U.S. patent application number 17/451191 was filed with the patent office on 2022-02-03 for separation system and method.
The applicant listed for this patent is Pentair Filtration Solutions, LLC. Invention is credited to John Byron Kelsey.
Application Number | 20220032212 17/451191 |
Document ID | / |
Family ID | |
Filed Date | 2022-02-03 |
United States Patent
Application |
20220032212 |
Kind Code |
A1 |
Kelsey; John Byron |
February 3, 2022 |
SEPARATION SYSTEM AND METHOD
Abstract
A filtration system and method is disclosed. The filtration
system includes a separation system with a primary process vessel
with a main body enclosing an internal volume, and a removable end
cap coupled to one of the ends of the main body. The primary
process vessel includes fluid apertures enabling a fluid stream to
enter or exit the inner volume. The separation system includes a
filter support positioned in the inner volume, and a filter
assembly coupled to the filter support. In some embodiments, the
separation system is fluidly coupled to another separation
system.
Inventors: |
Kelsey; John Byron; (Porter,
TX) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Pentair Filtration Solutions, LLC |
Hanover Park |
IL |
US |
|
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Appl. No.: |
17/451191 |
Filed: |
October 18, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15305856 |
Oct 21, 2016 |
11148071 |
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PCT/US2015/026944 |
Apr 21, 2015 |
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17451191 |
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61982192 |
Apr 21, 2014 |
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International
Class: |
B01D 17/04 20060101
B01D017/04; C10G 31/09 20060101 C10G031/09; C10G 33/06 20060101
C10G033/06; B01D 19/00 20060101 B01D019/00; B01D 17/00 20060101
B01D017/00; C10L 3/10 20060101 C10L003/10 |
Claims
1. A filtration method comprising: providing at least one
separation system, the separation system comprising: a primary
process vessel comprising a main body including first and second
ends, the main body enclosing an internal volume; and at least one
removable end cap coupled to at least one of the ends of the main
body; a plurality of fluid apertures arranged to enable at least
one fluid to enter or exit the internal volume of the primary
process vessel, the plurality of fluid apertures including at least
two fluid inlet ports and at least two fluid outlet ports; and at
least one filter support positioned in the internal volume; and at
least one filter assembly coupled to the at least one filter
support; and operating the at least one separation system using at
least one process configuration, the process configuration
comprising: passing at least one untreated fluid into the at least
two fluid inlet ports; filtering the at least one untreated fluid
using the at least one filter assembly to form at least one treated
fluid stream; and eluting the at least one treated fluid from the
primary process vessel using the at least two fluid outlet
ports.
2. The filtration method of claim 1, wherein the plurality of fluid
apertures comprises at least one vent, at least one drain, and at
least one control valve coupled to at least one aperture.
3. The filtration method of claim 1, wherein the process
configuration comprises passing four fluid inlet streams into the
primary process vessel using four inlet ports and two fluid outlet
streams out of the primary process vessel exiting through two
outlet ports.
4. The filtration method of claim 1, wherein the process
configuration comprises passing two fluid inlet streams into the
primary process vessel using two inlet ports and eluting four fluid
outlet streams from the primary process vessel exiting through four
fluid outlet ports.
5. The filtration method of claim 4, wherein the four outlet
streams comprise two continuous phase outlet streams and two
discontinuous phase outlet streams.
6. The filtration method of claim 1, wherein the process
configuration comprises passing two fluid inlet streams into the
primary process vessel using two inlet ports and eluting three
fluid outlet streams from the primary process vessel exiting
through three outlet ports.
7. The filtration method of claim 6, wherein the three outlet
streams comprise two discontinuous phase outlet streams and one
continuous phase outlet stream.
8. The filtration method of claim 1, wherein the process
configuration comprises passing two fluid inlet streams into the
primary process vessel using two inlet ports, eluting two fluid
outlet streams from the primary process vessel using two outlet
ports, and a re-injection process, the re-injection process
comprising passing a wash fluid from one fluid outlet port and into
a fluid inlet port.
9. The filtration method of claim 8, wherein the wash fluid
comprises amine water.
10. The filtration method of claim 8, wherein the process
configuration is a substantially continuous process.
11. The filtration method of claim 1, wherein the at least one
process configuration comprises sharing or exchanging fluid streams
between at least two separation systems using at least one aperture
of the plurality of fluid apertures.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 15/305,856, filed Oct. 21, 2016, which is a
National Stage Entry of International Patent Application No.
PCT/US2015/026944, filed Apr. 21, 2015, which claims priority to
U.S. Provisional Application No. 61/982,192, filed Apr. 21, 2014,
all of the disclosures of which are incorporated by reference
herein in their entirety.
BACKGROUND
[0002] Petroleum producers, refiners, and gas processors (including
onshore and offshore), and chemical manufacturers utilize
separation systems to filter, process, and recover hydrocarbons and
other chemical products from a variety of raw material process
streams. Separation systems of this nature need to account for an
inlet stream that can comprise a complex heterogeneous mixture of
solids, liquids, and gaseous materials that requires processing to
achieve separation of one or more components with a predetermined
efficiency.
