a Realizable k-ε turbulence model. Under the condition of an inlet flow velocity v = 20 m / s injected water, the ANSYS Fluent simulation model was used to obtain the convergence iteration number diagram, torque iteration number diagram, and static and dynamic pressure contour maps of the No. 5 guide wheel at the guide wheel, turbine, and main shaft. Figure 31 , 32 33, 34, and 35. The torque generated at the hydrocyclone mass outlet when it reaches steady state is 4495 N. m.

[0057] S36: Numerical simulation of guide wheel No. 6: The flow pattern of the 6-guide wheel reduces the flow cross-sectional area and increases the tortuosity and contraction / expansion of the flow channel. The cross-section of the flow channel in the inlet section first increases and then gradually decreases along the flow direction, then increases again in the middle section, and the cross-section of the flow channel in the outlet section is circular. After being guided by the guide wheel, the flow generates impact force and pressure difference, increases velocity and impacts the turbine, drives the turbine to rotate, and the turbine drives the rotating shaft to rotate.

[0058] Based on the No. 6 guide wheel, a fluid domain and solid domain separation model was performed using an unstructured mesh. Simulation verification was conducted using a Realizable k-ε turbulence model. Under the condition of an inlet flow velocity v = 20 m / s injected water, the ANSYS Fluent simulation model was used to obtain the convergence iteration number diagram, torque iteration number diagram, and static and dynamic pressure contour maps of the No. 6 guide wheel at the guide wheel, turbine, and main shaft. Figure 36 , 37 38, 39, and 40. The torque generated at the hydrocyclone mass outlet when it reaches steady state is 776.3 N. m.

[0059] Using the controlled variable method, the flow area of ​​the fixed curved channel was determined. Based on the No. 0 guide wheel, six more guide wheels were designed, including key parameters such as cross-sectional area variation and curvature radius adjustment. Torque, pressure drop, and conversion rate were clearly recorded (e.g., the No. 1 guide wheel has a torque of 1936 Nm and a pressure drop conversion rate of 1.11%), and a quantifiable comparison table was established. Multiple schemes were quickly tested using simulation, shortening the R&D cycle.

[0060] S37: Based on the simulation results of steps S31-S36 above, obtain the torque, pressure drop and pressure drop conversion rate of guide wheel 1, guide wheel 2, guide wheel 3, guide wheel 4, guide wheel 5 and guide wheel 6, and generate a comparison table, as shown in Table 1 (Comparison Table of Torque and Pressure Drop of Different Guide Wheels).

[0061]

[0062] Table 1 S4: Based on the comparison table (Table 1), the numerical simulation results of the torque of various guide wheels, pressure drop at the inlet and outlet, and pressure drop conversion rate are analyzed according to the comprehensive index evaluation criteria to obtain the optimal flow channel pattern.

[0063] The comprehensive evaluation criteria use torque, pressure drop, and pressure drop conversion rate as indicators to construct an evaluation system. Torque: Reflects energy conversion efficiency; the higher the value, the better. Pressure drop conversion rate: The lower the rate, the less energy is wasted; Pressure drop: The pressure-bearing capacity of the equipment and energy consumption must be taken into account.

[0064] The comparison table shows that guide wheel #3 has the highest manifold pressure drop conversion rate (1.36%), while guide wheel #0 has the lowest (1.61 MPa). Guide wheels #0, #1, #2, and #5 have similar pressure drop conversion rates (1.11%-1.20%). Guide wheel #1 achieves the best balance among the three: its torque is significantly higher than similar guide wheels (except for guide wheel #5), and its pressure drop conversion rate is the lowest (1.11%). A comprehensive evaluation was conducted using torque, pressure drop at the inlet and outlet, and pressure drop conversion rate as indicators. Under the same water discharge conditions, pressure drop conversion rate is the core selection criterion. Guide wheel #1, with a conversion rate of 1.11%, is the optimal solution, while its high torque output ensures lifting efficiency. Although guide wheel #5 has extremely high torque, its excessive pressure drop limits its practical application.

