Oil separator and separation method

Abstract

The invention discloses an oil separator and a separation method.The oil separator comprises a body mechanism, a centrifugal separation mechanism, a coalescence filtering mechanism, a heat exchange mechanism, a back flushing mechanism and a control system, and the body mechanism comprises a barrel, a shell, an air supply unit, an air outlet unit and an oil outlet unit; the centrifugal separation mechanism is used for enabling oil-containing gas entering the cylinder to rotate at a high speed, and primary separation of oil and gas is realized by virtue of centrifugal force; the coalescence filtering mechanism is arranged below the centrifugal separation mechanism, is used for capturing and coalescing fine oil drops entrained in gas subjected to primary separation, and comprises a first coalescence layer, a second coalescence layer and a third coalescence layer which are sequentially mounted in the barrel from top to bottom; the heat exchange mechanism is installed on the periphery of the coalescence filtering mechanism. The centrifugal separation mechanism and the gradient coalescence filtering mechanism are cooperatively arranged in the vertical barrel from top to bottom, so that the oil-gas separation efficiency is remarkably improved, and the operation stability is synchronously optimized.

Description

Technical Field

[0001] This invention belongs to the field of oil separator technology, specifically relating to an oil separator and a separation method. Background Technology

[0002] In systems such as refrigeration and air compressors, lubricating oil inevitably escapes with high-pressure gas. If this lubricating oil cannot be effectively separated and recovered, it will reduce the system's oil level, affecting compressor lubrication. Furthermore, oil entering the heat exchanger will decrease system efficiency. Therefore, oil separators are crucial components in these systems.

[0003] Existing oil separation technologies are mainly classified into centrifugal, filtration, and packing separators. Centrifugal separators utilize centrifugal force for separation, which is effective for separating large droplets, but has limited efficiency in separating fine oil mist below the micrometer level, and experiences significant resistance at high flow rates. Filtration or coalescing separators have good capture capabilities for small oil droplets, but if they directly process gases with high oil content, the filter element is prone to rapid saturation, leading to a sharp increase in pressure drop and a shortened lifespan. Currently, a single separation method often cannot simultaneously meet the requirements of high separation efficiency, low resistance loss, and long service life.

[0004] Therefore, in view of the above-mentioned technical problems, it is necessary to provide an oil separator and a separation method.

[0005] The information disclosed in this background section is intended only to enhance the understanding of the overall background of the invention and should not be construed as an admission or in any way implying that the information constitutes prior art known to those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide an oil separator and a separation method, which can provide a high-efficiency multi-stage centrifugal oil separator and its separation method with high separation efficiency, low pressure drop, reasonable structure and long maintenance cycle.

[0007] To achieve the above objectives, a specific embodiment of the present invention provides the following technical solution:

[0008] An oil separator includes a main body, a centrifugal separation mechanism, a coalescing filtration mechanism, a heat exchange mechanism, a backflushing mechanism, and a control system. The main body includes a cylinder, a shell, a gas supply unit, a gas outlet unit, and an oil outlet unit. The centrifugal separation mechanism causes the oil-containing gas entering the cylinder to rotate at high speed, achieving primary separation of oil and gas through centrifugal force. The coalescing filtration mechanism is located below the centrifugal separation mechanism and is used to capture and coalesce the fine oil droplets entrained in the gas after primary separation. It includes a first coalescing layer, a second coalescing layer, and a third coalescing layer installed sequentially from top to bottom within the cylinder. The heat exchange mechanism is installed around the coalescing filtration mechanism and is used to heat or cool the oil and gas transported within the coalescing filtration mechanism. The backflushing mechanism cleans the coalescing filtration mechanism using high-pressure gas output from the gas outlet unit. The control system is used for automated control and monitoring of the oil separator's operation.

[0009] In one or more embodiments of the present invention, the air supply unit includes an air inlet pipe that is installed through the cylinder and the side wall of the outer shell, and the air outlet of the air inlet pipe corresponds tangentially to the centrifugal separation mechanism; the oil outlet unit includes an oil outlet valve installed at the bottom of the cylinder and an oil outlet valve installed on the oil outlet valve.

