Filterless Cyclone Separator for Low Flow Gas
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Solution Overview
Problem
Cyclone/centrifugal separators with coalescing filter elements choke quickly due to small pore sizes, leading to high maintenance and replacement costs, especially in low flow rate applications, and existing separators are not designed for low pressure and low gas flow rates.
Innovation Solution
A centrifugal/cyclone separator design that separates particles and condensing mists without a filter element, utilizing an inlet spiral tube, conical fins, and a vortex finder extension, optimized for low gas flow rates from 30 to 150 Nl/h and capable of separating particles up to 10 microns in size, with a configuration allowing for two separators in series for enhanced separation efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a coalescing filter element is used in a cyclone separator, then separation efficiency is improved, but maintenance frequency increases due to quick choking from small pore sizes
Solution Approach 1:
The patent removes the coalescing filter element from the cyclone separator system entirely. The separator operates as a filterless device, extracting the problematic filtering component while maintaining separation functionality through optimized cyclone geometry and inlet spiral tube design.
Solution Approach 2:
The patent changes the operational parameters of the cyclone separator by optimizing the inlet spiral tube dimensions, conical fin geometry, and vortex finder configuration to achieve effective separation at low flow rates without requiring filter elements, thereby eliminating the choking issue.
2Productivity
If a cyclone separator is designed for high flow rate applications, then separation performance is improved, but it becomes ineffective for low gas flow rate applications
Solution Approach 1:
The patent applies local quality by creating regions of different flow characteristics within the separator. The inlet spiral tube generates a specific vortex pattern, while conical fins create localized high-velocity regions that enhance separation efficiency at low overall flow rates.
Solution Approach 2:
The patent introduces dimensional changes by extending the vortex finder below the second conical fin and using a multi-level conical fin structure. This vertical dimensionality enhancement allows the separator to maintain effective separation performance across a wider range of flow rates.
3Reliability
If filter elements are used to remove particles and mists, then separation capability is improved, but maintenance and replacement costs increase due to frequent choking
Solution Approach 1:
The patent extracts and eliminates the filter element from the system, replacing it with a filterless cyclone design that achieves separation through centrifugal forces and optimized geometry, thereby eliminating maintenance and replacement costs associated with filter elements.
Solution Approach 2:
The separator design allows particles and mists to be separated and collected at the bottom of the vessel without requiring filter elements. The system serves itself by using the kinetic energy of the incoming gas stream to perform the separation function that would otherwise require external filtering components.
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 provides a maintenance-free, robust separation of fine particles and condensing mists up to 10 microns without filter element replacement, suitable for low pressure and low gas flow rates, reducing maintenance costs and preventing carry-over issues common with traditional filters.
Implementation Method 1
a centrifugal/cyclone separator which separates particles, liquid droplets and or condensing mists (water based and or hydrocarbon based nature) from gases
Implementation Method 2
a first conical fin, and a second conical fin (4) disposed adjacent to said first conical fin (3) wherein said housing has an inner wall (20) and wherein said first conical fin and said second conical fin is spaced from said inner wall of said housing by 0.5 mm to 2 mm
Data Source
AI summary
At least one embodiment of the invention relates to a centrifugal/cyclone separator which separates particles, liquid droplets and or condensing mists (water based and or hydrocarbon based nature) from gases without using a filter element. The design relies on the use of the inlet spiral tube, a first conical fin and the second conical fin, and the step on the cylindrical body and the extension of the vortex finder below second conical fin. With another embodiment, the design differs in that it relies on the insert with threaded or open area forming a flow path like spiral tube, while relying on the same or similar components as with the first embodiment listed above.