A gas-liquid separation module with high separation efficiency and low flow resistance

Abstract

The application discloses a gas-liquid separation module with high separation efficiency and low flow resistance, which comprises a frame shell, a baffle and a cyclone rotor. A plurality of baffles are distributed in the frame shell in an equidistant array along the transverse direction and are fixed to the frame shell. Each two adjacent baffles form a group of curved flow channels, and a cyclone rotor is arranged in the middle of each group of curved flow channels. The outer end of the cyclone rotor is matched with the inner wall of the curved flow channel to form a dynamic closed one-way cyclone air inlet structure, so that the air flow on the windward side is guided to the leeward side with the rotation of the cyclone rotor. The traditional multi-baffle array inertial separation structure is creatively designed as a dynamic inertial separation structure combined with an arc-shaped curved air duct and a centrifugal cyclone structure. The close structural cooperation can effectively improve the gas-liquid separation efficiency, intercept and discharge the liquid impurities in the air, and the cyclone structure can also reduce the air flow resistance, so that the high-efficiency and low-resistance design of the gas-liquid separation structure is realized.

Description

Technical Field

[0001] This application belongs to the field of gas-liquid separation technology, specifically relating to a gas-liquid separation module that balances separation efficiency and low flow resistance. Background Technology

[0002] Gas turbines, diesel engines, air compressors, and other power machinery are widely used in industrial production. Air, as a crucial working medium, has a significant impact on the stability and reliability of equipment operation, as well as the production processes involving air, due to its liquid impurity content. For example, in high-humidity conditions such as marine environments or rainy weather, the air in gas turbines contains a significant amount of liquid water mist. This water mist can cause the resistance of the gas turbine's air filtration system to rise too quickly. If it enters the downstream air duct, it can easily cause or exacerbate corrosion of the duct and downstream equipment. Moist air entering the combustion chamber can also affect combustion stability. In the chemical industry, certain processes are sensitive to the humidity content of the air and require deep dehumidification. This involves condensation to remove moisture, followed by removal of liquid water using a gas-liquid separation module, thereby ensuring that the air humidity meets production requirements.

[0003] Gas turbines, diesel engines, and air compressors draw air from the natural environment and often face severe weather conditions such as rain and fog. They often need to be equipped with gas-liquid separation modules to pre-filter liquid and solid particles with larger particle sizes in the air.

[0004] Traditional gas-liquid separation modules mainly fall into two categories: inertial separation (baffle, centrifugal, etc.) and wire mesh filtration. Inertial separation, when used for high-flow-rate air handling, typically employs a baffle-type gas-liquid separation module. This module divides the air intake section into multiple bends using a set of parallel, equidistantly distributed baffles. These baffles have one or more bends, and the bends usually have hook structures to intercept water on the baffle surface and drain it to the bottom. In actual operation, the airflow changes direction as it passes through the bends. Liquid, due to its inertia, impacts the baffle surface, and the accumulated liquid flows downwards due to gravity. Some liquid may still flow inwards along the wall under the influence of the airflow, only to be intercepted by the hook structures and drained to the bottom. This structure has the following drawbacks in practical use: 1) The contradiction between filtration efficiency and resistance is significant. To improve the filtration efficiency of the baffle-type gas-liquid separation module, whether by reducing the spacing between the baffles or using more bends in the baffle structure, the airflow resistance of the gas-liquid separation module will be significantly increased. 2) To achieve higher filtration and separation efficiency, whether it is reducing the spacing between baffles or using a baffle structure with more bends, the weight and manufacturing cost of the structure will be significantly increased.

[0005] Wire mesh filter-type gas-liquid separation modules utilize a multi-layered, loosely woven mesh to form a filter structure for liquid filtration. While its high porosity facilitates efficient gas-liquid separation, it suffers from the following drawbacks: 1) High resistance: In practical applications, multiple layers of mesh are often used to ensure effective filtration. The thick structure leads to high resistance during normal operation due to liquid retention. 2) Dust and dirt accumulation: The wire mesh separation structure filters not only liquid particles but also solid impurities like dust. The accumulation of these impurities increases the filter's resistance, eventually requiring replacement or cleaning, resulting in high maintenance costs.

