3-d printed small-footprint cyclone separator without encapsulating vessel

Abstract

A 3-D printed small-footprint cyclone separator apparatus for separating similar-phase substances such as oil from contaminated water or separating dual-phase substances from a mixture containing both such as separating solids from a fluid mixture containing both solids and liquids. The cyclone separator apparatus including cyclone liners thereof is entirely 3D printed as a single integral unitary body preferentially from a metal alloy powder, and importantly lacks any encapsulating circumferential vessel with end plates of the prior art used in the past for maintaining individual cyclone liners in fixed position relative to each other, thereby saving weight and cost. Abrasion-resistant coatings or anodizations may be, after 3D printing, applied to the interior of each of the cyclone liners of the separator apparatus to improve wear resistance to abrasive materials and thereby improve the operative life of such cyclone liners and thus the cyclone separator apparatus.

Description

[0001] 3-D PRINTED SMALL-FOOTPRINT CYCLONE SEPARATOR

[0002] WITHOUT ENCAPSULATING VESSEL

[0003] FIELD OF THE INVENTION

[0004] The present invention relates to a cyclone separator apparatus for separating similar- phase substances such as oil from contaminated water, or alternatively separating dual-phase substances from a mixture containing both such as separating solids from a fluid mixture containing both solids and liquids or a mixture containing both solids and gases or liquids and gases, and more specifically relates to an improved cyclone apparatus having fewer constituent parts and thereby improved ease of manufacture and which does not require a surrounding encapsulating vessel and end plates and thereby has a reduced size / footprint and less material and weight over typical prior art cyclone separator devices.

[0005] BACKGROUND OF THE INVENTION AND DESCRIPTION OF THE PRIOR ART

[0006] The term “flowable fluid” or “flowable fluid stream” as used herein denotes a flowable media comprised of at least two single-phase components of different densities, such as two different-density liquids such as but not limited to oil and water, and / or a flowable fluid media which comprises two different-phase components of different densities, such as a gas and a solid, a gas and a liquid, or a solid and a liquid mixture.

[0007] Cyclone separators and hydrocylone separators are well known in the art and are used for separating a less dense component from a flowable fluid stream comprising a more dense component and a less dense component.

[0008] Advantageously cyclone separators and hydrocyclone separators (hydrocyclone separators being a particular type of cyclone separator and specifically a term of art referring to a cyclone separator used for separating less dense oil from fluid streams comprising oil and water) are able to operate to effect separation of the two components without any mechanically-moving parts.

[0009] -1-

[0010] 64013199\1 In its simplest form prior art cyclone separators (and similarly a hydrocyclone separator where oil is being separated from water) comprise one or more tapered cyclone tubes / liners each comprised of a hollow frusto-conical tube gradually tapering from a large diameter first end to a second mutually longitudinally opposite second end of lesser diameter. Each cyclone liner / tube is adapted to receive a flowable fluid stream introduced in a tangential direction and at a relatively high velocity at the first end of each e cyclonic liner, where such tangential entry direction imparts a spiral flow path to the introduced fluid stream within the cyclone liner as such introduced fluid then spirals toward the open second end of the cyclone liner.

[0011] As the introduced fluid stream spirals in the cyclone liner centrifugal force drives the more dense component(s) of the now-spiralling fluid stream to the outer portion of the spiralling column of fluid when moving toward the second narrower tapered end of the cyclone liner, while the less dense lighter component(s) are caused to occupy the inner central axis of the spiralling column of fluid. Continued supply of inlet fluid to the cyclone tube, due as well to the narrowing taper of the fluid column within the cyclone tube / liner, causes the less dense components to migrate in a spiral reverse path back toward the open first end of the cyclone liner. A vortex finder provided proximate the first end of the cyclone liner comprising an open channel allows the less dense component in the central vortex to flow therethough and be collected proximate the first end of the cyclone liner (typically referred to as the “overflow”) with the more dense now-separated component of the fluid stream (typically referred to as the “underflow”) flowing out of the open second end of the cyclone liner.

[0012] To increase throughput and increase quantities of separated components obtained from a given fluid stream over given time interval, prior art separators in some embodiments employ a bundle of cyclone liners / tubes with the cyclone liners / tubes all aligned in side-by-side in parallel relation, with the longitudinal axis of each cyclone liners / tubes being parallel and positioned such that first ends thereof are at a first end of the cyclone separator while all of the second ends were arranged at a mutually opposite second end of the cyclone separator. The cyclone liners of the prior art are each invariably

[0013] -2-

[0014] 64013199\1 mechanically formed and placed in an encapsulating vessel such that a fluid stream supplied under pressure to the encapsulating vessel would simultaneously allow introduction of the fluid stream at a first end of each cyclone tube , to allow separation of the light component from each fluid stream to proceed simultaneously in each cyclone liner. The encapsulating vessel further served to maintain the position of each cyclone liner in the aforesaid parallel juxtaposed relation within the vessel.

[0015] Prior art publications CA 2,209,582 entitled “Cyclone Separator Assembly”, GB 2,258,174 entitled “Hydrocylone Apparatus ”, GB 2,136,327 entitled “Multiple Hydrocyclone Apparatus ” , US 8,439,206 entitled “Cyclone Apparatus”, US 11,123,754 entitled “Liquid-Liquid-Solid Three-Phase Separator for Waste OiV as well as a deoiling hydrocyclone separator as manufactured and publicly sold by Eprocess Technologies Inc. of Melbourne, Australia, are each examples of such prior art cyclone separator designs. All of such publications teach cyclone separators which employ encapsulating vessels with end plates substantially bounding first and second ends of hydrocyclone liners for both securing the individual hydrocyclone liners and thus preventing their displacement also and for allowing such encapsulating vessel when filled with the fluid stream to thereby supply such fluid stream simultaneously and uniformly to a first end of each hydrocyclone liner for even and uniform distribution of such inlet fluid stream to each cyclone liner / tube.

[0016] For example, CA 2,209,582 entitled “Cyclone Separator Assembly” teaches in Fig. 1 thereof [similar to Fig. 1 (Prior Art) shown in this present application] a cyclone separator apparatus having a bundle of tapering cyclone liners 36 which are surrounded and secured by an encapsulating vessel ( hollow circular cylindrical body 2 with end plates 20, 30) , further having a fluid inlet passage 4 proximate a mid-region of such encapusulating vessel and which is in fluid communication with the interior thereof for supplying an inlet fluid steam. The encapsulating vessel (body 2) extends between end plates 20 & 30 which hold and secure the mutually-opposite first and second mutually opposite respective ends 39 & 41 of each hydrocyclone liner within the separator apparatus. Encapsulating vessel 2 and fluid inlet passage 4 mounted midsection thereby allow uniform supply of such inlet fluid stream to apertures within first ends of each of such hydrocyclone tubes / liners.