[0010] In one or more embodiments of the present invention, the air outlet unit includes a return air chamber, a return air hole, and an air outlet pipe. The return air chamber is formed between the cylinder and the outer shell. Multiple return air holes are provided and are arranged in an upward inclined manner from the inside to the outside of the cylinder, and are located below the coalescing filter mechanism and communicate with the return air chamber. The air outlet pipe is installed on the upper part of the top wall panel of the outer shell, and a first solenoid valve is installed on the air outlet pipe.

[0011] In one or more embodiments of the present invention, the centrifugal separation mechanism is fixedly installed inside the cylinder. The centrifugal separation mechanism includes a spiral guide vane and a mounting shaft. The spiral guide vane causes the oil and gas tangentially input through the air inlet pipe to rotate through the guide. The surface of the spiral guide vane is provided with a self-cleaning coating. The mounting shaft is fixedly arranged coaxially with the cylinder, and the spiral guide vane is fixedly connected to the side wall of the mounting shaft.

[0012] In one or more embodiments of the present invention, the pore sizes of the first coalescing layer, the second coalescing layer, and the third coalescing layer are arranged in a manner that decreases sequentially. The first coalescing layer is composed of a sintered metal mesh or a large-pore foam metal; the second coalescing layer is composed of glass fiber or a polymer fiber; the third coalescing layer is composed of an ultrafine glass fiber membrane or a PTFE coating; a flow guide is installed above the first coalescing layer, and a liquid collecting umbrella is installed below the third coalescing layer.

[0013] In one or more embodiments of the present invention, the coalescing filter mechanism further includes a high-voltage electrostatic coalescing module, the high-voltage electrostatic coalescing module including a pair of electrode plates, a plurality of through holes and a power line; the pair of electrode plates are respectively disposed between the first coalescing layer and the second coalescing layer, and between the second coalescing layer and the third coalescing layer; the plurality of through holes are arranged in an array on the electrode plates, and the through holes are configured as an inverted conical structure; the power line is used to provide external power to the electrode plates.

[0014] In one or more embodiments of the present invention, the heat exchange mechanism includes an annular housing, a heat source pipe, a cold source pipe, a pair of second solenoid valves, thermally conductive packing, and a flexible thermally conductive layer. The annular housing is installed around the coalescing filter mechanism and is made of a metal material with excellent thermal conductivity. The heat source pipe is installed inside the annular housing and its inlet and outlet ends extend to the outside of the housing. The cold source pipe is installed inside the annular housing and its inlet and outlet ends extend to the outside of the housing. The pair of second solenoid valves are respectively installed on the pipes on the outside of the housing, with their inlet ends on the heat source pipe and the cold source pipe. The thermally conductive packing fills the annular housing and is tightly fitted to the outer walls of the heat source pipe and the cold source pipe. The flexible thermally conductive layer fills the space between the outer wall of the annular housing and the coalescing filter mechanism. The heat source pipes are staggered, and both the heat source pipe and the cold source pipe are spiral pipes that rotate circumferentially around the annular housing.

[0015] In one or more embodiments of the present invention, the backflush mechanism includes a backflush pipe and a backflush nozzle. One end of the backflush pipe is installed on the side wall of the air outlet pipe located at the front end of the first solenoid valve, and the other end extends into the liquid collection umbrella and is located below the third coalescing layer. A third solenoid valve is installed on the backflush pipe. The backflush nozzle is installed on the end of the backflush pipe located in the liquid collection umbrella in a coaxial manner with the third coalescing layer. A plurality of microholes are provided on the upper wall plate of the backflush nozzle in a manner that diffuses in all directions.

[0016] In one or more embodiments of the present invention, the control system includes a differential pressure sensor and a temperature sensor, wherein the differential pressure sensor is installed on the upper and lower sides of the coalescing filter mechanism; and the temperature sensor is installed inside the coalescing filter mechanism.

