Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditions
Abstract The performance of surface oil–water cyclone separators impacts the measurement accuracy of crude oil produced from exploration and appraisal wells, thereby influencing the formulation of exploration and development plans. To obtain the optimal structural configuration for cyclone oil–water...
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SpringerOpen
2025-01-01
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| Series: | Journal of Engineering and Applied Science |
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| Online Access: | https://doi.org/10.1186/s44147-025-00585-0 |
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| author | Zhimin Li |
| author_facet | Zhimin Li |
| author_sort | Zhimin Li |
| collection | DOAJ |
| description | Abstract The performance of surface oil–water cyclone separators impacts the measurement accuracy of crude oil produced from exploration and appraisal wells, thereby influencing the formulation of exploration and development plans. To obtain the optimal structural configuration for cyclone oil–water separators, this study optimizes the design of a high-efficiency oil–water cyclone separator suitable for special conditions in well testing. A numerical simulation was performed using the discrete phase model to analyze the three-dimensional turbulent swirl field of the oil–water phases within the separator. Separation efficiency and pressure drop were used as evaluation criteria. The Plackett–Burman experimental method was employed to evaluate six factors affecting separation performance, with oil outlet diameter and cyclone chamber cone angle identified as significant factors. Mathematical models for separation efficiency and pressure drop were developed based on these factors. The central composite design method was then applied to investigate the interactive effects of oil outlet diameter and cyclone chamber cone angle on separation efficiency and pressure drop. The optimal parameter combination was determined: oil outlet diameter of 4.241 mm and cyclone chamber cone angle of 9.622°. The predicted separation efficiency was 93.870%, and the predicted pressure drop was 48.287 kPa. Field tests of the optimized cyclone separator verified the rationality of these optimized parameters, achieving a separation efficiency of 92.9%. This research offers a foundation for optimizing the design of oil–water cyclone separators. |
| format | Article |
| id | doaj-art-136a02fd072f498f9249923bef508214 |
| institution | Kabale University |
| issn | 1110-1903 2536-9512 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | SpringerOpen |
| record_format | Article |
| series | Journal of Engineering and Applied Science |
| spelling | doaj-art-136a02fd072f498f9249923bef5082142025-02-02T12:26:04ZengSpringerOpenJournal of Engineering and Applied Science1110-19032536-95122025-01-0172111810.1186/s44147-025-00585-0Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditionsZhimin Li0Petroleum Engineering Technology Research Institute of Sinopec Northwest Oilfield BranchAbstract The performance of surface oil–water cyclone separators impacts the measurement accuracy of crude oil produced from exploration and appraisal wells, thereby influencing the formulation of exploration and development plans. To obtain the optimal structural configuration for cyclone oil–water separators, this study optimizes the design of a high-efficiency oil–water cyclone separator suitable for special conditions in well testing. A numerical simulation was performed using the discrete phase model to analyze the three-dimensional turbulent swirl field of the oil–water phases within the separator. Separation efficiency and pressure drop were used as evaluation criteria. The Plackett–Burman experimental method was employed to evaluate six factors affecting separation performance, with oil outlet diameter and cyclone chamber cone angle identified as significant factors. Mathematical models for separation efficiency and pressure drop were developed based on these factors. The central composite design method was then applied to investigate the interactive effects of oil outlet diameter and cyclone chamber cone angle on separation efficiency and pressure drop. The optimal parameter combination was determined: oil outlet diameter of 4.241 mm and cyclone chamber cone angle of 9.622°. The predicted separation efficiency was 93.870%, and the predicted pressure drop was 48.287 kPa. Field tests of the optimized cyclone separator verified the rationality of these optimized parameters, achieving a separation efficiency of 92.9%. This research offers a foundation for optimizing the design of oil–water cyclone separators.https://doi.org/10.1186/s44147-025-00585-0Oil–water cyclone separatorNumerical simulationSeparation efficiencySeparation pressure dropCentral composite design method |
| spellingShingle | Zhimin Li Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditions Journal of Engineering and Applied Science Oil–water cyclone separator Numerical simulation Separation efficiency Separation pressure drop Central composite design method |
| title | Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditions |
| title_full | Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditions |
| title_fullStr | Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditions |
| title_full_unstemmed | Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditions |
| title_short | Optimization and experimental validation of a high-efficiency oil–water cyclone separator for well testing conditions |
| title_sort | optimization and experimental validation of a high efficiency oil water cyclone separator for well testing conditions |
| topic | Oil–water cyclone separator Numerical simulation Separation efficiency Separation pressure drop Central composite design method |
| url | https://doi.org/10.1186/s44147-025-00585-0 |
| work_keys_str_mv | AT zhiminli optimizationandexperimentalvalidationofahighefficiencyoilwatercycloneseparatorforwelltestingconditions |