Study on structure optimization and performance of downhole gas-liquid hydrocyclone under high gas-liquid ratio

doi:10.11949/0438-1157.20240030

CIESC Journal ›› 2024, Vol. 75 ›› Issue (3): 900-913.DOI: 10.11949/0438-1157.20240030

• Separation engineering • Previous Articles Next Articles

Study on structure optimization and performance of downhole gas-liquid hydrocyclone under high gas-liquid ratio

Lei XING¹^,²^,³(), Shuai GUAN¹^,², Minghu JIANG¹^,²(), Lixin ZHAO¹^,², Meng CAI²^,⁴, Hailong LIU⁵, Dehai CHEN¹^,²

^1.School of Mechanical Science and Engineering, Northeast Petroleum University, Daqing 163318, Heilongjiang, China
^2.Heilongjiang Key Laboratory of Petroleum and Petrochemical Multiphase Treatment and Pollution Prevention, Daqing 163318, Heilongjiang, China
^3.Postdoctoral Research Workstation in Daqing Oilfield, Daqing 163458, Heilongjiang, China
^4.Oil Production Engineering Research Institute of Daqing Oilfield, Daqing 163318, Heilongjiang, China
^5.Cold Energy Utilization Technology Center of Clean Energy Branch, CNOOC Energy Development Co. , Ltd. , Tianjin 300452, China

Received:2024-01-05 Revised:2024-02-14 Online:2024-05-11 Published:2024-03-25
Contact: Minghu JIANG

高气液比井下气液旋流分离器结构设计与性能分析

邢雷¹^,²^,³(), 关帅¹^,², 蒋明虎¹^,²(), 赵立新¹^,², 蔡萌²^,⁴, 刘海龙⁵, 陈德海¹^,²

^1.东北石油大学机械科学与工程学院，黑龙江大庆 163318
^2.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
^3.大庆油田博士后科研工作站，黑龙江大庆 163458
^4.大庆油田有限责任公司采油工程研究院，黑龙江大庆 163318
^5.中海油能源发展股份有限公司清洁能源分公司冷能利用技术中心，天津 300452

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:
国家自然科学基金项目(52304064);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);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);黑龙江省博士后资助项目(LBH-Z23039)

Abstract

Abstract:

To address challenges in efficient gas-liquid separation under high gas-liquid ratio conditions, a novel cyclone-gravity coupled downhole gas-liquid separator is proposed. Combining experimental research, numerical simulation and experimental design methods, the significance analysis and optimal design of the gas-liquid separator structural parameters were carried out, a mathematical relationship model between the significant structural parameters and the gas-liquid separation efficiency was established. The best matching scheme for structural parameters was established. The combined design of gravity sedimentation and hydrocyclone separation proves effective in achieving liquid phase deposition under high gas-liquid ratios, leading to high-efficiency gas-liquid separation. The results indicate that separation efficiency rises with liquid intake, stabilizing within a range. Within certain working conditions, the gas-liquid ratio initially enhances separation efficiency, then decreases. The optimal liquid intake is 42 m³/d, the optimum inlet pressure is 2 MPa, and the optimal gas-liquid ratio is 700∶1, 97% efficiency is achieved under optimal conditions. The simulation and experimental results align well, offering novel insights and references for the research and development of gas-liquid separation equipment.

Key words: hydrocyclone separation, separation performance, flow field characteristics, structural design, gas-liquid ratio

摘要：

针对井下高气液比工况气液高效分离难度大的问题，提出了一种旋流-重力耦合式井下气液分离器结构。结合实验研究、数值模拟及实验设计方法，对气液分离器结构参数进行显著性分析和优化设计，建立显著性结构参数与气液分离效率间的数学关系模型，确立了结构参数的最佳匹配方案。分析了入口流量、压力及气液比对气液分离器性能的影响规律。结果表明，重力沉降与旋流分离的结合设计可以实现高气液比条件下的液相沉积，进而实现气液两相的高效分离。分离器的分离效率随着进液量升高而升高，增幅逐渐趋于平稳。随着气液比增大，分离效率呈现先增加后降低的趋势。得出该气液分离器的最佳进液量为42 m³/d，最佳入口压力2 MPa，最佳气液比为700∶1，在最佳工况下分离效率为97%，模拟结果与实验结果呈现出较好的一致性。研究结果将为高气液比条件下气液分离装备研发提供新的思路和参考。

