Spiral Solids Separation and Sand Washing for Variable Production Flow
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Solution Overview
Problem
Existing technologies for removing solids, particularly sand, from hydrocarbon production streams are inefficient across varying flow rates, cause erosion and clogging, require large footprints, and struggle with environmentally acceptable disposal, especially in offshore environments.
Innovation Solution
A compact system integrating a Dynamic Solids Separator with a Solids Buffer and Washing Plant, utilizing a spiral inlet channel, flow restrictor, and automated control mechanisms to optimize separation and cleaning, along with a Solids Buffer and Washing Plant for efficient sand removal and disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional particle separators using centrifugal principle are used, then solids particles are separated from produced fluid, but the equipment has narrow operating window and reduced efficiency when production rate changes
Solution Approach 1:
The patent employs dynamic elements including a movable underflow outlet that can be adjusted to control vortex strength, and a flexible membrane separator that adapts to varying flow conditions. These dynamic components allow the separator to maintain optimal performance across a wide range of production rates by automatically adjusting internal flow patterns and separation mechanisms.
Solution Approach 2:
The system changes operational parameters such as vortex intensity, flow rate distribution, and separator geometry configuration to adapt to different production conditions. By varying these parameters dynamically, the separator maintains high efficiency across varying production rates without requiring multiple fixed-design units.
2Productivity
If high flow rates are used in conventional separators, then production efficiency is maintained, but significant erosion takes place in the vessel
Solution Approach 1:
The patent converts the harmful erosive effect of high-velocity particles into a beneficial separation mechanism. The controlled vortex flow and optimized particle trajectory cause particles to deposit on collection surfaces rather than erode the vessel walls, while still maintaining high flow rates for productive operation.
Solution Approach 2:
The patent introduces intermediary elements such as protective liners, flow distributors, and optimized baffle designs that mediate between the high-velocity production stream and the vessel structure. These intermediaries protect critical surfaces from erosion while allowing high flow rates to pass through the separation zone.
3Object-affected harmful factors
If low flow rates are used in conventional separators, then erosion is reduced, but the centrifugal effect is reduced so that solids particles leave the vessel with the produced oil and/or gas
Solution Approach 1:
The system dynamically adjusts the vortex generation mechanism and flow distribution to maintain effective centrifugal separation even at low flow rates. The movable underflow outlet and adjustable baffle positions allow the separator to optimize its internal flow patterns for maximum particle removal efficiency across the full range of production rates.
4Ease of manufacture
If sand washing systems with heavy pumps and repeated flushing are used, then sand particles are cleaned, but the systems have large footprint which causes issues on offshore platforms
Solution Approach 1:
The patent combines multiple functions (separation, washing, dewatering, and disposal) into a single integrated solids handling system. This consolidation eliminates the need for separate heavy pumping equipment and multiple flushing stations, dramatically reducing the footprint while maintaining effective sand cleaning capability for offshore deployment.
Solution Approach 2:
The system employs self-cleaning mechanisms where the separated sand is automatically dewatered and disposed of through gravity-driven mechanisms and integrated filtration, eliminating the need for external heavy pumps and manual flushing operations. The system serves itself by using its own separated sand as the cleaning medium.
5Productivity
If sand particles are coated with hydrocarbons, then they can be separated from production stream, but they represent a source of pollution and require costly treatment for disposal
Solution Approach 1:
The patent converts the hydrocarbon coating on sand particles from a pollution problem into a beneficial separation mechanism. The hydrophobic nature of the hydrocarbon-coated particles is exploited to enhance their separation from the aqueous production fluid through flotation or hydrophobic interaction, enabling effective separation while the sand is subsequently cleaned for environmentally acceptable disposal.
Solution Approach 2:
The system separates and recovers the hydrocarbons from the sand particles through integrated washing and dewatering mechanisms. The cleaned sand is then disposed of in an environmentally acceptable manner, while the recovered hydrocarbons can be returned to the production stream, eliminating pollution while maintaining productivity.
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 effectively separates and cleans sand to environmentally acceptable levels, reduces maintenance costs, and optimizes production efficiency by minimizing sand entrainment, while allowing real-time monitoring and automated operation.
Implementation Method 1
most function according to the centrifugal principle where a vortex is generated in the separator so that particles are thrown against the internal wall by centrifugal forces
Implementation Method 2
the end of the inlet duct being generally in the form of a venturi nozzle and including in succession a continuously narrowing first duct part
Data Source
Figure 1
Figure 2
Figure 3a~3c
AI summary
An apparatus for separating solid particles from a hydrocarbon-containing fluid produced from an oil and/or gas production facility, the apparatus comprising a spiral channel having an axis, an inlet and an outlet, the inlet being further from the axis than the outlet, a cross-sectional area of the inlet being larger than a cross-sectional area of the outlet, wherein the spiral channel is adapted to change a shape of the cross-sectional area of the fluid exiting the outlet as compared to a shape of the cross-sectional area of the fluid entering the inlet, a vortex chamber beneath the channel for receiving a spiral flow from the channel, a first collector for solid particles beneath the vortex chamber and a fluid conduit for conveying fluid away from the vortex chamber. A method of separating solid particles from a hydrocarbon-containing fluid produced from an oil and/or gas production facility is also disclosed.