Separator

This is a National Phase application based upon PCT/GB88/00715 filed Sept. 1, 1988.

This invention relates to a separator. In particular it relates to a separator for separating a relatively small volume e.g. up to 20% of a less dense liquid from a larger volume of a more dense liquid, for example separating small volumes of crude oil from production water from an oil well so that the separated water may be discharged in a virtually clean condition to the sea.

It is known to construct a separator for this use in tubular form of reducing circular cross-section from a wide end to a narrow end, having at least one tangentially-disposed inlet at or adjacent the wide end for introducing at relatively high velocity the mixture of liquids to be separated into the separator, and two outlets, the first disposed on the axis of the separator at the wide end for the removal of the less dense liquid component and the second disposed at or adjacent the narrow end for the removal of the more dense liquid component

During use of such a separator the less dense component, for example oil, moves towards the axis and forms a core and this moves towards the wide end, while the more dense component, e.g. sea-water, moves towards the wall of the separator and towards the narrow end. However it has been found that in some situations not all the less dense component in the central core moves towards the wide end; some of it remains stationary and some even moves towards the narrow end where it mixes with and contaminates the more dense component.

It is an object of the present invention to provide a separator in which the above disadvantageous effects are substantially reduced or overcome.

In accordance with a first aspect of the invention a separator for separating a mixture of liquids into a more dense component and a less dense component comprises an elongated tube having a circular cross-section which reduces in diameter from a wide end to a narrow end, at least one tangentially disposed inlet at or adjacent the wide end for the introduction at relatively high velocity of a mixture of liquids to be separated, at least one outlet for the removal of the less dense component on the axis of the separator, and at least one outlet for the removal of the more dense component, positioned in the vicinity of the narrow end of the separator, and pressure control means for controlling the pressure of the more dense component in the vicinity of the outlet for the more dense component.

The tube may be of any suitable shape. For example it may be of constant taper from a location adjacent the inlet towards the narrow end. Alternatively the convergence angle may vary, either abruptly, so that the tube comprises a plurality of frusto conical portions, or gradually, so that the interior surface of the tube is curved, the degree of curvature decreasing in a direction from the wide end of the separator towards the narrow end. The tube may include at least one cylindrical section, e.g. at the wide end and/or at the narrow end.

The outlet for the more dense component may extend for at least substantially the whole of the circumference of the tube, or may comprise at least one tangentially disposed port of any suitable cross-sectional shape, e.g. circular, elliptical, rectangular or square in the opposite sense to the said at least one inlet. The size of the outlet may be adjustable. For example it may be in the form of a gap between the tube and an outlet unit, which may be moveable along the axis of the separator, to vary the size of the gap. The adjacent surfaces of the end of the tube and of the outlet unit defining the gap may be tapered, the cross-sectional area of a surface on either tube or outlet unit increasing from the wide end towards the narrow end of the separator.

At least one other, intermediate, outlet for the more dense component may be provided at a pre-determined position on the wall of the separator between the two ends, with pressure control means for controlling the pressure of the more dense component in the vicinity of this, intermediate, outlet for the more dense component. The intermediate outlet may extend for substantially the whole of the circumference of the tube, or may comprise at least one tangentially disposed port of any suitable cross-sectional shape, e.g. circular, elliptical, rectangular or square, in the opposite sense to the said at least one inlet. The size of the intermediate outlet may be adjustable, and the outlet may, in some situations, be closed. However, no change of diameter should occur. For example in the case where it extends around the whole circumference of the tube it may comprise a gap between two adjacent lengths of the tube, and the gap may be adjusted by moving one length relative to an adjacent length along the tube axis. The surfaces of the two adjacent lengths defining the gap may be tapered, the cross-sectional area of a wide surface on either length increasing in a direction from the wide end towards the narrow end of the separator.

Preferably there are two diametrically opposed tangential inlets for the mixture of liquids to be separated, of any suitable cross-sectional shape, e.g. circular, oval, rectangular or square. However more than two inlets may be provided. The or each inlet may connect with a cylindrical end section of the tube.

The size of either outlet for the more dense component, i.e. at the narrow end and/or between the two ends, or the inlet(s) may be controlled either manually or automatically under the influence of one or more sensors for detecting changes in various parameters such as liquid flow rate, liquid composition i.e. relative proportions of each component, or pressure at various positions.

