Dual Cyclone Separator Common Inlet Design
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Solution Overview
Problem
Cyclonic separators face challenges in effectively separating liquid and gas phases due to limitations in size and design, leading to instability and inefficiency, particularly in high-vibration environments, and struggle to meet reinforcement requirements for pressure vessels.
Innovation Solution
A dual cyclone separator system with two cyclonic chambers housed within an outer shell, featuring a common tangential inlet and gas outlet tubes, which allows for more flexible sizing and improved stability, while simplifying welding requirements and enhancing separation efficiency through equal distribution of the process stream and increased sump volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple separators are used to meet separation requirements, then separation efficiency is improved, but the height and diameter become too narrow and tall to withstand high vibration
Solution Approach 1:
The patent combines two cyclone separators into a single integrated unit with a common inlet and shared sump. This merging approach maintains the separation efficiency of multiple cyclones while creating a more compact, wider configuration that better withstands vibration. The common inlet structure and shared sump allow the cyclones to work together as a unified system rather than separate tall units.
2Volume of stationary object
If separator dimensions are reduced to meet space constraints, then space utilization is improved, but the sump size becomes too limited for adequate residence time
Solution Approach 1:
The patent places two cyclone chambers within a shared outer shell structure, creating a nested configuration. The common sump is positioned below both cyclones, allowing efficient use of vertical space while maintaining adequate liquid collection volume. This nesting approach enables sufficient residence time within a compact overall footprint.
3Productivity
If involute or tangential inlets are used to achieve high momentum, then separation performance is improved, but welding reinforcement requirements become difficult to meet
Solution Approach 1:
The patent divides the inlet structure into separate sections for each cyclone chamber, with each inlet connecting to its respective cyclone. This segmentation allows for simpler, more straightforward welding connections compared to a complex shared involute inlet. Each inlet can be independently fabricated and attached, reducing the complexity of reinforcement requirements while maintaining the high momentum flow needed for effective separation.
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 dual cyclone separator design enhances separation efficiency, stability, and meets safety and welding standards, providing a more robust and efficient separation of immiscible phases with improved gas recovery and reduced vibration sensitivity.
Implementation Method 1
As a result of the velocity and the tangential angle at which the liquid/gas process stream enters the cyclonic chamber, centrifugal forces act on the process stream and cause it to spin around the curvature of the cyclonic chamber.
Implementation Method 2
A difference in the mass and densities of phases of the process stream cause the heavier phases to coalesce on the inner wall of the cyclonic chamber and travel in a downwards direction through the cyclonic chamber due to the force of gravity
Data Source
AI summary
A cyclonic separator is taught for separation of a mixed liquid phase/gas phase process stream. The cyclonic separator comprises an outer shell, at least two cyclonic chambers located within the outer shell, each cyclonic chamber having an upper end and a lower end; a single, common tangential inlet passing tangentially through the outer shell and into each of the at least two cyclonic chambers, proximal the upper ends thereof; a gas outlet tube located at least partially within each cyclonic chamber, extending axially from a lower gas outlet end located below the tangential inlet, to an upper gas outlet end extending out of each of the at least two cyclonic chambers, said upper gas outlet ends being in fluid communication with a common gas chamber located above the outer shell; and a circumferential recycle opening formed around and through a thickness each gas outlet tube, in a portion of each gas outlet tube located axially between the upper end of cyclonic chambers and the common gas chamber, said recycle opening thus being in fluid communication with an inside cavity of the outer shell.