[0003] Conventional separation technologies are usually assembled
and configured as multiple separation vessels interconnected with
piping, valve assemblies, and associated control and monitoring
systems. These technologies are often bulky, requiring a large
footprint, and are usually only configured to perform one type of
separation process, or minor variations of the process. These
systems are typically not configured for significantly different
processes or input streams unless they are substantially modified,
or coupled to a secondary separation and process system. Hence
there is a need for separation systems with improved compactness
and modularity, while providing flexible configurations enabling a
plurality of process options within a single unit.
SUMMARY OF THE INVENTION
[0004] Some embodiments of the invention include a filtration
system comprising at least one separation system comprising a
primary process vessel comprising a main body including first and
second ends. The main body encloses an internal volume, and at
least one removable end cap is coupled to at least one of the ends
of the main body. The primary process vessel comprises a plurality
of fluid apertures configured and arranged to enable at least one
fluid stream to enter or exit the inner volume of the primary
process vessel. The plurality of fluid apertures includes at least
one fluid inlet port and at least one fluid outlet port. Further,
the at least one separation system comprises at least one filter
support positioned in the inner volume, and at least one filter
assembly coupled to the at least one filter support.
[0005] In some embodiments, the plurality of fluid apertures
comprises at least one vent and at least one drain. In some
embodiments, the at least one separation system further comprises
at least one control valve coupled to at least one aperture. In
some embodiments, the at least one control valve is coupled to the
at least one aperture using a T-junction.
[0006] In some further embodiments of the invention, the filtration
system further comprises a support frame, the at least one
separation system mounted on the support frame. In some
embodiments, the support frame comprises at least one support
coupled to and at least partially supporting the primary process
vessel. In some embodiments, the separation system is fluidly
coupled to at least one other separation system using the at least
one aperture.
[0007] In some embodiments, the at least one filter assembly
includes at least one coalescing filter. In some further
embodiments, the at least one filter assembly includes at least one
filter configured and arranged to filter hydrocarbons.
[0008] Some embodiments of the invention include a filtration
method comprising providing at least one separation system
comprising a primary process vessel comprising a main body
including first and second ends. The main body encloses an internal
volume, and at least one removable end cap is coupled to at least
one of the ends of the main body. The primary process vessel
includes a plurality of fluid apertures configured and arranged to
enable at least one fluid stream to enter or exit the inner volume
of the primary process vessel. The plurality of fluid apertures
include at least one fluid inlet port and at least one fluid outlet
port, and at least one filter support is positioned in the inner
volume, and at least one filter assembly is coupled to the at least
one filter support. The filtration method includes operating the at
least one separation system using at least one process
configuration comprising passing at least one untreated fluid
stream into the at least one fluid inlet port, filtering the at
least one untreated fluid stream using the at least one filter
assembly to form at least one treated fluid stream, and eluting the
at least one treated fluid stream from the primary process vessel
using the at least one fluid outlet port.
[0009] In some embodiments of the filtration method, the plurality
of fluid apertures comprise at least one vent, at least one drain,
and at least one control valve coupled to at least one aperture. In
some embodiments of the filtration method, the process
configuration comprises passing four fluid inlet streams into the
primary process vessel using four inlet ports and two fluid outlet
streams out of the primary process vessel exiting through two
outlet ports.
[0010] In some embodiments of the filtration method, the process
configuration comprises passing two fluid inlet streams into the
primary process vessel using two inlet ports and eluting four fluid
outlet streams from the primary process vessel exiting through four
fluid outlet ports. In some embodiments, the four outlet streams
comprise two continuous phase outlet streams and two discontinuous
phase outlet streams.
[0011] In some embodiments of the filtration method, the process
configuration comprises passing two fluid inlet streams into the
primary process vessel using two inlet ports and eluting three
fluid outlet streams from the primary process vessel exiting
through three outlet ports. In some embodiments, the three outlet
streams comprise two discontinuous phase outlet streams and one
continuous phase outlet stream.
[0012] In some embodiments of the filtration method, the process
configuration comprises passing two fluid inlet streams into the
primary process vessel using two inlet ports, eluting two fluid
outlet streams from the primary process vessel using two outlet
ports, and a re-injection process, the re-injection process
comprising passing a wash fluid from one fluid outlet port and into
a fluid inlet port. In some embodiments, the wash fluid comprises
amine water. In some further embodiments, the process configuration
is a substantially continuous process.
[0013] In some embodiments of the filtration method, the at least
one process configuration comprises sharing or exchanging fluid
streams between at least two separation systems using the at least
one aperture.
DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 illustrates a perspective view of a separation system
in accordance with embodiments of the invention.
[0015] FIG. 2 illustrates a side cutaway view of a separation
system in accordance with embodiments of the invention.
[0016] FIG. 3 illustrates a top view of a separation system in
accordance with embodiments of the invention.
[0017] FIG. 4 illustrates a side view of a separation system in
accordance with embodiments of the invention.
[0018] FIG. 5 illustrates an end view of a separation system in
accordance with embodiments of the invention.
[0019] FIG. 6 illustrates a side view of a separation system
configured to handle four inlet streams in accordance with some
embodiments of the invention.
