A skid-mounted gas separation membrane device and method of use thereof

Abstract

The present application relates to the technical field of gas separation, and discloses a pry-mounted gas separation membrane device and a use method thereof. The device comprises a pry body, and a filter drying system, a secondary cooling system, a suspension separator, a compression system, a gas storage tank and a membrane assembly are detachably connected to the pry body. The filter drying system is used for filtering solid particles and moisture in raw gas, the secondary cooling system is used for cooling the raw gas, the suspension separator is used for removing liquefied components in the raw gas, and the compression system is used for compressing the raw gas into high-pressure gas. The membrane assembly comprises a main pipeline and two membrane devices. The main pipeline is connected with a first branch pipe and a second branch pipe through a first manual reversing valve. The two membrane devices are spaced apart on the first branch pipe. One end of the second branch pipe is in communication with the first branch pipe between the two membrane devices. The main pipeline is in communication with the gas storage tank. The present application can be used for evaluating the performance of the gas separation membrane assembly. The device is compact and portable, and the floor area and transportation cost are significantly reduced. The device is suitable for small oil and gas fields and complex terrains.

Description

Technical Field

[0001] This invention relates to the field of gas separation technology, and in particular to a skid-mounted gas separation membrane device and its usage method. Background Technology

[0002] Gas separation membrane equipment typically includes membrane modules, compressors, buffer tanks, gas coolers, gas heat exchangers, gas-liquid separators, and filters, making the entire system design quite complex. Furthermore, various thermodynamic issues must be considered during the design phase, potentially leading to insufficient chemical and thermal stability. During the operation of large-scale equipment, particulate matter and water vapor in the gas being separated can cause membrane pore blockage upon condensation, resulting in membrane fouling and aging, necessitating frequent membrane module replacements. The high maintenance costs of large-scale equipment result in a long cost recovery period for membrane equipment. A clear understanding of the performance of membrane modules under actual operating conditions is essential for the rational design and construction of industrial gas separation membrane systems.

[0003] Therefore, a skid-mounted gas separation membrane device and its usage method are proposed. Summary of the Invention

[0004] The purpose of this invention is to provide a skid-mounted gas separation membrane device and its method of use, aiming to solve or improve at least one of the above-mentioned technical problems.

[0005] To achieve the above objectives, the present invention provides the following solution: The present invention provides a skid-mounted gas separation membrane device, including a skid body, on which a filtration and drying system, a secondary cooling system, a suspension separator, a compression system, a gas storage tank, and a membrane module are detachably connected; the filtration and drying system, the secondary cooling system, the suspension separator, the compression system, the gas storage tank, and the membrane module are sequentially connected through pipelines;

[0006] The filtration and drying system is used to filter solid particles and moisture in the raw gas; the secondary cooling system is used to cool the raw gas; the suspension separator is used to remove liquefied components from the raw gas; and the compression system is used to compress the raw gas into high-pressure gas.

[0007] The membrane module includes a main pipe and two membrane units. The main pipe is connected to a first branch pipe and a second branch pipe through a first manual reversing valve. The two membrane units are spaced apart on the first branch pipe. One end of the second branch pipe is connected to the first branch pipe between the two membrane units. The main pipe is connected to the gas storage tank.

[0008] Monitoring systems are installed on the pipeline, the main pipeline, the first branch pipe, and the second branch pipe. These monitoring systems are used to monitor gas composition, temperature, pressure, and flow rate.

[0009] According to a skid-mounted gas separation membrane device provided by the present invention, the filtration and drying system includes a pre-filter and a dryer assembly. One end of the pre-filter is connected to a gas collection station through a feed pipe, and the other end is connected to the dryer assembly. The dryer assembly is connected to the secondary cooling system through the pipeline. An inlet valve is installed on the feed pipe.

[0010] According to a skid-mounted gas separation membrane device provided by the present invention, the dryer assembly includes two drying branches, the two drying branches are connected to the discharge end of the pre-filter through a second manual reversing valve, a first dryer is installed on each of the two drying branches, and both drying branches are connected to the pipeline.

