Microstructure-Based Contaminant Removal in Produced Water
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Solution Overview
Problem
Conventional methods for removing contaminants from produced water in hydrocarbon production operations, such as settling and chemical flotation, are inefficient for small hydrocarbon particles and generate waste, necessitating improved methods for effective separation and recovery of contaminants.
Innovation Solution
Introducing solid microstructures with a bulk density different from the fluid and a surface attractive to contaminants, allowing for their attachment and separation, potentially without chemicals, enabling the removal of small contaminant particles and facilitating their reuse.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional settling and filtering operations are used to remove contaminants from produced water, then separation of large hydrocarbon particles can be achieved, but small hydrocarbon particles (diameter less than about 100 micron) cannot be effectively separated and the process requires large vessels and long separation times
Solution Approach 1:
The patent introduces gas bubbles as an intermediary medium to facilitate the separation of small hydrocarbon particles. The bubbles attach to the particles and carry them to the surface, acting as a mediator between the particles and the separation process. This resolves the contradiction by enabling effective separation of small particles without requiring large vessels or long separation times, thus improving both separation efficiency and productivity.
Solution Approach 2:
The patent employs gas flotation, a pneumatic process, to separate contaminants from produced water. By injecting gas to form bubbles that rise through the water and carry attached particles to the surface, the system achieves rapid separation of fine particles. This pneumatic approach overcomes the limitations of conventional gravity-based settling, improving both separation efficiency for small particles and overall productivity.
2Manufacturing precision
If chemical additives and gas flotation aids are used to remove small oil particles, then separation efficiency can be improved, but chemical waste is generated that must be disposed of
Solution Approach 1:
The patent extracts and eliminates the need for chemical additives from the flotation process. By using pure gas bubbles without chemical polymers or surfactants, the system achieves effective separation of oil particles while avoiding the generation of chemical waste. This resolves the contradiction by maintaining high separation efficiency through physical means alone, thereby eliminating chemical waste disposal requirements.
Solution Approach 2:
The patent converts the natural buoyancy of gas bubbles, which would otherwise simply rise and escape, into a beneficial separation mechanism. By controlling bubble generation and attachment, the system transforms a passive physical phenomenon into an active contamination removal tool, achieving effective separation without harmful chemical additives and their associated waste disposal problems.
3Manufacturing precision
If gas bubbles are generated to float contaminants to the surface, then small contaminant particles can be removed, but the bubbles tend to rise, collide, and combine to form larger bubbles that are less effective in removing contaminants
Solution Approach 1:
The patent employs periodic or controlled gas injection to generate bubbles at consistent intervals, preventing random bubble coalescence. By regulating the timing and frequency of bubble generation, the system maintains stable bubble size distribution and prevents the formation of large ineffective bubbles. This periodic control mechanism resolves the contradiction by maintaining both contaminant removal efficiency and bubble size consistency throughout the process.
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 microstructure-based method effectively removes contaminants, including small hydrocarbon particles, reduces chemical usage, and allows for the recovery and reuse of contaminants, enhancing the efficiency and cost-effectiveness of the process.
Implementation Method 1
the microstructures can increase the buoyancy of oil or other contaminant particles in the fluid such that contaminant particles with diameters as small as 10 microns, or smaller, can be removed without requiring unreasonable settling times
Implementation Method 2
the surface of the microstructures can be attractive to the contaminant. For example, if the fluid is produced salt water that contains crude oil as a contaminant, and if the microstructures are formed of glass, the oil will be preferentially attracted to wet the solid
Implementation Method 3
the microstructures can carry the contaminants for separation, e.g., by rising or falling in the fluid due to the density of the microstructures being different from the fluid
Data Source
AI summary
A method and system for removing contaminants from a fluid are provided. The method can generally include providing microstructures in the fluid. At least some of the contaminants in the fluid are attracted to the microstructures and adhered to the microstructures. With the contaminants attached to the microstructures, the microstructures can be separated from the fluid so that the contaminants are thereby removed from the fluid.