Crude Oil Separation Vessel with Interface Washing

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Solution Overview

Problem

Offshore oil processing in deep water environments faces challenges due to the size, weight, and operational costs of processing units on floating supports, which are similar to onshore systems but require efficient stabilization, dewatering, and desalting of crude oil while managing complex emulsions and pressure variations.

Innovation Solution

A process and apparatus for separating crude oil into gas and degassed emulsion phases, followed by water and oil separation, utilizing a vessel with a water leg for washing and recovery, and optionally incorporating a water distribution system at the oil/water interface to enhance separation efficiency and reduce equipment needs on the topsides.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional onshore processing systems are applied to offshore floating units, then stabilization, dewatering, and desalting functions are achieved, but equipment size and weight on topsides increase

Engineering Contradiction:

Improvecrude oil treatment effectivenessVSAvoidprocessing equipment weight on topsides

Core Design Contradiction:

ReliabilityVSWeight of stationary object

Solution Approach 1:

The crude oil treatment process is divided into separate functional units: a first separator for gas/emulsion separation, a water distribution system for washing, and a second separator for water/oil separation. This segmentation allows each unit to be optimized independently and reduces the need for large integrated equipment on topsides.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention moves the washing function to a vertical dimension by implementing a water distribution system that introduces wash water at different heights within the separation vessel. This vertical arrangement reduces the horizontal footprint and equipment size required on the floating unit's topsides.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Reliability

If conventional three-phase separation is used, then gas, water, and oil are separated, but equipment complexity and operating costs increase

Engineering Contradiction:

Improvephase separation capabilityVSAvoidseparation process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The invention combines multiple separation functions into integrated vessels. The first separator handles both gas-liquid separation and emulsion degassing, while the second separator performs both washing and water-oil separation. This merging reduces the number of separate equipment items and simplifies the overall process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The separation vessels are designed to perform multiple functions: the first separator acts as both a gas separator and an emulsion treatment unit, while the second separator functions as both a washing vessel and a water-oil separator. This multi-functionality reduces equipment complexity compared to dedicated single-purpose units.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If water washing is implemented at the oil/water interface, then separation efficiency improves, but water consumption increases

Engineering Contradiction:

Improveseparation efficiencyVSAvoidwater consumption

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The water distribution system introduces wash water specifically at the oil/water interface region rather than throughout the entire vessel. This localized washing approach concentrates the cleaning action where emulsifiers and deposits accumulate most, improving separation efficiency while minimizing overall water consumption.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system performs preliminary washing of the emulsion phase before final water-oil separation. By introducing wash water at the interface during the separation process, emulsifiers are broken down and removed in advance, preventing their accumulation and improving the efficiency of subsequent separation stages.

Inventive Principle:

Principle #10Preliminary action

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

This approach reduces equipment size and weight on floating units, lowers operating costs, and achieves stabilization, dewatering, and desalting efficiently, with improved separation efficiency and reduced formation of deposits, while accommodating complex crudes and varying water content.

Implementation Method 1

separation of the said degassed emulsion into water and oil

Methodology Applied

Scientific EffectGravity separation: Gravitation

Implementation Method 2

separation of the crude into two phases (or fractions), i.e. gas and degassed emulsion

Methodology Applied

Scientific EffectDensity difference: Density Gradient

Data Source

PatentUS8790509B2Process for the treatment of crude oil, process for the separation of a water-in-oil hydrocarbon emulsion and apparatus for implementing the same

Publication Date: 2014.07.29 TOTALENERGIES SE

AI summary

The invention relates to a process for the purification of crude and apparatus for its implementation. This process comprises a separation into gas and degassed emulsion and separation of the degassed emulsion into water and oil. The invention also relates to a process of separating a hydrocarbon emulsion and apparatus for implementing this. This process comprises washing of the emulsion at an oil/water interface.