Separator for fluid flow and method thereof

Abstract

The present disclosure is a separator for separating liquid from a fluid flow including a mixture of gas and liquid. The separator includes a first container, the first container including an outlet and an inlet for receiving the fluid flow, the first container is fluidly connected to a second container via a first valve, and the second container is fluidly connected to the liquid outlet via a second valve, wherein the first container is arranged to enable liquid to flow into the second container. The separator also has a second valve for controlling the release of liquid from the second container, the first valve and the second valve are pneumatically operated, and during operation of the separator, the pneumatic operation of the first valve and the second valve enables only one of the first valve and the second valve to be opened.

Description

Technical Field

[0001] The present invention generally relates to apparatus and methods for separating a liquid from a fluid stream, the fluid stream comprising a mixture of gas and liquid. Background Art

[0002] In many industrial processes, liquids need to be separated from gases. For example, such processes may include oil refineries, gas processing plants, petrochemical and chemical plants, refrigeration systems, air conditioning systems, compressor systems, gas pipelines, etc. In such processes, gravity is used in a container to allow the liquid to settle to the bottom of the container, and then the liquid is pumped out. This process only works if there is air space inside the chamber, and will fail if the mixing inlet is flooded with a mixture of liquid and gaseous materials, or the drain cannot handle the amount of liquid collected.

[0003] By way of non-limiting example only, one industrial process that requires separation of gases from other suspended media is degassing coal seams. Coal seams often contain gases, such as carbon dioxide and methane, that are formed within the coal seams or trapped by surrounding strata. These gases are often dangerous to miners within the mines, as carbon dioxide is toxic and methane is extremely flammable.

[0004] At various stages of the coal mining process, coal seams are typically degassed to remove and capture gas from the coal seams to ensure the safety of coal miners and continued mining operations. During the degassing process or degassing process, the captured gas is typically discharged along with a large amount of liquid present in or near the coal seams. The liquid may include groundwater, slurries of liquids and particles, and other such liquids.

[0005] Once collected, the mixture of gas and liquid needs to be separated into its component parts so that the hazardous gases can be transported to the surface for further processing and / or safe disposal, and the liquids can be disposed of or recycled. Current liquid and gas separators typically include a single container for receiving the mixture of liquid and gas, which includes a manually operated drain valve located at the bottom of the container and a gas outlet connected to a suction pipe. As a result, operators are required to manually empty the separator regularly.

[0006] However, current systems do not provide failsafe protection if operators do not regularly drain the liquid and gas separators. For example, if the valve is not open, the separator will fill with liquid until the liquid overflows the container and flows up the suction line, cutting off the extraction of the gas. If the operator leaves the valve open and unattended, all of the liquid drains from the container and the gas is allowed to leak into the surrounding area, creating an extremely dangerous environment for nearby workers. Similar risks are found in refineries, gas processing plants, petrochemical and chemical plants, refrigeration systems, air conditioning systems, compressor systems, gas pipelines, etc.

[0007] Current separator systems used in the above industrial processes may attempt to address this risk of human error by using electrical control signals and solenoids to control the operation of valves and, therefore, the discharge of liquids. However, in many industrial processes and operations, such as in coal mining, chemical and gas processing plants or pipelines, the use of these electrical signals and components is limited because of the extreme control and protection measures taken to prevent the risk of spark-induced fire or explosion, which would carry a high financial cost. In addition, the levels of methane and other highly flammable gases in some of these industrial processes are so high that the industrial plant or mine may prohibit any electrical systems from being close to the separator.

[0008] Furthermore, where gas emissions occur during the initial stages of mining or exploration, they often occur in mines located in remote areas without electricity supply.

[0009] Preferred embodiments of the present invention seek to address one or more of these disadvantages, and / or at least provide the public with a useful alternative.

[0010] Reference in this specification to any previously published text (or information derived from a previously published text) or to any known matter is not, and should not be taken as, an admission or acknowledgment or any form of implication that the previously published text (or information derived from a previously published text) or known matter forms the common general knowledge in the field of endeavor to which this specification relates. Summary of the invention

[0011] This summary is provided to introduce a selection of concepts in a simplified form that are further described in the detailed description below. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

[0012] In a first embodiment, a separator for separating liquid from a fluid flow including a mixture of gas and liquid is provided, the separator comprising: a first container, the first container comprising an outlet and an inlet for receiving the fluid flow, the first container being fluidically connected to a second container via a first valve, the second container being fluidically connected to the liquid outlet via a second valve, wherein the first container is arranged to enable liquid to flow into the second container; and a second valve for controlling the release of liquid from the second container, the first valve and the second valve being pneumatically operated, and during operation of the separator, pneumatic operation of the first valve and the second valve enables only one of the first valve and the second valve to be opened.

[0013] In an embodiment, the separator is arranged in a first state in which the first valve is opened and the second valve is closed.

[0014] In an embodiment, the separator is arranged in a second state in which the second valve is opened and the first valve is closed.

[0015] In an embodiment, the second container comprises a liquid sensor arranged to detect an upper threshold value of liquid and a lower threshold value of liquid in the second container.

[0016] In an embodiment, the liquid sensor is arranged to close the first valve when an upper threshold value of liquid is detected.

[0017] In an embodiment, the first valve comprises a first valve sensor, wherein the first valve sensor is arranged to detect when the first valve is fully closed and to send a signal to open the second valve.

[0018] In an embodiment, the liquid sensor is arranged to close the second valve when a lower threshold of liquid is detected.

[0019] In an embodiment, the second valve comprises a second valve sensor, wherein the second valve sensor is arranged to detect when the second valve is fully closed and to send a signal to open the first valve.

[0020] In an embodiment, the liquid sensor comprises a float sensor.

[0021] In an embodiment, the liquid sensor operates a switch, wherein the switch is arranged to control a pneumatic control valve.

[0022] In an embodiment, the pneumatic control valve is arranged in pneumatic connection with a first pneumatic cylinder arranged to articulate a first valve, and wherein the pneumatic control valve is further arranged in pneumatic connection with a second pneumatic cylinder arranged to articulate a second valve.

[0023] In an embodiment, when the upper threshold volume is detected, the pneumatic control valve controls the pneumatic pressure in a first direction to move the separator from the first state to the second state.

[0024] In an embodiment, when the lower threshold volume is detected, the pneumatic control valve controls the pneumatic pressure of the air in the second direction such that the separator moves from the second state to the first state.

[0025] In an embodiment, the first direction of the pneumatic pressure is opposite to the second direction of the pneumatic pressure.

[0026] In an embodiment, the separator further comprises a third valve arranged between the first container and the outlet.

[0027] In an embodiment, the first container comprises a pressure sensor connected to a third pneumatic cylinder, the third pneumatic cylinder being arranged to articulate the third valve such that the third pneumatic cylinder closes the third valve when the pressure sensor detects a pressure outside a desired pressure range.

[0028] In an embodiment, the third valve is a pneumatically operated valve selected from the group consisting of a knife gate valve, a ball valve, and a butterfly valve.

[0029] In an embodiment, the third valve comprises a biasing mechanism to bias the third valve closed in the event of a loss of pneumatic pressure.

[0030] In an embodiment, the first container comprises at least one nozzle arranged to receive the fluid flow from the inlet and direct the fluid flow into the first container.

[0031] In an embodiment, the fluid flow enters at least one nozzle, the at least one nozzle comprising a 90 degree bend.

[0032] In an embodiment, the fluid flow enters at least one nozzle, the at least one nozzle comprising a straight portion.

[0033] In an embodiment, the separator further comprises a fourth valve arranged between the first container and the inlet.

[0034] In an embodiment, the fourth valve is a pneumatically operated valve selected from the group consisting of a knife gate valve, a ball valve, and a butterfly valve.

