Continuous Recirculation Sand Separation System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is an ongoing need for separators in oil and gas operations that can efficiently and quickly separate fluids produced during drill out and flow back into component parts, such as sand, water, and hydrocarbons, while minimizing rig-up times and improving separation efficiency.
Innovation Solution
The process involves a system with a hopper, recirculation chamber, diffuser, and shaker device, where a sand removal feed is processed through continuous recirculation loops to efficiently separate sand from water and gas, with the shaker device further drying the recovered sand.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separation methods are used for drill out and flow back fluids, then separation of sand from water and gas can be achieved, but rig-up times are excessive and separation efficiency is insufficient
Solution Approach 1:
The separation system is divided into multiple functional chambers (gas separation chamber, sand separation chamber, water separation chamber) that operate independently and simultaneously, allowing parallel processing of different separation tasks and reducing overall setup time while maintaining high separation efficiency
Solution Approach 2:
The recirculation chamber serves multiple functions: it receives mixed fluids from the wellbore, pre-separates gases, and feeds material to multiple separation chambers simultaneously, acting as a universal processing hub that reduces system complexity and setup time
2Manufacturing precision
If continuous recirculation is implemented to improve separation efficiency, then sand drying is enhanced, but system complexity increases
Solution Approach 1:
Multiple separation functions are merged into a single integrated system where the recirculation chamber feeds material to both the gas separation chamber and sand separation chamber simultaneously, reducing the number of separate systems needed while maintaining high drying efficiency through continuous recirculation
Solution Approach 2:
The recirculation chamber continuously processes material through multiple chambers in an unbroken sequence, ensuring constant separation action that enhances sand drying efficiency while the closed-loop design actually reduces overall system complexity compared to batch processing systems
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 and continuous recirculation of sand and water, resulting in drier sand recovery and reduced rig-up times, thereby enhancing the separation efficiency and environmental sustainability of oil and gas operations.
Implementation Method 1
flowing a first portion of the first mixture from the hopper to a diffuser
Implementation Method 2
flowing a diffuser mixture including the first portion of the first mixture and the first portion of the second mixture from the diffuser to a shaker device
Data Source
AI summary
One or two continuous recirculation loops are utilized for the well-site equipment that separates produced fluids into sand, liquid, and gas during drill out and flow back that occurs after fracturing a subterranean formation. When one recirculation loop is utilized, the recirculation loop continuously recirculates fluid between the recirculation chamber of the disclosed sand removal apparatus and a shaker device. When two recirculation loops are utilized, the first recirculation loop continuously recirculates fluid between a recirculation chamber of the disclosed sand removal apparatus and a shaker device, and the second recirculation loop continuously recirculates fluid between the recirculation chamber and a gas separator.