Systems and methods for mixture separation

Abstract

A separator includes an inlet manifold, a throat, and an outlet manifold. The inlet manifold is configured to receive a flow of a gas mixture. The throat pipe is attached to the inlet manifold. The throat tube separates heavier substances of the gas mixture from lighter substances of the gas mixture. An outlet manifold is attached to the throat. The outlet manifold includes an outlet valve and a throttle shaft. The outlet valve includes a tapered inlet and a bowl-shaped outlet. The throttle shaft includes a shaft and a conical head. The conical head is located within the conical inlet and the shaft extends through the bowl-shaped outlet. The bowl-shaped outlet, the tapered inlet, and the tapered head are sized and shaped to control a flow of heavier material through the outlet valve and a flow of gas mixture through the separator.

Description

[0001] Citations of Related Applications

[0002] This patent application claims priority to U.S. Provisional Patent Application No. 63 / 335,212, filed on April 26, 2022, which is incorporated herein by reference in its entirety. Technical Field

[0003] The present invention relates generally to the field of separating components of gas mixtures, and more particularly to apparatus for providing separation of gas mixtures by forming a generally spiral flow. Background Art

[0004] In many cases, it is necessary to separate the components of a gas mixture. For example, natural gas wells often contain the popular natural gas (CH4) as well as contaminants such as carbon dioxide (CO2), nitrogen (N2), and hydrogen sulfide (H2S). It is estimated that there are trillions of cubic feet of natural gas in the United States that need to be processed to separate the contaminants from the natural gas. In another example, a water source (e.g., impoundments, abandoned mines, reservoirs, lakes, oceans, etc.) may contain various substances, such as salt, arsenic, iron, copper, lead, zinc, cadmium, other metals, and runoff from fertilizers and pesticides. These substances may make the water source unusable and may seep into groundwater and have a devastating effect on water quality over a wide geographic area.

[0005] There are many conventional devices that can separate the components of mixed gases. However, many conventional devices have various drawbacks, such as high cost, complex installation, high maintenance cost and frequency, and remote deployment locations. Summary of the invention

[0006] The described technology includes methods, systems, devices and apparatus for a separator for separating components of a gas mixture. In some embodiments, the separator includes an inlet manifold, a throat and an outlet manifold. The inlet manifold is configured to receive a flow of a gas mixture. The inlet manifold forms a spiral flow of the gas mixture. The throat is attached to the inlet manifold and configured to receive a flow of a gas mixture from the inlet manifold. The throat separates the heavier substances of the gas mixture from the lighter substances of the gas mixture. The outlet manifold is attached to the throat and configured to receive a flow of the heavier substances from the throat. The outlet manifold includes an outlet valve and a throttle shaft. The outlet valve includes a conical inlet and a bowl-shaped outlet. The throttle shaft includes a shaft and a conical head. The conical head is located in the conical inlet, and the shaft extends through the bowl-shaped outlet. The size and shape of the bowl-shaped outlet, the conical inlet and the conical head are suitable for controlling the flow of the heavier substances through the outlet valve and the flow of the gas mixture through the separator.

[0007] Lighter substances include, for example, helium, neon, and methane. Heavier substances include, for example, carbon dioxide, nitrous oxide, sulfur dioxide, propane, butane, pentane, and halogenated gases (e.g., chlorofluorocarbons, hydrofluorocarbons, perfluorocarbons, sulfur hexafluoride, and nitrogen trifluoride). Heavier and lighter substances are relative to other substances in the gas mixture. For example, water vapor may be a heavier substance when the gas mixture is natural gas, but, for example, water vapor may be a lighter substance when the gas mixture is air or flue gas. One of ordinary skill will immediately recognize which species in a gas mixture will separate as heavier or lighter from other species based on molecular weight.

[0008] In some embodiments, a method for separating components of a gas mixture using a separator is provided. The method includes directing the gas mixture to an inlet manifold of the separator. The method also includes forming a spiral flow of the gas mixture in the inlet manifold. The method also includes directing the gas mixture from the inlet manifold to the throat of the separator. The method also includes separating the heavier substances of the gas mixture from the lighter substances of the gas mixture in the throat. The method also includes directing the flow of the heavier substances from the throat to the outlet manifold of the separator. The outlet manifold includes an outlet valve and a throttle shaft, the outlet valve includes a conical inlet and a bowl-shaped outlet, and the throttle shaft includes a shaft and a conical head. The conical head is located in the conical inlet, and the shaft extends through the bowl-shaped outlet. The method also includes using the bowl-shaped outlet, the conical inlet and the conical head to control the flow of the heavier substances through the outlet valve and the flow of the gas mixture through the separator. The size and shape of the bowl-shaped outlet, the conical inlet and the conical head are suitable for controlling the flow of the heavier substances through the outlet valve and the flow of the gas mixture through the separator.

