WO2011129697A1 - Dispositif et procédé pour la coalescence de gouttelettes dispersées dans un mélange en circulation - Google Patents

Dispositif et procédé pour la coalescence de gouttelettes dispersées dans un mélange en circulation Download PDF

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Publication number
WO2011129697A1
WO2011129697A1 PCT/NL2011/050256 NL2011050256W WO2011129697A1 WO 2011129697 A1 WO2011129697 A1 WO 2011129697A1 NL 2011050256 W NL2011050256 W NL 2011050256W WO 2011129697 A1 WO2011129697 A1 WO 2011129697A1
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Prior art keywords
flow channels
mixture
assembly
flow
liquids
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PCT/NL2011/050256
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English (en)
Inventor
Jozef Johannes Hubertus Brouwers
Hugo Theodoor Jean Liebrand
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COALESSENSE BV
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COALESSENSE BV
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D17/00—Separation of liquids, not provided for elsewhere, e.g. by thermal diffusion
    • B01D17/02—Separation of non-miscible liquids
    • B01D17/0217—Separation of non-miscible liquids by centrifugal force

Definitions

  • the invention relates to a device for coalescing droplets dispersed in a flowing mixture of at least two liquids with different mass density.
  • the invention also relates to a method for coalescing droplets dispersed in a flowing mixture of at least two liquids with different mass density, and to a method for separating a mixture of at least two liquids with different mass density into at least two fractions that each substantially comprise one of the at least two liquids.
  • Oil producers are increasingly facing problems with large amounts of water present in oil wells, in particular ageing oil wells. As a well matures, the amount of water in the oil may reach 90% and more.
  • the two liquids being substantially immiscible or non-soluble in one another form a dispersion of rather small oil droplets in a continuous water phase (or vice versa).
  • the main concern for the oil producer is to be able to efficiently separate the oil droplets from the water phase with a high selectivity, thereby obtaining high quality oil with a low amount of water.
  • Gravity separators are commonly used to separate dispersions and emulsions into their components. In such equipment, differences in densities of the two liquids cause droplets to rise or fall by their buoyancy. The greater the difference in densities, the easier the separation becomes. In order to settle fine droplets and ensure laminar flow, large vessels and long residence times are required. It may take five, ten, and or even thirty minutes to make a separation, depending on the physical properties of the mixture stream. If this time is not available, hazy, off spec products or intermediates that cause problems in downstream equipment are obtained.
  • Liquid-liquid coalescers are used to accelerate the merging of many droplets to form a lesser number of droplets, but with a greater diameter. This increases the buoyant forces and settling of the larger droplets downstream of the coalescer element then requires less residence time.
  • a known type of coalescers depends on settling of droplets and confine the distance a droplet can rise or fall between parallel plates or crimps of packing sheets.
  • Another type depends on interception of droplets and uses a multiplicity of fine wires or filaments to collect fine droplets as they travel in the laminar flow streamlines around them.
  • An essential step in coalescers is to combine, aggregate, or coalesce captured droplets.
  • This actual coalescing step is a complex function of surface tension and viscous effects, droplet momentum, and the dynamics of the sizes of the droplets in the dispersion.
  • the known coalescers accelerate the subsequent separation process in a gravity separator, there remains room for improvement, both with respect to the speed of separation and with respect to its selectivity. This is in particular the case when coalescing oil droplets dispersed in a mixture of oil and water.
  • the invention provides for this purpose a device for coalescing droplets dispersed in a flowing mixture of at least two liquids with different mass density, the device comprising:
  • rotating means in the form of a rotating assembly of flow channels that are accessible to the flowing mixture
  • the lighter fraction of the mixture (which corresponds to the oil fraction in a water/oil mixture) will migrate at least substantially to the inner side of the flow channels (the side closest to the center of rotation) and coalesce at this side, for instance in the form of a film, while the heavier fraction (which corresponds to the water fraction in a water/oil mixture) will migrate at least substantially to the outer side of the flow channels.
  • the coalesced lighter fraction breaks up into droplets at the downstream end of the flow channels.
  • the assembly of flow channels is designed such that the smallest distance between the inner walls of two flow channels is larger than 30 micron, the lighter fraction is collected at the end of the flow channels as droplets that are substantially larger than the incoming average droplet size prior to rotating.
  • the device therefore acts as a coalescer and the concentration of the at least two liquids with different mass density in the flowing mixture is substantially unaffected by the rotating means.
