Oil-gas separator with gas reheat exchanger

Abstract

The utility model discloses a kind of oil-gas separators with gas reheat heat exchanger, belong to oil-gas separation equipment technical field, it includes: oil-gas separator and reheat heat exchanger, the oil-gas separator includes: shell, separator head, sealing top cover and separation mechanism, the separation mechanism includes: folding filter core, filter core mounting plate and coarse separation flow guide ring, one side of shell is connected with compressed gas inlet flange and compressed gas outlet flange.This utility model solves the problem of condensate in gas transmission, without matching suction dryer and cold dryer, equipment investment cost is low, overall system reliability is higher, while also saving the power consumption of suction dryer and cold dryer, without matching suction dryer and cold dryer in gas system, equipment process is simpler, structure is more compact, land area is small, the design can be applied to process flow with process gas oil injection screw compressor, and also be used for common air power with air oil injection screw compressor.

Description

Technical Field

[0001] This utility model relates to the technical field of oil-gas separation equipment, and in particular to an oil-gas separator with a gas reheating heat exchanger. Background Technology

[0002] In the screw compressor industry, oil-injected screw compressors are the most widely used due to their oil lubrication, low operating temperature, low noise, long lifespan, and stable operation. Oil-injected screw compressors must be equipped with an oil-gas separator to separate oil and gas for normal and continuous operation. Furthermore, because compressed gas generally contains water vapor, condensate will precipitate after cooling. At this point, the gas is saturated with water vapor. This saturated gas will further cool in the pipeline, leading to continued condensation. Since pipelines are not always perfectly straight, with bends, low points, or deep underground sections, condensate will accumulate at the lower points of the pipeline. In winter, this can freeze and block the pipeline. Therefore, dehydration of compressed gas is crucial. This is typically achieved using a refrigerated dryer or desiccant dryer, or by heating the compressed gas after liquid water has been separated to above its dew point temperature, making it less likely for liquid water to remain in the pipeline.

[0003] The exhaust temperature of oil-injected screw compressors is generally controlled at around 85 degrees Celsius. 80% of the compressor's power consumption is converted into the internal energy of the oil. To ensure stable compressor operation, the circulating lubricating oil needs to be cooled by a cooler before entering the next cycle. Currently, oil-gas separators are a key component in oil-injected screw compressor systems, widely used in pneumatic or process gas compression fields. These separators mainly separate the lubricating oil from the compressed gas through centrifugal force and filtration to ensure gas purity and equipment lubrication. Traditional systems typically include an oil-gas separator, aftercooler, water-gas separator, and drying equipment such as a desiccant dryer or refrigerated dryer, forming a multi-stage processing flow. The oil-gas separator itself adopts a cylindrical structure, with internal filter elements and flow guiding mechanisms to achieve preliminary and fine separation of oil and gas. The separated gas needs to be cooled and dried before entering the delivery pipeline to prevent condensate from damaging the pipeline delivery system. This configuration has become standard practice in industry, but it presents certain complexity and cost issues.

[0004] The main drawback of existing technologies is that the systems rely too heavily on additional equipment to handle condensate, leading to high costs and low efficiency. The cooled gas temperature is often below the dew point, inevitably resulting in condensate precipitation, which must be dehydrated using a desiccant or refrigerated dryer. These devices not only increase initial investment but also impose higher operating power consumption and maintenance burdens. Furthermore, multiple devices connected in series complicate the system structure, increase its footprint, and are prone to more potential failure points. Condensate itself can also cause pipe corrosion and component blockage, shortening equipment lifespan and increasing downtime risks. In addition, traditional oil-gas separators fail to effectively utilize internal heat energy, resulting in energy waste, and the cooler size is often too large, further increasing costs. Therefore, we propose an oil-gas separator with a gas reheat heat exchanger to solve this problem. Utility Model Content

[0005] The purpose of this invention is to provide an oil-gas separator with a gas reheating heat exchanger to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution:

[0007] An oil-gas separator with a gas reheating heat exchanger includes: an oil-gas separator and a reheating heat exchanger. The oil-gas separator includes: a cylinder, a separator head, a sealing top cover, and a separation mechanism. The separation mechanism includes: a pleated filter element, a filter element mounting plate, and a coarse flow guide ring. One side of the cylinder is connected to a compressed gas inlet flange and a compressed gas outlet flange.