[0009] In some embodiments, the gas mixture is directed to the inlet manifold at a pressure of at least 5 psi (34 kPa). In some specific embodiments, the gas mixture is directed to the inlet manifold at a pressure of at least 50 psi (345 kPa). In some very specific embodiments, the gas mixture is directed to the inlet manifold at a pressure of at least 100 psi (689 kPa) and at most 1400 psi (9653 kPa). Pressure does not limit the separation capacity of the separators described herein; however, commercially viable separators operate at high pressures.

[0010] In some embodiments, the gas mixture is directed to the inlet manifold at a flow rate of at least 2 kg / s. In some specific embodiments, the gas mixture is directed to the inlet manifold at a flow rate of at least 5 kg / s. In some very specific embodiments, the gas mixture is directed to the inlet manifold at a flow rate of at least 5 kg / s and at most 200 kg / s. Flow rate will not limit the separation capacity of the separator described herein; however, commercially viable separators operate at high flow rates.

[0011] This Summary is intended to introduce some concepts in a simplified form that are further described in the Detailed Description below. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will be apparent from the following more specific written Detailed Description, which is directed to various embodiments, as further illustrated in the accompanying drawings and defined in the appended claims.

[0012] These and various other features and advantages will become apparent from a reading of the following detailed description. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] Figure 1 is a perspective view of an embodiment of a separator according to the present invention.

[0014] Figure 2 According to the present invention Figure 1 A side view of the separator is shown.

[0015] Figure 3 According to the present invention Figure 1 An end view of the separator is shown.

[0016] Figure 4 According to the present invention Figure 1 An end view of the separator is shown.

[0017] Figure 5 According to the present invention Figure 1 A perspective view of a portion of the inlet manifold of a separator is shown.

[0018] Figure 6 According to the present invention Figure 1 An end view of the inlet plate of the separator is shown.

[0019] Figure 7 According to the present invention Figure 1 A perspective view of the tapered inlet of the separator is shown.

[0020] Figure 8 According to the present invention Figure 1 A perspective view of the bowl-shaped outlet of the separator is shown.

[0021] Fig. 9 According to the present invention Figure 1 A perspective view of the throttle shaft of the separator is shown.

[0022] Fig.10 According to the present invention Figure 1 A schematic side cross-sectional view of a portion of an inlet manifold of a separator is shown.

[0023] Fig.11 According to the present invention Figure 1 A schematic side cross-sectional view of a portion of an outlet manifold of a separator is shown.

[0024] Fig.12 According to the present invention Figure 1 A schematic elevation view of a portion of an outlet manifold of a separator is shown.

[0025] Fig.13 According to the present invention Figure 1 A schematic front view and a schematic side cross-sectional view of a portion of a restrictor of a separator are shown.

[0026] Fig.14 is to use the Figure 1 A flow chart of a method of separating components of a gas mixture by a separator is shown.

[0027] Fig.15 is a perspective view of an alternative embodiment of a separator according to the present invention.

[0028] Fig.16 According to the present invention Fig.15 A side view of the separator is shown.

[0029] Fig.17 is to use the Figure 1 A flow chart of a method of separating components of a gas mixture by a separator is shown. DETAILED DESCRIPTION

[0030] The disclosed technology relates to a separator that can be used to partially or completely separate the components of a gas mixture. Specifically, the disclosed separator combines a high-speed swirling flow, thereby generating a tornado-like centrifugal force field, and a reverse flow field in the swirling flow, so that the heavier materials can be separated as a whole from the lightest materials.

[0031] In one application, the disclosed separators can be used to extract greenhouse gases from a gas stream. Figure 11 is a perspective view of an embodiment of separator 100. Separator 100 separates a mixture of liquids, solids, gases or any combination thereof (not shown). In applications for treating gas streams including greenhouse gases, separator 100 is connected to the outlet of a power plant or other greenhouse gas emission facility. The gas stream is conveyed to separator 100, where a tornado-like or spiral flow is formed due to the characteristics of separator 100. The tornado-like flow causes one or more components of the gas stream to be partially or completely separated. Greenhouse gases are discharged from the exhaust pipe of separator 100, and the remaining gases are directed to the atmosphere, processing facilities, storage tanks, other destinations or one or more additional separators for further processing. Advantageously, separator 100 is made primarily of non-moving parts, so it can be easily and efficiently used in almost any facility, and requires little maintenance or adjustment.

[0032] In some embodiments, the gas stream comprises or consists of air. The separator can be used, for example, to separate greenhouse gases from air. Greenhouse gases include, for example, carbon dioxide (heavier substances relative to other substances in the air) and methane (lighter substances relative to other substances in the air).

[0033] Figure 2 is a side view of the separator 100 . Figure 3 is an end view of separator 100 . Figure 4 is an end view of separator 100 . Figure 5 is a perspective view of a portion of the inlet manifold 102 . Figure 6 is an end view of the inlet plate 112 . Figure 7 is a perspective view of the tapered inlet 122 . Figure 8 is a perspective view of the bowl-shaped outlet 124 . Fig. 9 is a perspective view of the throttle shaft 120 . Fig.10 is a schematic side cross-sectional view of a portion of the inlet manifold 102 . Fig.11 is a schematic side cross-sectional view of a portion of the outlet manifold 106 .