  • the concentration of the at least two liquids in the flowing mixture at the inlet is substantially equal to the concentration of the at least two liquids in the flowing mixture at the outlet of the device.
  • the device is characterized in that the assembly of flow channels is designed such that the smallest distance between the inner walls of two flow channels is larger than 50 micron, even more preferred larger than 70 micron, and most preferred larger than 100 micron. It has turned out that a minimum available solid wall thickness (or two-dimensional surface) is desired at the outer end of the rotating assembly of flow channels to be able to retain the coalesced droplet size.
  • the device is typically able to coalesce micron-sized droplets dispersed in a flowing mixture to droplets that may be 10 to 50 times as large as the incoming average droplet size, without having to use voluminous equipment (i.e. the device can take a very compact form). Moreover, the mixture has to be treated in the device for a short period of time only to achieve the effect.
  • the rotating coalescer in the form of a rotating assembly of flow channels has the advantage that the average distance in the radial direction of the mixture from a wall is limited. Since the flow channels are many and of small size, a coalesced layer may readily be achieved in a relatively short time and with a high throughput, even when the available length of the flow channels is relatively limited (corresponding to the length in the axial direction of the rotating assembly).
  • the flow speeds of the mixture to be applied in the flow channels may be varied or optimised according to the properties of the mixture.
  • the number of flow channels can in principle be chosen within wide limits, it is recommended that the number of flow channels in the assembly is at least 500, more preferably at least 800 and most preferably at least 1000.
  • the flow channels of the rotating means of the device may have any desired form. It is thus possible to have them run in a random curve in the lengthwise direction or, conversely, make them almost linear.
  • the flow channels in the assembly preferably extend substantially linear and mutually parallel to the axis of rotation of the assembly.
  • the space between the flow channels in the assembly of flow channels may be accessible or inaccessible to the flowing mixture, for instance by being filled with material, thereby leaving the flow channels accessible to the flowing mixture only.
  • the space between the flow channels in the assembly of flow channels is accessible to the flowing mixture, this space is not or only partly filled up with material.
  • the assembly may for instance comprise a number of cylindrical flow channels that have been stacked in parallel to each other according to some stacking order, and the interstitial space filled up with a hardening material, such as an epoxy resin for instance.
  • a cross-section of the assembly comprises a number of circular flow channel cross-sections arranged according to some array, such as a rectangular or hexagonal array for instance, with the interstitial space optionally filled with solid material.
  • the smallest distance between the inner walls of two flow channels in such case corresponds to twice the wall thickness of the follow channels.
  • a device wherein the total inaccessible cross-sectional area of the rotating assembly of flow channels exceeds 20% of the total accessible cross-sectional area thereof.
  • the total inaccessible cross-sectional area of the assembly is the sum of all filled-up interstitial areas, whereas the total accessible cross-sectional area of the assembly is the total flow-through area, i.e. the sum of the cross-sectional areas of the flow channels.
  • the present embodiment produces a coalesced mixture having an increased ratio of average droplet size at the outlet to the average droplet size at the inlet.
  • a preferred variant of the device according to the invention comprises flow channels with singly-connected cross-section.
  • each flow channel has a cross-section extending along practically the whole length thereof which extends azimuthally around the axis of rotation at an angle smaller than 360° such that the azimuthal flow at an angle greater than 360° to the axis of rotation is substantially prevented.
  • each flow channel extends azimuthally around the axis of rotation at an angle smaller than 360° such that azimuthal flow at an angle greater than 360° to the axis of rotation is substantially prevented in each flow channel, wherein each flow channel is provided with wall portions extending substantially along the total length thereof, wherein the coalescence is bounded in radial and azimuthal directions relative to the axis of rotation.
  • each flow channel extends azimuthally around the axis of rotation at an angle smaller than 360° such that azimuthal flow at an angle greater than 360° to the axis of rotation is substantially prevented in each flow channel, wherein each flow channel is enclosed by a single wall extending substantially along the whole length thereof.
  • the invention also relates to a method for coalescing droplets dispersed in a flowing mixture of at least two liquids with different mass density.
  • the method comprises the steps of:
  • a method is provided wherein the rotational speed of the rotating assembly of flow channels and the pressure for forcing the mixture through the flow channels are regulated such that the ratio of the circumferential velocity in a flow channel furthest away from the center of rotation of the assembly to the average axial velocity in the flow channels ranges from 30 to 450, more preferred from 40 to 200, even more preferred from 50 to 150, and most preferred from 75 to 100.
