Biased Inlet Phase Separation for Stratified Well Fluids
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Solution Overview
Problem
Existing methods for downhole separation of oil and water phases in hydrocarbon production are complex and costly, with uncertainties related to water re-injection quality, as they rely on re-injection systems that can be prone to plugging due to oil contamination.
Innovation Solution
A system and method for downhole separation of fluid phases using a biased inlet device within a well or riser, which captures stratified fluid phases through flexible tubing, eliminating the need for water re-injection by utilizing gravity and jet pumps to separate oil and water phases before they reach turbulent flow regimes, thereby simplifying subsequent processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch processing is used for polyurethane synthesis, then product quality can be maintained, but production efficiency is low and labor costs are high
Solution Approach 1:
The patent replaces manual batch processing operations with an automated continuous flow system where reactants are pumped through a microchannel reactor. The continuous flow system eliminates the need for manual mixing, heating, and transfer operations, achieving both high productivity and controlled manufacturing through automation and standardized reactor design.
Solution Approach 2:
The patent changes the processing mode from batch to continuous flow, and utilizes microchannel geometry with specific surface-area-to-volume ratios to achieve rapid heat and mass transfer. The system operates at controlled flow rates and temperatures that optimize reaction efficiency while maintaining product quality, demonstrating parameter optimization for continuous manufacturing.
2Loss of energy
If conventional heating methods are used for phase separation, then energy consumption is high, but phase separation efficiency may be insufficient
Solution Approach 1:
The patent utilizes the phase transition phenomenon where the polymer precipitates from the reaction medium as it forms. The microchannel reactor design promotes rapid phase separation through controlled cooling and solvent removal, allowing the polymer to separate into distinct phases without requiring excessive external heating, thus reducing energy consumption while maintaining separation efficiency.
Solution Approach 2:
The patent extracts the phase separation function from a separate heating step and integrates it into the continuous flow reaction process itself. The microchannel structure enables inherent heat and mass transfer that promotes phase separation during flow, eliminating the need for additional energy-intensive heating steps while achieving reliable phase separation.
3Power
If high surface-area-to-volume ratio microchannels are used, then heat and mass transfer efficiency increases, but channel clogging becomes a risk
Solution Approach 1:
The patent employs dynamic flow conditions in the microchannel reactor, where reactants are continuously pumped at controlled rates. The flowing system prevents stagnation and reduces the risk of clogging by maintaining constant motion of the reaction mixture. The system can adjust flow rates to optimize heat and mass transfer while preventing particle accumulation that could cause clogging.
Solution Approach 2:
The patent designs the microchannel reactor with specific geometric features that create localized flow patterns and shear zones. These local variations in flow dynamics prevent particle deposition on channel walls while maintaining high surface-area-to-volume ratios for efficient heat and mass transfer. The channel geometry is optimized to balance transfer efficiency with clogging prevention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for efficient and cost-effective separation of oil and water phases at the wellhead, reducing the risk of emulsions and simplifying topside processing by leveraging natural stratification under low fluid velocity conditions, thus avoiding the complexities and costs associated with mixed flow regime separations.
Implementation Method 1
In-line phase separation
Implementation Method 2
The microchannel plate 14 provides a large surface area for heat and mass transfer
Implementation Method 3
The porous support 18 may be formed from sintered metal, sintered ceramic, woven or nonwoven mesh, or the like
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A method of separating fluid phases in a well or riser. The method comprises: locating an inlet device of a flexible tubing at a substantially horizontal portion of the well or riser, wherein a portion of the flexible tubing extends into the well or riser and the flexible tubing terminates at the inlet device; biasing the inlet device against a wall of the well or riser; and extracting a stratified fluid phase from the well or riser through the inlet device and flexible tubing, wherein a shape of the inlet device is configured to match a shape of the wall.