Cyclonic Solids Separator for High-Solids Hydrocarbon Streams
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Solution Overview
Problem
Current technologies lack a single separator capable of effectively handling high solids concentration and varying particle sizes in hydrocarbon production streams, leading to equipment wear, clogging, and high operational costs.
Innovation Solution
A compact cyclonic solids separator with a swirl-generating chamber and solids accumulation chamber, featuring a funnel-shaped frustoconical design and anti-swirl plates, which separates solids from fluids and manages slug flows, reducing equipment weight and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a combination of plug catcher and sand trap is used to handle high solids content streams, then the separator's ability to handle varying particle sizes and densities is improved, but the equipment weight and footprint increase
Solution Approach 1:
The patent combines the functions of a plug catcher and sand trap into a single integrated cyclonic separator. The device uses a swirl-generating chamber with tangential inlet for large particle separation and a solids accumulation chamber with upward flow for fine particle separation, merging multiple separation mechanisms into one compact unit that handles varying particle sizes and densities without requiring multiple separate equipment pieces
Solution Approach 2:
The cyclonic separator is designed as a universal device that can handle diverse solids including formation sand particles, proppants, plugs, and composite materials with varying densities (1200-4000 kg/m³) and sizes (up to 8 cm). The single device performs multiple functions: initial swirl separation, slug flow management, and fine particle accumulation, replacing the need for specialized equipment for each particle type
2Adaptability or versatility
If a combination of plug catcher and sand trap is used to handle high solids content streams, then the separator's ability to handle varying particle sizes and densities is improved, but the capital and operational costs increase
Solution Approach 1:
The patent combines the functions of a plug catcher and sand trap into a single integrated cyclonic separator. The device uses a swirl-generating chamber with tangential inlet for large particle separation and a solids accumulation chamber with upward flow for fine particle separation, merging multiple separation mechanisms into one compact unit that handles varying particle sizes and densities without requiring multiple separate equipment pieces
Solution Approach 2:
The cyclonic separator is designed as a universal device that can handle diverse solids including formation sand particles, proppants, plugs, and composite materials with varying densities (1200-4000 kg/m³) and sizes (up to 8 cm). The single device performs multiple functions: initial swirl separation, slug flow management, and fine particle accumulation, replacing the need for specialized equipment for each particle type
3Device complexity
If conventional separators are used for high solids content streams, then equipment simplicity is maintained, but equipment wear and clogging increase
Solution Approach 1:
The separator is divided into distinct functional zones: a swirl-generating chamber with tangential inlet for creating rotational flow and separating large particles, and a solids accumulation chamber with upward flow for capturing fine particles. This segmentation allows each zone to handle specific particle sizes and flow conditions, preventing clogging and wear that would occur in a single-chamber design
Solution Approach 2:
The patent changes flow parameters through the two-chamber design: the first chamber creates high-velocity swirl flow for coarse separation, while the second chamber provides low-velocity upward flow for fine particle capture. This parameter change prevents solids deposition and equipment clogging by maintaining appropriate flow velocities in each zone
4Device complexity
If conventional separators are used for high solids content streams, then equipment simplicity is maintained, but operational downtime increases
Solution Approach 1:
The separator is divided into distinct functional zones: a swirl-generating chamber with tangential inlet for creating rotational flow and separating large particles, and a solids accumulation chamber with upward flow for capturing fine particles. This segmentation allows each zone to handle specific particle sizes and flow conditions, preventing clogging and wear that would occur in a single-chamber design
Solution Approach 2:
The patent changes flow parameters through the two-chamber design: the first chamber creates high-velocity swirl flow for coarse separation, while the second chamber provides low-velocity upward flow for fine particle capture. This parameter change prevents solids deposition and equipment clogging by maintaining appropriate flow velocities in each zone
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 separator efficiently removes solids from high-solids-content streams, minimizing equipment wear and operational downtime while maintaining a compact footprint and reducing capital and operational expenses.
Implementation Method 1
a first section (1), arranged in a cylindrical housing (12), having an inlet (3) for a single or multiphase fluid flow (I) comprising solids, a fluid extraction pipe (5) and a solids outlet (4)
Implementation Method 2
The outer wall of the upper cylindrical pipe and inner wall of the swirl generating chamber forms a cylindrical annular section. Because of the swirling motion in the cylindrical annular section, solids are rapidly migrated out of the continuous single or multiphase fluid towards the inner wall of the swirl generating chamber
Implementation Method 3
the funnel-shaped frustoconical element has an upper opening (14) and a lower opening (15), wherein the diameter of the upper opening is larger than the diameter of the lower opening
Data Source
Figure 1
Figure 2a(A-A)~2b(B-B)
Figure 2c(C-C)
AI summary
The present invention provides a heavy solids separator for separating solids from fluids, comprising a swirl-generating chamber (1) and a solids accumulation chamber (2), wherein the swirl-generating chamber (1) comprises an inlet (3), a solids outlet (4) and a fluid extraction pipe (5) arranged at the centerline (C) of the chamber (1), the inlet arranged at an upper part of the swirl-generating chamber, the solids outlet is fluidly connected to the solids accumulation chamber and arranged in the bottom of the swirl-generating chamber, and the fluid extraction pipe (5) has a fluid inlet (6,19) comprising an opening (6) arranged at the centerline of the fluid extraction pipe, the opening facing the solids outlet (4), and a fluid outlet (7) for extracting fluid out of the swirl-generating chamber; and the solids accumulation chamber (2) comprises a solids inlet (8) fluidly connected to the solids outlet (4) of the swirl-generating chamber, and a solids outlet (9) arranged in a lower part of the solids accumulation chamber; and at least parts of the swirl-generating chamber and the solids accumulation chamber are arranged in a cylindrical housing (12) comprising a funnel-shaped frustoconical element (13) delimiting at least a lower section of the swirl-generating chamber and an upper section of the solids accumulation chamber, the funnel-shaped frustoconical element has an upper opening (14) and a lower opening (15), the upper opening having a larger diameter than the lower opening; wherein the solids accumulation chamber (2) comprises a fluid outlet (10) arranged above the level of the solids inlet (8) and fluidly connected downstream of the fluid outlet (7) of the fluid extraction pipe.