Structure optimization and performance analysis of axial-inlet downhole gas-liquid hydrocyclone

doi:10.16085/j.issn.1000-6613.2024-1561

Abstract

Abstract:

The single-well injection-production technology is an important initiative to realize the economic exploitation in the middle and late period of oil field. Gas-containing in the produced fluid is one of the key problems restricting the large-scale application of the single-well injection-production. In order to realize the efficient separation of gas and liquid in the narrow casing space and broaden the application scope of the single-well injection-production technology under gas-containing conditions. An axial-inlet downhole gas-liquid hydrocyclone (AIDGLC) was designed based on the principles of cyclone separation. The optimization research of AIDGLC structural parameters were carried out by using optimization methods combined with PB design, steepest climb design and response surface method, and the applicability analysis for the optimized structure under different operating parameters was carried out. The results showed that the significant structural parameters of AIDGLC were ranked as the length of cyclone cavity L₂, the depth length of overflow pipe L₆, the length of underflow pipe L₅, the inner diameter of overflow pipe D₁, and the matching scheme of significant structural parameters that could maximize the separation efficiency was L₂=284.92mm, L₅=100mm, L₆=3.80mm, and D₁=42.88mm. The gas separation efficiency of the optimized structure reached the maximum value of 99.86% when the gas content was 5%, the flow rate was 5m³/h, and the split ratio was 40%. The research results provide some reference for the development and application of downhole gas-liquid separators under gas-containing working conditions.

Key words: hydrocyclone, optimal design, gas-liquid flow, numerical simulation, significance analysis, performance analysis

摘要：

同井注采技术是实现油田中后期经济开采的重要举措，采出液含气是制约同井注采规模化应用的关键问题之一。为实现狭窄套管空间内气液的高效分离，拓宽含气工况下同井注采技术的适用范围，本文基于旋流分离原理设计了一种轴入式井下气液旋流分离器（axial-inlet downhole gas-liquid hydrocyclone，AIDGLC）。利用PB实验设计、最陡爬坡设计和响应曲面设计相结合的实验方法，对AIDGLC结构参数进行优化研究，并针对优化后结构开展不同操作参数的适用性分析。结果表明，AIDGLC的显著性结构参数排序为旋流腔长度L₂、溢流管插入长度L₆、底流管长度L₅、溢流管内径D₁，得出使分离效率达到最大值的显著性结构参数匹配方案为L₂=284.92mm、L₅=100mm、L₆=3.80mm、D₁=42.88mm。优化后结构在含气量为5%、流量为5m³/h、分流比为40%时，气相分离效率达最大值99.86%。研究结果为在含气工况下井下气液分离器的研制及应用提供了一定的借鉴和参考。

关键词: 旋流分离器, 优化设计, 气液两相流, 数值模拟, 显著性分析, 性能分析

CLC Number:

TQ051.8

XING Lei, LIU Duo, JIANG Minghu, ZHAO Lixin, LI Xinya, GAO Yang. Structure optimization and performance analysis of axial-inlet downhole gas-liquid hydrocyclone[J]. Chemical Industry and Engineering Progress, 2025, 44(11): 6161-6173.

邢雷, 刘铎, 蒋明虎, 赵立新, 李新亚, 高扬. 轴入式井下气液旋流分离器结构优化与性能分析[J]. 化工进展, 2025, 44(11): 6161-6173.

Figures/Tables 19

结构参数	尺寸/mm
螺旋流道长度L₁	200
柱段旋流腔长度L₂	500
一级锥段长度L₃	80
二级锥段长度L₄	150
底流管长度L₅	200
溢流管插入长度L₆	10
溢流管内径D₁	48
一级锥段底部外径D₂	44
二级锥段底部外径D₃	64

因素	符号	水平/mm		锥度/mm
因素	符号	低（-1）	高（+1）	锥度/mm
螺旋流道长度L₁	A	160	240	80
柱段旋流腔长度L₂	B	400	600	200
一级锥段长度L₃	C	70	90	20
二级锥段长度L₄	D	140	160	20
底流管长度L₅	E	160	240	80
溢流管插入长度L₆	F	5	15	10
溢流管内径D₁	G	32	48	16
一级锥段底部外径D₂	H	40	48	8
二级锥段底部外径D₃	J	60	68	8

