Electro-coalescer cell with turbulence-inducing shape for maximized performance

1. An electro-coalescer, comprising:

a fluid inlet;

a fluid outlet;

a power source; and

one or more pipes fluidly connecting the inlet and the outlet, each pipe having an electrode disposed therethrough;

wherein

each electrode is coupled to the power source,

each pipe is configured to connect to an electrical ground,

whereby an electric field is generated between the electrode and the pipe through which it is disposed, and

an internal surface of each of the one or more pipes is configured to induce turbulence in a fluid flowing through each of the one or more pipes,

wherein the internal surface is corrugated or has a twist structure.

2. The electro-coalescer as claimed in claim 1 , wherein the power source comprises a direct current power source,

wherein the direct current power source supplies a direct current that is optionally continuous or pulsed.

3. The electro-coalescer as claimed in claim 1 , further comprising:

a controller, comprising:

an inductor coupled in parallel with each electrode, the inductor and electrode defining a resonant circuit; and

a signal generator coupled to the power source and each electrode and operable to apply an alternating current signal to the electrode at a frequency corresponding to a resonant frequency of the resonant circuit in the presence of the fluid.

4. The electro-coalescer as claimed in claim 1 , wherein each of

the one or more pipes has a length to internal diameter ratio of up to about 50:1.

5. The electro-coalescer as claimed in claim 1 , wherein

at least one of the electrodes may be selectively turned off, such that a continuous phase may be allowed passage through the corresponding pipe.

6. The electro-coalescer as claimed in claim 1 , wherein

each of the one or more pipes is surrounded by a casing, and

between multiple pipes are one or more tubesheets.

7. The electro-coalescer as claimed in claim 1 , wherein

each electrode consists of a conductor surrounded by an electrically insulating sleeve.

8. The electro-coalescer as claimed in claim 1 , wherein

each electrode is made of an electrically conductive material, and

each of the one or more pipes is made of an electrically conductive material,

wherein each electrode optionally takes the shape of a rod or a tube.

9. The electro-coalescer as claimed in claim 1 , wherein

each electrode is in contact with the fluid and not in electrical contact with the corresponding pipe.

10. The electro-coalescer as claimed in claim 1 , wherein

each electrode is substantially straight.

11. A method of separating two fluid phases, comprising:

providing a flow of a process fluid comprising two or more phases, including a dominant phase and a dispersed phase, to an electro-coalescer as claimed in claim 1 ;

electrically grounding the one or more pipe(s);

applying a voltage to one or more of the electrode(s) of the electro-coalescer;

generating an electric field between the electrode(s) and the pipe(s);

passing the process fluid through the electric field;

wherein

the electric field induces electrocoalescence of droplets of the dispersed phase within the process fluid,

the internal surface of the pipe(s) induces turbulence and increases an interaction frequency between droplets of the dispersed phase, and

the droplets of the dispersed phase coalesce and

recovering a larger-droplet fluid, wherein an average droplet size of the dispersed phase at the outlet is increased as compared to an average droplet size of the dispersed phase at the inlet.

12. The method of separating two fluid phases as claimed in claim 11 , further comprising

generating the electric field using a direct current signal applied to each electrode, wherein the direct current signal is optionally continuous or pulsed.

13. The method of separating two fluid phases as claimed in claim 11 , further comprising:

providing an inductor coupled in parallel with each electrode, whereby the inductor, each electrode, each pipe, and the process fluid define a resonant circuit; and applying an alternating current signal to each electrode at a frequency corresponding to a resonant frequency of the resonant circuit in the presence of the process fluid.

14. The method of separating two fluid phases as claimed in claim 13 , wherein applying the alternating current signal comprises:

sensing a current of the alternating current signal; and

changing the frequency to minimize the sensed current.

15. The method of separating two fluid phases as claimed in claim 11 , wherein the turbulence induced by the internal surface of each pipe is sufficient to contribute to an increase in the average droplet size of the dispersed phase without causing significant redispersion of the dispersed phase.

16. The method of separating two fluid phases as claimed in claim 11 , wherein

the average droplet size of the dispersed phase at the outlet is at least 50% larger than the average droplet size of the dispersed phase at the inlet.

17. The method of separating two fluid phases as claimed in claim 11 , wherein

the dominant phase is an oil and the dispersed phase is an aqueous phase that can optionally contain dissolved salts.

