Systems and methods for mixture separation - Patents.com

Abstract

The separator includes an inlet manifold, a throat, and an outlet manifold. The inlet manifold is configured to receive a flow of the mixed gas. The throat is attached to the inlet manifold. The throat separates heavier gas species of the mixed gas from lighter gas species of the mixed gas. The outlet manifold is attached to the throat. The outlet manifold includes an outlet valve and a throttle shaft. The outlet valve includes a conical inlet and a bowl-shaped outlet. The throttle shaft includes a shaft and a conical head. The conical head is disposed within the conical inlet and the shaft extends through the bowl-shaped outlet. The bowl-shaped outlet, the conical inlet, and the conical head are sized and shaped to control the flow of the heavier species through the outlet valve and the flow of the mixed gas through the separator.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This patent application claims priority to U.S. Provisional Patent Application No. 63 / 335,212, filed April 26, 2022, which is incorporated by reference in its entirety. [Technical field]

[0002] The present invention relates generally to the field of separating components of a gas mixture, and more particularly to an apparatus that provides mixed gas separation by creating a generally helical flow. [Background technology]

[0003] There are many situations in which it is desirable to separate the constituent parts of a gas mixture. For example, natural gas wells typically contain the desired natural gas (CH4) along with contaminants such as carbon dioxide (CO2), nitrogen (N2) and hydrogen sulfide (H2S). It is estimated that there are trillions of cubic feet of natural gas in the United States that require processing to separate the contaminants from the natural gas. In another example, water sources such as reservoirs, abandoned mines, impoundments, lakes and oceans can contain a variety of substances, including salt, arsenic, iron, copper, lead, zinc, cadmium, other metals, and fertilizer and pesticide runoff. Such substances can render water sources unusable and can seep into mineral waters, causing devastating effects on water quality over large areas.

[0004] There are many conventional devices capable of separating the components of a gas mixture, however, many of the conventional devices suffer from various deficiencies, such as high cost, complex installation, maintenance cost and frequency, and deployment in remote locations. Summary of the Invention

[0005] The disclosed technology includes methods, systems, devices, and apparatus for a separator for separating components of a gas mixture. In some embodiments, the separator includes an inlet manifold, a throat, and an outlet manifold. The inlet manifold is configured to receive a flow of the gas mixture. The inlet manifold forms the gas mixture into a helical flow. The throat is attached to the inlet manifold and configured to receive the flow of the gas mixture from the inlet manifold. The throat separates heavy and light gas species of the gas mixture. The outlet manifold is attached to the throat and configured to receive the flow of the heavy gas species from the throat. The outlet manifold includes an outlet valve and a throttle shaft. The outlet valve includes a conical inlet and a bowl-shaped outlet. The throttle shaft includes a shaft and a conical head. The conical head is disposed within the conical inlet and the shaft extends through the bowl-shaped outlet. The bowl-shaped outlet, the conical inlet, and the conical head are sized and shaped to control the flow of the heavy species through the outlet valve and the flow of the gas mixture through the separator.

[0006] Light gas species include, for example, helium, neon, methane, etc. Heavy gas species include, for example, carbon dioxide, nitrous oxide, sulfur dioxide, propane, butane, pentane, halogenated gases (e.g., chlorofluorocarbons, hydrofluorocarbons, perfluorocarbons, sulfur hexafluoride, nitrogen trifluoride), etc. Heavy and light species are relative to other species in the gas mixture. For example, if the gas mixture is natural gas, water vapor is the heavier species, but if the gas mixture is air or flue gas, water vapor is the lighter species. One skilled in the art can readily recognize which species in a gas mixture are heavier or lighter than other species based on molecular mass.

[0007] In some embodiments, a method of separating components of a mixed gas using a separator is provided. The method includes flowing the mixed gas into an inlet manifold of the separator. The method also includes forming the mixed gas into a helical flow in the inlet manifold. The method further includes flowing the mixed gas from the inlet manifold to a throat of the separator. The method also includes separating heavier species of the mixed gas from lighter species of the mixed gas in the throat. The method further includes flowing the flow of the heavier gas species from the throat to an outlet manifold of the separator. The outlet manifold includes an outlet valve including a conical inlet and a bowl-shaped outlet, and a throttle shaft including a shaft and a conical head. The conical head is disposed within the conical inlet, and the shaft extends through the bowl-shaped outlet. The method also includes using the bowl-shaped outlet, the conical inlet, and the conical head to control the flow of the heavy species through the outlet valve and the flow of the mixed gas through the separator. The bowl-shaped outlet, conical inlet, and conical head are sized and shaped to control the flow of heavy species through the outlet valve and the flow of mixed gas through the separator.

