Wafer-Based Hydrocyclone for Pressure Reduction Without Emulsion Formation
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Solution Overview
Problem
Conventional pressure reduction methods in the oil-and-gas industry lead to increased turbulence and formation of oil-in-water or water-in-oil emulsions, making downstream oil-and-water separation less effective, which can result in non-compliant streams and increased treatment costs, especially in offshore applications where space and resources are limited.
Innovation Solution
A pressure reduction device, such as a wafer-based hydrocyclone or modified hydrocyclone with an underflow outlet but no overflow outlet, is used to reduce fluid stream pressure while minimizing shearing of oil and water droplets, promoting cyclonic flow and coalescence of droplets for improved separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If conventional choke or control valves are used to reduce fluid pressure, then pressure reduction is achieved, but turbulence increases causing oil and water droplets to break apart and form emulsions
Solution Approach 1:
The pressure reduction process is segmented into multiple stages using multiple wafers with progressively smaller apertures. The first wafer performs initial pressure reduction with larger apertures to minimize droplet shearing, while subsequent wafers with smaller apertures complete the pressure reduction. This segmentation allows pressure reduction to be achieved while maintaining droplet integrity and reducing emulsion formation.
2Stress or pressure
If pressure is reduced through conventional valves, then pressure control is improved, but downstream oil-and-water separation effectiveness deteriorates
Solution Approach 1:
The pressure reduction is segmented across multiple wafers rather than achieved in a single valve stage. This segmented approach reduces turbulence and droplet shearing at each stage, preserving droplet size and coalescence potential, thereby maintaining separation effectiveness downstream while achieving the required pressure control.
Solution Approach 2:
The wafer apertures are designed with specific dimensional parameters that change progressively from the first wafer to subsequent wafers. The aperture size, thickness, and material properties are optimized to control the pressure reduction profile and minimize turbulence, thereby maintaining separation effectiveness while achieving pressure control.
3Reliability
If additional treatment steps are added to improve separation, then separation quality improves, but treatment costs and equipment space requirements increase
Solution Approach 1:
The pressure reduction device performs preliminary action by minimizing droplet shearing and preventing emulsion formation at the source. By maintaining larger droplet sizes and reducing turbulence during pressure reduction, the system prepares the fluid stream for more effective downstream separation, reducing the need for additional treatment steps and chemicals.
Solution Approach 2:
The invention converts the potentially harmful effect of pressure reduction (which normally causes turbulence and emulsion formation) into a beneficial outcome. By using multiple wafers with optimized aperture parameters, the pressure reduction process itself becomes a means to maintain droplet integrity and improve separation, rather than creating problems that require additional treatment.
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 effectively reduces pressure without breaking oil and water droplets into smaller sizes, enhancing downstream separation efficiency and quality, reducing the need for additional chemicals, and accommodating high flow rates, thus improving the suitability of oil and water streams for use or disposal.
Implementation Method 1
The pressure reduction device, which may be a wafer-based hydrocyclone or a modified hydrocyclone having an underflow outlet but no overflow outlet, causes a cyclonic flow of the stream
Implementation Method 2
The pressure reduction device may be a wafer-based hydrocyclone or a modified hydrocyclone
Data Source
AI summary
A system and method for improving oil-and-water separation in a blended fluid stream are presented. The system includes a pressure reduction device that causes cyclonic flow in the stream. The pressure reduction device may be a wafer-based hydrocyclone or a modified hydrocyclone having an underflow outlet but no overflow outlet. The system may also include a valve that is located upstream or downstream of the pressure reduction device. Both the valve and the pressure reduction device reduce the pressure of the fluid stream while reducing the shearing of oil and water droplets within the stream. As a result, the droplets are more likely to coalesce and less likely to form emulsions, thus improving oil-and-water separation in downstream treatment processes.