[0017] An oil separation method, the separation method comprising:

[0018] S1. Centrifugal coarse separation: High-pressure oil-containing gas is transported to the centrifugal separation mechanism through the inlet pipe. Under the action of the spiral guide vanes, it forms a high-speed swirling flow in the upper space of the cylinder, achieving primary coarse separation.

[0019] S2, Gradient coalescence fine separation: The gas after centrifugal coarse separation passes through the first coalescence layer, the second coalescence layer and the third coalescence layer from top to bottom for multi-stage coalescence separation;

[0020] S3. Oil collection and return: The separated oil droplets flow into the bottom of the cylinder and are periodically discharged through the oil outlet unit;

[0021] S4. Clean gas discharge: After oil-gas separation, the gas is discharged from the gas outlet pipe;

[0022] In step S2, the gas is cooled and condensed or heated by a heat exchange mechanism, and / or the oil droplets are coalesced by a high-voltage electrostatic coalescence module.

[0023] Compared with existing technologies, this invention achieves a significant improvement in oil-gas separation efficiency and simultaneous optimization of operational stability by synergistically arranging the centrifugal separation mechanism and the gradient coalescing filter mechanism in a vertical cylinder from top to bottom. The cyclone generator performs high-speed centrifugal pretreatment on the intake air, efficiently removing most of the liquid oil droplets and greatly reducing the load on the subsequent coalescing filter unit. Secondly, the use of a gradient coalescing layer with decreasing pore size from top to bottom achieves step-by-step capture and deep coalescence of fine oil droplets, ensuring extremely high cleanliness of the final outlet gas. This compact structure with multi-stage series connection and functional partitioning not only greatly improves separation efficiency but also effectively slows down the clogging speed of the coalescing filter element due to the primary protection effect of the centrifugation stage, significantly reducing system pressure drop and maintenance frequency, thus possessing the comprehensive technical advantages of high efficiency, low resistance, and long service life. Attached Figure Description

[0024] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0025] Figure 1 This is a front view of an oil separator according to an embodiment of the present invention;

[0026] Figure 2 This is a perspective view of an oil separator according to an embodiment of the present invention;

[0027] Figure 3 This is a cross-sectional view of an oil separator according to an embodiment of the present invention;

[0028] Figure 4 This is a cross-sectional view of an oil separator according to an embodiment of the present invention;

[0029] Figure 5 This is an exploded view of the coalescing filtration mechanism in this invention;

[0030] Figure 6 This is a cross-sectional view of the connection between the coalescing filtration mechanism and the heat exchange mechanism in this invention;

[0031] Figure 7 This is a schematic diagram of the swirl generator in this invention;

[0032] Figure 8 This is a schematic diagram of the heat source pipe and the cold source pipe in this invention.

[0033] Explanation of key figure labels:

[0034] 1-Main body, 11-Cylinder, 12-Outer shell, 13-Return air chamber, 14-Inlet pipe, 15-Return air hole, 16-Outlet pipe, 17-First solenoid valve, 18-Outlet oil pipe, 19-Outlet oil valve, 2-Centrifugal separation mechanism, 21-Spiral guide vane, 22-Mounting shaft, 3-Coalescing filtration mechanism, 31-First coalescing layer, 32-Second coalescing layer, 33-Third coalescing layer, 34-Electrode plate, 35-Through hole, 36-Guide shroud, 37-Collecting umbrella, 4-Heat exchange mechanism, 41-Annular box, 42-Heat source pipe, 43-Cold source pipe, 44-Second solenoid valve, 45-Heat-conducting packing, 46-Flexible heat-conducting layer, 5-Backflush mechanism, 51-Backflush pipe, 52-Backflush nozzle, 53-Third solenoid valve. Detailed Implementation

[0035] To enable those skilled in the art to better understand the technical solutions in this disclosure, the technical solutions in the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this disclosure, and not all embodiments. Based on the embodiments in this disclosure, all other embodiments obtained by those skilled in the art without creative effort should fall within the scope of protection of this disclosure.

