Centrifugal Cylinder Solid Debris Separator for Hydraulic Fracturing
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Solution Overview
Problem
Hydraulic fracturing operations generate large quantities of abrasive solid debris that damage surface equipment used in oil and gas well production, as conventional separators are unable to effectively capture and manage these solids during high-pressure flow-back situations.
Innovation Solution
A centrifugal cylinder within a spherical pressure-containment vessel captures solid debris through centrifugal force, with optional abrasion-resistant lining and interception baffles directing the debris into a sump, preventing damage to the equipment and allowing for efficient separation and removal of solids from the production stream.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separators are used to separate hydrocarbons during flow-back operations, then hydrocarbon separation is achieved, but solid debris damages the equipment and reduces reliability
Solution Approach 1:
The centrifugal separator is positioned upstream in the flow-back line to remove solid debris before the fluid reaches conventional separators and other sensitive equipment. This preliminary separation action prevents sand and debris from causing damage downstream, thereby protecting equipment reliability without interfering with the primary hydrocarbon separation function.
2Object-affected harmful factors
If solid debris is not removed upstream, then equipment vulnerability to abrasion increases, but adding conventional filtration increases device complexity
Solution Approach 1:
The invention replaces complex mechanical filtration systems with a centrifugal separation system that uses rotational force to separate solids from fluids. The centrifugal separator uses a spinning basket or drum that generates centrifugal force to throw heavy solid particles outward while allowing lighter hydrocarbons to pass through, providing abrasion protection without requiring complex filtration mechanisms.
3Reliability
If a centrifugal separator is added to remove solid debris, then equipment protection is improved, but the device complexity increases
Solution Approach 1:
The flow-back separation system is segmented into two distinct functional stages: first, the centrifugal separator removes solid debris and sand from the stream; second, conventional separators handle hydrocarbon separation. This segmentation allows each component to specialize in its specific function, with the centrifugal separator protecting downstream equipment while keeping the overall system modular and manageable despite the added complexity.
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
The apparatus effectively captures and prevents abrasive solid debris from damaging equipment, achieving high efficiency in separating solids from the well production stream, with computational fluid dynamics simulations indicating over 85% separation efficiency for sand particles.
Implementation Method 1
The centrifugal cylinder is configured to receive the high pressure stream and separate solid debris therefrom using centrifugal force
Implementation Method 2
the heavier solid debris moving outward to the cylinder inner wall, where it falls by gravity, exiting the centrifugal cylinder and entering the lower interior spherical space
Data Source
AI summary
A well production stream solid debris separator apparatus. The apparatus includes a spherical vessel. A cylindrical sump extends below and radially from the spherical vessel. A centrifugal cylinder is positioned within the spherical vessel, the centrifugal cylinder having an axis concentric with a diameter of the spherical vessel and having an open bottom. An outlet port passes through the cylindrical vessel and through the spherical vessel with the outlet port opposed to the cylindrical sump. An inlet port passes through the spherical vessel and passes into the centrifugal cylinder substantially tangential to an inner surface of the centrifugal cylinder.