Multiphase Separator with Solids Cleaning and Water Recycling
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Solution Overview
Problem
Current oil and gas production technologies require extensive equipment and a large footprint to separate the four phases of hydrocarbon-containing fluids, leading to high capital and production costs, as well as environmental concerns due to the contamination and costly disposal of solid particles.
Innovation Solution
An apparatus and method that integrates a solids separator and a fluid separator to efficiently separate oil, water, gas, and solid phases from a multiphase hydrocarbon-containing fluid, with a solids cleaning system to remove residual oil from solids and a water cleaning and recycling system to purify water for reuse, thereby reducing equipment needs and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sequential separation equipment is used to separate solids, water, gas and oil, then complete phase separation is achieved, but the footprint and capital cost increase significantly
Solution Approach 1:
The patent combines multiple separation functions (solids separation, water removal, gas-oil separation) into a single integrated separator vessel. The separator performs all four-phase separation in one unit, eliminating the need for multiple sequential separation equipment and reducing the overall footprint while maintaining complete phase separation capability
Solution Approach 2:
The separator is designed as a multi-functional device that simultaneously performs solids separation, water removal, and gas-oil separation. This universal separator handles all phase separation requirements in a single piece of equipment, reducing capital cost and space requirements compared to dedicated equipment for each separation function
2Measurement precision
If multiphase flow meters are installed on each well, then accurate phase flow measurement is achieved, but the acquisition and installation cost becomes prohibitive
Solution Approach 1:
Instead of installing expensive multiphase flow meters on each well, the system uses a single flow meter at the separator inlet to measure the total combined flow from all wells. This provides a cost-effective approximation that eliminates the need for multiple expensive measurement devices while still enabling production monitoring and allocation
3Object-affected harmful factors
If solids are removed and stockpiled on-site, then environmental compliance is maintained, but large volumes require significant storage space and periodic transportation
Solution Approach 1:
The system continuously extracts and removes solids from the production stream through the separator, preventing accumulation on-site. By taking solids out of the system and directing them to off-site disposal facilities, the patent eliminates the need for large on-site storage spaces and associated environmental management issues
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 integrated system allows for efficient and cost-effective separation and cleaning of all four phases, reducing environmental impact and operational costs by enabling continuous recycling of cleaned water and local disposal of cleaned solids.
Implementation Method 1
a solids separator in fluid communication with the inlet, the solids separator being configured to separate solid particles from the multiphase hydrocarbon-containing fluid
Implementation Method 2
a fluid separator in fluid communication with the solids separator and arranged to receive the remaining multiphase hydrocarbon-containing fluid, the fluid separator being configured to separate the remaining multiphase hydrocarbon-containing fluid into an oil phase, a water phase and a gas phase
Data Source
AI summary
An apparatus for treating a multiphase hydrocarbon-containing fluid in an oil and/or gas production facility, the apparatus comprising: (a) an inlet for a multiphase hydrocarbon-containing fluid, wherein the inlet comprises a first pipe network configured to be connectable to a plurality of oil well heads in an oil field; (b) a separation system comprising: (i) a solids separator in fluid communication with the inlet; (ii) a solids outlet connected to the solids separator; (iii) a fluid separator in fluid communication with the solids separator, the fluid separator being configured to separate the remaining multiphase hydrocarbon-containing fluid into an oil phase, a water phase and a gas phase; (iv) an oil outlet connected to the fluid separator; (v) a gas outlet connected to the fluid separator; and (vi) a water outlet connected to the fluid separator; (c) a solids cleaning system connected to the solids outlet, wherein the solids cleaning system is configured to clean deposits of residual oil from the solid particles separated by the solids separator to provide cleaned solid particles and first residual oil, the solids cleaning system having a first output for outputting the cleaned solid particles and a second output configured to output the first residual oil; and (d) a water cleaning and recycling system connected to the water outlet, wherein the water cleaning and recycling system is configured to clean residual oil from the water phase separated by the fluid separator, the water cleaning and recycling system comprising an oil filter for separating the residual oil from the water phase to provide cleaned water and second residual oil, the oil filter having a third output for recycling the cleaned water to at least one well head of the oil field, wherein the third output comprises a second pipe network configured to be connectable to the at least one well head of the oil field, and a fourth output configured to output the second residual oil. Also disclosed is a corresponding method.