[0020] FIG. 7 illustrates a side view of a separation system
configured to handle multiple inlet streams and with four outlet
streams in accordance with some embodiments of the invention.
[0021] FIG. 8 illustrates a side view of a separation system
configured to handle two inlet streams and with three outlet
streams in accordance with some embodiments of the invention.
[0022] FIG. 9 illustrates a side view of a separation system
configured to handle two inlet streams and with two outlet streams
and a re-injection process stream in accordance with some
embodiments of the invention.
[0023] FIG. 10 illustrates a top view of a modular separation
system including three coupled separation systems in accordance
with some embodiments of the invention.
[0024] FIG. 11 illustrates an end view of a modular separation
system including three coupled separation systems in accordance
with some embodiments of the invention.
DETAILED DESCRIPTION
[0025] Before any embodiments of the invention are explained in
detail, it is to be understood that the invention is not limited in
its application to the details of construction and the arrangement
of components set forth in the following description or illustrated
in the following drawings. The invention is capable of other
embodiments and of being practiced or of being carried out in
various ways. Also, it is to be understood that the phraseology and
terminology used herein is for the purpose of description and
should not be regarded as limiting. The use of "including,"
"comprising," or "having" and variations thereof herein is meant to
encompass the items listed thereafter and equivalents thereof as
well as additional items. Unless specified or limited otherwise,
the terms "mounted," "connected," "supported," and "coupled" and
variations thereof are used broadly and encompass both direct and
indirect mountings, connections, supports, and couplings. Further,
"connected" and "coupled" are not restricted to physical or
mechanical connections or couplings.
[0026] The following discussion is presented to enable a person
skilled in the art to make and use embodiments of the invention.
Various modifications to the illustrated embodiments will be
readily apparent to those skilled in the art, and the generic
principles herein can be applied to other embodiments and
applications without departing from embodiments of the invention.
Thus, embodiments of the invention are not intended to be limited
to embodiments shown, but are to be accorded the widest scope
consistent with the principles and features disclosed herein. The
following detailed description is to be read with reference to the
figures, in which like elements in different figures have like
reference numerals. The figures, which are not necessarily to
scale, depict selected embodiments and are not intended to limit
the scope of embodiments of the invention. Skilled artisans will
recognize the examples provided herein have many useful
alternatives and fall within the scope of embodiments of the
invention.
[0027] Moreover, the figures disclosed and described herein
represent high-level visualizations. Those of ordinary skill in the
art will appreciate that each figure is presented for explanation
only and does not include each and every decision, function, and
feature that may be implemented. Likewise, the figures and related
discussions are not intended to imply that each and every
illustrated decision, function, and feature is required or even
optimal to achieve the disclosed desired results.
[0028] Some embodiments of the invention as illustrated in FIGS.
1-11 provide a compact, flexible, and modular separation and
filtration technology that can be used to process a wide variety of
material streams including solids, fluids, including liquids, and
gases, and mixtures thereof. Some embodiments of the invention can
separate, filter, process, and recover hydrocarbons and other
chemical products or materials from a wide variety of raw material
process streams. Moreover, the embodiments as described and
illustrated herein offer process flexibility to enable
customization to one or more processes depending on the input
stream and output stream specification and efficiency.
[0029] FIG. 1 illustrates a perspective view of a separation system
100 according to some embodiments of the invention. In some
embodiments as shown, the separation system 100 can comprise a
primary process vessel 115 including a main body 200 including a
first end 125 and a second end 150. In some embodiments, at least
one of the ends 125, 150 can be at least partially opened to enable
access to an internal portion of the main body 200 (shown in FIG. 1
as internal volume 210 in FIG. 2). In some embodiments of the
invention, the first end 125 can include a first removeable end cap
225. In some embodiments, the first removeable end cap 225 can be
coupled to the main body 200 using a plurality of removeable bolts
260. However, any conventional coupling mechanisms or devices can
be used to couple and uncouple the first removeable end cap 225. To
enable access to the internal volume 210, the plurality of bolts
260 can be removed from the first end 125 of the main body 200, and
the first removeable end cap 225 can be decoupled, opened, and/or
removed from the main body 200. Further, the main body 200 can be
at least partially sealed at the first end 125 by coupling the
first removeable end cap 225 to the first end 125. In some further
embodiments of the invention, the second end 150 can include a
second removeable end cap 250. In some embodiments, the second
removeable end cap 250 can be coupled to the main body 200 using a
plurality of removeable bolts 260. By removing the plurality of
bolts 260, the second removeable end cap 250 can be removed from
the second end 150 of the main body 200 to enable access to the
internal volume 210. Further, the main body 200 can be sealed at
the second end 150 by coupling the second removeable end cap 250 to
the second end 150. In some embodiments, the first removeable end
cap 225 and the second removeable end cap 250 can be substantially
the same. In some embodiments, the first removable end cap 225 and
the second removable end cap 250 can be exchanged. For example, in
some embodiments, the first removeable end cap 225 can be coupled
to the main body 200 at the second end 150, and the second
removeable end cap 250 can be coupled to the main body 200 at the
first end 125.
