Gas Diffuser Hopper Tank for Frac Sand Separation
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Solution Overview
Problem
The petroleum industry faces challenges in efficiently separating frac sand, water, and gas from pumped oil in hydraulic fracturing processes, as existing methods do not effectively remove gases to prevent hazardous conditions and do not facilitate the reuse of frac sand.
Innovation Solution
A separation apparatus comprising a gas diffuser, a hopper, and a tank that allows gas to be released into the atmosphere before effluent enters the hopper, with a drag chain assembly to remove solids and allow liquid to spill into the tank for separation, enabling the efficient separation of oil, water, and sand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas is not removed from effluent before processing, then the separation process becomes more complex, but hazardous conditions may arise
Solution Approach 1:
The gas diffuser performs gas removal as a preliminary action before the effluent enters the hopper for solid-liquid separation. By releasing gas to the atmosphere through the diffuser's outlets before further processing, the system prevents hazardous conditions from developing while maintaining a relatively simple overall structure.
2Productivity
If frac sand is not separated and reused, then operational costs increase, but the separation process becomes more complex
Solution Approach 1:
The separation process is segmented into distinct functional zones: the gas diffuser handles gas removal, the hopper handles solid frac sand separation, and the tank handles liquid separation. This segmentation allows frac sand to be effectively separated and reused, improving operational efficiency while keeping each component relatively simple in design.
3Device complexity
If a simple separation structure is used, then device complexity is reduced, but effective separation of gas, sand, and liquid cannot be achieved
Solution Approach 1:
The apparatus is divided into three main segmented components with distinct functions: gas diffuser (gas separation), hopper (solid separation), and tank (liquid separation). Each segment is designed for its specific separation task, achieving effective multi-phase separation without requiring an overly complex integrated structure.
Solution Approach 2:
The hopper acts as an intermediary component between the gas diffuser and the tank. It receives effluent from the diffuser, separates solids (frac sand) by gravity, and allows the liquid portion to flow into the tank for further separation. This intermediary structure enables effective separation while maintaining system simplicity.
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 apparatus safely releases gas, prevents hazardous conditions, and allows for the effective separation and potential reuse of frac sand, reducing operational costs and enhancing the efficiency of oil extraction.
Implementation Method 1
Gas in the effluent is released from the effluent and into the atmosphere
Implementation Method 2
solids and liquid in the effluent fall into the hopper
Implementation Method 3
liquid in the effluent spills over a top portion of the hopper and into the tank
Data Source
AI summary
A separation apparatus for separating constituents from effluent. The separation apparatus includes a gas diffuser, a hopper, and a tank. The gas diffuser includes an inlet inner tube for receiving effluent from a well. The hopper is disposed at least partially below the gas diffuser, and the tank is connected to the hopper. The gas diffuser is configured so that gas in the effluent is released from the effluent and into the atmosphere before the effluent enters the hopper. The hopper is configured so that liquid effluent in the hopper spills over a top portion of the hopper and into the tank.