A separator that reduces gas flow erosion and corrosion from flowback

Abstract

The utility model discloses a kind of separators reducing airflow scouring and flowback fluid corrosion, it is related to shale gas impurity removal equipment technical field.The utility model includes separator body, the separator side wall is equipped with air inlet pipe, top is equipped with air outlet pipe, bottom is equipped with blowdown pipe, air inlet pipe, air outlet pipe and body inner wall are equipped with ceramic lining.Energy dissipation layer is arranged in separator body, energy dissipation layer is formed by the accumulation of several smooth-surface gallium nitride porcelain balls, air inlet pipe end is located in energy dissipation layer.Energy dissipation layer upper is equipped with ceramic buffer layer, ceramic buffer layer upper is provided with the mist catching net for capturing the water mist carried by flowback fluid, liquid level meter is connected outside between ceramic buffer layer and mist catching net, liquid level meter is communicated with the space below energy dissipation layer, forming a communicating vessel structure.The utility model can effectively slow down airflow scouring, reduce liquid corrosion to equipment, improve gas-liquid-solid separation efficiency and the safety and reliability of separator operation.

Description

Technical Field

[0001] This utility model relates to the technical field of shale gas impurity removal equipment, specifically to a separator that reduces airflow erosion and backflow fluid corrosion. Background Technology

[0002] Shale gas, as an unconventional natural gas resource, differs significantly from conventional natural gas in its development and production process. Due to the unique geological characteristics of shale gas reservoirs, gas wells often carry high-flow-rate flowback fluid and large amounts of cementing sand during the initial development stages. If these impurities are not effectively separated, they can cause severe erosion and corrosion to downstream equipment such as gathering and transmission pipelines and separators, leading to frequent equipment failures and increasing operational risks.

[0003] To meet the demands of rolling development and low-cost large-scale development of shale gas fields, surface gathering and transportation processes typically employ skid-mounted and modular designs to enable rapid equipment installation and reuse. However, in existing technologies, the erosion resistance and corrosion resistance of domestically produced materials are generally insufficient, resulting in a high failure rate for skid-mounted desanders under high flow rates and strong backflow conditions. The compact layout of the equipment also leads to frequent overlapping operations on-site, further increasing safety hazards.

[0004] Most common natural gas desanding devices currently available employ a series installation of desanders after the primary needle valve of the gas well. These devices separate sand-laden particles through internal filters, ceramic rings, or packing support layers. However, these devices primarily rely on mechanical filtration and a single ceramic component for pressure buffering. The high-pressure airflow entering the device often concentrates its impact on a single area, easily causing erosion damage. Furthermore, liquid and sand particles are often mixed, and traditional filter layers struggle to simultaneously address both liquid backflow corrosion and sand erosion, resulting in insufficient desanding efficiency and device lifespan.

[0005] Chinese patent document CN210117361U, published on February 28, 2020, discloses a high-efficiency high-pressure packed natural gas desander, including a desander cylinder. A desander inlet is located at the bottom of one side of the cylinder, and a desander outlet is located at the top of one side. Inside the cylinder, from top to bottom, are fixed a head, a primary filter screen, a secondary filter screen, a high-pressure resistant ceramic ring, and a packing support mesh. Support legs are fixedly connected to the four corners of the bottom of the cylinder, and a discharge pipe is fixedly connected to the middle of the bottom. While this desander can achieve solid-liquid separation in natural gas to a certain extent, it still has the following shortcomings: 1. Limited erosion resistance: This design only uses high-pressure resistant ceramic rings in certain areas, and areas subjected to concentrated airflow impact are still prone to erosion damage, making it unsuitable for the high-pressure, high-speed operating conditions of shale gas wells; 2. Insufficient corrosion resistance: Acidic components in the flowback fluid can still cause equipment corrosion; 3. Inability to monitor the accumulation of flowback fluid. Summary of the Invention

