Separator Assembly for Flowback Water VOC Control
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Solution Overview
Problem
Conventional flowback water handling in hydraulic fracturing operations leads to significant emissions of hazardous air pollutants and volatile organic compounds due to inadequate retention times and pressure drops, posing environmental and health hazards.
Innovation Solution
A separator assembly designed to control flow velocity and retain VOCs and HAPs, featuring a tank with specific chamber configurations, bulkheads, and flow control mechanisms to prevent gas flashing and emissions, allowing for efficient separation and containment of oil, water, and gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional gas production units operate at high pressure (100-1400 psig) with direct-fired production separators, then three-phase separation of sales gas, condensate/oil, and flowback water is achieved, but inadequate retention times and large pressure drops cause flashing off of gas and emission of VOCs and HAPs
Solution Approach 1:
The separator is divided into multiple chambers (gas separation chamber, liquid separation chamber, vaporization chamber) with internal bulkheads and partitions that create controlled flow paths. This segmentation allows different phases to be separated in dedicated zones while maintaining adequate retention times and preventing premature gas flashing, thereby reducing VOCs and HAPs emissions while preserving separation effectiveness.
Solution Approach 2:
The separator performs preliminary vaporization and condensation of VOCs and HAPs before the flowback water enters atmospheric storage tanks. By pre-vaporizing these contaminants in a controlled manner within the separator chambers, the system prevents their subsequent flashing off and emission to the atmosphere, addressing the harmful emissions issue while maintaining the overall separation process.
2Device complexity
If flowback water is dumped directly into atmospheric storage tanks after pressure reduction, then storage is simplified, but large pressure drop from 1400 psig to atmospheric pressure causes flashing off of gas and severe fire/explosion dangers
Solution Approach 1:
The separator performs preliminary vaporization of VOCs and HAPs in controlled chambers before the flowback water is discharged to atmospheric storage. This pre-vaporization occurs under controlled pressure and temperature conditions within the separator, preventing the sudden flashing off that would occur during direct pressure reduction to atmospheric conditions, thereby eliminating fire/explosion hazards while maintaining storage simplicity.
Solution Approach 2:
The separator acts as an intermediary device between the high-pressure production stream and atmospheric storage tanks. It includes intermediate vaporization chambers and controlled flow paths that gradually reduce pressure and facilitate controlled vaporization of hazardous components before discharge, thereby mediating the transition from high-pressure to atmospheric conditions and eliminating the associated safety hazards.
3Adaptability or versatility
If conventional separators are used with large pressure drops, then operational flexibility is maintained, but substantial amounts of VOCs and HAPs are emitted to the atmosphere violating environmental regulations
Solution Approach 1:
The separator is segmented into multiple functional chambers with controlled pressure zones that allow gradual pressure reduction and controlled vaporization of VOCs and HAPs. This segmented design maintains operational flexibility for handling various flow rates and pressure conditions while ensuring that hazardous emissions are captured and contained within the separator system, preventing atmospheric releases in compliance with environmental regulations.
Solution Approach 2:
The separator employs controlled parameter changes in temperature and pressure within different chambers to facilitate gradual vaporization and condensation of VOCs and HAPs. By dynamically adjusting these parameters within the separator's controlled environment, the system maintains operational flexibility for different processing conditions while ensuring complete vaporization and containment of hazardous components, preventing emissions to the atmosphere.
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 separator assembly effectively reduces atmospheric emissions of VOCs and HAPs, enhancing safety and compliance with environmental regulations by ensuring proper separation and storage of flowback fluids.
Implementation Method 1
a three-phase separation of the sales gas, the condensate/oil, and the flowback water
Implementation Method 2
separation and containment of oil, water, and gases
Implementation Method 3
retain VOCs and HAPs... preventing gas flashing and emissions
Data Source
AI summary
A separator assembly has a tank and a lid removably attached to a top side of the tank so as to create a gas tight seal with the top side of the tank. The tank has an influent chamber, a separator chamber, an oil chamber, and an effluent chamber in fluid communication with one another. A pipe extends from the separator channel to the effluent chamber allowing the passage of water from the separator chamber to effluent chamber. A plurality of vertical plates are positioned in the separator chamber to define a serpentine path from the influent chamber to the oil chamber.