Flow Back Separation System with Hydrocyclones and Linear Shaker
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Solution Overview
Problem
Current methods for separating solids from hydrocarbon well slurries are inefficient, particularly in effectively removing entrained gases and achieving complete dewatering of solids, leading to suboptimal processing outcomes.
Innovation Solution
A flow back separation system comprising a V-shaped tank with degassing units, shaftless augers, hydrocyclones, and a linear shaker, which collectively remove entrained gases, settle and process solids, and facilitate dewatering and recirculation of slurry components, enhancing the separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current separation methods are used, then the process is simpler, but the effectiveness of removing entrained gases and achieving complete dewatering is insufficient
Solution Approach 1:
The separation system is divided into distinct functional sections: a V-shaped compartment for initial settling and gas removal, hydrocyclone units for centrifugal separation, and a linear shaker for final dewatering. Each section handles a specific aspect of the separation process, improving overall effectiveness while maintaining manageable complexity through modular design
Solution Approach 2:
Multiple separation mechanisms are combined within a single integrated system: gravity settling in the V-shaped compartment, centrifugal force in the hydrocyclones, and mechanical vibration in the linear shaker. This merging of different separation principles achieves complete dewatering and effective gas removal that would be difficult with any single method
2Reliability
If a single separation stage is used, then the device is simpler, but the dewatering is incomplete
Solution Approach 1:
The system implements continuous multi-stage separation where slurry flows sequentially through the V-shaped compartment, hydrocyclone units, and linear shaker. Each stage processes the output of the previous stage, ensuring continuous removal of liquids and gases until complete dewatering is achieved, with the shaftless auger continuously conveying processed solids to the next stage
Solution Approach 2:
The V-shaped compartment performs preliminary settling and gas removal before the slurry enters the hydrocyclone units. This preliminary action reduces the gas content and performs initial solid-liquid separation, making the subsequent centrifugal separation more effective and reducing the burden on later dewatering stages
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 separates solids from hydrocarbon well slurries by removing entrained gases and achieving efficient dewatering, resulting in improved processing outcomes and optimized solid recovery.
Implementation Method 1
The one or more degassing units may remove an entrained gas from the slurry and discharge a first slurry
Implementation Method 2
The first series of baffles may cause a first settling of a first solids within the first slurry
Implementation Method 3
The shaftless auger may be configured for rotation to cause the first solids to move to the rear section of the compartment
Implementation Method 4
The suction pump may be configured to pump a second slurry containing the first solids through the first conduit
Implementation Method 5
The one or more hydrocyclone units may receive and process the second slurry to produce an overflow comprising a first clean fluid and an underflow comprising the first solids
Implementation Method 6
The linear shaker may be configured to receive the underflow from the one or more hydrocyclone units and to cause a dewatering of the first solids to produce a dried first solids
Implementation Method 7
The linear shaker may be further configured to convey the dried first solids to a storage device for disposal
Implementation Method 8
The linear shaker may produce an underflow comprising a third slurry comprising a second solids. The linear shaker may be configured for depositing the third slurry into the compartment at its rear section for recirculation through the first conduit
Implementation Method 9
The second series of baffles may cause a second settling of a third solids
Implementation Method 10
The third solids may be moved to the rear section of the compartment by the rotation of the shaftless auger
Implementation Method 11
The underflow weir may be configured to cause the first clean fluid to flow under the underflow weir
Implementation Method 12
The overflow pipe may be configured to provide an outlet for the first clean fluid to exit the tank
Data Source
AI summary
A flow back system for separating solids from a slurry recovered from a hydrocarbon well. The system includes a V-shaped tank with a first series of baffles configured to cause the settling of solids that are moved by a shaftless auger to a conduit fluidly connected to hydrocyclones mounted over a linear shaker. The overflow from the hydrocyclones is discharged through a second conduit back into the tank for processing by a second series of baffles resulting in a clean effluent. The clean effluent is recirculated in the well.