Multi-Stage Sand Separation System for Hydraulic Fracturing
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Solution Overview
Problem
Existing separator systems for hydraulic fracturing, such as cyclone separators and sedimentation tanks, often require a large footprint due to their sequential operation, which can be a challenge in space-constrained wellsite environments.
Innovation Solution
A multi-stage separator system that includes a cyclone separator coupled with a pressure tank having a partitioned collection and separation chamber, allowing for the efficient separation and collection of solids, liquids, and gases, with the pressure tank's design minimizing the overall system footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cyclone separators and sedimentation tanks are used in series, then solids removal and fluid phase separation are achieved, but the system footprint becomes large
Solution Approach 1:
The patent combines the solids collection function and the fluid phase separation function into a single integrated pressure tank. The pressure tank includes a solids collection chamber that receives solids from the cyclone separator, and a fluid separation chamber that separates liquids and gases. This merging of functions eliminates the need for separate sedimentation tanks, thereby reducing the overall system footprint while maintaining effective solids removal and fluid phase separation.
Solution Approach 2:
The pressure tank is designed as a multi-functional unit that simultaneously performs solids collection, liquid separation, and gas separation. The single pressure tank replaces multiple dedicated devices (solids collection tank and sedimentation tank), making the system more compact without compromising the reliability of each separation function.
2Reliability
If multiple separate separator devices are used, then complete fluid phase separation is achieved, but space utilization is reduced
Solution Approach 1:
The patent merges multiple separator functions into a single pressure tank structure. The pressure tank contains both a solids collection chamber and a fluid separation chamber, allowing it to perform the work of multiple separate devices. This integration improves space utilization by consolidating equipment while maintaining complete fluid phase separation capability through the partitioned internal structure.
3Area of stationary object
If a compact separator system is used, then footprint is reduced, but separation efficiency may be compromised
Solution Approach 1:
The pressure tank is segmented into distinct functional chambers: a solids collection chamber and a fluid separation chamber. This segmentation allows each chamber to be optimized for its specific separation function while being housed within a single compact pressure tank structure. The partition wall between chambers ensures that solids and fluids are separated efficiently without requiring multiple external devices, thus maintaining separation efficiency while reducing footprint.
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 solids from liquids and gases, reducing the physical space required for the separator system while maintaining efficient fluid phase separation, thereby optimizing space utilization in wellsite applications.
Implementation Method 1
The cyclone separator operates at steady state by imparting a generally helical flowpath in a fluid. In such a flow, the denser particulate matter drops out into a hopper, because of its greater density, while the less-dense liquids and gases flow inward and up through an outlet.
Implementation Method 2
The cyclone separator operates at steady state by imparting a generally helical flowpath in a fluid. In such a flow, the denser particulate matter drops out into a hopper, because of its greater density
Implementation Method 3
The pressure tank includes a partition wall between a collection chamber and a separation chamber defined in the pressure tank. The collection chamber receives at least a portion of the solids component from the first outlet, and the separation chamber receives at least a portion of the liquid component and the gaseous component from the second outlet.
Data Source
AI summary
A separator system includes a separator including an inlet configured to receive a mixed fluid, a first outlet, and a second outlet. The separator system includes a pressure tank physically coupled to the separator, and including a partition wall defining a collection chamber and a separation chamber in the pressure tank, a first inlet communicating with the collection chamber and coupled to the separator to receive at least some of the solids component from the separator, and a second inlet communicating with the separation chamber and in communication with the separator. The second inlet is configured to receive at least some of the liquid component and the gaseous component from the separator. The pressure tank also includes a first drain in communication with the collection chamber, and a first liquid outlet in communication with the separation chamber. The pressure tank includes a gas outlet in communication with the separation chamber.