Flowback Fluid Separator System with Solids Removal
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Solution Overview
Problem
Conventional horizontal separators for processing flowback fluid from hydraulic fracturing are inefficient due to sand accumulation, which increases retention time and decreases efficiency, and lack individual metering capabilities for multiple wellheads.
Innovation Solution
A system with multiple first and second stage separators, each with independent temperature, pressure, and retention time control, and a manifold skid for distributing flowback fluids to separate gas, liquids, and solids efficiently, allowing for individual wellhead metering and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large horizontal separator is used to process flowback fluid from multiple wellheads, then all phases (gas, liquid, solids) can be separated in one vessel, but sand accumulation increases retention time and decreases processing efficiency
Solution Approach 1:
The patent divides the single horizontal separator into multiple separate processing stages: a vertical separator for gas-liquid separation followed by a horizontal separator for liquid-solids separation. This segmentation allows each stage to specialize in specific separation functions, preventing sand accumulation in the gas separation zone and reducing overall retention time while maintaining effective phase separation.
Solution Approach 2:
The patent extracts the solids separation function from the main horizontal separator by introducing a dedicated solids removal system with sand drains and a sand hopper. This allows continuous removal of sand from the process stream, preventing accumulation that would otherwise increase retention time and reduce processing efficiency.
2Measurement precision
If a single horizontal separator processes flowback fluid from multiple wellheads, then equipment complexity is reduced, but individual wellhead metering and evaluation become impossible
Solution Approach 1:
The patent assigns a dedicated metering device to each wellhead, creating individual measurement points before the flowback fluid enters the separation system. This segmentation enables precise monitoring and evaluation of each wellhead's production characteristics while maintaining a relatively simple overall system configuration through the use of standard metering instruments.
3Reliability
If solids are removed upstream before the horizontal separator, then sand-fill in the separator is avoided, but the solids separation devices are exposed to higher temperature and pressure causing damage and wear
Solution Approach 1:
The patent performs preliminary gas-liquid separation in the vertical separator before the fluid reaches the horizontal separator. This preliminary action removes the bulk of gases and liquids upstream, allowing the subsequent horizontal separator to operate under more favorable conditions with reduced sand-fill issues, while the solids removal system is designed to handle the remaining solids at lower stress levels.
Solution Approach 2:
The patent introduces a vertical separator as an intermediary device between the wellheads and the horizontal separator. This intermediary performs the initial gas-liquid separation, protecting the downstream horizontal separator from excessive sand accumulation and reducing the wear and thermal stress on solids handling components.
4Productivity
If chemical agents are added to treat flowback fluid, then separation of chemical components is improved, but the complexity of the processing system increases
Solution Approach 1:
The patent employs passive separation mechanisms using the natural density differences between phases (gas rises, liquid settles, solids sink) without requiring active chemical treatment systems. The vertical and horizontal separators utilize gravity-based separation, eliminating the need for complex chemical dosing equipment, injection systems, and chemical storage facilities while maintaining effective phase separation.
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 approach reduces retention time, increases efficiency, and enables safe, controlled processing of flowback fluids by actively separating solids and optimizing gas and liquid separation, overcoming the limitations of conventional systems.
Implementation Method 1
The phases and components of the flowback fluid separate in the horizontal separator as the flowback fluid settles. The amount of time required for sufficient process separation is known as retention time. In the horizontal separator, gases release to the top, oil rises above water, and denser sand falls to the bottom.
Implementation Method 2
In this position for flowback fluid, the temperature and pressure for solids separation systems are higher, and more likely to be damaged. The wear of abrasive sand upstream can shorten the working life of upstream solid separation devices for flowback fluid.
Data Source
AI summary
The system and method for processing flowback fluid include a plurality of wellheads producing flowback fluid flows, a plurality of first stage separators corresponding to at least one wellhead of an installation with multiple wellheads and multiple flowback fluid flows, a plurality of metering devices corresponding to each first stage separator, and a second stage separator in fluid connection with the metering devices and the first stage separators. The second stage separator includes a solids separator to further control the storage volumes of the first and second stage separators and retention time in the second stage separator by removing solids.