[0030] In some embodiments of the invention, the primary process
vessel 115 can be suspended and/or supported on a frame or other
mounting structure. For example, as shown in at least FIG. 1, in
some embodiments, the primary process vessel 115 can be coupled to
a support frame 300 using at least one support. For example, in
some embodiments, using at least a first support 325 and/or a
second support 350, the primary process vessel 115 can be supported
and suspended by the frame 300. In some embodiments, the frame 300
can comprise a ladder-type structure comprising frame sides coupled
to end supports. For example, in some embodiments, the frame 300
can comprise a first frame side 310 and a second frame side 315
coupled together at their ends by a plurality of cross-bars. For
example, in some embodiments, the frame 300 can comprise a first
end support 320 and a second end support 322. As shown at least in
FIGS. 1, 3, and 10, in some embodiments, the frame 300 can comprise
a first frame side 310 and a second frame side 315 coupled together
at their ends by the first end support 320, and a second end
support 322 forming a generally rectangular frame base 305. In this
example embodiment, the first frame side 310 and the second frame
side 315 are generally parallel, and the first end support 320 and
a second end support 322 are generally parallel.
[0031] In some embodiments, the primary process vessel 115 can be
coupled to the frame 300 using a plurality of vertical supports.
For example, in some embodiments, two or more vertical supports can
be used to mount the primary process vessel 115 to the frame, with
each vertical support extending from a cross-bar generally adjacent
to each end of the frame. For example, in some embodiments, the
frame 300 can comprise at least a first cross support 312 and a
second cross support 317 coupled to and extending between the first
frame side 310 and the second frame side 315. In some embodiments,
the cross-supports 312, 317 can be positioned generally equally
spaced from each end of the frame base 305. In some other
embodiments, the cross-supports 312, 317 can be positioned adjacent
each end of the frame base 305, where the distance between the
first frame support 312 at one end of the frame base 305 is
different from the distance between the second frame support 317 at
the opposite end of the frame base 305.
[0032] FIG. 3 illustrates a top view of a separation system 100
according to one embodiment of the invention, and FIG. 5
illustrates an end view of a separation system 100 according to one
embodiment of the invention. In some embodiments, the primary
process vessel 115 can be mounted substantially centrally within
the frame 300. For example, in some embodiments, the distance of
the first end 125 of the primary process vessel 115 to the first
end support 320 of the support frame 300 can be generally the same
as the distance of the second end 150 of the primary process vessel
115 is to the second end support 322. Further, in some embodiments,
the primary process vessel 115 can be positioned within the support
frame 300 so that the vessel is generally the same distance from
the first frame side 310 and the second frame side 315. In some
other embodiments, the primary process vessel 115 can be mounted
substantially off-center within the frame 300. For example, in some
embodiments, the first end 125 of the primary process vessel 115
can be positioned closer to the first end support 320 of the
support frame 300 than the second end 150 of the primary process
vessel 115 is to the second end support 322. In some further
embodiments, the primary process vessel 115 can be positioned
closer to the first frame side 310 that the second frame side
315.
[0033] In some other embodiments of the invention, either end 125,
150 of the primary process vessel can extend beyond an end of the
support frame 300. For example, in some embodiments, the first end
125 of the primary process vessel can extend beyond the first end
support 320 of the support frame 300. In some other embodiments,
the second end 150 of the primary process vessel 115 can extend
beyond the second end support 322 of the support frame 300. In some
other embodiments, the primary process vessel 115 can be larger
than that depicted in FIGS. 1-11 and/or the support frame 300 can
be smaller than illustrated so that each end 125, 150 of the
primary process vessel 115 can extend beyond the respective end of
the support frame 300.
[0034] Some embodiments of the invention can include one or more
filters or other process assemblies positioned within at least a
portion of the primary process vessel. These filters and/or
assemblies can be used to process and/or filter solids, liquids,
and gases, and mixtures thereof. For example, FIG. 2 illustrates a
side cutaway view of the separation system 100 shown in FIG. 1
including at least one filter assembly 375. In some embodiments,
the separation system 100 can comprise at least one filter assembly
375 positioned within the primary process vessel 115. In this
example, the primary process vessel 115 includes at least one
filter assembly 375 positioned inside the primary process vessel
115. Some embodiments include two filter assemblies 375 positioned
inside the primary process vessel 115, and in some further
embodiments, the primary process vessel 115 can include three or
more filter assemblies 375. In some embodiments, the filter
assembly 375 can include at least one filter 385 mounted or couple
to at least one filter support 395. In some embodiments, each
filter assembly 375 can comprise more or fewer filters 385.
Further, in some embodiments, each filter 385 is mounted to its own
filter support 395. In other embodiments, multiple filters 385 can
be mounted to a single support 395. The example shown in FIG. 2
includes two filter assemblies 375, however more or less filter
assemblies 375 can be positioned within the primary process vessel
115 depending on the capacity of the primary process vessel 115,
the size of the filter assemblies 375, and/or the process
requirements or specifications of the separation system 100.
