Oil-water separation system using hydrophobic/hydrophilic materials for capacity increase and improving produced water quality

1. An oil-water separation system comprising:

a vessel configurated to receive an oil-water mixture and to pass a treated water, wherein the treated water comprises a lower concentration of oil than the oil-water mixture;

a first overflow baffle configured to direct the oil-water mixture fluid flow over the first overflow baffle;

an oil collector upstream of the first overflow baffle configured to skim and recover a portion of the oil upstream of the first overflow baffle;

a first underflow baffle positioned downstream along a fluid flow pathway of the first overflow baffle and configured to direct the oil-water mixture fluid flow under the first underflow baffle; and

a second overflow baffle comprising:

a first portion being attached to the first overflow baffle at a level above a bottom of the vessel and below a bottom end of the first underflow baffle, and

a second portion disposed at an acute angle of less than 90 degrees from horizontal coated in a copper-based hydrophobic material positioned downstream along the fluid flow pathway of the first underflow baffle, configured with a mesh having a plurality of perforations, and configured to direct fluid flow over the second overflow baffle and through the plurality of perforations wherein oil agglomerates upwards; and

wherein the second overflow baffle permits a water portion of the oil-water mixture to traverse through the mesh and an oil portion of the oil-water mixture to traverse over the mesh.

2. The system of claim 1 , wherein the first overflow baffle is oriented substantially vertically in the vessel.

3. The system of claim 1 , wherein the first underflow baffle is oriented substantially vertically in the vessel.

4. The system of claim 1 , wherein the second overflow baffle is disposed at an angle relative to the first underflow baffle.

5. The system of claim 4 , wherein the second overflow baffle comprises a hydrophilic-oleophobic material, the hydrophilic-oleophobic material permitting a water portion of the oil-water mixture to traverse through the mesh and an oil portion of the oil-water mixture to traverse over the mesh.

6. The system of claim 5 , further comprising an oil skimming trough disposed above the second overflow baffle and configured to collect an oil portion of the oil-water mixture as the oil rises over the second overflow baffle.

7. The system of claim 1 , wherein the first overflow baffle and the first underflow baffle are substantially parallel and allow for a narrowly distributed residence time of the oil-water mixture within the vessel.

8. The system of claim 1 , further comprising a water exit port disposed at a lower portion of the vessel and downstream along a fluid flow pathway of the second overflow baffle.

9. An oil-water separation system comprising:

a vessel configurated to receive an oil-water mixture and to pass a treated water, wherein the treated water comprises a lower concentration of oil than the oil- water mixture;

an oil collector upstream of a first overflow baffle configured to skim and recover a portion of the oil upstream of the first overflow baffle;

a first overflow baffle configured to direct the oil-water mixture fluid flow over the first overflow baffle;

a first underflow baffle positioned downstream of the first overflow baffle in the direction of fluid flow configured to direct the oil-water mixture fluid flow under the first underflow baffle;

a second overflow baffle coated in a copper-based hydrophobic material positioned downstream along the fluid flow pathway of the first underflow baffle wherein oil agglomerates upwards, configured to direct fluid flow over the second overflow baffle, the second overflow baffle comprising:

a first portion being attached to the first overflow baffle at a level above a bottom of the vessel and below a bottom end of the first underflow baffle, the first portion traversing under the first underflow baffle and being substantially perpendicular to the first overflow baffle; and

a second portion being attached to the first portion and being positioned downstream of the first underflow baffle in the direction of fluid flow and including a second overflow baffle section disposed at an acute angle of less than 90 degrees from horizontal; and

a water exit port located below the first portion of the second overflow baffle.

10. The system of claim 9 , wherein the first overflow baffle is oriented substantially vertically in the vessel.

11. The system of claim 9 , wherein the first underflow baffle is oriented substantially vertically in the vessel.

12. The system of claim 9 , wherein the second portion of second overflow baffle is disposed at an angle relative to the first portion.

13. The system of claim 9 , wherein the second portion of the second overflow baffle is a plate structure or a mesh structure.

14. The system of claim 13 , wherein the second overflow baffle comprises a hydrophilic-oleophobic material configured to cause the oil to bead on the plate and rise to the oil-water interface layer.

15. The system of claim 13 , wherein the second overflow baffle comprises a hydrophilic-oleophobic material configured to pass the water through the mesh and cause the oil to bead and rise to the oil-water interface layer.

16. The system of claim 13 , further comprising an oil skimming trough positioned above the second overflow baffle configured to collect an oil portion of the oil-water mixture as the oil rises over the second overflow baffle.

17. The system of claim 9 , wherein the first overflow baffle and the first underflow baffle are substantially parallel and allow for a narrowly distributed residence time of the oil-water mixture within the vessel.

18. The system of claim 9 , further comprising a feed inlet distributor configured to provide the oil-water mixture to a separation compartment.

19. The system of claim 18 , wherein the oil collector is configured for receiving oil separated from the oil-water mixture in the separation compartment.