Abstract
Cyclonic devices are ubiquitous in industrial processes and have been used for particle separation for decades. However, designing a highly efficient, compact cyclone for erratic flow conditions and particles of varying types, sizes and density remains a challenge. This paper aims to present the challenges, lessons learnt and recent development in cyclone technology for solid separation.
Primarily, a discussion on typical cyclonic desander geometries is conducted. Failures and sub-optimal operation of cyclonic wellhead desanders within the company are analysed, and subsequently the failure mechanisms and factors leading to inefficiencies are identified. Computational Fluid Dynamics (CFD) simulations and flow loop testing are further performed to verify the particle separation efficiency and quantify the erosion risks of the typical cyclone geometries.
The typical cyclonic geometries are considerably less efficient in multiphase-flows compared to the gas-solid or liquid-solid flows. As a result, the overflow section of the cyclone often contains particles larger than the design specification. Changing operating envelope over time, for example, reducing production and changing flow regime affects cyclone efficiency over time. Based on a systematic analysis of the desander failures in the fields, a few design improvements have been proposed to overcome these limitations, resulting in a novel technology. This new cyclonic technology with multiple barrier system can successfully maintain the 98% target removal of 10microns particle under erratic multiphase-flows conditions. Furthermore, it can be designed to handle various types of particles e.g., sands, HgS and other solids. The versatility of this system provides promising technology for ageing fields with excessive solids production.
