Electrocoalescer Separator Inlet Electrode Assembly
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Solution Overview
Problem
Prior art vessel-based electrocoalescer separators have inefficiencies due to a short settling section and low flow velocities, leading to reduced coalescence rates and increased fouling, which limits oil dehydration efficiency.
Innovation Solution
The electrocoalescer separator design features an electrode assembly located in the inlet section with multiple rod-shaped electrodes and fluid pipes, creating an annular flow channel and a space between pipes for initial bulk separation, increasing the main settling section length and flow velocity, thereby enhancing coalescence and separation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrocoalescer assembly is arranged in the middle of the vessel at a distance from the inlet section, then initial phase separation can occur before electrostatic treatment, but the settling section becomes too short resulting in reduced separation efficiency
Solution Approach 1:
The electrode assembly is moved from the middle of the vessel to the inlet section, changing the spatial arrangement from a downstream configuration to an upstream configuration. This dimensional repositioning allows the electrocoalescer to treat the fluid stream immediately upon entry, maximizing the available length for settling while maintaining effective phase separation.
2Reliability
If the fluid is electrostatically treated at relatively low flow velocities, then the electrocoalescer can operate safely, but the collision rate between water droplets decreases leading to reduced coalescence rate
Solution Approach 1:
The electrocoalescer assembly is positioned in the inlet section to perform preliminary electrostatic treatment on the fluid stream before it enters the settling section. This preliminary action charges the water droplets early in the process, enabling them to coalesce more effectively as they travel through the settling section, thereby increasing the overall coalescence rate without compromising operational stability.
3Reliability
If low flow velocity is used in the electrocoalescer, then secondary droplet formation and water droplet chain formation are more likely, but high flow velocity reduces treatment effectiveness
Solution Approach 1:
By positioning the electrocoalescer in the inlet section, the system performs droplet charging and initial coalescence promotion before the fluid enters the settling section. This preliminary action creates larger, more stable droplets that are less prone to secondary formation or chain formation during settling, thereby eliminating the need to choose between low velocity effectiveness and high velocity harm reduction.
4Productivity
If low flow velocity is used in the electrocoalescer, then fouling in the cells increases, but high flow velocity improves throughput
Solution Approach 1:
The electrocoalescer assembly positioned in the inlet section performs preliminary droplet treatment and coalescence promotion before fluid enters the settling section. This preliminary action reduces the concentration of fine, problematic droplets that cause fouling, allowing the system to operate at higher flow velocities without excessive fouling issues, thereby improving overall throughput.
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 design increases coalescence efficiency, reduces secondary droplet formation, and minimizes fouling by increasing the droplet collision rate and turbulence, while allowing for a more compact or efficient vessel with improved separation performance.
Implementation Method 1
Robust and efficient electrocoalescers able to handle high watercuts and high temperatures can greatly increase the overall efficiency of separators in crude oil processing systems
Implementation Method 2
a liquid obstruction element is arranged downstream the fluid inlet, such that a major part of a liquid component of a fluid stream entering the inlet section during use may be forced to pass through the fluid pipes via the pipe inlets
Implementation Method 3
the outer surfaces of the multiple fluid pipes are separated to provide a space between the multiple fluid pipes, the space is in fluid communication with the fluid inlet in the inlet section, such that a fluid flow entering the inlet section may pass through said space before entering the pipe inlets
Implementation Method 4
increasing the main settling section length and flow velocity, thereby enhancing coalescence and separation performance
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention provides a separator comprising a vessel (1) and an electrode assembly (2), wherein the vessel (1) has an inlet section (3), a main settling section (14) and an outlet section (4) and comprises a fluid inlet (5) arranged in the inlet section (3), and an oil outlet (7) and a water outlet (8) arranged in the outlet section (4); the electrode assembly (2) is arranged in the inlet section and comprises at least one fluid pipe (9) and at least one rod-shaped electrode (10), the fluid pipe surrounds at least parts of the rod-shaped electrode and comprises a pipe inlet (11) arranged in the inlet section and a pipe outlet (12) arranged in fluid communication with the main settling section, wherein a liquid obstruction element (13) is arranged downstream the fluid inlet, such that at least a major part of a liquid component of a fluid stream entering the inlet section via the fluid inlet, during use, may be forced to pass through the at least one fluid pipe via the pipe inlet before entering the main settling section.