[0008] The reheating heat exchanger includes: a heat exchanger mounting plate, a heat exchange tube mounting plate, a U-shaped heat exchange tube, and a heat exchanger head. A baffle is fixedly installed inside the heat exchanger head, and a reheating gas inlet flange and a reheating gas outlet flange are connected to one side of the heat exchanger head.

[0009] Preferably, the heat exchanger mounting plate is fixedly installed on one side of the cylinder, the heat exchange tube mounting plate is fixedly installed on the other side of the heat exchanger mounting plate by heat exchanger fixing bolts, the U-shaped heat exchange tube is connected to one side of the heat exchange tube mounting plate, and the U-shaped heat exchange tube is configured in multiple groups.

[0010] Preferably, the separator head is fixedly connected to the bottom end of the cylinder, and a top cover mounting plate is fixedly connected to the top end of the cylinder. The sealing top cover is fixedly installed on the top of the top cover mounting plate by top cover fixing bolts.

[0011] Preferably, one side of the cylinder is connected to an oil suction pipe, the bottom end of the oil suction pipe extends to the bottom of the inner side of the cylinder, and the other end of the oil suction pipe is connected to an oil suction port flange.

[0012] Preferably, the bottom of the separator head is fixedly equipped with a support leg, and the bottom of the separator head is connected to an oil drain flange.

[0013] Preferably, the other side of the cylinder is connected to an oil filler flange, a high liquid level sensor interface flange, and a low liquid level sensor interface flange.

[0014] Preferably, the filter element mounting plate is fixedly installed inside the cylinder, and the folded filter element is fixedly installed on the inner side of the filter element mounting plate by filter element fixing bolts, and the coarse guide ring is fixedly installed at the bottom of the filter element mounting plate.

[0015] Preferably, the compressed gas outlet flange and the compressed gas inlet flange are respectively located above and below the filter element mounting plate;

[0016] The compressed gas inlet flange is tangent to the inner wall of the cylinder, and a safety valve interface flange is connected to the top of the other side of the cylinder.

[0017] The advantages of this utility model compared to the prior art are as follows:

[0018] 1. The oil-gas separator with a gas reheating heat exchanger described in this utility model effectively solves the problem of condensation during compressed gas transportation by integrating the reheating heat exchanger into the oil-gas separator. In traditional systems, the temperature of compressed gas drops below the dew point after cooling, leading to condensation and causing pipeline corrosion and equipment damage. This device uses high-temperature lubricating oil at the bottom of the oil-gas separator to reheat the cooled gas, raising its temperature above the dew point, thus preventing condensation. This not only protects the transportation pipeline and downstream equipment but also eliminates the need for additional drying equipment, improving the overall reliability of the system. Simultaneously, the reheating process utilizes waste heat from the separator, achieving energy recycling and reducing energy waste. This design ensures that the gas remains dry during transportation, extending equipment lifespan and reducing maintenance frequency.

[0019] 2. In this utility model, an oil-gas separator with a gas reheating heat exchanger addresses the issue that traditional compressed gas systems require drying equipment such as desiccant dryers and refrigerated dryers to treat condensate. These devices are not only expensive but also increase the complexity of installation and maintenance. This device directly heats the gas through a reheating heat exchanger, avoiding condensate precipitation and eliminating the need for desiccant dryers and refrigerated dryers. This not only reduces initial purchase costs but also saves on energy consumption and daily maintenance expenses for these devices. Furthermore, since the reheating process removes some of the heat from the lubricating oil, the corresponding lubricating oil cooler can be designed to be smaller, further reducing the cost of the cooling system. The overall system structure is simplified, resulting in more economical and efficient operation.

