Wellsite Demulsifier Testing Vessel with Guided Wave Radar
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Solution Overview
Problem
The co-extraction of water with hydrocarbons from oil and gas wells requires expensive separation and treatment processes, and existing methods lack efficient means to test demulsifiers effectively at process conditions, leading to suboptimal emulsion breaking and increased costs.
Innovation Solution
A system comprising a pressurized and heated vessel with a guided wave radar and a computer-controlled heating system to mimic process conditions, allowing for accurate testing of demulsifiers by measuring pressure, temperature, and microwave echoes to assess emulsion breaking efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If expensive separation and treatment processes are used to handle co-extracted water, then water removal is achieved, but operational costs increase significantly
Solution Approach 1:
The demulsifier is applied at the wellsite before production, breaking the emulsion in advance to facilitate easier and less costly separation later. This preliminary action prevents the formation of difficult-to-separate emulsions that would require expensive treatment processes
Solution Approach 2:
A demulsifier chemical is introduced as an intermediary substance to facilitate the separation of oil and water phases. The demulsifier acts as a mediator that reduces interfacial tension between oil and water droplets, enabling gravitational separation without expensive equipment
2Ease of manufacture
If conventional testing methods are used for demulsifiers, then testing can be performed, but emulsion breaking efficiency under real process conditions cannot be accurately assessed
Solution Approach 1:
The testing system replicates actual process parameters including temperature, pressure, and fluid composition. By changing and controlling these parameters to match field conditions, the test results accurately reflect real-world demulsifier performance
Solution Approach 2:
The wellsite testing system creates a scaled-down copy of the actual production environment. By copying the real process conditions (temperature, pressure, emulsion composition) in a portable vessel, accurate performance data is obtained without requiring full-scale field testing
3Ease of operation
If demulsifier testing is performed without matching process conditions, then testing is simpler, but test results do not predict field performance
Solution Approach 1:
The portable testing system is designed to be universally applicable at any wellsite, combining multiple functions (heating, pressurization, mixing, measurement) in a single integrated unit. This multi-functionality maintains operational simplicity while achieving accurate condition-matched testing
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
This system enables efficient and accurate testing of demulsifiers, improving dry crude oil product quality, reducing demulsifier usage, and lowering operational costs by predicting emulsion breaking capabilities under real-world conditions.
Implementation Method 1
The guided wave radar is configured to generate a reference pulse of microwave energy
Implementation Method 2
The guided wave radar is configured to detect a surface echo reflected from the mixture within the internal cavity defined by the vessel
Implementation Method 3
The heater is configured to provide heat to the mixture within the internal cavity defined by the vessel
Implementation Method 4
The heater surrounds at least a portion of the vessel. The heater is configured to provide heat to the mixture within the internal cavity
Data Source
AI summary
An apparatus includes a vessel configured to be pressurized and heated at a well site to match desired process conditions at which a demulsifier is to break an emulsion of crude oil. The vessel includes a first end, a second end, an inlet pipe, and an outlet pipe. The inlet pipe receives crude oil and a demulsifier and mixes the crude oil and the demulsifier to form a mixture. The apparatus includes a heater surrounding at least a portion of the vessel. The heater is configured to provide heat to the mixture. The apparatus includes a guided wave radar configured to generate a reference pulse of microwave energy and detect a surface echo reflected from the mixture.