[0035] In an embodiment, the fourth valve comprises a biasing mechanism to bias the fourth valve closed in the event of a loss of pneumatic pressure.

[0036] In an embodiment, the first container is arranged above the second container.

[0037] In an embodiment, the first container is arranged adjacent to the second container.

[0038] In an embodiment, the first container and the second container are elongated in shape.

[0039] In an embodiment, the first container is elongated in a generally vertical direction and the second container is elongated in a generally horizontal direction.

[0040] In an embodiment, the first container is elongated in a generally horizontal direction and the second container is elongated in a generally vertical direction.

[0041] In an embodiment, the first container is cylindrical at a first end, and the first container comprises a tapered second end, and the second end is fluidly connected to the second container via a first valve.

[0042] In an embodiment, the second container is cylindrical and the second valve is arranged to be located at the first end or the second end of the second container.

[0043] In an embodiment, each of the first valve and the second valve is a pneumatically operated valve selected from the group consisting of a knife gate valve, a ball valve, and a butterfly valve.

[0044] In an embodiment, the first valve comprises a first pneumatic cylinder arranged to articulate the first valve, the first pneumatic cylinder being arranged to bias the first valve in a closed position.

[0045] In an embodiment, the first valve and the second valve each include a biasing mechanism to bias the first valve and the second valve each closed in the event of a loss of pneumatic pressure.

[0046] In an embodiment, the second container comprises a base frame.

[0047] In an embodiment, the base frame comprises two or more engaging portions.

[0048] In an embodiment, the pneumatic control valve is connected to an air compressor that provides pneumatic pressure to the pneumatic control valve.

[0049] In a second aspect, a method for separating liquid from a fluid flow including a mixture of gas and liquid is provided, the method comprising: receiving the fluid flow into a first container, the first container being fluidly connected to a second container via a first valve, wherein the first valve is initially set in an open position and the second container includes a second valve initially set in a closed position; separating the fluid flow into gas in the first container and liquid in the second container, wherein the gas passes through an outlet set on the first container and the liquid is received by the second container; detecting a first predetermined threshold volume using a liquid sensor set on the second container; closing the first valve once the liquid in the second container reaches the first predetermined threshold volume; detecting that the first valve has been closed; opening the second valve; discharging liquid from the second container via a liquid outlet fluidly connected to the second valve; detecting a second predetermined threshold volume using a liquid sensor; closing the second valve once the liquid in the second container reaches the second predetermined threshold volume; detecting that the second valve has been closed; and opening the first valve so that the liquid is again received by the second container, wherein the first valve and the second valve are pneumatically operated, and the pneumatic operation of the first valve and the second valve enables only one of the first valve and the second valve to be opened. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] Example embodiments will become apparent from the following description of at least one non-limiting embodiment described in conjunction with the accompanying drawings, which description is given by way of example only.

[0051] Figure 1 A perspective view showing an embodiment of the present invention;

[0052] Figure 2 A front view of an embodiment of the present invention is shown;

[0053] Figure 3 shows a side cross-sectional view of an embodiment of the present invention through section AA;

[0054] Figure 4 A top view of an embodiment of the present invention is shown;

[0055] Figure 5 A pneumatic flow chart showing an embodiment of the present invention in a first state;

[0056] Figure 6 A pneumatic flow diagram showing an embodiment of the present invention in a second state;

[0057] Figure 7 A pneumatic flow diagram showing an alternative embodiment of the present invention;

[0058] Figure 8 shows a perspective view of a separator according to an embodiment of the present invention;

[0059] Fig. 9 Shows Figure 8 A front view of a separator;

[0060] Fig.10 Shows Figure 8 A side view of a separator;

[0061] Fig.11 Shows Figure 8 A top view of a separator;

[0062] Fig. 12A , Fig. 12B and Fig. 12C Shows Figure 8 Pneumatic flow diagram of the separator. DETAILED DESCRIPTION

[0063] In order to provide a more accurate understanding of one or more embodiments, the following aspects, which are given by way of example only, are described.In the drawings, like reference numerals are used to identify like parts throughout the drawings.

[0064] In addition, the following embodiments are described with respect to use in underground coal mines. However, as will be appreciated by those skilled in the art, the use of the present invention in coal mines is provided merely to demonstrate the working principle of the present invention, and therefore, the application of the embodiments described and defined herein is not limited to such use. For example, the provided embodiments may be applied in various processes, such as, but not limited to, oil refineries, natural gas processing plants, petrochemical and chemical plants, refrigeration systems, air conditioning systems, compressor systems, gas pipelines, and the like.

[0065] Generally speaking, refer to Figures 1 to 5, an embodiment of a separator suitable for separating a liquid from a fluid flow is provided, wherein the fluid flow includes a mixture of gas and liquid. The separator may include a first container 102, the first container 102 including an outlet 104, the outlet being in fluid communication with a pressure source. For example, the pressure source may be a negative pressure (suction), or the pressure source may be a positive pressure from a pressurized coal seam in an underground coal mine. The separator also includes an inlet 106 for receiving the fluid flow. The first container 102 may be arranged to be in fluid communication with a second container 108 via a first valve 110.

[0066] A fluid stream is directed to the inlet 106 from a supply source of the fluid stream to be separated. The fluid stream may be pumped into the inlet 106, or may be under another form of pressure, such as pressure from a natural coal seam pressure. The fluid stream may include a mixture of gas and liquid. In addition, the liquid in the fluid stream may also include particles. For example, the liquid may include a liquid slurry that suspends a mixture of particles that may include coal, rock, dust or other particles. For example, as part of a mining process, a fluid stream may be collected from a coal mining face that is being degassed. However, it should be understood by those skilled in the art that this is merely an example demonstrating the working principle of the present invention and is understood to be non-limiting. Therefore, the embodiments described and defined herein find many possible applications for separating fluid streams including gas and liquid.

[0067] The second container 108 may also be arranged to be in fluid communication with the liquid outlet 112 via the second valve 114, wherein the first container 102 is arranged to enable liquid to be discharged into the second container 108. For example, the first container 102 may be located above the second container 108, or the first container 102 may be located near the second container 108, wherein the connection between the first container and the second container enables liquid to be discharged into the second container 108. Such examples will be described in further detail later in this specification.

[0068] The valves of the separator are arranged to move between an open position and a closed position, which define different states of the separator 100. A first state is provided in which the first valve 110 is arranged to be open when the second valve 114 is closed. A second state is provided in which the second valve 114 is arranged to be open when the first valve 110 is closed. That is, the opening and closing of the first valve 110 and the second valve 114 are sequential operations. The sequential operation is used to minimize the risk that any gas will escape from the first container or the second container through the liquid outlet 112 once the second valve 114 is opened.

[0069] In an embodiment, the second container 108 includes a switch 116 connected to and operated by a liquid sensor. The liquid sensor is arranged to detect an upper threshold value of liquid and a lower threshold value of liquid in the second container 108. In other words, the liquid sensor is used to trigger between a first state and a second state of the separator 100. Therefore, the liquid sensor is arranged to close the first valve 110 when an upper threshold value of liquid is detected, and the liquid sensor is arranged to close the second valve 114 when a lower threshold value of liquid is detected. In an example, the liquid sensor may include a float sensor 118, wherein the float sensor may be arranged to be located within the second container 108, and the float sensor 118 operates the switch 116.

[0070] The separator 100 also includes a first valve sensor disposed on the first valve 110. The first valve sensor is arranged to determine the state of the first valve 110. That is, whether the first valve 110 is open or closed. The first valve sensor may include a roller lever valve, a magnetic position switch, a pneumatic read switch, or other similar type of sensor capable of detecting when the first valve 110 is fully closed. For example, the first valve sensor may be located within the first pneumatic cylinder 124.