[0020] 3. In this utility model, an oil-gas separator with a gas reheating heat exchanger is described. Traditional oil-gas separation systems often require multiple independent devices, such as separators, coolers, and dryers, resulting in a scattered layout and large space occupation. This device directly integrates the reheating heat exchanger on one side of the oil-gas separator cylinder, and performs heat exchange through U-shaped heat exchange tubes, making the entire device highly integrated. This integrated design reduces pipe connections and external components, making the system more compact and easier to install and maintain. At the same time, the simplified process reduces the risk of leakage and improves the stability of equipment operation. The compact design is particularly suitable for industrial sites with limited space, effectively optimizing the plant layout. Compared with traditional coolers, the reheating heat exchanger used in this design does not have the shell side of a shell-and-tube heat exchanger, making cleaning and maintenance more convenient and cost-effective.

[0021] 4. In this utility model, the oil-gas separator with a gas reheating heat exchanger addresses the issue that condensate in the gas delivery system can lead to pipeline corrosion, valve blockage, and equipment malfunctions, causing downtime and affecting production continuity. This equipment ensures that the gas temperature remains above the dew point through reheating, fundamentally eliminating condensate formation and reducing the risk of corrosion and blockage. Furthermore, the built-in safety valve interface and liquid level sensor interface enhance monitoring and protection capabilities, ensuring timely response to abnormal pressure or oil level. This improved reliability reduces the probability of accidents and guarantees continuous production.

[0022] 5. In this utility model, the oil-gas separator with a gas reheating heat exchanger addresses the issue that in traditional systems, the cooled gas requires additional energy for heating or drying. This device directly utilizes the heat from the lubricating oil during oil-gas separation to reheat the gas, reducing external energy consumption. This waste heat recovery method lowers the overall energy consumption of the system, aligning with the concept of green manufacturing. Furthermore, since it eliminates the need for high-efficiency equipment such as desiccant dryers and refrigerated dryers, it also reduces the electricity demand of these devices. The energy-saving effect is not only reflected in reduced operating costs but also in reduced carbon emissions, making it environmentally friendly. In addition, the smaller cooler design further conserves resources and materials, supporting sustainable development. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall three-dimensional structure of an oil-gas separator with a gas reheating heat exchanger proposed in this utility model.

[0024] Figure 2 This is a three-dimensional structural diagram of the reheat heat exchanger proposed in this utility model;

[0025] Figure 3 This is a cross-sectional structural diagram of an oil-gas separator with a gas reheating heat exchanger proposed in this utility model;

[0026] Figure 4 This is a partial cross-sectional view of an oil-gas separator with a gas reheating heat exchanger proposed in this utility model.

[0027] Figure 5 for Figure 3 A magnified view of part A in the middle.

[0028] In the diagram: 1. Compressed gas inlet flange; 2. Compressed gas outlet flange; 3. Filter element fixing bolts; 4. Top cover fixing bolts; 5. Sealing top cover; 6. Top cover mounting plate; 7. Folded filter element; 8. Filter element mounting plate; 9. Safety valve interface flange; 10. Coarse separator guide ring; 11. Cylinder body; 12. Oil filler flange; 13. High liquid level sensor interface flange; 14. Low liquid level sensor interface flange; 15. Separator head; 16. Support leg; 17. Oil drain flange; 18. Heat exchanger mounting plate; 19. Heat exchanger tube mounting plate; 20. Heat exchanger fixing bolts; 21. Partition plate; 22. Reheated gas inlet flange; 23. Reheated gas outlet flange; 24. Heat exchanger head; 25. U-shaped heat exchanger tube; 26. Oil suction port flange; 27. Oil suction pipe. Detailed Implementation

[0029] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0030] Reference Figure 1-5 An oil-gas separator with a gas reheating heat exchanger includes: an oil-gas separator and a reheating heat exchanger. The oil-gas separator includes: a cylinder 11, a separator head 15, a sealing top cover 5, and a separation mechanism. The separation mechanism includes: a pleated filter element 7, a filter element mounting plate 8, and a coarse flow guide ring 10. One side of the cylinder 11 is connected to a compressed gas inlet flange 1 and a compressed gas outlet flange 2.

