Liquid separator for separating liquid from gas and heat exchanger with liquid separator

Abstract

The utility model relates to a liquid separator for separating liquid from gas and a heat exchanger with the liquid separator. A liquid separator (2) for separating a liquid from a gas, characterised in that the liquid separator (2) consists of a plurality of assemblies (14) consisting of plate-like liquid separation elements (15) which extend parallel to one another and are vertically oriented during use of the liquid separator (2), the assemblies (14) being vertically stacked one on top of the other during use of the liquid separator (2), wherein a liquid collector (19) is provided below each assembly (4), the liquid collector having a reservoir (20) for collecting the liquid separated by the liquid separation element (15) from the respective assembly (14) and discharging it to a discharge chamber (21).

Description

TECHNICAL FIELD

[0001] The present utility model relates to a liquid separator for separating liquid from gas.

[0002] More specifically, the present utility model aims at using a heat exchanger with a liquid separator to separate and discharge liquid from the cooled gas after cooling the gas. BACKGROUND

[0003] As is known, in a compressor plant, a low pressure gas, such as ambient air, is compressed into a high pressure gas.

[0004] In this process, heat is generated, so that the temperature of the compressed gas is higher than the required temperature, and therefore needs to be cooled.

[0005] The compressor plant usually comprises a plurality of successive compressor elements or compression stages, in which the gas is compressed in different steps.

[0006] The gas is cooled between the different compression stages and after the last compression stage.

[0007] This cooling takes place between the compression stages to improve the efficiency of the next compression stage.

[0008] After the last compression stage, cooling is performed to ensure that the supplied compressed gas has the required temperature.

[0009] It is also known that, when the compressed gas is cooled, the liquid present in the gas can condense in the form of vapour.

[0010] This liquid in the compressed gas can cause problems in the next compression stage or in the consumer network.

[0011] Therefore, it is important to remove the moisture or condensate from the compressed gas before it flows to the next compression stage or to the consumer network.

[0012] In order to cool the compressed gas and remove the moisture from the cooled gas, several solutions are known.

[0013] The first solution consists of a heat exchanger with a cooler for cooling the compressed gas, in which a liquid separator is provided externally to the heat exchanger, such as a cyclonic liquid separator.

[0014] This cyclonic liquid separator causes relatively high friction losses, resulting in pressure losses.

[0015] There are also liquid separators that use gravity to separate the condensate from the gas flow.

[0016] Although the pressure losses generated here are small, the efficiency is not high at high gas flow rates. They must therefore be implemented relatively large.

[0017] As described in BE 1015880, heat exchangers equipped with a cooling section and an integrated liquid separator are also known.

[0018] The liquid separator comprises a series of vertical corrugated walls which are arranged next to the cooling section of the heat exchanger.

[0019] The advantage of such a heat exchanger is that it can not only be manufactured in a compact and relatively inexpensive manner, but can also easily be fitted or integrated into a compressor device.

[0020] When the heat exchanger and the condensate separator are connected to each other as two separate components, the additional friction losses which usually occur between the connection of the heat exchanger and the condensate separator are also eliminated.

[0021] Such a heat exchanger is used in a horizontal position, wherein the heat exchanger extends in a horizontal plane and the heat exchanger is arranged close to the top wall, for example on top of a compressor unit.

[0022] The height of the heat exchanger, i.e. the dimension in the vertical direction, is limited in this position. The height of the vertical corrugated walls arranged next to the cooling section is therefore also limited.

[0023] This means that the condensate separated by the vertical corrugated walls only has to travel a limited distance, at most equal to the height of these walls, before it can finally enter the designated liquid collector.

[0024] However, not all compressor devices allow the heat exchanger to be integrated on top of the compressor device and in a horizontal position.

[0025] Sometimes, due to lack of space or other limitations or constraints, the heat exchanger has to be arranged in a vertical position, wherein the heat exchanger is tilted 90° so that it extends in a vertical plane.

[0026] The disadvantage of such a heat exchanger with an integrated liquid separator is that it cannot be arranged in a vertical position.

[0027] In principle, there would not be much difference if the cooling section of the heat exchanger would extend in a vertical plane instead of a horizontal plane.