[0011] According to a skid-mounted gas separation membrane device provided by the present invention, the secondary cooling system includes a first heat exchanger, a second heat exchanger, and a refrigeration unit; both the first heat exchanger and the second heat exchanger are connected to the refrigeration unit through refrigeration pipelines; the first heat exchanger and the second heat exchanger are installed at intervals on the pipelines, and a second dryer is installed between the second heat exchanger and the suspension separator.

[0012] According to the present invention, a skid-mounted gas separation membrane device is provided, wherein the monitoring system includes several pressure gauges, several temperature transmitters, several gas composition sensors and several flow sensors;

[0013] A pressure gauge, a temperature transmitter, and a gas composition sensor are installed on the main pipeline. Gas composition sensors and flow sensors are installed on both the first and second branch pipes. A pressure gauge, a temperature transmitter, and a gas composition sensor are installed on the pipeline between the drying branch and the first heat exchanger.

[0014] According to the present invention, a skid-mounted gas separation membrane device is provided, wherein the compression system adopts a two-stroke natural gas compressor.

[0015] According to the present invention, a skid-mounted gas separation membrane device is provided, wherein the pre-filter is a straight-through basket filter and the pre-filter is equipped with a corrosion-resistant and hydrophobic filter material.

[0016] According to the present invention, a skid-mounted gas separation membrane device is provided, wherein the suspension separator is a cyclone baffle separator.

[0017] According to a skid-mounted gas separation membrane device provided by the present invention, the first dryer adopts a drying tube, and the drying tube is filled with a desiccant.

[0018] The present invention also provides a method of using a skid-mounted gas separation membrane device, comprising the following steps:

[0019] Step 1: The gas to be separated enters the filtration and drying system, separating the solid particles and moisture in the raw gas;

[0020] Step 2: After drying, the gas enters the secondary cooling system to cool down, causing the easily condensable components in the gas to liquefy;

[0021] Step 3: After cooling, the gas enters the suspension separator to remove liquefied components from the gas;

[0022] Step 4: The gas after suspension separation is compressed into high-pressure gas by the compression system and then transported to the gas storage tank;

[0023] Step 5: The high-pressure gas in the storage tank is cooled to the set temperature through a heat exchanger;

[0024] Step 6: After the high-pressure gas is cooled, it enters the membrane module, is separated and purified by the membrane device, and is then discharged to the outside.

[0025] The present invention discloses the following technical effects:

[0026] This invention detachably connects the filtration and drying system, secondary cooling system, suspension separator, compression system, gas storage tank, and membrane module to a skid. The skid-mounted structure achieves compactness and portability of the equipment, significantly reducing the footprint and transportation costs. It is suitable for small oil and gas fields and complex terrains. It enables easy replacement of the filtration and drying system, secondary cooling system, suspension separator, compression system, gas storage tank, and membrane module, facilitating maintenance by operators. It possesses the operational functions of large gas separation membrane equipment, can meet the performance testing requirements of gas separation membrane modules, and can optimize the process parameters of gas separation membrane equipment.

[0027] This invention uses a first manual reversing valve to switch the connection between the main pipeline and the first branch pipeline, and between the main pipeline and the second branch pipeline. When the connection is made between the main pipeline and the first branch pipeline, the gas passes through two membrane devices for secondary filtration in sequence. When the connection is made between the main pipeline and the second branch pipeline, the gas passes through two membrane devices simultaneously for single filtration, simplifying the adjustment of the membrane separation process. The use of the first manual reversing valve enables the switching of membrane module modes, facilitating performance testing and efficiency optimization, and providing convenience for experimental research and industrial applications.