关键词: 旋流分离, 分离性能, 流场特性, 结构设计, 气液比

CLC Number:

TQ 051.8

Lei XING, Shuai GUAN, Minghu JIANG, Lixin ZHAO, Meng CAI, Hailong LIU, Dehai CHEN. Study on structure optimization and performance of downhole gas-liquid hydrocyclone under high gas-liquid ratio[J]. CIESC Journal, 2024, 75(3): 900-913.

邢雷, 关帅, 蒋明虎, 赵立新, 蔡萌, 刘海龙, 陈德海. 高气液比井下气液旋流分离器结构设计与性能分析[J]. 化工学报, 2024, 75(3): 900-913.

Figures/Tables 17

Fig.1 Structure and working principle of cyclone-gravity coupled downhole gas-liquid separator

Table 1 Initial structure parameters of fluid domain of gas-liquid separator

结构参数	数值
螺旋流道长度L₁/mm	100
分离腔长度L₂/mm	80
沉降腔长度L₃/mm	100
分离腔直径D₁/mm	94
沉降腔直径D₂/mm	86
锥角θ/(°)	40

Fig.2 Grid independence test

Fig.3 Grid division of structural computing domain

Table 2 Factors and level values of PB test

因素		水平
编号	名称	下水平（-1）	上水平（+1）
A	螺旋流道长度L₁/mm	100	200
B	分离腔长度L₂/mm	100	500
C	锥度θ/(°)	20	80
D	沉降腔长度L₃/mm	100	500
E	沉降腔直径D₂/mm	80	92

Fig.4 Flow chart of experimental process

Table 3 PB test scheme and simulation results

序号	A	B	C	D	E	分离效率E/%
1	1	1	-1	-1	-1	70.2
2	1	-1	1	1	1	33.9
3	-1	-1	-1	-1	-1	80.4
4	-1	-1	-1	1	-1	85.5
5	1	-1	1	1	-1	89.8
6	1	1	-1	1	1	61.9
7	-1	1	1	1	-1	78.1
8	-1	1	1	-1	1	60.9
9	1	-1	-1	-1	1	73.9
10	-1	1	-1	1	1	60.7
11	1	1	1	-1	-1	70.7
12	-1	-1	1	-1	1	28

Fig.5 Pareto diagram of the influence of factors on expected value

Table 4 BBD design and test results

序号	气液分离腔长度x₁	锥度x₂	沉降腔长度x₃	分离效率/%
1	0	0	0	85.1
2	-1	-1	0	82.9
3	1	-1	0	79.4
4	1	1	0	79.3
5	0	0	0	85.1
6	1	0	1	80.6
7	0	1	-1	80.4
8	0	1	1	82.6
9	1	0	-1	78.3
10	0	-1	1	81.5
11	0	0	0	85.1
12	-1	1	0	83.6
13	-1	0	1	81.1
14	0	0	0	85.1
15	0	-1	-1	80.4
16	-1	0	-1	83.1
17	0	0	0	85.1

Fig.6 Comparison of simulated and experimental result at optimal working conditions

Fig.7 Gas phase distribution under different injection rate

Fig.8 Distribution of tangential velocity at different inlet flow rates

Fig.9 Effect of liquid intake on separation efficiency

Fig.10 Comparison of experimental and simulation results

Fig.11 Gas phase distribution at different gas-liquid ratios

Fig.12 Effect of gas-liquid ratio on separation efficiency

Fig.13 Comparison of separation efficiency curves with different gas-liquid ratios at liquid intake of 42 m3/d

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Study on structure optimization and performance of downhole gas-liquid hydrocyclone under high gas-liquid ratio

高气液比井下气液旋流分离器结构设计与性能分析

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