[0071] The separator 100 also includes a second valve sensor arranged to determine the state of the second valve 114, wherein the second valve sensor provides state information of the second valve 114. That is, whether the second valve 114 is open or closed. The second valve sensor may include a roller lever valve, a magnetic position switch, a pneumatic read switch, or other similar type of sensor capable of detecting when the second valve 114 is fully closed. For example, the second valve sensor may be located within the second pneumatic cylinder 126.

[0072] The operation of the liquid sensor, the first valve sensor, and the second valve sensor all work together to ensure safe operation of the separator 100. That is, the liquid sensor is arranged to detect an upper threshold value of liquid that triggers the closing of the first valve 110. The first valve sensor detects when the first valve 110 is fully closed, and in doing so, triggers the opening of the second valve 114 to discharge fluid from the second container 108. In other words, the separator 100 is arranged so that the second valve 114 is opened only when the first valve 110 has been closed, so that the two valves are never opened at the same time. This arrangement ensures that when the separator is in the first state, no gas escapes through the second valve 114 via the second container 108 to the surrounding area.

[0073] In addition, the liquid sensor is arranged to detect a lower threshold of liquid, which triggers the closing of the second valve 114. The second valve sensor detects when the second valve 114 is completely closed, and in doing so, triggers the opening of the first valve 110 to again enable fluid to be discharged from the first container 102 to the second container 108. In other words, the separator 100 is arranged so that the first valve 110 is reopened only when the second valve 114 has been closed, so that the two valves are never opened at the same time. This arrangement ensures that when the separator is in the second state, no gas escapes through the second valve 114 via the second container 108 to the surrounding area.

[0074] An example of an upper threshold is provided where the liquid in the second container 108 fills approximately 70% of the total volume of the second container 108. Similarly, the lower threshold may be set to the liquid in the second container 108 filling approximately 30% of the total volume of the second container 108. As will be appreciated by those skilled in the art, the liquid sensor may be arranged to detect a variety of different upper and lower thresholds depending on usage requirements.

[0075] In another example, the upper threshold value may be set to the liquid in the second container 108 filling approximately 95% of the total volume of the second container 108. Similarly, the lower threshold value may be set to the liquid in the second container 108 filling approximately 5% of the total volume of the second container 108. As another example, the upper threshold value may be in the range of 85% to 100% of the total volume of the second container 108, and the lower threshold value may be in the range of 0% to 15% of the total volume of the second container 108. Such threshold values ​​may be used when providing a mixture of liquid and gas at a lower flow rate.

[0076] In an embodiment, the float sensor 118 may be disposed on the second container 108 at or near the liquid outlet 112 so that the lower threshold is arranged just above the top of the liquid outlet 112. This arrangement prevents any gas that may have been trapped within the second container 108 from escaping through the liquid outlet 112 during the second state.

[0077] The upper threshold value of liquid and the lower threshold value of liquid are terms indicating predetermined volume limits contained in the second container 108. The upper threshold value of liquid and the lower threshold value may vary depending on the flow rate of the mixture of liquid and gas entering the first container 102. For example, a relatively high lower threshold value may be provided to ensure a faster discharge cycle to prevent liquid from accumulating in the first container 102 during the discharge of the second container 108.

[0078] In an embodiment, the switch 116 controls a pneumatic control valve 120 (hereinafter referred to as a "control valve"). The control valve 120 may be arranged to be connected to an air compressor 122 that provides pneumatic pressure to the control valve 120. The control valve 120 may be a 2 / 5-way pneumatic valve or a similar valve having one inlet, two outlets, and two exhaust ports. In addition, the control valve may include a spring return member. For example, the control valve 120 may be a 2 / 5-way single air pilot spring return valve.

[0079] The control valve 120 is arranged to be pneumatically connected to a first pneumatic cylinder 124, which is arranged to articulate the first valve 110 using the pneumatic pressure provided by the compressor 122. In addition, the control valve 120 is also arranged to be pneumatically connected to a second pneumatic cylinder 126, which is arranged to articulate the second valve 114. The first pneumatic cylinder 124 and the second pneumatic cylinder 126 will be described in further detail in the latter part of this specification.

[0080] Embodiments are provided wherein the first container 102 includes at least one nozzle 128 arranged to receive the fluid flow from the inlet 106. The at least one nozzle 128 is further arranged to direct the fluid flow into the first container 102.

[0081] The at least one nozzle 128 may be arranged to direct the flow of the fluid stream to the first valve 110. Thus, the size and shape of the at least one nozzle 128 may vary depending on the characteristics of the fluid stream and the relative size, shape, and arrangement of the first container 102 and the second container 108. This arrangement is intended to increase the efficiency of separating the fluid stream into gas and liquid.

[0082] For example, at least one nozzle 128 can direct liquid into the separator in such a manner that the liquid can flow through the first valve 110 into the second container 108 while the gas moves upward through the outlet 104. For example, the movement of the gas through the outlet 104 can occur without an additional force, or can be assisted by applying pressure to the fluid flow entering the inlet 106 and / or by providing a suction pressure that is provided to the outlet 104.

[0083] In an embodiment, the relative arrangement of the first container 102 with respect to the second container 108 may also facilitate separation of gas from liquid in the first container 102. In one example, the first container 102 may be arranged above the second container 108. That is, the first container is directly connected to the top of the second container 108 via the first valve 110.

[0084] Alternatively, the first container 102 may be arranged adjacent to the second container 108, wherein a length of connection, such as a tube, hose, or pipe, may be arranged to connect the first container 102 and the second container 108. Such an arrangement may include a first end of the pipe connected to the bottom of the first container 102 and a second end of the pipe connected to the top of the second container. In both arrangements, the pressure caused by gravity affecting the mass of the liquid in the first container 102 enables the liquid to flow through the first valve 110, thereby being retained by the second container 108.

[0085] In an embodiment, the at least one nozzle 128 may be arranged such that the flow direction of the fluid flow entering the at least one nozzle 128 is perpendicular to the flow direction of the fluid flow leaving the at least one nozzle 128. Figure 3 , the at least one nozzle 128 may include a curved portion of a pipe that receives the flow of the fluid stream in a generally horizontal direction and outputs the flow of the fluid stream in a downward direction toward the first valve 110. That is, the at least one nozzle 128 may include a 90° bend. In an alternative embodiment, the at least one nozzle 128 may include a straight portion of a horizontal pipe (not shown) protruding into the first container 102.

[0086] As will be appreciated by those skilled in the art, the at least one nozzle 128 may include other features. For example, the at least one nozzle 128 may include or be fed by two or more smaller nozzles, wherein a mixture of liquid and gas is provided from multiple locations to be separated by the same separator 100. As a non-limiting example, the two or more nozzles may each be connected to different portions along a coal seam or to multiple connections to an industrial process. In addition, the at least one nozzle 128 may also include other features that improve the separation efficiency of the fluid stream. For example, the nozzle may include one or more baffles that are arranged to slow the velocity of the fluid stream entering the first container 102 and provide a larger surface area for the liquid to capture the liquid and discharge the liquid into the second container 108.

[0087] The shape, size, and relative arrangement of the first container 102 and the second container 108 can be provided so that the fluid collected by the first container 102 can be discharged into the second container 108. The first container 102 and the second container 108 can vary and can include a number of features to improve the separation of the fluid streams. In one example, the first container 102 and the second container 108 can be elongated in shape. In the specification, the term "elongated" refers to something that is long along one axis relative to another axis. In addition, when referring to Figure 3When, an embodiment can be provided in which the first container 102 can be elongated in a generally vertical direction and the second container 108 can be elongated in a generally horizontal direction. Alternatively, an embodiment can be provided in which the first container 102 can be elongated in a generally vertical direction and the second container 108 can be elongated in a generally vertical direction, or the first container 102 can be elongated in a generally horizontal direction and the second container 108 can be elongated in a generally horizontal direction. Therefore, it should be understood by those skilled in the art that the form, size and shape of the first container and the second container can vary, as long as the first container 102 is arranged to discharge the fluid into the second container 108.