[0008] In some embodiments, the mixed gas is flowed to the inlet manifold at a pressure of at least 5 psi (34 kPa). In some specific embodiments, the mixed gas is flowed to the inlet manifold at a pressure of at least 50 psi (345 kPa). In some very specific embodiments, the mixed gas is flowed to the inlet manifold at a pressure of at least 100 psi (689 kPa) and up to 1400 psi (9653 kPa). Pressure is not a limitation on the separation capabilities of the separators described herein, and commercially available separators nevertheless operate at high pressures.

[0009] In some embodiments, the mixed gas is flowed into the inlet manifold at a flow rate of at least 2 kg / sec. In some specific embodiments, the mixed gas is flowed into the inlet manifold at a flow rate of at least 5 kg / sec. In some very specific embodiments, the mixed gas is flowed into the inlet manifold at a flow rate of at least 5 kg / sec and up to 200 kg / sec. The flow rate is not a limitation on the separation capabilities of the separators described herein, and commercially available separators nevertheless operate at high flow rates.

[0010] This Summary is provided to introduce in a simplified form some of the concepts that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended for use to limit the scope of the claimed subject matter. Other features, details, utilities, and advantages of the claimed subject matter will become apparent from the following more particularly written detailed description of various embodiments, as further illustrated in the accompanying drawings and defined in the appended claims.

[0011] These and various other features and advantages will become apparent from a reading of the following detailed description. [Brief description of the drawings]

[0012] [Figure 1] FIG. 1 is a perspective view of an embodiment of a separator according to the present invention. [Diagram 2] FIG. 2 is a side view of the separator shown in FIG. 1 according to the present invention. [Diagram 3] FIG. 2 is an end view of the separator shown in FIG. 1 in accordance with the present invention. [Figure 4] FIG. 2 is an end view of the separator shown in FIG. 1 in accordance with the present invention. [Diagram 5] FIG. 2 is a perspective view of a portion of the inlet manifold of the separator shown in FIG. 1 in accordance with the present invention. [Figure 6] FIG. 2 is an end view of the inlet plate of the separator shown in FIG. 1 in accordance with the present invention. [Figure 7]FIG. 2 is a perspective view of a cone-shaped inlet of the separator shown in FIG. 1 in accordance with the present invention. [Figure 8] FIG. 2 is a perspective view of a bowl-shaped outlet of the separator shown in FIG. 1 in accordance with the present invention. [Figure 9] FIG. 2 is a perspective view of a throttle shaft of the separator shown in FIG. 1 in accordance with the present invention. [Figure 10] 2 is a schematic side cutaway view of a portion of the inlet manifold of the separator shown in FIG. 1 in accordance with the present invention. [Figure 11] 2 is a schematic side cutaway view of a portion of the outlet manifold of the separator shown in FIG. 1 in accordance with the present invention. [Figure 12] FIG. 2 is a schematic front view of a portion of the outlet manifold of the separator shown in FIG. 1 in accordance with the present invention. [Figure 13] 2 is a schematic front view and a schematic side cutaway view of a portion of the throttle of the separator shown in FIG. 1 in accordance with the present invention. [Figure 14] FIG. 2 is a flow diagram of a method for separating components of a gas mixture using the separator shown in FIG. 1 according to the present invention. [Figure 15] FIG. 13 is a perspective view of an alternative embodiment of a separator according to the present invention. [Figure 16] FIG. 16 is a side view of the separator shown in FIG. 15 in accordance with the present invention. [Figure 17] FIG. 2 is a flow diagram of a method for separating components of a gas mixture using the separator shown in FIG. 1 according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] The disclosed technology is directed to a separator useful for partially or completely separating components of a gas mixture. Specifically, the disclosed separator combines a high velocity swirling flow that produces a tornado-like centrifugal field with a countercurrent flow field within the swirling flow in a manner that allows the heavier species as a group to be separated from the lightest species.

[0014] In one application, the disclosed separator can be used to extract greenhouse gases from a gas stream. FIG. 1 is a perspective view of an embodiment of a separator 100. The separator 100 separates a mixture of liquids, solids, gases, or any combination thereof (not shown). In an application to process a gas stream containing greenhouse gases, the separator 100 is connected to the outlet of a power plant or other greenhouse gas emission facility. The gas stream is transmitted to the separator 100, which, depending on the characteristics of the separator 100, forms a tornado-like or spiral flow. The tornado-like flow partially or completely separates one or more components of the gas stream. From the separator, the greenhouse gases are exhausted through the exhaust pipe of the separator 100, and the remaining gas is flowed to the atmosphere, a treatment facility, a storage tank, other destinations, or one or more additional separators for further processing. Advantageously, the separator 100 is made primarily of non-moving parts and therefore can be easily and efficiently employed in almost any facility and requires little maintenance or adjustment.

[0015] In some embodiments, the gas stream comprises or consists of air. The separator can be used, for example, to separate greenhouse gases from air. Greenhouse gases include, for example, carbon dioxide, which is a heavier species relative to other species in air, and methane, which is a lighter species relative to other species in air.

