多级螺旋分离器结构优化设计与性能分析

doi:10.11949/0438-1157.20230993

化工学报 ›› 2023, Vol. 74 ›› Issue (11): 4587-4599.DOI: 10.11949/0438-1157.20230993

多级螺旋分离器结构优化设计与性能分析

邢雷¹^,²^,³(), 苗春雨¹, 蒋明虎¹^,³(), 赵立新¹^,³, 李新亚¹^,³

^1.东北石油大学机械科学与工程学院，黑龙江大庆 163318
^2.大庆油田博士后科研工作站，黑龙江大庆 163458
^3.黑龙江省石油石化多相介质处理及污染防治重点实验室，黑龙江大庆 163318

收稿日期:2023-09-21 修回日期:2023-11-11 出版日期:2023-11-25 发布日期:2024-01-22
通讯作者: 蒋明虎
作者简介:邢雷（1990—），男，博士，副教授，Nepuxinglei@163.com
基金资助:
国家自然科学基金区域创新发展联合基金重点支持项目(U21A20104);国家自然科学基金青年基金项目(52304064);中国博士后科学基金项目(2023M730481);黑龙江省自然科学基金项目(LH2022E017)

Optimal design and performance analysis of multi-stage spiral separator

Lei XING¹^,²^,³(), Chunyu MIAO¹, Minghu JIANG¹^,³(), Lixin ZHAO¹^,³, Xinya LI¹^,³

^1.School of Mechanical Science and Engineering, Northeast Petroleum University, Daqing 163318, Heilongjiang, China
^2.Postdoctoral Research Workstation in Daqing Oilfield, Daqing 163458, Heilongjiang, China
^3.Heilongjiang Key Laboratory of Petroleum and Petrochemical Multiphase Treatment and Pollution Prevention, Daqing 163318, Heilongjiang, China

Received:2023-09-21 Revised:2023-11-11 Online:2023-11-25 Published:2024-01-22
Contact: Minghu JIANG

摘要/Abstract

摘要：

为解决井下油水分离水力旋流器串接工艺较为复杂的问题，基于串联旋流分离原理提出一种新型多级螺旋分离器结构。利用响应曲面设计结合计算流体动力学方法，构建多级螺旋分离器参数与分离效率间的数学关系模型，得出最佳结构参数匹配方案，并针对最优结构模型系统地探究在一定范围内不同入口流量、油相体积分数及分流比对应的分离性能变化规律。开展室内分离性能实验，对数值模拟结果的准确性及优化结果的高效性进行验证。结果表明，优化后的结构可使分离效率由91.0%提高至96.2%。对比不同入口流量条件下的分离性能，得出最佳入口流量为2.5 m³/h；在一定范围内，随着油相体积分数及溢流分流比的增加，分离效率均呈先增大后减小趋势，其中模拟效率最高可达99.72%，实验效率可达97.70%，进一步验证了模拟结果的可靠性及优化结果的高效性。

关键词: 旋流分离, 油水分离, 数值模拟, 优化设计, 分离性能, 计算流体力学

Abstract:

In order to solve the problem of the complicated process of downhole oil-water separation hydrocyclones connection in parallel, a new structure of multi-stage spiral separator is proposed based on the principle of tandem hydrocyclone separation. Response surface method combined with computational fluid dynamics is used to build a mathematical relationship model between the structural parameters and the separation efficiency of a multi-stage spiral separator, resulting in an optimal structural parameter, and systematically explored the optimal structural model within a certain range. The separation performance changes corresponding to different inlet flow rates, oil phase volume fractions and split ratios. Indoor separation performance experiments are conducted to verify the accuracy of numerical simulation results and the efficiency of optimization results. The results showed that the optimized structure could increase the separation efficiency from 91.0% to 96.2%. Comparison of separation performance at different inlet flow rates, the optimal inlet flow rate of 2.5 m³/h was obtained; within a certain range, with the increase of oil phase volume fraction and overflow split ratio, the separation efficiency showed a tendency of increasing and then decreasing, of which the simulated efficiency could reach up to 99.72%, and the experimental efficiency could reach up to 97.70%, which further verified the reliability of the simulation results and the efficiency of optimization results.

Key words: hydrocyclone separation, oil-water separation, numerical simulation, optimal design, separation performance, computational fluid dynamics

中图分类号:

TQ 051.8

邢雷, 苗春雨, 蒋明虎, 赵立新, 李新亚. 多级螺旋分离器结构优化设计与性能分析[J]. 化工学报, 2023, 74(11): 4587-4599.

Lei XING, Chunyu MIAO, Minghu JIANG, Lixin ZHAO, Xinya LI. Optimal design and performance analysis of multi-stage spiral separator[J]. CIESC Journal, 2023, 74(11): 4587-4599.

