Multi-phase Emulsion Separator with Folded Flow Channels
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Solution Overview
Problem
Conventional separators face challenges in efficiently separating water, gas, and oil within a limited footprint, as they rely on gravity and often fail to utilize space effectively, leading to incomplete phase separation and reduced retention time for fluids.
Innovation Solution
The implementation of directed flow channels that fold back along the length of the separator vessel, allowing multiple stages of separation and extended retention time for fluids, combined with sediment chambers and Weir plates for precise separation of water and oil, minimizes space usage while enhancing separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional gravity-based separation is used, then the separator can operate with simple structure, but the footprint area is large and separation efficiency is insufficient
Solution Approach 1:
The patent transforms the conventional linear horizontal flow path into a three-dimensional folded flow path that utilizes vertical space. The flow channel folds back on itself multiple times within the vessel, converting a two-dimensional footprint problem into a three-dimensional space utilization solution, thereby achieving compact footprint while maintaining extended retention time.
Solution Approach 2:
The flow channel is designed to nest within itself by folding back, creating a compact configuration where the fluid path is contained within a smaller external footprint. The channel enters, travels forward, folds back, and exits in a nested arrangement that maximizes space efficiency.
2Device complexity
If conventional gravity-based separation is used, then the separator can operate with simple structure, but the retention time is insufficient for complete phase separation
Solution Approach 1:
By utilizing vertical folding of the flow channel, the patent extends the retention time without proportionally increasing the vessel volume. The three-dimensional folded path allows fluid to traverse a longer distance through the separation zones, enhancing phase separation completeness while maintaining a compact overall structure.
Solution Approach 2:
The flow channel design incorporates preliminary separation zones where phases begin to separate before entering the main separation chambers. This preliminary action enhances the efficiency of the subsequent separation stages, allowing for more complete phase separation within the available retention time.
3Device complexity
If space is not utilized effectively, then the separator can have simpler internal configuration, but the separation efficiency is reduced
Solution Approach 1:
The patent employs vertical folding of flow channels to utilize previously unused vertical space within the vessel. This three-dimensional configuration allows multiple flow paths to coexist within the same footprint, effectively increasing the separation capacity and efficiency without adding complex external structures.
Solution Approach 2:
The internal space is segmented into multiple functional zones including sediment chambers, coalescer sections, and separated flow paths for different phases. This segmentation allows each zone to perform its specific separation function efficiently, maximizing overall separation productivity within the compact configuration.
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 achieves improved separation efficiency by utilizing unused space, extending fluid travel paths, and allowing multiple stages of separation, resulting in purer oil and water outputs with reduced stirring, thus optimizing the separation process within a compact footprint.
Implementation Method 1
Due to their reliance on gravity for portions of their operations
Implementation Method 2
separating the various solid, gaseous and liquid components
Implementation Method 3
followed by a coalescer
Implementation Method 4
water separation chamber and one oil collection chamber separated by at least a first Weir plate
Data Source
AI summary
A well flow separator vessel having a sediment chamber at the inlet end of the vessel with a knock-down billet, followed by a coalescer and a first horizontal flow path between an upper horizontal divider and a lower horizontal divider extending the cylinder length from the sediment chamber towards the distal end of the vessel. At the far end of the first flow path, gasses are received through a scrubber/demister into a second horizontal flow path between the upper horizontal divider and the top side of the vessel, also extending the cylinder length, except directing flow in the reverse direction back towards the inlet end of the vessel towards a gas outlet. Also at the far end of the first flow path, combined liquids fall into a third horizontal flow path between the lower horizontal divider and the bottom side of the body extending the cylinder length towards the inlet end of the vessel, and having at a first one water separation chamber and one oil collection chamber separated by at least a first Weir plate, wherein the oil collection chamber terminates at the bulkhead. A plurality of outlets is provided for removing sediment, water and oil from the chambers and gas second horizontal flow path.