Electrostatic Coalescing Device Insulated Electrode Plate
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Solution Overview
Problem
Existing electrostatic coalescing devices for oil and water emulsions face challenges with high-voltage connectivity issues, flexibility, and clogging, particularly in harsh oil field environments, where stable emulsions are difficult to separate using gravitational settling alone.
Innovation Solution
An electrostatic coalescing device with fully insulated metal electrode plates and transformers, utilizing a low-voltage connection to an external power source, eliminating the need for high-voltage connectors and allowing on-site assembly and adjustment, with a configuration that prevents clogging and maintains a strong electric field over a larger area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-voltage connectors are used to connect electrodes to external power supply, then electrostatic field can be established, but the system becomes bulky, highly sensitive to fouling, and not flexible
Solution Approach 1:
The patent extracts the transformer from the fluid processing environment and places it outside the vessel. Only low-voltage connections penetrate the vessel wall, while the high-voltage side remains isolated from the fluid. This eliminates bulky high-voltage connectors inside the vessel and reduces sensitivity to fouling.
Solution Approach 2:
The patent introduces an insulated electrode plate as an intermediary element. The electrode plate is electrically isolated from the vessel wall through insulation material, allowing high-voltage potential to be maintained without direct connection to the vessel. This intermediary structure eliminates the need for complex high-voltage penetrations through the vessel wall.
2Reliability
If traditional electrostatic coalescing devices are used, then water droplet coalescence is promoted, but the devices are not flexible and difficult to assemble on-site
Solution Approach 1:
The patent segments the electrostatic coalescing system into modular components: insulated electrode plates that can be independently positioned and connected. Each plate is a self-contained unit with insulation already applied, allowing for easy assembly and disassembly on-site without requiring complex integration of high-voltage connections.
Solution Approach 2:
The transformer is extracted from the internal structure and placed outside the vessel. This removes the most complex component (high-voltage wiring and connections) from the on-site assembly requirements, allowing the internal electrode structure to be assembled using simple low-voltage connections or even post-assembly energization.
3Ease of manufacture
If gravitational settling is used alone, then simple separation is achieved, but stable emulsions are difficult to separate and water remains in oil
Solution Approach 1:
The patent employs alternating current (AC) voltage applied to the electrode plates, creating a periodically reversing electric field. This periodic action causes continuous polarization and depolarization of water droplets, enhancing their coalescence efficiency in stable emulsions where gravitational settling alone is insufficient. The alternating field prevents droplet charging saturation and maintains continuous coalescence promotion.
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 solution enhances the separation of water from oil by creating a robust, flexible, and efficient electrostatic field within the coalescing device, reducing the risk of fouling and clogging, and enabling longer retention times in the electric field, thus improving the separation efficiency and reducing production losses.
Implementation Method 1
transformer having a first end of a high voltage winding connected electrically to the metal plate within the insulation
Implementation Method 2
Different electric potentials are applied to the electrodes so as to form an electric field between each pair of adjacent electrodes
Implementation Method 3
promote the coalescence of water contained in a water-in-oil emulsion flowing through the flow passages between the electrodes
Implementation Method 4
taking advantage of the fact that water and oil have different permittivity
Implementation Method 5
oil will be extracted together with water. The water has to be removed from the oil and this is mainly done by means of settling tanks in which the oil is permitted to settle under the action of gravity
Data Source
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AI summary
The invention concerns an electrostatic coalescing device comprising: - a vessel (1) or a pipe (1) through which a mixture of fluids flows, - at least one metal electrode plate (2) and transformer (4) arranged inside said pipe/vessel (1), wherein said electrode plate (2) and transformer (4) are fully enclosed by insulation (3), and wherein said transformer (4) is energized from an external alternating low voltage source/power supply (5) located outside the vessel/pipe (1), said transformer having a first end of a high voltage winding (4a) connected electrically to the metal plate (2) within the insulation (3).