[0016] FIG. 2 is a side view of separator 100. FIG. 3 is an end view of separator 100. FIG. 4 is an end view of separator 100. FIG. 5 is a perspective view of a portion of inlet manifold 102. FIG. 6 is an end view of inlet plate 112. FIG. 7 is a perspective view of conical inlet 122. FIG. 8 is a perspective view of bowl-shaped outlet 124. FIG. 9 is a perspective view of throttle shaft 120. FIG. 10 is a schematic cutaway side view of a portion of inlet manifold 102. FIG. 11 is a schematic cutaway side view of a portion of outlet manifold 106. FIG. 12 is a schematic front view of a portion of outlet manifold 106. FIG. 13 is a schematic front and cutaway side view of a portion of throttle shaft 120.

[0017] The separator 100 generates converging spiral inlet flows of the mixed gas for separating the components, diverging exhaust flows of some components, and countercurrent exhaust flows of other components. In general, the combination of the converging spiral inlet flows of the mixture and the spiral countercurrent exit flows of one or more separated components of the mixture together may be considered as a tornado-like flow. The separator 100 includes an inlet manifold 102 that increases the angular velocity of the mixed gas and at least partially separates the mixed gas. The separator 100 also includes a throat 104 that receives the mixed gas from the inlet manifold 102 and further separates the mixed gas. The mixed gas is separated into a flow of heavier species and a flow of lighter species. The separator 100 can be constructed of any material suitable to withstand the forces in the separator and the corrosive or other damaging effects of the mixture being separated. Such materials include stainless steel, alloys, polymers, or other composite resin type materials.

[0018] The heavy species stream enters the outlet manifold 106 and the light species stream separates from the heavy species stream at the throat 104 and flows back through the throat 104 as a countercurrent flow. The outlet manifold 106 also includes an outlet valve or throttle 108 for controlling the flow from the outlet manifold 106. The separator can be used to separate greenhouse gases from a gas stream being emitted from a power plant or other greenhouse gas emitting facility.

[0019] In the illustrated embodiment, the mixed gas is flowed into an inlet manifold 102 of the separator 100, which is sized and shaped to form the mixed gas into a high-velocity swirling or helical flow. Specifically, the inlet manifold 102 includes two inlet pipes 110 formed in a spiral that form the mixture into a high-velocity swirling or helical flow. The inlet manifold 102 also includes an inlet plate 112 that includes a spirally formed inlet channel 114 that also forms the mixed gas into a high-velocity swirling or helical flow. In operation, a mixture of liquids, solids, gases, or any combination thereof is introduced into the inlet manifold 102 at high velocity. The mixed gas passes through the inlet manifold 102 in a spiral. As the mixed gas rotates within the inlet manifold 102, its angular velocity increases in part as a function of the convergence angle of the inlet manifold 102. Upon reaching the outlet of the inlet manifold 102, some or all of the separation of the mixed gas occurs. In general, the angular velocity of the gas mixture through the convergent inlet manifold 102 causes the gas mixture to separate such that the higher mass components of the gas mixture are located toward the outermost portion of the flow and the lower mass components of the gas mixture are located toward the inner portion of the flow. In one embodiment, the spiral flow includes loosely defined stratified layers of decreasing mass components located radially inward from the most massive outer layer. In a configuration adapted to separate the mixture according to molecular mass, the highest mass molecular species migrate toward the outer portion of the flow during separation, causing separation such that the lower molecular mass species are confined to the interior of the higher molecular mass species.

[0020] The mixed gas is fed into the two inlet pipes 110 where a high speed circular flow is initiated and communicated to the inlet manifold 102 to form an accelerating converging spiral flow. In any embodiment of the separator 100, the mixed gas should be fed into the two inlet pipes 110 at a velocity such that the velocity of the spiral flow through the separator 100 does not meet or exceed the speed of sound. In one example, the mixed gas is fed into the two inlet pipes 110 such that the mixed gas has an angular velocity of about 0.5 Mach in the inlet manifold 102 adjacent to the throat 104. In some embodiments, the two inlet pipes 110 may be positioned at an angle or tangentially to a portion of the inlet manifold 102 to help promote a high speed circular flow in the inlet manifold 102.

[0021] The inlet manifold 102 may be directly connected to the outlet manifold 106. In one particular embodiment of the invention, the throat 104 defines a substantially cylindrical chamber interposed between the inlet manifold 102 and the outlet manifold 106. Thus, the mixed gas rotates from the inlet manifold 102 to the throat 104. Within the throat 104, further separation of the mixed gas occurs as it rotates through the throat 104 towards the outlet manifold 106. Also within the throat 104, a spiral countercurrent flow is formed, primarily of the light components. The countercurrent flow is generally within the larger diameter exhaust flow of the heavier components. Further separation occurs along the countercurrent flow, such that some of the heavy components separate, change direction and merge into the outlet manifold 106.