[0006] For the reasons mentioned above, while ensuring that the filtration and separation efficiency meets the usage requirements, reducing the flow resistance of the gas-liquid separation module, as well as reducing the weight of the structure and the amount of maintenance, are the practical needs of gas turbines and other power machinery for gas-liquid separation modules. Summary of the Invention

[0007] This invention addresses the shortcomings of existing technologies by providing a gas-liquid separation module that balances separation efficiency with low flow resistance.

[0008] The above-mentioned objective of this invention is achieved through the following technical solution: A gas-liquid separation module that balances separation efficiency and low flow resistance includes a frame shell, baffles, and a swirl rotor. Multiple baffles are arranged in a horizontally evenly spaced array inside the frame shell and are fixedly connected to the frame shell. A set of curved flow channels is formed between every two adjacent baffles. A swirl rotor is set in the middle of each set of curved flow channels. The swirl rotor is rotatably connected to the upper and lower frames of the frame shell. The outer end of the swirl rotor cooperates with the inner wall of the curved flow channel to form a dynamic closed unidirectional swirl air intake structure, so that as the swirl rotor rotates, the airflow on the windward side is guided to the leeward side.

[0009] Furthermore, the main body of the frame shell is a rectangular frame structure, with a row of threaded posts fixed vertically along the horizontal direction on its inner top surface. An adjustable threaded sleeve is installed on each threaded post, and a row of circular countersunk holes is provided along the horizontal direction on its inner bottom surface. The threaded sleeve at the top and the circular countersunk holes at the bottom are aligned one by one, and a drainage pipe is provided at the bottom. An upstream blade fixing component and a downstream blade fixing component are respectively provided at the middle position along the height of the frame shell on the windward and leeward sides. Both the upstream blade fixing component and the downstream blade fixing component adopt the toothed blade fixing component, and a U-shaped insertion is formed between the teeth.

[0010] Furthermore, the upstream blade fixing component is detachably fixed to the frame shell using bolts, while the downstream blade fixing component is fixed to the frame shell using welding.

[0011] Moreover, each baffle plate adopts a continuous reverse four-bend plate, which is welded from two continuous reverse double-bend plates, and the middle part is X-shaped. The two ends of each baffle plate are respectively inserted and fixed to the U-shaped socket on the upstream blade fixing component and the U-shaped socket on the downstream blade fixing component. The curved flow channel formed between two adjacent baffle plates is inclined to the windward side of the gas-liquid separation module. The two adjacent baffle plates and the swirl rotor form a concentric embrace structure. The outer envelope circle of the swirl rotor and the baffle plate are in micro-gap fit, so that the blades always maintain a dynamic micro-gap seal with the baffle plates on both sides during the rotation of the swirl rotor.

[0012] Furthermore, the curved flow channel formed by the two adjacent baffles cooperates with the built-in swirl rotor to form an air inlet duct on the windward side and an air outlet duct on the leeward side; the inner wall surface corresponding to the air inlet duct is provided with linear textures along the height direction to facilitate the downward flow of accumulated liquid; the X-shaped structure in the middle of the baffle forms a groove structure on the windward side for effective liquid interception and drainage.

[0013] Furthermore, the swirl rotor is connected to the upper and lower frames of the frame housing via connecting accessories; the connecting accessories include a top connecting seat, a bottom connecting seat, and a bearing rotating pair; the lower end of the top connecting seat is interference-fitted with the upper end of the swirl rotor, and the upper end of the top connecting seat is clearance-fitted with a threaded sleeve fixed to the upper frame, forming a rotating pair; the upper end of the bottom connecting seat is interference-fitted with the lower end of the swirl rotor, and the lower end of the bottom connecting seat is tight-fitted with the inner ring of the bearing rotating pair, and the outer ring of the bearing rotating pair is securely inserted into the corresponding circular countersunk hole structure at the bottom of the frame housing.

[0014] Moreover, the swirl rotor adopts an integral molding structure of a hollow tube shaft and three blades. The blades are connected along the tangent of the outer circle of the tube shaft and are evenly distributed along the circumference. The blades are generally arc-shaped, and the outer ends are provided with hook-shaped small arc structures. The outer envelope circle of the swirl rotor blades is concentric with the tube shaft.

