Coalescer Device Helical Impeller Vertical Flow Emulsion Separation
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Solution Overview
Problem
Current methods for separating immiscible liquid phases in emulsions, such as oil-water emulsions, are inefficient and slow, requiring significant time and resources, and lack effective solutions for achieving a 'perfect cut' without high pressures or aeration.
Innovation Solution
A coalescer device with a helical impeller disposed within a draft tube, which creates a vertical flow through the emulsion, allowing for the separation of immiscible liquids by rotating at a low speed to enhance coalescence without mixing, thereby improving the separation efficiency and rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If gravity-based separation is used, then the separation process is simple, but the separation rate is too slow and produces too small an incremental yield
Solution Approach 1:
The patent applies preliminary action by introducing air bubbles into the emulsion before the main separation process. These pre-introduced bubbles attach to dispersed droplets, increasing their buoyancy and preparing them for faster rise during separation. This pre-treatment accelerates the overall separation rate without requiring complex equipment modifications.
Solution Approach 2:
The patent changes physical parameters by introducing gas bubbles into the liquid emulsion, altering the density and buoyancy characteristics of the dispersed phase. This parameter change enables faster separation by modifying the driving force for phase separation, thereby increasing productivity while reducing separation time.
2Productivity
If coalescer devices like electrostatic coalescer systems are used, then coalescence rate is accelerated, but the devices remain relatively slow and inefficient
Solution Approach 1:
The patent uses air bubbles as an intermediary substance to facilitate coalescence. Instead of using complex electrostatic fields or mechanical coalescers, simple air bubbles act as mediators that bring dispersed droplets into contact with each other, promoting coalescence through gentle mixing and reduced device complexity.
Solution Approach 2:
The patent applies pneumatic principles by introducing gas bubbles into the liquid emulsion to enhance separation. This pneumatic approach uses gas-liquid interactions to accelerate coalescence and separation, achieving improved productivity without the complexity of electrostatic or mechanical coalescing devices.
3Productivity
If hydrocyclone devices are used, then centrifugal force drives water to outer area, but the devices remain relatively slow and inefficient
Solution Approach 1:
The patent applies preliminary action by pre-introducing air bubbles into the emulsion before separation. This pre-treatment enhances the buoyancy of dispersed droplets, allowing gravity-based separation to become more efficient without requiring high centrifugal forces, thus reducing the stress and complexity associated with hydrocyclone devices.
Solution Approach 2:
The patent enables self-service separation by allowing the emulsion to separate under its own buoyancy forces enhanced by pre-introduced bubbles. This eliminates the need for external centrifugal force application, reducing device complexity and operational stress while maintaining separation efficiency.
4Productivity
If dual action pumping systems are used, then oil and water are pumped to surface, but the systems remain relatively slow and inefficient
Solution Approach 1:
The patent applies pneumatic principles by introducing air bubbles into the emulsion to enhance separation. This pneumatic approach accelerates coalescence and separation through gas-liquid interactions, achieving improved productivity without the complexity of dual action pumping systems.
Solution Approach 2:
The patent changes physical parameters by introducing gas bubbles, which alters the density and buoyancy characteristics of the dispersed phase. This parameter change enables faster separation under gravity alone, eliminating the need for complex pumping systems while maintaining high separation speed.
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 method achieves a significant increase in coalescence rate, with at least 20% more liquid separation in 40 minutes and over 100% more in 20 minutes compared to gravity-based methods, while maintaining a simple construction and adaptability for land-based and offshore oil recovery operations.
Implementation Method 1
a coalescer device comprising a container, draft tube and a means for causing a vertical flow of fluid (vertical flow causing means) The draft tube is disposed inside the container and is oriented essentially vertically in the emulsion; and the helical impeller is disposed inside the draft tube and operable for causing a vertical flow of fluid therethrough
Implementation Method 2
rotating the helical impeller disposed within the draft tube at a rotation rate of 30 to 120 revolutions per minute and causing a vertically-directed flow of the emulsion through the draft tube
Implementation Method 3
In batch and continuous gravity separation processes, achieving a perfect separation takes too long
Data Source
AI summary
The present invention generally relates to a coalescer device and separation method employing the coalescer device for coalescing material comprising a dispersed liquid phase from an emulsion.