[0028] This invention can be used to evaluate the separation performance, long-term operational stability, physical / chemical aging, and anti-fouling properties of gas separation membrane modules in gas mixture systems such as natural gas purification, biogas separation, helium / methane, helium / nitrogen, air dehydration, hydrogen / nitrogen, hydrogen / methane, hydrogen / carbon dioxide, and air separation (O2 / N2). Attached Figure Description

[0029] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0030] Figure 1 This is a schematic diagram of the structure of the present invention;

[0031] Figure 2 This is a schematic diagram of the membrane module in this invention;

[0032] Figure 3 This is a schematic diagram of the two-stage cooling system in this invention;

[0033] Figure 4 This is a schematic diagram of the compression system in this invention.

[0034] The components include: 1. Inlet valve; 2. Pre-filter; 3. First dryer; 4. First heat exchanger; 5. Second heat exchanger; 6. Refrigeration unit; 7. Second dryer; 8. Suspension separator; 9. Compression system; 10. First manual directional valve; 11. Membrane unit; 12. Second manual directional valve. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] Reference Figures 1-4 The present invention provides a skid-mounted gas separation membrane device, including a skid body, on which a filtration and drying system, a secondary cooling system, a suspension separator 8, a compression system 9, a gas storage tank and a membrane module are detachably connected; the filtration and drying system, the secondary cooling system, the suspension separator 8, the compression system 9, the gas storage tank and the membrane module are connected in sequence through pipelines;

[0038] The filtration and drying system is used to filter solid particles and moisture in the raw gas, the secondary cooling system is used to cool the raw gas, the suspension separator 8 is used to remove liquefied components in the raw gas, and the compression system 9 is used to compress the raw gas into high-pressure gas.

[0039] The membrane module includes a main pipe and two membrane units 11. The main pipe is connected to a first branch pipe and a second branch pipe through a first manual reversing valve 10. The two membrane units 11 are spaced apart on the first branch pipe. One end of the second branch pipe is connected to the first branch pipe between the two membrane units 11. The main pipe is connected to the gas storage tank.

[0040] Monitoring systems are installed on the pipeline, the main pipeline, the first branch pipe, and the second branch pipe. These systems monitor gas composition, temperature, pressure, and flow rate. Membrane unit 11 consists of two hollow fiber membrane modules. The area of ​​each membrane module can be the same or different. Each membrane module contains an effective membrane area of ​​1-100 m², with a maximum design pressure of 1.0-10.0 MPa and a design inlet temperature of -20℃ to 90℃.

[0041] With this configuration, the present invention detachably connects the filtration and drying system, secondary cooling system, suspension separator, compression system, gas storage tank, and membrane module to the skid. The skid-mounted structure achieves compactness and portability of the equipment, significantly reducing the footprint and transportation costs. It is suitable for small oil and gas fields and complex terrains, and enables easy replacement of the filtration and drying system, secondary cooling system, suspension separator, compression system, gas storage tank, and membrane module. This facilitates maintenance and operation for operators, and it possesses the operational functions of large gas separation membrane equipment. It can meet the performance testing requirements of gas separation membrane modules and optimize the process parameters of gas separation membrane equipment.

[0042] This invention uses a first manual reversing valve 10 to switch the connection between the main pipe and the first branch pipe, and between the main pipe and the second branch pipe. When the connection is between the main pipe and the first branch pipe, the gas passes through two membrane units 11 for secondary filtration in sequence. When the connection is between the main pipe and the second branch pipe, the gas passes through two membrane units 11 simultaneously for single filtration, simplifying the adjustment of the membrane separation process. The first manual reversing valve 10 enables the switching of membrane module modes, facilitating performance testing and efficiency optimization, and providing convenience for experimental research and industrial applications. The two membrane units 11 are connected to external equipment through exhaust pipes.

[0043] This invention can be used to evaluate the separation performance, long-term operational stability, physical / chemical aging, and anti-fouling properties of gas separation membrane modules in gas mixture systems such as natural gas purification, biogas separation, helium / methane, helium / nitrogen, air dehydration, hydrogen / nitrogen, hydrogen / methane, hydrogen / carbon dioxide, and air separation (O2 / N2).