[0015] The advantages and positive effects of this invention are as follows: This invention creatively transforms the traditional multi-flanged array inertial separation structure into a dynamic inertial separation structure that combines an arc-shaped bend air duct with a centrifugal vortex structure. Its tight structural design can effectively improve gas-liquid separation efficiency, intercept and remove liquid impurities in the air, while the vortex structure can reduce airflow resistance, thus achieving a high-efficiency, low-resistance design for the gas-liquid separation structure.

[0016] Compared with the prior art, the present invention has the following advantages: 1. By combining the bending and turning inertial interception with the centrifugal force generated by rotation, the inertial separation effect is enhanced, while the flow resistance is controlled at a low level, thus achieving a high-efficiency and low-resistance design for the gas-liquid separation structure.

[0017] 2. The swirl rotor adopts a tangential arc structure and a hook design at the end of the blades. It is fitted with a micro-gap between the rotor and the baffle plate, which can meet the structural requirements of liquid interception and drainage, and effectively reduce the airflow resistance.

[0018] 3. The air inlet channel formed by the baffle and rotor has a linear textured structure along the height direction on one side, which can increase the resistance to lateral liquid flow and facilitate the downward discharge of accumulated liquid.

[0019] 4. Reduce the number of baffle plates while ensuring separation efficiency, thus reducing installation workload. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of a single gas-liquid separation module of the present invention; Figure 2 The following are schematic diagrams of the frame shell of the present invention: 2a, first angle view; 2b, second angle view. Figure 3 The diagram shows the structure of the gas-liquid separation channel unit of the present invention, which consists of two adjacent baffles and a swirling rotor; 3a, top view; 3b, perspective view. Figure 4 4a is a top view and 4b is a perspective view of the swirl rotor structure of the present invention. Figure 5 Schematic diagram of the baffle structure of the present invention; 5a, top view; 5b, perspective view; Figure 6 Examples of the installation and use of the gas-liquid separation module of the present invention: 6a, front view; 6b, side view; In the diagram: 1. Frame shell; 1-1. Main body; 1-2. Threaded sleeve; 1-3. Circular countersunk hole; 1-4. Drainage pipe; 1-5. Upstream blade fixing component; 1-6. Downstream blade fixing component; 2. Baffle; 2-1. X-shaped structure; 2-2. Linear texture; 3. Swirl rotor; 3-1. Hollow tube shaft; 3-2. Blades; 4. Inlet side air duct; 5. Outlet side air duct; 6. Top connecting seat; 7. Bottom connecting seat; 8. Bearing rotating pair. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0022] For a gas-liquid separation module that balances separation efficiency and low flow resistance, please refer to [link / reference]. Figures 1-6The invention features a gas-liquid separation module comprising a frame housing 1, baffles 2, and a swirling rotor 3. Multiple baffles are arranged in a horizontally spaced array inside the frame housing and are fixedly connected to it. A set of curved flow channels is formed between every two adjacent baffles. A swirling rotor is positioned at the center of each curved flow channel. The baffles and swirling rotor are made of aluminum alloy. The swirling rotor is rotatably connected to the upper and lower frames of the frame housing. The outer end of the swirling rotor engages with the inner wall of the curved flow channel to form a dynamic, closed, unidirectional swirling air intake structure, thereby guiding the airflow from the windward side to the leeward side as the swirling rotor rotates.

[0023] The main body 1-1 of the frame shell is a rectangular frame structure. A row of threaded posts is vertically fixed along the horizontal direction on its inner top surface. An adjustable threaded sleeve 1-2 is installed on each threaded post, used to limit the upper end of the cyclone rotor. A row of circular countersunk holes 1-3 is provided along the horizontal direction on its inner bottom surface, with the top threaded sleeve aligned with the bottom circular countersunk holes. The width of the frame on the windward and leeward sides is designed to match the cyclone gas-liquid separator to prevent airflow bypass. A drain pipe 1-4 is provided at the bottom to output the diverted liquid. An upstream blade fixing component 1-5 and a downstream blade fixing component 1-6 are respectively located at the midpoint of the frame shell height on the windward and leeward sides. Both the upstream and downstream blade fixing components are toothed blade fixing components. The upstream blade fixing component is bolted to the frame shell (removable), while the downstream blade fixing component is welded to the frame shell. The toothed blade fixing component has an L-shaped bent structure with equally spaced U-shaped inlets on one side. The size and spacing of the inlets match the baffle plate of the object being fixed. The two blade fixing components are fixed to the rectangular frame structure using fasteners or welding. When installing the gas-liquid separation structure, it can be fixed to the equipment frame using fasteners or welding.