FIG. 1 shows a simplified longitudinal cross-section through a separator according to the invention;

FIG. 2 shows how the angle .alpha. is defined;

FIGS. 3-5 show in simplified form, three alternative constructions of part of the separator shown in FIG. 1;

FIGS. 6 and 7 show, in simplified form, two alternative forms of the second body section of the separator shown in FIG. 1;

FIG. 8 shows how the angle .beta. is defined;

FIG. 9 shows, in simplified form, the construction of the separator shown in FIG. 1 at the narrow end thereof; and

FIG. 10 shows a longitudinal cross-section through a cyclone separator in accordance with a specific embodiment of the invention.

A cyclone separator in accordance with the present invention is shown in FIG. 1 and comprises an elongated tube having a cylindrical inlet section 1, a first body section 2 and a second body section 3. The separator also comprises an outlet unit (see FIG. 9). For convenience the separator is shown with thin walls but in practice they may be much thicker to withstand internal pressures of the liquids being separated.

The inlet section 1, in the form of a short cylindrical tube, has a cross-sectional area A.sub.M, and corresponding diameter D.sub.M in the range from about 20 mm to about 120 mm, typically about 70 mm, and a length L, up to about 500 mm. Preferably L,=D.sub.M. Two diametrically opposed, tangentially disposed inlet ports 5a and 5b are provided, leading to the inlet section 1 from inlet pipes (not shown) through which a mixture of water and up to 20% crude oil may be fed at high velocity to the separator interior. The inlet section is provided with a disc-shaped end cover 7, which in this example is not provided with an axially disposed outlet for the less dense component. The inlet ports may be of any suitable cross-section, although in FIG. 1 the ports have a circular cross-section of diameter D,. The total cross-sectional area of the inlet ports A, may lie in the range given by the equation:

Preferably

The inlet section 1 is connected to the first body section 2 which as shown in FIG. 1 is of constant taper to provide the interior surface 8 with a constant convergence angle .alpha. between the point A where the inlet section joins the first body section and the point B where an intermediate outlet 6 for the more dense component is provided.

The convergence angle .alpha. preferably lies in the range from about 30' to about 10.degree. e.g. about 2.degree., although smaller convergence angles are possible, down to about 1'-5', if the separator inlet diameter D.sub.M is small. A preferred value of .alpha. is 1.8.degree.. At point B as shown in FIG. 1 the diameter D.sub.2 of the separator has reduced to a value given by the equation: ##EQU1## with a preferred value being ##EQU2## Other shapes of the first body section 2 are possible. For example the convergence angle may vary, either abruptly, so that the first body section 2 comprises a plurality of frusto-conical portions, the convergence angle decreasing from one portion to the next in a direction away from the inlet section 1, or gradually so that the interior surface 8 of the body section 2 is curved, the degree of curvature decreasing in a direction away from the inlet section 1, as illustrated in FIG. 4. In all the different shapes overall convergence angle .alpha. from point A to point B as illustrated in FIG. 2, lies within the range given above, and has the same preferred values.

As shown in FIG. 1 the separator is provided with an intermediate outlet 6 for the more dense component in the form of a circumferential gap between the first body section 1 and the second body section 3. Pressue conrol means for controlling the pressure of the more dense component in the vicinity of the intermediate outlet is provided but not shown in FIG. 1. Such means may comprise a pressure control valve. The size of the gap may be varied by moving the sections towards or away from one another so as to alter the longitudinal dimension L.sub.2 shown in FIG. 1. Preferably the value of L.sub.2 is defined by the equation: ##EQU3## or, preferably ##EQU4##

In this preferred range L.sub.2 lies between 4.0 mm and 8.0 mm for a D.sub.M of about 70 mm.

As shown in FIG. 1 the second body section is cylindrical in shape and has an internal diameter D.sub.3. The value of D.sub.3 lies within the range given by the equation: ##EQU5## with a preferred value being:

It is to be noted that if D.sub.3 <D.sub.2 then L.sub.2 can be negative with the limit given by the equation:

In other words the end of the second body section 3 adjacent the gap 6 may protrude inside the interior of the first body section 2.

As shown in FIGS. 3, 4 and 5 alternatively the intermediate outlet 6 may comprise one or more outlet ports of any suitable cross-sectional shape. Two diametrically-opposed, tangentially disposed rectangular ports 6a and 6b are shown in FIG. 3, two diametrically disposed, tangentially disposed circular ports 6c and 6d are shown in FIG. 4 and one tangentially disposed circular port 6e is shown in FIG. 5. The second body section 3 in all constructions shown in FIGS. 3, 4 and 5 is a continuation of the first body section 2.