[0034] Fig.12 is a schematic elevation view of a portion of the outlet manifold 106 . Fig.13 are a schematic front view and a schematic side cross-sectional view of a portion of the throttle shaft 120 .

[0035] Separator 100 produces the convergent spiral flow of gas mixture to separate the divergent exhaust flow of some components and the reverse exhaust flow of other components. Generally speaking, the combination of the spiral reverse exit flow of the convergent spiral flow of mixture and one or more separated components of mixture can be considered as tornado-shaped flow together. Separator 100 includes inlet manifold 102, which increases the angular velocity of mixture, at least partially separates gas mixture. Separator 100 also includes throat 104, which receives the mixture from inlet manifold 102 and further separates gas mixture. Gas mixture is separated into the flow of heavier material and the flow of lighter material. Separator 100 can be made of any material suitable for bearing the corrosion or other damaging effects of the force in the separator and the separated mixture. Such material includes stainless steel, alloy, polymer or other composite resin type materials.

[0036] The heavier material flows into the outlet manifold 106, and the flow of lighter material is separated from the flow of heavier material in the throat 104 and flows back through the throat 104 as a counter-flow. The outlet manifold 106 also includes an outlet valve or restrictor 108 for controlling the flow from the outlet manifold 106. The separator can be used to separate greenhouse gases from the gas stream emitted by a power plant or other greenhouse gas emitting facility.

[0037] In the illustrated embodiment, the gas mixture is directed to the inlet manifold 102 of the separator 100, and the size and shape of the inlet manifold 102 are suitable for forming the mixture into a high-speed swirl or spiral flow. Specifically, the inlet manifold 102 includes two spiral inlet pipes 110, which form the mixture into a high-speed swirl or spiral flow. The inlet manifold 102 also includes an inlet plate 112, which includes a spiral inlet channel 114, which also forms the gas mixture into a high-speed swirl or spiral flow. In operation, a mixture of liquid, solid, gas, or any combination thereof is introduced into the inlet manifold 102 at high speed. The gas mixture spirals through the inlet manifold 102. As the gas mixture rotates through the inlet manifold 102, its angular velocity partially increases as the convergence angle of the inlet manifold 102 changes. Once the outlet of the inlet manifold 102 is reached, partial or complete separation of the mixture will occur. In general, the angular velocity of the gas mixture passing through the converging inlet manifold 102 causes the gas mixture to separate such that higher mass components of the gas mixture are located toward the outermost portion of the flow, while lower mass components of the gas mixture are located toward the inner portion of the flow. In some cases, the spiral flow will include a roughly defined layered structure, wherein the mass components decrease radially inward from the highest mass outer layer. In a configuration suitable for separating the mixture according to molecular weight, during the separation process, the highest mass molecular species will migrate toward the outer portion of the flow, thereby causing the separation such that the lower molecular weight species will be confined to the inner portion of the higher molecular weight species.

[0038] The gas mixture is fed into the two inlet pipes 110, where a high-speed cyclic flow begins, and is delivered to the inlet manifold 102 to form an accelerated converging spiral flow. In any embodiment of the separator 100, the mixture should be fed into the two inlet pipes 110 at a certain speed so that the speed of the spiral flow through the separator 100 does not meet or exceed the speed of sound. In one example, the gas mixture is fed into the two inlet pipes 110 so that the gas mixture has an angular velocity of about 0.5 Mach in the inlet manifold 102 adjacent to the throat 104. In some embodiments, the two inlet pipes 110 can be arranged at a certain angle or tangentially to multiple portions of the inlet manifold 102 to help promote high-speed cyclic flow in the inlet manifold 102.

[0039] The inlet manifold 102 may be directly connected to the outlet manifold 106. In one embodiment of the present invention, the throat 104 defines a generally cylindrical chamber between the inlet manifold 102 and the outlet manifold 106. Thus, the gas mixture spins out of the inlet manifold 102 and enters the throat 104. Within the throat 104, further separation of the mixture occurs as the mixture spins through the throat 104 toward the outlet manifold 106. Moreover, within the throat 104, the spiral counterflow is primarily formed by lighter components. Counterflow is typically within an exhaust stream of heavier components of larger diameter. Along the counterflow, further separation occurs, causing some of the heavier components to separate, change direction, and merge into the outlet manifold 106.

[0040] The inlet manifold 102 guides the gas mixture into the throat 104, where a high-speed swirl or spiral flow is fully developed. The high-speed swirl separates one or more components of the mixture partially or completely from other components in the mixture. The high-speed swirl in the throat 104 generates a high-speed swirl centrifugal force field and a reverse flow field in the swirl, so that at least some heavier materials are separated from lighter materials. The heavier materials are guided to the outlet manifold 106, and the lighter materials are guided to the outlet pipe 116 of the inlet manifold 102. Specifically, the high-speed swirl generates a reverse flow field, the direction of which is opposite to the flow direction of the tornado-shaped or spiral flow. The reverse flow field guides the lighter materials out of the separator 100 through the outlet pipe 116.

