Ultrasonic Demulsifier Control for Real-Time Flow Separation
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Solution Overview
Problem
Existing methods for controlling chemical demulsification in oil production are inefficient and costly, as they rely on fixed demulsifier injection rates, leading to high costs and inefficiencies due to the high logistical and environmental impact of demulsifiers, and lack effective monitoring strategies to optimize demulsifier dosage.
Innovation Solution
A device and method using ultrasonic waves to extract acoustic variables, combined with fuzzy logic, to dynamically control demulsifier injection based on real-time flow regime analysis, minimizing demulsifier use and ensuring efficient phase separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large amount of chemical demulsifier is added to subsea pipes, then the emulsion is destabilized and viscosity is reduced, but the logistical and acquisition cost increases significantly
Solution Approach 1:
The patent implements a closed-loop feedback control system that continuously monitors flow regime parameters (velocity, temperature, pressure, composition) and dynamically adjusts demulsifier injection rates. Sensors detect real-time emulsion characteristics and feed this information to a controller that modulates the dosing pump, ensuring optimal separation efficiency while minimizing chemical consumption compared to fixed high-dosage methods
Solution Approach 2:
The system transitions from static fixed-rate injection to dynamic adaptive dosing by continuously adjusting demulsifier flow rate based on real-time process conditions. The injection rate varies dynamically with changes in flow velocity, temperature, pressure, and emulsion composition, allowing the system to maintain optimal performance across varying operational conditions while reducing overall chemical usage
2Reliability
If fixed injection flow rate is used regardless of process conditions, then the control system is simple, but the separation efficiency is compromised due to over-injection or under-injection
Solution Approach 1:
The control system incorporates multiple sensors (flow meters, temperature sensors, pressure transducers, composition analyzers) that continuously monitor process conditions and feed this data to a controller. The controller processes this feedback information and dynamically adjusts demulsifier injection rates, maintaining reliable phase separation across varying conditions while avoiding the inefficiencies of fixed-rate injection
Solution Approach 2:
The patent replaces simple mechanical fixed-rate injection mechanisms with an intelligent control system that uses sensors, processors, and actuators. This substitution enables adaptive dosing based on real-time process data, improving separation reliability while the modular sensor-controller-actuator architecture keeps the system manageable in complexity
3Productivity
If demulsifier is dosed directly in the oil flow line through metering pumps, then the emulsion breakup is ensured, but the cost increases due to the price of the demulsifier
Solution Approach 1:
The system applies partial action by injecting demulsifier at precisely the amount needed for effective emulsion breakup rather than using excessive doses. The feedback control system calculates the minimum required dosage based on real-time emulsion characteristics and process conditions, injecting only this necessary amount through metering pumps, thereby ensuring effective destabilization while minimizing chemical consumption and cost
Solution Approach 2:
The system dynamically changes injection parameters (flow rate, timing, duration) based on real-time process conditions such as flow velocity, temperature, pressure, and emulsion composition. By adapting these parameters to match actual process needs, the system maintains high destabilization efficiency while optimizing demulsifier consumption and reducing costs
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 solution reduces demulsifier usage, lowers operational costs, and enhances phase separation efficiency by adapting demulsifier dosage to process conditions, providing a more economical and environmentally friendly demulsification process.
Implementation Method 1
an ultrasonic wave device, located downstream of the flow conditioner, emits ultrasonic waves toward the multiphase fluid. These waves are directed at the emulsion within the liquid phase. The energy from the ultrasonic waves helps break the emulsion into its individual components
Data Source
AI summary
The present invention relates to a method for controlling chemical demulsification in flow comprising: generating a sound pulse (Apulser); receiving a modified sound pulse (Areceiver); processing the modified sound pulse (Areceiver), generating inputs for a controller; and controlling, by means of a controller, the parameters related to the emission of demulsifier. In addition, the invention also comprises a device for controlling chemical demulsification in flow.