The total outlet area A.sub.3 of the outlet port 6e or both outlet ports 6a and 6b or 6c and 6d may lie in the range given by the equation:

Preferably two outlets are used with the preferred value being

A.sub.2 is the cross-sectional area of the tube at the point B in FIG. 1, and corresponds to the diameter D.sub.2. This is the diameter immediately adjacent the intermediate outlet on the side closer to the wide end of the separator.

The arrangement of the outlet ports 6a, 6b etc. is in the opposite sense to the inlet ports 5a and 5b.

The second body section 3, as shown in the construction in FIG. 1 may be cylindrical. However, alternatively it may be formed with a frusto-conical mouth portion, as shown between points C and E in FIG. 6, the remainder being cylindrical, as shown between points E and D. Alternatively it may be curved as shown in FIG. 4, or of wholly frusto-conical form, as shown in FIG. 7. In all instances the overall angle of convergence .beta. between points C and D (see FIG. 8) lies in the range 0.degree. to about 5.degree.. The overall length L.sub.3 of the second body section 3 lies in the range given by the equation:

But the values of .beta. and L.sub.3 must be such that:

and

Preferably the second body section 3 has a cylindrical shape so that .beta.=0 and D.sub.4 =D.sub.3, and also the value of L.sub.3 is such that it lies in the range given by the equation;

with the preferred value of L.sub.3 =7D.sub.M

As shown in FIG. 9 the outlet 10 for the more dense component at the narrow end of the separator leads into a closed chamber 12. The component is fed from the chamber 12 through a restriction or other pressure control means such as a valve 13. The pressure of the outflowing component is thereby controlled. If several separators are used in parallel, the discharges of the more dense component may be into one chamber.

The outlet 10 shown in FIG. 9 extends around the whole circumference of the end of the second body section 3. Preferably the outlet is characterised by the axial width L.sub.5 of the outlet, the taper angle .gamma. of the conical deflector 15 disposed in the chamber and the diameter D.sub.6 of the base of the deflector. The values of these dimensions lie in the following preferred ranges ##EQU6## However the maximum value of D.sub.6 may be larger than 4D.sub.4. The upper limit depends on the size and shape of the chamber 12 or other practical limitations.

Alternatively the outlet 10 may be in the form of one or more tangentially disposed outlet ports of any suitable shape e.g. circular, rectangular or square, similar to the intermediate outlet ports 6a, 6b, 6c etc., and in the opposite sense the inlet ports 5a, 5b.

The less dense component of the mixture forms as a central core within the liquid and is removed from the separator via an axially disposed outlet 11 in the form of a narrow tube 19, the end of which is preferably tapered so as to form a sharp edge 17. The tube extends towards the interior of the separator beyond the extremity 18 of the second body section 3. The tube 19 may have an enlarged diameter outwardly from the separator beyond the extremity 18 of the second body section 3.

The internal diameter D.sub.5 of the tube is selected depending on the proportions of the liquid components being separated but may be varied within the range given by the following equation:

a preferred range (for low concentrations of the less dense component) being

The length L.sub.4 the tube 19 extends within the separator may be varied within the range:

a preferred value being ##EQU7##

One specific embodiment of the invention is shown in FIG. 10 and comprises a cyclone separator in the form of an elongated tube having a cylindrical inlet section 101, a first body section 102 and a second body section 103. The separator also comprises an outlet unit 104.

The inlet section 101 in the form of a short cylindrical tube having a diameter D.sub.M of 70 mm and a length L,=50 mm is provided with two tangentially disposed inlet ports 105a and 105b of circular cross-section diametrically opposed to one another leading from inlet pipes 106a and 106b through which a mixture of water and up to 2.0% crude oil may be fed at high velocity to the separator. The inlet section is provided with an end cover 107.

The inlet section 101 is connected to a tubular first body section 102 by any suitable means. The first body section 102 has a tapered interior having a frusto-conical surface 83, the convergence angle .alpha. of the surface 83 having a value of 1.8.degree.. The length L of the first body section is 835 mm. The minimum diameter D.sub.2 of the first body section is 17.5 mm.

At the end of the first body section 102 remote from the inlet section 101 is positioned a tubular second body section 103 having a cylindrical interior, i.e. the diameter of the interior surface 112 is constant. The diameter D.sub.3 (=14 mm) of surface 112 of the second body section 103 is slightly less than the diameter D.sub.2 (=17.5 mm) of frusto-conical surface 83 closest to the second body section 103, a small circumferential gap 113 being provided between the first body section 102 and the second body section 103. This gap 113 provides an outlet for the more dense component which discharges into a cylindrical chamber 84 surrounding the gap 113 and thence out through a pressure controlling valve 85. The position of the second body section 103 relative to the first body section 102 is adjustable by means (not shown in FIG. 1) to vary the size of the gap 113. Typically the axial length L.sub.2 of the gap is between 1 mm and 10 mm. Two 0 ring seals 86, 87 are provided in grooves 88, 89 in the outer cylindrical surface of the first body section 102 allowing the first body section to slide in or out of the chamber 84 as required.

