Cyclonic Separator and Electrostatic Coalescer for Crude Oil Demulsification

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Solution Overview

Problem

Crude oil demulsification is inefficient in existing technologies, leading to salt-related corrosion and deposition in downstream equipment, with issues in separation rate, residual water content, and water quality for treatment.

Innovation Solution

A system comprising a cyclonic separator and an electrostatic coalescer within a storage tank, where cyclonic flow separates multi-phase fluid streams into gas and liquid phases, and the electrostatic coalescer demulsifies the liquid stream by inducing coalescence of water droplets using an electric field.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional demulsification methods are used, then crude oil can be separated into oil and water phases, but the separation rate is slow and residual water content remains high

Engineering Contradiction:

Improveseparation rateVSAvoidresidual water content

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The device segments the demulsification process into two distinct stages: (1) cyclonic separation that rapidly removes bulk water and gas phases, and (2) electrostatic coalescence that removes residual water droplets. This segmentation allows each stage to optimize for its specific function, achieving both high separation rate and low residual water content

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cyclonic separator performs preliminary action by removing the majority of water and gas phases before the liquid stream enters the electrostatic coalescer. This preliminary separation reduces the burden on the electrostatic coalescer, allowing it to focus on removing smaller residual droplets more effectively

Inventive Principle:

Principle #10Preliminary action

2Productivity

If conventional demulsification equipment is used, then oil and water can be separated, but downstream equipment size and costs increase due to inefficient separation

Engineering Contradiction:

Improvedemulsification efficiencyVSAvoiddownstream equipment size

Core Design Contradiction:

ProductivityVSVolume of stationary object

Solution Approach 1:

The device merges two separation mechanisms (cyclonic separation and electrostatic coalescence) into a single integrated unit that fits within the storage tank. This combination achieves superior demulsification efficiency in one compact device, eliminating the need for larger downstream separation equipment

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If water is not separated from crude oil, then crude oil can be stored and processed, but salt content causes corrosion and deposition in downstream equipment

Engineering Contradiction:

Improveequipment reliabilityVSAvoidsalt-related corrosion

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The device performs preliminary water separation before crude oil leaves the storage tank, removing water that contains dissolved salts. By eliminating this water source early, the system prevents salt deposition and corrosion in downstream equipment, improving reliability without requiring additional corrosion protection measures

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 effectively demulsifies crude oil, reducing downstream equipment size and costs, improving water quality for treatment, and minimizing salt-related issues by separating oil and water phases efficiently within the storage tank.

Implementation Method 1

The cyclonic separator is configured to induce cyclonic flow of the multi-phase fluid stream to separate the multi-phase fluid stream into a gas stream and a liquid stream

Methodology Applied

Scientific EffectCyclonic flow: Cyclone Separation

Implementation Method 2

separate the multi-phase fluid stream into a gas stream and a liquid stream

Methodology Applied

Scientific EffectDensity gradient separation: Density Gradient

Implementation Method 3

The electrostatic coalescer is configured to demulsify the liquid stream by causing coalescence of liquid droplets of one of the first or second liquid phases

Methodology Applied

Scientific EffectElectrostatic coalescence: Electrostatic Induction

Implementation Method 4

causing coalescence of liquid droplets using an electric field

Methodology Applied

Scientific EffectElectric field: Electric Field

Data Source

PatentUS11376524B2Crude oil demulsification

Publication Date: 2022.07.05 SAUDI ARABIAN OIL CO

AI summary

A system includes a device disposed within a storage tank. The device includes a cyclonic separator and an electrostatic coalescer. The cyclonic separator is configured to receive and separate phases of a multi-phase fluid stream. The cyclonic separator is configured to induce cyclonic flow of the multi-phase fluid stream to separate the multi-phase fluid stream into a gas stream and a liquid stream. The liquid stream includes a first liquid phase and a second liquid phase. The cyclonic separator is configured to discharge at least a portion of the gas stream and at least a portion of the liquid stream. The electrostatic coalescer is downstream of and fluidically connected to the second outlet of the cyclonic separator. The electrostatic coalescer is configured to demulsify the liquid stream by causing coalescence of liquid droplets of one of the first or second liquid phases.