[0006] To overcome the defects and shortcomings of the existing technology, this invention provides a separator that reduces gas flow erosion and backflow fluid corrosion. This invention enables efficient separation of sand particles and liquids in high-pressure gas flows from gas wells, reducing equipment failure rates. This utility model is achieved through the following technical solution: A separator for reducing airflow erosion and backflow liquid corrosion includes a separator body. An air inlet pipe is connected to the side wall of the separator body, an air outlet pipe is located at the top, and a drain pipe is connected to the bottom. The air inlet pipe, air outlet pipe, and the inner wall of the separator body are all lined with ceramic. An energy dissipation layer is disposed within the separator body. The energy dissipation layer is formed by stacking several gallium nitride ceramic balls with smooth outer surfaces. One end of the air inlet pipe is located within the energy dissipation layer. Above the energy dissipation layer is a ceramic buffer layer for guiding the airflow to rise evenly and separating sand particles from the backflow liquid. A level gauge is disposed above the ceramic buffer layer. A mist trapping net is disposed above the ceramic buffer layer for capturing water mist carried by the backflow liquid. A level gauge is externally connected between the ceramic buffer layer and the mist trapping net. The level gauge communicates with the space below the energy dissipation layer to form a communicating vessel structure.

[0007] The energy dissipation layer is formed by stacking a first gallium nitride ceramic ball and a second gallium nitride ceramic ball in a hierarchical manner. The first gallium nitride ceramic ball is located near the intake pipe, while the second gallium nitride ceramic ball is located away from the intake pipe. The diameter of the first gallium nitride ceramic ball is larger than that of the second gallium nitride ceramic ball.

[0008] The fog-catching net has a double-layer structure, with the mesh size of the upper fog-catching net being finer than that of the lower fog-catching net.

[0009] The level gauge is connected to the separator body via a level gauge mounting flange, with one end located between the ceramic buffer layer and the mist eliminator, and the other end located between the energy dissipation layer and the bottom of the separator body.

[0010] The separator body has a split structure, with the upper and lower half of the separator connected by a flange and a steel ring seal at the flange connection.

[0011] The connection between the upper and lower separators is located between the energy dissipation layer and the ceramic buffer layer.

[0012] The air outlet pipe is connected to the center of the top of the separator body, and the sewage pipe is connected to the center of the bottom of the separator body.

[0013] The ceramic buffer layer is connected to the separator body via a detachable slot.

[0014] The fog-catching net is connected to the separator body via a detachable slot.

[0015] The gallium nitride ceramic ball is fixed by a detachable limiting mesh or support frame.

[0016] Compared with the prior art, the beneficial technical effects of this utility model are as follows: 1. This utility model effectively improves the device's resistance to backflow liquid corrosion and extends its service life by installing ceramic liners on the inner wall and inlet / outlet of the container. Furthermore, the stacked arrangement of smooth gallium nitride ceramic spheres, which bury the air inlet, disperses the impact of high-pressure airflow, significantly reducing the probability of localized equipment failure due to high-pressure erosion. The ceramic buffer layer further evens the distribution of airflow and sand / liquid, allowing for more thorough sand sedimentation and liquid separation. The level gauge and communicating vessel structure enable real-time monitoring of liquid accumulation, and combined with the drain pipe, rapid liquid discharge is achieved. The mist trap effectively collects small droplets, preventing liquid from entering downstream equipment with the gas, thereby improving the overall efficiency of sand and liquid removal.

[0017] 2. In this utility model, the energy dissipation layer adopts a graded stacking structure. When the airflow first enters, it is first dispersed by large spheres to reduce the instantaneous impact force, and then the flow field is refined by small spheres to improve the uniformity of airflow. This avoids the problem of flow deviation or dead zone that is easy to form by a single sphere diameter, improves the separation efficiency, and at the same time reduces the scouring load of the airflow on the subsequent buffer layer.

[0018] 3. In this utility model, the mist-catching net is arranged in upper and lower levels. First, the lower coarse net captures large droplets, and then the upper fine net captures small droplets, forming a step-by-step filtration. This avoids the risk of premature clogging of a single-layer fine net, extends the service life of the mist-catching net, improves the thoroughness of water mist separation in the gas, and ensures that the outlet gas is dry and pure.

[0019] 4. In this utility model, the level gauge is sealed to the separator body through a mounting flange, and its two ends are respectively arranged in adjacent positions of the ceramic buffer layer and the energy dissipation layer. It can accurately reflect the liquid level height of the deposited liquid, avoid liquid level errors, and facilitate timely sewage discharge by operators.

[0020] 5. In this utility model, the separator body adopts an upper and lower split structure and is connected by a flange and steel ring for sealing, which not only ensures the overall sealing and pressure resistance performance, but also facilitates the disassembly, maintenance and replacement of internal components of the equipment.

