Superior sand control for unconsolidated / consolidated formations,  a non-invasive approach to desanding. Maximize production, reduce costs and minimize risks.

 

The SandZapper is a solids-liquids hydrocyclone separator that typically removes 90% of particles 20 microns and larger from raw production fluid streams at the surface, preventing sanding of FWKO’s, heater treaters, tanks, and other facility processing equipment

 

SHORT & LONG TERM SAVINGS

 

Improve operational profitability!  Place the SandZapper after the wellhead or header(s) of known sand producing wells, or upstream of FWKO to capture entire field’s sand:

 

✓ Optimize operating efficiencies of surface equipment

✓ Decrease separator and tank cleanout expenses

✓ Reduce shutdown frequency to eliminate lost production revenues

✓ Extend the lifecycle of facility equipment, especially valves, chokes, and piping

✓ ASAP offers the best warranties in the business!

 

OTHER SANDZAPPER APPLICATIONS

 

ASAP can achieve efficient removal of solids as small as 10 microns and process flows up to 1,575gpm:

 

• Polish wastewater for injection wells

• Process Frac Flowback Water

• Capture solids at construction dewatering projects

• Wastewater pre-treatment in lieu of sand or other multimedia filtration units

 

SANDZAPPER DESIGN BENEFITS

 

• SandZapper helps operators improve their sand control efforts for a specific problematic well or for a complete oilfield  experiencing formation sand  problems

• Because the SandZapper has a very small footprint, it can be easily installed at existing facilities

• SandZapper can process from 500 to 132,000 bfpd

• Hydrocyclonesare built in ceramic and resist temperatures up to 800°F

• Minimal pressure drop required (15 psi) 

• Separation process never stops: even when solids are discharged to the accumulator tank, the hydrocyclones are still capturing solids without interference

• Option to install a solar/ electrical powered automated valve system that controls the discharge frequency of the solids

• Minimal moving parts or electronics

• Units can also be arranged in parallel to fulfill any volume requirements

 

DESIGN CRITERIA SANDZAPPER 5K2D

 

• Operating Temperature: 250° F

• Process Capacity: 750 to 5,250 bfpd

• Normal Operating Pressure: 50-200 psi

• Differential Pressure: > 15 psi

• Admission Connection: Flanged 3"- ANSI 150

• Discharge Connection: Flanged 3"- ANSI 150

• Weight: 900 kg/1,984 lb

 

 

THE SANDZAPPER HYDROCYCLONE CONSISTS OF 5 PARTS OR FEATURES

 

1. Cylinder Diameter

• The diameter of a hydrocyclone is defined as the inner diameter of the cylinder body. ASAP’s standard model has an internal diameter of 3". Hydrocyclone's diameter is the most important measurement for the proper selection of the size of the unit. The cylinder diameter is directly proportional to the capacity and inversely proportional to particle size separation.

 

2. Cone Angle

• It keeps the force of angular acceleration on the rotating fluids that departs from the inlet. The correct angles of the cone have been achieved through many years of study in the field.  The cone angle is inversely proportional to particle size separation.
   

3. Input Area (Inlet)

• The inlet converts the flow coming through the pipe into a vortex flow pattern with minimal radial turbulence. The input area is directly proportional to the flow capacity and inversely proportional to particle size separation.

 

4. Vortex (Vortex Finder)

• The Vortex is an annular cylinder surrounding the overflowing fluid. It is located at the center of the inlet chamber and allows annular flow for the incoming radial jet. The diameter of the vortex is proportional to the capacity and inversely proportional to particle size separation.

 

5. Apex (Hydrocyclone Lower Opening)

• The lower opening (apex) of the hydro cyclone is the section in which the solids exit the unit.The Apex is located at the bottom of the cyclone for units installed vertically, although the SandZapper can  also be installed in a variety of angles depending on the application.

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FUNCTION OF ACCUMULATOR

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• Positioning an Accumulator below the Rejection Chamber prevents lighter oil/emulsion from being inadvertently captured and removed from the raw fluid stream 

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• Solids forced downward into the Rejection Chamber will settle all the way down to the bottom of the Accumulator

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• When the cavity of the Accumulator is detected to be full of solids slurry, the system automatically initiates a Discharge Cycle, isolating the Accumulator from the Rejection Chamber (and process fluid), then opening the Accumulator Drain Valve and a vacuum break valve (or actuating pneumatics for discharge assistance).

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• The water mixed with captured solids slurry in the cavity of the Accumulator prevents build-up of dangerous gas or the possibility of flashing