[0017] -3-

[0018] 64013199\1 US 8,439,206 entitled “Cyclone Apparatus” is similar in configuration. Specifically, while US ‘206 advantageously divides the interior of the encapsulating vessel into two separate regions 11,12 thereby alternatively providing the option of allowing fluid flow through region 12, region 11 , or simultaneously through combination of regions 12 & 11 (ref. Fig. 3 thereof), disadvantageously as may be seen from Fig. 1 US ‘206 such configuration nevertheless maintains a design having an encapsulating vessel 2 sandwiched between two end plates 19 & 28, the latter being used to maintain and position hydrocyclone liners 25 in mutual fixed parallel relation. Such design disadvantageously results in a relatively large footprint for such apparatus, to say nothing of considerable added weight and material use as well as complexity of manufacture due to a relative plethora of constituent parts.

[0019] To similar effect, and by way of further example, GB 2,258,174 entitled “Hydrocylone Apparatus ”, in Fig. 3 thereof, teaches a hydrocyclone apparatus having a generally hollow cylindrical pressure vessel 110 comprising a pair of sections 112 and 114, having flange portions 112A and 114A, again having dividing plates 121 and 122 for mounting therebetween and thereby indididually affixing each of the cyclone liners 150 within the apparatus.

[0020] Likewise GB 2,136,327 entitled “Multiple Hydrocyclone Apparatus ” teaches, in Fig. 2 thereof a closed housing 1 having a cylindrical body 2, with partition plates 8, 9 & 10 . Cyclone frusto-conical elements 40 are disposed in the feed chamber 11 between plates 9 & 10, wherein at least plate 10 has holes 10a therein to engage and hold one end of each cyclone element 40 and thereby maintain the position of such cyclone liners within the encapsulating body 2, where the longitudinal axis of each cyclone element 40 is each parallel.

[0021] Likewise, the prior art de-oiling hydrocyclone manufactured by eProcess Technologies Inc. of Melbourne, Australia, an illustration of which is shown in Fig. 1A & 1C (Prior Art) of this within application, teaches a hydrocyclone apparatus 1 of similar configuration. Specifically, Fig. 1A & 1C (Prior Art) of this within application teach a

[0022] -4-

[0023] 64013199\1 hydrocyclone apparatus 1 having an encapsulating vessel 6 having at least one end plate 10 and 11 for securing first ends 8 of a plurality of hydrocylone liners 5 relative to each other and in fixed parallel relation . An inlet fluid stream is supplied to the encapsulating vessel 6 via an inlet flange 2, whereby such inlet fluid stream may then flow to the respective first end 8 of the hydrocyclone liners 5 encapsulated and surrounded by vessel 6, and by then entering each of such hydrocyclone liners 5 through a tangential aperture therein be accordingly imparted with a spiral flow.

[0024] US 6,918,494 entitled “Hydrocyclone Separator Packaging” in Fig. 1 thereof, shows a prior art hydrocyclone apparatus 50 having a similar configuration possessing an encapsulating vessel 12 similar to that described above. Fig. 2 of US 6,918,494 discloses an improvement where the axial positioning of the larger-diameter first end of each hydrocyclone tubes / liners 24 having tangential entrance aperture 31 is axially staggered between end plates 14, 16 and relative to the axial positioning of other first ends of hydrocyclone tubes 24 within encapsulating vessel 12, which due to such axial staggering results in a desirable reduction of the overall diameter of such a deoiling separator. Nevertheless and disadvantageously, US 6,918,494 continues to teach and employ an encapsulating vessel 12 surrounding hydrocyclone liners 24, with end plates 14, 16 respectively securing first ends and second ends of hydrocyclone liners 24 so as to maintain them as each being in parallel fixed relation (albeit axially offset) to each other and accordingly being individually replaceable.

[0025] Lastly, but also similarly, US 11,123,754 provides a plurality of cyclone units 1 likewise fixed in an encapsulating vessel (oil-bath heating tank (tank body 14)] by support end steel plates 6 & 7.

[0026] Disadvantageously , however, as regards each of the aforementioned prior art teachings, use of an encapsulating vessel and associated end plates to fix and hold respective ends of the hydrocyclone liners in relative fixed position to each other and in parallel relation adds considerable weight and footprint (volume and area) of such a hydrocylone separator, to say nothing as to the added material cost and increased time to

[0027] -5-

[0028] 64013199\1 manufacture relating to the relative plethora of a number of individual components needing to be bolted together, resulting in such large footprint for such a device.

[0029] Moreover, and disadvantageously, when desiring to replace single hydrocylone liner or tube due to abrasive wear, frequently remaining hydrocyclone liners also at the same time are worn and life-expired (particularly if the inlet fluid stream for separation is as intended evenly distributed between hydrocyclone liners). Replacement of the hydrocylone liners requires unbolting of the end plates in the encapsulating vessel and necessary removal of fluid connections of such hydrocyclone separator with each of the inlet flanges coupled to the encapsulating vesssel, As well, the overflow flanges typically connected to an end cap of the separator and which receives the less dense component from the hydrocylone liners, the underflow flanges which receive the more dense component (typically water with oil separated therefrom), as well as the individual removal of each worn hydrocyclone liner, all need to be decoupled to effect such maintenance or replacement. . Such is a necessarily a time-consuming and involved process and has required a relatively large footprint hydrcocyclone which makes extensive use of material and which has a plurality of individual components which adds to the cost of manufacture of such prior art cyclone separators.

[0030] Thus there exists a real need for a cyclone separator which has fewer constituent parts and thereby improved ease of manufacture, and which does not require a surrounding encapsulating vessel and thereby has a reduced size / footprint and less material and weight over typical prior art devices.

[0031] Other prior art hydrocylone devices possess similar or other drawbacks.

[0032] For example, WO 2004 / 06281 entitled “Hydrocylone Bundle” teaches a plurality of hydrocylone liners and a plate assembly, wherein pairs of hydrocyclone liners each with an associated end-caps may be positioned in opposition. In such manner the underflow fluid stream from a hydrocyclone liner exiting from second end of hydrocyclone liner may , via channels within an end cap / plate, be directed to flow into first end of an oppositely oriented

[0033] -6-

[0034] 64013199\1 hydrocyclone liner, thereby using pairs of hydrocyclone liners to successively separate less dense components from an inlet stream which may then have at least 3 separate components of different densities.

[0035] Disadvantageously, however, such prior art hydrocylone device, as may be seen from the individual pairs various underflow and overflow end plates depicted in each of Figs. 5A& 5B, 6A&6B, 7A & 7B, 8A&8B, 9A&9B, 10 & 11 of WO 2004 / 06281, necessarily requires a multitude of individual machined end plates / end caps to operationally achieve such objective, and is thus necessarily mechanically complicated and requires complete dis-assembly and re-assembly of the unit to replace individual cyclone tubes.

[0036] Accordingly, and despite the prior art devices, a real need exists for improved cyclone separators.