[0036] like Figures 1-4 As shown, an oil separator according to one embodiment of the present invention includes a main body 1, a centrifugal separation mechanism 2, a coalescing filter mechanism 3, a heat exchange mechanism 4, a backflushing mechanism 5, and a control system. The main body 1 includes a cylinder 11, a shell 12, a gas supply unit, a gas outlet unit, and an oil outlet unit. The centrifugal separation mechanism 2 is used to generate high-speed rotation of the oil-containing gas entering the cylinder 11, and to achieve primary separation of oil and gas by relying on centrifugal force. The coalescing filter mechanism 3 is located below the centrifugal separation mechanism 2 and is used to capture and coalesce the fine oil droplets entrained in the gas after primary separation. It includes a first coalescing layer 31, a second coalescing layer 32, and a third coalescing layer 33 installed sequentially from top to bottom in the cylinder 11. The heat exchange mechanism 4 is installed around the coalescing filter mechanism 3 and is used to heat or cool the oil and gas transported in the coalescing filter mechanism 3. The backflushing mechanism 5 cleans the coalescing filter mechanism 3 by outputting high-pressure gas from the gas outlet unit. The control system is used for automatic control and monitoring of the operation of the oil separator.

[0037] The working principle of this oil separator is as follows: high-pressure oil-containing gas is first transported to the cylinder 11 through the gas supply unit. Then, under the action of the centrifugal separation mechanism 2, the oil-containing gas forms a high-speed swirling flow in the upper part of the cylinder body mechanism 1, and the centrifugal force is used to achieve the primary separation of most of the liquid oil droplets. Subsequently, the preliminarily purified gas passes through the first coalescing layer 31, the second coalescing layer 32 and the third coalescing layer 33. Through the step-by-step interception, collision and coalescence, the fine oil mist entrained therein is deeply captured and removed, and finally the oil and gas are efficiently separated. The clean gas is discharged through the gas outlet unit, thereby achieving efficient and multi-stage gas-liquid separation. When the coalescing filter mechanism 3 processes oil and gas, the heat exchange mechanism 4 cools and condenses or heats the gas to promote the coalescence of oil droplets. At the same time, the control system detects the pressure difference inside the cylinder 11. If the coalescing filter mechanism 3 becomes clogged, the control system will cause the high-pressure gas delivered by the gas outlet unit to be delivered through the backflushing mechanism 5 to backflush and clean the first coalescing layer 31, the second coalescing layer 32 and the third coalescing layer 33, so that the coalescing filter mechanism 3 can process oil and gas with high efficiency.

[0038] like Figures 1-4 As shown, the air supply unit includes an air inlet pipe 14 installed through the side walls of the cylinder 11 and the outer shell 12. The outlet of the air inlet pipe 14 is tangentially aligned with the centrifugal separation mechanism 2. High-pressure oil-containing gas is tangentially transported through the air inlet pipe 14 to the spiral guide vane 21, causing the high-pressure gas to rotate at high speed under the guidance of the spiral guide vane 21. This achieves primary separation of most of the liquid oil droplets through centrifugal force. The oil outlet unit includes an oil outlet valve 18 installed at the bottom of the cylinder 11 and an oil outlet valve 19 installed on the oil outlet valve 18. After the liquid oil droplets are separated in the cylinder 11, the liquid oil is stored at the bottom of the cylinder 11 and discharged through the oil outlet valve 18 after the oil outlet valve 19 is opened periodically.