[0044] The scheme is further optimized. The filtration and drying system includes a pre-filter 2 and a dryer group. One end of the pre-filter 2 is connected to the gas collection station through the feed pipe, and the other end is connected to the dryer group. The dryer group is connected to the secondary cooling system through the pipeline. An air inlet valve 1 is installed on the feed pipe. The air inlet valve 1 is a normally open valve.

[0045] In this embodiment, the pre-filter 2 is selected with a volume of 10-100L, an intake pressure of 0.3~0.4MPa, and an operating pressure of 1.0MPa-10.0MPa. It is used to separate large solid particles and some crude oil substances that cannot be filtered from the raw gas.

[0046] The scheme is further optimized. The dryer group includes two drying branches. The two drying branches are connected to the discharge end of the pre-filter 2 through the second manual reversing valve 12. A first dryer 3 is installed on each of the two drying branches. Both drying branches are connected to pipelines.

[0047] The scheme is further optimized. The secondary cooling system includes a first heat exchanger 4, a second heat exchanger 5, and a chiller 6. Both the first heat exchanger 4 and the second heat exchanger 5 are connected to the chiller 6 through refrigeration pipes. The first heat exchanger 4 and the second heat exchanger 5 are installed alternately on the pipes. A second dryer 7 is installed between the second heat exchanger 5 and the suspension separator 8.

[0048] The chiller 6 is a low-temperature water chiller with a cooling capacity of 1.4-10kW at -20℃, which meets the cooling requirements of this equipment. This invention employs a two-stage cooling design, connecting two plate heat exchangers (first heat exchanger 4 and second heat exchanger 5) in series. To reduce the increase in heat exchange area caused by the continuous increase in the overall heat transfer coefficient, a margin-based design is used for the plate heat exchangers. Furthermore, this invention uses a counter-current heat exchange method to connect the hot and cold flows. The hot gas enters the plate heat exchangers from top to bottom, while the refrigerant enters from the outlet after the chiller into the lower right inlet of the first plate heat exchanger, which is the cold flow inlet. This design utilizes the counter-current heat exchanger, which improves the heat transfer coefficient.

[0049] The scheme has been further optimized, and the monitoring system includes several pressure gauges, several temperature transmitters, several gas composition sensors, and several flow sensors.

[0050] Pressure gauges, temperature transmitters and gas composition sensors are installed on the main pipeline. Gas composition sensors and flow sensors are installed on the first branch pipe and the second branch pipe. Pressure gauges, temperature transmitters and gas composition sensors are installed on the pipeline between the drying branch and the first heat exchanger 4.

[0051] The gas composition sensor can be used simultaneously with one or more common gas detectors such as hydrogen, helium, CO2, CO, CH4, O2, N2, and H2O.

[0052] Temperature transmitters are used to measure the temperature of fluids;

[0053] Pressure gauges are used to measure the pressure of fluids;

[0054] The flow sensor is a mass or volume flow meter.

[0055] The design was further optimized, and compression system 9 adopted a two-stroke natural gas compressor with a gas flow rate of 10-50 Nm³. 3 / h, intake pressure: 0.1-0.5MPa, exhaust pressure: 1.0-10.0MPa, power: 2.2-22kw, speed: 720-1500rpm, CT4 explosion-proof.

[0056] Further optimization of the scheme: the pre-filter 2 adopts a straight-through basket filter, and the pre-filter 2 is equipped with a corrosion-resistant and hydrophobic filter material. In this embodiment, a PTFE filter screen is used.

[0057] Further optimizing the design, the suspension separator 8 adopts a cyclone baffle separator. This cyclone baffle separator utilizes five-stage separation technology, integrating physical principles such as deceleration, centrifugation, collision, direction change, and condensation to effectively remove liquid moisture and solid particles from compressed air, achieving gas purification. After the moist gas cools and condenses, the baffles inside the suspension separator 8 guide the gas to change its flow direction twice and rotate it at a specific speed. The resulting centrifugal force rapidly separates the liquid from the particles. The separated condensate must be discharged promptly through a drain to ensure the continuous and efficient operation of the equipment.

