Downhole Coalescer for Solids Separation in Multi-Bore Wells
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Solution Overview
Problem
The challenge of separating solids from disposal fluid downhole in oil and gas wells is significant, as solids can impair fluid flow and plug downhole equipment, making it difficult to manage water cut and reduce disposal costs.
Innovation Solution
Deploying downhole coalescers to separate residual hydrocarbons and remove solids from disposal fluid, allowing for efficient separation and disposal of solids downhole, thereby preventing injectivity impairment and ensuring that oil is not re-injected.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If downhole separation is implemented to reduce water cut, then the value of produced fluids increases and disposal costs decrease, but solids may dislodge from formation and plug downhole equipment
Solution Approach 1:
The separation process is divided into multiple stages: initial gravity separation of water, followed by coalescence of residual hydrocarbons on plate surfaces, and finally solids removal through filtration media. This segmentation allows each stage to address specific separation needs without interfering with equipment functionality.
Solution Approach 2:
Coalescer plates with hydrophobic surfaces act as intermediaries that preferentially attract and coalesce hydrocarbon droplets from the water phase, while solids are captured by filtration media. This intermediary mechanism separates different phases and solids without requiring direct contact between all components, preventing plugging.
2Quantity of substance
If coalescer plates are used to separate hydrocarbons from water, then hydrocarbon recovery increases, but device complexity increases
Solution Approach 1:
The coalescer plates are arranged in parallel configurations that create equipotential flow paths, allowing gravity-driven separation without requiring complex pumping or pressure differential systems. The plates are positioned to utilize natural buoyancy forces, simplifying the overall device structure while maintaining effective hydrocarbon recovery.
Solution Approach 2:
The hydrophobic coating on coalescer plates provides self-cleaning properties where separated hydrocarbons automatically coalesce and detach from plate surfaces due to surface tension forces. This self-service mechanism reduces the need for external cleaning systems or complex operational interventions, maintaining high recovery efficiency without increasing device complexity.
3Productivity
If multiple separation mechanisms are deployed downhole, then separation efficiency increases, but energy consumption increases
Solution Approach 1:
The system utilizes gravity as a counterbalancing force to drive the separation process. Water, being denser than hydrocarbons, naturally settles downward while hydrocarbons rise upward through the coalescer plates. This gravity-driven mechanism eliminates or reduces the need for energy-consuming pumps or agitators, maintaining high separation efficiency with minimal energy input.
Solution Approach 2:
The system employs hydraulic principles where pressure differentials created by fluid flow itself drive the separation process through the coalescer plates and filtration media. The kinetic energy of the incoming fluid stream provides the driving force for separation, reducing or eliminating the need for additional energy input from external sources.
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 use of downhole coalescers effectively separates solids from disposal fluid, preventing plugging and ensuring efficient fluid flow, which increases the value of produced fluids and decreases disposal costs by managing water cut effectively.
Implementation Method 1
a plurality of coalescer plates positioned within the upper flow path. Each of the coalescer plates configured to separate droplets of production fluid from the nonproduction fluid with sediment
Implementation Method 2
The coalescer plates may be angled to allow the hydrocarbon, which may include oil droplets, to flow upwards. The solids may slide off the top side portion of each of the plates and settle into a collection area
Data Source
AI summary
Some implementations relate to a downhole separation system configured to be positioned downhole in a well formed in a subsurface formation, wherein the downhole separation system is configured to receive a formation fluid from the subsurface formation and configured to separate the formation fluid into a first fluid primarily comprised of a production fluid and a second fluid primarily comprised of a nonproduction fluid, the downhole separation system including, at least a first coalescer to be positioned within a downhole tubular, wherein the first coalescer is configured to separate out at least a portion of debris and the production fluid from the second fluid.