Flowback Separation Vessel with Vapor Barrier and Debris Control
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Solution Overview
Problem
The oilfield industry faces challenges in efficiently separating and reclaiming fluid mixtures, known as Flowback, which contain unwanted gases, liquids, solids, and water from wellbores, due to the debris left by plug removal during hydraulic fracturing, leading to costly and environmentally complex processing.
Innovation Solution
A sealed vessel apparatus with a chamber, inlet conduits, a liquids discharge line forming a P trap, a vacuum breaker valve, and separate gas and solids discharge conduits, along with a rotary valve for controlled solids discharge, is used to collect and separate the fluid mixture into distinct streams, preventing gas release to the atmosphere and maintaining a vapor barrier.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plugs are removed during drill out process, then wellbore is cleared for production, but debris is left in the wellbore causing problems with subsequent operations
Solution Approach 1:
The patent extracts and removes plug debris from the wellbore using a debris removal device that travels through the wellbore and collects debris particles, separating them from the production stream before they can cause problems in subsequent operations
Solution Approach 2:
The patent introduces a debris removal device as an intermediary component between the plug removal process and production operations. This device acts as a mediator that captures and removes debris without interfering with hydrocarbon production
2Object-affected harmful factors
If Flowback is collected in frac tanks, then unwanted fluids are contained, but expensive and environmentally complex processing is required
Solution Approach 1:
The patent segments the Flowback separation process into distinct functional zones within a single vessel: gas separation zone, liquid settling zone, and solids accumulation zone. This segmentation allows different phases to be handled separately and efficiently without requiring multiple external processing units
Solution Approach 2:
The patent designs a multi-functional separation vessel that simultaneously performs gas venting, liquid containment, solids separation, and debris removal. This single device replaces the need for separate frac tanks and multiple processing systems, reducing overall system complexity
3Stress or pressure
If gas is released to atmosphere during separation, then pressure is relieved, but environmental safety is compromised
Solution Approach 1:
The patent converts the potentially harmful gas emission into a beneficial process by routing gases through a controlled discharge system that monitors and manages emissions. The gas venting mechanism is designed to release pressure safely while minimizing environmental impact through controlled discharge pathways
Data Source
AI summary
Techniques and apparatus for separating a Flowback mixture received from a wellbore. Employing a vessel or system of vessels to receive the fluid mixture and configured to manage the discharge of gases, liquids, and solids to maintain a vapor barrier in the vessel(s) to prevent unwanted release of gas to the atmosphere.