[0037] Specifically, a real need exists for improved cyclone separators, including one :

[0038] - which has fewer constituent parts and thereby improved ease of manufacture;

[0039] -which does not require a surrounding encapsulating vessel and end plates and thereby has a reduced size / footprint and less material and weight over typical prior art devices;

[0040] -which thus may, if desired , be easily replaced when worn; and

[0041] -which may if desired be easily successively coupled in succession in so- called “daisy-chain” manner to thereby achieve separation of three or more various density components from within a single inlet fluid stream.

[0042] -7-

[0043] 64013199\1 SUMMARY OF THE INVENTION AND SOME OF ITS EMBODIMENTS

[0044] The present invention accordingly has, as one of its non- limiting objects the provision of a low- cost small-footprint (and thus low material use) cyclone separator for separating a less dense component within a flowable fluid stream from a more dense component within such flowable fluid stream .

[0045] The present invention has as another of its objects the provision of a low-cost device which, when becoming worn due to abrasive elements within an inlet fluid stream or when desired to be changed due to an altered inlet fluid stream with different components requiring smaller or larger cyclone liners, may be easily and quickly substituted with a new replacement unit.

[0046] Accordingly, in a first broad embodiment of the present invention, the present invention provides a 3-D printed cyclone separator apparatus for separating a less dense component from a more dense component within said flowable fluid stream. The cyclone separator comprises a plurality of 3-D printed, elongate cyclone tubes, each 3-D printed cyclone tube having a larger diameter first end tapering to a longitudinally-opposite second end of lesser diameter than the first end. The cyclone tubes are each 3-D printed in mutually adjacent position with respective first ends thereof forming a first end of the cyclone separator apparatus and the respective second ends thereof forming a second end of said cyclone separator apparatus so as to form a single integral unitary body holding the 3-D printed cyclone tubes in fixed relation to each other.

[0047] The first end of the cyclone separator apparatus is adapted to receive the flowable fluid stream entering the cyclone separator apparatus. The second end of the cyclone separator apparatus is adapted to allow egress of said more dense component from the cyclone separator apparatus.

[0048] Advantageously, by 3-D printing the cyclone tubes in mutually adjacent position with respective first ends so as to form a single integral unitary body holding the 3-D printed cyclone tubes in fixed relation to each other, the cyclone apparatus is made lighter,

[0049] -8-

[0050] 64013199\1 simpler, and with less material than conventional prior art cyclone separators by avoiding having to use any encapsulating circumferential vessel with end plates for maintaining individual cyclone tubes in fixed position relative to each other and in parallel relation .

[0051] The 3-D printed cyclone separator apparatus incorporating the above features may be configured in two(2) separate individual embodiments .

[0052] In the first individual embodiment the flowable fluid stream enters the cyclone separator axially at a first end, with the underflow(more dense component) exiting the cyclone separator at a second mutually opposite longitudinally-opposed opposite end, with the overflow (the less-dense component of the fluid stream) being collected in a collection plenum proximate the first end of the cyclone separator apparatus.

[0053] Specifically, in the first individual embodiment, the first ends of each of said 3-D printed cyclone tubes each have an axial channel or aperture therein, said axial channel or aperture extending to and in fluid communication with a helically spiralling channel, said helical spiralling channel spiraling a portion of a distance within said first end of each 3-D printed cyclone tube and from said first end thereof towards said second end thereof, wherein said helically spiralling channel is adapted to impart a helically spiralling flow to said flowable fluid stream received from said axial channel or aperture within each of said 3-D printed cyclone tubes.

[0054] The cyclone separator apparatus of the first individual embodiment is further provided with a 3-D printed inlet cavity situated proximate the first end of the cyclone separator apparatus and configured for receiving the flowable fluid stream and directing the flowable fluid stream into the axial channel or aperture at each of the first ends of each of said 3-D printed cyclone tubes. Each of the 3-D printed cyclone tubes proximate the first end possesses :

[0055] (i) a vortex finder channel proximate the first end of each of the cyclone tubes, adapted to allow the less dense component of said flowable fluid stream to flow from within each respective 3-D printed cyclone tube .

[0056] -9-

[0057] 64013199\1 A 3-D printed collection plenum is provided which circumferentially surrounds each of the 3-D printed cyclone tubes at the first end thereof, and is integrally formed with each of the 3-D printed cyclone tubes The collection plenum is in fluid communication with each of the first ends of the cyclone tubes and serves to collect the less dense (overflow) component from the vortex finder channel of each of the 3D printed cyclone tubes.

[0058] In such first individual embodiment the inlet cavity may be situated along a longitudinal axis of the cyclone separator apparatus, and theflowable fluid stream enters the inlet cavity in an axial direction parallel to a longitudinal axis.

[0059] In a further refinement of such first individual embodiment, the collection plenum preferentially has a collection flange thereon in fluid communication with an interior of the collection plenum and adapted to allow said less dense component (“overflow”) to flow out of and be withdrawn from said collection plenum.

[0060] The configuration of the second embodiement will now be described.

[0061] Tthe second individual embodiment is configured so as to cause the flowable fluid stream to enter the cyclone separator at the first end thereof radially , namely tangentially or perpendicular to a longitudinal axis of the cyclone separator. It is further configured to allow the underflow (i.e. the more dense component which has been cyclonically purified to have removed therefrom the less dense component) to. exit the cyclone separator at a second mutually opposite longitudinally-opposed opposite end, with the “overflow” (i.e. the cyclonically separated less-dense component of the fluid stream) being directed to a 3- D printed reject cavity situated proximate the first end of the cyclone separator apparatus and preferentially co-axial with the longitudinal axis of the cyclone separator.

[0062] Specifically, in the second individual embodiment of the cyclone separator apparatus, a 3-D printed reject cavity is situated proximate the first end of cyclone separator for collecting overflow . Such reject cavity is situated preferably co-axially with the longitudinal axis of the cyclone separator for collecting said less dense component. A 3-D printed distribution plenum is further provided, circumferentially surrounding each of

[0063] -10-

[0064] 64013199\1 the 3D printed cyclone tubes at said first end thereof. Such 3-D printed distribution plenum is adapted for initially receiving the flowable fluid stream when entering said cyclone separator apparatus and uniformly distributing the flowable fluid stream to the respective first ends of each of the 3D printed cyclone tubes.

[0065] Each of the 3-D printed cyclone tubes proximate said first end thereof are provided with a vortex finder channel, in fluid communication with said reject cavity and centrally located within or at said first end of each of said 3-D printed cyclone tubes and substantially extending axially out of or from said first end of each of said 3D printed cyclone tubes and the distribution plenum and into the reject cavity. The vortex finder channel is configured to permit the less dense component to flow from within a respective 3-D printed cyclone tube out of the first end thereof and out of the distribution plenum and into the reject cavity.

[0066] In addition, the second embodiment comprises a helical spiralling channel spiraling a portion of a distance within the first end of each 3-D printed cyclone tube towards said second end thereof. Such helical spiralling channel is in fluid communication with the d distribution plenum.. The helically spiralling channel is adapted to impart a helically spiralling flow to the flowable fluid stream received from the distribution plenum.