[0022] The inlet manifold 102 directs the gas mixture to the throat 104 where the high-speed swirling or spiral flow is fully developed. The high-speed swirling flow causes one or more components of the gas mixture to be partially or completely separated from the other components along with the gas mixture. The high-speed swirling flow in the throat 104 results in a high-speed swirling centrifugal field and an in-swirling countercurrent flow field, causing at least some of the heavier species to be separated from the lighter species. The heavier species are directed to the outlet manifold 106 and the lighter species are directed to the outlet pipe 116 of the inlet manifold 102. Specifically, the high-speed swirling flow creates a countercurrent flow field that is directed in a direction opposite to the flow direction of the tornado-like or spiral flow. The countercurrent flow field causes the lighter species to exit the separator 100 through the outlet pipe 116.

[0023] Specifically, in the illustrated embodiment, the inlet manifold 102 further includes a conical chamber 134. The conical chamber 134 includes a continuous inner conical sidewall 136 arranged to cooperate with the inlet passages 114 of the inlet plate 112. In one embodiment, the inner conical sidewall 136 of the conical chamber 134 is aligned and abuts the inlet passages 114 of the inlet plate 112. The inner conical sidewall 136 adjacent the inlet passages 114 has approximately the same diameter as the inlet passages 114 to provide a smooth transition of the mixture flowing over the seam between the inlet passages 114 and the inner conical sidewall 136. Additionally, the inner conical sidewall 136 of the conical chamber 134 is abutted and aligned with the throat 104. The inner conical sidewall 136 adjacent the throat 104 has approximately the same diameter as the throat 104 to provide a smooth transition of the mixture as it flows over the seam between the throat 104 and the inner conical sidewall 136. The smooth transition helps to avoid flow disturbances that may disrupt separation of the mixture.

[0024] As shown in FIGS. 10 and 12, the conical chamber 134 includes a first diameter 138 and a second diameter 140. The first diameter 138 is the outer diameter of the conical chamber 134 and the inner diameter of the inlet passage 114. The second diameter 140 is the inner diameter of the conical chamber 134 and the inner diameter of the throat 104. In the illustrated embodiment, the first diameter 138 is approximately 4 inches and the second diameter 140 is approximately 1 inch. Additionally, the inner conical sidewall 136 defines a first angle 142 that varies continuously along a length 144 of the conical chamber 134. The first angle 142 has a maximum value of approximately 60° at the first diameter 138 and decreases to approximately 0° at the second diameter 140. The length 144 is approximately 2 inches.

[0025] The conical chamber 134 reduces disturbances to the diverging spiral flow of the mixed gas. In some embodiments, the flow of the mixed gas from the inlet channel 114 to the conical chamber 134 may be disturbed by a sudden volume difference between the inlet channel 114 and the conical chamber 134, which may result in pressure fluctuations. Such pressure fluctuations may reduce the separation efficiency of the components of the mixed gas in the inlet manifold 102. The orientation of the inlet channel 114 relative to the conical chamber 134 may reduce the pressure fluctuations. Specifically, the inlet channel 114 has a spiral shape that forms a spiral flow into the conical chamber 134.

[0026] As the mixture rotates through the conical chamber 134, the heavier species generally segregate toward the inner conical sidewall 136 and the lighter species generally segregate toward the center. For mixtures containing two species, the heavier species migrates toward the inner conical sidewall 136 and the lighter species migrates toward the center. For gas mixtures containing two or more components or species, stratified zones of at least some of the components are formed as the gas mixture flows around and through the conical chamber 134, with the heaviest species or components in the outer zone adjacent the inner conical sidewall 136, the lighter components forming zones inward from the outer zone, and the lightest components forming zones adjacent the center. The amount of separation between the species depends, in part, on the input velocity of the gas mixture into the conical chamber 134, the difference in mass between the species or components, the difference in specific gravity between the components, the difference in atomic numbers between the components, the presence and strength of chemical bonds, and the convergence angle of the conical chamber 134. Thus, various degrees of separation are achieved within the conical chamber 134.

[0027] The mixed gas separates into constituent parts or species along the length 144 of the conical chamber 134 as the mixed gas converges toward the throat 104. The throat 104 includes an outer sidewall 146 that defines a cylindrical flow passage 148. The outer sidewall 146 of the throat 104 has approximately the same diameter as the second diameter 140 of the conical chamber 134. Although illustrated herein with a constant radius along its length, the throat may be slightly converging or diverging toward the outlet manifold 106.

[0028] From the outlet of the conical chamber 134, the mixed gas flows into the throat 104. Within the throat 104, the mixed gas transitions from a generally converging spiral flow to a fairly uniform spiral flow moving toward the outlet manifold 106 and continues to separate into its component parts. The length of the throat 104 is optional, and in one range of particular embodiments is between 1 inch and 12 inches. The length and diameter of the throat 104 may vary in particular embodiments as a function of the number and size of the components of the mixed gas, the pressure or velocity at which the mixed gas is forced into the plenum, the angle and length of the conical input passage, the amount of separation required, and other factors.