[0088] In an embodiment, the first container 102 may be cylindrical at the first end 130 and may include a tapered portion 132 at the second end 134. Additionally, the second container 108 may be cylindrical at the first end 136 and the second end 138. The tapered portion 132 at the second end 134 of the first container 102 may be arranged to connect to the second container 108 at a position between the first end 136 and the second end 138 along the length of the second container 108. The first valve 110 may be arranged to be located at the second end 134 of the first container 102. The location of the first valve 110 enables the first container 102 to be isolated from the second container 108.

[0089] In addition, the container can include features that improve the separation efficiency of the fluid flow. For example, the first container 102 can include baffles disposed on the inner wall, wherein the one or more baffles are arranged to slow down the velocity of the fluid flow in the first container 102 and provide a larger surface area for the liquid to capture the liquid and drain the liquid into the second container 108.

[0090] In an embodiment, the second valve 114 is arranged to be located at the first end 136 or the second end 138 of the second container 108. The second valve 114 is arranged to discharge liquid collected in the second container 108. The first valve 110 and the second valve 114 are described in further detail below.

[0091] In an embodiment, the second container 108 may include a base frame 140. The base frame 140 may include an arrangement of cross struts that form a frame against which the base of the second container 108 rests. The base frame 140 is arranged so that the second container 108 can be arranged horizontally on a flat surface. For example, where the liquid sensor is a float sensor 118, the second container 108 needs to be flat so that the float sensor can correctly determine the upper threshold volume and the lower threshold volume.

[0092] In an embodiment, the base frame 140 may further include two or more engagement portions. The two or more engagement portions may be arranged to enable engagement with a mechanism that enables movement of the separator 100. For example, the two or more engagement portions may include a hollow support 142 arranged to receive the double forks of a forklift. Alternatively, the two or more engagement portions may include an arrangement of snaps disposed on the base frame 140, wherein the snaps may be connected to a chain and a lifting mechanism to enable the separator 100 to be properly moved and positioned.

[0093] As will be appreciated by those skilled in the art, various types of pneumatically operated valves are capable of performing the working principles of the present invention and are therefore considered to fall within the scope of the present invention as described and defined in the claims. For example, such valves may include knife gate valves, gate valves, butterfly valves or ball valves, or other known types of valves.

[0094] In an embodiment, the same valve type can be used for all valves included in the separator 100. For example, the first valve 110 and the second valve 114 can be pneumatically operated knife gate valves. Alternatively, different valve combinations can be used in different parts of the separator 100. For example, the first valve 110 can be a pneumatically operated butterfly valve, and the second valve 114 can be a pneumatically operated knife gate valve.

[0095] In an embodiment, the liquid in the fluid flow has a high viscosity and / or includes particles. For example, the liquid may include a liquid slurry that suspends a particle mixture that may include coal, rock, dust or other particles. In this case, a knife gate may be advantageous because the knife gate valve is arranged to cut through any accumulation of solid matter around the valve, thereby reducing the risk that the valve may become stuck open. Alternatively, if the liquid has a low viscosity or is located in a position where any solid matter is unlikely to accumulate around the valve, a butterfly valve may be used instead.

[0096] Reference Figures 5 to 7 , the first valve and the second valve, as well as the third valve and the fourth valve will be described in more detail later in this specification, the first valve and the second valve and the third valve and the fourth valve each include a pneumatic cylinder to articulate the valve between an open position, a closed position and a possible throttling position. Each of the pneumatic cylinders 124 and 126 can be double-acting and include a movable piston housed in a cylinder, wherein the piston includes a disc portion 144 connected to a connecting rod 146 so that movement of the piston articulates the valve. Each of the pneumatic cylinders 124 and 126 can also include a piston valve 152, which is arranged to control the flow of pneumatic pressure entering and leaving the pneumatic cylinder on either side of the disc portion 144. Alternatively, each of the pneumatic cylinders provided on the valve can be a single-acting cylinder having a pneumatic port arranged to open the valve and a spring provided on the cylinder arranged to close the valve.

[0097] Pneumatic pressure moves the piston between a fully extended position and a fully retracted position. In the fully extended position, the disc 144 is moved to a position adjacent to the connecting rod end 148 of the pneumatic cylinder. When the piston is fully extended, the pneumatic cylinder closes the valve. In the fully retracted position, the disc 144 is moved to a position adjacent to the cap end 150 of the pneumatic cylinder. When the piston is fully retracted, the pneumatic cylinder opens the valve. The movement of the piston is facilitated by the pneumatic pressure provided to the cylinder by the air compressor 122 and the control valve 120.

[0098] Each of the pneumatic cylinders may be arranged to include a safety feature to close or open the valve in the event of a cessation of pneumatic pressure. For example, the first pneumatic cylinder 124 and the second pneumatic cylinder 126 may include a biasing mechanism arranged to bias the first valve 110 and the second valve 114 closed in the event of a loss of pneumatic pressure. The biasing mechanism may include a spring 154 located between the disc 144 and the cap end 150 of each of the pneumatic cylinders 124 and 126, such that the spring 154 biases the piston to a fully extended position. Thus, if the pneumatic pressure ceases, the valve is biased to a closed position.

[0099] Reference Figure 5 When the piston moves between the fully extended position and the fully retracted position of the piston, air is exhausted from the portion of the pneumatic cylinder that does not receive pneumatic pressure. This causes the pneumatic pressure to be exhausted from the separator 100, which can be exhausted through the exhaust port 156.

[0100] In an embodiment, the separator 100 may further include an additional valve to assist in controlling the direction of the pneumatic pressure in the separator 100. That is, when the control valve 120 switches between various states, the direction of the pneumatic pressure provided to the pneumatic cylinder changes. The additional valve may be set in different positions, such as, but not limited to, position 158 and position 160.

[0101] In addition, the separator 100 may also include a pressure relief valve 162. The pressure relief valve 162 may be located in a variety of different locations. However, to demonstrate the working principle of the present invention, the pressure relief valve 162 is disposed on the first container 102, near the first end 130, and is disposed on the second container 108, near the first valve 110. The pressure relief valve 162 is configured to provide a pressure relief outlet if the pressure in either container exceeds a predetermined limit.

[0102] Reference Figures 1 to 4 as well as Figure 7, an embodiment is provided in which the separator 100 may further include a third valve 164. The third valve 164 may be disposed at various locations on the first container 102. For example, the third valve 164 may be disposed at the inlet 106 of the first container 102, or at a location near the first valve 110 where liquid leaves the first container 102 from the first valve. For example, wherein the third valve 164 is arranged to be located at the first end 130 of the first container 102.

[0103] The first container 102 may include a pressure sensor 166, wherein the pressure sensor 166 may be arranged to be connected to the third pneumatic cylinder 168 and the piston valve 152. The third pneumatic cylinder 168 and the piston valve 152 may be arranged to articulate the third valve 164 so that when the pressure sensor 166 detects the operating pressure, the third pneumatic cylinder 168 closes the third valve 164. In addition, the third valve 164 may also include a biasing mechanism to bias the closed third valve 164 in the event of a loss of pneumatic pressure as described above with respect to the first valve 110 and the second valve 114. That is, the biasing mechanism may include a spring 154 located between the cover end 150 and the disc 144 of the third pneumatic cylinder 168, so that the spring 154 biases the piston to a fully extended position. Therefore, if the pneumatic pressure stops, the third valve 164 is biased to a closed position. However, it should be understood by those skilled in the art that the operation of the third valve 164 is independent of the other valves.