[0065] By combining three indicators—torque, pressure drop, and conversion rate (e.g., the No. 1 guide impeller configuration has the highest torque and the lowest conversion rate)—the limitations of relying on a single indicator are avoided. The flow pattern is flexibly selected based on reservoir conditions (e.g., the No. 5 guide impeller configuration is chosen for high-viscosity reservoirs) to enhance practical application value. The effectiveness of simulation-driven optimization is demonstrated (e.g., the No. 1 flow pattern is proven to be optimal through the above process), thereby strengthening the credibility of the technology.

[0066] Traditional hydrocyclones suffer from 30%-45% ineffective pressure drop losses due to insufficient matching between channel geometry parameters and multiphase flow fields. This optimization method addresses this by designing multiple guide wheels (e.g., 0 to 6) to optimize channel cross-sectional area changes, curvature radius adjustments, and multi-stage contraction and expansion structures, resulting in smoother fluid flow and a significant improvement in pressure drop conversion rate. For example, the smooth transition design of guide wheel 1 reduces pressure drop losses by 15%-20%, effectively minimizing energy waste.

[0067] This hydrocyclone optimizes the flow channel geometry of the guide wheel, controlling the pressure drop conversion rate between 1.11% and 1.36%. For example, the No. 1 guide wheel achieves the lowest pressure drop conversion rate (1.11%), with a pressure drop of only 21.63 MPa, reducing ineffective energy consumption by approximately 80% compared to traditional methods. By reducing ineffective pressure drop losses and improving energy conversion efficiency, the optimized hydrocyclone structure addresses adaptability issues under complex reservoir conditions, laying the foundation for large-scale deployment. Even in reservoir environments with frequently changing multiphase flow regimes, this hydrocyclone maintains stable lifting performance. This hydrocyclone reduces system energy consumption by more than 30%. Taking the No. 1 guide wheel as an example, its unit energy output is approximately 40% higher than traditional methods, aligning with the trend of green and low-carbon energy development.

[0068] The optimization measures and results for the flow patterns of each guide wheel are as follows: The flow pattern of guide wheel No. 1: By reducing the cross-sectional area of ​​the inlet channel and ensuring a smooth transition, combined with the gradual expansion of the cross-sectional area of ​​the outlet channel, the pressure drop loss is reduced by 15%-20%. Simulation results show that its torque reaches 1936N. With a pressure drop conversion rate of only 1.11%, it becomes the flow pattern with the best overall performance.

[0069] The flow channel design of guide wheel No. 2: A streamlined curved surface design suppresses vortex generation, reducing pressure drop to 11.34 MPa (drag coefficient reduced by 18%), but resulting in lower torque (992 N). It is suitable for scenarios that are sensitive to voltage drop.

[0070] The flow pattern of the No. 3 guide impeller: Based on the kinetic energy gradient optimization theory, the design efficiently converts dynamic pressure energy into turbine impact force by gradually reducing the inlet section cross-sectional area to 60% of its original size and restoring it to 80% at the outlet section. Although it has the highest pressure drop conversion rate (1.36%), its torque is only 131 N. It is more suitable for high-flow-rate, low-viscosity reservoirs.

[0071] The flow pattern of the No. 4 guide wheel: the inlet section curvature radius was optimized (reduced by 2mm), and the torque was increased to 488N. However, the pressure drop (5.95 MPa) and conversion rate (1.21%) are both at a moderate level.

[0072] The flow pattern of guide wheel No. 5: The double-curvature flow channel design (10mm inlet radius, 6mm outlet radius) increases the torque to 4495N. However, the pressure drop is as high as 51.27 MPa, making it suitable for high-viscosity crude oil extraction.