[0067] In a further refinement of the second individual embodiment the cyclone separator apparatus is configured so as to permit the flowable fluid stream to enter the cyclone apparatus via the 3-D printed distribution plenum, in a direction transverse or perpendicular to said longitudinal axis of said cyclone separator apparatus.

[0068] In the second individual embodiment the distribution plenum may have a plurality of distribution flanges circumferentially spaced thereabout for evenly distributing the fluid stream within the distribution plenum and thus evenly to the first end of each of the 3-D printed cyclone tubes.

[0069] In either of the first or second individual embodiments, each of the 3-D printed cyclone tubes may further have a longitudinal axis which is non-parallel and slightly canted at an acute angle to the respective longitudinal axis of each of remaining of said 3-D

[0070] -l i¬

[0071] 64013199\1 printed cyclone tubes .

[0072] In a specific embodiment the cyclone separator apparatus is used as a hydrocyclone for for separating oil from a single phase inlet stream comprised of water and oil.

[0073] Accordingly, the present invention further provides for a 3-D printed hydrocyclone separator apparatus for separating a less dense component, namely a liquid hydrocarbon, namely oil, from within a flowable fluid stream comprised of oil and a more dense component, namely water.

[0074] In such embodiment a plurality of 3-D printed, elongate hydrocyclone tubes are provided, each of the hydrocyclone tubes having a larger diameter first end tapering to a longitudinally-opposite second end of lesser diameter than the first end. Each of the 3-D printed hydrocyclone tubes are each 3-D printed in mutually adjacent position with respective first ends thereof forming a first end of the hydrocyclone separator apparatus and the respective second ends thereof forming a second end of said hydrocyclone separator apparatus so as to form a single integral unitary body holding the 3-D printed cyclone tubes in fixed relation to each other.

[0075] The first end of the hydrocyclone separator apparatus is adapted to receive the flowable fluid stream entering the hydrocyclone separator apparatus. The second end of the hydrocyclone separator apparatus is adapted to allow egress of the more dense “underflow” component from the hydrocyclone separator apparatus. Advantageously, by 3-D printing the hydrocyclone tubes so as to form a single integral unitary body holding the 3-D printed cyclone tubes in fixed relation to each other the hydrocyclone separator apparatus of the present invention is able to avoid having to use any encapsulating circumferential vessel having end plates to maintain the individual cyclone tubes in fixed position relative to each other and in parallel relation, and thus avoids additional weight , space, and material costs.

[0076] In a first individual embodiment of the hydrocyclone embodiment, such apparatus is further provided with a 3D-printed inlet cavity situated proximate the first end of said hydrocyclone apparatus and configured for receiving the flowable fluid stream and

[0077] -12-

[0078] 64013199\1 directing the flowable fluid stream along a longitudinal axis of the 3-D printed hydrocyclone separator apparatus into respective of the first ends of each of the 3-D printed hydrocyclone tubes. A 3-D printed collection plenum is further provided circumferentially surrounding each of the 3-D printed hydrocyclone tubes at the first end thereof integrally 3D-printed with each of the 3-D printed hydrocyclone tubes, for collecting the “overflow” oil from each of the 3-D printed hydrocyclone tubes. Each of the 3-D printed hydrocylone tubes proximate the first end thereof are provided with :

[0079] (i) a spiral inlet channel , in fluid communication with said inlet cavity, which spirals a portion of a distance within each cyclone tube towards said second end of each of said hydrocylcone tubes, adapted to receive and cause said flowable fluid stream when received axially from said inlet cavity and thereafter entering a respective first end of the hydrocylcone tubes, to adopt a spiral flowpath therewithin toward the second end of said hydrocylone separator apparatus; and

[0080] (ii) a vortex finder channel within the first end of each of the hydrocyclone tubes, adapted to allow the oil to flow from within each respective hydrocyclone tube into the collection plenum.

[0081] Alternatively, as regard the hydrocyclone embodiment, in a second individual embodiment thereof such 3-D printed hydrocyclone separator apparatus a 3-D printed reject cavity situated proximate the first end thereof for collecting underlow, namely the less dense oil . A 3-D printed distribution plenum is further provided circumferentially surrounding each of the hydrocyclone tubes at the first end thereof which is adapted for initially receiving the flowable fluid stream when entering the hydrocyclone separator apparatus.

[0082] Each of the 3-D printed hydrocylone tubes proximate the first end of each have:

[0083] (i) a spiral inlet channel in fluid communication with the distribution plenum and spiraling a portion of a distance towards said second end of each of the hydrocyclone tubes, adapted to cause the flowable fluid stream

[0084] -13-

[0085] 64013199\1 after having entered said distribution plenum from a tangential or perpendicular direction relative to a longitudinal axis of the hydrocyclone apparatus and thereafter entering a respective first end of each of the hydrocylone tubes, to adopt a spiral flowpath therewithin toward the second end of said hydrocylone apparatus; and

[0086] (ii) a vortex finder channel, in fluid communication with the reject cavity and centrally located within or at the first end of each of the hydrocyclone tubes and extending substantially axially out of or from the first end of each of the hydrocyclone tubes and the distribution plenum and into the reject cavity. The vortex finder channel is adapted to permit the oil in the flowable fluid stream to flow from within a respective hydrocyclone tube axially out of the first end thereof and out of the distribution plenum and into the reject cavity for collection of such “overflow”.

[0087] Each of the 3-D printed hydrocyclone tube / liners may have a longitudinal axis, wherein the longitudinal axis is non-parallel and slightly canted at an acute angle to the respective longitudinal axis of each of remaining of the 3-D printed hydrocyclone tubes / liners.

[0088] The cyclone / hydrocyclone separator apparatus of the present invention may be 3-D printed using any materials, but most preferentially is printed from a powdered metal or metal alloy.

[0089] To be useful in high corrosion environments, preferentially the cyclone separator apparatus is 3-D printed using a corrosion resistant metal alloy such as a stainless steel.

[0090] In addition, considering the high velocity vortices that are generated in the cyclone separator tubes where the flowable inlet fluid stream contains abrasive materials such as sand, drill tailings, and the like therein which tend to abrade and wear interior surfaces of cyclone separator tubes / liners, the present invention contemplates the cyclone separator apparatus be 3-D printed from not only a corrosion-resistant powdered metal alloy but further from an abrasion-resistant powdered steel alloy.

[0091] -14-

[0092] 64013199\1 Steels having relatively good corrosion resistance and good wear resistancd, but that are further suitable for 3-D printing from powdered quantities thereof , are abrasionresistant steel alloys comprised of one or more of AR200, AR235, AR400, AR500 and AR600 abrasion resistant steel.

[0093] Powdered metal or powdered metal alloys of this type may be 3-D printed using a using a powder bed fusion technique selected from the group of existing powder bed fusion techniques known to persons of skill in the art,, namely laser melting (SLM) and electron beam melting (EBM).

