Hydrocyclone and Ceramic Membrane Separator for Multi-Phase Compositions
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Solution Overview
Problem
Existing separation technologies for multi-phase compositions, such as produced water, face challenges including bio-fouling, large space requirements, and inefficiencies in removing solid particles, particularly in underwater drilling operations where space is limited.
Innovation Solution
A separator system integrating one or more hydrocyclones and ceramic membranes within a compact casing, where the ceramic membranes are positioned downstream of the hydrocyclone or integrated into its tapered section, effectively separating aqueous, oleaginous, and solid phases into distinct density streams while minimizing bio-fouling and space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If membrane separation or filtration processes are used to separate solid particles from multi-phase compositions, then separation efficiency is improved, but bio-fouling occurs requiring constant replacement of membranes and filters
Solution Approach 1:
The system segments the separation process into two distinct stages: first, hydrocyclones perform coarse separation to remove oil droplets and organic compounds; second, ceramic membranes perform fine separation to remove solid particles. This segmentation prevents bio-fouling by eliminating organic contaminants before they reach the membrane surface, while maintaining high separation efficiency through the combined action of both separation mechanisms.
Solution Approach 2:
The hydrocyclone performs preliminary separation of oil droplets and organic compounds from the multi-phase composition before the mixture reaches the ceramic membrane. This preliminary action removes the substances that would cause bio-fouling, protecting the membrane and extending its operational life while maintaining efficient solid particle separation.
2Reliability
If hydrocyclones are used to remove oil droplets and organic compounds, then bio-fouling is reduced, but efficiency in removing solid particles is insufficient
Solution Approach 1:
The separation function is segmented between hydrocyclones and ceramic membranes: hydrocyclones handle oil droplet and organic compound removal, while ceramic membranes handle solid particle removal. This segmentation allows each component to optimize its specific function, with the membrane providing high-efficiency solid separation without suffering from bio-fouling.
Solution Approach 2:
The hydrocyclone acts as an intermediary device between the raw multi-phase composition and the ceramic membrane. It pre-treats the mixture by removing organic contaminants, creating a cleaner feed stream for the membrane that maintains high solid particle removal efficiency while preventing bio-fouling.
3Measurement precision
If multiple separation units are combined in series or parallel to achieve comprehensive separation, then separation capability is improved, but space requirements become substantial
Solution Approach 1:
The ceramic membranes are disposed within the separator casing that also contains the hydrocyclones, creating a nested configuration where one separation system is integrated into the same housing as the other. This nesting approach allows comprehensive multi-phase separation capability while minimizing the overall space footprint by eliminating the need for separate external housing for each separation unit.
Solution Approach 2:
The hydrocyclone and ceramic membrane separation systems are merged into a single integrated apparatus with a common separator casing and coordinated flow paths. This combination achieves the separation capabilities of multiple independent units while reducing the total space required by consolidating housings, piping, and support structures.
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 system achieves efficient separation of multi-phase compositions into lesser-density, medium-density, and greater-density fluids, meeting water quality standards for reuse in hydrocarbon drilling and refining, with reduced bio-fouling and a compact footprint suitable for limited spaces.
Implementation Method 1
Hydrocyclones can be used to remove oil droplets and other organic compounds from multi-phase compositions
Implementation Method 2
hydrocyclonic separation
Implementation Method 3
Membrane separation or filtration processes may provide for efficient separation of solid particles from multi-phase compositions
Implementation Method 4
gravity oil separation (settling)
Data Source
AI summary
Separators for separating a multi-phase composition include a separator casing defining a chamber and a permeate outlet, at least one hydrocyclone within the separator casing, and at least one ceramic membrane. Each hydrocyclone includes a hydrocyclone inlet, a tapered section downstream of the hydrocyclone inlet, an accepted outlet, and a reject outlet. The ceramic membrane may be disposed within the separator casing and downstream of the accepted outlet of the hydrocyclone or may be disposed within at least a portion of the tapered section of the hydrocyclone. The ceramic membrane includes a retentate side and a permeate side, where the permeate side is in fluid communication with the chamber. Systems and methods for separating a multi-phase composition into a lesser-density fluid, a greater-density fluid, and a medium-density fluid using the separators are also disclosed.