Cyclonic Gas-Liquid Separator With Flow-Driven Agitator
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Solution Overview
Problem
Conventional separators for gas-liquid streams with particulate matter face issues such as solids consolidation blocking liquid release and limited efficiency due to gravitational forces, particularly in applications like gas extraction from coal seams where efficient separation of gas, liquid, and solids is required without gas loss into the liquid stream.
Innovation Solution
A cyclonic separator design where the gas, water, and particles enter tangentially, causing the liquid and particulate matter to swirl to the outside, with a float-operated valve system that allows continuous separation of liquids from gases, preventing gas loss and solids buildup by using a float to control the discharge of liquids and gases through separate outlets, and includes an agitator system to manage solids accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional separator with gravitational separation is used, then the structure is simple, but solids consolidate and block the liquid release outlet
Solution Approach 1:
The patent introduces a rotating shaft with agitators that rotates in response to fluid flow to prevent solids consolidation. The shaft rotation speed varies with flow conditions, dynamically adapting to keep the outlet clear without requiring complex external drive mechanisms.
Solution Approach 2:
The system uses the kinetic energy of the incoming fluid flow itself to drive the agitator shaft through hydrodynamic coupling. The fluid flow directly powers the rotation needed to prevent solids buildup, eliminating the need for external motors or power sources.
2Device complexity
If gravitational separation is used, then the device complexity is low, but the separation efficiency is limited
Solution Approach 1:
The patent introduces a pre-separation chamber where solids are agitated and suspended before entering the main separation zone. This preliminary action prevents solids from settling and interfering with the gas-liquid separation process, improving overall efficiency without major structural changes.
Solution Approach 2:
The rotating agitators create dynamic fluid motion that enhances the separation process. The rotation generates centrifugal forces and turbulent flow patterns that accelerate phase separation beyond what static gravitational separation can achieve.
3Loss of substance
If a float-operated valve system is used for continuous separation, then gas loss into liquid stream is prevented, but the device complexity increases
Solution Approach 1:
The float-operated valve system is self-regulating, using the weight of the float and buoyancy forces to automatically open or close valves based on liquid level. This eliminates the need for external control systems, sensors, or power sources while preventing gas loss effectively.
Solution Approach 2:
The float mechanism uses buoyancy as a counteracting force to the weight of the valve assembly. When liquid level rises, the float's buoyant force overcomes the valve weight to close the gas outlet, preventing gas loss without requiring active control.
4Productivity
If cyclonic separation is used, then separation efficiency improves, but solids may block the discharge outlet
Solution Approach 1:
The patent incorporates a rotating shaft with agitators positioned at the cyclone outlet that rotate in response to fluid flow. This dynamic action continuously breaks up and redistributes solids, preventing consolidation and blockage while maintaining the high separation efficiency of cyclonic action.
Solution Approach 2:
The outlet region is segmented into multiple zones with different flow patterns and agitation intensities. This segmentation allows solids to be continuously moved and redistributed rather than consolidating in a single discharge point, preventing blockages.
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
Enables continuous, efficient separation of liquids from gases without gas loss into the liquid stream, effectively removing particulate matter and preventing solids from blocking the outlet, maintaining operational efficiency by using gravitational and rotational forces to manage fluid flow and prevent consolidation.
Implementation Method 1
The swirling motion induces a radial acceleration which acts on the fluid causing more dense materials to be forced near the wall of the cyclone
Implementation Method 2
where they slow and are pulled down by gravitational force to the cyclone base where they are discharged
Implementation Method 3
a float which is contained in the cyclone separator and cause it to open a valve at the bottom of the device
Data Source
AI summary
The invention is a separator designed to separate an incoming stream of liquid, gas, and some particulate matter into a separate gas stream, and a separate liquid stream containing the particulate matter. This is achieved through cyclonic action and the use of a float to operate internal valves within the cyclone. The float is mounted on a shaft which is rotated by the motion of the incoming fluid stream and this motion is used to agitate the solids in the liquid so as to prevent the outlet port from becoming jammed. The outlet port also has an auger contained therein that removes particulate matter.