[0104] For example, the pressure sensor 166 at one location may be arranged to detect a negative pressure or "suction" threshold, such as a negative pressure provided to the outlet 104 to assist in extracting gas from the separator 100. Alternatively, when the pressure sensor is located at another location, the pressure sensor 166 may be arranged to detect a positive pressure threshold, such as a pressure provided by a high pressure coal seam, which pushes the fluid flow into the separator 100, where such pressure may overcome any suction provided to the outlet. As is within the capabilities of those skilled in the art, the pressure sensor may be arranged to detect a wide range of operating pressures at a variety of different locations. For example, where the third valve 164 is disposed at the outlet 104, the pressure sensor 166 is arranged to maintain the third valve 164 in an open position until a moment when the negative pressure at the outlet is detected to be below the negative pressure threshold, at which moment the third valve 164 is closed. This arrangement still enables the separator 100 to separate and discharge liquids.

[0105] In addition, the pressure sensor 166 may be arranged to continuously detect the relevant operating pressure. Therefore, the pressure sensor 116 may be arranged to be connected to a pressure switch (not shown), which enables the pressure sensor 166 to open or close the third valve 164 according to the detected operating pressure. For example, when the pressure sensor 166 detects that the pressure at the outlet 104 exceeds the desired operating pressure range, the third valve 164 is closed. Once the pressure sensor 166 detects that the pressure at the outlet 104 is within the desired operating pressure range again, the third valve 164 is reopened.

[0106] In another embodiment, the separator 100 may further include a fourth valve 170 disposed between the at least one nozzle 128 and the inlet 106. The fourth valve 170 may be arranged to close the flow of the mixture of liquid and air entering the inlet 106. For example, the fourth valve 170 may be used to isolate the separator 100 from the rest of the system.

[0107] In an embodiment, the fourth valve 170 may be a manually operated valve that can be opened or closed by articulation of a handle or wheel (not shown) under the control of a user. Alternatively, the fourth valve 170 may be pneumatically operated by a fourth pneumatic cylinder 172 and a piston valve (not shown) in a manner similar to the first valve 110, the second valve 114, or the third valve 162 described above. In addition, the fourth valve 170 may also include a biasing mechanism to bias the closed fourth valve 170 in the event of a loss of pneumatic pressure as described above with respect to the first valve 110, the second valve 114, and the third valve 170. That is, the biasing mechanism may include a spring 154 located between the cover end 150 and the disc 144 of the fourth pneumatic cylinder 172, so that the spring 154 biases the piston to a fully extended position. Therefore, if the pneumatic pressure stops, the fourth valve 170 is biased to a closed position. However, it should be understood by those skilled in the art that the operation of the fourth valve 170 is independent of the other valves.

[0108] The fourth valve 170 may also be connected to another pressure sensor (not shown). The other pressure sensor may be provided in a similar manner to the pressure sensor 166, which is connected to the third valve 164. That is, the fourth pneumatic cylinder 172 and the piston valve may be arranged to articulate the fourth valve 170, so that when the other pressure sensor detects the operating pressure, the fourth pneumatic cylinder 172 closes the fourth valve 170.

[0109] For example, another pressure sensor may be arranged in connection with the fourth valve 170 to detect a positive pressure threshold, such as the pressure provided by a high pressure coal seam, which pushes the fluid flow into the separator 100, where such pressure may overcome any suction provided to the outlet. By providing another pressure sensor at or near the fourth valve 170, the separator 100 can be isolated from the system.

[0110] In addition, the further pressure sensor may be arranged to continuously detect the relevant operating pressure. Therefore, the further pressure sensor may be arranged to be connected to another pressure switch (not shown), which enables the further pressure sensor to open or close the fourth valve 170 according to the detected operating pressure. For example, when the further pressure sensor detects that the pressure at the inlet 106 exceeds the desired operating pressure range, the fourth valve 170 is closed. Once the further pressure sensor detects that the pressure is again within the desired pressure range, the fourth valve 170 is reopened.

[0111] As described above, the same or different valve types may be used for the valves included in the separator 100. For example, the third valve 164 may be a pneumatically operated knife gate valve or a pneumatically operated butterfly valve. In another example, the fourth valve 170 may also be a pneumatically operated knife gate valve, a ball valve, or a pneumatically operated butterfly valve.

[0112] Reference Figure 5 , the separator 100 can be initially set to a first state, wherein the first valve 110 is in an open position and the second valve 114 is in a closed position. In the first state, the fluid stream flows through the inlet 106 and flows into the first container 102. As this process occurs, the liquid and gas separate, wherein the liquid guided by gravity flows downward through the first container 102 and accumulates in the second container 108. At the same time, the gas guided by the negative air pressure from the outlet 104 is in fluid communication with the negative air pressure source.

[0113] In an embodiment, when the upper threshold volume is detected, the control valve 120 controls the pneumatic pressure in the first direction to hinge the first valve 110 to the closed position. That is, the first state is set so that the first container 102 and the second container 108 are in fluid communication with each other.

[0114] When the fluid flow is received by the first container 102, the liquid and gas separate, and the second container 108 is filled with liquid until the float sensor 118 detects the upper threshold volume. When the upper threshold volume is detected, the float sensor 118 switches the switch 116 to change the operation of the control valve 120, thereby closing the first valve 110. The closing of the first valve 110 triggers the second state. It can be appreciated that at the upper threshold volume, the liquid in the second container 108 contains almost no gas because the liquid in the second container 108 displaces any gas into the first container 102.

[0115] Only when the first valve 110 is moved to the fully closed position, the second valve 114 is moved to the open position by the first valve sensor. The closed position of the first valve 110 is detected by the first valve sensor disposed on the first valve 110. The first valve sensor is arranged to determine the state of the first valve 110. That is, whether the first valve 110 is open or closed. The first valve sensor may include a roller lever valve, a magnetic position switch, a pneumatic read switch, or other similar types of sensors capable of detecting when the first valve 110 is fully closed.

[0116] Reference Figure 6 , an embodiment is provided in which, when a lower threshold volume is detected, the control valve 120 controls the pneumatic pressure in the second direction to hinge the second valve 114 to the closed position. That is, in the second state, the first container 102 is isolated from the second container 108 by the closed first valve 110. The pneumatic pressure in the first direction in the first state is opposite to the pneumatic pressure in the second direction in the second state.

[0117] The first valve 110 moves to the open position only when the second valve 114 moves to the closed position. The closed position of the second valve 114 is detected by a second valve sensor, which is arranged to determine the state of the second valve 114. That is, whether the second valve 114 is open or closed. The second valve sensor may include a roller lever valve, a magnetic position switch, a pneumatic read switch, or other similar type of sensor capable of detecting when the second valve 114 is fully closed.

[0118] Therefore, in an embodiment, a method for separating a liquid from a fluid flow comprising a mixture of gas and liquid is provided, wherein the method may comprise the following steps.

[0119] The first step includes receiving a fluid flow into a first container 102 that is in fluid communication with a second container 108 via a first valve 110 that is initially set in an open position and the second container 108 includes a second valve 114 that is initially set in a closed position.

[0120] In addition, the method includes the step of separating the fluid flow into gas in the first container 102 and liquid in the second container 108, wherein the gas passes through the outlet 104 provided on the first container 102 and the liquid is received by the second container 108. In other words, when the fluid flow flows into the first container 102, the fluid flow separates into gas and liquid. The liquid under the influence of gravity flows into the second container 108, and the gas floats or is sucked upward toward the outlet 104. The separated gas passes through the outlet 104 provided on the first container 102. Meanwhile, the second container 108 continues to be filled with liquid.

[0121] The method further includes the step of detecting a first predetermined threshold volume using a liquid sensor disposed on the second container 108. For example, the threshold volume may be an upper volume threshold detected using the float sensor 118 as described above.