18. The method of separating two fluid phases as claimed in claim 11 , wherein

the dispersed phase is an oil and the dominant phase is an aqueous phase that can optionally contain dissolved salts.

19. The method of separating two fluid phases as claimed in claim 11 , further comprising

feeding the larger-droplet fluid recovered from the outlet of the electro-coalescer into a fluids separator downstream;

performing fluids separation on the larger-droplet fluid to separate the dispersed phase and the dominant phase; and

separately discharging the dispersed phase via a dispersed phase outlet and the dominant phase via a dominant phase outlet.

20. The method of separating two fluid phases as claimed in claim 11 , further comprising

feeding an inlet fluid into a solids separator that is upstream of the electro-coalescer;

performing solids separation on the inlet fluid to separate solids, creating a reduced-solid fluid;

discharging the solids via a solids outlet and the reduced-solid fluid via an outlet of the solids separator; and

feeding the reduced-solid fluid into the inlet of the electro-coalescer.

21. The method of separating two fluid phases as claimed in claim 11 , further comprising

feeding an inlet fluid into a flash evaporator that is upstream of the electro-coalescer;

performing flash evaporation on the inlet fluid to separate a gas, creating a reduced-gas fluid;

discharging the gas via a gas outlet and the reduced-gas fluid via an outlet of the flash evaporator; and

feeding the reduced-gas fluid into the inlet of the electro-coalescer.

22. A method for separating a dispersed phase from a dominant phase in a fluid comprising oil and an aqueous phase, the method comprising:

supplying the inlet fluid to at least one of a flash evaporator or a solids separator to produce a fluid with reduced gas and/or reduced solids;

feeding the inlet fluid or a reduced-solid fluid into the flash evaporator, performing flash evaporation to separate natural gas from the reduced-solid fluid or the inlet fluid, discharging the natural gas via a gas outlet, and creating a reduced-gas fluid that is output via an outlet of the flash evaporator;

feeding the inlet fluid or the reduced-gas fluid into the solids separator, performing solids separation to separate solids from the reduced-gas fluid or the inlet fluid, discharging the solids via a solids outlet, and creating the reduced-solid fluid that is output via an outlet of the solids separator;

feeding the reduced-gas and/or the reduced-solid fluid to an electro-coalescer as claimed in claim 1 and performing electrocoalescence to increase average droplet size of the dispersed phase in the dominant phase in the reduced-gas and/or the reduced-solid fluid, and creating a larger-droplet fluid that is output via an outlet of the electro-coalescer; and

feeding the larger-droplet fluid into a fluids separator, performing fluids separation on the larger-droplet fluid to separate the aqueous phase and the oil, and separately discharging the aqueous phase via a water outlet and the oil via an oil outlet.

23. A separation system for separating one or more dispersed phases from a dominant phase in an inlet fluid, the system comprising:

a flash evaporator that separates a gas from the inlet fluid and/or a reduced-solid fluid, creates a reduced-gas fluid, discharges the gas via a gas outlet, and outputs the reduced-gas fluid via an outlet of the flash evaporator;

a solids separator that separates solids from the inlet fluid and/or the reduced-gas fluid, creates the reduced-solid fluid, discharges the solids via a solids outlet, and discharges a reduced-gas and/or reduced-solids fluid via an outlet of the solids separator;

an electro-coalescer as claimed in claim 1 that performs electrocoalescence to increase average droplet size of the dispersed phases in the dominant phase within the reduced-gas and/or reduced-solids fluid producing a larger-droplet fluid, and outputs the larger-droplet fluid via an outlet of the electro-coalescer; and

a fluids separator that separates the larger-droplet fluid into the dispersed phases and the dominant phase, and separately discharges the dispersed phases via one or more dispersed phase outlets and the dominant phase via a dominant phase outlet.

24. An electro-coalescer, comprising:

a fluid inlet;

a fluid outlet;

a power source;

a pipe fluidly connecting the inlet and the outlet; and

an electrode extending through a bore of the pipe; wherein

the electrode is coupled to the power source,

whereby an electric field is generated between the electrode and the pipe,

an internal surface of the pipe is configured to induce turbulence in a fluid flowing through the pipes,

wherein the electrode extends along an axis parallel with the bore of the pipe without touching the internal surface of the pipe, and

wherein the internal surface of the pipe is corrugated or has a twist structure.