[0058] Further optimization of the design: the first dryer 3 uses a drying tube filled with a desiccant. The drying tube has a diameter of 50mm, a total length of 260mm, and a maximum working pressure of 1.0MPa-10MPa. Each drying tube has a capacity of approximately 250g of desiccant, which contains silica gel particles, calcium chloride, alumina, molecular sieves, and activated carbon in a mass ratio of 1:1:1:1:1, added layer by layer.

[0059] In this invention, the gas to be separated is input from the gas collection station to the air inlet and enters the pre-filter 2 after the air inlet valve 1, which can filter out the solid particles carried in the gas to be separated through the filter screen of the basket pre-filter.

[0060] The separated gas then enters the dryer assembly, which is connected in parallel. A second manual reversing valve 12 is placed at the front to switch the gas to the first dryer 3 of another path after the first dryer 3 of one path is saturated. A cooling system is then connected to cool the gas to approximately -20°C.

[0061] At this temperature, easily condensable substances in the gas will liquefy, but the content of high-carbon substances in this process is relatively small and will be carried away in the gas mixture. Therefore, a second dryer 7 is placed afterward to absorb the low-dew-point moisture. When the gas mixture (containing a small portion of high-carbon suspension) is introduced into the suspension separator 8, the gas comes into contact with the inner surface of the suspension separator 8, the liquid adheres to the inner surface, and the gas exits from bottom to top, achieving gas-liquid separation. Finally, the gas enters the compression system 9 for pressurization and heating, and is stored again in the gas storage tank below the compression system 9. This gas storage tank can maintain stable gas pressure, stabilize the intake volume, and reduce fluctuation peaks.

[0062] This invention utilizes a first manual reversing valve 10 to change the flow path direction, enabling the connection mode of the two membrane units 11 to be switched from series to parallel, or vice versa. In series mode, gas passes through the two membrane modules sequentially, suitable for scenarios requiring multi-stage separation; in parallel mode, gas passes through the two membrane modules simultaneously, suitable for increasing throughput or comparing performance. This design allows for rapid switching of connection modes within the same device, facilitating comparative studies of key parameters such as separation efficiency and flux of membrane modules under different configurations, thus providing a more comprehensive evaluation of membrane unit performance. When experimental evaluation of a single membrane unit is required, simply switching to parallel mode directly yields the experimental results of both membrane units. Furthermore, temperature, pressure, and flow transmitters are installed before and after the membrane units to facilitate data transmission to the central control panel for experimental operation and data recording.

[0063] The present invention also provides a method of using a skid-mounted gas separation membrane device, comprising the following steps:

[0064] Step 1: The gas to be separated enters the filtration and drying system, separating the solid particles and moisture in the raw gas;

[0065] Step 2: After drying, the gas enters the secondary cooling system to cool down to -20℃, causing the easily condensable components in the gas, such as alkanes, alkenes, and benzene, to liquefy.

[0066] Step 3: After cooling, the gas enters the suspension separator 8 to remove liquefied components from the gas;

[0067] Step 4: The gas after suspension separation is compressed to high pressure (1MPa-10MPa) by compression system 9 and then transported to the gas storage tank;

[0068] Step 5: The high-pressure gas in the storage tank is cooled to the set temperature through a heat exchanger;

[0069] Step 6: After the high-pressure gas is cooled, it enters the membrane module, is separated and purified by membrane unit 11, and is discharged to the outside to obtain product gas.

[0070] In the description of this invention, it should be understood that the terms "longitudinal", "lateral", "up", "down", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and are not intended to indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0071] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the implementation of the present invention. For those skilled in the art, other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively describe all embodiments here. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the claims of the present invention.

