Inclined Pipe Holes for Liquid-Gas Separation
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Solution Overview
Problem
Current methods for separating water, oil, and gas from mixtures in pipes face challenges such as high shear stresses, emulsion formation, and limitations on flow velocity, which restrict the efficiency and effectiveness of separation processes, particularly in offshore oil and gas production.
Innovation Solution
A separation system utilizing a pipe with inclined and profiled holes along the wall, allowing water and oil/gas to be separated by reducing flow velocity from 2-3 m/s to 0.7-1 m/s, avoiding surfactant activation, minimizing gas droplet flow, and ensuring coalescence of dense droplet layers, enabling efficient separation at higher velocities than stratified flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separation is performed using dynamical processes based on centrifugal force, then separation efficiency is improved, but large shear stresses are created and emulsions are produced
Solution Approach 1:
The patent replaces the mechanical centrifugal force system with a gravity-based separation system using inclined holes. Instead of using dynamic mechanical processes that create shear stresses, the invention uses static gravity separation where the inclined hole geometry (angle and profile) naturally directs different phases to different outlets without generating harmful shear forces or emulsions.
Solution Approach 2:
The patent changes the geometric parameters of the separation system by using specifically designed inclined holes with optimized angles and profiles. This geometric parameter change allows the system to achieve separation based on phase density differences under gravity, avoiding the need for high-speed rotational mechanics while maintaining effective separation.
2Object-generated harmful factors
If separation is performed using gravitation only, then emulsion formation is avoided, but velocity must be kept low which increases separator dimensions
Solution Approach 1:
The patent changes the geometric parameters of the hole configuration (inclination angle, profile shape, size) to optimize the separation process. This allows the system to handle higher flow velocities while maintaining gravity-based separation, effectively decoupling the velocity limitation from the separator dimensions.
Solution Approach 2:
The patent introduces a new dimensional aspect to gravity separation by using inclined holes at specific angles rather than vertical or horizontal configurations. This angular dimension allows the system to exploit both gravity and the flow direction, enabling higher velocities to be handled effectively while maintaining phase separation.
3Productivity
If dispersed flow is maintained in the inlet pipe, then high flow rates are achieved, but separation quality deteriorates
Solution Approach 1:
The patent segments the flow separation process into distinct stages by using multiple inclined holes at different positions and angles along the pipe. This segmentation allows the system to handle dispersed high-velocity flow in the inlet while progressively separating phases through strategically positioned holes, maintaining both high flow rates and separation quality.
Solution Approach 2:
The patent applies preliminary action by using the first inclined holes to begin the separation process early in the pipe, creating initial phase division before the flow reaches the main separation section. This preliminary separation prepares the flow for more efficient final separation while allowing high inlet velocities to be maintained.
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 water and oil, allowing for reduced pipe dimensions and extended operation of oil and gas wells by maintaining separation quality independent of extraction velocity and location of holes, with the ability to handle well-mixed phases and high flow velocities.
Implementation Method 1
Separation by use of gravitation only presupposes the velocity in the pipe/separator to be low enough for the flowing mixture to flow in separate layers
Implementation Method 2
ensuring coalescence of dense droplet layers
Data Source
AI summary
The present invention is directed to both a method for ensuring optimal conditions for separation, and a separator device for extraction of water, oil and gas from a mixture of water-oil-gas flowing in a straight pipe or straight channel. A separator comprises a certain length of pipe with diameter larger than or equal an inlet pipe and several inclined and profiled holes along the separator pipe wall. Holes in the pipe wall at the bottom of the pipe are provided for extraction of water, and one or more groups of inclined holes in the pipe wall at the top of the pipe are provided for extraction of oil and possible gas. Water and oil/gas are separated such that dispersed flow in the inlet is reduced to velocity equal or less than that of the separated flow at the outlet of the separator.