[0021] 6. In this utility model, the connection is located between the energy dissipation layer and the ceramic buffer layer, which avoids the connection part from being directly subjected to the intake air impact, reduces the wear and leakage risk of the connection part, and improves the sealing reliability.

[0022] 7. In this invention, the ceramic buffer layer and the mist-catching net are installed via detachable slots, facilitating disassembly, cleaning, or replacement after long-term operation, reducing maintenance costs and maintaining good performance. The gallium nitride ceramic balls are fixed by a detachable mesh or support frame, preventing displacement due to long-term operation, while also facilitating periodic replacement or repacking, improving structural stability and maintenance convenience. Attached Figure Description

[0023] Figure 1 This is a cross-sectional view of the structure of this utility model.

[0024] Marked in the image: 1. Separator body; 2. Inlet pipe; 3. Outlet pipe; 4. Drain pipe; 5. Energy dissipation layer; 6. Gallium nitride ceramic ball; 7. Ceramic buffer layer; 8. Mist eliminator; 9. Level gauge mounting flange; 10. Upper separator; 11. Lower separator; 12. Level gauge. Detailed Implementation

[0025] The technical solution of this utility model will be clearly and completely described below with reference to specific embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0026] Example 1 As the most basic embodiment of this utility model, this embodiment provides a separator that reduces airflow scouring and backflow liquid corrosion, including a separator body 1. The side wall of the separator body 1 is connected to an air inlet pipe 2, the top is provided with an air outlet pipe 3, and the bottom is connected to a drain pipe 4. The air inlet pipe 2, the air outlet pipe 3, and the inner wall of the separator body 1 are all provided with ceramic liners. An energy dissipation layer 5 is provided inside the separator body 1. The energy dissipation layer 5 is formed by stacking several gallium nitride ceramic balls 6 with smooth outer surfaces. One end of the air inlet pipe 2 is located inside the energy dissipation layer 5. A ceramic buffer layer 7 is provided above the energy dissipation layer 5 to guide the airflow to rise evenly and separate sand particles and backflow liquid. A mist trapping net 8 is provided above the ceramic buffer layer 7 to capture water mist carried by the backflow liquid. A liquid level gauge 12 is externally connected between the ceramic buffer layer 7 and the mist trapping net 8. The liquid level gauge 12 is connected to the space below the energy dissipation layer 5 to form a communicating vessel structure.

[0027] In this embodiment, by setting an energy dissipation layer 5 composed of gallium nitride ceramic balls 6 inside the separator, and using it in conjunction with a ceramic buffer layer 7, a level gauge 12, and a mist eliminator 8, multi-stage processing of high-pressure shale gas is achieved. When the airflow enters the energy dissipation layer 5, it is dispersed and slowed down, reducing the impact on the separator body 1; the ceramic buffer layer 7 ensures the airflow rises evenly and promotes the sedimentation and separation of sand particles and backflow liquid; the level gauge 12 and the space below the energy dissipation layer 5 form a communicating vessel structure, enabling direct monitoring of the liquid level and ensuring operational safety; the mist eliminator 8 effectively removes water mist entrained in the airflow, making the separated gas purer. Overall, this achieves the effects of reducing airflow erosion and backflow liquid corrosion, improving separation efficiency, and extending equipment lifespan. Example 2 As a preferred embodiment of the present invention, this embodiment is a further detailed supplement and explanation of the technical solution of the present invention based on the above embodiment 1. In this embodiment, the energy dissipation layer 5 is formed by stacking a first gallium nitride ceramic ball and a second gallium nitride ceramic ball in stages. The first gallium nitride ceramic ball is located near the intake pipe 2, and the second gallium nitride ceramic ball is located away from the intake pipe 2. The diameter of the first gallium nitride ceramic ball is larger than that of the second gallium nitride ceramic ball.

[0028] In this embodiment, a graded stacking structure of gallium nitride ceramic balls is used in the energy dissipation layer 5. Larger balls are arranged near the air inlet to reduce the impact of high-pressure airflow, while smaller balls are arranged further away from the air inlet to further refine the flow field, thus gradually slowing down and homogenizing the airflow. This structure avoids the problems of flow deviation and dead zones that are easily caused by single-diameter balls, improves the separation efficiency of gas and solid phases, further enhances the removal capacity of backflow liquid and sand particles, and reduces the scouring burden of airflow on the buffer layer and the mist eliminator 8.

