多杯等流型油水分离器优化设计及实验研究
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摘要
随着油田含水率的升高，导致举升能耗和集输系统能耗增加，地面工程建设和改造工作量日益增多，水的问题越来越受到重视。本文立足于中国石油天然气股份公司《高含水油田提高采收率关键技术》课题，根据多杯等流理论和浅池理论设计出一种新型重力式油水分离器——多杯等流型油水分离器。通过理论分析和实验研究，对分离器结构进行优化设计，将其应用于同井注采和油田地面污水处理中，并进行了现场试验。
本文首先介绍了分离器分离原理、结构和工作过程，并分析了油滴在沉降杯中的上升运动和聚并过程。对液体在分离器中流动过程进行理论研究和Fluent软件模拟，确定中心管流动阻力和进液孔局部阻力系数，据此编制了分离器设计计算软件。利用软件进行大量计算，在保证等流的前提条件下，给出不同流量条件下分离器中心管进液孔分布方案。
油水分离器分离效果的关键是沉降杯的形状，设计了24种形状的沉降杯，通过室内实验，对沉降杯进行优选。研究发现，亲油材质的沉降杯底倾角越小，越容易形成不断沿棱角向上运动的连续油膜，分离效果越好；棱数越多，油滴与杯底接触面积越大，分离效果越好。在这24种沉降杯中，带尖加一个隔板的皇冠状沉降杯分离效果最好。该沉降杯杯底瓦棱状倾角30°，12棱，杯身为筒状，长46.5mm，上缘形状与上一个杯底瓦棱状相吻合，内装亲油材质，且与杯底形状相同的隔板。
为解决分离器内沉砂导致分离器分离效果变差的问题，进行了分离器排砂实验，在沉降杯底打排砂孔可以起到排砂作用，中心管进液孔也有一定的排砂功能。综合考虑排砂效果和油水分离效果，排砂孔应为：孔径3mm，4孔，上下沉降杯排砂孔错位排列，并与进液孔错开。这种分离器与无排砂孔分离器相比，在含水95%条件下，液面下降速度仅降低了2.6%。
为进一步提高油水分离效率，在沉降杯中添加亲油滤料，根据相渗理论，这可以提高水的相对渗透率，降低油的相对渗透率，从而提高油水分离效果。通过室内实验，优选出沉降杯中添加厚度为14mm覆膜石英砂滤料效果最好，相比带尖加一个隔板的皇冠状分离器，在含水95%条件下，进液量可以提高59%。
将优化设计后的多杯等流型油水分离器应用于同井注采和地面污水处理，进行了现场试验。
同井注采工艺为下层开采、而后回注到上层的双抽油泵工艺，由采出抽油泵、密封活塞、桥式封隔器、注入抽油泵和井下油水分离器组成。同井注采工艺现场试验10口井，平均产液量由103.48t/d下降到32.5t/d，降低产液量达到70.79t/d；含水由95.29%下降到87.32%，下降7.97个百分点，节能效果明显。
在地面污水处理现场试验中，采用了粗粒化和加剂提高油滴粒径的方法，进一步提高分离效率。添加14mm石英砂滤料皇冠状分离器，在保证分离效果和分离效率的条件下，其处理量是现场沉降罐的49.3倍。使用粗粒化装置后，在保证分离效果和分离效率的条件下，其处理量是现场沉降罐的187.4倍。药剂可以提高油滴粒径，在实验的5种药剂中，S1药剂20mg/L时处理效果最佳，建议加药地点为转油站，也可以井口加药，不建议在联合站内各点加药。
多杯等流型油水分离器在油田应用，可以减少地面污水处理系统负荷，降低生产运行成本和固定投资，提高油田采收率、实现油田可持续发展。
The increase of oilfield water content leads to increasing energy consumption in liftingand gathering system and more work in ground engineering construction and renovation,therefore water has received more and more attention. Based on “Key Technology to EnhanceOil Recovery in High Water Cut Oil Field” project of PetroChina Company Limited, a newtype of gravity oil-water separator—multicup isoflux oil-water separator—is devised.Multicup isoflux theory and shallow tank theory are used in the separator. Through theoreticalanalysis and experimental research, the structure of separator is optimized, then apply theoptimized separator in injection-production in the same well and produced water treatmentand field experiment is carried out.
The separation principle, structure and working process of separator are first introducedin this dissertation, and the upward movement and coalescence process of oil droplets in thesettling cups are analyzed. The flow process of fluid in the separator is researchedtheoretically and simulated by Fluent. Both the flow resistance of center tube and localresistance coefficient of liquid inlet hole are determined. Then design calculation software ofseparator is compiled. A large number of calculations are carried out, in the premise of isoflow,distribution of liquid inlet holes in center tube is provided under the condition of differentflow rates.