[0029] In some embodiments, the mixture of gases is forced into the plenum at a pressure of at least 5 psi (34 kPa). In some specific embodiments, the mixture of gases is forced into the plenum at a pressure of at least 50 psi (345 kPa). In some very specific embodiments, the mixture of gases is forced into the plenum at a pressure of at least 100 psi (689 kPa) and up to 1400 psi (9653 kPa).

[0030] In some embodiments, the mixture of gases is forced into the plenum at a rate of at least 2 kg / s. In some specific embodiments, the mixture of gases is forced into the plenum at a rate of at least 5 kg / s. In some very specific embodiments, the mixture of gases is forced into the plenum at a rate of at least 5 kg / s and up to 200 kg / s.

[0031] In another separator (not shown), an exhaust port may be defined in the outer sidewall 146 of the throat 104 to remove heavier components. Additionally, a variable length throat 104 may be employed. In one embodiment, a variable length throat (not shown) has a first cylindrical sleeve connected to the inlet manifold 102 and a second cylindrical sleeve connected to the outlet manifold 106. The sleeves have slightly different diameters to allow one sleeve to slide within the other. Thus, by moving one sleeve relative to the other, the overall length of the throat can be adjusted. For example, if each sleeve is 3 inches, then by fully inserting one sleeve within the other, the overall length of the throat will be approximately 3 inches. By completely separating the sleeves and leaving a portion of one sleeve within the other, a throat length of approximately 6 inches can be achieved. Additionally, the throat can be adjusted to any length between 3 and 6 inches. In such an embodiment, care should be taken to minimize the boundary edge formed between the two sleeve portions of the throat to avoid creating excessive turbulence.

[0032] The outlet pipe 116, preferably a cylindrical pipe, is disposed within the inlet manifold 102. Moreover, the outlet pipe 116 is preferably disposed along the axis of the throat 104, and the outlet pipe 116 is in fluid communication with the throat 104. Upon interacting with the throttle 108, the low molecular weight components form a partial or total countercurrent flow, rotating the mixed gas between the inlet manifold 102 and through the throat 104 toward the throttle 108. When the separator 100 is used to process greenhouse gases from a gas stream exhausted from a power plant, the heavy components, such as greenhouse gases (carbon dioxide), are passed through the outlet manifold 106, and the light components, such as water vapor, are passed through the outlet pipe 116. The diameter of the outlet pipe 116 may vary depending on the particular embodiment. In one example, the diameter of the outlet pipe 116 is slightly smaller than the diameter of the throat 104.

[0033] The outlet manifold 106 directs the heavier species out of the separator 100 and controls the flow of the mixture into and out of the separator 100. Specifically, the outlet valve or throttle 108 of the outlet manifold 106 includes an outlet valve basin 118 and a throttle shaft 120 partially disposed within the outlet valve basin 118. The throat 104 directs the heavier species into the outlet valve basin 118, and the outlet valve basin 118 and the throttle shaft 120 are sized and shaped to control the flow of the heavier species through the outlet valve or throttle 108. Specifically, the outlet valve basin 118 includes a conical inlet 122 and a bowl-shaped outlet 124. The throttle shaft 120 has a conical head 126 that complements the shape of the conical inlet 122 and is disposed within the conical inlet 122. The conical head 126 has rounded edges 132. The throttle shaft 120 also has a shaft 128 that extends from the outlet valve or throttle 108 through a bowl-shaped outlet 124 that channels heavier species to two outlet pipes 130 that channel heavier species out of the separator 100. This arrangement promotes exhaust flow of the heavier mass components of the gas mixture in the throat to the diffuser chamber, while the flow of lower molecular mass components toward the diffuser chamber is blocked by the exhaust cone.

[0034] 11, the conical inlet 122 includes a first diameter 154 and a second diameter 156. The first diameter 154 is the inner diameter of the conical inlet 122 and the inner diameter of the throat 104. The second diameter 156 is the outer diameter of the conical inlet 122. In the illustrated embodiment, the first diameter 154 is approximately 1 inch and the second diameter 156 is approximately 4 inches. Additionally, the inner conical sidewall 136 defines a first angle 158 of approximately 60 degrees.

[0035] The outlet valve or throttle 108 controls the flow of heavier species through the outlet valve or throttle 108 by varying the position of a throttle shaft 120 within the outlet valve or throttle 108. Specifically, the throttle shaft 120 is inserted into the conical inlet 122 such that the conical head 126 at least partially restricts the flow of heavier species into the conical inlet 122, reducing the flow of heavier species into the outlet valve or throttle 108 and reducing the flow of the mixture into the separator 100. Conversely, the throttle shaft 120 is extracted from the conical inlet 122 such that the conical head 126 increases the flow of heavier species into the conical inlet 122, increasing the flow of the mixture into the separator 100.

