Direct Contact Condensing for Oil-Water Vapor Fines

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Solution Overview

Problem

Current thermal desorption methods and systems face challenges in efficiently managing fine solids in vapor streams, leading to contamination and reduced processing rates due to inefficient separation of oil, water, and solids, which can result in environmental issues and equipment complexity.

Innovation Solution

A direct contact condensing system that eliminates the need for gravity-based separation processes, using a Recovered Fluid Condenser (RFC) that recirculates an emulsion of oil, water, and fines, allowing for continuous condensation of vapors without separation, and utilizes a centrifuge to separate the components post-processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If gravity-based separation processes are used to separate oil, water, and fine solids, then separation of phases occurs, but system complexity and equipment footprint increase

Engineering Contradiction:

Improveseparation effectivenessVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the gravity-based separation equipment (settling vessels, rag layers, multiple separation units) from the condensation system. Instead of using separated water or oil for condensation, the system uses the emulsion directly, removing the need for complex gravity separation infrastructure while maintaining effective phase separation through centrifugal force alone.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The emulsion serves multiple functions simultaneously: it acts as the condensation medium, the separation fluid, and the transport medium for fine solids. The centrifuge performs both separation and concentration functions in a single unit, eliminating the need for multiple specialized separation equipment.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If extensive residence time is provided for separation in gravity vessels, then separation quality improves, but processing rate decreases

Engineering Contradiction:

Improveseparation qualityVSAvoidprocessing rate

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the gravity-based mechanical separation system with a centrifugal separation system. The centrifuge uses rotational force to achieve rapid separation of oil, water, and fine solids in minutes rather than requiring days of gravitational settling, thus maintaining high separation quality while dramatically increasing processing rate.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If cyclones and bag filters are used to remove fine solids at high temperatures, then fines removal occurs, but system complexity and energy consumption increase

Engineering Contradiction:

Improvefines removal efficiencyVSAvoidenergy costs

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent performs fines removal at ambient temperature in the condensation system before the material would require high-temperature processing. By using the emulsion to capture and separate fines during condensation, the system eliminates the need for subsequent high-temperature cyclone or bag filter operations, reducing energy consumption while maintaining effective fines removal.

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 significantly reduces energy costs, system complexity, and equipment footprint while effectively managing fine solids, improving the recovery of hydrocarbons and valuable solids from waste streams by maintaining the emulsion in a stable form for efficient processing.

Implementation Method 1

combining the vapor stream with a liquid stream from a jet pump

Methodology Applied

Scientific EffectJet pump: Injector

Implementation Method 2

routing the mixture to a heat exchanger to cool the mixture and condense any remaining vapors

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Implementation Method 3

routing a portion of the emulsion to a centrifuge to separate an oil stream, a water stream, and a solids stream

Methodology Applied

Scientific EffectCentrifugal separation: Centrifugal Separation

Implementation Method 4

combining the vapor stream with a liquid stream from a jet pump, forming a mixture

Methodology Applied

Scientific EffectDirect contact condensation: Condensation

Data Source

PatentUS11179654B2Methods and systems for processing a vapor stream from a thermal desorption process

Publication Date: 2021.11.23 CALAERIS ENERGY & ENVIRONMENT

AI summary

Methods and systems for treating an oil/water vapor stream containing solids fines. Routing a feed composition of oil/water vapors containing fine solids to a condensing unit, combining the feed composition with a cooled OWS emulsion, forming a warmed OWS emulsion. The warmed OWS emulsion is routed to a surge vessel containing a volume of surge OWS emulsion, where after a first portion of the surge OWS emulsion is routed to a heat exchanger, forming the cooled OWS emulsion, and a second portion of the surge OWS emulsion is routed to an OWS separation unit. The OWS separation unit may be one or more disc stack centrifuges, in some cases preceded by one or more decanting centrifuges. In certain embodiments the oil/water vapor stream containing solids fines is generated from a thermal desorption unit, such as a turbulent vacuum thermal desorption unit. Systems may be integrated with thermal desorption units and drilling rigs.