[0041] Specifically, in the illustrated embodiment, the inlet manifold 102 further includes a tapered chamber 134. The tapered chamber 134 includes a continuous inner tapered sidewall 136 that is arranged to cooperate with the inlet channel 114 of the inlet plate 112. In one embodiment, the inner tapered sidewall 136 of the tapered chamber 134 abuts against the inlet channel 114 of the inlet plate 112 and is aligned with the inlet channel 114 of the inlet plate 112. The inner tapered sidewall 136 adjacent to the inlet channel 114 has approximately the same diameter as the inlet channel 114 to provide a smooth transition of the mixture as the mixture flows through the joint between the inlet channel 114 and the inner tapered sidewall 136. In addition, the inner tapered sidewall 136 of the tapered chamber 134 abuts against the throat 104 and is aligned with the throat 104. The inner tapered sidewall 136 adjacent the throat 104 has approximately the same diameter as the throat 104 to provide a smooth transition of the mixture as it flows through the joint between the throat 104 and the inner tapered sidewall 136. The smooth transition helps avoid disturbances in the flow that could interfere with separation of the mixture.

[0042] like Fig.10 and Fig.12 As shown, the tapered chamber 134 includes a first diameter 138 and a second diameter 140. The first diameter 138 is the outer diameter of the tapered chamber 134 and the inner diameter of the inlet passage 114. The second diameter 140 is the inner diameter of the tapered chamber 134 and the inner diameter of the throat 104. In the illustrated embodiment, the first diameter 138 is approximately 4 inches and the second diameter 140 is approximately 1 inch. In addition, the inner tapered sidewall 136 defines a first angle 142 that continuously changes along the length 144 of the tapered chamber 134. The maximum first angle 142 is approximately 60° at the first diameter 138, and the angle decreases to approximately 0° at the second diameter 140. The length 144 is approximately 2 inches.

[0043] The tapered chamber 134 reduces interference with the divergent spiral flow of the gas mixture. In some embodiments, the flow of the gas mixture from the inlet channel 114 to the tapered chamber 134 may be disturbed by the rapid volume difference between the inlet channel 114 and the tapered chamber 134, which may cause pressure fluctuations. Such pressure disturbances may result in a lower efficiency of component separation of the gas mixture within the inlet manifold 102. The orientation of the inlet channel 114 relative to the tapered chamber 134 can reduce pressure fluctuations. Specifically, the inlet channel 114 has a spiral shape that forms a spiral flow entering the tapered chamber 134.

[0044] As the mixture rotates through the conical chamber 134, heavier substances generally separate toward the inner conical sidewall 136, while lighter substances generally separate toward the center. In the case where the mixture contains two substances, the heavier substance will migrate toward the inner conical sidewall 136, while the lighter substance will migrate toward the center. In the case where the gas mixture contains more than two components or substances, as the gas mixture flows around and through the conical chamber 134, at least some of the components will form stratified bands, wherein the heaviest substance or component having an outer band adjacent to the inner conical sidewall 136 is located in an outer band near the inner conical sidewall 136, the lighter components form bands from the outer bands inward, and the lightest components form bands adjacent to the center. The amount of separation between the substances will depend in part on the input velocity of the gas mixture entering the conical chamber 134, the mass difference between the substances or components, the specific gravity difference between the components, the atomic number difference between the components, the presence and strength of any chemical bonds, and the convergence angle of the conical chamber 134. Therefore, different degrees of separation will be achieved within the conical chamber 134.

[0045] As the gas mixture converges toward the throat 104, the gas mixture separates into component parts or substances along the length 144 of the tapered chamber 134. The throat 104 includes an outer sidewall 146 that defines a cylindrical passage 148. The outer wall 146 of the throat section 104 has a diameter that is approximately the same as the second diameter 140 of the tapered chamber 134. Although shown herein as having a constant radius along its length, the throat may converge or diverge slightly toward the outlet manifold 106.

[0046] The gas mixture flows from the outlet of the tapered chamber 134 into the throat 104. Within the throat 104, the gas mixture transitions from a generally converging spiral flow to a fairly uniform spiral flow moving toward the outlet manifold 106 and continues to separate into its component parts. The throat 104 can be any length, and one range in a particular implementation is from one inch to twelve inches. In a particular implementation, the length and diameter of the throat 104 can vary depending on the number and size of the components of the gas mixture, the pressure or velocity at which the gas mixture is forced into the chamber, the angle and length of the tapered input passage, the amount of separation desired, and other factors.

[0047] In some embodiments, the gas mixture is forced into the gas chamber at a pressure of at least 5 psi (34 kPa). In some specific embodiments, the gas mixture is forced into the gas chamber at a pressure of at least 50 psi (345 kPa). In some very specific embodiments, the gas mixture is forced into the gas chamber at a pressure of at least 100 psi (689 kPa) and at most 1400 psi (9653 kPa).