[0094] In addition, in light of the desire to further increase the life and wear resistance of the cyclone separator apparatus of the present invention, such 3D printed cyclone separator apparatus may have interior surfaces , after 3D printing thereof, coated with or have deposited thereon an abrasion-resistant material.

[0095] A suitable abrasion-resistant coating is a ceramic coating applied using either chemical vapour deposition or physical vapour deposition.

[0096] Alternatively, the 3-D printed cyclone separator apparatus may be entirely 3-D printed from an abrasion-resistant ceramic.

[0097] To further assist in reducing abrasive wear on the interior of the cyclone tubes / liners, the invention lends itself to easily in a single step, such as immersion the 3-D printed unitary body in an anodizing electrochemical bath, so as to coat or electrochemically apply an abrasion -esistant material to an interior periphery of each of the cyclone tubes / liners.

[0098] For further explanation and description of the scope of the aforementioned embodiments of the invention, reference is to also be had to the remainder of this specification.

[0099] -15-

[0100] 64013199\1 BRIEF DESCRIPTION OF THE DRAWINGS

[0101] Further advantages and permutations and combinations of the invention will now appear from the above and from the following detailed description of various particular embodiments of the invention, taken together with the accompanying drawings each of which are intended to be non-limiting, in which:

[0102] FIG. 1A is a perspective cut-away view of a prior art cyclone apparatus for cyclonically separating oil from water;

[0103] FIG. IB is an enlarged perspective cut-away view of one of the prior art cyclone tubes / liners of FIG. 1A, showing schematically spiral flows therewithin of respectively a less dense component (oil) and a more dense component (water) in two mutually opposite directions;

[0104] FIG. 1C is side elevation view in partial cross-section of a prior art hydrocyclone device similar to that shown in Fig.lA;

[0105] FIG. 2 is a partial cross-section side elevation view of a prior art hydrocyclone apparatus similar to that shown and described in prior art US 6,800,208 and US 7,291,268;

[0106] FIG. 3 is side perspective view of a first individual embodiment of the cyclone separator apparatus of the present invention;

[0107] FIG. 4 is a cross-sectional view of the first embodiment shown in Fig. 3, along plane Z-Z of Fig. 3;

[0108] FIG. 5 is a partial front side perspective view of the first embodiment shown in Fig- 3, shown for simplicity without flanges at either end ;

[0109] FIG. 6 is a rear side perspective view of the first embodiment shown in Fig. 5,

[0110] -16-

[0111] 64013199\1 again with flanges being omitted from respective first and second ends thereof;

[0112] FIG. 7 is an enlarged partial perspective cross-section taken along plane A-A of Fig- 5;

[0113] FIG. 8 is a partial side elevation cross-sectional view of the cyclone apparatus shown in FIG. 7;

[0114] FIG. 9 is an enlarged view of region “B” shown in FIG. 8;

[0115] FIG. 10 is side perspective view of a second individual embodiment of a cyclone separator apparatus of the present invention;

[0116] FIG. 11 is a cross-sectional view of the second embodiment shown in FIG. 10, taken along plane Y-Y of FIG. 12;

[0117] FIG. 12 is a front side perspective view of the second embodiment shown in FIG. 10;

[0118] FIG. 13 is a rear side perspective view of the second embodiment shown in FIG. 10;

[0119] FIG. 14 is an enlarged partial perspective cross-section taken along plane Y-Y of FIG. 12;

[0120] FIG. 15 is an enlarged view of region “X” shown in FIG. 14;

[0121] FIG. 16 is a partial side elevation cross-sectional view of the cyclone separator apparatus shown in FIG. 10;

[0122] FIG. 17 is an enlarged view of one of cyclonic tubes in region ‘B’ of FIG. 8;

[0123] FIG. 18 is an enlarged view of one of cyclonic tubes in region ‘D’ of FIG.15; and

[0124] -17-

[0125] 64013199\1 FIG. 19 is an enlarged isolated partial view of the vortex finder portion of each of the cyclone tubes in each of the first and second embodiments of the present invention.

[0126] To facilitate understanding, identical reference numerals have been used where possible in each of the appended figures to designate identical elements that are common to each of the figures of the present invention.

[0127] It is further contemplated that elements disclosed in one embodiment shown in one of the aforesaid figures may be beneficially utilized on other embodiments shown in the above figures, without specific recitation.

[0128] DETAILED DESCRIPTION OF SOME PREFERRED EMBODIMENTS

[0129] FIG. 1A (Prior Art) shows a perspective cut-away view, and FIG. 1C (Prior Art) shows a partial cut-away side elevation view, of a prior art hydrocyclone separator apparatus 1. A hollow cylindrical vessel 6, bolted to or having end plates / walls 10, 13, encapsulates and contains therewith a plurality of hydrocyclone tubes / liners 6.

[0130] The plurality of individual elongate tapered hydrocyclone liners / tubes 4 [also shown schematically in isolated view Fig. IB (Prior Art)] each have a first larger diameter inlet end 7 and a second, longitudinally mutually opposite second 17 of a smaller diameter. Each of hydrocyclone liners / tubes 5 are provided with a tangential aperture 8 in fluid communication with an interior of vessel 6 to thereby allow flow of inlet stream which has flowed into encapsulating hollow vessel 6 to thereafter flow into a first end 7 of each hydrocylone liner 5 in a radially tangentially manner to thereafter impart a swirling flow to the inlet fluid in each hydrocylone liner 5.

[0131] End plates 10 and 13 are used to position and retain mutually opposite first and second ends of cyclone liners / tubes 5 in a parallel fixed relative position within cyclone separator 1. Blind flange 12 is bolted to vessel 6 and sandwiches therebetween end plate 10. At the opposite second end of cyclone apparatus 1, plate 13 holding second ends 13 of

[0132] -18-

[0133] 64013199\1 each of hydrocylone liners 5 is sandwiched between blind flange 18 which is bolted to vessel 6.

[0134] Disadvantageously, however and as noted previously herein, such prior art teaches use of an encapsulating vessel and associated end plates to fix and hold respective ends of the hydrocyclone liners in relative fixed position to each other and in parallel . Such configuration adds considerable weight and footprint (volume and area) of such a hydrocylone separator, to say nothing as to the added material cost and increased time to manufacture relating to the relative plethora of a number of individual components needing to be bolted together.

[0135] FIG. 2 (Prior Art) teaches a cyclone separator having an inlet end ‘A’ and a capped mutually-opposite end ‘B’, further comprising a bundle of pairs of hydrocyclone liners 5a, 5b arranged in juxtaposed , mutually opposite direction, with the second end 122 of hydrocylone liner 5a adjacent to the first end of hydrocyclone liner 5b. Such prior art cyclone separator design requires a complicated and machined end cap to direct flow from the second end of liner 5a into the first end of liner 5b, with resultant complexity in machining and cost of manufacture.