[0035] In some embodiments of the invention, the at least one
filter assembly 375 can be positioned substantially centrally
within the primary process vessel 115, and can extend from a
location positioned generally adjacent to an axially center of the
primary process vessel 115 towards an end 125, 150 of the primary
process vessel 115. In the example shown in FIG. 2 including two
filter assemblies 375, a first filter 385 can extend from a
location positioned generally adjacent to an axial center of the
primary process vessel 115 towards a first end 125 of the primary
process vessel 115, and a second filter 385b can extend from a
location positioned generally adjacent to an axially center of the
primary process vessel 115 towards a second end 150 of the primary
process vessel 115. As illustrated in FIG. 4, the first and second
filter assemblies 375a, 375b can be separated by a distance of
about twenty four inches. In some other embodiments, the filter
assemblies 375a, 375b can be separated by a lesser or a greater
distance than about twenty four inches. For example, in some
embodiments, the filter assemblies 375a, 375b can be proximate each
other. In other embodiments, the filter assemblies 375a, 375b
adjacently positioned or coupled.
[0036] In some embodiments, the at least one filter assembly 375 of
the separation system 100 can include one or more flexible and/or
modular filters and/or other process assemblies positioned in at
least a portion of the primary process vessel 115. For example,
some embodiments of the invention can comprise dual fluid stream
particle separation that can operate with twice the capacity of a
conventional filter separator. Some further embodiments can include
a liquid/liquid coalescing separation providing twice the capacity
of a conventional filter separator. Some embodiments can include a
compact Hydrocarbon Recovery Technology System (hereinafter
referred to as HRT.RTM.) manufactured by Pentair, Inc. HRT.RTM. is
a registered trademark of Pentair, Inc., or one of its global
affiliates. In this embodiment, the separation system 100 can
include HRT.RTM. technology, and can be used for water management
in onshore and offshore applications such as salt water disposal
oil applications. In this example, the separation system 100
including HRT.RTM. can remove solids as fine as 1/2 micron to
99.98% efficiency with hydrocarbon concentrations greater than 5%,
and with hydrocarbon specific gravities as high as 0.98. This can
allow effective separation of hydrocarbons as heavy as polynuclear
aromatic oils, and can intercept and recover stable emulsified
hydrocarbons, blocking substantially all hydrocarbons from passing
through the separation process.
[0037] In some further embodiments of the invention, the at least
one filter assembly 375 of the separation system 100 can include a
compact Pentair polar extraction system. For example, in some
embodiments, the primary vessel can include Pentair Porous Media's
POLAREX.RTM. technology. In this instance, the separation system
100 can provide chemical manufacturers, refiners and gas processors
improved separation of entrained and dissolved contaminants
relative to that achievable through implementation of conventional
water wash or solvent scrubbing towers. Conventional approaches to
washing or scrubbing are often limited by contact efficiency and
subsequent separation efficiency, resulting in limited performance
and large capital investments. The POLAREX.RTM. platform can
include a single stage, high efficiency, structured
contactor/separator within the separation system 100, and can be
applied to the extraction of soluble components from either liquid
or gas process streams. Further, the separation system 100 equipped
in this way can be applied to both contaminant removal
(e.g.--caustic, dissolved acids, salts, acid gases or reaction
byproducts) as well as recovery of valuable products or solvents
(e.g.--recover soluble amines from treated LPG) for as little as
20% of the capital associated with a conventional wash system.
Further, when applied to batch chemical processes, the technology
can increase process speed and operational flexibility. Traditional
approaches to neutralization or product washing require a lengthy
neutralization or wash step followed by decanting and transfer. Not
only do these steps slow reactor turn over, they also frequently
result in carry-over of salts and impurities due to the limited
separation effectiveness of decanting, particularly with emulsified
product/water mixtures. By implementing the POLAREX.RTM. technology
within the separation system 100, neutralization or washing can
proceed on-line during product transfer, allowing the wash/decant
steps to be eliminated entirely.
[0038] In some other embodiments of the invention, the at least one
filter assembly 375 of the separation system 100 can include a
process technology comprising a LIQUISEP.RTM. technology from
Pentair, Inc. This technology was developed to address the inherent
deficiencies of conventional coalescers, making it possible to
remove essentially all immiscible water dispersions from
hydrocarbon process streams. The LIQUISEP.RTM. technology overcomes
the limitations of conventional separators, vane pack coalescers,
wire mesh coalescers and even "high efficiency" mesh pads and
filter separators, achieving superior separations under demanding
conditions. LIQUISEP technology makes use of proprietary
LIQUIFORM.TM. media and an APEX.RTM. element design to intercept
entrained droplets of even submicron geometries and effectively
remove them from the process. The high surface energy LIQUIFORM.TM.
media effectively disrupts the stabilized water droplets, allowing
for efficient capture. Additionally, the fiber geometries are
specifically designed to promote accumulation and removal of free
water from the process stream. The APEX.RTM. element design works
in concert with the media technology promoting uniform fluid flow,
while minimizing the potential for turbulence and high fluid
velocities which might interfere with water removal from the
process stream. LIQUISEP.RTM. technology protects critical assets
from water contamination and the salts, acids and bases which it
may contain. Application of the LIQUISEP.RTM. technology allows
optimized performance of downstream treaters, salt beds, exchangers
and reactors while assuring the elimination of haze from finished
products.