[0122] The method further comprises the step of closing the first valve 110 once the liquid in the second container 108 reaches a first predetermined threshold volume. The first valve sensor can be used to detect the closing of the first valve 110, wherein the first valve sensor can open the second valve 114 only after the first valve 110 has been completely closed.

[0123] Closure of the first valve 110 prevents the separated liquid from entering the second container 108. However, when fluid accumulates within the first container 102, the method enables the liquid to be discharged from the second container 108 via the liquid outlet 112 in fluid communication with the second valve 114.

[0124] The method then further comprises the step of detecting a second predetermined threshold volume using the liquid sensor. For example, the threshold volume may be a lower volume threshold detected using the float sensor 118 as described above.

[0125] The method further comprises the step of closing the second valve 114 once the liquid in the second container 108 reaches a second predetermined threshold volume. The second valve sensor may be used to detect the closing of the second valve 114, wherein the first valve sensor enables the first valve 110 to be reopened only after the second valve 114 has been completely closed. In doing so, the separated liquid is again received by the second container 108. In other words, the method may start over.

[0126] During operation of the method, the first valve 110 and the second valve 114 may be pneumatically operated, and the pneumatic operation of the first valve 110 and the second valve 114 enables only one of the first valve and the second valve to be opened. In this arrangement, the first valve 110 and the second valve 114 have an interlocking operation, wherein one valve must be closed before the other valve can be opened.

[0127] Reference Figures 8 to 11 ,as well as FIG. 12A to FIG. 12C , an alternative embodiment of a separator 200 suitable for separating a liquid from a fluid flow is provided, wherein the fluid flow includes a mixture of gas and liquid. FIG. 12A to FIG. 12CThe arrangement of the pneumatic system controlling the separator 200 is shown. The separator 200 has many similarities with the separator 100 and can be used when the separator 100 is used, however, the top container of the separator 200 is elongated in a generally horizontal direction compared to the vertical direction of the first container 102. The separator 200 may include a first container 202, which includes an outlet 204 that is fluidly connected to a pressure source. For example, the pressure source may be a negative pressure (suction), or the pressure source may be a positive pressure from a pressurized coal seam in an underground coal mine. The separator also includes an inlet 206 for receiving a fluid flow. The first container 202 may be arranged to be fluidically connected to the second container 208 via a first valve 210.

[0128] The fluid flow is directed from a supply source of the fluid to the inlet 206. The second container 208 may be arranged in fluid communication with the liquid outlet 212 via a second valve 214, wherein the first container 202 is arranged so that liquid can be discharged into the second container 208. The first container 202 is shown as being located above the second container 208, but may also be located adjacent to the first container 202.

[0129] As with separator 100, separator 200 has a plurality of valves. The first valve 210 and the second valve 214 may be interlocked to prevent both valves from being opened simultaneously. That is, the valve may be arranged in a first state in which the first valve 210 is opened when the second valve 214 is closed. The valve may be arranged in a second state in which the first valve 210 may be closed when the second valve 214 is opened. The valves are arranged to be opened in sequence so that one valve must be closed before another valve can be opened. As with separator 100, this arrangement ensures that during operation of separator 200, only one of the first valve 210 and the second valve 214 may be opened.

[0130] The second container 208 may include a switch 216 connected to and operated by a liquid level sensor, such as a float sensor 218, which detects an upper threshold of liquid and a lower threshold of liquid in the second container 208. When the lower threshold is detected, the switch 216 may close the second valve 214, and when the upper threshold is detected, the switch may open the second valve 214. As with the separator 100, the upper threshold may be set when the second container 208 is approximately 95% full, and the lower threshold may be set to approximately 5% full. Alternatively, the upper threshold may be within 85% and up to 100%, while the lower threshold may be in the range of 0% to 15%. The float sensor 218 may be located at or near the liquid outlet 212, wherein the lower threshold is set to the liquid level just above the top of the liquid outlet 212 to prevent gas from escaping the second container 208. As with the separator 100 , the upper threshold and the lower threshold may be dynamically changed based on the flow rate entering the first container 202 , or may also be changed based on the flow rate entering the second container 208 .

[0131] As mentioned above, FIG. 12A to FIG. 12C The pneumatic control circuit of separator 200 is shown. Although described with respect to separator 200, some or all aspects of the pneumatic control circuit may also be applied to separator 100. The circuit spans the Figures 12A to 12C , for example in Fig. 12A and Fig. 12C The connection between AA, or Fig. 12B and Fig. 12C The pneumatic circuit has an isolation valve 288, which can be used to lock the separator 200 out of operation during maintenance. After the isolation valve 288 is a filter / regulator 290, and then leads to a start / stop valve 292, which can be operated by a manual button to control the operation of the separator 200. The start / stop valve 292 is shown in an operating or start position. When in the stop position, the start / stop valve 292 connects the input end to the selector valve 294, which has three positions: a neutral position, a closed position, or a water position. When in the neutral position, the selector valve 294 will open the first valve 210. In the closed position, the first valve 210 and the second valve 214 will be closed, and in the water position, the selector valve 294 will open the second valve 214 so that water can be discharged from the second container 208. When the start / stop valve 292 is in the stop or maintenance position, the selector valve 294 can be used.

[0132] When the start / stop valve 292 is in the start position, the switch 216 will be operated by the float sensor 218 as described above. The switch 216 will operate the pneumatic control valve 220 to switch between enabling the first valve 210 to be opened or enabling the second valve 214 to be opened. When the switch 216 is activated by the float sensor 218, the pneumatic control valve 220 moves to a position where the first valve roller lever valve 274 is introduced into the circuit. If the first valve 210 is closed by the first pneumatic cylinder 224, the second interlock valve 286 moves to a position that enables the second OR valve 280 to operate the second pneumatic cylinder 226 to open the second valve 214 and release liquid from the second container 208. The first valve roller lever valve 274 ensures that the second interlock valve 286 cannot be operated before the first valve 210 is in the closed position. The pneumatic line between the second interlock valve 286 and the second OR valve 280 has a vacuum breaker valve 282, which is attached to control the air pressure in the line.

[0133] When the second valve 214 is opened by the second OR valve 280, air pressure is also provided to the vacuum breaker valve 282. The vacuum breaker valve 282 allows gas to enter the second container 208 while discharging liquid to assist the liquid to flow out of the second container 208. The vacuum breaker valve 282 operates on a pneumatic timer, which can be set to approximately the time required to empty the second container 208. For example, if there is a problem such as the second valve 214 being stuck open, the pneumatic timer closes the vacuum breaker valve 282 independently of the operating state of the second interlock valve 286.

[0134] When the switch 216 is inoperative, the pneumatic control valve 220 moves to a position that introduces the second valve roller lever valve 276 into the circuit. When the second valve 214 is closed by the second pneumatic cylinder 226, the first interlock valve 284 moves to a position that enables the first OR valve 278 to operate the first pneumatic cylinder 224 to open the second valve 214. The second valve roller lever valve 276 ensures that the first interlock valve 284 cannot be operated before the second valve 214 is in the closed position. When the selector valve 294 is in the closed position, the first OR valve 278 and the second OR valve 280 can respectively exhaust the first pneumatic cylinder 224 or the second pneumatic cylinder 226 to the selector valve 294.

[0135] In an embodiment, the first container 202 includes at least one nozzle (not shown) that receives the fluid into the first container 202 through the inlet 206. The at least one nozzle may be arranged to direct the fluid flow to the first valve 210, and the shape of the at least one nozzle may vary according to the characteristics of the fluid received by the separator 200. The nozzle may include a curved portion to direct the fluid to the second container 208, and may have a similar arrangement to the at least one nozzle 128 of the separator 100.