[0136] FIG. 3 shows as side perspective view of the first individual embodiment 20 of the 3-D printed cyclone separator apparatus 20 of the present invention,.

[0137] Flanges 24 , 25 are provide at opposite ends to allow such cyclone separator apparatus 20 to be inserted between and respectively bolted to and intermediate two respective flange ends of a pipe (not shown).

[0138] FIG. 4 shows a partial side cross-sectional view of the first individual embodiment 20, with flanges 24, 25 shown in Fig. 3 being omitted for simplicity from respective first and second ends ‘A’, ‘B’ .

[0139] As seen from FIGS. 3 & 4, the 3-D printed cyclone separator apparatus 20 comprises a plurality of 3-D printed, elongate cyclone tubes 21 . Each 3-D printed cyclone tube 21 has a larger diameter first end 22 tapering to a longitudinally-opposite second

[0140] -19-

[0141] 64013199\1 end 23 of lesser diameter than said first end 22.

[0142] Elongate cyclone tubes 21 are each 3-D printed in mutually adjacent position with respective first ends 22 thereof forming a first end ‘A’ of cyclone separator apparatus 20 and the d respective second ends 23 thereof forming a second end ‘B’ of cyclone separator apparatus 20, so as to form a single integral unitary body 20’ holding 3-D printed cyclone tubes 21 in fixed relation to each other.

[0143] FIG. 5 is a partial front side perspective view of the first embodiment 20, shown for simplicity without flanges 24, 25 at either respective end ‘A’, ‘B’.

[0144] FIG. 6 is a rear side perspective view of the first individual embodiment 20, again with flanges 24, 25 being omitted for simplicity from respective first and second ends thereof ‘A’, ‘B’.

[0145] A 3-D printed inlet cavity 26 is situated proximate first end 22 of cyclone separator apparatus 20 and configured for receiving flowable fluid stream 28 and directing flowable fluid stream 28 into each of first ends 22 of each of the 3-D printed cyclone tubes 21 in the manner hereinafter described.

[0146] Specifically, 3-D printed inlet cavity 26 is situated proximate the first end ‘A’ of the d cyclone separator apparatus 20 and configured for receiving flowable fluid stream 28 and directing the flowable fluid stream into the axial channel or aperture 40 of each of said first ends 22 of each of said 3-D printed cyclone tubes 21.

[0147] A 3-D printed collection plenum 30 is further provided, circumferentially surrounding each of 3-D printed cyclone tubes 21 at the first end 22 thereof. Collection plenum 20 is integrally formed with each of 3-D printed cyclone tubes 21, and is adapted for collecting less dense component 29 (i.e. the “overflow”) from fluid stream 28 and the axial channel / aperture 40 when such less dense component 29 has been separated by cyclone tubes 21 from inlet fluid stream 28.

[0148] -20-

[0149] 64013199\1 One or more collection flanges 33 may be in fluid communication with collection plenum 30, for allowing withdrawal of less dense component 29 from collection plenum 30.

[0150] First end 22 of the cyclone separator apparatus 20 is adapted to receive, via axial channels 40, the flowable fluid stream 20 entering the cyclone separator apparatus 20.

[0151] Specifically, as best seen from FIG’S 7, 8, 9 & 17, in embodiment 20 first ends 22 of each of 3-D printed cyclone tubes 21 each have an axial channel or aperture 40 therein. Axial channel or aperture 40 extends to and in fluid communication with a helically spiralling channel 42. Helical spiralling channel 42 spirals a portion of a distance within the d first end 22 of each 3-D printed cyclone tube 21 and from the first end 22 thereof towards the second end 23 thereof.

[0152] Helical spiralling channel 42, due to such helical spiral characteristic and directing flow tangentially along the periphery of the interior of the cyclone tubes 21, is thus adapted to impart a helically spiralling flow to the flowable fluid stream 28 received from the 3-D printed inlet cavity 26 and axial channel or aperture 40.

[0153] The second end 23 of the cyclone separator apparatus 20 is adapted to allow egress of the more dense component 27 (i.e. underflow) from cyclone separator apparatus 20.

[0154] Again, as best seen from Figs. 7, 8, 9 & 17 , each of 3-D printed cyclone tubes 21 proximate said first end 22 thereof are provided with a vortex finder channel 50 within first end 22 of each of cyclone tubes 21. Vortex finder channel 50 is adapted to allow the less dense component 29 of flowable fluid stream 28 to flow from within each respective 3-D printed cyclone tube 21 and into collection plenum 30, as described below.

[0155] FIG. 10 shows a is side perspective view of the second individual embodiment 60 of a cyclone separator apparatus of the present invention;

[0156] FIG. 11 is a partial side cross-sectional view of the second individual

[0157] -21-

[0158] 64013199\1 embodiment 60, taken along plane Y-Y of FIG. 12 . FIG. 12 shows s a front side perspective view of the second embodiment 60 . FIG. 13 is a rear side perspective view of the second embodiment 60.

[0159] As seen from FIGS. 10, 11, 12, 13, 14, 15, 16 & 18 which depict features common to the second individual embodiment 60, second embodiment 60 comprises, similar to first embodiment 20, a plurality of 3-D printed, elongate cyclone tubes 21 . Each 3-D printed cyclone tube 21 has a larger diameter first end 22 tapering to a longitudinally- opposite second end 23 of lesser diameter than the first end 22. Elongate cyclone tubes 21 are each 3-D printed in mutually adjacent position with respective first ends 22 thereof forming a first end ‘A’ of cyclone separator apparatus 60 and respective second ends 23 thereof forming a second end ‘B’ of cyclone separator apparatus 60. In such manner there is formed a single integral unitary body 60’ holding 3-D printed cyclone tubes 21 in fixed relation to each other.

[0160] A first end ‘A’ of 3-D printed cyclone separator apparatus 60 is adapted to receive the flowable fluid stream 28 entering cyclone separator apparatus 60 via distribution plenum 62 proximate first end “A”, as more fully described below. A second mutually opposite end ‘B’ of cyclone separator apparatus 60 is adapted to allow egress of more dense component 27 (i.e. the underflow) from cyclone separator apparatus 60.

[0161] Notably, second embodiment 60 differs in configuration from first embodiment 20 specifically in at least the following manner.

[0162] Specifically, in second embodiment 60 as perhaps best seen from FIGS.’s 10, 11, 12, & 13, the cavity for collecting the less dense component 29 during cyclonic separation in each of the cyclone tubes 21 is not via a common collection plenum 30 circumferentially encompassing the cyclone tubes 21 proximate their first ends as shown for example in FIGS. 3-6, but rather by way of a 3-D printed reject cavity 70 preferentially situated proximate said first end ‘A’ of cyclone separator apparatus 60 and co-axial with a longitudinal axis 75 of said cyclone separator apparatus 60. The reject cavity thus collects the less dense component 29 as it is in fluid communication with respective first ends 22

[0163] -22-

[0164] 64013199\1 of each of the 3-D printed cyclone tubes 21.

