Heat Exchanger Pneumatic Flocculation for Produced Water Treatment
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Solution Overview
Problem
Current methods for treating produced water from offshore oil platforms are complex, costly, and require significant space and time, failing to efficiently meet environmental standards for oil and grease content.
Innovation Solution
A system and method of pneumatic flocculation using gas injection into heat exchangers, positioned between the hydrocyclone and the floater, to improve oil removal efficiency by increasing the average diameter of gas/oil flocs and enhancing flotation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional treatment methods (hydrocyclone, flotation, filtration) are used to meet environmental standards for oil and grease content, then the treatment capacity and separation efficiency are improved, but the equipment complexity, space requirements, and operational time increase significantly
Solution Approach 1:
The patent combines the hydrocyclone separation process with pneumatic flocculation in a single integrated unit. The hydrocyclone receives produced water, separates oil-water emulsion, and the clarified water flows to a pneumatic flocculation device where air injection promotes flocculation of remaining oil droplets. This merging of separation and flocculation functions into a coordinated system reduces overall equipment complexity while maintaining high removal efficiency for meeting environmental standards.
Solution Approach 2:
The patent employs pneumatic flocculation by injecting air (gas phase) into the water-oil emulsion to promote flocculation of oil droplets. The air injection creates turbulence and facilitates collision between oil droplets, causing them to aggregate into larger flocs that are more easily removed. This pneumatic approach enhances the separation efficiency without requiring complex mechanical agitation systems, thereby reducing device complexity while improving oil and grease removal.
2Manufacturing precision
If multiple treatment stages (coagulation, flocculation, filtration, membrane filtration) are implemented to reduce oil and grease content, then the treatment effectiveness is improved, but the treatment time and operational duration increase
Solution Approach 1:
The patent applies preliminary hydrocyclone separation before the pneumatic flocculation stage. The hydrocyclone pre-separates the bulk oil-water emulsion, removing the majority of oil content before the water enters the pneumatic flocculation device. This preliminary action reduces the load on the subsequent flocculation and filtration stages, thereby reducing the overall treatment time while maintaining effectiveness in meeting environmental standards for oil and grease content.
3Manufacturing precision
If advanced treatment processes (microbubble flotation, ultraviolet treatment, ozone oxidation) are used to achieve high removal efficiency, then the oil and grease content is reduced effectively, but the operational costs and system complexity increase significantly
Solution Approach 1:
The patent employs a self-service approach by using the produced water itself as the medium for pneumatic flocculation. The air injection system utilizes the existing water flow and adds minimal chemicals or energy input. The process leverages the natural properties of the water-oil emulsion and the energy from air injection to achieve flocculation, eliminating the need for expensive external treatment systems such as ultraviolet lamps, ozone generators, or complex microbubble flotation equipment, thereby significantly reducing implementation costs while maintaining effective oil and grease removal.
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 proposed method significantly reduces the oil and grease content in produced water, achieving efficiencies that meet or exceed environmental standards with simpler, cost-effective, and space-efficient equipment.
Implementation Method 1
pneumatic flocculation with gas injection into heat exchangers
Implementation Method 2
injection of inert gas into heat exchangers
Implementation Method 3
flotation technique in a high-capacity centrifugal cell
Implementation Method 4
separation of an oil/water emulsion
Implementation Method 5
high-capacity centrifugal cell
Data Source
AI summary
The present disclosure provides embodiments that aim at removing oil from produced water resulting from oil extraction through in-line pneumatic flocculation with gas (air) injection into heat exchangers, wherein the heat exchangers are positioned between the hydrocyclone and the floater. In this way, the present disclosure proposes a produced water treatment system including a flash tank (I), a hydrocyclone (II), a flotation unit with reduced or dissolved gas (IV), a heat exchanger (III) arranged between the hydrocyclone (II) and a flotation unit with reduced or dissolved gas (IV), where the pneumatic flocculation occurs.