Pressurized Air-Slurry Separation With Controlled Pressure Letdown
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Solution Overview
Problem
Deep-sea mining operations face challenges in efficiently separating and handling pressurized solid/liquid slurries while accommodating a gaseous phase, such as air, without unfavorable velocities and flow conditions, which existing systems struggle to manage effectively.
Innovation Solution
An air-slurry separation system comprising a separating tank pressure vessel with an air-slurry inlet, diffuser to reduce flow velocity, air release outlet, fine and coarse slurry outlets, and pressure letdown systems using fixed chokes, variable orifice valves, and hydrocyclones to control flow and particle size, along with solid-liquid separation devices and dryers to manage the slurry flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If compressed air is injected into a vertical riser pipe for deep sea mining, then the air lift system creates suction to transport solids, but the air expands many times its original volume by the time it reaches the surface
Solution Approach 1:
The system divides the air-slurry mixture into separate phases using a separator that divides the flow into an air phase outlet and a slurry phase outlet, preventing mixed discharge and allowing independent optimization of each phase's flow characteristics
Solution Approach 2:
A diffuser is introduced as an intermediary component between the riser and separator to reduce flow velocity and distribute the air-slurry mixture evenly, preventing unfavorable flow conditions while managing the volume expansion
2Speed
If the discharge at the surface is pressurized to several atmospheres to prevent unfavorable velocities and flow conditions, then flow conditions improve, but the system complexity and equipment requirements increase
Solution Approach 1:
The system uses a separator designed to handle pressurized inputs and maintain appropriate pressure levels throughout the separation process, allowing discharge at several atmospheres without requiring additional pressurization equipment while preventing unfavorable flow conditions
Solution Approach 2:
The system utilizes pneumatic principles where pressurized air serves dual purposes: providing the lift force for solids transport and maintaining appropriate discharge pressure to prevent unfavorable flow conditions, eliminating the need for separate pressurization equipment
3Reliability
If a separator is designed to handle pressurized air-slurry mixtures, then effective separation is achieved, but the pressure vessel requirements and equipment complexity increase
Solution Approach 1:
The separator is designed as a multi-functional pressure vessel that simultaneously performs separation, pressure management, and flow distribution functions, reducing the need for separate equipment while maintaining separation effectiveness for pressurized air-slurry mixtures
Solution Approach 2:
The system manages pressure as a key parameter throughout the separation process, using the pressure differential between inlet and outlet to drive separation while maintaining conditions that prevent unfavorable flow, thereby achieving reliable separation with appropriate pressure vessel design
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively separates air and slurry phases, controlling flow velocities and particle sizes, allowing for efficient processing and storage of fine and coarse slurries at atmospheric pressure, reducing the need for pumps and minimizing equipment requirements.
Implementation Method 1
a diffuser adapted to reduce air-slurry flow velocity through the inlet into the separating tank pressure vessel
Implementation Method 2
pressure letdown systems using fixed chokes, variable orifice valves, and hydrocyclones to control flow and particle size
Implementation Method 3
a screen on the fine slurry outlet limiting the maximum particle size that can enter the fine slurry flowline
Implementation Method 4
compressed air is injected into a vertical riser pipe in the ocean. The air rises from the injection point and the mixture of air/water/solids has a density less than the surrounding seawater. This creates a suction (lift)
Implementation Method 5
pressure letdown systems using fixed chokes, variable orifice valves, and hydrocyclones to control flow and particle size
Data Source
AI summary
A method and apparatus for the separation of gas and liquid-solid slurry under pressure, and passage of the liquid-solid slurry to an atmospheric discharge.