Magnetic Separator with Helical Screw for Ferrous Particle Discharge
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Solution Overview
Problem
Existing magnetic separating apparatuses for oil and gas process liquids or slurries face challenges in completely discharging small ferrous particles, leading to clogging and system downtime, and are not suitable for permanent integration into rig packages.
Innovation Solution
A magnetic separator apparatus with a concentric cylindrical design, featuring a helical screw flight and a magnet assembly that generates varying magnetic field strengths along its length, includes a retaining surface to hold particles and a particle release surface to move them to a low magnetic field area for discharge, allowing for self-cleaning without human intervention and integration into a rig package flowline.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If magnetic separator apparatus is used to separate ferrous particles from liquid or slurry, then ferrous particles are effectively removed, but the apparatus requires human intervention for cleaning and removal of collected particles
Solution Approach 1:
The screw conveyor is designed to automatically discharge collected ferrous particles without human intervention. The rotating helical flights convey particles along the conveyor body, and the varying magnetic field strength allows particles to be released at the discharge end, enabling the apparatus to clean itself continuously during operation.
Solution Approach 2:
The magnetic field strength varies along the length of the screw conveyor - strong at the collection end to attract particles, and weaker at the discharge end to allow particle release. This gradient in magnetic field parameters enables automatic particle discharge without manual cleaning.
2Reliability
If magnetic field strength is increased to improve particle collection, then ferrous particles are more effectively attracted, but small particles fail to discharge and cause clogging
Solution Approach 1:
The magnetic field strength is not uniform throughout the apparatus but varies locally along the screw conveyor length. The field is strong at the collection end for effective particle attraction and weaker at the discharge end to facilitate particle release, preventing clogging while maintaining reliable operation.
Solution Approach 2:
The magnetic field parameter changes along the conveyor - high field strength for particle collection transitions to low field strength for particle discharge. This parameter variation ensures small particles can be both collected effectively and discharged without causing clogs.
3Adaptability or versatility
If traditional magnetic separator apparatus is used, then particle separation is achieved, but the apparatus cannot be permanently integrated into rig package flowlines
Solution Approach 1:
The screw conveyor design with varying magnetic field strength serves multiple functions: it collects ferrous particles, conveys them along the apparatus, and automatically discharges them. This multi-functional design allows permanent integration into rig package flowlines without requiring separate cleaning mechanisms or complex auxiliary systems.
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 apparatus effectively separates and discharges ferrous particles, preventing clogging and enabling continuous operation, while being designed for permanent integration into oil and gas exploration and production facilities.
Implementation Method 1
a magnet assembly extending along at least a part of the longitudinal axis, such that ferrous particles are attracted to an internal cylindrical surface of the annular volume
Implementation Method 2
at least one helical screw flight on one of the first or second cylindrical sheaths, and extending substantially or fully across the annular volume; wherein the at least one screw flight and the cylindrical sheath on which it is mounted is operable to be rotated with respect to the magnet assembly to convey particles along the apparatus
Data Source
AI summary
The application provides an apparatus for removing ferrous particles from an oil or gas process liquid or slurry and a method of use. The apparatus has a first inner cylindrical sheath and a second outer cylindrical sheath arranged concentrically on a longitudinal axis to create an annular volume. A helical screw flight on the first or second cylindrical sheaths extends across the annular volume, and a magnet assembly extends along the longitudinal axis, such that ferrous particles are attracted to a surface of the annular volume. The apparatus has an inlet a discharge outlet, and a ferrous particle collection location. The screw flight and the cylindrical sheath operable to rotate with respect to the magnet assembly to convey particles to the collection location. The apparatus includes a retaining surface to retain collected particles.