Centrifugal Cyclone Separator for High-Solids Well Flow
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Solution Overview
Problem
Current systems for separating and managing subterranean well flow, which includes solids, water, and hydrocarbons, face challenges such as particulate-induced abrasion and plugging of production equipment, and existing separation methods are not efficient in handling high-volume, high-solids-content flows effectively.
Innovation Solution
A well production separation system comprising a centrifugal separator with a cyclone module and a spherical separator, equipped with a swirl inducer, that efficiently separates particulates from liquids and gases, and includes a liquid/gas recycle circuit and instrumented components for monitoring and control, allowing for modular configuration and easy transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional separation equipment (sand knock out, desanders, separating tanks) is used to separate particulates from well flow, then some separation is achieved, but the systems are not efficient for high-volume, high-solids-content flows and cause abrasion and plugging of equipment
Solution Approach 1:
The system divides the separation process into multiple stages using multiple cyclone separators arranged in parallel and series configurations. Each cyclone handles a portion of the high-volume flow, distributing the separation load and preventing any single unit from becoming overwhelmed or clogged, thereby maintaining high productivity while reducing equipment stress and abrasion.
2Productivity
If existing separation methods are used for high-volume, high-solids-content flows, then equipment is available, but separation efficiency is insufficient
Solution Approach 1:
The system merges multiple cyclone separators into a unified separation system that handles high-volume, high-solids-content flows collectively. By combining multiple separation units with identical or varying capacities, the system achieves the necessary throughput and separation efficiency for challenging well flow conditions that single conventional units cannot handle effectively.
3Productivity
If modular configuration with multiple cyclone separators is implemented, then separation efficiency increases, but device complexity increases
Solution Approach 1:
The cyclone separators are designed as universal, modular units that can be configured in various parallel and series arrangements to meet different separation requirements. Each module performs the same core separation function but can be scaled and arranged flexibly, reducing operational complexity despite increased separation capacity. The standardized design allows for easy maintenance and replacement of individual modules without affecting the entire system.
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 increased particulate separation efficiency, effective separation of hydrocarbons from particulate slurry, ease of modification for changing well conditions, and ease of transport and operation, improving overall well production efficiency.
Implementation Method 1
a first centrifugal separator disposed above or on top of the spherical separator. The centrifugal separator comprises an access flange at an upper end, which provides access to an inlet manifold configured to receive well production and discharge the well production into a cyclone module
Implementation Method 2
The system comprises a first centrifugal separator disposed above or on top of the spherical separator
Implementation Method 3
a spherical separator having a particulate outlet at a lower end opposite the inlet. The spherical separator comprises an inlet flange coupled to the particulate outlet from the centrifugal separator
Implementation Method 4
The spherical separator comprises an inlet flange coupled to the particulate outlet from the centrifugal separator and configured to receive the particulate slurry and discharge liquid and gas components from the particulate slurry
Data Source
AI summary
A well production particulate measurement system having a stationary frame removably mountable to tank, a hopper coupled to the frame and moveable relative to the frame; a well production inlet configured to receive well production and discharge the particulates and liquid into the hopper, and to strip at least a portion of a gas phase from the well production; and a weight transducer coupled to the system and configured to sense a weight of particulates in the hopper.