In-line Flow Separator for Liquid Stratification
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Solution Overview
Problem
Conventional gravity tank separators for oil pipelines are bulky and inefficient, particularly in offshore operations, and require significant space and resources, while existing in-line separation methods still rely on gravitational settling and are not optimized for liquids of similar densities.
Innovation Solution
An in-line flow separator with an upwardly inclined pipeline section that utilizes gravitational stratification to separate liquids of differing densities, where the denser liquid forms a sump and is extracted at a rate equal to its flow rate, allowing for continuous separation without stagnant retention, and includes a system to control the extraction rate based on the behavior of the sump tail or liquid cut.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gravity tank separators are used for oil pipelines, then separation of water from oil is achieved, but the equipment becomes bulky and requires significant space
Solution Approach 1:
The patent transitions from conventional horizontal tank separators to a vertical in-line configuration where the separator is positioned within the pipeline itself. This dimensional change allows separation to occur in the vertical direction while maintaining continuous horizontal flow through the pipeline, eliminating the need for large external tank spaces.
Solution Approach 2:
The separator is nested within the existing pipeline infrastructure, with the separation chamber integrated into the pipeline wall. This allows the separation function to be embedded within the transport system rather than requiring separate external equipment, thereby reducing overall space requirements.
2Reliability
If tank separators are used for centralized facilities, then separation is achieved, but production pipelines become overloaded and larger more costly
Solution Approach 1:
The separator performs water separation in advance within the pipeline itself, before the fluids reach centralized facilities. This preliminary separation action reduces the water load on downstream infrastructure and eliminates the need for oversized pipeline capacity to handle water-laden flows.
Solution Approach 2:
The patent extracts the separation function from centralized facilities and relocates it to distributed in-line positions within the pipeline. This extraction allows separation to occur at multiple points along the pipeline, reducing the burden on any single centralized facility and allowing for smaller, more manageable infrastructure.
3Volume of stationary object
If in-line separation is used for liquids of similar densities, then equipment size is reduced, but separation efficiency is insufficient
Solution Approach 1:
The patent introduces dynamic flow control mechanisms that adjust the flow characteristics within the separation chamber to optimize separation efficiency. By dynamically managing flow velocity, residence time, and fluid mixing, the system achieves effective separation of liquids with similar densities while maintaining a compact in-line configuration.
Solution Approach 2:
The patent employs an intermediary substance or mechanism within the separation chamber that facilitates the separation process. This intermediary element enhances the separation efficiency between liquids of similar densities by providing additional separation mechanisms beyond simple gravitational settling, such as flow-induced separation or interfacial tension exploitation.
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
Enables efficient, space-saving, and continuous separation of liquids in pipelines, reducing equipment size and operational costs, and is adaptable for various industries beyond oil, with minimal obstructions and pressure losses, and can handle liquids of similar densities effectively.
Implementation Method 1
an uphill section of pipeline which, in use, carries a gravitationally stratified flow of a first liquid and a second denser liquid
Data Source
AI summary
An in-line flow separator (1) comprises an uphill section (2) of pipeline which, in use, carries a gravitationally stratified flow of a first liquid (3) and a second denser liquid (4). The second liquid (4) forms a sump (5) extending uphill from the foot of the uphill section (2), and an interface between the first and second liquids on the uphill section is inclined from the horizontal. An extraction port (6) in the pipeline extracts the second liquid from the sump.