[0028] However, tilting the heat exchanger 90° means that the vertical walls must also be tilted or rotated 90°.

[0029] This means that the liquid separated by the walls can no longer be separated by gravity, since the walls are now extending horizontally.

[0030] To solve this problem, the walls can be moved back to a vertical position, in which the walls extend along the entire height of the heat exchanger, by tilting 90° so that the height of the heat exchanger is now much higher than in the case of the conventional horizontal position.

[0031] This also means, therefore, that the condensate separated by the walls, in particular at the top of these walls, must travel a longer distance before finally entering the discharge pipe and can be discharged.

[0032] As a result, at least some of the droplets formed will be carried by the cooled compressed gas flowing through the walls at a relatively high speed and will eventually return to the compressed gas.

[0033] This means that, in this vertical position, the efficiency of the separation of the liquid can never reach the same efficiency as that of this heat exchanger in the horizontal position. SUMMARY

[0034] The present invention aims to overcome at least one of the above and other drawbacks by providing a liquid separator that can be arranged in a vertical position without greatly reducing the efficiency of the separation of the liquid.

[0035] The present invention relates to a liquid separator for separating a liquid from a gas, characterized in that the liquid separator consists of a plurality of assemblies of substantially plate-shaped liquid separation elements, which extend substantially parallel to each other and are oriented vertically during use of the liquid separator, which assemblies are stacked vertically on top of each other during use of the liquid separator, wherein a liquid collector is provided below each assembly, which liquid collector has a storage for collecting the liquid separated by the liquid separation elements from the respective assembly and discharging it to a discharge chamber provided for this purpose.

[0036] The advantage is that, by providing stacked assemblies of liquid separation elements, each with a liquid collector below it, the condensate separated by the liquid separation elements must travel a limited distance before finally entering the storage.

[0037] Once the liquid enters the storage, it cannot be carried back by the gas flow.

[0038] Since the condensate only has to travel a limited distance before finally entering the storage, this means that, once the condensate is formed, it will quickly finally enter the storage, so that the probability of the condensate being carried away by the gas flow is almost zero.

[0039] A vertical heat exchanger with such a liquid separator has the same efficiency as a known horizontal heat exchanger with a liquid separator.

[0040] In a practical embodiment, the discharge chamber is formed as a discharge duct extending over at least a part of the height of the liquid separator on a side wall of the liquid separator, which side wall of the liquid separator extends parallel to the direction of the gas flow through the liquid separator during use of the liquid separator.

[0041] By providing the discharge chamber not only at the lower part of the liquid separator, but also allowing it to extend over the height of the liquid separator, in combination with the liquid collector, the separated condensate can be discharged at various points.

[0042] The discharge chamber should be located on a side wall of the liquid separator extending between the inlet and the outlet of the liquid separator. That is, the discharge chamber should not be located on the side where the inlet or the outlet of the liquid separator is located.

[0043] According to an embodiment, the side wall of the liquid separator is formed by a partition wall between the stacked assembly of liquid separation elements and the discharge chamber, which partition wall provides a seal between the assembly and the discharge chamber.

[0044] According to a preferred feature of the invention, the liquid collector is configured as a container functioning as a storage section, the container having a top wall and a bottom, wherein the top wall is provided with an aperture or passage to allow the liquid separated by the liquid separation elements to be discharged into the storage section.

[0045] The aperture or passage in the top wall will ensure that the liquid condensate separated by the assembly above and then flowing downwards via the liquid separation elements until the top wall can finally enter the container or storage section.

[0046] Once the condensate reaches the container, it is shielded from the gas flow by the container. This means that it can no longer be carried away by the gas flow, or in other words, the condensate has effectively been separated once it has finally entered the container.

[0047] Preferably, the bottom of the container extends at an angle with respect to the horizontal plane and slopes downwards towards the discharge chamber when the liquid separator is in use.

[0048] The slope of the bottom will ensure that all separated condensate is quickly and smoothly directed to the discharge chamber under the influence of gravity.

[0049] In this case, the container of the liquid collector can have a plurality of upright sides between the top wall and the bottom, wherein the container is provided with a passage in a first side of these upright sides close to the bottom of the storage section, the first side facing the discharge chamber.

