Bubble Size Feedback Control for Oil-Water Separation
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Solution Overview
Problem
Existing oil-water separators face challenges in maintaining efficient separation of phases, particularly when produced water inflows fluctuate, leading to reduced efficiency due to varying bubble sizes that fall outside an optimal range.
Innovation Solution
A system with a dynamic mixer and bubble control system that monitors and adjusts bubble sizes within a desired range using a controller, camera module, and adjustable valves to maintain optimal separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional oil-water separator is used without bubble size control, then the device complexity is low, but the separation efficiency decreases when produced water inflows fluctuate
Solution Approach 1:
The patent implements a dynamic mixer that can adjust its mixing intensity and a bubble control system that modifies bubble size in real-time based on inflow conditions. This dynamic adjustment capability allows the separator to maintain optimal separation efficiency across varying produced water inflows, directly resolving the contradiction between maintaining high productivity and avoiding excessive device complexity.
Solution Approach 2:
The patent changes physical parameters of the flotation process by controlling bubble size within a specific range (0.5-5 mm diameter) and adjusting mixing intensity. By dynamically modifying these parameters in response to inflow fluctuations, the system maintains separation efficiency without requiring a completely redesigned complex system.
2Productivity
If bubble size is not controlled within optimal range, then the operation is simple, but the separation efficiency decreases
Solution Approach 1:
The patent incorporates a feedback control system that monitors bubble size and adjusts mixing intensity accordingly. The controller receives information about bubble diameter and automatically modifies operating parameters to keep bubbles within the optimal 0.5-5 mm range, maintaining high separation efficiency while automating the operation to preserve ease of use.
Solution Approach 2:
The bubble control system operates autonomously by self-adjusting mixing intensity based on real-time bubble size measurements. This self-service capability maintains optimal separation conditions without requiring constant manual intervention, thus preserving ease of operation while ensuring high productivity.
3Productivity
If mixing intensity is increased to maintain small bubble sizes, then separation efficiency improves, but energy consumption increases
Solution Approach 1:
The patent uses dynamic adjustment of mixing intensity that matches actual process needs. Rather than continuously operating at high intensity, the mixer adapts its power consumption to maintain bubbles within the optimal size range, reducing energy waste while preserving separation efficiency. The controller modulates power based on real-time conditions.
Solution Approach 2:
The patent optimizes the relationship between mixing intensity and bubble size by identifying and maintaining bubbles within the 0.5-5 mm diameter range. This parameter optimization ensures that sufficient mixing energy is applied to create effective bubbles without excessive energy consumption, achieving efficient separation at moderate energy costs.
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
Enhances the percentage of oil separation from water by maintaining bubble sizes within a threshold, improving the efficiency of oil-water separation processes.
Implementation Method 1
The mixing system serves to mix the multiphase fluid flowing from the downstream end of the first conduit with flotation gas from the flotation gas source so as to produce at the outlet an enhanced multiphase fluid having bubbles of the flotation gas therein
Implementation Method 2
A bubble control system is associated with the second conduit and serves to perform a measurement associated with a size of the bubbles of the flotation gas in the enhanced multiphase fluid
Implementation Method 3
The water phase coming from the separation at the well-head or subsequent separators may be discharged into the sea after a cleansing that involves the partial removal of gas, oil, chemicals and other impurities
Implementation Method 4
a combined degassing and flotation tank, which is particularly suited for use in separation processes where a water phase containing oil and gas are separated
Data Source
AI summary
Disclosed herein is a device and methods for enhancing oil separation from produced water. One such method includes mixing a multiphase fluid having at least a water phase and an oil phase with a flotation gas, according to at least one operating condition, so as to produce an enhanced multiphase fluid having bubbles of the flotation gas therein. The oil phase is then separated from the water phase using a separator. At least one property associated with the enhanced multiphase fluid is monitored. The operating condition is adjusted as a function of the monitored property so as to increase a percentage of the oil phase separated from the water phase by the separator over a percentage of the oil phase that would be separated from the water phase without adjustment of the operating condition.