Inline Demulsification Device Ultrasonic Wave Separation
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Solution Overview
Problem
Current oil extraction processes face challenges with high water-cut levels, leading to costly and environmentally unfriendly chemical injection methods for de-emulsifying crude oil, which result in prolonged settling times, incomplete separation, and potential corrosion, hindering oil production and downstream processes.
Innovation Solution
An inline demulsification system incorporating an ultrasonic wave device and flow conditioner to separate multiphase fluids into liquid and gas phases, utilizing ultrasonic waves to demulsify emulsions and adjust flow profiles to mitigate power loss, allowing for real-time control of demulsification processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If de-emulsifying chemicals are injected into pipeline segments to reduce molecular forces between hydrocarbon and water molecules, then emulsion intensity is reduced, but the process becomes costly and environmentally unfriendly
Solution Approach 1:
The patent replaces chemical injection with an ultrasonic demulsification device that uses mechanical ultrasonic waves to break emulsions. The ultrasonic device generates cavitation and mechanical forces that disrupt the emulsion structure, eliminating the need for chemical additives while maintaining effective demulsification
Solution Approach 2:
The patent changes the physical parameters of the fluid by applying ultrasonic energy at specific frequencies and intensities. This alters the emulsion's physical state through cavitation and mechanical vibration, achieving demulsification through physical parameter modification rather than chemical intervention
2Reliability
If cascades of downstream storage tanks are used to achieve further separation by gravity, then separation is achieved, but settling time increases causing substantial decrease of oil production throughput
Solution Approach 1:
The ultrasonic demulsification device performs preliminary action by breaking down the emulsion structure before the fluid enters storage tanks. This pre-treatment reduces the settling time required in downstream tanks, allowing faster throughput while maintaining separation effectiveness
Solution Approach 2:
The ultrasonic treatment enables the system to skip the lengthy gravity settling process by rapidly breaking emulsions in-line. This rushes through the demulsification step that would otherwise require prolonged storage tank settling, significantly increasing production throughput
3Reliability
If de-emulsification process is used to separate oil and water, then separation is achieved, but complete separation is not guaranteed leading to severe corrosion in oil-carrying pipelines for water concentration exceeding 2%
Solution Approach 1:
The ultrasonic device provides more effective mechanical disruption of emulsion droplets compared to gravity separation alone. The cavitation and shear forces from ultrasonic waves achieve more complete separation, reducing water content below corrosion-threshold levels more reliably than gravity settling
4Reliability
If ultrasonic waves are emitted towards multiphase fluid to demulsify emulsion, then demulsification efficiency is improved, but power loss occurs due to gas phase presence
Solution Approach 1:
The flow conditioner segments the multiphase flow to create a more favorable flow profile where the liquid phase is better distributed. This segmentation allows ultrasonic energy to be more effectively transmitted through the liquid phase while minimizing interference from gas pockets, reducing power loss
Solution Approach 2:
The flow conditioner creates local variations in flow quality by generating swirl and redistributing phases. This local quality improvement ensures that ultrasonic probes operate in regions with optimal liquid-phase contact, maximizing demulsification efficiency while minimizing energy loss to gas phases
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
This approach enhances oil-water separation efficiency, reduces costs, minimizes environmental impact, and increases oil production throughput by effectively breaking emulsions and preventing corrosion, while allowing for adaptable operation based on real-time fluid properties.
Implementation Method 1
an ultrasonic wave device, provided downstream from the flow conditioner, including one or more ultrasonic probes for emitting ultrasonic waves towards the multiphase fluid, wherein the ultrasonic waves demulsify at least a portion of the emulsion
Implementation Method 2
an inline flow conditioner for separating a multiphase fluid into a liquid phase and a gas phase
Data Source
AI summary
Embodiments of the present disclosure describe an inline demulsification system (400, 430) including an inline flow conditioner (402,410) for separating a multiphase fluid into a liquid phase (420) and a gas phase (422), wherein the liquid phase (420) includes an emulsion; and an ultrasonic wave device (404), provided downstream from the flow conditioner (402, 410), including one or more ultrasonic probes (442) for emitting ultrasonic waves (452) towards the multiphase fluid, wherein the ultrasonic waves (452) demulsify at least a portion of the emulsion. Embodiments of the present disclosure also describe related systems and methods.