Corrugated Settling Cup for Downhole Gas-Liquid Separation
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Solution Overview
Problem
Current downhole gas-liquid separation devices in oilfields have low efficiency, especially for fluids with viscosity greater than 2 mPa·s, which hinders improved pump efficiency and oil production.
Innovation Solution
A multi-cup uniform flux gas anchor featuring corrugated settling cups with a rising external profile at 30°˜60° and 6˜18 ridges, facilitating gas aggregation and separation by distributing fluid flow evenly through multiple cups, ensuring effective gas-liquid separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a smooth external surface settling cup is used, then the streamlined profile allows small gas bubbles to be evenly distributed along the external side, but this does not facilitate aggregation of the small gas bubbles, resulting in low separation efficiency
Solution Approach 1:
The patent applies curvature by transforming the smooth streamlined profile into a corrugated profile with multiple ridges and valleys. The corrugated shape creates curved surfaces that facilitate bubble aggregation through surface tension effects and altered flow patterns, directly resolving the contradiction between streamlined shape and aggregation capability
Solution Approach 2:
The patent applies local quality by creating different surface characteristics at different locations on the settling cup. The corrugated profile introduces localized regions (ridges and valleys) with distinct geometric properties that promote bubble aggregation in specific zones, rather than uniform distribution across the entire surface
2Quantity of substance
If a large amount of mixture is introduced into the gas anchor, then the separation process occurs through swirling flow in various flow passages, but this results in very low separation efficiency, especially for fluid with viscosity greater than 2 mPa·s
Solution Approach 1:
The patent applies segmentation by dividing the single large settling cup into multiple smaller settling cups arranged in series. This segmentation reduces the flow rate through each individual cup, allowing sufficient residence time for separation even with viscous fluids, while maintaining high overall throughput capacity
Solution Approach 2:
The patent applies dimensional change by transitioning from a single large-volume separation chamber to multiple smaller chambers arranged in a series configuration. This multi-dimensional arrangement increases the total separation capacity while maintaining low flow rates in each chamber, effectively handling both high quantity and high efficiency requirements
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 corrugated settling cups enhance gas-liquid separation efficiency, reducing gas content in pumped fluid, increasing oil production, and saving energy by improving pump efficiency and reducing submergence depth.
Implementation Method 1
small gas bubbles are evenly distributed along the external side of the cup, and are less likely to contact each other, which does not facilitate aggregation of the small gas bubbles
Implementation Method 2
the settling speed of the fluid in the settling cup is greatly decreased, thereby enabling the two-phase fluid of gas and liquid to be separated in the settling cups
Implementation Method 3
it is known from the Stokes' Law that the gas rising speed is proportional to the square of the diameter of gas bubbles
Data Source
AI summary
A corrugated settling cup (5) is provided, wherein the cup has a cup body, an opening and a location step (52) are provided at the bottom (55) of the cup body, several location holes (53) are formed at the top of the location step (52), location projections (54) corresponding to the location holes (53) are formed at the bottom (55) of the corrugated settling cup (5), wherein the external profile of the corrugated settling cup body rises along the axial direction in a corrugated shape. A multi-cup uniform flux gas anchor is provided, wherein the gas anchor includes a central pipe (7), several corrugated settling cups (5), several settling cups protection bodies (6) and a well-flushing valve (9), wherein the external profile of the corrugated settling cup body rises along the axial direction in a corrugated shape.