[0050] According to an embodiment, the liquid separation elements are configured as corrugated plates provided with hook-shaped ribs extending transversely, which hook-shaped ribs form vertical flow channels extending over the entire height or almost the entire height of the liquid separation elements.

[0051] The utility model also relates to a heat exchanger with liquid separator, and the liquid separator is the liquid separator according to the utility model, wherein, the heat exchanger further includes cooling part and separation part, wherein, the cooler is combined into the cooling part, is used for cooling gas, has the entrance for the gas to be cooled and the outlet for the gas after cooling;Wherein, the liquid separator is combined in the separation part, is used for separating liquid from the gas after cooling, has the entrance and the outlet for the gas after cooling;Wherein, the cooler outlet element is arranged between the cooling part and the separation part, and the cooler outlet element connects the outlet of the cooler to the entrance of the liquid separator. BRIEF DESCRIPTION OF DRAWINGS

[0052] In order to better show the features of the utility model, some preferred embodiments of the liquid separator and the heat exchanger with such liquid separator according to the utility model are described below by non-limiting examples with reference to the drawings, wherein:

[0053] Figure 1 The heat exchanger with liquid separator according to the utility model is schematically shown in perspective view;

[0054] Figure 2 The heat exchanger with liquid separator in Figure 1 is shown, but the side is partially cut away;

[0055] Figure 3 The schematic perspective view of the liquid separator inside Figure 1 and Figure 2 is shown;

[0056] Figure 4a The liquid collector in Figure 3 is schematically shown in perspective view;

[0057] Figure 4b An alternative embodiment of the fluid collector of Figure 4a is shown;

[0058] Figure 5a The view according to Figure 3 is schematically shown in arrow F5;

[0059] Figure 5b Details of Figure 5a are shown. DETAILED DESCRIPTION

[0060] In Figure 1 , the heat exchanger 1 with liquid separator 2 according to the utility model is schematically shown.

[0061] In Figure 2 , the same heat exchanger 1 is shown, wherein, in this case, a part of the housing 3a, 3b, 3c is omitted.

[0062] According to the utility model, the heat exchanger 1 with the liquid separator 2 comprises a cooling section 4 and a separation section 5.

[0063] A cooler 6 is incorporated into the cooling section 4 to cool the gas.

[0064] The cooler 6 has an inlet 7 for the gas to be cooled, which is normally connected or connectable to the outlet of a compressor or compressor element for receiving the warm or hot gas from the compressor or compressor element.

[0065] The cooler 6 is also provided with an outlet 8 for the cooled gas that has been cooled after passing through the cooler 6.

[0066] In this case, the cooler 6 is an air-cooled cooler, which means that air is used as a cooling medium to cool the gas.

[0067] The liquid separator 2 is incorporated into the separation section 5 to separate the liquid from the cooled gas.

[0068] The liquid separator 2 comprises an inlet 9 and an outlet 10 for the cooled gas.

[0069] As shown in Figure 1 and Figure 2 between the cooling section 4 and the separation section 5, or thus between the cooler 6 and the liquid separator 2, a cooler outlet element 11 is provided, which connects the outlet 8 of the cooler 6 to the inlet 9 of the liquid separator 2.

[0070] The cooler outlet element 11 thus guides the gas from the outlet 8 of the cooler 6 to the inlet 9 of the liquid separator 2.

[0071] In the example shown, but not necessarily for the utility model, the outlet 8 of the cooler 6 is at an angle to the inlet 9 of the liquid separator 2. Or, more precisely, the direction of the gas flow that exits the cooler 6 via the outlet 8 is different from the direction that the gas flow must have to flow into the liquid separator 2 via the inlet 9 of the liquid separator 2.

[0072] As shown in Figure 1 and Figure 2 In the example shown, the cooling section 4 and the separation section 5 each have their own housing 3a and 3c, and the cooling outlet element 11 also does so, namely with a housing 3b.

[0073] The utility model does not exclude that the heat exchanger 1 with the liquid separator 2 is provided with one housing 3a, 3b, 3c, in which the cooling section 4, the separation section 5 and the cooler outlet element 11 are arranged.

[0074] According to the utility model, the liquid separator 2 extends in a vertical plane during use.

[0075] This means that the largest dimension extends in the vertical plane.