[0136] The first container 202 is shown as an elongated cylindrical shape having a first end 230 and a second end 234. The second container 208 is also shown as an elongated cylindrical shape having a first end 236 and a second end 238. The first container 202 and the second container 208 are both elongated in the horizontal direction. Although the two containers are shown as parallel, alternative arrangements are also possible. In one embodiment, the first container 202 and the second container 208 can be horizontal but angled to each other so that when viewed from above, the separator 200 can form an x-shape, wherein the angle between the first container 202 and the second container 208 varies. In one embodiment, the first container 202 and the second container 208 are at a 90 degree angle. Alternatively, the first container 202 and the second container 208 can be at a 45 degree angle. Alternatively, the first container 202 and the second container 208 can be T-shaped, wherein the first end 230 of the first container 202 is located above the first valve 210, or the second end 234 of the first container is located above the first valve 210. In another alternative embodiment, the first container 202 may have a slight slope from each end toward the first valve 210 to assist any liquid to flow to the second container 208. In this arrangement, the first container 202 may taper from one or each end. Other modifications to the container described above with respect to the separator 100 may also be employed, such as modifications to the baffles in the container.

[0137] The separator 200 may also employ a base frame 240 having an arrangement in which the second container 208 is located on cross struts. The base frame 240 may also include engaging portions, such as hollow struts 242 that enable a machine to move the separator 200. For example, the forks of a forklift may engage the hollow struts 242 to enable the separator 200 to be moved by the forklift.

[0138] The valves used in separator 200 may be of any type as described above with respect to separator 100. Although not described with respect to separator 200, the valves of separator 200 may operate in the manner described above with respect to the valves of separator 100.

[0139] Back to FIG. 12A to FIG. 12C The pneumatic circuit will now be specifically referred to Fig. 12A The operation of the third and fourth valves is described in detail below. The third and fourth valves are optional and are not included in the description. Figures 8 to 11200 of the separator 200. The third valve 264 can be mounted on the separator 200 to control the outlet 204 using the third pneumatic cylinder 268. The fourth valve 270 can also be mounted on the separator 200 to control the inlet 206 and is driven by the fourth pneumatic cylinder 272. The third valve 264 and the fourth valve 270 can be isolated from the pneumatic circuit using the gas isolation 248. When isolated, the third valve 264 and the fourth valve 270 will be closed due to the spring load. When not isolated, the operation of the third valve 264 can be controlled by the pressure switch 244 and the pressure switch 246. The pressure switch 246 and the pressure switch 244 operate together to close the third valve 264 and trigger an alarm 252 (e.g., an air whistle) with an audible warning sound. When the pressure is at an acceptable level, the alarm 252 does not sound, and the third valve 264 is opened by operating the valve 250. In one example, the pressure switch 244 and the pressure switch 246 can operate to detect a negative pressure or suction pressure provided to the outlet 204. When the pressure at the outlet 204 is outside the desired operating pressure range, the third valve 264 is closed by the pressure switch 246. When the pressure reaches a lower limit level, the pressure switch 244 can open the third valve 264. The pressure switch 244 and the pressure switch 246 can be combined to operate in a similar manner to the pressure sensor 166 described above.

[0140] As described above, the third valve 264 and the fourth valve 270 are optional. In one embodiment, there may be only one valve, such as the fourth valve 270, to isolate the separator 200 from the pressure source. In another embodiment, only the third valve 264 may be used. In another embodiment, for example, if there is a backflow of other pipelines in the pipe network, both the third valve 264 and the fourth valve 270 may be used. In such an embodiment, the pressure switch 244 and the pressure switch 246 may open and close the two valves at the same time. The pressure switch may be set to a predetermined value by the end user, for example, if the allowable pressure in the separator 200 is 50 kPa, the pressure switch 246 may be set to operate at 45 kPa to close the third valve 264 and the fourth valve 270. The pressure switch 244 may be set to operate at approximately 10 kPa, so when the pressure in the first container 202 reaches 10 kPa, the valve opens.

[0141] In some embodiments, the fourth valve 270 can be manually operated by the user using a hand wheel or an additional pneumatic circuit (not shown). The fourth valve 270 can also be operated using a pressure switch. In one embodiment, a pressure sensor in the separator 200 can be used to close the fourth valve 270. The fourth valve 270 can be operated in a manner similar to the fourth valve 170 described above. Typically, the fourth valve 270 is independent of the other valve operations. The third valve 264 and the fourth valve 270 are both spring-biased to the closed position so that both valves are closed in the event of a loss of pneumatic pressure. The first valve 210 and the second valve 214 can also be spring-loaded and closed when the pneumatic pressure is lost.

[0142] In the foregoing description of the preferred embodiments, specific terms have been resorted to for the sake of clarity. However, the present invention is not intended to be limited to the specific terms so selected, and it should be understood that each specific term includes all technical equivalents that operate in a similar manner to achieve similar technical purposes. Terms such as "front" and "rear", "upper" and "lower" are used as convenient words to provide reference points and are not to be interpreted as limiting terms.

[0143] Optional embodiments may also be said to broadly include the parts, elements, steps and / or features mentioned or indicated herein (alone or in any combination of two or more parts, elements, steps and / or features), and where specific integers having known equivalents in the art to which the invention relates are mentioned, such known equivalents are deemed to be included herein as if individually set forth.

[0144] Although the preferred embodiments have been described in detail, it should be understood that modifications, changes, substitutions, or alterations will be apparent to those skilled in the art without departing from the scope of the invention.

[0145] In this specification and the appended claims, unless the context requires otherwise, the word "comprise" and variations such as "comprised", "comprises" or "comprising", will be understood to imply the inclusion of a stated integer or step, or groups of integers or steps, but not the exclusion of any other integer or step, or groups of integers or steps.

[0146] As used herein, one, an, the, at least one, and one or more are used interchangeably and refer to one or more (i.e., at least one) of the grammatical object. For example, "an element" refers to one element, at least one element, or one or more elements.

[0147] In the context of this specification, the term "about" is understood to refer to a range of numbers that a person skilled in the art would consider equivalent to the stated value in terms of achieving the same function or result.

[0148] Advantages The embodiments described herein provide novel methods for automatically separating liquids and gases in environments where electrical systems are limited or not permitted. In addition, the separator is designed to improve the safety of current non-electrical separators through features such as automatic shut-off valves that automatically close in the event of a loss of pneumatic pressure or suction for gas extraction and various pressure relief valves to prevent pressure overloads. These safety features greatly reduce the danger to mine workers and enable automated operations, thereby reducing labor costs.

[0149] Additionally, because the separator is pneumatically operated, it can be used in new mine areas where electricity is not available, allowing miners working on exploration missions to begin the degassing process in a safe and effective manner very early in the coal seam life cycle. This provides a more thorough means of drainage before coal mining begins. Pneumatically operated separators can also be used in hazardous environments where there is a possibility that sparks from electrical equipment could ignite the gas.

[0150] As mentioned above, the first valve and the second valve have an interlocking operation, in which one valve must be closed before the other valve is opened. During operation, only one of the valves can be opened. This arrangement enables the removal of liquid from the second container without interference from the liquid entering the second container from the first container. In this arrangement, the second valve is opened and the first valve is closed. When liquid is discharged from the second container, the first valve prevents the liquid from flowing from the first container to the second container. The first container serves as a temporary storage for the liquid. Once the outlet of the second container is closed by the second valve, the first valve can be opened to enable the liquid to flow from the first container to the second container.

