Spherical Separator for High-Pressure Solid Particle Removal
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Solution Overview
Problem
Conventional separators are ineffective in handling high velocity fluid streams with a wide range of solid particle sizes, leading to equipment damage and contamination, particularly at hydrocarbon wellheads, due to their inefficiency in separating small particles at high velocities and pressures.
Innovation Solution
A spherical separator system utilizing gravitational, centrifugal, and Coriolis forces, along with mechanical filtration, to effectively separate solid particles from high-pressure, high-velocity fluid streams, allowing for a wide range of solid sizes and fluid constituents, and reducing the system's size, weight, and material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separators are used to separate solid particles from fluid streams, then separation function is provided, but they are ineffective at high velocities and cannot handle wide ranges of particle sizes, leading to equipment damage and contamination
Solution Approach 1:
The separator is divided into multiple functional zones: an inlet region that directs fluid tangentially to create centrifugal force, a separation region with a collection surface at the bottom for particle deposition, and an outlet region. This segmentation allows each zone to perform a specific function in the separation process, enabling effective handling of particles across a wide size range at high velocities
Solution Approach 2:
The separator employs a curved collection surface at the bottom of the vessel that is substantially perpendicular to the incoming fluid stream. This curved geometry optimizes particle deposition by directing centrifugal forces toward the collection surface, improving separation efficiency for particles of varying sizes and densities while maintaining compact design
2Stress or pressure
If conventional separators are designed to handle high pressure and velocity, then they require larger size and heavier materials, but this increases cost and complexity
Solution Approach 1:
The curved collection surface and streamlined internal geometry distribute fluid flow and pressure more evenly throughout the separator structure. This reduces stress concentration points and allows the use of lighter materials while maintaining the ability to withstand high operating pressures up to 20,000 psi, thereby reducing overall weight and material costs
Solution Approach 2:
The separator design optimizes the angle and curvature of the collection surface to maximize particle deposition efficiency at high velocities. By carefully selecting geometric parameters such as the curvature radius and surface orientation, the system achieves effective separation without requiring oversized or over-engineered components, reducing both weight and material usage
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 efficiently separates solid particles from high-pressure, high-velocity fluid streams, reducing equipment damage and contamination, while being compact, lightweight, and cost-effective, capable of operating at pressures up to 20,000 psi.
Implementation Method 1
The spherical separator utilizes gravitational, centrifugal, and Coriolis forces
Implementation Method 2
The spherical separator utilizes gravitational, centrifugal, and Coriolis forces
Implementation Method 3
The spherical separator utilizes gravitational, centrifugal, and Coriolis forces
Implementation Method 4
The spherical separator utilizes gravitational, centrifugal, and Coriolis forces, along with mechanical filtration
Data Source
AI summary
Disclosed is a system and method to separate solid particle components from a fluid that includes a spherical vessel with a tangential inlet to introduce the fluid and a fluid exhaust and filter arranged on the center line of the interior of the vessel. A combination of pressurized fluid and solid particles enter at the tangential inlet and move primarily in a circular path around the interior of the vessel. The circular path results in the larger mass particles settling at the vessels lower region. Less massive particles may be entrained in the exiting fluid flow toward a filter element where they are removed from the exiting fluid. The vessel has an opening to remove the trapped separated particles.