[0031] The reheating heat exchanger includes: a heat exchanger mounting plate 18, a heat exchange tube mounting plate 19, a U-shaped heat exchange tube 25, and a heat exchanger head 24. A partition plate 21 is fixedly installed inside the heat exchanger head 24, and a reheating gas inlet flange 22 and a reheating gas outlet flange 23 are connected to one side of the heat exchanger head 24.

[0032] In this embodiment, the heat exchanger mounting plate 18 is fixedly installed on one side of the cylinder 11, and the heat exchange tube mounting plate 19 is fixedly installed on the other side of the heat exchanger mounting plate 18 by the heat exchanger fixing bolts 20. The U-shaped heat exchange tube 25 is connected to one side of the heat exchange tube mounting plate 19, and multiple sets of U-shaped heat exchange tubes 25 are provided.

[0033] In this embodiment, the separator head 15 is fixedly connected to the bottom end of the cylinder 11, and the top end of the cylinder 11 is fixedly connected to the top end of the top end of the cylinder 11. The sealing top end 5 is fixedly installed on the top end of ...

[0034] In this embodiment, one side of the cylinder 11 is connected to an oil suction pipe 27, the bottom end of the oil suction pipe 27 extends to the bottom of the inner side of the cylinder 11, and the other end of the oil suction pipe 27 is connected to an oil suction port flange 26.

[0035] In this embodiment, a support leg 16 is fixedly installed at the bottom of the separator head 15, and an oil drain flange 17 is connected to the bottom of the separator head 15.

[0036] In this embodiment, the other side of the cylinder 11 is connected to the oil filling port flange 12, the high liquid level sensor interface flange 13, and the low liquid level sensor interface flange 14.

[0037] In this embodiment, the filter element mounting plate 8 is fixedly installed inside the cylinder 11, and the folded filter element 7 is fixedly installed on the inner side of the filter element mounting plate 8 by the filter element fixing bolt 3, and the coarse flow guide ring 10 is fixedly installed at the bottom of the filter element mounting plate 8.

[0038] In this embodiment, the compressed gas outlet flange 2 and the compressed gas inlet flange 1 are respectively located above and below the filter element mounting plate 8;

[0039] The compressed gas inlet flange 1 is tangent to the inner wall of the cylinder 11, and the top of the other side of the cylinder 11 is connected to the safety valve interface flange 9.

[0040] In this embodiment, during use, the compressed gas inlet flange 1 is connected to the exhaust port of the screw compressor via a pipeline. Taking a biogas compressor with an inlet temperature of 30 degrees Celsius, a relative humidity of 80%, an inlet pressure of atmospheric pressure, and an exhaust pressure of 0.8 MPa as an example, based on the physical properties of biogas, it can be calculated that the dew point temperature of biogas at an exhaust pressure of 0.8 MPa is approximately 70.9 degrees Celsius. In this biogas screw compressor system, the oil-gas mixture compressed by the screw compressor main unit is generally controlled at an exhaust temperature of around 85 degrees Celsius using a temperature control valve. This temperature is higher than the dew point temperature, therefore no condensate is formed in the oil-gas mixture. At this time, the oil-containing gas discharged from the screw compressor enters the cylinder 11 through the pipe connected to the compressed gas inlet flange 1 on the oil-gas separator. Since the compressed gas inlet flange 1 is arranged tangent to the inner wall of the cylinder 11, the oil-gas mixture will rotate at high speed and move downward along the cylinder 11 and the coarse guide ring 10. When rotating, a large centrifugal force will be generated. The oil droplets will be thrown onto the cylinder wall of the cylinder 11 by the centrifugal force and will settle to the bottom. The gas that has separated most of the lubricating oil will enter the pleated filter element 7 from the space between the coarse guide ring 10 and the pleated filter element 7. At this time, the small amount of lubricating oil mist contained in the compressed gas will be intercepted by the pleated filter element 7 and agglomerated into larger oil droplets that settle to the bottom of the oil-gas separator. At this time, the compressed gas that has completely separated the lubricating oil will be discharged from the compressed gas outlet flange 2.