[0048] In some embodiments, the gas mixture is forced into the gas chamber at a flow rate of at least 2 kg / s. In some specific embodiments, the gas mixture is forced into the gas chamber at a flow rate of at least 5 kg / s. In some very specific embodiments, the gas mixture is forced into the gas chamber at a flow rate of at least 5 kg / s and at most 200 kg / s.

[0049] In an alternative separator (not shown), an exhaust port can be defined in the outer sidewall 146 of the throat 104 to remove heavier components. In addition, a variable length throat 104 can be used. In one example, a variable length throat (not shown) has a first cylindrical sleeve connected to the inlet manifold 102 and a second cylindrical sleeve connected to the outlet manifold 106. The diameter of the sleeve is slightly different, so that one sleeve can slide in another sleeve. Therefore, the total length of the throat can be adjusted by moving a sleeve relative to another sleeve. For example, if each sleeve is three inches, then by fully inserting a sleeve into another sleeve, the total length of the throat will be about three inches. By completely separating the sleeves but leaving a certain part of a sleeve in another sleeve, a throat length of about 6 inches can be achieved. In addition, the throat can be adjusted to any length between three inches and six inches. In such an embodiment, it should be noted that the boundary edge formed between the two sleeve parts of the throat should be minimized to avoid causing excessive turbulence.

[0050] An outlet pipe 116 (preferably a cylindrical pipe) is disposed within the inlet manifold 102. In addition, the outlet pipe 116 is preferably disposed along the axis of the throat 104, and the outlet pipe 116 is in fluid communication with the throat 104. When interacting with the throttle 108, the lower molecular weight component partially forms a generally countercurrent flow so that the gas mixture rotates and flows generally between the inlet manifold 102 and through the throat 104 toward the throttle 108. In the case where the separator 100 is used to process greenhouse gases from a gas stream discharged from a power plant, heavier components (e.g., greenhouse gases (carbon dioxide)) are directed through the outlet manifold 106, while lighter components (e.g., water vapor) flow through the outlet pipe 116. The diameter of the outlet pipe 116 may vary depending on the specific implementation. In one example, the diameter of the outlet pipe 116 is slightly smaller than the diameter of the throat 104.

[0051] The outlet manifold 106 directs the heavier material out of the separator 100 and controls the flow of the mixture into and out of the separator 100. Specifically, the outlet valve or throttle 108 of the outlet manifold 106 includes an outlet valve slot 118 and a throttle shaft 120 partially located in the outlet valve slot 118. The throat 104 directs the heavier material to the outlet valve slot 118, and the size and shape of the outlet valve slot 118 and the throttle shaft 120 are suitable for controlling the flow of the heavier material through the outlet valve or throttle 108. Specifically, the outlet valve slot 118 includes a tapered inlet 122 and a bowl-shaped outlet 124. The throttle shaft 120 has a tapered head 126 that conforms to the shape of the tapered inlet 122 and is located in the tapered inlet 122. The tapered head 126 has a rounded edge 132. The throttle shaft 120 also has a shaft 128 that extends out of the outlet valve or throttle 108 through the bowl-shaped outlet 124. The bowl-shaped outlet 124 directs the heavier material to two outlet tubes 130 which direct the heavier material out of the separator 100. With this arrangement, within the throat, the exhaust flow of the heavier mass components of the gas mixture toward the diffusion chamber is promoted, while the exhaust cone interrupts the flow of the lower molecular weight components toward the diffusion chamber.

[0052] like Fig.11 As shown, the tapered inlet 122 includes a first diameter 154 and a second diameter 156. The first diameter 154 is the inner diameter of the tapered inlet 122 and the inner diameter of the throat 104. The second diameter 156 is the outer diameter of the tapered inlet 122. In the illustrated embodiment, the first diameter 154 is approximately 1 inch and the second diameter 156 is approximately 4 inches. In addition, the inner tapered sidewall 136 defines a first angle 158 of approximately 60°.

[0053] The outlet valve or throttle 108 controls the flow of the heavier material through the outlet valve or throttle 108 by changing the position of the throttle shaft 120 within the outlet valve or throttle 108. In particular, the throttle shaft 120 is inserted into the conical inlet 122 so that the conical head 126 at least partially restricts the flow of the heavier material into the conical inlet 122 to reduce the flow of the heavier material into the outlet valve or throttle 108 and reduce the flow of the mixture into the separator 100. Conversely, the throttle shaft 120 is withdrawn from the conical inlet 122 so that the conical head 126 increases the flow of the heavier material into the conical inlet 122 and increases the flow of the gas mixture into the separator 100.