[0039] like Figure 2 and Figure 3As shown, the exhaust unit includes a return air chamber 13, return air holes 15, and an exhaust pipe 16. The return air chamber 13 is formed between the cylinder 11 and the outer shell 12. Multiple return air holes 15 are provided and are arranged upwards from the inside to the outside of the cylinder 11, located below the coalescing filter mechanism 3 and communicating with the return air chamber 13. The exhaust pipe 16 is installed on the upper part of the top wall panel of the outer shell 12, and a first solenoid valve 17 is installed on the exhaust pipe 16. After the oil-containing high-pressure gas completes final separation through the coalescing filter mechanism 3 within the cylinder 11, the high-pressure gas in the cylinder 11 can enter the return air chamber 13 through the multiple return air holes 15 and then be discharged through the exhaust pipe 16. The upward tilt of the vent 15 prevents liquid oil droplets from entering. At the same time, the vent pipe 16 is located at the top, so that when the high-pressure gas after oil-gas separation is discharged, it does not carry liquid oil droplets. In order to further ensure that the high-pressure gas does not carry liquid oil droplets, an oil filter screen can be installed in the vent 15, so that only high-pressure gas can pass through the vent pipe 16.

[0040] like Figure 3 and Figure 7 As shown, the centrifugal separation mechanism 2 is fixedly installed inside the cylinder 11. The centrifugal separation mechanism 2 includes a spiral guide vane 21 and a mounting shaft 22. The spiral guide vane 21 guides the oil and gas tangentially input through the air inlet pipe 14 to rotate. The surface of the spiral guide vane 21 is coated with a self-cleaning coating. The mounting shaft 22 is fixedly installed coaxially with the cylinder 11, and the spiral guide vane 21 is fixedly connected to the side wall of the mounting shaft 22. High-pressure oil-laden gas enters the fixed centrifugal separation mechanism 2 from the top and is then guided by the spiral guide vane 21 to form a rotating airflow, causing the oil and gas to rotate and spray downwards. Oil droplets are thrown towards the inner wall of the cylinder 11 by centrifugal force. The purified gas changes direction at the bottom through the guide vane and enters the next separation stage. The fixed installation of the centrifugal separation mechanism 2 ensures both strength and alignment accuracy, and conforms to fluid mechanics principles, making it the optimal engineering solution.

[0041] Preferably, the pore sizes of the first coalescing layer 31, the second coalescing layer 32, and the third coalescing layer 33 are arranged in a progressively smaller manner. By gradually decreasing the pore size, deep capture and coalescence of oil droplets of different sizes can be achieved, allowing the micro-droplets to "grow" and fall due to gravity. The first coalescing layer 31 is composed of a sintered metal mesh or large-pore foam metal; the second coalescing layer 32 is composed of glass fiber or polymer fiber; the third coalescing layer 33 is composed of an ultrafine glass fiber membrane or a PTFE membrane; a flow guide hood 36 is installed above the first coalescing layer 31, and a liquid collecting umbrella 37 is installed below the third coalescing layer 33.

[0042] like Figures 4-6As shown, the coalescing filter mechanism 3 also includes a high-voltage electrostatic coalescing module, which includes a pair of electrode plates 34, multiple through holes 35, and a power line. The pair of electrode plates 34 are respectively disposed between the first coalescing layer 31 and the second coalescing layer 32, and between the second coalescing layer 32 and the third coalescing layer 33. The multiple through holes 35 are arranged in an array on the electrode plates 34, and the through holes 35 are configured as inverted conical structures. The power line is used to provide external power to the electrode plates 34. The electrode plates 34 utilize electrostatic force to polarize, directionally move, and collide and coalesce the micro oil droplets, greatly improving the separation efficiency of submicron-level oil mist. This allows a strong and uniform electrostatic field to be established in the coalescing filter mechanism 3 through the high-voltage electrostatic coalescing module, causing the micro oil droplets to become charged, polarized, and collide and coalesce. Multiple through holes 35 make the electrode plate 34 a grid plate, which enables the electrode plate 34 to establish an electric field while providing a guiding surface for the downward flow of oil droplets through multiple inverted conical through holes 35. On the other hand, it can increase the effective area of ​​the electric field.