实验组	因素									E/%
实验组	A（L₁）	B（L₂）	C（L₃）	D（L₄）	E（L₅）	F（L₆）	G（D₁）	H（D₂）	J（D₃）	E/%
1	240	600	70	160	240	15	32	40	60	93.690
2	160	600	90	140	240	15	48	40	60	93.942
3	240	400	90	160	160	15	48	48	60	95.596
4	160	600	70	160	240	5	48	48	68	95.088
5	160	400	90	140	240	15	32	48	68	95.232
6	160	400	70	160	160	15	48	40	68	95.777
7	240	400	70	140	240	5	48	48	60	95.997
8	240	600	70	140	160	15	32	48	68	94.526
9	240	600	90	140	160	5	48	40	68	95.299
10	160	600	90	160	160	5	32	48	60	94.655
11	240	400	90	160	240	5	32	40	68	95.724
12	160	400	70	140	160	5	32	40	60	96.224

实验组	L₂/mm	L₅/mm	L₆/mm	D₁/mm	E/%
1	390	155	4.8	33.5	95.271
2	380	150	4.6	35	95.942
3	370	145	4.4	36.5	96.353
4	360	140	4.2	38	96.492
5	350	135	4	39.5	96.626
6	340	130	3.8	41	96.691
7	330	125	3.6	42.5	96.755
8	320	120	3.4	44	96.898
9	310	115	3.2	45.5	97.117
10	300	110	3	47	96.942
11	290	105	2.8	48.5	96.684
12	280	100	2.6	50	96.433
13	270	95	2.4	51.5	95.925

因素	符号	单位	水平
因素	符号	单位	低水平（-1）	中心点（0）	高水平（+1）
柱段旋流腔长度L₂	B	mm	280	310	340
底流管长度L₅	E	mm	100	115	130
溢流管插入长度L₆	F	mm	2.6	3.2	3.8
溢流管内径D₁	G	mm	41	45.5	50

类型	自由度	离散平方和	均方	F	P
模型	14	9.48	0.68	13.84	<0.0001
x₁	1	6.35	6.35	129.84	<0.0001
x₂	1	1.02	1.02	20.76	0.0004
x₃	1	0.81	0.81	16.48	0.0012
x₄	1	0.30	0.30	6.20	0.0259
x₁x₂	1	1.634×10^-4	1.634×10^-4	3.341×10^-3	0.9547
x₁x₃	1	2.782×10^-4	2.782×10^-4	5.688×10^-3	0.9410
x₁x₄	1	1.538×10^-4	1.538×10^-4	3.143×10^-3	0.9561
x₂x₃	1	0.24	0.24	5.01	0.0420
x₂x₄	1	4.290×10^-5	4.290×10^-5	8.770×10^-4	0.9768
x₃x₄	1	0.46	0.46	9.34	0.0085
x $12$	1	0.032	0.032	0.65	0.4338
x $22$	1	0.018	0.018	0.36	0.5573
x $32$	1	0.22	0.22	4.44	0.0536
x $42$	1	6.486×10^-3	6.486×10^-3	0.13	0.7212
残差	14	0.68	0.049
失拟项	10	0.68	0.068
纯误差	4	0	0
总计	28	10.16

类型	自由度	离散平方和	均方	F	P
模型	14	9.48	0.68	13.84	<0.0001
x₁	1	6.35	6.35	129.84	<0.0001
x₂	1	1.02	1.02	20.76	0.0004
x₃	1	0.81	0.81	16.48	0.0012
x₄	1	0.30	0.30	6.20	0.0259
x₁x₂	1	1.634×10^-4	1.634×10^-4	3.341×10^-3	0.9547
x₁x₃	1	2.782×10^-4	2.782×10^-4	5.688×10^-3	0.9410
x₁x₄	1	1.538×10^-4	1.538×10^-4	3.143×10^-3	0.9561
x₂x₃	1	0.24	0.24	5.01	0.0420
x₂x₄	1	4.290×10^-5	4.290×10^-5	8.770×10^-4	0.9768
x₃x₄	1	0.46	0.46	9.34	0.0085
x $12$	1	0.032	0.032	0.65	0.4338
x $22$	1	0.018	0.018	0.36	0.5573
x $32$	1	0.22	0.22	4.44	0.0536
x $42$	1	6.486×10^-3	6.486×10^-3	0.13	0.7212
残差	14	0.68	0.049
失拟项	10	0.68	0.068
纯误差	4	0	0
总计	28	10.16

随机实验组	L₂/mm	L₅/mm	L₆/mm	D₁/mm	E/%
1	305	120	3.1	45	97.2295
2	318	115	2.8	46	97.1714
3	329	105	3.7	42	97.3951
4	294	127	3.5	43	97.1689
5	337	122	3.0	48	97.3562
6	287	110	3.3	50	97.4032
7	301	125	3.6	44	97.2929
8	332	116	3.2	49	97.4380
9	320	103	2.7	47	97.1848
10	311	128	2.9	41	97.0616

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