As can be seen in FIG. 10 the gap 113 is formed between a frusto-conical surface 114 on the end of the first body section 102 remote from the inlet section 101 and a conical surface 115 on the adjacent end of the second body section 103. The surfaces 114 and 115 are such that they diverge on a direction away from the inlet section 101 at a divergence angle W typically 30.degree.. The overall length L.sub.3 of the second body section is 500 mm.

Adjacent the end 116 of the second body section 103 (i.e. at the narrow end of the separator) remote from the inlet section 101 there is positioned an outlet unit 104. This is in the form of a thick-walled tube within the bore of which is an inner tube 117 having an internal diameter in the range 2 mm-3 mm. This inner tube 117 is a sliding fit within the outlet unit 104, has a constant internal diameter in the range 4 mm-7 mm, and its axis coincident with the axis of the remaining parts of the separator. An elongation 118 of the inner tube 117 extends a short distance L.sub.4 into the separator from the narrow end 116 thereof towards the inlet section 101, so that the inner tube mouth 122 is spaced apart from the narrow end 116. The mouth 122 of the tube is externally tapered to form a sharp edge at its extremity within the separator.

The surface 119 of the second body section 103 facing the outlet unit 104 is frusto-conical and the surface 120 of the outlet unit 104 facing the second body section 103 is conical. A small circumferential gap 121 is provided between the surfaces 119 and 120 to form a second outlet for the more dense component which discharges into a cylindrical chamber 91 surrounding the gap 121 and thence out through a pressure controlling valve 92. The surfaces 119 and 120 diverge in a direction away from the inlet section 1 at a divergance angle .omega. typically 30.degree..

The position of the outlet unit relative to the second body section 103 may be adjusted by means (not shown in FIG. 1) to vary the size of the gap 121. Typically the axial length L.sub.5 of the gap is 0-10 mm e.g. 5 mm. Two 0 ring seals 94, 95 are provided in grooves 96, 97 in the outer cylindrical surface of the outlet unit 104, allowing it to slide into or out of the chamber 92 as required. Additionally suitable means may be provided for sliding the inner tube 117 within the outlet unit 104, thus varying the axial length L.sub.4 (typically 80 mm) of the elongation 118 and hence moving the mouth 122 thereof to be positioned at any required distance from the narrow end 116 of the separator.

The mouth 122 of the inner tube 117 in the outlet unit 4 provides an outlet for the removal of the less dense component i.e. oil, from the separator. This inner tube 117 may be connected to a suitable valve and/or pump as required.

In use of the separator of this embodiment (as shown in FIG. 10) the mixture of liquids to be separated, water and crude oil, is fed at high speed into the separator through the inlet ports 105a and 105b. By adjusting the positions of the second body section 103 and the outlet unit 104 the sizes of the gaps 113 and 121 may be varied. Fluid flow and pressure are also varied. Since the less dense component i.e. the oil, moves towards the axis of the separator this may be removed through the mouth 122 of the inner tube 117. Additionally since the more dense component i.e. water, moves towards the wall of the separator i.e. the interior surfaces 83 and 112, some is removed through the gap 113 between the first and second body sections 102 and 103 (if open), while the remainder is removed through the gap 121 between the second body section 103 and the outlet unit 104. By suitable adjustment of the pressure of water by means of valves 85 and 93, of the flow rate of oil through the outlet 122, and of the relative positions of the second body section 103, the outlet unit 104 and the mouth 122, virtually clean water may be obtained from the outlets 113 or 121.

When the separator illustrated in FIG. 10 was operated to separate a mixture of about 400 parts per million of light oil (less dense component) in water (more dense component), the oil having a mean droplet diameter of 37 microns, the following results were achieved:

The operating conditions were:

It was also found that when a separator similar to that illustrated in FIG. 10 but with a slightly longer first body section 102 tapering to a minimum diameter D.sub.2 of 14 mm i.e. equal to the internal diameter D.sub.3 of the second body section 103, was operated under similar inlet pressure conditions but with the gap 113 between the first and second body sections closed the following results were obtained: