# US 12,006,810 B2 · Downhole separator > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,006,810 B2 - Document ID: US12006810B2 - Status: Granted - Kind: B2 - Application number: 18/087,791 - Filed: 2022-12-22 - Published: 2023-06-22 - Granted: 2024-06-11 - Earliest claimed: 2020-06-24 - Assignees: Oilify New-tech Solutions Inc. - Applicants: Oilify New-Tech Solutions Inc. - Inventors: Jeffrey Charles Saponja - Web page: https://patentgrep.com/patent/US12006810B2 ## CPC - E21B 43/38: in the well - E21B 43/121: {Lifting well fluids (monitoring of down-hole pump systems E21B47/008)} - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS ## Abstract There is provided a system for producing hydrocarbon material from a subterranean formation. The system includes a gas separator for separating gaseous material from reservoir fluid obtained from the subterranean formation. The system is configured to mitigate interference to the separation. ## Claims ### Claim 1 A system comprising a separator, emplaced within a wellbore string passage of a wellbore string that is lining a wellbore through which hydrocarbon material is producible from an oil reservoir within a subterranean formation, wherein: the separator and the wellbore string are co-operatively configured such that, in response to inducement by a pump: while reservoir fluid is disposed within a reservoir fluid-receiving zone, disposed within the wellbore string passage, the reservoir fluid is conducted upwardly, via an annular passage disposed between the separator and the wellbore string, from the reservoir fluid-receiving zone to a gas separation zone, disposed within the wellbore string passage, such that the reservoir fluid becomes emplaced within the gas separation zone, with effect that the reservoir fluid flow is separated into at least a downwardly-flowing gas-depleted reservoir fluid and an upwardly flowing gas-enriched reservoir fluid, wherein the separation includes separation in response to buoyancy forces within the gas separation zone; and while the separated gas-depleted reservoir fluid is flowing downwardly from the gas separation zone, the separator diverts the downwardly-flowing gas-depleted reservoir fluid such that the downwardly-flowing gas-depleted reservoir changes direction and an upwardly-flowing gas-depleted reservoir fluid, being conducted via an upwardly-conducting gas-depleted reservoir fluid conductor, is established, such that the separator includes the upwardly-conducting gas-depleted reservoir fluid conductor; wherein: the gas separation zone co-operates with the reservoir fluid, emplaced within the gas separation zone, such that the reservoir fluid, emplaced within the gas separation zone, occupies the gas separation zone, such that the gas separation zone is occupied by the reservoir fluid only; and the wellbore string passage defines a separation-promoting cross-section, traversed by both of the gas separation zone and the upwardly-conducting gas-depleted reservoir fluid conductor, and the area of the separation-promoting cross-section of the wellbore string passage, occupied by the gas separation zone, includes a circular area, and the circular area defines at least 70% of the total cross-sectional area of the separation-promoting cross-section of the wellbore string passage. ### Claim 2 (depends on 1) The system as claimed in claim 1; wherein: the separator and the wellbore string are further co-operatively configured such that the separation-promoting cross-section, of the wellbore string passage, is disposed within a vertical section of the wellbore. ### Claim 3 (depends on 1) The system as claimed in claim 1; wherein: the gas separation zone includes a cylindrical space, traversing the cross-section, and the cylindrical space has a diameter of at least one (1) inch and a height of at least 12 inches. ### Claim 4 (depends on 1) The system as claimed in claim 1; wherein: the reservoir fluid includes entrained solids. ### Claim 5 (depends on 1) The system as claimed in claim 1; wherein: the circular area of the separation-promoting cross-section of the wellbore string passage, occupied by the gas separation zone, defines at least 80% of the total cross-sectional area of the separation-promoting cross-section of the wellbore string passage. ### Claim 6 (depends on 1) The system as claimed in claim 1; wherein: the separator defines a flow receiving communicator, such that receiving of the downwardly-flowing gas-depleted reservoir fluid by the separator, for the diverting, is effected by the flow receiving communicator; and the ratio, of (i) the cross-sectional flow area of the separation-promoting cross-section of the wellbore string passage, to (ii) the cross-sectional flow area of the flow receiving communicator, is less than 1.1:1. ### Claim 7 (depends on 1) The system as claimed in claim 1; further comprising: a pressurized gas-depleted reservoir fluid conductor for conducting the gas-depleted reservoir fluid, that has been pressurized by the pump, to the surface; wherein: the pump fluidly coupled to the upwardly-conducting gas-depleted reservoir fluid conductor; and the pressurized gas-depleted reservoir fluid conductor and the wellbore string are co-operatively configured such that a gas-enriched reservoir fluid-conducting passage is defined within a space disposed between the pressurized gas-depleted reservoir fluid conductor and the wellbore string; and the gas-enriched reservoir fluid-conducting passage is disposed in fluid communication with the gas separation zone for conducting the upwardly flowing gas-enriched reservoir fluid from the gas separation zone. ### Claim 8 (depends on 1) The system as claimed in claim 1; wherein: the wellbore string is a casing string. ### Claim 9 A system comprising a separator, emplaced within a wellbore string passage of a wellbore string that is lining a wellbore through which hydrocarbon material is producible from an oil reservoir within a subterranean formation, wherein: the separator and the wellbore string are co-operatively configured such that, in response to inducement by a pump: while reservoir fluid, is disposed within a reservoir fluid-receiving zone, disposed within the wellbore string passage, the reservoir fluid is conducted upwardly, via an annular passage disposed between the separator and the wellbore string, from the reservoir fluid-receiving zone to a gas separation zone, disposed within the wellbore string passage, such that the reservoir fluid becomes emplaced within the gas separation zone, with effect that the reservoir fluid flow is separated into at least a downwardly-flowing gas-depleted reservoir fluid and an upwardly flowing gas-enriched reservoir fluid, wherein the separation includes separation in response to buoyancy forces within the gas separation zone; and while the separated gas-depleted reservoir fluid is flowing downwardly from the gas separation zone, the separator diverts the downwardly-flowing gas-depleted reservoir fluid such that the downwardly-flowing gas-depleted reservoir changes direction and an upwardly-flowing gas-depleted reservoir fluid, being conducted via an upwardly-conducting gas-depleted reservoir fluid conductor, is established, such that the separator includes the upwardly-conducting gas-depleted reservoir fluid conductor; wherein: the gas separation zone co-operates with the reservoir fluid, emplaced within the gas separation zone, such that the reservoir fluid, emplaced within the gas separation zone, occupies the gas separation zone, such that the gas separation zone is occupied by the reservoir fluid only; and the upwardly-conducting gas-depleting reservoir fluid conductor includes an eccentrically-disposed portion, disposed eccentrically relative to a central longitudinal axis of the wellbore string and the eccentrically-disposed portion is disposed laterally relative to an adjacent portion of the gas separation zone. ### Claim 10 (depends on 9) The system as claimed in claim 9; wherein: the reservoir fluid includes entrained solids. ### Claim 11 (depends on 9) The system as claimed in claim 9; wherein: the eccentrically-disposed portion is spaced-apart from the wellbore string by less than 0.75 inches. ### Claim 12 (depends on 9) The system as claimed in claim 9; wherein: the eccentrically-disposed portion is spaced-apart from the wellbore string by less than 0.5 inches. ### Claim 13 (depends on 9) The system as claimed in claim 9; wherein: the cross-sectioned profile of the eccentrically-disposed portion is non-circular. ### Claim 14 (depends on 9) The system as claimed in claim 9; wherein: the eccentrically-disposed portion has a total length of at least six (6) feet. ### Claim 15 (depends on 9) The system as claimed in claim 9; wherein: the separation zone is disposed within a vertical section of the wellbore. ### Claim 16 (depends on 9) The system as claimed in claim 9; wherein: the separator defines a flow receiving communicator, such that receiving of the downwardly-flowing gas-depleted reservoir fluid by the separator, for the diverting, is effected by the flow receiving communicator; and the ratio, of (i) the cross-sectional flow area of a traversed portion of the wellbore string passage that is traversed by the adjacent portion of the gas separation zone, to (ii) the cross-sectional flow area of the flow receiving communicator, is less than 1.1:1. ### Claim 17 (depends on 9) The system as claimed in claim 9; further comprising: the pump fluidly coupled to the upwardly-conducting gas-depleted reservoir fluid conductor, and; a pressurized gas-depleted reservoir fluid conductor for conducting the gas-depleted reservoir fluid, that has been pressurized by the pump, to the surface; wherein: the pressurized gas-depleted reservoir fluid conductor and the wellbore string are co-operatively configured such that a gas-enriched reservoir fluid-conducting passage is defined within a space disposed between the pressurized gas-depleted reservoir fluid conductor and the wellbore string; and the gas-enriched reservoir fluid-conducting passage is disposed in fluid communication with the gas separation zone for conducting the upwardly flowing gas-enriched reservoir fluid from the gas separation zone. ### Claim 18 (depends on 9) The system as claimed in claim 9; wherein: the wellbore string is a casing string. ### Claim 19 (depends on 9) The system as claimed in claim 9; wherein: the wellbore string passage defines a separation-promoting cross-section, traversed by both of the eccentrically-disposed portion, of the upwardly-conducting gas-depleted reservoir fluid conductor, and the adjacent portion of the gas separation zone. ### Claim 20 (depends on 19) The system as claimed in claim 19; wherein: the area of the separation-promoting cross-section of the wellbore string passage, occupied by the adjacent portion of the gas separation zone, includes a circular area traversed by the adjacent portion of the gas separation zone, and the circular area defines at least 70% of the total cross-sectional area of the separation-promoting cross-section of the wellbore string passage. ### Claim 21 A system comprising a separator, emplaced within a wellbore string passage of a wellbore string that is lining a wellbore through which hydrocarbon material is producible from an oil reservoir within a subterranean formation, wherein: the separator and the wellbore string are co-operatively configured such that, in response to inducement by a pump: while reservoir fluid is disposed within a reservoir fluid-receiving zone, disposed within the wellbore string passage, the reservoir fluid is conducted upwardly, via an annular passage disposed between the separator and the wellbore string, from the reservoir fluid-receiving zone to a gas separation zone, disposed within the wellbore string passage, such that the reservoir fluid becomes emplaced within the gas separation zone, with effect that the reservoir fluid flow is separated into at least a downwardly-flowing gas-depleted reservoir fluid and an upwardly flowing gas-enriched reservoir fluid, wherein the separation includes separation in response to buoyancy forces within the gas separation zone; and while the separated gas-depleted reservoir fluid is flowing downwardly from the gas separation zone, the separator diverts the downwardly-flowing gas-depleted reservoir fluid such that the downwardly-flowing gas-depleted reservoir changes direction and an upwardly-flowing gas-depleted reservoir fluid, being conducted via an upwardly-conducting the gas-depleted reservoir fluid conductor, is established, such that the separator includes the upwardly-conducting gas-depleted reservoir fluid conductor; wherein: the gas separation zone defines a downhole completion-free space that is unoccupied by a downhole completion; and the wellbore string passage defines a separation-promoting cross-section, within which is disposed the downhole completion-free space and which is traversed by the upwardly-conducting gas-depleted reservoir fluid conductor, and the area of the separation-promoting cross-section of the wellbore string passage, occupied by the downhole completion-free space, includes a circular area, and the circular area defines at least 70% of the total cross-sectional area of the cross-section of the wellbore string passage. ### Claim 22 (depends on 21) The system as claimed in claim 21; wherein: the circular area of the separation-promoting cross-section of the wellbore string passage, occupied by the gas separation zone, defines at least 80% of the total separation-promoting cross-sectional area of the cross-section of the wellbore string passage. ### Claim 23 (depends on 21) The system as claimed in claim 21; wherein: the downhole completion-free spaces includes a cylindrical space, and the cylindrical space has a diameter of at least one (1) inch and a height of at least 12 inches. ### Claim 24 (depends on 21) The system as claimed in claim 21; wherein: the separator and the wellbore string are further co-operatively configured such that the separation-promoting cross-section is disposed within a vertical section of the wellbore. ### Claim 25 (depends on 21) The system as claimed in claim 21; wherein: the separator defines a flow receiving communicator, such that the receiving of the separated gas-depleted reservoir fluid by the separator is effected by the flow receiving communicator; and the ratio, of (i) the cross-sectional flow area of separation-promoting cross-section of the wellbore string passage, to (ii) the cross-sectional flow area of the flow receiving communicator, is less than 1.1:1. ### Claim 26 A system comprising a separator, emplaced within a wellbore string passage of a wellbore string that is lining a wellbore through which hydrocarbon material is producible from an oil reservoir within a subterranean formation, wherein: the separator and the wellbore string are co-operatively configured such that, in response to inducement by a pump: while reservoir fluid is disposed within a reservoir fluid-receiving zone, disposed within the wellbore string passage, the reservoir fluid is conducted upwardly, via an annular passage disposed between the separator and the wellbore string, from the reservoir fluid-receiving zone to a gas separation zone, disposed within the wellbore string passage, such that the reservoir fluid becomes emplaced within the gas separation zone, with effect that the reservoir fluid flow is separated into at least a downwardly-flowing gas-depleted reservoir fluid and an upwardly flowing gas-enriched reservoir fluid, wherein the separation includes separation in response to buoyancy forces within the gas separation zone; and while the separated gas-depleted reservoir fluid is flowing downwardly from the gas separation zone, the separator diverts the downwardly-flowing gas-depleted reservoir fluid such that the downwardly-flowing gas-depleted reservoir changes direction and an upwardly-flowing gas-depleted reservoir fluid, being conducted via an upwardly-conducting gas-depleted reservoir fluid conductor, is established, such that the separator includes the upwardly-conducting gas-depleted reservoir fluid conductor; wherein: the gas separation zone defines a downhole completion-free space that is unoccupied by a downhole completion; and the upwardly-conducting gas-depleted reservoir fluid conductor includes an eccentrically-disposed portion, disposed eccentrically relative to a central longitudinal axis of the wellbore string, and the eccentrically-disposed portion is disposed laterally relative to an adjacent portion of the downhole completion-free space. ### Claim 27 (depends on 26) The system as claimed in claim 26; wherein: the eccentrically-disposed portion is spaced-apart from the wellbore string by less than 0.75 inches. ### Claim 28 (depends on 26) The system as claimed in claim 26; wherein: eccentrically disposed portion is spaced-apart from the wellbore string by less than 0.5 inches. ### Claim 29 (depends on 26) The system as claimed in claim 26; further comprising: the pump fluidly coupled to the upwardly-conducting gas-depleted fluid conductor; and a pressurized gas-depleted reservoir fluid conductor for conducting the gas-depleted reservoir fluid, that has been pressurized by the pump, to the surface; wherein: the pressurized gas-depleted reservoir fluid conductor and the wellbore string are co-operatively configured such that a gas-enriched reservoir fluid-conducting passage is defined within a space disposed between the pressurized gas-depleted reservoir fluid conductor and the wellbore string; and the gas-enriched reservoir fluid-conducting passage is disposed in fluid communication with the gas separation zone for conducting the upwardly flowing gas-enriched reservoir fluid from the gas separation zone. ### Claim 30 (depends on 26) The system as claimed in claim 26; wherein: the gas separation zone is disposed within a vertical section of the wellbore. ### Claim 31 (depends on 26) The system as claimed in claim 26; wherein: the separator defines a flow receiving communicator, such that the receiving of the downwardly-flowing gas-depleted reservoir fluid by the separator is effected by the flow receiving communicator; and the ratio, of (i) the cross-sectional flow area of a traversed portion of the wellbore string passage, that is traversed by the adjacent portion of the downhole completion-free zone, to (ii) the cross-sectional flow area of the flow receiving communicator, is less than 1.1:1. ### Claim 32 (depends on 26) The system as claimed in claim 26; wherein: the wellbore string passage defines a separation-promoting cross-section, traversed by both of the eccentrically-disposed portion, of the upwardly-conducting gas-depleted reservoir fluid conductor, and the adjacent portion of the downhole completion-free space. ### Claim 33 (depends on 32) The system as claimed in claim 32; wherein: the area of the separation-promoting cross-section of the wellbore string passage, occupied by the downhole completion-free space, includes a circular area, and the circular area defines at least 70% of the total cross-sectional area of the cross-section of the wellbore string passage.