图/表 21

图1 多级螺旋分离器工作原理

Fig.1 Working principle of multi-stage spiral separator

图2 多级螺旋分离器结构示意图

Fig.2 Structure of multi-stage spiral separator

表1 多级螺旋分离器结构参数

Table 1 Structural parameters of multi-stage spiral separator

结构参数	数值	结构参数	数值
D₁/mm	6	L₁/mm	8
D₂/mm	8	L₂/mm	30
D₃/mm	12	L₃/mm	8
D₄/mm	22	L₄/mm	25
D₅/mm	10	L₅/mm	25
D₆/mm	6	L₆/mm	50
D₇/mm	8	L₇/mm	200
D₈/mm	22	L₈/mm	200
D₉/mm	25	L₉/mm	100
R₁/mm	10

图3 网格无关性检验结果

Fig.3 Result of grid independence tests

图4 实验装置及工艺流程1—搅拌器; 2—储水罐; 3—储油罐; 4—柱塞泵; 5—螺杆泵; 6—变频调节器; 7—静态混合器;8—阀; 9—浮子流量计; 10—压力表; 11—取样阀; 12—实验样机; 13—样机实物; 14—废液循环罐

Fig.4 Experimental facilities and process

表2 因素水平设计

Table 2 Factors and levels design

因素	水平
因素	高（+1）	低（-1）	中心点（0）
油相体积分数x₁/%	9	1	5
一二级间距x₂/mm	300	100	200
二三级间距x₃/mm	300	100	200

表3 BBD设计及实验结果

Table 3 Design and results of box-Behnken design

实验序号	x₁/%	x₂/mm	x₃/mm	E/%
1	5	200	200	91.0
2	9	100	200	81.1
3	5	300	300	90.9
4	1	100	200	97.1
5	9	200	300	81.1
6	1	300	200	97.9
7	5	300	100	90.1
8	5	100	100	90.2
9	5	200	200	91.0
10	5	100	300	90.5
11	9	300	200	80.8
12	1	200	300	97.9
13	5	200	200	91.0
14	9	200	100	81.3
15	1	200	100	96.9
16	5	200	200	91.0
17	5	200	200	91.0

表4 回归模型的方差分析结果

Table 4 The model results of variance analysis

类型	离差平方和	自由度	均方	F值	P
模型	547.58	9	60.84	5495.48	<0.0001
x₁	536.28	1	536.28	48438.31	<0.0001
x₂	0.0800	1	0.0800	7.23	0.0312
x₃	0.4512	1	0.4512	40.76	0.0004
x₁x₂	0.3025	1	0.3025	27.32	0.0012
x₁x₃	0.3600	1	0.3600	32.52	0.0007
x₂x₃	0.0625	1	0.0625	5.65	0.0492
x₁²	8.85	1	8.85	799.59	<0.0001
x₂²	0.4447	1	0.4447	40.17	0.0004
x₃²	0.2632	1	0.2632	23.77	0.0018
残差	0.0775	7	0.0111	—	—
失拟项	0.0775	3	0.0258	—	—
纯误差	0	4	0	—	—

表5 回归模型误差统计分析

Table 5 The model results of statistic analysis

统计项目	数值	统计项目	数值
标准偏差	0.1052	R²	0.999
均值	90.05	adjusted R²	0.999
C.V.	9.69%	predicted R²	0.997
		adeq precision	212.66

图5 优化前后结构及油相体积分数对比

Fig.5 Comparison of structure and oil phase volume fraction between before and after optimization

图6 不同流量条件下各级流道出口处速度变化曲线

Fig.6 Change of velocity at the outlet of the flow channel in different flow rate conditions

图7 不同流量条件下中心轴线处轴向速度曲线分布

Fig.7 Axial velocity distribution at center axis in different flow rate conditions

图8 不同流量条件下中心轴线处油相体积分数分布曲线

Fig.8 Oil phase volume fraction distribution at the center axis in different flow rate conditions

图9 不同流量条件下中心轴线处压力分布曲线

Fig.9 Pressure distribution at center axis in different flow rate conditions

图10 不同处理量条件下对应的分离效率及底流压降

Fig.10 Separation efficiency and bottom flow pressure drop in different flow rate conditions

图11 不同油相体积分数条件下各级流道出口处速度变化曲线

Fig.11 Change of velocity at the outlet of the flow channel in different oil volume fraction conditions

图12 不同油相体积分数条件下中心轴线处油相体积分数分布曲线

Fig.12 Oil phase volume fraction distribution at the center axis in different oil volume fraction conditions

图13 不同油相体积分数条件下各级流道出口处油相体积分数变化曲线

Fig.13 Change of oil volume fraction at the outlet of the flow channel in different oil volume fraction conditions

图14 不同油相体积分数条件下中心轴线处压力分布曲线

Fig.14 Pressure distribution at center axis in different oil volume fraction conditions

图15 不同油相体积分数条件下对应的分离效率

Fig.15 Separation efficiency in different oil volume fraction conditions

图16 不同分流比条件下对应的分离效率

Fig.16 Separation efficiency in different split ratio conditions

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多级螺旋分离器结构优化设计与性能分析

Optimal design and performance analysis of multi-stage spiral separator

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