[0039] In some further embodiments of the invention, the at least
one filter assembly 375 of the separation system 100 that can
include a process technology comprising a ProcessOR.RTM. process
technology from Pentair, Inc. ProcessOR.RTM. provides high
performance solid-liquid separation for solid contaminants ranging
from sub-micron particulates as small as viruses to particles
several hundred microns in size. In this instance, the liquids can
range from aqueous to hydrocarbon systems with viscosities up to
60,000 cP, and can be applied to the oil and gas, refinery,
chemical, petrochemical and power industries. In another
embodiment, a Pentair COMPAX.RTM. coreless element can be included,
and fluid flows from the outside-to-the-inside. This technology can
include an extended surface area media configuration utilizing our
proprietary NexCel.RTM. media. The media provides robust
performance in glycol and aqueous service as well as hydrocarbon
applications in some embodiments.
[0040] HRT.RTM., POLAREX.RTM., LIQUISEP.RTM., LIQUIFORM.TM.,
APEX.RTM., ProcessOR.RTM., COMPAX.RTM., and NexCel.RTM. are
registered trademarks of Pentair, LTD., or one of its global
affiliates.
[0041] In order to process an input stream comprising solids,
and/or gas, and/or liquid, and mixtures thereof, the separation
system 100 can include various ports, valves, drains, and
associated connectors and junctions to enable entry of one or more
input streams into the primary process vessel 115. For example,
referring to at least FIG. 2, some embodiments include ports 400
coupled to or integrated with the primary process vessel 115. Some
embodiments include a plurality of ports 400 including a first port
410, and a second port 420, and a third port 430 extending from the
top of the primary process vessel 115. Further, some embodiments
include a plurality of ports 400 positioned at the bottom of the
primary process vessel 115. For example, some embodiments include a
fourth port 440, and a fifth port 450, and a sixth port 460. In
some embodiments, any one of the plurality of ports 400 can be
positioned on other regions of the primary process vessel 115.
[0042] In some embodiments, the separation system 100 can include
one or more fluid control valves. For example, some embodiments
include a plurality of valves 500 configured to control entry or
exit of a fluid from the separation system 100. Referring to FIGS.
1, 6-9, and 10, some embodiments include at least a first valve
520, a second valve 540, and a third valve 560 positioned on one
side of the primary process vessel 115. Further, some embodiments
include at least a fourth valve 570, fifth valve 580, and a sixth
valve 590 positioned on an opposite side of the primary process
vessel 115. In some embodiments, any one of the plurality of valves
500 can be positioned on other regions of the primary process
vessel 115.
[0043] Some embodiments include one or more control valves coupled
to one or more ports to enable control of a fluid stream into
and/or out of the primary process vessel 115. For example,
referring to at least FIGS. 1 and 4, some embodiments include at
least one end control valve 600 coupled to at least one port. In
some embodiments, the at least end control valve 600 can be coupled
to at least one T-junction 620. In some embodiments, at least one
coupling pipe 640 can be coupled to the at least one T-junction 620
to facilitate transfer of a fluid stream into or out of the primary
process vessel 115. Some embodiments include additional control
valves, junctions and coupling pipes. For example, in some
embodiments, the at least one central control valve 700 can be
coupled to at least one T-junction 720. In some embodiments, at
least one coupling pipe 740 can be coupled to the at least one
T-junction 720 to facilitate transfer of a fluid stream into or out
of the primary process vessel 115.
[0044] In some embodiments, the separation system 100 can comprise
additional fluid inlets or outlets. For example, some embodiments
include a plurality of vents 800 extending from the primary process
vessel 115. In some embodiments, the separation system 100 can
comprise a first vent 820, a second vent 830, and a third vent 840
coupled to or integrated with the primary process vessel 115. In
some further embodiments, the separation system 100 can include one
or more drains. In some embodiments, the separation system 100
includes a plurality of drains 850 including a first drain 860, a
second drain 870, and a third drain 880. In some embodiments, any
one of the vents 800 and/or drains 850 can vent or drain a fluid.
In some embodiments, fluid can exit the primary process vessel 115
through any one of the vents 800 and/or drains 850. In other
embodiments, fluid can enter the primary process vessel 115 through
any one of the vents 800 and/or drains 850.
[0045] In some embodiments of the invention, the separation system
100 can be configured to process fluids in a variety of manners
using a variety of process configurations. The flexible design can
allow for multiple flow paths within the need for a different
treatment vessel. Moreover, the primary process vessel 115 can be
configured to separate a plurality of different fluid streams. For
example, in some embodiments, the primary process vessel 115 can be
configured to separate four different fluid streams (e.g.,
particle-laden fluid streams).
[0046] FIGS. 6-9 illustrate various process configurations of the
separation system 100. For example, FIG. 6 illustrates a side view
of a separation system 100 configured to handle four inlet streams
according to one embodiment of the invention. This configuration
(shown as process configuration 102) includes an outside element to
inside element flow vessel configured to handle four particle laden
inlet streams. The symmetrical design allows for multiple flow
paths without the need for a different vessel. Further, the vessel
is configured to separate up to four different particle-laden
liquid streams. The equipment occupies only 2/3 space required to
co-locate two individual vessels of comparable size and
configuration. Some embodiments offer a simplified interconnect
piping and instrumentation configuration as compared to two
separate vessels.
