Microwave Oil-Water Separator with Metallic Grids
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Solution Overview
Problem
Conventional methods for separating oil and water in crude oil compositions face challenges such as residual chemical demulsifiers in aquatic environments, limited exposure to microwave energy due to small applicator sizes, and inefficiencies in separating high-water-content or tightly emulsified crude oils.
Innovation Solution
A system and method utilizing a gravity dehydrator vessel equipped with a heat exchanger, metallic grids, a faraday cage, and a microwave generator to separate oil and water through a combination of steam heating, electromagnetic radiation, electrostatic fields, and gravitational forces, with adjustable parameters for optimal separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional microwave-based separation techniques are used in single-mode resonance applicators, then microwave separation can be achieved, but the cross-sectional area is very small compared to crude oil piping, making sufficient exposure time difficult to achieve
Solution Approach 1:
The patent combines multiple separation techniques (microwave heating, electrostatic coalescence, gravity separation, and chemical demulsification) into a single integrated vessel, allowing the crude oil to undergo all separation processes simultaneously in one pass through the system
Solution Approach 2:
The separation vessel serves multiple functions: it acts as a microwave applicator, an electrostatic coalescer, a gravity separator, and a chemical treatment zone, eliminating the need for multiple separate equipment units
2Reliability
If conventional electrostatic coalescers are used with large settling tanks and electrodes, then separation can be achieved under laminar flow conditions, but the device size becomes very large
Solution Approach 1:
The patent merges electrostatic coalescence with microwave heating and gravity separation in a compact integrated vessel, achieving reliable separation without requiring large settling tank volumes
Solution Approach 2:
The patent operates the electrostatic coalescer at higher frequencies (1-100 MHz) compared to conventional systems (0-50 kHz), changing the operating parameters to achieve effective separation in a more compact configuration
3Productivity
If chemical demulsifiers are used in high quantities to separate oil and water, then separation efficiency improves, but high quantities of chemical demulsifiers remain in the water, causing toxic effects in aquatic environments
Solution Approach 1:
The patent replaces heavy reliance on chemical demulsifiers with physical separation mechanisms including microwave heating, electrostatic coalescence, and gravity separation, significantly reducing chemical usage and associated environmental toxicity
Solution Approach 2:
The patent uses demulsifier injection plates as intermediaries that facilitate phase separation through controlled chemical dosing combined with physical separation forces, reducing the total quantity of chemicals needed while maintaining separation efficiency
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 system effectively separates crude oil into distinct layers, enhancing oil and water separation efficiency, reducing energy consumption, and minimizing chemical usage, while accommodating crude oils with varying water contents and emulsion strengths.
Implementation Method 1
a heat exchanger upstream of the gravity dehydrator vessel, the heat exchanger being configured to heat the crude oil composition via steam heating
Implementation Method 2
a microwave generator operatively connected to the gravity dehydrator vessel, and a waveguide carrying microwave energy from the microwave generator
Implementation Method 3
a mesh metal structure made from electrically conducting material that forms a faraday cage within the gravity dehydrator vessel
Implementation Method 4
The metallic grids are partially bonded to form two electrically isolated sets of grids, and one of the two sets of grids is electrically bonded to the shell wall of the gravity dehydrator vessel
Implementation Method 5
a gravity dehydrator vessel having a shell wall, as well as an inlet that is configured to receive the crude oil composition and a demulsifier agent
Data Source
AI summary
A system and method for oil and water separation of a crude oil composition are provided. The system includes a gravity dehydrator vessel, a heat exchanger upstream of the gravity of the dehydrator vessel, and a plurality of metallic grids located within the gravity dehydrator vessel. The system further includes a mesh metal structure within the gravity dehydrator vessel, a microwave generator operatively connected to the gravity dehydrator vessel, and a waveguide carrying microwave energy from the microwave generator. The system and method separate water and emulsions from the crude oil composition by forming an upper crude oil layer, a middle oil-water emulsion layer, and a lower oily water layer.