[0041] The gas is cooled by a pipe connected to the compressed gas outlet flange 2 and then fed into the cooler in the compressor system. The cooled gas is typically around 40°C, which is below its dew point temperature. Therefore, condensation will occur, and the cooled gas will then enter a water-gas separator for further water-gas separation. After the liquid water is separated, the compressed gas is saturated, meaning its dew point temperature is 40°C. If the compressed gas is then heated to 60°C (reheated), even if it cools down somewhat in the delivery pipeline, as long as it doesn't fall below its dew point temperature of 40°C, no condensation will occur.

[0042] By connecting the compressed gas to the reheat gas inlet flange 22, the compressed gas exchanges heat with the high-temperature hot oil at the bottom of the oil-gas separator through the U-shaped heat exchange tube 25. Since the high-temperature hot oil also rotates to a certain extent under the impact of the rotating gas above, and the lubricating oil at the bottom of the oil-gas separator is also constantly flowing and circulating through the oil suction pipe 27, the lubricating oil can effectively generate convection and exchange heat with the U-shaped heat exchange tube 25. The number and length of the U-shaped heat exchange tube 25 can be designed according to the required reheat temperature. The reheated gas that reaches the predetermined temperature will enter the downstream conveying pipeline through the reheat gas outlet flange 23.

[0043] After the oil settles to the bottom of the oil-gas separator and is heated and reheated, it is injected into the compressor main unit through the oil suction pipe 27 and the oil suction port flange 26 under the action of pressure difference, and then enters the next cycle.

[0044] In this embodiment, since the reheated gas carries away some of the heat from the lubricating oil in the oil-gas separator, the matching lubricating oil cooler can be designed to be smaller, the cooling system cost is lower, and the problem of condensation in gas transportation is solved. Therefore, there is no need to match the desiccant dryer and the refrigerated dryer. The equipment investment cost is low, the overall system reliability is higher, and the power consumption of the desiccant dryer and the refrigerated dryer is also saved.

[0045] The gas system does not require a desiccant or a refrigerated dryer, making the equipment process simpler, the structure more compact, and the footprint smaller.

[0046] This patent can be applied not only to process gas-injected screw compressors for process flow applications, but also to common air-injected screw compressors for pneumatic applications.

[0047] In this embodiment, the safety valve interface flange 9 is located on the top side of the cylinder 11 and is used to install the safety valve. The safety valve is a key safety device of the pressure vessel. When the internal pressure of the cylinder 11 rises abnormally above the set value, the safety valve will automatically open to release the excessive pressure, prevent the equipment from exploding or being damaged, ensure the safe operation of the oil-gas separator within the design pressure range, avoid structural damage and potential accidents, and thus maintain the continuity and reliability of the separation process.

[0048] The oil filling port flange 12 is located on one side of the cylinder 11. By replenishing oil in time through the oil filling port flange 12, an appropriate amount of oil can be maintained in the cylinder 11.

[0049] The high-level sensor interface flange 13 and the low-level sensor interface flange 14 are located on the other side of the cylinder 11, and are used to install the high-level sensor and the low-level sensor, respectively. The high-level sensor monitors whether the oil level is too high, and the low-level sensor monitors whether the oil level is too low. The sensors are usually connected to the control system, and trigger an alarm or automatic adjustment when the oil level is abnormal. The high-level sensor prevents the oil level from being too high, avoiding the lubricating oil being carried out of the separator by the compressed gas, causing gas contamination and oil loss. An excessively high oil level may also increase internal gas resistance and affect the separation effect. The low-level sensor prevents the oil level from being too low, ensuring that there is enough lubricating oil for lubrication and cooling, avoiding poor lubrication and overheating of the compressor.