[0047] As depicted in FIG. 6, some embodiments include a process
configuration 102 that comprises a plurality of inlet streams 900
and a plurality of outlet streams 950. For example, in some
embodiments, during one or more fluid process phases, the
separation system 100 can comprise a first inlet stream 910
entering the primary process vessel 115 through the first port 410,
and a second inlet stream 920 entering the primary process vessel
115 through the fourth port 440. Further, the separation system 100
can comprise a third inlet stream 930 entering the primary process
vessel 115 through the third port 430, and a fourth inlet stream
940 entering the primary process vessel 115 through the sixth port
460. Further, the process configuration 102 can comprise a
plurality of outlet streams 950. For example, in some embodiments,
the process configuration 102 can comprise a first outlet stream
960 exiting the process configuration 102 through the second port
420, and a second outlet stream 970 exiting through the fifth port
450.
[0048] Some embodiments of the invention include an inside element
to outside element flow. In this example, the primary process
vessel 115 can be configured to handle multiple emulsified inlet
streams. The symmetrical design allows for multiple flow paths
without the need for a different vessel, and can be configured to
separate two emulsified liquid streams. For example, FIG. 7
illustrates a side view of a separation system 100 configured to
handle multiple inlet streams and with four outlet streams
according to one embodiment of the invention. As depicted, the
process configuration 104 can comprise a fluid outlet 975 exiting
the primary process vessel 115 through the first port 410, a fluid
outlet 980 exiting the primary process vessel 115 through the
fourth port 440, a fluid outlet 985 exiting the primary process
vessel 115 through the third port 430, and a fluid outlet 987
exiting the primary process vessel 115 through the sixth port 460.
The process configuration 104 can also comprise a fluid inlet 990
entering the primary process vessel 115 through the second port
420, and a fluid inlet 995 entering the primary process vessel
through the fifth port 450.
[0049] In some embodiments of the invention, the process
configuration 104 can comprise at least one continuous process
phase and/or at least one discontinuous phase. For example, some
embodiments include the fluid outlet 975 comprising a continuous
process phase, and/or the fluid outlet 985 comprising a continuous
process phase. Further, in some embodiments, the fourth port 440
can elute a discontinuous phase as the fluid outlet 980, and the
sixth port 460 can elute a discontinuous phase through the fluid
outlet 987.
[0050] FIG. 8 illustrates a side view of a separation system 100
configured to handle two inlet streams with three outlet streams
according to one embodiment of the invention. This example
embodiments includes a hydrocarbon recovery technology
configuration vessel (primary process vessel 115) configured to
handle two particle-laden inlet streams. The symmetrical design
allows for multiple flow paths without the need for a different
vessel. The hydrocarbon recovery configuration separates particles
in a primary phase, and liquid-liquid separation in a secondary
phase. As depicted, the process configuration 106 can include fluid
inlets 1100, 1125, fluid outlets 1135, 1150, 1155, and a blind
1145. In some embodiments, a fluid stream can enter the primary
process vessel 115 through a first port 410 as fluid inlet 1100,
and a fluid stream can enter the primary process vessel 115 through
a fourth port 440 as fluid inlet 1125. Further, a fluid stream can
exit the primary process vessel 115 through the second port 420 as
fluid outlet 1135, the third port 430 as fluid outlet 1150, and the
sixth port 460 as fluid outlet 1155. In some embodiments, the fluid
outlets 1135, 1150 1155 can comprise a discontinuous phase.
[0051] FIG. 9 illustrates a side view of a separation system 100
configured to handle two inlet streams, two outlet streams, and a
re-injection process stream according to one embodiment of the
invention. In this instance, the use of a polar extraction
configuration vessel (primary process vessel 115) configured to
handle two particle-laden inlet streams includes a symmetrical
design that can allow for multiple flow paths without the need for
a different vessel. The polar extraction configuration separates
particles in the primary phase, and performs a polar extraction in
the secondary phase, followed by a final separation phase. For
example, the process configuration 108 can comprise a fluid inlet
1200 passing through the first port 410, and the fluid inlet 1225
passing through the fourth port 440. Further, using the second port
420 (as fluid outlet 1250) and the fifth port 450 as fluid inlet
1275, a wash out and re-injection process can be implemented. For
example, in some embodiments, the fluid outlet 1250 can comprise an
amine water wash "W1", and the fluid inlet 1275 can comprise a
re-injection "W2". In some embodiments, fluid can exit the primary
process vessel as fluid outlet 1300 through the third port 430 and
as fluid outlet 1325 through the sixth port 460.
[0052] In some embodiments, two or more of the separation systems
100 shown in FIGS. 1-9 and described herein can be coupled to form
a separation system including a plurality of separation systems
100. For example, FIG. 10 illustrates a top view of a modular
separation system 1000 including three coupled separation systems
100 according to one embodiment of the invention, and FIG. 11
illustrates an end view of a modular separation system 1000
including three coupled separation systems 100 as shown in FIG. 10.