  • the preferred ranges allow to coalesce incoming droplets as small as 1 micron, even for a mixture wherein the two liquids differ in mass density to a small extent only.
  • a typical example of a liquid/liquid mixture wherein the two liquids differ in mass density to a small extent only is an oil/water mixture.
  • any flow disturbance in the flow channels may disrupt or negatively affect the coalescence of the lighter fraction on the inner walls of the channels.
  • any component of the rotation in the plane perpendicular to the axis of the flow channels can cause a Coriolis force, whereby an internal eddying is created in the flow channels in the plane perpendicular to the channel axis.
  • the method and device according to the invention are adapted to diminish or even prevent such disturbances.
  • coalescence is improved in an embodiment of the method wherein the rotational speed of the flow channels is regulated such that the ratio of the centrifugal pressure in a flow channel furthest away from the center of rotation of the assembly to the average axial pressure drop over the flow channels ranges from 20 to 200, whereby the centrifugal pressure is given by
  • ⁇ denotes the rotational speed of the assembly
  • ⁇ represents the dynamic viscosity of the mixture
  • u denotes the average axial velocity in the flow channels
  • Ro, L and d c represent the largest distance to the center of rotation of the assembly (for a cylindrical assembly of flow channels this corresponds to the radius of the assembly), the length of the flow channels, and the hydraulic diameter of the flow channels respectively. Since the ratio of centrifugal pressure to average axial pressure is a dimensionless number the dimensions used in the above relations have to be consistent only.
  • Generally accepted dimensions are metric and include for instance [rad.sec 1 ] for ⁇ , [m] for distances Ro, L and d c , [m.sec _1 ] for u, [Pa.sec] for ⁇ , and [kg.m 3 ] for p.
  • Even more preferred is an embodiment of the method wherein the rotational speed of the flow channels is regulated such that the ratio of the centrifugal pressure in a flow channel furthest away from the center of rotation of the assembly to the average axial pressure drop over the flow channels ranges from 30 to 100.
  • Another embodiment of the method according to the invention is characterized in that the flow in the flow channels is substantially laminar.
  • the process conditions and the channel dimensions are chosen such that the Reynolds number is significantly lower than 2000, and generally amounts to about 1000.
  • the invention further relates to a method for separating a mixture of at least two liquids with different mass density into at least two fractions that each substantially comprise one of the at least two liquids, the method comprising coalescing droplets dispersed in the flowing mixture according to the method described above, and thereafter subjecting the mixture thus obtained to a conventional separation.
  • the subsequent separation is not limited to any separation method in particular and may be a gravity separator, a centrifugal separator, a (hydro)cyclone, a plate pack separator, and the like.
  • figure 1 shows a schematic view in perspective of a device according to the invention
  • figure 2 schematically shows an enlarged part of a cross section of the rotating assembly of flow channels according to line A-A of the device of figure 1
  • figure 3 represents a graph of the efficiency of the coalescing process carried out in a device according to the invention.
  • FIG 4 represents a table of experimental results obtained for a number of Examples of the method according to the invention.
  • a device 1 for coalescing oil droplets dispersed in a flowing water/oil mixture is shown.
  • Device 1 comprises a cylindrical housing 2 confined by an upstream end plate 3 and a downstream end plate 4.
  • the housing comprises rotating means in the form of a rotating assembly 5 of flow channels 6, arranged mutually parallel to an axis of rotation 7.
  • the rotation axis 7 is supported by bearings 8 and 9 that are provided in end plates 3 and 4 respectively.
  • Device 1 is further provided with an inlet 10 that tangentially connects to the rotating means through an entrance chamber 11.
  • the oil/water mixture is accelerated to the desired angular velocity, and the swirling mixture also drives the rotating assembly 5. Another possibility is to drive the rotating assembly 5 by a motor.
  • the oil/water mixture is pumped through the inlet 10 by pressure means in the form of an hydraulic pump (not shown) for forcing the mixture through the flow channels 6.
  • the entrance chamber 11 is further provided with a static blade 12 which helps in adjusting the flow of water to allow a smooth entry into the rotating assembly 5. Entrance chamber 11 is also instrumental in separating out any solid particles that may be present in the water to prevent clogging of the flow channels 6.
  • the cross-section of rotating assembly 5 according to the line A-A is shown in enlarged view in figure 2.
  • the flow channels 6 occupy a part of the cross-section which is accessible to the flowing oil/water mixture, while the part between the flow channels 6 is inaccessible to the flowing mixture.
  • This inaccessible part 20 is hatched in figure 2 and may be manufactured from stainless steel for instance.
  • the total inaccessible cross-sectional area 20 of the rotating assembly 5 of flow channels 6 exceeds 20% of the total accessible cross-sectional area thereof (the sum of the areas of all flow channels 6), and more preferred exceeds 40% of the total accessible cross-sectional area of the rotating assembly 5.
