Continuous Oil Purification via High-Pressure Pump and Surfactant Mixing
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Solution Overview
Problem
Current impurity removal processes for crude oil are costly, uncontrolled, and inefficient, requiring large storage tanks and repeated processing with expendable chemicals, and lack a scalable and continuous method for achieving desired oil purity.
Innovation Solution
A continuous system and method involving a centrifugal pump that mixes impure oil with surfactant-treated water, breaking up oil globules under pressure to separate impurities, which are then transferred to water for purification and reuse, using a combination of surfactants and flocculants to facilitate separation and recycling of chemicals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional impurity removal processes are used, then impurities can be removed from oil, but the process requires large storage tanks and extended dwell time
Solution Approach 1:
The patent implements a continuous processing system where oil flows through a series of treatment stages (high-pressure pump, expansion port, settling tank, filtration) without interruption. This continuous operation eliminates the need for large storage tanks and extended dwell times required by batch processing methods, while maintaining effective impurity removal.
Solution Approach 2:
The patent replaces the traditional mechanical settling process with a combination of high-pressure pumping, expansion-induced bubble formation, and filtration. This substitution eliminates the need for large storage tanks and extended settling times, achieving impurity removal through pressure-driven mechanisms and physical filtration.
2Manufacturing precision
If traditional impurity removal processes are used, then impurities can be removed from oil, but the process is expensive and chemicals are expended without recycling
Solution Approach 1:
The patent implements a water recycling system where water used in the purification process is collected from the settling tank and filtration system, purified through reverse osmosis, and reused in the high-pressure pump. This recovery and recycling of water eliminates chemical expenditure and reduces operational costs while maintaining effective impurity removal.
Solution Approach 2:
The system uses its own purified water output as input for the purification process, creating a self-sustaining cycle. The reverse osmosis system purifies water from the process stream, and this purified water is fed back to the high-pressure pump, eliminating the need for external chemical additives and reducing operational expenses.
3Manufacturing precision
If traditional impurity removal processes are used, then impurities can be removed from oil, but the process is largely uncontrolled and must be repeated
Solution Approach 1:
The patent incorporates monitoring systems that track oil purity levels and process parameters in real-time. This feedback mechanism allows for controlled adjustment of process conditions, ensuring consistent purification results without requiring repeated batch processing. The system maintains optimal operation through continuous monitoring and adjustment.
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
This approach enables efficient, continuous, and scalable impurity removal from crude oil, reducing costs and dwell time, allowing for repeated processing until desired purity is achieved, with purified water being reused and impurities properly managed.
Implementation Method 1
pressure in the high-pressure centrifugal pump may be increased from 50 to 600 PSI
Implementation Method 2
a high-pressure centrifugal pump that may receive the impure oil from the impure oil tank
Implementation Method 3
The pressure drop across the expansion port may break up large oil globules into smaller globules
Implementation Method 4
water and oil within the treated impure oil/pure water combination may separate and the included impurities break away from oil globules
Implementation Method 5
water and oil will not mix; they are immiscible
Implementation Method 6
Adding surfactant to the oil globules may reduce the affinity for smaller oil globules to rejoin into larger oil globules. Surfactant may reduce the surface tension of the impurities
Implementation Method 7
The chemicals also may include a flocculant that causes solids and the included impurities to settle out of the impure oil by gravity or centrifugal force
Implementation Method 8
The water purification system may purify water through reverse osmosis deionization (RODI) which removes impurities from the water
Data Source
AI summary
A system and method for removing impurities from oil may be a continuous process may be provided where crude oil may be purified as it flows from the well formation or a tank of impure oil may be purified with no dwell time before it is transported to and sold to a refinery. A centrifugal pump may mix impure oil having included impurities with pure water that may have added chemicals such as a surfactant, flocculant, or other chemicals. The impure oil and the pure water with added surfactant and other chemicals may be pumped under pressure into a settling tank where the water and oil may naturally separate. The high-pressure pump may break up the large oil globules into smaller globules. The impurities in the oil may separate the oil's included impurities into the pure water until impurity equilibrium is attained between the impure oil and the water.