Although shown with three separation and process units, other
embodiments can include more or fewer separation and process units
coupled in identical or similar ways. Further, as shown, in some
embodiments, one or more inlet or outlet tubes can be coupled to
form at least one fluid coupling between one separation system 100
and another separation system 100. For example, in some
embodiments, the modular separation system 1000 can comprise a
first separation system 100a coupled to a second separation system
100b, coupled to a third separation system 100c.
[0053] In some embodiments, the modular separation system 1000 can
comprise a plurality of fluidly coupled separation systems. For
example, in some embodiments, the modular separation system 1000
can comprise a first separation system 100a fluidly coupled to a
second separation system 100b, fluidly coupled to a third
separation system 100c. In some embodiments, fluid streams entering
or exiting the modular separation system 1000 can be controlled by
one or more valves. For example, as shown in FIG. 11, in some
embodiments, the modular separation system 1000 can comprise a
first separation system 100a including an end control valve 600a,
and a second separation system 100b including an end control valve
600b, and a third separation system 100c including an end control
valve 600c.
[0054] In some embodiments, the modular separation system 1000 can
include various pipe connectors, junctions, and coupling pipes
configured to transfer fluid streams into and out of the modular
separation system 1000, and between the separation systems 100a,
100b, 100c. For example, in some embodiments, the first separation
system 100a can include a T-junction 620a coupled to the end
control valve 600a, a T-junction 620b coupled to the end control
valve 600b, and a T-junction 620c coupled to the end control valve
600c.
[0055] In some embodiments, the modular separation system 1000 can
comprise coupling pipes configured to transfer fluid streams
between the various process modules of the modular separation
system 1000. For example, in some embodiments, the separation
system 100a can comprise a coupling pipe 750 extending from one
side of the T-junction 620a, and a coupling pipe 752 extending from
an opposite side of the T-junction 620a. Further, in some
embodiments, the separation system 100b can comprise a coupling
pipe 754 extending from one side of the T-junction 620b, and a
coupling pipe 756 extending from an opposite side of the T-junction
620b. Further, in some embodiments, the separation system 100c can
comprise a coupling pipe 758 extending from one side of the
T-junction 620c, and a coupling pipe 760 extending from an opposite
side of the T-junction 620c.
[0056] Referring to FIGS. 1 and 10, with the modular separation
system 1000 including multiple coupled primary process vessels 115,
each with a central control valve 700 and T-junction 720 (not shown
in FIG. 10 as the central control valve 700 and T-junction 720 are
below the primary process vessel), the modular separation system
1000 can include further fluid coupling junctions for transfer of
fluid streams between the separation system 100a, 100b, 100c. In
this instance, the combination of valve and pipe-tee coupled to a
coupling tube can enable fluid to flow to and from at least one
separation system 100 to at least one other separation system 100.
Further, this combination of valve and pipe-tee coupled to a
coupling tube can enable fluid to flow between at least one
separation system generally horizontally within the coupling tube,
and to flow from the coupling tube to at least one separation
system 100 through at least one valve and into at least one inlet
with a flow that is generally perpendicular to the flow in the at
least one coupling tube. Further, some embodiments can utilize a
reverse flow of fluid comprising a fluid to flow between at least
one separation system and at least one other separation system
and/or a coupling pipe. For example, in some embodiments, fluid can
flow from at least one separation system through at least one valve
from at least one outlet with a flow and pass into at least one
coupling tube and flow generally perpendicular to the flow in the
outlet tube and/or valve.
[0057] In some embodiments, the modular separation system 1000 can
comprise coupling pipe 770 extending from the separation system
100a on one side and the coupling pipe 772 extending from the
separation system 100a on an opposite side. Further, the modular
separation system 1000 can comprise coupling pipe 774 extending
from the separation system 100b on one side and the coupling pipe
776 extending from the separation system 100b on an opposite side.
Further, the modular separation system 1000 can comprise coupling
pipe 778 extending from the separation system 100c on one side and
the coupling pipe 780 extending from the separation system 100c on
an opposite side. In some embodiments, the coupling pipe 772 is
fluidly coupled to the coupling pipe 774. Furthermore, in some
embodiments, the coupling pipe 776 is fluidly coupled to the
coupling pipe 778. In some other embodiments, either of the
coupling pipes 770, 780 can be coupled to other separation systems
100 (e.g., when the modular separation system 1000 includes more
than three fluidly coupled separation systems 100). In the example
embodiments shown in FIGS. 10 and 11, a fluid flow can be
established between the separation systems 100a, 100b, 100c. In
some embodiments, any of the aforementioned coupling tubes 750,
752, 754, 756, 760, 770, 772, 774, 776, 778, 780 can be supported
by the support frame 300.
[0058] It will be appreciated by those skilled in the art that
while the invention has been described above in connection with
particular embodiments and examples, the invention is not
necessarily so limited, and that numerous other embodiments,
examples, uses, modifications and departure from the embodiments,
examples and uses are intended to be encompassed by the claims
attached hereto. The entire disclosure of each patent and
publication cited herein is incorporated by reference, as if each
such patent or publication were individually incorporated by
reference herein. Various features and advantages of the invention
are set forth in the following claims.
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