  • a particularly favourable rotating assembly 5 comprises flow channels 6 for which the smallest distance 21 between the inner walls of two flow channels 6 is larger than 30 micron, and more preferred larger than 50 micron.
  • oil droplets are centrifuged to the inner wall (the wall part closest to the center of rotation) of each channel 6. Oil droplets hit the wall of a channel and coalesce into a film 22 that moves thickens in the downstream direction of the assembly 5.
  • Oil depleted water 23 flows through the remaining cross-section of the channels 6. Upon reaching the end of the channels 6, the coalesced film 22 breaks- up into droplets under the influence of the centrifugal forces. The droplets thus produced have a larger average size than the average droplet size at the inlet 10.
  • Device 1 may operate at widely varying flow rates but typically operates at a volume flow of 20 m 3 /hr for instance, while rotating at a rotational speed of 1500 rpm.
  • the pressure means are typically able to produce pressures of up to 30 bar, although higher pressures may be envisaged.
  • Device 1 further comprises an outlet 14 connecting downstream to the rotating assembly 5 via separation chamber 13.
  • Chamber 13 acts as an axial centrifuge and is entirely filled with fluid, in casu the oil/water mixture.
  • the large oil droplets as produced by the assembly 5 of flow channels 6 are collected around the axis 7 of the assembly 5 while the oil-depleted (cleaned) water is forced to leave the assembly 5 at the outer radius at outlet 14.
  • This water is then available for further separation in conventional installations such as plate pack separators, IGF installations and/or hydrocyclones.
  • Separation chamber 13 may comprise blades (not shown) and other means that minimize secondary flows and turbulence, since these may disrupt the formed coalesced droplets and disturb the separation of the oil from the water fraction.
  • the heavy fraction comprises purified water with a minor component of residual oil
  • the lighter fraction comprises a dispersion of oil and water, in which the oil is present as relatively large droplets, allowing for easy recovery of this 'waste' oil fraction.
  • This oil fraction is led through an outlet 15 to a suitable separator, which may be a centrifugal separator 16 or any other conventional separator for recovering the waste oil, or directly to a container.
  • a specific embodiment of a device 1 according to the invention has been used for a number of experiments that demonstrate the invented method. This specific
  • Device 1 was further equipped with two 30 m 3 buffer tanks allowing for continuous operating of the device and a precise oil-injection system combined with a disrupting mechanism to create the desired oil cut and oil droplet size.
  • d P 5o is defined as the droplet size that has a 50% probability to be coalesced in the assembly of the given length and channel diameter.
  • Tests were performed with a clean water volume flow between 10 and 20 ffiVhr, oil inlet concentrations adjustable from 50 to 300 ppm, and rotational velocities of the assembly 5 ranging from 750 to 1000 rpm. Iso-kinetic sample points were available to take samples from the flow to determine the oil content. The samples were taken at the inlet 10, at a location in the entrance chamber 11 just prior to entry into the assembly 5 of flow channels 6, and at the heavy fraction (oil depleted clean water) outlet 14. The samples were analysed for oil content (hexane-extraction). .
  • the break-up droplet diameter was observed to be 465, 349 and 232 micron respectively.
  • the droplets are therefore enlarged 25 times (from 9,3 to 232 micron).
  • the velocity could be raised up to 7000 rpm to obtain a break-up droplet size of 50 micron still.
  • the test results are shown in the table of figure 4. In the first series of tests (test 1 to 5), the device was utilized as a single, standalone coalescing unit, with a focus on achieving a low oil concentration in the water outlet 14.
  • tests 8 and 9 The third series of tests (tests 8 and 9) was performed with the Facet plate separator connected to the water outlet 14 of device 1. Only part of the water outlet flow was connected to the plate separator, as it was designed to have a volume flow of 1 m 3 /hr maximum. The tests were performed with a volume flow rate of 750 1/hr through the plate separator. It showed good results, as oil concentrations after the plate separator are very low.
  • the device according to the invention effectively reduces the oil content in an oil/water mixture by more than 90 %, while at the same time creating an oil/water mixture with relatively large oil droplets available for downstream separators.
  • Droplets larger than 4,6 micron are separated with a 50% probability and coalesced into droplets of 230 micron and larger.
  • Droplets are enlarged up to 25 times in the device of the invention. Thousands of channels each function as a small centrifuge, resulting in high throughputs while maintaining a high efficiency.
  • the inlet and outlet sections of the device By providing the inlet and outlet sections of the device with arrangements such as blades allow to minimize shearing and premature break-up of oil droplets.
  • the device has a large operating window and may maintain a constant high efficiency level. It also has the possibility to separate impurities such solids and heavy particles from the oil/water mixture prior to entering the flow channels of the rotating assembly.