[0073] The flow pattern of guide wheel #6: The impact force is increased through a tortuous flow channel, with a torque of 776.3 N. The pressure drop conversion rate is 1.20%, but the pressure drop (9.30 MPa) is higher than that of the No. 1 guide wheel.

[0074] Torque tests on different guide rollers showed that guide roller #5 had a torque of 4495 N. The guide wheel's performance, far exceeding that of other flow channel patterns, indicates that it achieves more efficient kinetic energy conversion through its double-curvature flow channel design. Although the pressure drop of guide wheel No. 5 is relatively high (51.27 MPa), its high torque characteristics make it suitable for high-viscosity reservoir scenarios.

[0075] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. The scope of patent protection of the present invention shall be determined by the claims. Similarly, any equivalent structural changes made based on the description and drawings of the present invention shall also be included within the scope of protection of the present invention.

Claims

1. A novel hydrocyclone, comprising a connecting cylinder (1) and a guide wheel outer cylinder (2), wherein a guide wheel (3) and a turbine (4) are coaxially arranged inside the guide wheel outer cylinder (2), and a main shaft (5) is coaxially fixedly connected to the middle part of the turbine (4), wherein the guide wheel (3) is composed of an inner ring (7) and an outer ring (8), wherein the outer side of the outer ring (8) is fixedly connected to the guide wheel outer cylinder (2), and the inner ring (7) is fixedly connected to the inside of the outer ring (8), characterized in that: The outer ring (8) has multiple curved flow channels (9) evenly distributed on its outer ring. The length of the curved flow channel (9) in the axial direction is greater than the length of the inner ring (7) in the axial direction. The curved flow channel (9) is U-shaped and penetrates the outer ring (8) and is opened on the surface of the inner ring (7).

2. The novel hydrocyclone according to claim 1, characterized in that: The width of the outer ring (8) is greater than the width of the inner ring (7), and the thickness of the outer ring (8) is less than the width of the inner ring (7).

3. The novel hydrocyclone according to claim 1, characterized in that: The curved flow channel (9) is U-shaped in general, including an inlet section, a deflection section and an outlet section. The cross-sections of the inlet section, deflection section and outlet section show a trend of increasing area and then decreasing area. The maximum cross-section of the inlet section is smaller than the maximum cross-section of the outlet section.

4. A novel hydrocyclone according to claim 3, characterized in that: The cross-sections of the inlet and outlet sections gradually increase along the flow direction.

5. A novel hydrocyclone according to claim 3 or 4, characterized in that: The inlet section includes a first arc-shaped end and a first expansion section. The outer side of the first expansion section includes a first side and a second side. The angle between the second side and the inner side of the first expansion section is smaller than the angle between the first side and the inner side of the first expansion section.

6. A novel hydrocyclone according to claim 3 or 4, characterized in that: The outlet section includes a second expansion section and a second arc-shaped end.

7. A novel hydrocyclone according to claim 3, characterized in that: The cross-section of the flow channel of the deflection section generally shows a trend of increasing area and then decreasing again, and both sides of the deflection section are arc-shaped.

8. A novel method for optimizing the structure of a hydrocyclone, characterized in that, Includes the following steps: Design various flow patterns for the guide wheel; Based on a comprehensive evaluation of the torque and pressure drop at the inlet and outlet of each flow channel, the selected flow channel pattern is determined.

9. The structural optimization method for a novel hydrocyclone according to claim 8, characterized in that: The torque of each flow channel and the pressure drop generated at the inlet and outlet are obtained through simulation calculation.

10. The structural optimization method for a novel hydrocyclone according to claim 8, characterized in that: The design method for the flow channel is the controlled variable method. First, the flow area of ​​the channel is determined to be equal. The preliminary design is carried out by changing the cross-sectional area of ​​the channel, adjusting the radius of curvature, and using a multi-stage contraction and expansion structure. Then, the kinetic energy is converted into turbine impact force through Bernoulli's principle and kinetic energy gradient optimization to complete the final design.

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