[0036] In the illustrated embodiment, the conical inlet 122 and the conical head 126 have approximately the same angle relative to the longitudinal axis of the separator 100. The conical head 126 and the conical inlet 122 define a conical exhaust flow passage 150 therebetween. The diffuser cone further defines a blunt end 152 at its apex. The blunt end 152 is disposed coaxially with the axis of the throat 104 and thus with the overall longitudinal axis of the separator 100. While the blunt shape is preferred, other shapes for the blunt end 152 of the conical head 126 are possible.

[0037] The blunt end 152 is generally located near the outlet of the throat 104. In one embodiment, the outlet valve or throttle 108 is configured to move along its longitudinal axis. Thus, the blunt end 152 may be positioned relative to the outlet of the throttle 104. The width of the conical exhaust passage 150, i.e., the distance between the conical head 126 and the conical inlet 122, may be increased or decreased by positioning the outlet valve or throttle 108 away from or toward the throat 104, respectively. Such adjustment also increases or decreases the circumference of the outlet valve or throttle 108 and the annular opening between the throat 104 and the conical exhaust passage 150. In general, the outlet valve or throttle 108 may be adjusted longitudinally to change the pressure within the throat 104 and exhaust passage 150, thereby affecting the backflow of light species exiting the outlet pipe 130.

[0038] Separation of the gas mixture occurs, in part, due to large centrifugal-like forces acting on the gas mixture as it spirals down the conical chamber 134 and along the throat 104. Within the throat 104, heavier species of the gas mixture collect adjacent the outer sidewall 146 and lighter species collect near the longitudinal axis of the throat 104. At the exit of the throat 104, the heavier gas species spiral into a flow passage 150. The lighter species encounter a region adjacent the blunt end 152 of the outlet valve or throttle 108.

[0039] 13, the conical head 126 includes a diameter 160 and a length 162 that defines an angle 164. The diameter 160 is smaller than the second diameter 156, which is the outer diameter of the conical inlet 122, so that the conical head 126 can move within the conical inlet 122. In the illustrated embodiment, the diameter 160 is approximately 3.5 inches, the length 162 is approximately 1.3 inches, and the angle 164 is approximately 30 degrees.

[0040] The light species exit the separator 100 in a flow counter to the flow of the mixed gas through the flow passage 150 and the outer flow in the throat 104. Typically, the pressure in the separator 100 will be greater than atmospheric pressure. The outlet pipe 116 is at or near atmospheric pressure which helps promote counter flow of the light species or components collected along the axis of the throat 104, but allows the heavy species collected along the outer sidewall 146 of the throat 104 to exit through the flow passage 150. Incomplete separation, slight turbulence, and other factors can cause some light species components to flow through the flow passage 150 with the heavy species and some heavy species to exit the outlet pipe 116 with the light species. In the counter flow in the throat 104, further separation also occurs as the flow continues in a spiral. In the counter flow, some heavy species change direction to be exhausted as they merge with the heavy species in the outer exhaust flow.

[0041] In this field, the outlet valve or throttle 108 is mounted movably along the axis of the separator 100 in some embodiments. The movable outlet valve or throttle 108 allows the position of the blunt end 152 and the size of the flow passage 150 to be changed. Additionally, in embodiments where the mixed gas is fed to the separator 100 by a pump, the pressure and input rate of the mixed gas to the separator 100 can also be adjusted. In some applications where the contaminants are evenly and fairly uniformly distributed, such as greenhouse gas separation, the separator 100 may be optimized once in the field for maximum separation and then left alone. In other embodiments where the portion of the components of the mixed gas may vary, it may be advantageous to provide a control system that monitors the ratio of the components exhausted through the exhaust to the components permeated from the outlet flow passage and makes appropriate adjustments to the pressure of the mixed gas, the position of the diffuser cone, or both.

[0042] In one embodiment, there is a control system (not shown) that optimizes the operation of the separator 100. The control system may include a controller with outputs or control lines to various components that control the separator. The controller may change the input pressure or the position of the outlet valve or throttle 108, or both, and analyze the mixture at the various sensor locations to determine if separation has improved. The controller may continue to change the pressure, change the outlet valve or throttle 108, or both, to optimize separation. Additionally, control lines may be connected with other components to change the pressure within the separator 100, the input rate of the mixture, and other parameters.

[0043] For mixtures of gases having more than two species, in some arrangements, multiple separators 100 may be employed in series to separate one species per separator. For example, a first separator may be configured such that only the heaviest gas species enters flow passage 150, while the two lighter gas species flow through an exit pipe 116. The exit pipe 116 may then be connected to a compressor to feed the remaining mixture of the two species to a second separator configured to separate the remaining heavy species from the remaining light species.