[0054] In the illustrated embodiment, the conical inlet 122 and the conical head 126 have approximately the same angle relative to the longitudinal axis of the separator 100. The conical head 126 and the conical inlet 122 define a conical exhaust passage 150 therebetween. The diverging cone further defines a blunt end 152 at its apex. The blunt end 152 is coaxially disposed with the axis of the throat 104 and, therefore, with the overall longitudinal axis of the separator 100. Although a blunt shape is preferred, other shapes of the end 152 of the conical head 126 are possible.

[0055] The blunt end 152 is generally located near the outlet of the throat 104. In one implementation, the outlet valve or throttle 108 is configured to move along its longitudinal axis. Therefore, the blunt end 152 can be positioned relative to the outlet of the throat 104. By positioning the outlet valve or throttle 108 away from or toward the throat 104, the width of the tapered discharge passage 150, i.e., the distance between the tapered head 126 and the tapered inlet 122, can be increased or decreased, respectively. Such adjustment will also increase or decrease the annular opening around the outlet valve or throttle 108 and between the throat 104 and the tapered exhaust passage 150. Generally, the outlet valve or throttle 108 can be adjusted longitudinally to change the pressure within the throat 104 and the outlet passage 150, thereby affecting the reverse flow of lighter materials from the outlet pipe 130.

[0056] The separation of the gas mixture occurs in part due to the high centrifugal forces acting on the gas mixture as it spirals down the conical chamber 134 and along the throat 104. Within the throat 104, the heavier material of the gas mixture collects adjacent the outer side wall 146, while the lighter material collects near the longitudinal axis of the throat 104. At the outlet of the throat 104, the heavier material spirals into the passage 150. The lighter material contacts an area adjacent the blunt end 152 of the outlet valve or restrictor 108.

[0057] like Fig.13 As shown, the conical head 126 includes a diameter 160 and a length 162 and defines an angle 164. The diameter 160 is smaller than the second diameter 156, which is the outer diameter of the conical inlet 122, so that the conical head 126 can move within the conical inlet 122. In the illustrated embodiment, the diameter 160 is approximately 3.5 inches, the length 162 is approximately 1.3 inches, and the angle 164 is approximately 30°.

[0058] The lighter material flows out of the separator 100 in a flow pattern that is opposite to the flow of the gas mixture through the passage 150 and the external flow in the throat 104. Typically, the pressure within the separator 100 will be above atmospheric pressure. The outlet pipe 116 is at or near atmospheric pressure, which will help promote the reverse flow of the lighter material or components collected along the axis of the throat 104, but will allow the heavier material collected along the outer side wall 146 of the throat 104 to flow out through the passage 150. Incomplete separation, slight turbulence and other factors may cause some lighter material components to flow through the passage 150 with the heavier material, and may cause some heavier material to flow out of the outlet pipe 116 with the lighter material. In the reverse flow in the throat 104, as the flow continues to spiral, further separation also occurs. In the reverse flow, some heavier materials merge with the heavier materials in the external exhaust flow, thereby changing direction and being discharged.

[0059] In the field, in some cases, the outlet valve or throttle 108 is movably mounted along the axis of the separator 100. The movable outlet valve or throttle 108 allows the position of the blunt end 152 and the size of the channel 150 to be changed. In addition, in the implementation mode where the gas mixture is fed into the separator 100 by a pump, the pressure and input speed of the mixture entering the separator 100 can also be adjusted. In some applications, such as in greenhouse gas separation, the pollutants are evenly and fairly evenly distributed, and the separator 100 can be optimized once on site for maximum separation and then maintained in the current state. In other implementation modes where multiple parts of the components of the gas mixture can be changed, it may be advantageous to provide a control system to monitor the proportion of the components discharged through the exhaust device and the components transmitted from the outlet channel and to make appropriate adjustments to the pressure of the gas mixture, the position of the diffusion cone, or both.

[0060] In one embodiment, a control system (not shown) optimizes the operation of separator 100. The control system may include a controller, which includes an output or a control line for controlling the various components of the separator. The controller may change the position of the input pressure or outlet valve or throttle valve 108 or both, and analyze the mixture at each sensor location to determine whether separation is improved. The controller may continue to change the pressure, change the outlet valve or throttle valve 108, or change both, to optimize separation. In addition, the control line may be connected with other components to change the pressure in the separator 100, the input speed of the mixture and other parameters.

[0061] In a gas mixture with more than two substances, in some arrangements, multiple separators 100 may be used in series so that each separator separates one substance. For example, a first separator may be configured so that only the heaviest substance enters passage 150, while the two lighter substances flow through outlet pipe 116. The outlet pipe 116 may then be connected to a compressor to send the mixture of the two remaining substances to a second separator configured to separate the remaining heavier substance from the remaining lighter substance.

[0062] As can be seen from the above discussion, depending on the processing needs of any particular application, multiple separators 100 are connected to the mixture source in series, parallel, or a combination of series and parallel to process the mixture. For example, the separators can be arranged in parallel to process a large amount of mixture. Alternatively, the size of the separator can be modified according to the volume processing requirements. Alternatively, the separators can be arranged in a series configuration to achieve further separation of the target components of the mixture, or the separation can be focused on a specific component of the gas mixture. When incomplete separation occurs in a single separator, the separators can also be arranged in series. For example, multiple separators can be arranged in series and in parallel to separate carbon dioxide from air.