[0024] Each baffle plate is constructed using a continuous reverse four-bend plate. In this invention, each baffle plate is welded together from two continuous reverse double-bend plates, with an X-shaped central section. Both ends of each baffle plate are respectively inserted and fixed into U-shaped sockets on the upstream and downstream blade fixing components. The curved flow channel formed between adjacent baffle plates is inclined to the windward side of the gas-liquid separation module. Adjacent baffle plates and the swirling rotor form a concentric embrace structure. The outer envelope of the swirling rotor and the baffle plates are fitted with a micro-gap, ensuring that the blades maintain a dynamic micro-gap seal with the baffle plates during rotor rotation.

[0025] The curved flow channel formed by two adjacent baffles cooperates with the built-in swirl rotor to form an air inlet duct 4 on the windward side and an air outlet duct 5 on the leeward side. The inner wall surface of the air inlet duct is treated with a linear texture 2-2 along the height direction to facilitate the downward flow of accumulated liquid. The X-shaped structure 2-1 in the middle of the baffle forms a groove structure on the windward side, which can effectively intercept and drain liquid. The arc-shaped side surface of the baffle and the swirl rotor, which are concentrically matched, can ensure the dynamic closed cooperation between the blades and the baffles during the rotation of the swirl rotor.

[0026] The vortex rotor is connected to the upper and lower frames of the frame housing via connecting accessories. Specifically, the connecting accessories include a top connecting seat 6, a bottom connecting seat 7, and a bearing rotating pair 8. The lower end of the top connecting seat is interference-fitted with the upper end of the vortex rotor, and the upper end of the top connecting seat is clearance-fitted with a threaded sleeve fixed to the corresponding upper frame, forming a rotating pair. The upper end of the bottom connecting seat is interference-fitted with the lower end of the vortex rotor, and the lower end of the bottom connecting seat is tight-fitted with the inner ring of the bearing rotating pair. The outer ring of the bearing rotating pair is securely fitted with a corresponding circular countersunk hole structure at the bottom of the frame housing.

[0027] The swirl rotor adopts an integral molding structure of hollow tube shaft 3-1 and three blades 3-2. The blades are connected along the outer circle tangent of the tube shaft and are evenly distributed along the circumference. The blades are generally arc-shaped, and hook-shaped small arc structures are provided at the outer ends. The outer envelope circle of the swirl rotor blades is concentric with the tube shaft.

[0028] In actual use, the frame shell of a single gas-liquid separation module is welded and fixed to the equipment mounting surface, and the drain pipes of the upper and lower gas-liquid separation modules are connected as one unit through external pipelines to drain the water underwater.

[0029] The working principle of the gas-liquid separation module of this invention, which balances separation efficiency and low flow resistance, is as follows: When the gas-liquid separation module is working, the airflow enters from the windward side, is bent by the baffle, and then passes through the right semi-circular channel. The vortex rotor begins to rotate under the action of the airflow. Throughout the process, the vortex rotor blades and the baffle maintain a dynamic seal. When the airflow passes through the first bend, the intercepted droplets are intercepted and discharged downwards by the X-structure in the middle of the baffle. When the airflow enters the swirling space formed by the vortex blades and the baffle, the droplets separate due to inertia under the action of centrifugal force and bending, and the accumulated liquid is discharged downwards.

[0030] The solution proposed in this invention is expected to effectively intercept droplets larger than 10 micrometers. At an inlet flow rate of 2.6 m / s, the flow resistance is approximately 20 Pa, which is significantly better than the commonly used corrugated plate inertial separator.

