Gas Flotation Cell for Continuous Effluent Brine Processing
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Solution Overview
Problem
Current methods for separating oil and water in crude oil production and refining are inefficient, as they require batch extraction of oil-coated solids and emulsions, disrupting the separation process and failing to effectively remove dissolved organic species like benzene, leading to environmental and operational challenges.
Innovation Solution
A method involving a closed system with a gas flotation cell for continuous processing of interface emulsions, water, and solids, using extraction points and valves to control removal rates, and injecting a reverse emulsion breaker to aid separation, with recycled water and gas for further processing, ensuring no air emissions and efficient contaminant removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If batch extraction method is used to remove solids and emulsion, then the vessel can be cleaned, but the oil and water separation process and production process are disrupted
Solution Approach 1:
The patent implements continuous extraction of solids and emulsion through multiple extraction points positioned at different levels in the separator vessel. This allows uninterrupted removal of contaminants while maintaining continuous oil-water separation and production processes, eliminating the need for batch shutdowns.
Solution Approach 2:
The extraction system is divided into multiple extraction points (first, second, third extraction points) at different vertical positions in the vessel. Each point targets specific layers (solids at bottom, interface emulsion in middle, oil at top), enabling simultaneous continuous removal of different contaminant types without disrupting overall separation.
2Reliability
If conventional benzene extraction units are used, then benzene can be removed from effluent water, but high volumes of steam pressure are required and fouling occurs from heavy hydrocarbon entrainment
Solution Approach 1:
The patent uses a gas flotation cell to extract benzene and other organic contaminants from effluent water through gas-liquid contact. This alternative extraction method eliminates the need for high-volume steam pressure systems and reduces fouling from heavy hydrocarbon entrainment while maintaining effective benzene removal.
Solution Approach 2:
The patent replaces the mechanical steam pressure-based extraction system with a gas flotation cell that uses gas-liquid contact and flotation mechanisms. This substitution reduces complexity and steam requirements while achieving the same contaminant removal function.
3Quantity of substance
If effluent water contains heavy hydrocarbon interface emulsion, then the emulsion can be present in the water stream, but it settles in refinery process sewer causing plugging and flow restriction problems
Solution Approach 1:
The patent uses a reverse emulsion breaker to convert the harmful heavy hydrocarbon interface emulsion into a beneficial separated state. The reverse emulsion breaker transforms the emulsion into distinct oil and water phases that can be easily separated and removed, preventing sewer plugging while managing the emulsion content.
Solution Approach 2:
The patent changes the physical-chemical parameters of the emulsion by injecting reverse emulsion breaker chemicals. This alters the emulsion stability and interfacial properties, causing the heavy hydrocarbon emulsion to break and separate into removable phases, eliminating the plugging problem.
4Ease of operation
If cleaning processes are used to remove sewer restrictions, then flow restrictions can be cleared, but leaks and loss of containment integrity occur
Solution Approach 1:
The patent prevents sewer plugging before it occurs by continuously removing heavy hydrocarbon emulsion at the source using the reverse emulsion breaker and gas flotation cell. This preliminary action eliminates the need for subsequent cleaning operations that would risk causing leaks and compromising containment integrity.
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
Enables continuous operation with reduced disruption, effective removal of oil, water, and contaminants, meeting environmental standards by maintaining a stable interface emulsion layer and recycling treated water and gas for further use, thus improving process efficiency and compliance.
Implementation Method 1
passing the interface emulsion, water, and solids through a gas flotation cell. The cell, which is preferably a vertical induced gas flotation cell, separates the oil and water contained in the interface emulsion
Implementation Method 2
The basic method of separating a mixture of oil and water is by use of gravity. These separators range from rather unsophisticated holding vessels—which simply provide an enclosed container wherein the oil and water mixture can rest with reduced turbulence, thereby allowing the oil to float to an upper part of the vessel and water to settle to a lower part of the vessel
Implementation Method 3
injecting a reverse emulsion breaker to aid separation
Data Source
AI summary
A system and method for processing interface emulsion, water, and solids contained within a separator vessel that comprises the steps of continually extracting those components from the vessel and then passing them through a gas flotation cell. The cell, which is preferably a vertical induced gas flotation cell, separates the oil and water contained in the interface emulsion and discharges recovered oil from an upper portion of the cell and treated water from a bottom portion of the cell. The recovered oil and treated water may be further processed and recycled to the vessel or sent elsewhere. The treated water may also be recycled to the cell or sent to a process sewer. Fuel gas residing in an upper portion of the cell may be cooled and passed through a splitter. All the steps of occur in a closed system with no air emissions.