[0076] "During use" means when the liquid separator 2 or the heat exchanger 1 is installed for use, thus not during for example production or transport of the liquid separator 2 or the heat exchanger 1.

[0077] When in the following reference is made to "vertical", this refers to a vertical direction or dimension that extends vertically during use of the liquid separator 2 or the heat exchanger 1.

[0078] As Figure 1 is shown, the cooler 6 has the shape of a beam with a height H, a length L and a width B, wherein the height H and the length L are the largest dimensions. The height H extends in a vertical plane, wherein the width B and the length L extend in a horizontal plane.

[0079] In this way, the heat exchanger 1 can be said to be upright. This is in sharp contrast to known heat exchangers with integrated liquid separators that extend in a horizontal plane, and thus can be said to be laid flat.

[0080] As a result, the largest side wall 13 of the cooler 6 also extends vertically, i.e. upright. This is also the plane over which the cooling gas will flow, i.e. the cooling gas flows perpendicular to this largest side wall 13, whereas the gas to be cooled will flow through the cooler 6 parallel to this side wall 13 - in the figures from the right side where the inlet 7 is located to the left side where the outlet 8 is located.

[0081] Due to the construction or structure of the heat exchanger 1, the liquid separator 2 will also extend in a vertical plane.

[0082] According to the invention, the liquid separator 2 is composed of a plurality of assemblies 14 of substantially plate-shaped liquid separation elements 15, which during use of the heat exchanger 1 are substantially parallel to each other and oriented vertically.

[0083] In Figure 2 , in particular in Figure 3 , these assemblies 14 are clearly visible.

[0084] In the figures shown, there are five assemblies 14, but there can also be more or less than five assemblies 14.

[0085] According to the invention, as Figure 2 and Figure 3 is shown, when the liquid separator 2 is in use, i.e. when the liquid separator 2 extends in a vertical plane, these assemblies 14 are stacked vertically on top of each other.

[0086] The liquid separating elements 15 are configured as corrugated plates, which are provided with transversely extending hook-shaped ribs 16, which form vertical flow channels 17, which extend over the entire height or almost the entire height of the liquid separating elements 15.

[0087] The flow channels 17 are located on both sides of the corrugated plates, wherein they are alternately arranged on one side and on the other side, as Figure 3 is shown.

[0088] The vertical flow channels 17 have a substantially semicircular cross section, but this is not essential to the utility model, wherein the open side faces the direction of the incoming gas flow.

[0089] In the example shown, each liquid separating element 15 has four such ribs 16 with associated flow channels 17, and each assembly 14 has nine liquid separating elements 15, but this is not essential to the utility model.

[0090] The number of flow channels 17 and the number of liquid separating elements 15 will depend on the size and its properties of the liquid separator 2 and / or the heat exchanger 1.

[0091] In Figure 5a , it can be clearly seen that the outermost liquid separating elements 15' of each assembly 14, i.e. the liquid separating elements located at the edges of the assembly 14 and abutting against the side wall 18 of the liquid separator 2, are only partial liquid separating elements 15', wherein the flow channels 17 or ribs 16 pointing towards the side wall 18 have been removed or are missing from these liquid separating elements 15'. Or, in other words, the ribs 16 on the outermost liquid separating elements 15' on the side facing away from the other liquid separating elements 15 are missing or have been removed. Thus, in these outermost liquid separating elements 15', the flow channels 17 are only located on one side of the liquid separating element 15'.

[0092] This is in order to avoid dead zones in the assembly 14 between the side wall 18 of the liquid separator 2 and the liquid separating elements 15', through which the cooled-off gas cannot enter.

[0093] Furthermore, according to the utility model, a liquid collector 19 is arranged below each assembly 14, which has a storage portion 20 to collect the condensate or liquid separated by the liquid separating elements 15 from the respective assembly 14 and to discharge it to a discharge chamber 21 arranged for this purpose.

[0094] In this case, the discharge chamber is formed as a discharge pipe, which extends over at least a part of the height of the liquid separator 2, as Figure 1 and Figure 3 is shown.

[0095] In the example shown, the discharge pipe extends over the entire height of the liquid separator 2.