[0063] Fig.14 A method for separating the components of a mixture using a separator is shown. The method includes directing 802 a gas mixture to an inlet manifold of the separator. The method also includes forming 804 a spiral flow of the gas mixture in the inlet manifold. The method also includes directing 806 the gas mixture from the inlet manifold to the throat of the separator. The method also includes separating 808 the heavier substance of the gas mixture from the lighter substance of the gas mixture in the throat. The method also includes directing 810 the flow of the heavier substance from the throat to the outlet manifold of the separator. The outlet manifold includes an outlet valve and a throttle shaft, the outlet valve includes a conical inlet and a bowl-shaped outlet, and the throttle shaft includes a shaft and a conical head. The conical head is located in the conical inlet, and the shaft extends through the bowl-shaped outlet. The method also includes using the bowl-shaped outlet, the conical inlet and the conical head to control 812 the flow of the heavier substance through the outlet valve and the flow of the gas mixture through the separator. The size and shape of the bowl-shaped outlet, the conical inlet and the conical head are suitable for controlling the flow of the heavier substance through the outlet valve and the flow of the gas mixture through the separator.

[0064] Fig.15 is a perspective view of an alternative embodiment of separator 900 . Fig.16 is a side view of separator 900. Separator 900 is substantially similar to separator 100, except that separator 900 includes a straight inlet tube 910 and a single outlet tube 930 directed downwardly. In addition, separator 900 also includes an outlet valve or throttle 908 including a cylindrical outlet 924, and a throttle shaft 920 including a conical head 926 including a cylindrical edge 932.

[0065] The separator described herein partially or completely separates a mixture of liquid, solid, gas, or any combination thereof. Specifically, the disclosed separator produces a high-speed cyclone to separate the heavier material in the gas mixture from the lighter material in the gas mixture. For example, the separator described herein can be used to separate greenhouse gases from a gas stream discharged from a power plant or other greenhouse gas emission facility.

[0066] Fig.17 A method for separating components of a gas mixture using a separator is shown. The method includes directing 801 the gas mixture to an inlet manifold of the separator. The method also includes forming 802 a spiral flow of the gas mixture in the inlet manifold. The method also includes directing 803 the gas mixture from the inlet manifold to the throat of the separator. The method also includes separating 804 the heavier substance of the gas mixture from the lighter substance of the gas mixture in the throat. The method also includes directing 805 the flow of the heavier substance from the throat to the outlet manifold of the separator. The outlet manifold includes an outlet valve and a throttle shaft, the outlet valve includes a conical inlet and a bowl-shaped outlet, and the throttle shaft includes a shaft and a conical head. The conical head is located in the conical inlet, and the shaft extends through the bowl-shaped outlet. The method also includes using the bowl-shaped outlet, the conical inlet and the conical head to control 806 the flow of the heavier substance through the outlet valve and the flow of the gas mixture through the separator. The size and shape of the bowl-shaped outlet, the conical inlet and the conical head are suitable for controlling the flow of the heavier substance through the outlet valve and the flow of the gas mixture through the separator.

[0067] Example 1. Separation of carbon dioxide from flue gas and air.

[0068] Figure 1 The separator was modeled using Ansys computational fluid dynamics software (SimuTech, Rochester, New York, USA). A mixture of 5% carbon dioxide and 95% air was simulated in the system at an input flow rate of 20 kilograms per second (kg / s). The mixture represented flue gas. Carbon dioxide was one of the heavier species in the simulation. The output stream of the heavier species produced by the separator contained more than 90% carbon dioxide by mass. Similar results were observed at a flow rate of 5 kg / s.

[0069] Air was also simulated in the system at an input flow rate of 20 kg / s. The simulated air contained 0.044% carbon dioxide. Carbon dioxide is one of the heavier species in this simulation. The output stream of heavier species produced by the separator contains more than 0.5% carbon dioxide by mass.

[0070] These results show that 3 to 4 separators operating in parallel can produce a heavy gas stream containing more than 90% of the carbon dioxide in air.

[0071] Example 2. Separation of water from natural gas

[0072] Figure 1 The separation of methane and carbon dioxide is used to remove water vapor and carbon dioxide from raw natural gas (feed gas). The feed gas mainly contains methane, and the feed gas also has a water concentration of 1.8 lbs / MMSCF (about 38 parts per million parts mass / volume). The separator is capable of producing an output stream containing up to 20 lbs / MMSCF (about 420 parts per million parts mass / volume) of heavier materials. The separator also removes 7 to 70% of the carbon dioxide from the methane.

