Micro-bubble Induced Gas Flotation Cell for Fine Oil Separation
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Solution Overview
Problem
Current Induced Gas Flotation (IGF) cells face challenges in achieving high efficiency and meeting discharge regulations for produced water in the Gulf of Mexico, particularly in separating small oil droplets, as they are limited by the size of bubbles created and the inability to effectively remove fine oil droplets and emulsified oils.
Innovation Solution
The integration of micro-bubbles with traditional induced gas flotation technology, utilizing a Dissolved Gas Flotation (DGF) system that includes a multi-phase pump, low-pressure eductor, high-shear static mixer, and modified globe valves to create uniform micro-bubbles that combine with macro-bubbles to enhance separation efficiency, allowing for the removal of small oil droplets by adjusting bubble size and gas flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional induced gas flotation technology is used, then the system structure is simple and easy to operate, but the separation efficiency is insufficient and cannot effectively remove fine oil droplets
Solution Approach 1:
The patent combines induced gas flotation (IGF) technology with dissolved gas flotation (DGF) technology in a single integrated system. The IGF section generates macro-bubbles while the DGF section generates micro-bubbles, and both bubble types work together to float oil droplets of different sizes, achieving high separation efficiency without requiring completely separate treatment systems
Solution Approach 2:
The flotation system is divided into distinct functional sections: an IGF section with inducers that create macro-bubbles, and a DGF section with spargers that generate micro-bubbles. This segmentation allows each section to optimize its bubble generation mechanism for specific droplet size ranges while working together in the same treatment system
2Manufacturing precision
If only macro-bubbles are used in flotation, then the device complexity is low, but the ability to remove fine oil droplets is limited
Solution Approach 1:
Different regions of the system produce different bubble sizes tailored to specific needs: the IGF section produces larger macro-bubbles (0.5-5 mm) effective for larger oil droplets, while the DGF section produces smaller micro-bubbles (10-100 μm) effective for fine oil droplets. Each zone's bubble characteristics are optimized for its specific separation function
Solution Approach 2:
The system controls bubble size as a key parameter by using different generation mechanisms: IGF uses inducers creating macro-bubbles through mechanical agitation, while DGF uses spargers creating micro-bubbles through gas dissolution and release. This parameter control allows targeted removal of oil droplets across different size ranges
3Manufacturing precision
If the bubble size is not controlled, then the operation is simple, but the separation performance cannot meet stringent discharge requirements
Solution Approach 1:
The system incorporates adjustable parameters including gas flow rates to both IGF and DGF sections, and the operational timing of each section. This dynamic control allows operators to optimize bubble size distribution and separation performance for different influent conditions while maintaining relatively simple operation through straightforward parameter adjustments
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 significantly improves the separation efficiency of IGF cells, enabling the removal of fine oil droplets and emulsified oils, meeting stringent discharge requirements by creating a wide range of bubble sizes that can float even the smallest oil droplets to the surface, thereby enhancing overall treatment performance.
Implementation Method 1
The gas flows through a series of shearing stages, including the multi-stage centrifugal shearing pump
Implementation Method 2
high shear and turbulence at the throat
Implementation Method 3
high shear static mixer and a series of modified globe valves to create excessive shear and turbulence
Implementation Method 4
extreme pressure drop and turbulence in globe valves
Implementation Method 5
extreme pressure drop and turbulence in globe valves
Implementation Method 6
micro-bubbles created by dissolved gas flotation assemble in conjunction with induced gas flotation macroscopic bubbles and improve the overall technique of flotation and/or removal
Implementation Method 7
low pressure eductor, high shear static mixer
Data Source
AI summary
A method and apparatus for separating two fluids, one lighter in specific gravity than the other, including the steps of providing a single vessel, having a primary separation chamber and a gas flotation chamber; separating fluids in the primary separation chamber to allow for free and suspended solids along with free oil and grease and gas to be removed from the fluids in the primary separation chamber; flowing the fluids into the gas flotation chamber portion; providing a first induced gas flow; combining a second gas flow of micro-bubbles with the first gas flow; and introducing the combined gas flow into the gas flotation chamber portion to provide a source of micro-sized dispersed bubbles in the fluid to accelerate the lift necessary for separation of fine oil droplets, emulsified oil droplets, from the water flowing in the flotation chamber portion. The apparatus for introducing the micro-bubbles to be comingled with the first induced gas flow includes a static mixer, a DGF pump, eductor and a series of globe valves which can be part of the gas flotation system or retrofitted to an existing gas flotation system.