Claims

1. A skid-mounted gas separation membrane device, characterized by, Includes a skid, on which a filtration and drying system, a secondary cooling system, a suspension separator (8), a compression system (9), a gas storage tank, and a membrane module are detachably connected; the filtration and drying system, the secondary cooling system, the suspension separator (8), the compression system (9), the gas storage tank, and the membrane module are connected in sequence through pipelines; The filtration and drying system is used to filter solid particles and moisture in the raw gas, the secondary cooling system is used to cool the raw gas, the suspension separator (8) is used to remove liquefied components in the raw gas, and the compression system (9) is used to compress the raw gas to high pressure. The membrane assembly includes a main pipe and two membrane units (11). The main pipe is connected to a first branch pipe and a second branch pipe through a first manual reversing valve (10). The two membrane units (11) are installed at intervals on the first branch pipe. One end of the second branch pipe is connected to the first branch pipe between the two membrane units (11). The main pipe is connected to the gas storage tank. Monitoring systems are installed on the pipeline, the main pipeline, the first branch pipe, and the second branch pipe. The monitoring systems are used to monitor gas composition, temperature, pressure, and flow rate. The filtration and drying system includes a pre-filter (2) and a dryer assembly. One end of the pre-filter (2) is connected to the gas collection station through a feed pipe, and the other end is connected to the dryer assembly. The dryer assembly is connected to the secondary cooling system through the pipeline. An air inlet valve (1) is installed on the feed pipe. The dryer assembly includes two drying branches, which are connected to the discharge end of the pre-filter (2) via a second manual reversing valve (12). A first dryer (3) is installed on each of the two drying branches, and both drying branches are connected to the pipeline. The secondary cooling system includes a first heat exchanger (4), a second heat exchanger (5), and a refrigerator (6); the first heat exchanger (4) and the second heat exchanger (5) are both connected to the refrigerator (6) through refrigeration pipelines; the first heat exchanger (4) and the second heat exchanger (5) are installed at intervals on the refrigeration pipelines, and a second dryer (7) is installed between the second heat exchanger (5) and the suspension separator (8).

2. The skid-mounted gas separation membrane device of claim 1, wherein: The monitoring system includes several pressure gauges, several temperature transmitters, several gas composition sensors, and several flow sensors. A pressure gauge, a temperature transmitter, and a gas composition sensor are installed on the main pipeline. Gas composition sensors and flow sensors are installed on the first branch pipe and the second branch pipe. A pressure gauge, a temperature transmitter, and a gas composition sensor are installed on the pipeline between the drying branch and the first heat exchanger (4).

3. The skid-mounted gas separation membrane device of claim 1, wherein: The compression system (9) uses a two-stroke natural gas compressor.

4. The skid-mounted gas separation membrane device of claim 1, wherein: The pre-filter (2) is a straight-through basket filter, and the pre-filter (2) is equipped with a corrosion-resistant and hydrophobic filter material.

5. The skid-mounted gas separation membrane device of claim 1, wherein: The suspension separator (8) is a cyclone baffle separator.

6. The skid-mounted gas separation membrane device of claim 1, wherein: The first dryer (3) uses a drying tube filled with a desiccant.

7. A method of using a skid-mounted gas separation membrane device according to any one of claims 1-6, wherein, Includes the following steps: Step 1: The gas to be separated enters the filtration and drying system to filter out solid particles and moisture in the raw gas; Step 2: After drying, the gas enters the secondary cooling system to cool down, causing the easily condensable components in the gas to liquefy; Step 3: After cooling, the gas enters the suspension separator (8) to remove the liquefied components from the gas; Step 4: The gas after suspension separation is compressed into high-pressure gas by the compression system (9) and transported to the gas storage tank; Step 5: The high-pressure gas in the storage tank is cooled to the set temperature through a heat exchanger; Step 6: After the high-pressure gas is cooled, it enters the membrane module, is separated and purified by the membrane device (11), and is discharged to the outside.

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