[0165] Further, in second embodiment 60, the cavity or plenum for providing the inlet fluid stream is not located at one longitudinal end of the cyclone separator as shown for example in FIG’s. 3-6 as per first embodiment 20, but rather is, as best seen in FIG’s 10- 13, a 3-D printed distribution plenum 72 is instead provided which circumferentially surrounds each of said 3D printed cyclone tubes 21 at said first end ‘A’ . Distribution plenum 72 is adapted for initially receiving, via distribution flanges 80 circumferentially spaced about the outer periphery of such distribution plenum 72, the flowable fluid stream 28. . The flowable fluid stream 28 thus enters the distribution plenum 72 in a perpendicular manner, and either radially aligned or tangential to the central longitudinal axis 75 thereof, and is thereafter distributed it evenly to first ends 22 of each of cyclone tubes 21, and more particularly , as further explained below, to helical spiralling channels 42’ of each of cyclone separator tubes 21.

[0166] In second embodiment 60 , as best shown in FIGS. 14, 15, 16, & 18, first ends 22 of each of said 3-D printed cyclone tubes 21 have a vortex finder channel 50’ in fluid communication with the reject cavity 70 and centrally located within first end 22 of each of said 3-D printed cyclone tubes 21, and extending axially out of or from the first end 22 of each of said 3D printed cyclone tubes 21 and said distribution plenum 72 and into said reject cavity 70. Vortex finder channel 50’ is adapted to permit the less dense component to flow from within a respective 3-D printed cyclone tube out of the first end thereof and into the reject cavity 70.

[0167] As best shown in FIG. 15 , each of said 3-D printed cyclone tubes 21 of the second embodiment 60, proximate said first end 22 thereof, further possess a helical spiralling channel 42’ spiraling a portion of a distance within the first end 22 of each 3-D printed cyclone tube 21 and from the first end 22 thereof towards the second end 23 thereof, in fluid communication with distribution plenum 72. The helically spiralling channel 42’ proximate the first end of each of said cyclone tubes 21 is adapted to receive said fluid stream from said distribution plenum 72 and impart a helically spiralling flow to the flowable fluid stream received from distribution plenum 72.

[0168] -23-

[0169] 64013199\1 FIG. 19 shows a portion of a cyclone separator tube 21 common to both embodiments, having a helical spiralling channel 42, 42’ for creating a spiral flow in cyclone tubes 21, and also a vortex finder channel 50, 50’, through which a vortex of less dense component 29 flows, for flow into the collection plenum 30 in the first embodiment 20, or alternatively for flow into the reject cavity 70 in the second embodiment 60.

[0170] As explained earlier in the Summary of the Invention, and as shown in FIG. 16 with respect to the second embodiment 60 (but equally applicable to the first embodiment 20) each of 3-D printed cyclone separator tubes 21 may have a longitudinal axis 76a, 76b, wherein said longitudinal axis 76a, 76b, is non-parallel and slightly canted at an acute angle to the respective longitudinal axis of each of remaining of said 3-D printed cyclone tubes 21 . By converging the cyclone tubes 21 in such manner at second end ‘B’ of cyclone separator apparatus 20, 60, such unitary body 20’, 60’ occupies less volumetric space and thus less material can be employed / needed for 3-D printing such unitary body 20’, 60’ and thus costs savings can advantageously be obtained. For a complete definition of the invention and its intended scope, reference is to be made to the summary of the invention and the appended claims read together with and considered with the disclosure and drawings herein.

[0171] -24-

[0172] 64013199\1

Claims

ClaimsWe claim:

1. A 3-D printed cyclone separator apparatus for separating a less dense component within a flowable fluid stream from a more dense component within said flowable fluid stream, comprising:- a plurality of 3-D printed, elongate cyclone tubes, each 3-D printed cyclone tube having a larger diameter first end tapering to a longitudinally-opposite second end of lesser diameter than said first end;-said plurality of 3-D printed cyclone tubes each 3-D printed in mutually adjacent position with respective first ends thereof together forming a first end of said cyclone separator apparatus and said respective second ends thereof together forming a second end of said cyclone separator apparatus, so as to form a single integral unitary body holding said 3-D printed cyclone tubes in fixed relation to each other; said first end of said cyclone separator apparatus adapted to receive said flowable fluid stream ; and said second end of said cyclone separator apparatus adapted to allow egress of said more dense component from said cyclone separator apparatus; and wherein said cyclone separator apparatus further lacks any encapsulating circumferential vessel with end plates for maintaining individual cyclone tubes in fixed position relative to each other and in parallel relation .

2. The 3-D printed cyclone separator apparatus as claimed in claim 1, said first ends of each of said 3-D printed cyclone tubes each having an axial channel or aperture therein, said axial channel or aperture extending to and in fluid communication with a helically spiralling channel, said helical spiralling channel spiraling a portion of a distance within said first end of each 3-D printed cyclone tube and from said first end thereof towards said second end thereof, wherein said helically spiralling channel is adapted to impart a-25-64013199\1helically spiralling flow to said flowable fluid stream received from said axial channel or aperture within each of said 3-D printed cyclone tubes; said cylone separator apparatus further having a 3-D printed inlet cavity situated proximate said first end of said cyclone separator apparatus and configured for receiving said flowable fluid stream and directing said flowable fluid stream into said axial channel or aperture at each of said first ends of each of said 3-D printed cyclone tubes; each of said 3-D printed cyclone tubes proximate said first end thereof further having: a vortex finder channel, adapted to allow said less dense component of said flowable fluid stream to flow from within each respective 3-D printed cyclone tube ; and a 3-D printed collection plenum circumferentially surrounding each of said 3-D printed cyclone tubes at said first end thereof, integrally formed with each of said 3-D printed cyclone tubes, for collecting said less dense component from said vortex finder channel of each of said 3D printed cyclone tubes.

3. The cyclone separator apparatus as claimed in claim 2, wherein said 3-D printed inlet cavity is situated along a longitudinal axis of said cyclone separator apparatus, and said flowable fluid stream enters said inlet cavity in an axial direction parallel to said longitudinal axis.

4. The cyclone separator apparatus as claimed in claim 2, said collection plenum thereof further having a collection flange thereon in fluid communication with an interior of said collection plenum and adapted to allow said less dense component to flow out of and be withdrawn from said collection plenum.

