Multi-phase flow separation apparatus with vapor lock
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Solution Overview
Problem
Existing systems for separating solid particulates from multiphase fluid flows in the oil and gas industry face challenges such as equipment erosion, plugging, and contamination, leading to safety and environmental hazards due to high fluid velocities and ineffective separation methods.
Innovation Solution
A multi-phase flow separation apparatus utilizing a vessel with a primary and secondary enclosure and diffusers creates a vapor lock to decelerate fluid flow, employing three-dimensional flow dispersion and differential densities to separate solid particulates by gravity and momentum, without the need for filter media, allowing for efficient removal of particulates through vapor locks and channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high fluid velocities are used to elutriate particles up the well, then particle separation efficiency is improved, but equipment erosion and catastrophic failure risk increase
Solution Approach 1:
The separation apparatus divides the separation process into distinct functional zones: an elutriation section for particle removal, a separation section for phase separation, and a collection section for accumulated particles. This segmentation allows high velocity flow to be confined to specific zones where it can effectively remove particles without causing widespread equipment erosion throughout the entire system.
Solution Approach 2:
The patent introduces an intermediary separation medium (liquid phase) that facilitates particle removal. The liquid phase acts as a carrier that transports particles from the gas stream, allowing high velocity gas flow to remove particles efficiently while the liquid phase absorbs the erosive impact on equipment surfaces.
2Device complexity
If conventional separation methods are used, then equipment simplicity is maintained, but particulate contamination and plugging occur
Solution Approach 1:
The patent merges multiple separation mechanisms into a single integrated apparatus: gravitational settling, inertial separation, and elutriation are combined in one device. This consolidation achieves effective particulate removal without requiring multiple separate equipment components, thus avoiding increased system complexity while eliminating contamination issues.
Solution Approach 2:
The separation apparatus utilizes three-dimensional flow patterns and multiple spatial dimensions for particle removal. By creating vertical, horizontal, and radial flow components within the separation chamber, the system achieves comprehensive particle separation efficiency without adding excessive complexity to the overall device structure.
3Productivity
If extended use of desander is required, then particulate removal effectiveness is improved, but operational time and cost increase
Solution Approach 1:
The separation apparatus is designed for continuous operation with no interruption to the separation process. The continuous flow path and automatic particle accumulation and removal mechanisms eliminate the need for extended operational periods or periodic maintenance shutdowns, achieving effective particulate removal while minimizing time loss.
Solution Approach 2:
The system incorporates self-cleaning and self-draining features where accumulated particles are automatically removed through the separation process and collection mechanisms. This self-service capability eliminates the need for extended manual intervention or prolonged operational cycles, reducing time loss while maintaining high particulate removal effectiveness.
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 reduces fluid velocity, separates solid particulates from the gas stream, and accumulates them at the bottom of the vessel, reducing equipment wear and contamination, while being more compact and cost-effective compared to prior art, thereby enhancing safety and operational efficiency.
Implementation Method 1
The at least one flow opening comprises one or more bottom edges of the sidewall... the tank is filled with liquid to a level above the at least one flow opening such that the enclosure and the channels each form a vapor lock
Implementation Method 2
separates solid particulates from the gas stream, and accumulates them at the bottom of the vessel
Implementation Method 3
employing three-dimensional flow dispersion and differential densities to separate solid particulates by gravity and momentum
Data Source
AI summary
A multi-phase flow separation apparatus has a tank with at least one inlet and at least one outlet, and an enclosure within the tank. The at least one inlet communicates an input flow into the enclosure. The enclosure has a sidewall defining an open bottom and at least one flow opening below the height of the inlet of the tank. The at least one outlet of the tank is outside the enclosure and above the at least one flow opening of the enclosure.