Gas-Liquid Separator with Float Valves for Produced Water
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Solution Overview
Problem
Existing systems for managing gas and liquid mixtures in gas wells vent valuable gas into the atmosphere, leading to pollution and pressure issues in liquid gathering systems, as gas accumulation increases pressure and prevents efficient liquid flow.
Innovation Solution
A device that separates gas from liquid streams using a tangentially entered combined flow in an annular space, allowing gas to be collected and vented separately while preventing liquid entry into gas systems and gas entry into water systems, operating in two modes based on pressure differences between gas and liquid systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas is vented to the atmosphere through collection tanks or air eliminator devices, then gas accumulation in the liquid gathering system is removed, but valuable gas is lost as pollution and the system requires complex venting infrastructure
Solution Approach 1:
The patent extracts gas from the liquid-gas mixture by allowing gas to rise to the top of the separator vessel where it accumulates against a float-operated valve. When sufficient gas accumulates to displace the float, the valve opens and gas is directed to a gas collection system rather than being vented to atmosphere. This extraction principle separates the valuable gas component for recovery while removing it from the liquid gathering system.
Solution Approach 2:
The patent introduces a float-operated valve mechanism as an intermediary between the separator vessel and the gas collection system. This intermediary automatically controls gas transfer based on gas accumulation levels, opening to allow gas passage when the float is displaced and closing when gas pressure equalizes. This intermediary enables automated gas recovery without requiring continuous monitoring or complex control systems.
2Loss of substance
If gas accumulates in the water gathering system, then gas can be separated and potentially recovered, but gathering system pressure increases and liquid flow efficiency decreases
Solution Approach 1:
The patent segments the gathering system into separate gas and liquid pathways using a separator vessel with distinct outlets. Gas accumulates in the upper portion of the vessel while liquid exits through a lower outlet, preventing gas from mixing with and pressurizing the liquid gathering system. This segmentation allows gas to be recovered without increasing liquid system pressure, as each phase is managed independently through its own outlet pathway.
Solution Approach 2:
The patent resolves the pressure conflict by transitioning from a single-phase vertical flow to a two-phase separated flow system. Gas is directed horizontally to a gas collection system while liquid flows vertically downward to the gathering system. This dimensional separation in the outlet configurations allows simultaneous gas recovery and liquid flow maintenance without pressure interference between the two systems.
3Loss of substance
If a separator device is installed to remove gas from produced water, then gas can be captured for sale and liquid flow is optimized, but the device complexity increases with multiple vessels, valves, and floats
Solution Approach 1:
The patent merges multiple functions into a single integrated separator vessel: gas-liquid separation, gas accumulation, float-operated valve control, and automated gas transfer to collection system. By combining these functions in one vessel rather than using separate devices for each function, the patent reduces overall system complexity while achieving gas capture for sale and maintaining liquid flow optimization.
Solution Approach 2:
The patent implements self-service through float-operated valves that automatically respond to gas accumulation levels. When gas accumulates and displaces the float, the valve opens to release gas; when gas pressure equalizes and the float returns, the valve closes. This self-regulating mechanism eliminates the need for external control systems, sensors, or manual operation, reducing device complexity while enabling automated gas capture and transfer.
4Stress or pressure
If the separator allows independent pressure control for gas and liquid systems, then each system can operate at optimal pressure, but the valve control mechanism becomes more complex to prevent liquid entry to gas system and gas entry into water system
Solution Approach 1:
The patent uses float-operated valves as intermediaries between the separator vessel and the gas/liquid collection systems. These valves automatically respond to pressure and level changes, opening or closing based on float position without requiring external control. This intermediary mechanism enables independent pressure control for gas and liquid systems while preventing backflow or cross-contamination through automatic valve operation driven by physical float displacement.
Solution Approach 2:
The float-operated valves provide automatic feedback control: when gas accumulates and raises the float, the valve opens to release gas; when gas pressure equalizes and the float descends, the valve closes. Similarly, liquid level changes move the float to control liquid discharge. This feedback mechanism maintains independent pressure control for gas and liquid systems while using simple mechanical float-valve coupling rather than complex electronic or pneumatic control systems.
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 the capture and sale of gas without venting it to the atmosphere, maintaining independent pressures for gas and liquid systems, thereby reducing pollution and optimizing liquid flow by removing accumulated gas, allowing for lower supply pressures and preventing gas entry into water systems.
Implementation Method 1
a combined stream tangentially enters an outer vessel of the device to begin flow spinning in an annular space between inner and outer vessels. This flow profile will tend to separate gases from liquids and allow the gases to rise into the top of the inner vessel
Implementation Method 2
When enough gas accumulates to displace adequate liquid to change the state of a top float from 'floating' to 'not floating', the gas motor valve is opened to allow accumulated gas to exit into a gas collection system
Implementation Method 3
When enough liquid comes into the vessel to float the lower float then the lower motor valve opens and gas system pressure pushes the liquid into the water system
Data Source
AI summary
A device for capturing gas included within a produced-water stream is described. Gas and water pressure coordination is not required. Controls prevent liquid entry to the gas system and prevent gas entry into the water system. A gas/liquid separator receives an inner vessel lower end. A separator inlet receives a combined fluid stream. A liquid line passes into the inner vessel and down into the separator below the inlet so that liquid separated from the combined stream will flow up the liquid line. Motor valves are in the liquid line and in a gas line. The gas line extends from the inner vessel upper end. The gas line conveys gas from the inner vessel upper end to a gas collection system. A top float in the inner vessel activates the gas line motor valve. A bottom float in the inner vessel activates the liquid line motor valve.