Tilted Coalescence Plates for Compact Oil-Water Separation
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Solution Overview
Problem
Existing separation technologies for mixtures of immiscible fluid phases with different densities, such as oil and water, are limited by space constraints and high costs, particularly in offshore and downhole applications, where traditional coalescence and hydrocyclone separators are not feasible due to size and pressure drop issues.
Innovation Solution
A compact coalescence separation apparatus with a tubular body and stacked coalescence plates tilted at an angle, featuring a reduced spacing between plates and a truncated-conical design, allowing efficient separation of oil and water phases in both surface and downhole environments with reduced encumbrance and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional coalescence separators are used, then separation efficiency is improved, but device size and encumbrance increase
Solution Approach 1:
The separator is divided into multiple functional zones: a coalescence zone with tilted plates for initial oil-water separation, and a gravitational separation zone for final phase separation. This segmentation allows each zone to perform its specific function efficiently while keeping the overall device compact.
Solution Approach 2:
The patent introduces tilted coalescence plates arranged at an angle to the horizontal plane, utilizing the angular dimension to enhance separation efficiency. The tilted plates create vertical velocity components that improve coalescence while reducing the horizontal footprint of the device.
2Speed
If hydrocyclone separators are used, then separation speed is improved, but pressure drop increases
Solution Approach 1:
The separation process is segmented into two stages: rapid coalescence in the first zone followed by gravitational separation in the second zone. This allows the system to achieve fast initial separation without the high pressure drops associated with single-stage hydrocyclone separators.
Solution Approach 2:
The patent replaces the purely mechanical centrifugal force system of hydrocyclones with a combination of coalescence mechanisms and gravitational separation. This substitution reduces reliance on high-velocity mechanical forces, thereby reducing pressure drop while maintaining separation speed.
3Manufacturing precision
If coalescence plates are tilted, then separation efficiency is improved, but structural complexity increases
Solution Approach 1:
The coalescence plates are deliberately tilted at an angle to the horizontal plane, creating an asymmetric structure that enhances separation efficiency by generating vertical velocity components. This asymmetric design is simple enough to manufacture while providing significant performance improvement.
Solution Approach 2:
The patent employs curved or inclined plate surfaces that guide fluid flow smoothly through the separator. These curved elements improve separation efficiency by optimizing flow patterns while maintaining manufacturing simplicity through standard fabrication techniques.
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 apparatus achieves efficient separation of oil and water phases with reduced overall size and cost, enabling installation in space-limited areas and ensuring high separation efficiency, even when tilted, while maintaining the purity of aqueous phases for reinjection into oil formations.
Implementation Method 1
coalescence separators which promote the joining of oil drops (dispersed phase) dispersed in water (continuous phase) in larger-dimensioned drops
Implementation Method 2
a gravitational separation area
Implementation Method 3
oil drops (dispersed phase) dispersed in water (continuous phase) in larger-dimensioned drops which are separated into a layer which floats on the aqueous layer
Data Source
AI summary
The present invention relates to an apparatus (1) for the coalescence-separation of a mixture comprising two fluid phases mutually immiscible other and with a different specific density, characterized in that it comprises a tubular body (2) closed at opposite ends, of which, considering the apparatus in the configuration of use, one is higher than the other, at least one inlet mouth (5) of the mixture to be separated which is defined on the side surface of the tubular body (2), at least one outlet mouth (6) of the fluid phase with a lower specific density separated from the mixture which is defined close to the end of the tubular body at an upper height, at least one outlet mouth (7) of the fluid phase with a greater specific density separated from the mixture which is defined close to the end of the tubular body at a lower height and at least a set of coalescence plates (8) which is housed inside said tubular body (2), wherein each of the coalescence plates (8) has a flow plate (9) of the mixture which is tilted by an angle a with respect to a plane orthogonal to the longitudinal axis (A) of the tubular body (2) and which has a lower edge (92) facing the end of the tubular body (2) at a lower height and in fluid communication with a distribution channel (11) of the mixture to be separated, which is defined inside the tubular body (2) and is in fluid communication with the inlet mouth (5), and an upper edge (93) facing the end of the tubular body (2) at an upper height and in fluid communication with an outflow channel (12) of at least the fluid phase with a greater specific density, which is defined in the tubular body (2) and is in fluid communication with at least the outlet mouth (7) of said fluid phase with a greater specific density, and wherein the coalescence plates (8) are mutually arranged parallel and on top of each other at a defined reciprocal distance, pairs of coalescence plates (8) mutually adjacent forming a respective flow and separation channel (10) of the mixture.