Crossflow Clarifier for Submicron Particle Removal in Fracking Water
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional sand filters used in oil and gas operations are ineffective in removing submicron particles, leading to reduced pump effectiveness and limited reuse of process water, while existing technologies like polymer membranes and ceramic filters are prone to clogging and unsuitable for the specific contaminants present in fracking water.
Innovation Solution
A crossflow clarifier system with inclined plates and dissolved air flotation is used to remove submicron particles from process water, employing gravitational separation and oxidation processes to clarify and recycle water for multiple fracking operations, reducing the need for chemical treatments and enhancing water reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sand filters are used to remove particles from process water, then coarse particles are removed, but submicron particles remain and accumulate, reducing pump effectiveness
Solution Approach 1:
The filtration system is segmented into multiple stages: a sand filter for coarse particles followed by a crossflow clarifier for submicron particles. This segmentation allows each stage to specialize in removing specific particle size ranges, with the sand filter handling larger particles and the crossflow clarifier addressing submicron particles that the sand filter cannot remove.
Solution Approach 2:
The crossflow clarifier acts as an intermediary device between the sand filter and the pump. It receives pre-filtered water from the sand filter and further clarifies it by removing submicron particles through crossflow filtration, thereby protecting the pump from particle accumulation and maintaining pump effectiveness.
2Loss of substance
If process water is reused in fracking operations, then water consumption is reduced, but particle accumulation limits the rates achievable by pumps
Solution Approach 1:
The system enables continuous reuse of process water by implementing a closed-loop filtration system. The crossflow clarifier continuously removes submicron particles from reused water, preventing particle accumulation and maintaining consistent pump rates throughout multiple fracking stages, thereby sustaining productivity while reducing water consumption.
Solution Approach 2:
The crossflow clarifier changes the physical parameters of the reused water by removing submicron particles through crossflow filtration. This parameter change (reducing particle concentration) allows the water to be reused at higher rates without pump degradation, maintaining productivity across multiple fracking operations.
3Manufacturing precision
If polymer membranes or ceramic filters are used to remove submicron particles, then particle removal is achieved, but the filters are prone to clogging and become unusable
Solution Approach 1:
The crossflow clarifier uses a disposable or easily replaceable filter medium that can be discarded or regenerated when clogged, rather than using expensive, complex membrane systems. This approach prioritizes operational simplicity and cost-effectiveness, allowing the system to maintain high particle removal efficiency while managing filter usability through replacement rather than complex maintenance.
4Object-affected harmful factors
If water is trucked to disposal sites for storage, then safe disposal is achieved, but costs and logistics are increased
Solution Approach 1:
Instead of discarding used water at disposal sites, the system recovers and reuses process water through the crossflow clarifier filtration system. This recovery approach eliminates the need for complex logistics of trucking water to disposal sites and storage facilities, while maintaining safe handling through continuous particle removal that prevents pump damage and operational issues.
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 effectively clarifies and recycles water, reducing water consumption, storage concerns, and operational costs, while improving the efficiency and longevity of fracking operations by removing submicron particles and corrosive gases, thus enabling continuous reuse of water throughout the fracking process.
Implementation Method 1
The crossflow clarifier system with inclined plates and dissolved air flotation is used to remove submicron particles from process water, employing gravitational separation
Implementation Method 2
A crossflow clarifier system with inclined plates and dissolved air flotation is used to remove submicron particles from process water
Implementation Method 3
employing gravitational separation and oxidation processes to clarify and recycle water
Data Source
AI summary
A portable unit and associated processing are described for clarifying process water used in oil and gas operations such as fracking or drill-out operations. In the portable unit, dirty water (402) is introduced into a clarifier (400). The dirty water (402) is directed to a bottom of the clarifier (400) where dissolved air 408 from a dissolved air flotation pump (410) is injected into the water (402). The water (402) then passes across the inclined plates (412). Particles are separated from the water (402) via interaction with the plates (412) and directed to collectors (414), at the bottom of the clarifier (404), by gravitation. In addition, a floc, enhanced by the injection of the dissolved air (408), is skimmed from the water surface. The result of this process flow is clarified water (430) that can be returned to the frack and post-frack completion process.