[0043] like Figure 6 and Figure 8 As shown, the heat exchange mechanism 4 includes an annular housing 41, a heat source pipe 42, a cold source pipe 43, a pair of second solenoid valves 44, thermally conductive packing 45, and a flexible thermally conductive layer 46. The annular housing 41 is installed around the coalescing filter mechanism 3 and is made of a metal material with excellent thermal conductivity. The heat source pipe 42 is installed inside the annular housing 41 and its inlet and outlet ends extend to the outside of the outer shell 12. The cold source pipe 43 is installed inside the annular housing 41 and its inlet and outlet ends extend to the outside of the outer shell 12. Two solenoid valves 44 are respectively installed on the pipes located outside the outer casing 12 at the inlet ends of the heat source pipe 42 and the cold source pipe 43; the thermally conductive filler 45 is filled inside the annular box 41 and is tightly attached to the outer walls of the heat source pipe 42 and the cold source pipe 43; the flexible thermally conductive layer 46 is filled between the outer wall of the annular box 41 and the coalescing filter mechanism 3; the heat source pipes 42 and 43 are arranged alternately, and both the heat source pipes 42 and the cold source pipe 43 are set as spiral pipes that rotate around the annular box 41.

[0044] Specifically, when cooling is required: the system connects the cooling medium circuit, allowing the cooling medium to circulate within the heat source pipe 42, absorbing heat from the oil and gas inside the cylinder 11 before flowing out. The entire process occurs within an independent closed loop. When heating is required: the system switches the second solenoid valve 44, disconnecting the cooling circuit and connecting the heating medium circuit. This medium circulates independently within the cold source pipe 43, releasing heat to the oil and gas, thus heating them. Therefore, based on the needs of oil-gas separation, targeted heating or cooling of the oil and gas can be achieved, increasing the coalescence of liquid oil droplets and significantly improving separation efficiency. Simultaneously, to improve heat transfer efficiency for rapid heating or cooling of the oil and gas, thermally conductive filler 45 and a flexible thermally conductive layer 46 are used to enhance heat transfer efficiency.

[0045] Optionally, when using the heat exchange mechanism 4, the heat source and cold source it uses can be selected according to the equipment's own conditions. When the equipment itself carries a heat source and cold source, it can selectively connect with the heat exchange mechanism 4; if it is inconvenient to connect or there is no heat or cold source, it can be considered to provide them from the outside.

[0046] like Figures 1-4 As shown, the backflush mechanism 5 includes a backflush pipe 51 and a backflush nozzle 52. One end of the backflush pipe 51 is installed on the side wall of the air outlet pipe 16 located at the front end of the first solenoid valve 17, and the other end extends into the liquid collection umbrella 37 and is located below the third coalescing layer 33. The third solenoid valve 53 is installed on the backflush pipe 51. The backflush nozzle 52 is installed on the end of the backflush pipe 51 located in the liquid collection umbrella 37 in a coaxial manner with the third coalescing layer 33. The upper wall of the backflush nozzle 52 is provided with a plurality of microholes that are inclined and diffuse in all directions.

[0047] Specifically, when the detection element in the control system detects a large pressure difference inside the cylinder 11, the coalescing filter mechanism 3 needs to be cleaned. During cleaning, by closing the first solenoid valve 17 and opening the third solenoid valve 53, the high-pressure gas that has completed oil-gas separation can be delivered to the backflush nozzle 52 through the backflush pipe 51. Then, after being atomized and diffused by the backflush nozzle 52, it is blown upward from the bottom of the third coalescing layer 33, sequentially blowing through the third coalescing layer 33, the second coalescing layer 32, and the first coalescing layer 31. The high-speed reverse airflow sequentially penetrates the micropores of the third coalescing layer 33, the second coalescing layer 32, and the first coalescing layer 31, generating huge shearing and peeling forces on the oil film and oil droplets attached to the filter material fibers, "tearing" them off. For solid particles embedded deep in the filter material, the reverse airflow loosens and disperses them, causing them to fall off the filter material. Thus, the coalescing filter mechanism 3 is quickly cleaned by high-pressure gas backflush.

