Multi-Phase Flow Separator with Vapor Lock and Labyrinth Path
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for separating solid particulates from multiphase fluid flows in the oil and gas industry face issues such as equipment erosion, contamination, and high maintenance costs due to ineffective separation methods, particularly in high-velocity gas wells where particulates can cause catastrophic failures and environmental damage.
Innovation Solution
A multi-phase flow separation apparatus utilizing a vessel with a primary and secondary enclosure system that creates a vapor lock to decelerate fluid flow, employing labyrinthine paths and multiple 90-degree turns to separate solid particulates by gravity and momentum, without the need for filter media, allowing for efficient removal of solids through the bottom of the vessel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high fluid stream velocities are used to elutriate particles up the well, then particle separation efficiency is improved, but equipment erosion increases leading to catastrophic failure
Solution Approach 1:
The separation apparatus divides the separation process into multiple stages: a primary separation zone where particles are removed from the fluid stream, and a secondary elutriation zone where remaining particles are separated using controlled fluid velocities. This segmentation allows the system to achieve high particle separation efficiency while limiting equipment erosion to acceptable levels by not relying on extremely high velocities throughout the entire separation process.
2Productivity
If conventional separation methods are used in high-velocity gas wells, then particle removal is attempted, but equipment erosion causes catastrophic failure
Solution Approach 1:
The apparatus introduces an intermediary separation zone with controlled fluid dynamics that acts as a buffer between the high-velocity gas stream and the equipment. In this intermediary zone, particles are removed through a combination of gravitational settling and controlled elutriation, reducing the direct impact of high-velocity flow on equipment while maintaining effective particle removal.
3Reliability
If particulates are not effectively separated, then equipment erosion and plugging occur, but adding more separation equipment increases system complexity
Solution Approach 1:
The separation apparatus merges multiple separation mechanisms into a single integrated unit: gravitational settling, inertial separation, and elutriation all occur within one continuous flow path. This consolidation achieves reliable particle removal without requiring multiple separate separation equipment, thereby reducing overall system complexity while improving equipment reliability.
4Reliability
If extended use of desander is required, then particle separation continues, but operational time and maintenance costs increase
Solution Approach 1:
The separation apparatus is designed for continuous operation with no shutdowns or extended maintenance periods. The continuous flow path allows particles to be removed throughout the entire production process, eliminating the need for extended operational periods with desanders and reducing both time loss and maintenance costs while maintaining effective particle separation.
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 and utilizes density differences to separate solid particulates from the gas stream, reducing equipment erosion and maintenance costs while maintaining a compact design, capable of handling a wide range of process conditions.
Implementation Method 1
employing labyrinthine paths and multiple 90-degree turns to separate solid particulates by gravity and momentum, without the need for filter media
Implementation Method 2
separate solid particulates by gravity and momentum
Implementation Method 3
separate solid particulates by gravity and momentum
Data Source
AI summary
A multi-phase flow separation apparatus has a vessel having a fluid inlet, a fluid outlet, and an enclosure separating the fluid inlet and the fluid outlet. The enclosure has an open bottom that extends below the fluid inlet and the fluid outlet. The open bottom of the enclosure has a plurality of distributed points of egress that are below the fluid inlet and the fluid outlet. The fluid inlet induces an inlet flow vector on an inflow of fluid. Each point of egress defines a flow path, that, when defined as the path of least resistance from the fluid inlet to the fluid outlet while traversing the respective point of egress, includes a reversal of the inlet flow vector.