[0073] The above description, examples and data provide a complete description of the structure and use of exemplary implementations of the present invention. Since many implementations of the present invention can be made without departing from the spirit and scope of the present invention, the present invention exists in the following appended claims. In addition, the structural features of different embodiments can be combined in another embodiment without departing from the claims. Although embodiments and applications of the present invention have been shown and described, it is obvious to those skilled in the art who benefit from this disclosure that more modifications than those described above are possible without departing from the inventive concepts herein. Therefore, the present invention is not limited by the spirit of the appended claims.

Claims

1. A separator for separating components of a gas mixture, comprising: an inlet manifold configured to receive a flow of a gas mixture, wherein the inlet manifold forms the gas mixture into a spiral flow; a throat attached to the inlet manifold and configured to receive a flow of the gas mixture from the inlet manifold, wherein the throat separates heavier species of the gas mixture from lighter species of the gas mixture; and an outlet manifold attached to the throat and configured to receive the flow of the heavier material from the throat, the outlet manifold comprising: an outlet valve including a tapered inlet and a bowl-shaped outlet; and a throttle shaft including a shaft and a conical head, wherein the conical head is located within the conical inlet and the shaft extends through the bowl-shaped outlet; Wherein, the bowl-shaped outlet, the conical inlet and the conical head are sized and shaped to control the flow of heavier materials through the outlet valve and the flow of the gas mixture through the separator.

2. The separator according to claim 1, wherein: The inlet manifold includes at least one inlet pipe having a spiral shape.

3. The separator according to claim 2, wherein: The at least one inlet pipe includes two inlet pipes in a spiral shape.

4. The separator according to claim 1, wherein: The inlet manifold includes an inlet plate defining at least one inlet channel having a spiral shape.

5. The separator according to claim 4, wherein: The inlet manifold includes a tapered chamber defining a continuous inner tapered sidewall.

6. The separator according to claim 5, wherein: The continuous inner tapered sidewall abuts the at least one inlet channel.

7. The separator according to claim 5, wherein: The continuous inner tapered sidewall abuts the throat.

8. The separator according to claim 5, wherein: The inlet manifold includes an outlet tube disposed along an axis of the throat and the tapered chamber.

9. The separator according to claim 1, wherein: The conical head includes a blunt end located near the outlet of the throat.

10. The separator according to claim 1, wherein: The outlet manifold includes at least one outlet tube configured to direct heavier material from the separator.

11. A method of separating components of a gas mixture using a separator, the method comprising: directing the gas mixture to an inlet manifold of a separator; forming a spiral flow of the gas mixture in the inlet manifold; directing the gas mixture from the inlet manifold to a throat of the separator; separating heavier matter of the gas mixture from lighter matter of the gas mixture within the throat; directing the flow of the heavier material from the throat to an outlet manifold of the separator, the outlet manifold comprising an outlet valve and a throttle shaft, the outlet valve comprising a conical inlet and a bowl-shaped outlet, the throttle shaft comprising a shaft and a conical head, wherein the conical head is located within the conical inlet and the shaft extends through the bowl-shaped outlet; and The bowl-shaped outlet, the conical inlet and the conical head are used to control the flow of the heavier material through the outlet valve and the flow of the gas mixture through the separator, wherein the size and shape of the bowl-shaped outlet, the conical inlet and the conical head are suitable for controlling the flow of the heavier material through the outlet valve and the flow of the gas mixture through the separator.

12. The method according to claim 11, wherein: The inlet manifold includes at least one inlet tube having a spiral shape, and wherein forming the gas mixture into a spiral flow within the inlet manifold at least partially includes directing the gas mixture into the at least one inlet tube.

13. The method according to claim 12, wherein: The at least one inlet pipe includes two inlet pipes in a spiral shape.

14. The method according to claim 11, wherein: The inlet manifold includes an inlet plate defining at least one inlet channel having a spiral shape, and wherein forming the gas mixture into a spiral flow within the inlet manifold includes at least partially directing the gas mixture into the at least one inlet channel.

15. The method according to claim 14, wherein: The inlet manifold includes a tapered chamber defining a continuous inner tapered sidewall, and wherein forming the gas mixture into a spiral flow within the inlet manifold includes at least partially directing the gas mixture into the tapered chamber.

16. The method according to claim 15, wherein: The continuous inner tapered sidewall abuts the at least one inlet channel, and wherein the at least one inlet channel and the continuous inner tapered sidewall form a smooth transition from the inlet plate to the tapered chamber.

17. The method according to claim 15, wherein: The continuous inner tapered sidewall abuts the throat, and wherein the at least one inlet passage and the throat form a smooth transition from the tapered chamber to the throat.

18. The method according to claim 15, wherein: The inlet manifold includes an outlet pipe arranged along an axis of the throat and the tapered chamber, and wherein the method further includes directing the flow of the lighter material from the throat to the outlet pipe.

19. The method according to claim 11, wherein: Controlling the flow of heavier material through the outlet valve and the flow of the gas mixture through the separator using the bowl-shaped outlet includes moving the conical head within the conical inlet.

20. The method according to claim 19, wherein: Moving the conical head toward the conical inlet reduces the flow of heavier materials out of the separator.

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