[0029] Example 3 As another preferred embodiment of the present invention, this embodiment is a further detailed supplement and explanation of the technical solution of the present invention based on the above embodiment 2. In this embodiment, the mist-catching net 8 has a double-layer structure, and the mesh of the upper mist-catching net is finer than that of the lower mist-catching net; the liquid level gauge 12 is connected to the separator body 1 through the liquid level gauge mounting flange 9, with one end located between the ceramic buffer layer 7 and the mist-catching net 8, and the other end located between the energy dissipation layer 5 and the bottom of the separator body 1.

[0030] Example 4 As the preferred embodiment of this utility model, this embodiment provides a separator that reduces airflow erosion and backflow liquid corrosion, including a separator body 1. An air inlet pipe 2 is connected to the side wall of the separator body 1, an air outlet pipe 3 is provided at the top, and a drain pipe 4 is connected to the bottom. The air inlet pipe 2, the air outlet pipe 3, and the inner wall of the separator body 1 are all lined with ceramic to improve overall erosion and corrosion resistance. An energy dissipation layer 5 is provided inside the separator body 1. The energy dissipation layer 5 is formed by stacking several gallium nitride ceramic balls 6 with smooth outer surfaces. One end of the air inlet pipe 2 is located inside the energy dissipation layer 5. Above the energy dissipation layer 5, a ceramic buffer layer 7 is provided to guide the airflow to rise evenly and separate sand particles and backflow liquid. The ceramic buffer layer 7 is installed on the inner wall of the separator body 1 via a detachable slot. The main function of the ceramic buffer layer 7 is... The airflow is guided to rise evenly, while further separating the sand particles from the return liquid, avoiding local airflow impact. A mist-catching net 8 is installed above the ceramic buffer layer 7 to capture the water mist carried by the return liquid. A level gauge 12 is externally connected between the ceramic buffer layer 7 and the mist-catching net 8. The level gauge 12 is connected to the space below the energy dissipation layer 5 to form a communicating vessel structure. The level gauge is reliably and sealed to the separator body 1 through the level gauge mounting flange 9. Its lower end is connected to the liquid deposition space between the energy dissipation layer 5 and the bottom of the separator body 1, forming a communicating vessel structure, so as to accurately display the liquid level height of the deposited liquid in real time. The upper end of the level gauge 12 is located between the ceramic buffer layer 7 and the mist-catching net 8, which is convenient for operators to observe and maintain. The mist-catching net 8 is also installed and connected to the separator body 1 through a detachable slot for later cleaning or replacement.

[0031] Furthermore, the energy dissipation layer 5 is formed by stacking a first gallium nitride ceramic ball and a second gallium nitride ceramic ball in a hierarchical manner. The first gallium nitride ceramic ball is located near the intake pipe 2, while the second gallium nitride ceramic ball is located away from the intake pipe 2. The diameter of the first gallium nitride ceramic ball is larger than that of the second gallium nitride ceramic ball. By stacking large and small balls together, the high-speed airflow can be dispersed by the large balls first, and then the flow field can be further refined by the small balls to improve the energy dissipation and solid-liquid separation efficiency.

[0032] The fog-catching net 8 has a double-layer structure, with the mesh size of the upper fog-catching net being finer than that of the lower fog-catching net.

[0033] The separator body 1 has a split structure, with the upper half separator 10 and the lower half separator 11 connected by flanges. The flanges are welded to the corresponding upper half separator 10 and lower half separator 11, and a steel ring seal is provided at the flange connection to ensure sealing and durability under high pressure conditions. Simultaneously, this connection is designed between the energy dissipation layer 5 and the ceramic buffer layer 7, preventing the flange connection from being directly eroded by high-speed airflow or high-concentration slurry.

[0034] The air outlet pipe 3 is connected to the center of the top of the separator body 1, and the sewage pipe 4 is connected to the center of the bottom of the separator body 1.

[0035] The gallium nitride ceramic ball 6 is fixed by a detachable limiting mesh or support frame.

