Continuous Recirculation Separation for Drill-Out Flowback Fluids
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Solution Overview
Problem
There is a need for separators in oil and gas operations that minimize rig-up times while efficiently separating fluids produced during drill out and flow back into component parts, such as gas, sand, and liquids, with improved efficiency and effectiveness.
Innovation Solution
A system and process utilizing one or two continuous recirculation loops to separate fluids, where a first loop circulates fluid between a recirculation chamber, a hopper, and a shaker device, and a second loop circulates fluid between the recirculation chamber and a gas separator, facilitating continuous separation of sand and liquids, and then gas from the sand and liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separation systems are used, then fluid separation can be achieved, but rig-up times are extended and efficiency is reduced
Solution Approach 1:
The patent combines multiple separation functions (sand removal, liquid-gas separation, and fluid recirculation) into an integrated system. The recirculation chamber serves multiple purposes: it receives separated fluids, allows sand to settle, and distributes cleaned fluids to various outlets including gas separation and production streams, thereby reducing the need for separate rigid separation systems.
Solution Approach 2:
The system employs dynamic recirculation where fluids are continuously circulated through the recirculation chamber, allowing adaptive separation based on real-time flow conditions. The system can adjust flow distribution between different outlets (gas separation, production, or disposal) based on operational requirements, providing flexibility without requiring multiple fixed separation systems.
2Reliability
If continuous recirculation is implemented, then separation effectiveness is improved, but system complexity increases
Solution Approach 1:
The recirculation chamber is designed as a multi-functional unit that performs sand settling, fluid mixing, flow distribution, and supports both gas separation and production streams. This universal design reduces the need for multiple specialized separation devices, thereby improving reliability without proportionally increasing system complexity.
Solution Approach 2:
The system maintains continuous recirculation of fluids through the recirculation chamber, ensuring constant separation effectiveness. This continuous operation allows the system to handle varying production conditions without interruption, improving reliability while using a single continuous system rather than multiple batch-processing devices.
3Productivity
If rapid fluid separation is achieved, then productivity increases, but separation completeness may be compromised
Solution Approach 1:
The continuous recirculation system maintains ongoing separation action without interruption. Fluids are continuously circulated through the recirculation chamber where sand settles and gases separate, ensuring complete separation over time while maintaining high productivity through uninterrupted operation.
Solution Approach 2:
The system uses flow distribution and recirculation patterns to feedback and adjust separation effectiveness. By continuously monitoring and adjusting flow rates through different outlets (gas separation, production, or disposal), the system ensures complete separation while maintaining rapid processing speeds.
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 system achieves efficient and rapid separation of fluids into gas, sand, and liquids, reducing rig-up times and enhancing the effectiveness of fluid recovery and recycling in oil and gas operations.
Implementation Method 1
flowing a first portion of the first mixture from the hopper to a diffuser
Implementation Method 2
flowing a diffuser mixture including the first portion of the first mixture and the first portion of the second mixture from the diffuser to a shaker device
Implementation Method 3
flowing a shaker recycle liquid from the shaker device to the hopper
Implementation Method 4
flowing a second portion of the second mixture to a gas separator
Data Source
AI summary
One or two continuous recirculation loops are utilized for the well-site equipment that separates produced fluids into sand, liquid, and gas during drill out and flow back that occurs after fracturing a subterranean formation. When one recirculation loop is utilized, the recirculation loop continuously recirculates fluid between the recirculation chamber of the disclosed sand removal apparatus and a shaker device. When two recirculation loops are utilized, the first recirculation loop continuously recirculates fluid between a recirculation chamber of the disclosed sand removal apparatus and a shaker device, and the second recirculation loop continuously recirculates fluid between the recirculation chamber and a gas separator.