[0050] The drain flange 17 is located at the bottom of the separator head 15 and is used to drain waste oil, water or impurities deposited at the bottom of the separator. During operation, the lubricating oil will accumulate contaminants and needs to be cleaned and drained regularly. Regularly draining oil through the drain flange 17 can remove the deposits at the bottom of the cylinder 11, prevent oil quality deterioration, blockage or corrosion of internal components. This helps to maintain the cleanliness of the lubricating oil, ensure the separation effect and normal heat exchange of the reheat heat exchanger. At the same time, regular oil draining is also part of maintenance and can improve the overall reliability of the equipment.

[0051] The above provides a detailed description of an oil-gas separator with a gas reheat heat exchanger provided by this utility model. Specific embodiments have been used to illustrate the principle and implementation of this utility model. The descriptions of these embodiments are merely for the purpose of helping to understand the method and core idea of ​​this utility model. It should be noted that those skilled in the art can make various improvements and modifications to this utility model without departing from its principles, and these improvements and modifications also fall within the protection scope of the claims of this utility model.

Claims

1. An oil and gas separator with gas reheat exchanger, characterized in that, include: An oil-gas separator and a reheat heat exchanger, wherein the oil-gas separator includes: a cylinder (11), a separator head (15), a sealing top cover (5), and a separation mechanism, wherein the separation mechanism includes: a pleated filter element (7), a filter element mounting plate (8), and a coarse flow guide ring (10), and one side of the cylinder (11) is connected to a compressed gas inlet flange (1) and a compressed gas outlet flange (2); The reheating heat exchanger includes: a heat exchanger mounting plate (18), a heat exchange tube mounting plate (19), a U-shaped heat exchange tube (25), and a heat exchanger head (24). A partition plate (21) is fixedly installed inside the heat exchanger head (24). A reheating gas inlet flange (22) and a reheating gas outlet flange (23) are connected to one side of the heat exchanger head (24).

2. The oil-gas separator with a gas reheat heat exchanger according to claim 1, characterized in that, The heat exchanger mounting plate (18) is fixedly installed on one side of the cylinder (11), and the heat exchange tube mounting plate (19) is fixedly installed on the other side of the heat exchanger mounting plate (18) by heat exchanger fixing bolts (20). The U-shaped heat exchange tube (25) is connected to one side of the heat exchange tube mounting plate (19), and the U-shaped heat exchange tube (25) is set in multiple groups.

3. The gas reheat exchanger oil and gas separator of claim 1, wherein, The separator head (15) is fixedly connected to the bottom end of the cylinder (11), and the top end of the cylinder (11) is fixedly connected to the top end of ...

4. The gas reheat exchanger oil and gas separator of claim 1, wherein, One side of the cylinder (11) is connected to an oil suction pipe (27), the bottom end of the oil suction pipe (27) extends to the bottom of the inner side of the cylinder (11), and the other end of the oil suction pipe (27) is connected to an oil suction port flange (26).

5. The gas reheat exchanger oil and gas separator of claim 1, wherein, The bottom of the separator head (15) is fixedly installed with a support leg (16), and the bottom of the separator head (15) is connected to an oil drain flange (17).

6. The gas reheat exchanger oil and gas separator of claim 1, wherein, The other side of the cylinder (11) is connected to the oil filling port flange (12), the high liquid level sensor interface flange (13), and the low liquid level sensor interface flange (14).

7. The gas reheat exchanger oil and gas separator of claim 1, wherein, The filter element mounting plate (8) is fixedly installed inside the cylinder (11), and the folded filter element (7) is fixedly installed on the inner side of the filter element mounting plate (8) by the filter element fixing bolt (3). The coarse flow guide ring (10) is fixedly installed at the bottom of the filter element mounting plate (8).

8. The gas reheat exchanger oil and gas separator of claim 1, wherein, The compressed gas outlet flange (2) and the compressed gas inlet flange (1) are respectively located above and below the filter element mounting plate (8); The compressed gas inlet flange (1) is tangent to the inner wall of the cylinder (11), and a safety valve interface flange (9) is connected to the top of the other side of the cylinder (11).

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