[0036] The principle of this embodiment is as follows: By sequentially setting an energy dissipation layer 5, a ceramic buffer layer 7, a level gauge 12, and a mist eliminator 8 inside the separator, a multi-stage separation and protection structure is formed. After the high-pressure sand- and liquid-containing airflow enters through the inlet pipe 2, it first enters the energy dissipation layer 5. When the airflow passes through the smooth gallium nitride ceramic ball stack, it undergoes multiple collisions, and its kinetic energy is significantly consumed, dispersing the high-pressure airflow. Solid particles and liquid droplets partially settle to the bottom under the action of gravity. Subsequently, the homogenized airflow enters the ceramic buffer layer 7, where it is further diverted and slowed down, achieving secondary separation of sand particles and return liquid. During this process, the level gauge 12 reflects the liquid level of the lower deposited liquid in real time through the communicating vessel structure, facilitating the control of sewage discharge. When the airflow rises to the top, it passes through the double-layer filtration of the mist eliminator 8, effectively capturing residual water mist in the airflow and ensuring that the gas discharged from the outlet pipe 3 is basically dry.

[0037] In this embodiment, through multi-stage separation and protection measures, the separation achieves optimal performance in reducing airflow erosion, improving corrosion resistance, enhancing sand-liquid separation, and demisting, effectively ensuring the long-term stable operation of the separator.

Claims

1. A separator for reducing airflow erosion and backflow fluid corrosion, comprising a separator body (1), characterized in that: The separator body (1) has an air inlet pipe (2) connected to its side wall, an air outlet pipe (3) at its top, and a sewage pipe (4) at its bottom. The air inlet pipe (2), the air outlet pipe (3), and the inner wall of the separator body (1) are all lined with ceramic. An energy dissipation layer (5) is provided inside the separator body (1). The energy dissipation layer (5) is formed by stacking several gallium nitride ceramic balls (6) with smooth outer surfaces. One end of the air inlet pipe (2) is located inside the energy dissipation layer (5). A ceramic buffer layer (7) is provided above the energy dissipation layer (5) to guide the airflow to rise evenly and separate sand particles from the return liquid. A mist trapping net (8) is provided above the ceramic buffer layer (7) to capture the water mist carried by the return liquid. A liquid level gauge (12) is connected between the ceramic buffer layer (7) and the mist trapping net (8). The liquid level gauge (12) is connected to the space below the energy dissipation layer (5) to form a communicating vessel structure.

2. The separator for reducing airflow erosion and backflow fluid corrosion according to claim 1, characterized in that: The energy dissipation layer (5) is formed by stacking a first gallium nitride ceramic ball and a second gallium nitride ceramic ball in stages. The first gallium nitride ceramic ball is located near the intake pipe (2), and the second gallium nitride ceramic ball is located away from the intake pipe (2). The diameter of the first gallium nitride ceramic ball is larger than that of the second gallium nitride ceramic ball.

3. The separator for reducing airflow erosion and backflow fluid corrosion according to claim 2, characterized in that: The fog-catching net (8) has a double-layer structure, with the mesh size of the upper fog-catching net being finer than that of the lower fog-catching net.

4. The separator for reducing airflow erosion and backflow fluid corrosion according to claim 3, characterized in that: The level gauge (12) is connected to the separator body (1) via the level gauge mounting flange (9), with one end located between the ceramic buffer layer (7) and the mist trap (8), and the other end located between the energy dissipation layer (5) and the bottom of the separator body (1).

5. A separator for reducing airflow erosion and backflow fluid corrosion according to claim 4, characterized in that: The separator body (1) is a split structure, with the upper half separator (10) and the lower half separator (11) connected by a flange, and a steel ring seal is provided at the flange connection.

6. The separator for reducing airflow erosion and backflow fluid corrosion according to claim 5, characterized in that: The connection between the upper half separator (10) and the lower half separator (11) is located between the energy dissipation layer (5) and the ceramic buffer layer (7).

7. A separator for reducing airflow erosion and backflow fluid corrosion according to claim 1, characterized in that: The air outlet pipe (3) is connected to the top center of the separator body (1), and the sewage pipe (4) is connected to the bottom center of the separator body (1).

8. A separator for reducing airflow erosion and backflow fluid corrosion according to claim 1, characterized in that: The ceramic buffer layer (7) is connected to the separator body (1) via a detachable slot.

9. A separator for reducing airflow erosion and backflow fluid corrosion according to claim 1, characterized in that: The fog-catching net (8) is connected to the separator body (1) via a detachable slot.

10. A separator for reducing airflow erosion and backflow fluid corrosion according to claim 1, characterized in that: The gallium nitride ceramic ball (6) is fixed by a detachable limiting mesh or support frame.

Images