[0031] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

Claims

1. A gas-liquid separation module that balances separation efficiency and low flow resistance, characterized in that: It includes a frame shell, baffles, and a swirl rotor. Multiple baffles are arranged in a horizontal array at equal intervals inside the frame shell and are fixedly connected to the frame shell. A set of curved flow channels is formed between every two adjacent baffles. A swirl rotor is set in the middle of each set of curved flow channels. The swirl rotor is connected to the upper and lower frames of the frame shell in a rotatable manner around its center. The outer end of the swirl rotor cooperates with the inner wall of the curved flow channel to form a dynamic closed unidirectional swirl air intake structure, so that as the swirl rotor rotates, the airflow on the windward side is guided to the leeward side.

2. The gas-liquid separation module that balances separation efficiency and low flow resistance according to claim 1, characterized in that: The main body of the frame shell is a rectangular frame structure. A row of threaded posts is fixed vertically along the horizontal direction on the inner top surface. An adjustable threaded sleeve is installed on each threaded post. A row of circular countersunk holes is provided along the horizontal direction on the inner bottom surface. The threaded sleeve at the top and the circular countersunk holes at the bottom are aligned one by one. A drainage pipe is provided at the bottom. An upstream blade fixing component and a downstream blade fixing component are respectively provided at the middle position along the height of the frame shell on the windward and leeward sides. Both the upstream blade fixing component and the downstream blade fixing component adopt the toothed blade fixing component, and a U-shaped insertion is formed between the teeth.

3. The gas-liquid separation module that balances separation efficiency and low flow resistance according to claim 2, characterized in that: The upstream blade fixing component is fixed to the frame shell by bolts, and the downstream blade fixing component is fixed to the frame shell by welding.

4. The gas-liquid separation module that balances separation efficiency and low flow resistance according to claim 2, characterized in that: Each baffle plate is made of a continuous reverse four-bend plate, which is welded together from two continuous reverse double-bend plates, and has an X-shape in the middle. The two ends of each baffle plate are respectively inserted and fixed to the U-shaped sockets on the upstream blade fixing component and the downstream blade fixing component. The curved flow channel formed between two adjacent baffle plates is inclined to the windward side of the gas-liquid separation module. The two adjacent baffle plates and the swirl rotor form a concentric embrace structure. The outer envelope circle of the swirl rotor and the baffle plate are fitted with a micro-gap, so that the blades always maintain a dynamic micro-gap seal with the baffle plates on both sides during the rotation of the swirl rotor.

5. The gas-liquid separation module that balances separation efficiency and low flow resistance according to claim 4, characterized in that, The curved flow channel formed by two adjacent baffles cooperates with the built-in swirl rotor to form an air inlet duct on the windward side and an air outlet duct on the leeward side. The inner wall surface corresponding to the air inlet duct is provided with linear textures along the height direction to facilitate the downward flow of accumulated liquid. The X-shaped structure in the middle of the baffle forms a groove structure on the windward side for effective liquid interception and drainage.

6. The gas-liquid separation module that balances separation efficiency and low flow resistance according to claim 2, characterized in that, The swirl rotor is connected to the upper and lower frames of the frame housing via connecting accessories. The connecting accessories include a top connecting seat, a bottom connecting seat, and a bearing rotating pair. The lower end of the top connecting seat is interference-fitted with the upper end of the swirl rotor, and the upper end of the top connecting seat is fitted with a threaded sleeve fixed to the upper frame with a clearance fitting, forming a rotating pair. The upper end of the bottom connecting seat is interference-fitted with the lower end of the swirl rotor, and the lower end of the bottom connecting seat is tightly fitted with the inner ring of the bearing rotating pair. The outer ring of the bearing rotating pair is tightly fitted with a corresponding circular countersunk hole structure at the bottom of the frame housing.

7. The gas-liquid separation module that balances separation efficiency and low flow resistance according to claim 1, characterized in that: The swirl rotor adopts an integral structure of a hollow tube shaft and three blades. The blades are connected along the tangent of the outer circle of the tube shaft and are evenly distributed along the circumference. The blades are generally arc-shaped, with hook-shaped small arc structures at the outer ends. The outer envelope circle of the swirl rotor blades is concentric with the tube shaft.

Images