Compressor Separator Baffle Louvers
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Solution Overview
Problem
Existing compressor system separator tanks are inadequate in effectively separating compressed gas from lubricants, as they fail to efficiently remove lubricant mist, leading to suboptimal performance in certain applications.
Innovation Solution
A horizontal compressor system separator tank with a vertically positioned baffle that has multiple openings and overhanging louvers on one side, designed to direct gas flow and facilitate lubricant separation, along with a relief passage for free lubricant flow, enhancing the separation efficiency without additional energy input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a simple separator tank design is used, then the device complexity is low, but the lubricant separation efficiency is insufficient
Solution Approach 1:
The separator tank is divided into multiple functional zones using a baffle plate with multiple openings, creating distinct separation chambers that improve lubricant removal efficiency while maintaining reasonable structural complexity
Solution Approach 2:
A baffle plate with strategically positioned openings and overhanging louvers is introduced as an intermediary element to enhance the separation process, allowing compressed gas to pass through while effectively trapping and removing lubricant mist
2Manufacturing precision
If a baffle with multiple openings and overhanging louvers is added, then the lubricant separation efficiency is improved, but the device complexity increases
Solution Approach 1:
The baffle plate is segmented with multiple openings arranged in specific patterns, creating multiple flow paths that enhance separation efficiency while distributing the structural complexity across manageable sections
Solution Approach 2:
Overhanging louvers are added to the baffle openings, transitioning from a two-dimensional flat plate to a three-dimensional structure that utilizes vertical space to improve lubricant trapping without proportionally increasing horizontal complexity
3Manufacturing precision
If the baffle openings are reduced in size, then the lubricant mist separation is improved, but the compressed gas flow resistance increases
Solution Approach 1:
The total opening area is segmented into multiple smaller openings distributed across the baffle plate, increasing the surface area for lubricant separation while maintaining adequate gas flow capacity through the distributed arrangement
Solution Approach 2:
Overhanging louvers are positioned to extend into the gas flow path, creating a three-dimensional flow pattern that enhances lubricant mist impingement on the baffle surface while allowing compressed gas to pass through with reduced pressure drop
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 solution effectively separates compressed gas from lubricant mist, improving the efficiency of the separation process and allowing for the reuse of lubricants, thereby enhancing the overall performance of the compressor system.
Implementation Method 1
a baffle, wherein the baffle sits vertically within the separator tank disposed intermediate the inlet and the outlet
Implementation Method 2
the plurality of louvers are oriented to point in a direction toward an end of the baffle
Implementation Method 3
the relief is formed in a bottom of the baffle such that the passage permits lubricant to flow freely from one side of the baffle to the other
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A separator tank useful to separate a compressed gas from a byproduct of compression (such as a lubricant/coolant used in the compression process) can include one or more baffles. The baffles used in the separator tank can include a number of passages to permit a flow of compressed gas to pass. The passages can include a louver to assists in directing the flow and/or assist in further separation of the compressed gas from the lubricant/coolant. The louvers can appear on one side of the baffle, and in one form are located solely on the downstream side of the baffle. The baffle can include a relief for liquid leveling within the tank. Any number of approaches can be used to make the baffle, including cutting and/or stamping.