[0096] In the example of the drawings, but not necessarily for the present application, the discharge chamber 21 is located on a side wall 18 of the liquid separator 2, which extends parallel to the direction of the gas flow through the liquid separator 2.

[0097] Alternatively, in other words, the side wall 18 extends between the inlet 9 and the outlet 10 of the liquid separator 2. In other words, the discharge chamber 21 is not located on the side of the inlet 9 or the outlet 10 of the liquid separator 2.

[0098] In this case, the side wall 18 of the liquid separator 2 is formed by a partition wall 22 between the stack assembly 14 of liquid separation elements 15 and the discharge chamber 21 and provides a seal therebetween. In Figure 3 In the example of the drawings, the partition wall 22 is clearly visible.

[0099] The partition wall 22 will ensure that the condensate that has already been separated is isolated from the gas stream of the cooled gas flowing through the liquid separator 2, thus preventing the condensate or condensate droplets from being sucked back into the gas stream.

[0100] The fluid collectors 19 are configured as a container 24 for the storage 20. They are shown in more detail in Figures 4a to 5b In the example of the drawings, the fluid collectors 19 are shown in more detail.

[0101] In this case, the liquid collectors 19 have the shape of a tray, wherein the liquid collectors have a limited height.

[0102] The container 24 comprises a top wall 25, a bottom 26 and four upright side faces 27a, 27b, 27c, 27d.

[0103] In the top wall 25, holes 28 or passages are provided to allow the liquid or condensate separated by the liquid separation elements 15 to drain and collect in the storage 20.

[0104] It can be said that the liquid separation elements 15 are arranged on the top wall 25 such that the condensate captured by the liquid separation elements 15, in particular by the flow channels 17, flows under the influence of gravity to the top wall 25 and then ultimately via these holes 28 into the storage 20 below the top wall 25.

[0105] In order to discharge the liquid to the discharge chamber 21, the container 24 of the liquid collector 19 is provided with a passage 29 in the upright first side face 27d, which faces the discharge chamber 21, close to the bottom 26 of the container 24.

[0106] In this case, the first side face 27d will form part of or coincide with the partition wall 22.

[0107] Alternatively, the first side face 27d can also be adjacent to or abut against the partition wall 22, and the partition wall 22 is provided with a corresponding passage.

[0108] In Figure 4a embodiments, in which the liquid separator 2 is used, the bottom 26 of the container 24 extends at an angle relative to the horizontal and is inclined towards the discharge chamber 21.

[0109] That is, the bottom 26 is inclined towards the passage 29. This will facilitate the flow of condensate discharged into the storage section 20 under the influence of gravity towards the passage 29 and further towards the discharge chamber 21.

[0110] In Figure 4b an alternative embodiment of the bottom 26 is shown, in which the bottom 26 is inclined towards both the first side 27d and the opposite side 27b. The passage 29 will also be provided in the opposite side 27b.

[0111] In this embodiment, the discharge chamber 21 will be provided on the opposite side 27b or a flow channel or conduit will be provided extending from the passage 29 in the opposite side 27b to the discharge chamber 21 on the first side 27d.

[0112] The operation of the liquid separator 2 is very simple, as described below.

[0113] Gas, for example compressed air from a compressor, a compressor element or a compressor installation, enters the heat exchanger 1 with the liquid separator 2 via the inlet 7 of the cooler 6 in the cooling section 4.

[0114] The compressed gas to be cooled flows through the cooler 6 in the cooling section along the direction of the arrow P in Figure 1 the middle.

[0115] Figure 1 The arrow P in the middle shows the path taken by the compressed gas in the heat exchanger 1.

[0116] In Figure 1 the example, the compressed gas flows through the cooler 6 from right to left.

[0117] At the same time, a cooling gas flows through the heat exchanger, more specifically through the cooler 6. The purpose of this cooling gas is to extract heat from the compressed gas.

[0118] The cooling gas flows through the cooler 6 in a direction perpendicular to the compressed gas, as indicated by the arrow R.

[0119] As the compressed gas passes through the cooler 6, it will be cooled by transferring its heat to the cooling gas in a known manner.

[0120] When the compressed gas reaches the outlet 8 of the cooler 6, it will have the desired temperature.

[0121] After passing through the cooler 6, the cooled compressed gas enters the cooler outlet element 11.