The separation effect of oil-water separator is mainly decided by the shape of settlingcup.24kinds of settling cups with different shapes are designed and the best one is picked outthrough laboratory experiment. The research shows that the smaller the dip angle of settlingcup bottom is, the more likely it is to form continuous oil film moving upward along declinededge, and the separation effect is better; the more the edges are, the larger the contact area ofcup bottom is, and the effect is better. Among the24kinds of settling cups, the crown-shapeone with cusp and a battle has the best separating effect, it has cylinder,46.5mm long cup and12edges, its dip angle of settling cup bottom is30°, the upside part inosculates with the ridgeon the bottom of the above one. The cup is with oil wet material and a battle that is the samein shape with cup bottom.
In order to solve the problem that sand settling in separator leads to poor separationeffect, sand drainage experiment of separator is carried out. Punching in the bottom of settlingcup can help remove sand, liquid inlet hole also has this function. Synthesizes the effect ofsediment sand and oil separation, the diameter of sand drainage outlet is3mm and the outlet number is four. The outlets in the up-cup stagger those in the down-cup, and both themstagger liquid inlets. Compared with separator without outlet, drawdown speed of liquid levelis reduced by only2.6%when the water content is95%.
In order to further improve the efficiency of oil-water separation, oil wet filter material isadded in settling cup, which can improve relative permeability of water and reduce therelative permeability of oil so that improve the effect of oil-water separation. Throughlaboratory experiment, settling cup that adding coated quartz sand with the thickness of14mmhas the best effect, compared with crown-shape settling cup with cusp and a battle, liquid flowcan increase by59%, when the water content is95%.
Apply the optimized multicup isoflux oil-water separator in injection-production in thesame well and produced water treatment, and field experiment is carried out.
Injection-production in the same well is realized by two pumps, one is placed underlayerfor exploiting and the other uplayer for reinjecting. This system is consisted of extractionpump, packed piston, bridge type packer, injection pump and downhole oil-water separator.Test this technology in ten wells, the average producing fluid volume reduces from103.48t/ddown to32.5t/d, fell70.79t/d; Water content reduces from95.29%to95.29%, fell by7.97%,which have a remarkable energy saving effect.
In the field experiment of produced water treatment, applying coalescence equipmentand additive that can enlarge the oil droplets size to further improve the separation efficiency.In the premise of separation efficiency and effect, the treatment capacity of crown-shapesettling cups that adding coated quartz sand with the thickness of14mm is49.3times that offield settling tank. After the coalescence equipment is applied, the treatment capacity is187.4times that of field settling tank. Adding additive can improve the size of oil droplets, S1hasthe best effect among the five kinds of tested agents when concentration is20mg/L.Recommended dosing sites are transfer station and wellhead, central processing station is notrecommended.
Appling multicup isoflux oil-water separator in oil field can reduce the load of groundproduced water treatment system, decrease the production cost and fixed investment, improvethe oil recovery and realize sustainable development in oil field.
本文首先介绍了分离器分离原理、结构和工作过程，并分析了油滴在沉降杯中的上升运动和聚并过程。对液体在分离器中流动过程进行理论研究和Fluent软件模拟，确定中心管流动阻力和进液孔局部阻力系数，据此编制了分离器设计计算软件。利用软件进行大量计算，在保证等流的前提条件下，给出不同流量条件下分离器中心管进液孔分布方案。
油水分离器分离效果的关键是沉降杯的形状，设计了24种形状的沉降杯，通过室内实验，对沉降杯进行优选。研究发现，亲油材质的沉降杯底倾角越小，越容易形成不断沿棱角向上运动的连续油膜，分离效果越好；棱数越多，油滴与杯底接触面积越大，分离效果越好。在这24种沉降杯中，带尖加一个隔板的皇冠状沉降杯分离效果最好。该沉降杯杯底瓦棱状倾角30°，12棱，杯身为筒状，长46.5mm，上缘形状与上一个杯底瓦棱状相吻合，内装亲油材质，且与杯底形状相同的隔板。
为解决分离器内沉砂导致分离器分离效果变差的问题，进行了分离器排砂实验，在沉降杯底打排砂孔可以起到排砂作用，中心管进液孔也有一定的排砂功能。综合考虑排砂效果和油水分离效果，排砂孔应为：孔径3mm，4孔，上下沉降杯排砂孔错位排列，并与进液孔错开。这种分离器与无排砂孔分离器相比，在含水95%条件下，液面下降速度仅降低了2.6%。
为进一步提高油水分离效率，在沉降杯中添加亲油滤料，根据相渗理论，这可以提高水的相对渗透率，降低油的相对渗透率，从而提高油水分离效果。通过室内实验，优选出沉降杯中添加厚度为14mm覆膜石英砂滤料效果最好，相比带尖加一个隔板的皇冠状分离器，在含水95%条件下，进液量可以提高59%。
将优化设计后的多杯等流型油水分离器应用于同井注采和地面污水处理，进行了现场试验。
同井注采工艺为下层开采、而后回注到上层的双抽油泵工艺，由采出抽油泵、密封活塞、桥式封隔器、注入抽油泵和井下油水分离器组成。同井注采工艺现场试验10口井，平均产液量由103.48t/d下降到32.5t/d，降低产液量达到70.79t/d；含水由95.29%下降到87.32%，下降7.97个百分点，节能效果明显。
在地面污水处理现场试验中，采用了粗粒化和加剂提高油滴粒径的方法，进一步提高分离效率。添加14mm石英砂滤料皇冠状分离器，在保证分离效果和分离效率的条件下，其处理量是现场沉降罐的49.3倍。使用粗粒化装置后，在保证分离效果和分离效率的条件下，其处理量是现场沉降罐的187.4倍。药剂可以提高油滴粒径，在实验的5种药剂中，S1药剂20mg/L时处理效果最佳，建议加药地点为转油站，也可以井口加药，不建议在联合站内各点加药。
多杯等流型油水分离器在油田应用，可以减少地面污水处理系统负荷，降低生产运行成本和固定投资，提高油田采收率、实现油田可持续发展。
