Gun Barrel Recirculation Nozzle Assembly for Oil Recovery
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Solution Overview
Problem
Existing gun barrels are inefficient in crude oil recovery, often resulting in hydraulic efficiency of 3%, contamination with iron sulfide, iron carbonate, and calcium carbonate, and significant downtime due to maintenance and cleaning.
Innovation Solution
A system and method for enhanced oil-water separation that recirculates fluid from the bottom of a gun barrel, separator, or AST tank back to the top, improving hydraulic efficiency and reducing downtime through the use of internal or external recirculation lines and nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional gravity separation is used in gun barrels, then the structure is simple and easy to operate, but the hydraulic efficiency is very low (around 3%) and oil recovery is inefficient
Solution Approach 1:
The separator is divided into multiple functional zones: an oil zone at the top, a water zone at the bottom, and a recirculation system with nozzles that segments the flow path. This segmentation allows oil to be recovered from the top while water is recirculated from the bottom, significantly improving hydraulic efficiency without requiring a completely complex new structure
Solution Approach 2:
The recirculation system performs preliminary action by continuously circulating water from the bottom back to the top before new crude oil enters the separator. This pre-circulated water helps maintain separation efficiency and prevents solids accumulation, improving oil recovery efficiency proactively rather than reactively
2Reliability
If the separator operates continuously without recirculation, then the device complexity is low, but solids and sludge accumulate forming crusts and rag layers that reduce separation quality and require frequent shutdowns
Solution Approach 1:
The recirculation system enables continuous useful action by constantly circulating water from the bottom of the separator back to the top. This continuous circulation prevents solids and sludge from accumulating and forming crusts or rag layers, maintaining separation quality and allowing the separator to operate continuously without frequent shutdowns for cleaning
Solution Approach 2:
The recirculation system implements feedback by taking water from the bottom outlet and returning it to the top inlet. This feedback loop continuously removes accumulated solids and maintains the separation interface quality, enabling reliable continuous operation while the added complexity of the recirculation piping and pump is justified by the elimination of shutdowns
3Productivity
If recirculation is implemented to improve separation efficiency, then hydraulic efficiency improves and cleaner oil and water are returned, but the device complexity increases due to additional piping and pumps
Solution Approach 1:
The recirculation system serves multiple functions simultaneously: it improves hydraulic efficiency by enhancing the separation process, prevents solids accumulation and crust formation, maintains the oil-water interface quality, and enables continuous operation. This multi-functionality justifies the added complexity of the piping and pump system, as one subsystem performs several critical functions that would otherwise require separate equipment
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 recirculation system significantly improves hydraulic efficiency, returns cleaner oil and water, and reduces downtime for maintenance and cleaning, enhancing the overall separation process.
Implementation Method 1
fluid is taken from the bottom (or near bottom) of the tank and returned to the upper portion of the tank through piping and/or one or more nozzles
Implementation Method 2
the tank provides a controlled environment where these components can separate based on their density differences
Implementation Method 3
gravity acts on the mixture, causing separation based on Stokes Law predicated on the density differences between the components
Data Source
AI summary
A tank recirculation assembly comprising a recirculation line that draws fluid from the lower portion of a tank; and a pump that directs the recirculated fluid vertically toward and into the upper portion of the tank. The assembly comprises piping, pumping process and/or nozzles that spray the recirculated fluid across the surface oil inside of the tank. Recirculation is incorporated to enhance the recovery of more and cleaner oil by spraying as much of the surface area of the oil recovery zone to keep it clean. The then dispersed fluid travels down through the pad and reacts to help disperse and remove the interface that conglomerates in between the oil and water interface.