5. The cyclone separator apparatus as claimed in claim 1, having : a 3-D printed reject cavity situated proximate said first end of cyclone separator apparatus and co-axial with a longitudinal axis of said cyclone separator apparatus, for-26-64013199\1collecting said less dense component, in fluid communication with respective first ends of each of said 3-D printed cyclone tubes; a 3-D printed distribution plenum circumferentially surrounding each of said 3D printed cyclone tubes at said first end thereof adapted for initially receiving said flowable fluid stream when entering said cyclone separator apparatus; each of said 3-D printed cyclone tubes proximate said first end thereof further having: a vortex finder channel, in fluid communication with said reject cavity and centrally located within or at said first end of each of said 3-D printed cyclone tubes and substantially extending axially out of or from said first end of each of said 3D printed cyclone tubes and said distribution plenum and into said reject cavity, said vortex finder channel adapted to permit said less dense component to flow from within a respective 3-D printed cyclone tube out of said first end thereof and into said reject cavity; and a helical spiralling channel spiraling a portion of a distance within said first end of each 3-D printed cyclone tube and from said first end thereof towards said second end thereof, in fluid communication with said distribution plenum, wherein said helically spiralling channel proximate said first end of each of said cyclone tubes is adapted to receive said fluid stream from said distribution plenum and impart a helically spiralling flow to said flowable fluid stream received from distribution plenum.

6. The cyclone separator apparatus as claimed in claim 3, configured so as to permit said flowable fluid stream to enter said cyclone apparatus via said 3-D printed distribution plenum in a direction transverse or perpendicular to said longitudinal axis of said cyclone separator apparatus.

7. The cyclone separator apparatus as claimed in claim 3, said distribution plenum having a plurality of distribution flanges circumferentially spaced thereabout for evenly distributing said fluid stream within said distribution plenum.-27-64013199\18. The cyclone separator apparatus as claimed in claim 1, 2, or 5, each of said 3-D printed cyclone tubes having a longitudinal axis, wherein said longitudinal axis of each cyclone tube is non-parallel and slightly canted at an acute angle to the respective longitudinal axis of each of remaining of said 3-D printed cyclone tubes .

9. A 3-D printed hydrocyclone separator apparatus for separating a less dense component, namely a liquid hydrocarbon, namely oil, from within a flowable fluid stream comprised of said oil and a more dense component, namely water, comprising:- a plurality of 3-D printed, elongate hydrocyclone tubes, each of said hydrocyclone tubes having a larger diameter first end tapering to a longitudinally-opposite second end of lesser diameter than said first end;-said plurality of 3-D printed hydrocyclone tubes each 3-D printed in mutually adjacent position with respective first ends thereof forming a first end of said hydrocyclone separator apparatus and said respective second ends thereof forming a second end of said hydrocyclone separator apparatus, so as to form a single integral unitary body holding said 3-D printed cyclone tubes in fixed relation to each other; said first end of said hydrocyclone separator apparatus adapted to receive said flowable fluid stream entering said hydrocyclone separator apparatus; and said second end of said hydrocyclone separator apparatus adapted to allow egress of said more dense component from said hydrocyclone separator apparatus; and wherein said hydrocyclone separator apparatus lacks any encapsulating circumferential vessel with end plates for maintaining individual cyclone tubes in fixed position relative to each other and in parallel relation .

10. The 3-D printed separator apparatus as claimed in claim 1 or 9, wherein said 3-D printed separator apparatus is 3-D printed using a powdered metal or powdered metal alloy and using a using a powder bed fusion technique selected from the group of powder bed fusion techniques consisting of selective laser melting (SLM) and electron beam melting (EBM).-28-64013199\111. The 3-D printed separator apparatus as claimed in claim 10, wherein said powdered metal alloy is an abrasion-resistant steel alloy.

12. The 3-D printed cyclone separator apparatus as claimed in claim 11, wherein said abrasion resistant steel alloy is comprised of one or more of AR200, AR235, AR400, AR500 and AR600 abrasion resistant steel.

13. The 3-D printed separator apparatus as claimed in claim 1 or 9 , wherein interior surfaces of said 3D-printed cyclone tubes are, after 3D printing of said separator apparatus, each coated with or have deposited thereon an abrasion resistant material.

14. The 3-D printed separator apparatus as claimed in claim 13, wherein said abrasion resistant material is applied after 3-D printing of said separator apparatus and is a ceramic coating applied using either chemical vapour deposition or physical vapour deposition.

15. The 3-D printed hydrocyclone separator apparatus as claimed in claim 9, having : a 3D-printed inlet cavity situated proximate said first end of said hydrocyclone apparatus and configured for receiving said flowable fluid stream and directing said flowable fluid stream along a longitudinal axis of said 3-D printed hydrocyclone separator apparatus into respective of said first ends of each of said 3-D printed hydrocyclone tubes; a collection plenum circumferentially surrounding each of said 3-D printed hydrocyclone tubes at said first end thereof integrally 3D-printed with each of said 3-D printed hydrocyclone tubes, for collecting said oil from each of said 3-D printed hydrocyclone tubes; each of said 3-D printed hydrocylone tubes proximate said first end thereof having: a spiral inlet channel , in fluid communication with said 3-D printed inlet cavity, which spirals a portion of a distance within each cyclone tube towards said second end of each of said hydrocylcone tubes, adapted to receive and cause said flowable fluid stream when received axially from said 3-D printed inlet cavity and thereafter entering a respective first end of said hydrocylcone tubes, to adopt a spiral flowpath therewithin toward said second end of said hydrocylone separator apparatus; and-29-64013199\1a vortex finder channel within said first end of each of said hydrocyclone tubes, in fluid communication with said collection plenum, adapted to allow said less dense oil component to flow from within each respective hydrocyclone tube into said collection plenum.

16. The 3-D printed hydrocyclone separator apparatus as claimed in claim 9, having : a 3-D printed reject cavity situated proximate said first end thereof for collecting said less dense oil; a 3-D printed distribution plenum circumferentially surrounding each of said hydrocyclone tubes at said first end thereof adapted for initially receiving said flowable fluid stream when entering said hydrocyclone separator apparatus; each of said hydrocylone tubes proximate said first end of each having: a spiral inlet channel in fluid communication with said distribution plenum and spiraling a portion of a distance towards said second end of each of said hydrocyclone tubes, adapted to cause said flowable fluid stream after having entered said distribution plenum from a tangential or perpendicular direction relative to a longitudinal axis of said hydrocyclone apparatus and thereafter entering a respective first end of each of said hydrocylone tubes, to adopt a spiral flowpath therewithin toward said second end of said hydrocylone apparatus; and an vortex finder channel, in fluid communication with said reject cavity and centrally located within or at said first end of each of said hydrocyclone tubes and substantially extending axially out of or from said first end of each of said hydrocyclone tubes and said distribution plenum and into said reject cavity, said vortex finder channel adapted to permit said oil in said flowable fluid stream to flow from within a respective hydrocyclone tube axially out of said first end thereof and out of said distribution plenum and into said reject cavity.

17. The 3-D printed hydrocyclone separator apparatus as claimed in claim 9, each of said 3--30-64013199\1D printed hydrocyclone tubes having a longitudinal axis, wherein said longitudinal axis of each 3-D printed hydrocyclone tube is non-parallel and slightly canted at an acute angle to the respective longitudinal axis of each of remaining of said 3-D printed hydrocyclone tubes .-31-64013199\1

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