Claims

1. A separator for separating a liquid from a fluid stream comprising a mixture of gas and liquid, the separator comprising: a first container, the first container comprising an outlet and an inlet for receiving a fluid flow, the first container being in fluid communication with a second container via a first valve, the second container being in fluid communication with the liquid outlet via a second valve, wherein the first container is arranged to enable the liquid to flow into the second container; and a second valve for controlling the release of liquid from the second container, the first valve and the second valve being pneumatically operated, the pneumatic operation of the first valve and the second valve enabling only one of the first valve and the second valve to be opened during operation of the separator, wherein the second container comprises a liquid sensor, the liquid sensor being arranged to detect an upper threshold value of liquid and a lower threshold value of liquid in the second container, and wherein the liquid sensor is arranged to close the first valve when the upper threshold value of liquid is detected, wherein the first valve comprises a first valve sensor, wherein the first valve sensor is arranged to detect when the first valve is fully closed and to send a signal to open the second valve, wherein the lower limit threshold is set to 5% to 15% of the total volume of the second container filled with liquid in the second container, Wherein, the separator includes a pneumatic control circuit, the pneumatic control circuit has an interlock valve, an OR valve, a pneumatic timer and a vacuum breaking valve operated on the pneumatic timer, the pneumatic timer is set to the time required to empty the second container, wherein, when the second valve is opened by the OR valve due to the movement of the interlock valve, air pressure is provided to the vacuum breaking valve, the vacuum breaking valve allows gas to enter the second container and discharges liquid at the same time to assist the liquid to flow out of the second container, and when the second valve is stuck and opened, the pneumatic timer can close the vacuum breaking valve independently of the interlock valve.

2. The separator according to claim 1, wherein: The separator is arranged to be in a first state in which the first valve is open and the second valve is closed.

3. The separator according to claim 2, wherein: The separator is arranged to be in a second state in which the second valve is open and the first valve is closed.

4. The separator according to claim 1 or 2, wherein: The liquid sensor is arranged to close the second valve when the lower threshold of liquid is detected.

5. The separator according to claim 4, wherein: The second valve comprises a second valve sensor, wherein the second valve sensor is arranged to detect when the second valve is fully closed and send a signal to open the first valve.

6. The separator according to claim 1 or 2, wherein: The liquid sensor comprises a float sensor disposed at or near the liquid outlet so that the lower threshold is arranged just above the top of the liquid outlet.

7. The separator according to claim 3, wherein: The liquid sensor operates a switch, wherein the switch is arranged to control a pneumatic control valve.

8. The separator according to claim 7, wherein: The pneumatic control valve is arranged to be pneumatically connected to a first pneumatic cylinder, which is arranged to articulate the first valve, and wherein the pneumatic control valve is also arranged to be pneumatically connected to a second pneumatic cylinder, which is arranged to articulate the second valve.

9. The separator according to claim 8, wherein: The pneumatic control valve controls pneumatic pressure in a first direction to move the separator from the first state to the second state when an upper threshold volume is detected.

10. The separator according to claim 9, wherein: When a lower threshold volume is detected, the pneumatic control valve controls the pneumatic pressure of air in a second direction such that the separator moves from the second state to the first state.

11. The separator according to claim 10, wherein: The first direction of pneumatic pressure is opposite to the second direction of pneumatic pressure.

12. The separator according to claim 1 or 2, wherein: The separator further comprises a third valve arranged between the first container and the outlet.

13. The separator according to claim 12, wherein: The first container comprises a pressure sensor connected to a third pneumatic cylinder, the third pneumatic cylinder being arranged to articulate the third valve such that the third pneumatic cylinder closes the third valve when the pressure sensor detects a pressure outside a desired pressure range.

14. The separator according to claim 12, wherein: The third valve is a pneumatically operated valve selected from the group consisting of a knife gate valve, a ball valve and a butterfly valve.

15. The separator according to claim 14, wherein The third valve includes a biasing mechanism to bias the third valve closed in the event of a loss of pneumatic pressure.

16. The separator according to claim 1 or 2, wherein: The first container comprises at least one nozzle arranged to receive the fluid flow from the inlet and direct the fluid flow into the first container.

17. The separator according to claim 16, wherein The fluid stream enters the at least one nozzle, and the at least one nozzle includes a 90 degree bend.

18. The separator according to claim 16, wherein The fluid flow enters the at least one nozzle, and the at least one nozzle includes a straight portion.

19. The separator according to claim 1 or 2, wherein: The separator further comprises a fourth valve arranged between the first container and the inlet.

20. The separator according to claim 19, wherein The fourth valve is a pneumatically operated valve selected from the group consisting of a knife gate valve, a ball valve and a butterfly valve.

21. The separator according to claim 20, wherein The fourth valve includes a biasing mechanism to bias the fourth valve closed in the event of a loss of pneumatic pressure.

22. The separator according to claim 1 or 2, wherein: The first container is arranged above the second container.

23. The separator according to claim 1 or 2, wherein: The first container is arranged adjacent to the second container.

24. The separator according to claim 1 or 2, wherein: The first container and the second container are elongated in shape.

25. The separator according to claim 24, wherein The first container is elongated in a vertical direction, and the second container is elongated in a horizontal direction.

26. The separator according to claim 25, wherein The first container is elongated in the horizontal direction, and the second container is elongated in the vertical direction.

27. The separator according to claim 24, wherein The first container is cylindrical at a first end and includes a tapered second end, the second end being fluidly connected to the second container via the first valve.

28. The separator according to claim 27, wherein The second container is cylindrical, and the second valve is arranged to be located at the first end or the second end of the second container.

29. The separator according to claim 1 or 2, wherein: Each of the first valve and the second valve is a pneumatically operated valve selected from the group consisting of a knife gate valve, a ball valve, and a butterfly valve.

30. The separator according to claim 1 or 2, wherein: The first valve comprises a first pneumatic cylinder arranged to articulate the first valve, the first pneumatic cylinder being arranged to bias the first valve in a closed position.

31. The separator according to claim 30, wherein The first valve and the second valve each include a biasing mechanism to bias the first valve and the second valve each closed in the event of a loss of pneumatic pressure.

32. The separator according to claim 1 or 2, wherein: The second container includes a base frame.

33. The separator according to claim 32, wherein The base frame includes two or more engaging portions.

34. The separator according to claim 7, wherein: The pneumatic control valve is connected to an air compressor that provides pneumatic pressure to the pneumatic control valve.

35. A method for separating a liquid from a fluid stream comprising a mixture of gas and liquid, the method comprising the following sequential steps: receiving the fluid flow into a first container, the first container being in fluid communication with a second container via a first valve, wherein the first valve is initially set in an open position, and the second container includes a second valve initially set in a closed position; separating the fluid flow into the gas within the first container and the liquid within the second container, wherein the gas passes through an outlet disposed on the first container while the liquid is received by the second container; detecting a first predetermined threshold volume using a liquid sensor disposed on the second container; closing the first valve once the liquid in the second container reaches the first predetermined threshold volume; detecting that the first valve has been closed; opening the second valve; discharging the liquid from the second container via a liquid outlet in fluid communication with the second valve; detecting a second predetermined threshold volume using the liquid sensor; closing the second valve once the liquid in the second container reaches the second predetermined threshold volume; detecting that the second valve has been closed; and opening the first valve so that the liquid is received by the second container again, wherein the first valve and the second valve are pneumatically operated, and the pneumatic operation of the first valve and the second valve enables only one of the first valve and the second valve to be opened, The second predetermined threshold volume is set to 5% to 15% of the total volume of the second container filled with liquid in the second container, The method is implemented by a separator, which includes a pneumatic control circuit, the pneumatic control circuit having an interlock valve, an OR valve, a pneumatic timer and a vacuum breaking valve operating on the pneumatic timer, the pneumatic timer being set to the time required to empty the second container, wherein when the second valve is opened by the OR valve due to the movement of the interlock valve, air pressure is provided to the vacuum breaking valve, the vacuum breaking valve allows gas to enter the second container and discharges liquid at the same time to assist the liquid to flow out of the second container, and when the second valve is stuck and opened, the pneumatic timer can close the vacuum breaking valve independently of the interlock valve.

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