[0044] As will be appreciated from the above discussion, depending on the processing needs of any particular application, multiple separators 100 may be connected to a mixture source in a series arrangement, a parallel arrangement, or a combination of series and parallel arrangements to process the mixture. For example, separators may be arranged in parallel to process large volumes of the mixture. Alternatively, the separators may be scaled depending on the volumetric processing requirements. Alternatively, separators may be arranged in a series configuration to achieve further separation of target components of the mixture. Or to focus the separation on a particular component of the gas mixture. Separators may also be arranged in series in cases where incomplete separation occurs in a single separator. For example, multiple separators may be arranged in series or parallel to separate carbon dioxide from air.

[0045] FIG. 14 illustrates a method of separating components of a mixture using a separator. The method includes flowing 802 the mixed gas into an inlet manifold of the separator. The method also includes forming 804 the mixture of gases into a spiral flow in the inlet manifold. The method further includes flowing 806 the mixed gas from the inlet manifold to a throat of the separator. The method also includes separating 808 heavier species of the mixed gas from lighter species of the mixed gas in the throat. The method further includes flowing 810 the flow of the heavier gas species from the throat to an outlet manifold of the separator. The outlet manifold includes an outlet valve including a conical inlet and a bowl-shaped outlet, and a throttle shaft including a shaft and a conical head. The conical head is disposed within the conical inlet, and the shaft extends through the bowl-shaped outlet. The method also includes controlling 812 the flow of the heavier species through the outlet valve and the flow of the mixed gas through the separator using the bowl-shaped outlet, the conical inlet, and the conical head. The bowl-shaped outlet, the conical inlet, and the conical head are sized and shaped to control the flow of heavy species through the outlet valve and the flow of mixed gas through the separator.

[0046] Figure 15 is a perspective view of an alternative embodiment of separator 900. Figure 16 is a side view of separator 900. Separator 900 is substantially similar to separator 100, except that separator 900 includes a straight inlet pipe 910 and a single downwardly facing outlet pipe 930. In addition, separator 900 also includes an outlet valve or throttle 908 that includes a cylindrical outlet 924, and a throttle shaft 920 that includes a conical head 926.

[0047] The separators described herein partially or completely separate components of a mixture of liquids, solids, gases, or any combination thereof. Specifically, the disclosed separators generate a high velocity swirling flow that separates heavier species in the mixture from lighter species in the mixture. For example, the separators described herein can be used to separate greenhouse gases from gas streams emitted from power plants or other greenhouse gas emitting facilities.

[0048] FIG. 17 illustrates a method of separating components of a gas mixture using a separator. The method includes flowing 801 the gas mixture into an inlet manifold of the separator. The method also includes forming 802 the gas mixture into a spiral flow in the inlet manifold. The method further includes flowing 803 the gas mixture from the inlet manifold to a throat of the separator. The method also includes separating 804 heavier species of the gas mixture from lighter species of the gas mixture in the throat. The method further includes flowing 805 the heavier gas species flow from the throat to an outlet manifold of the separator. The outlet manifold includes an outlet valve comprising a conical inlet and a bowl-shaped outlet, and a throttle shaft comprising a shaft and a conical head. The conical head is disposed within the conical inlet, and the shaft extends through the bowl-shaped outlet. The method also includes controlling 806 the flow of the heavy species through the outlet valve and the flow of the gas mixture through the separator using the bowl-shaped outlet, the conical inlet, and the conical head. The bowl outlet, conical inlet and conical head are sized and shaped to control the flow of heavy species through the outlet valve and the flow of mixed gas through the separator.

[0049] Example 1. Separation of carbon dioxide from exhaust gas and air The separator in Figure 1 was modeled using Ansys computational fluid dynamics software (SimuTech, Rochester, New York, United States). A mixture of 5% carbon dioxide and 95% air was modeled in the system with an input flow rate of 20 kilograms per second (kg / s). This mixture is representative of exhaust gas. In this simulation, carbon dioxide was treated as the heavier species. The separator produced an output stream of heavy species containing more than 90 mass percent carbon dioxide. Similar results were observed with a flow rate of 5 kg / s.

[0050] Air was also modeled in the system with an input flow rate of 20 kg / s. The modeled air contained 0.044% carbon dioxide. Carbon dioxide was one of the heavier species in this simulation. The separator produced an output stream of heavier species containing over 0.5 mass percent carbon dioxide.

[0051] These results suggest that by operating three or four separators in parallel, it is possible to produce a heavy gas stream containing more than 90 percent carbon dioxide from air.

[0052] Example 2. Separation of water from natural gas The separator in Figure 1 was used to remove water vapor and carbon dioxide from raw natural gas (feed gas). The feed gas contained primarily methane, and the feed gas also had a water concentration of 1.8 pounds (lbs) / MMSCF (approximately 38 ppm mass / volume). The separator was capable of producing an output stream of heavier species containing up to 20 lbs / MMSCF (approximately 420 ppm / million mass / volume). The separator also removed 7-70% of the carbon dioxide from the methane.