The increase of oilfield water content leads to increasing energy consumption in liftingand gathering system and more work in ground engineering construction and renovation,therefore water has received more and more attention. Based on “Key Technology to EnhanceOil Recovery in High Water Cut Oil Field” project of PetroChina Company Limited, a newtype of gravity oil-water separator—multicup isoflux oil-water separator—is devised.Multicup isoflux theory and shallow tank theory are used in the separator. Through theoreticalanalysis and experimental research, the structure of separator is optimized, then apply theoptimized separator in injection-production in the same well and produced water treatmentand field experiment is carried out.
The separation principle, structure and working process of separator are first introducedin this dissertation, and the upward movement and coalescence process of oil droplets in thesettling cups are analyzed. The flow process of fluid in the separator is researchedtheoretically and simulated by Fluent. Both the flow resistance of center tube and localresistance coefficient of liquid inlet hole are determined. Then design calculation software ofseparator is compiled. A large number of calculations are carried out, in the premise of isoflow,distribution of liquid inlet holes in center tube is provided under the condition of differentflow rates.
The separation effect of oil-water separator is mainly decided by the shape of settlingcup.24kinds of settling cups with different shapes are designed and the best one is picked outthrough laboratory experiment. The research shows that the smaller the dip angle of settlingcup bottom is, the more likely it is to form continuous oil film moving upward along declinededge, and the separation effect is better; the more the edges are, the larger the contact area ofcup bottom is, and the effect is better. Among the24kinds of settling cups, the crown-shapeone with cusp and a battle has the best separating effect, it has cylinder,46.5mm long cup and12edges, its dip angle of settling cup bottom is30°, the upside part inosculates with the ridgeon the bottom of the above one. The cup is with oil wet material and a battle that is the samein shape with cup bottom.
In order to solve the problem that sand settling in separator leads to poor separationeffect, sand drainage experiment of separator is carried out. Punching in the bottom of settlingcup can help remove sand, liquid inlet hole also has this function. Synthesizes the effect ofsediment sand and oil separation, the diameter of sand drainage outlet is3mm and the outlet number is four. The outlets in the up-cup stagger those in the down-cup, and both themstagger liquid inlets. Compared with separator without outlet, drawdown speed of liquid levelis reduced by only2.6%when the water content is95%.
In order to further improve the efficiency of oil-water separation, oil wet filter material isadded in settling cup, which can improve relative permeability of water and reduce therelative permeability of oil so that improve the effect of oil-water separation. Throughlaboratory experiment, settling cup that adding coated quartz sand with the thickness of14mmhas the best effect, compared with crown-shape settling cup with cusp and a battle, liquid flowcan increase by59%, when the water content is95%.
Apply the optimized multicup isoflux oil-water separator in injection-production in thesame well and produced water treatment, and field experiment is carried out.
Injection-production in the same well is realized by two pumps, one is placed underlayerfor exploiting and the other uplayer for reinjecting. This system is consisted of extractionpump, packed piston, bridge type packer, injection pump and downhole oil-water separator.Test this technology in ten wells, the average producing fluid volume reduces from103.48t/ddown to32.5t/d, fell70.79t/d; Water content reduces from95.29%to95.29%, fell by7.97%,which have a remarkable energy saving effect.
In the field experiment of produced water treatment, applying coalescence equipmentand additive that can enlarge the oil droplets size to further improve the separation efficiency.In the premise of separation efficiency and effect, the treatment capacity of crown-shapesettling cups that adding coated quartz sand with the thickness of14mm is49.3times that offield settling tank. After the coalescence equipment is applied, the treatment capacity is187.4times that of field settling tank. Adding additive can improve the size of oil droplets, S1hasthe best effect among the five kinds of tested agents when concentration is20mg/L.Recommended dosing sites are transfer station and wellhead, central processing station is notrecommended.
Appling multicup isoflux oil-water separator in oil field can reduce the load of groundproduced water treatment system, decrease the production cost and fixed investment, improvethe oil recovery and realize sustainable development in oil field.
引文
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