[0048] It should be noted that, in order to ensure that the high-pressure gas output by the third solenoid valve 53 can effectively treat the impurities cleaned after backflushing the coalescing filter mechanism 3, the outer sidewalls of the flow guide hood 36 and the annular box 41 are respectively spaced between the inner sidewall of the cylinder 11. This allows the impurities blown out through the upper end of the first coalescing layer 31 after backflushing to be guided by the flow guide hood 36 and then left along the inner sidewall of the cylinder 11, and then discharged through the bottom of the cylinder 11, thereby cleaning the cleaned impurities.

[0049] Preferably, the control system includes a differential pressure sensor and a temperature sensor. The differential pressure sensor is installed on the upper and lower sides of the coalescing filter mechanism 3; the temperature sensor is installed inside the coalescing filter mechanism 3. The differential pressure sensor monitors the pressure difference inside the cylinder 11 in real time, and the temperature sensor monitors the internal temperature of the coalescing filter mechanism 3. The control system also employs automated control programs such as microcontrollers, and the equipment is equipped with other monitoring and control components required for automated control, including but not limited to automated control programs for backflushing, drainage, etc.

[0050] An oil separation method, the separation method comprising:

[0051] S1. Centrifugal coarse separation: High-pressure oil-containing gas is transported to the centrifugal separation mechanism 2 through the air inlet pipe 14. Under the action of the spiral guide vane 21, it forms a high-speed swirling flow in the upper space of the cylinder 11 to achieve primary coarse separation.

[0052] S2, Gradient coalescence fine separation: The gas after centrifugal coarse separation passes through the first coalescence layer 31, the second coalescence layer 32 and the third coalescence layer 33 from top to bottom for multi-stage coalescence separation;

[0053] S3. Oil collection and return: The separated oil droplets flow into the bottom of the cylinder 11 and are periodically discharged through the oil outlet unit;

[0054] S4. Clean gas discharge: After oil-gas separation, the gas is discharged from the gas outlet pipe 16.

[0055] In step S2, the gas is cooled and condensed or heated by the heat exchange mechanism 4, and / or the oil droplets are coalesced by the high-voltage electrostatic coalescence module.

[0056] It will be apparent to those skilled in the art that this disclosure is not limited to the details of the exemplary embodiments described above, and that this disclosure can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of this disclosure is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within this disclosure. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0057] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. An oil separator, characterized in that, include: The main body structure includes a cylinder, an outer shell, an air supply unit, an air outlet unit, and an oil outlet unit; The centrifugal separation mechanism is used to make the oil-containing gas entering the cylinder rotate at high speed, and to achieve primary separation of oil and gas by relying on centrifugal force. A coalescing filter mechanism is located below the centrifugal separation mechanism and is used to capture and coalesce the fine oil droplets entrained in the gas after primary separation. It includes a first coalescing layer, a second coalescing layer and a third coalescing layer installed sequentially from top to bottom inside the cylinder. The heat exchange mechanism is installed on the periphery of the coalescing filter mechanism and is used to heat or cool the oil and gas transported inside the coalescing filter mechanism. The backflushing mechanism cleans the coalescing filter mechanism using high-pressure gas output from the exhaust unit; The control system is used for the automated control and monitoring of the oil separator during operation.

2. The oil separator according to claim 1, characterized in that, The air supply unit includes an air inlet pipe that is installed through the cylinder and the side wall of the outer shell, and the air outlet of the air inlet pipe corresponds tangentially to the centrifugal separation mechanism; the oil outlet unit includes an oil outlet valve installed at the bottom of the cylinder and an oil outlet valve mounted on the oil outlet valve.

3. An oil separator according to claim 2, characterized in that, The air outlet unit includes: The return air chamber is formed between the cylinder and the outer shell; Multiple return air holes are provided and are arranged in an upward inclined manner from the inside to the outside of the cylinder, and are located below the coalescing filter mechanism and communicate with the return air chamber. An exhaust pipe is installed on the upper part of the top wall panel of the outer casing, and a first solenoid valve is installed on the exhaust pipe.

