EMAT-Based Fluid Emulsion Separation with Reduced Demulsifiers

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Solution Overview

Problem

Existing technologies face challenges in efficiently separating emulsified water from crude oil, leading to significant accumulation in storage tanks and pipelines, which complicates the handling and refining process.

Innovation Solution

A system utilizing electromagnetic acoustic transducers (EMATs) generates electromagnetic and magnetic fields to produce acoustic wave energy, causing mechanical agitation and disruption within fluid emulsions, thereby separating the constituents.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If electromagnetic acoustic transducers (EMATs) are used to generate acoustic wave energy to separate fluid emulsion, then the separation efficiency is improved and chemical demulsifiers are reduced, but the device complexity and energy consumption increase

Engineering Contradiction:

Improveseparation efficiencyVSAvoiddevice complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces chemical demulsifiers with electromagnetic acoustic transducers that generate acoustic wave energy to separate fluid emulsion. The EMATs convert electrical energy to mechanical acoustic waves through electromagnetic fields, which then physically break apart the emulsion without requiring chemical additives. This substitution of mechanical/electromagnetic action for chemical action improves separation efficiency while reducing chemical usage.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes acoustic wave energy at specific frequencies to resonate with and disrupt the emulsion structure. By controlling the electromagnetic field parameters and acoustic wave frequency, the system optimizes separation efficiency. The EMATs generate acoustic waves that match the resonant frequency of the emulsion droplets, causing them to break apart more effectively.

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If electromagnetic acoustic transducers (EMATs) are used to generate acoustic wave energy to separate fluid emulsion, then the environmental impact is minimized by reducing chemical demulsifiers, but the energy consumption increases

Engineering Contradiction:

Improveenvironmental impactVSAvoidenergy consumption

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If a sleeve is used to couple EMATs to the fluid container, then the acoustic wave energy transmission is improved, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveacoustic wave energy transmissionVSAvoidmanufacturing difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent introduces a sleeve as an intermediary component between the EMATs and the fluid container. The sleeve couples the EMATs to the container, providing a stable mounting structure that ensures efficient transmission of acoustic wave energy from the EMATs through the container wall into the fluid emulsion. This intermediary component simplifies the overall assembly and improves energy transmission reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 system effectively breaks down fluid emulsions into separate phases, reducing the need for chemical demulsifiers and minimizing environmental impact while ensuring efficient separation and recovery of components.

Implementation Method 1

each EMAT generates an electromagnetic field with the at least one coil and a magnetic field with the at least one magnet to interact with the electromagnetic field such that the interaction of the magnetic field and the electromagnetic field causes acoustic wave energy

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS20250214869A1Processing a fluid emulsion

Publication Date: 2025.07.03 SAUDI ARABIAN OIL CO

AI summary

A system includes a fluid container formed of a conductive metal and at least one opening; a plurality of electromagnetic acoustic transducers (EMATs) coupled with the fluid container; and a control system communicably coupled to each of the plurality of EMATs and configured to transmit a pattern of electrical signals to the plurality of EMATs to cause the plurality of EMATs to energize so that each EMAT generates an electromagnetic field with the at least one coil and a magnetic field with the at least one magnet to interact with the electromagnetic field to generate acoustic wave energy directed through the fluid container and to a hydrocarbon fluid emulsion within the fluid container to at least partially separate the hydrocarbon fluid emulsion into at least a water phase and a hydrocarbon phase.