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  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Centrifugal Separators (AREA)

Abstract

L'invention porte sur un dispositif pour la coalescence de gouttelettes dispersées dans un mélange en circulation d'au moins deux liquides ayant différentes masses volumiques. Le dispositif comprend un moyen tournant sous la forme d'un ensemble tournant de canaux de circulation qui sont accessibles au mélange en circulation, un moyen de pression servant à forcer le mélange à passer dans les canaux de circulation, une entrée pour le mélange raccordée au moyen tournant et une sortie raccordée au moyen tournant pour l'évacuation du mélange coalescé. La plus petite distance entre les parois internes de deux canaux de circulation est supérieure à 30 micromètres. Le dispositif permet de produire un mélange comprenant des gouttelettes coalescées de grande taille qui sont efficacement séparées par la suite. L'invention porte également un procédé pour la coalescence de gouttelettes dans un mélange en circulation.
PCT/NL2011/050256 2010-04-15 2011-04-14 Dispositif et procédé pour la coalescence de gouttelettes dispersées dans un mélange en circulation Ceased WO2011129697A1 (fr)

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NL2004559 2010-04-15
NL2004559A NL2004559C2 (en) 2010-04-15 2010-04-15 Device and method for coalescing droplets dispersed in a flowing mixture.

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014089579A1 (fr) * 2012-12-07 2014-06-12 Cypho, Inc. Système de génération d'émulsion d'orifice commun
US9884327B2 (en) 2012-11-23 2018-02-06 Alfa Laval Corporate Ab Centrifugal separator having frame secured within a vessel
US10710101B2 (en) 2012-11-23 2020-07-14 Alfa Laval Corporate Ab Centrifugal separator having a vortex generator
US11118218B2 (en) 2012-09-12 2021-09-14 Cypho, Inc. Common port emulsion generation system
US12023637B2 (en) 2020-03-23 2024-07-02 Mark A. Gray Capillary tube droplet generation systems and methods

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US507442A (en) * 1893-10-24 Atto lentsch
US3695509A (en) * 1969-08-08 1972-10-03 Termomeccanica Italiana Spa Centrifugal separator for separating emulsions
US3931927A (en) * 1973-01-12 1976-01-13 Standard Oil Company Centrifuge
US6083147A (en) * 1995-07-25 2000-07-04 Centritech Hb Apparatus and method for discontinuous separation of solid particles from a liquid
US20060225386A1 (en) * 2005-02-17 2006-10-12 Bert Brouwers Method for removing contaminating gaseous components from a natural gas stream
US20090301296A1 (en) * 2006-02-23 2009-12-10 Romico Hold A.V.V. Device and method for separating a flowing medium mixture into fractions

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US507442A (en) * 1893-10-24 Atto lentsch
US3695509A (en) * 1969-08-08 1972-10-03 Termomeccanica Italiana Spa Centrifugal separator for separating emulsions
US3931927A (en) * 1973-01-12 1976-01-13 Standard Oil Company Centrifuge
US6083147A (en) * 1995-07-25 2000-07-04 Centritech Hb Apparatus and method for discontinuous separation of solid particles from a liquid
US20060225386A1 (en) * 2005-02-17 2006-10-12 Bert Brouwers Method for removing contaminating gaseous components from a natural gas stream
US20090301296A1 (en) * 2006-02-23 2009-12-10 Romico Hold A.V.V. Device and method for separating a flowing medium mixture into fractions

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11118218B2 (en) 2012-09-12 2021-09-14 Cypho, Inc. Common port emulsion generation system
US9884327B2 (en) 2012-11-23 2018-02-06 Alfa Laval Corporate Ab Centrifugal separator having frame secured within a vessel
US10710101B2 (en) 2012-11-23 2020-07-14 Alfa Laval Corporate Ab Centrifugal separator having a vortex generator
WO2014089579A1 (fr) * 2012-12-07 2014-06-12 Cypho, Inc. Système de génération d'émulsion d'orifice commun
US12023637B2 (en) 2020-03-23 2024-07-02 Mark A. Gray Capillary tube droplet generation systems and methods

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