Gas-Liquid Impingement Separator with Return Channels
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Solution Overview
Problem
Existing gas-liquid separators for chemical processes are inefficient in removing liquid droplets with small inertia, often require energy-intensive methods, suffer from high pressure drops, and can plug due to solidification, leading to loss of valuable reactants and products.
Innovation Solution
A gas-liquid separation enhancer with a central or peripheral return channel and longitudinally extending vanes is positioned within a conduit to direct liquid droplets under gravity, separating them from the gas stream efficiently without the need for rinsing liquids or complex constructions, and can be placed in various positions within a conduit system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inertial separators are used to remove liquid droplets from gas streams, then droplets with large inertia can be effectively separated, but droplets with small inertia cannot be removed efficiently
Solution Approach 1:
The separator divides the gas stream into multiple parallel flow paths using a series of plates with openings. This segmentation increases the number of impingement surfaces and creates multiple opportunities for droplet separation, improving overall removal efficiency across different droplet sizes
Solution Approach 2:
The invention transitions from simple inertial impingement to a multi-dimensional separation mechanism by combining inertial effects with gravitational drainage. Liquid collected on plate surfaces flows downward through drainage holes to collection channels, adding a vertical dimension to the separation process
2Productivity
If packed columns are used to remove liquid droplets, then efficient separation is achieved, but severe pressure drop occurs
Solution Approach 1:
The invention extracts the drainage function from the separation plates themselves by incorporating drainage holes directly in the plates and providing separate collection channels. This separates the impingement function (plates) from the drainage function (channels), allowing optimized design of each function independently
Solution Approach 2:
The design utilizes hydraulic principles by providing sloped collection channels that use gravity to drain accumulated liquid away from the separation plates, preventing liquid buildup that would increase pressure drop
3Productivity
If chill plates are used to remove liquid droplets, then effective separation is achieved, but considerable energy is consumed
Solution Approach 1:
The separator uses the natural inertia of liquid droplets and gravity-driven drainage to achieve separation without requiring external energy input. The system is self-service in that it utilizes the inherent physical properties of the gas-liquid mixture itself to drive the separation process
4Productivity
If in-line filters are used to remove liquid droplets, then separation is achieved, but they are prone to plugging and require frequent cleaning
Solution Approach 1:
The invention extracts the filtration function from a separate filter component and integrates it into the separation plates themselves. The plates with openings act as both structural supports and filtration elements, eliminating the need for separate filter media that would clog
Solution Approach 2:
The separation plates function as porous structures with controlled openings that allow gas passage while intercepting liquid droplets. The geometric configuration of the plates and openings provides filtration capability without the clogging issues of traditional filter media
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 liquid droplets from gas streams with low pressure drop and minimal energy consumption, preventing plugging and loss of valuable materials, and can be used in various conduit layouts, including those with sloped conduits.
Implementation Method 1
The central return channel directs liquid in a downward direction under the force of gravity in an opposite sense to the direction of the stream of gas and liquid droplets
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 2d~3
AI summary
A gas liquid separator adapted to be inserted into a conduit is disclosed. The gas-liquid separator includes downward sloping vanes and optionally, one or more return channels. The vanes may have an opening along the length thereof, and a bottom lip to channel accumulated liquid to the conduit wall or to sloped return channels. If the conduit is not sloped such that the captured droplets are returned to the originating vessel, sloped return channel/channels are used to return the captured droplets to the vessel from which the gas stream originated. With a central return channel, the vanes can be attached directly to the channel with the resulting assembly having a fishbone shape. When a central return channel is not used, the vanes can be attached to a central plate or spine with the resulting spine-vanes assembly again having a fishbone shape. The separation enhancers can be used in a variety of conduit configurations. Furthermore, a plurality of separation enhancers can be utilized in an exhaust gas conduit to increase the removal efficiency.