4. An oil separator according to claim 3, characterized in that, The centrifugal separation mechanism is fixedly installed inside the cylinder, and the centrifugal separation mechanism includes: A spiral guide vane is used to guide the oil and gas tangentially input through the intake pipe to rotate. The surface of the spiral guide vane is provided with a self-cleaning coating. The mounting shaft is fixedly installed coaxially with the cylinder, and the spiral guide vane is fixedly connected to the side wall of the mounting shaft.

5. An oil separator according to claim 1, characterized in that, The pore sizes of the first, second, and third coalescing layers are arranged in a sequentially decreasing manner, and The first coalescing layer is composed of a sintered metal mesh or a large-pore foam metal. The second coalescing layer is composed of glass fiber or polymer fiber; The third coalescing layer is composed of an ultrafine glass fiber membrane or a PTFE coating. Furthermore, a flow guide is installed above the first coalescing layer, and a liquid collection umbrella is installed below the third coalescing layer.

6. An oil separator according to claim 5, characterized in that, The coalescing filtration mechanism further includes a high-voltage electrostatic coalescing module, which comprises: A pair of electrode plates are respectively disposed between the first coalescing layer and the second coalescing layer, and between the second coalescing layer and the third coalescing layer; Multiple through holes are arranged in an array on the electrode plate, and the through holes are configured with an inverted conical structure; The power module is used to provide external power to the electrode plates.

7. An oil separator according to claim 6, characterized in that, The heat exchange mechanism includes: The annular housing, installed around the coalescing filter mechanism, is made of a metal material with excellent thermal conductivity. The heat source pipe is installed inside the annular box and its inlet and outlet ends extend to the outside of the outer shell; The cold source pipe is installed inside the annular enclosure and its inlet and outlet ends extend to the outside of the outer shell; A pair of second solenoid valves are respectively installed on the pipes located on the outside of the housing at the inlet ends of the heat source pipe and the cold source pipe; Thermally conductive filler is used to fill the annular box and fit tightly against the outer walls of the heat source pipe and the cold source pipe. A flexible thermally conductive layer is filled between the outer wall of the annular box and the coalescing filter mechanism; The heat source pipes are arranged alternately, and both the heat source pipes and the cold source pipes are spiral pipes that rotate around the circumference of the annular box.

8. An oil separator according to claim 7, characterized in that, The backflush mechanism 5 includes: A backflush pipe, one end of which is installed on the side wall of the air outlet pipe located at the front end of the first solenoid valve, and the other end extends into the liquid collection umbrella and is located below the third coalescing layer. The backflush pipe is equipped with a third solenoid valve. The backflush nozzle is installed coaxially with the third coalescing layer on one end of the backflush tube inside the liquid collection umbrella. The upper wall plate of the backflush nozzle is provided with a plurality of microholes that are inclined and diffuse in all directions.

9. An oil separator according to claim 1, characterized in that, The control system includes: Differential pressure sensors are installed on the upper and lower sides of the coalescing filter mechanism; Temperature sensor, installed inside coalescing filter mechanism.

10. An oil separation method, used in an oil separation apparatus as described in any one of claims 1 to 9, characterized in that, The separation method includes: S1. Centrifugal coarse separation: High-pressure oil-containing gas is transported to the centrifugal separation mechanism through the inlet pipe. Under the action of the spiral guide vanes, it forms a high-speed swirling flow in the upper space of the cylinder, achieving primary coarse separation. S2, Gradient coalescence fine separation: The gas after centrifugal coarse separation passes through the first coalescence layer, the second coalescence layer and the third coalescence layer from top to bottom for multi-stage coalescence separation; S3. Oil collection and return: The separated oil droplets flow into the bottom of the cylinder and are periodically discharged through the oil outlet unit; S4. Clean gas discharge: After oil-gas separation, the gas is discharged from the gas outlet pipe; In step S2, the gas is cooled and condensed or heated by a heat exchange mechanism, and / or the oil droplets are coalesced by a high-voltage electrostatic coalescence module.

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