[0122] As the gas stream passes through the assembly 14, the flow channel 17 will capture condensate droplets from the gas stream.

[0123] The condensate droplets will flow down via the flow channel 17 and be collected on the top wall 25 of the liquid collector 19.

[0124] The cooled compressed gas will then exit the liquid separator 2 via the outlet 10.

[0125] The condensate that ends up on the top wall 25 of the liquid collector will finally enter the container 24 through the holes 28 in the top wall 25 and will be guided through the inclined bottom 26 to the channel 29 and through the channel into the drain chamber 21.

[0126] For example, a drain pipe 30 is connected to the drain chamber 21 to allow further drainage of the condensate.

[0127] When the cooled compressed gas exits the liquid separator 2 through the outlet 10, it will be free of condensate or moisture and it can be passed on to a subsequent compressor stage or compressed gas consumer network.

[0128] The utility model is by no means limited to the embodiments described by way of example and shown in the drawings, but the liquid separator according to the utility model or the heat exchanger with the liquid separator can be realized in various shapes and dimensions without departing from the scope of the utility model defined in the claims.

Claims

1. A liquid separator (2) for separating liquid from gas, characterized in that The liquid separator (2) is composed of a plurality of assemblies (14) of plate-shaped liquid separation elements (15) which extend parallel to each other and are oriented vertically during use of the liquid separator (2), which assemblies (14) are stacked vertically on top of each other during use of the liquid separator (2), wherein a liquid collector (19) is provided below each assembly (14), which liquid collector has a storage portion (20) for collecting liquid separated by the liquid separation elements (15) from the respective assembly (14) and discharging it to a discharge chamber (21).

2. The liquid separator of claim 1, wherein, The discharge chamber (21) is formed as a discharge duct which extends over at least a part of the height of the liquid separator (2) on a side wall (18) of the liquid separator (2), which side wall of the liquid separator extends parallel to the direction of the gas flow through the liquid separator (2) during use of the liquid separator (2).

3. The liquid separator of claim 2, wherein, The side wall (18) of the liquid separator (2) is formed by a partition wall (22) between the stacked assemblies (14) of liquid separation elements (15) and the discharge chamber (21), which partition wall provides a seal between the assemblies and the discharge chamber.

4. The liquid separator according to any one of claims 1-3, characterized in that: The liquid collector (19) is configured as a container (24) which serves as the storage portion (20), which container has a top wall (25) and a bottom portion (26), wherein the top wall (25) is provided with an aperture (28) to allow liquid separated by the liquid separation elements (15) to be discharged into the storage portion (20).

5. The liquid separator of claim 4, wherein, The container (24) of the liquid collector (19) has a plurality of upright side faces (27a, 27b, 27c, 27d) between the top wall (25) and the bottom portion (26), wherein the container (24) is provided with a passage (29) in a first side face (27d) of these upright side faces (27a, 27b, 27c, 27d) which is proximate to the bottom portion (26) of the storage portion (20), the first side face (27d) facing the discharge chamber (21).

6. The liquid separator of claim 4, wherein, In use of the liquid separator (2), the bottom portion (26) of the container (24) extends at an angle with respect to the horizontal and is inclined towards the discharge chamber (21).

7. The liquid separator of any one of claims 1-3, wherein, The liquid separation elements (15) are configured as corrugated plates on which transversely extending hook-shaped ribs (16) are provided, which hook-shaped ribs form vertical flow channels (17) which extend over the entire height of the liquid separation elements (15).

8. A heat exchanger with a liquid separator (2), characterized in that The liquid separator is the liquid separator according to any one of claims 1-7, wherein the heat exchanger (1) is further provided with a cooling portion (4) and a separation portion (5), wherein a cooler (6) is incorporated into the cooling portion (4) for cooling the gas, having an inlet (7) for the gas to be cooled and an outlet (8) for the cooled gas; wherein the liquid separator (2) is incorporated in the separation portion (5) for separating liquid from the cooled gas, having an inlet (9) for the cooled gas and an outlet (10); wherein a cooler outlet element (11) is provided between the cooling portion (4) and the separation portion (5), which cooler outlet element connects the outlet (8) of the cooler (6) to the inlet (9) of the liquid separator (2).

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