[0053] The above specification, examples and data provide a complete description of the structure and use of exemplary embodiments of the invention. Because many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. Moreover, structural features of different embodiments can be combined in yet other embodiments without departing from the scope of the recited claims. While embodiments and applications of the invention have been shown and described, it will be apparent to one skilled in the art having the benefit of this disclosure that many more modifications than those described above can be made without departing from the inventive concepts herein. Accordingly, the invention is not to be limited except in the spirit of the appended claims.

Claims

1. 1. A separator for separating components of a gas mixture, comprising: an inlet manifold configured to receive a flow of the mixed gas, the inlet manifold forming the mixed gas into a helical flow; a throat attached to the inlet manifold and configured to receive a flow of the mixed gas from the inlet manifold, the throat separating heavier species of the mixed gas from lighter species of the mixed gas; and an outlet manifold attached to the throat and configured to receive a flow of heavier species from the throat, the outlet manifold comprising: an outlet valve including a cone-shaped inlet and a bowl-shaped outlet; and a throttle shaft including a shaft and a conical head, the conical head being disposed within the conical inlet and the shaft extending through the bowl-shaped outlet; Including, A separator in which the bowl-shaped outlet, the conical inlet, and the conical head are sized and shaped to control the flow of heavier gas species through the outlet valve and the flow of mixed gases through the separator.

2. 2. The separator of claim 1, wherein the inlet manifold includes at least one inlet pipe formed in a helical configuration.

3. 3. The separator of claim 2, wherein the at least one inlet pipe comprises two inlet pipes formed in a spiral.

4. 10. The separator of claim 1, wherein the inlet manifold includes an inlet plate defining at least one inlet channel formed in a spiral shape.

5. 5. The separator of claim 4, wherein the inlet manifold includes a conical chamber defining a continuous inner conical sidewall.

6. 6. The separator of claim 5, wherein the continuous inner conical sidewall is tangent to at least one inlet channel.

7. 6. The separator of claim 5, wherein the continuous inner conical sidewall is tangent to the throat.

8. 6. The separator of claim 5, wherein the inlet manifold includes an outlet pipe disposed along the axis of the throat and the conical chamber.

9. 2. The separator of claim 1, wherein the conical head includes a blunt end disposed near an outlet of the throat.

10. 10. The separator of claim 1, wherein the outlet manifold comprises at least one outlet pipe configured to flow heavier species from the separator.

11. 1. A method for separating components of a gas mixture using a separator, comprising: flowing the mixed gas into an inlet manifold of a separator; forming the gas mixture into a helical flow in an inlet manifold; flowing the mixed gas from an inlet manifold to a throat of a separator; separating heavier species of the gas mixture from lighter species of the gas mixture in the throat; directing the flow of heavier gas species from the throat to a separator outlet manifold, the outlet manifold including an outlet valve having a conical inlet and a bowl-shaped outlet, and a throttle shaft including a shaft and a conical head, the conical head being disposed within the conical inlet and the shaft extending through the bowl-shaped outlet; and using a bowl-shaped outlet, a conical inlet, and a conical head to control the flow of heavier species through the outlet valve and the flow of mixed gas through the separator, the bowl-shaped outlet, the conical inlet, and the conical head being sized and shaped to control the flow of heavier species through the outlet valve and the flow of mixed gas through the separator; The method includes:

12. 12. The method of claim 11, wherein the inlet manifold includes at least one inlet pipe formed in a helical shape, and forming the mixed gas into a helical flow in the inlet manifold includes, at least in part, flowing the mixed gas through the at least one inlet pipe.

13. The method of claim 12 , wherein the at least one inlet pipe comprises two inlet pipes formed in a helical configuration.

14. 12. The method of claim 11, wherein the inlet manifold includes an inlet plate defining at least one inlet passage formed in a helical shape, and forming the mixed gas into a helical flow within the inlet manifold includes, at least in part, flowing the mixed gas through the at least one inlet passage.

15. 15. The method of claim 14, wherein the inlet manifold includes a conical chamber defining a continuous inner conical sidewall, and forming the mixed gas into a helical flow within the inlet manifold includes, at least in part, flowing the mixed gas into the conical chamber.

16. 16. The method of claim 15, wherein the continuous inner conical sidewall abuts the at least one inlet passage, and the at least one inlet passage and the continuous inner conical sidewall form a smooth transition from the inlet plate to the conical chamber.

17. 16. The method of claim 15, wherein the continuous inner conical sidewall borders the throat, and the at least one inlet passage and the throat form a smooth transition from the conical chamber to the throat.

18. 16. The method of claim 15, wherein the inlet manifold includes a throat and an outlet pipe disposed along an axis of the conical chamber, the method further comprising the step of passing the light species stream from the throat through the outlet pipe.

19. 12. The method of claim 11, wherein controlling the flow of heavier species through the outlet valve and the flow of mixed gas through the separator with the bowl-shaped outlet comprises moving a conical head within a conical inlet.

20. 20. The method of claim 19, further comprising reducing the flow of heavier species out of the separator by moving the conical head towards the conical inlet.

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