Helical Impingement Separator for Gas Stream Liquid Removal
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Solution Overview
Problem
Traditional systems for removing particulate and liquids from flowing gas streams are inefficient, require frequent maintenance, and produce hazardous waste, especially at varying gas flow rates and high liquid-to-gas ratios, leading to operational interruptions and potential damage to compressors.
Innovation Solution
A system comprising a hydraulically connected separator vessel and waste liquid recovery tank with duplex-filtered side streams, using a helical separator with coaxial tubes and fins for impingement separation, allowing continuous operation and easier maintenance, with liquid injection to encapsulate particulate and facilitate hydraulic removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filter separators are used to remove liquid and particulate from gas streams, then some separation capability is provided, but the system can only remove about 10% by weight of liquid before liquids begin to pass through and the system requires frequent shutdowns for maintenance
Solution Approach 1:
The system divides the separation function into multiple stages: a cyclone separator for bulk liquid removal, followed by a filter separator for fine particulate removal. This segmentation allows each component to handle specific portions of the separation task, enabling the system to process much higher liquid volumes continuously without shutdowns.
Solution Approach 2:
The system uses a cyclone separator that employs centrifugal force generated by rotating gas flow to separate liquids and particulates. The hydraulic connection between the cyclone and filter separator allows automated blowdown using compressed gas, enabling continuous operation without manual intervention for maintenance.
2Ease of operation
If traditional filter separators are used, then separation is provided, but changing or cleaning filter elements is complex and labor-intensive requiring system shutdown and pressure reduction
Solution Approach 1:
The filter separator is equipped with an automated blowdown system that uses compressed gas from the process itself to flush accumulated liquids and particulates from the filter elements. This self-cleaning capability eliminates the need for manual disassembly and cleaning, allowing continuous operation without shutdowns or pressure reductions.
Solution Approach 2:
The system maintains continuous gas flow and separation operation while the filter elements are being cleaned through the automated blowdown process. The hydraulic connection and valve system enable cleaning to occur without interrupting the separation function, ensuring uninterrupted operation.
3Adaptability or versatility
If traditional filter separators are used, then some liquid removal is achieved, but the system is not adaptable to varying gas flow rates and high liquid-to-gas weight ratios
Solution Approach 1:
The cyclone separator design allows the gas flow rate and centrifugal force to dynamically adjust based on operating conditions. The system automatically adapts to varying gas flow rates and liquid-to-gas ratios, maintaining effective separation across a wide range of conditions without requiring manual adjustment or reducing reliability.
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 system effectively removes a high volume of liquids and particulate with reduced maintenance needs, adaptable to various gas stream conditions, and minimizes hazardous waste production, maintaining operational status during cleaning and reducing the frequency of interruptions.
Implementation Method 1
A flowing gas stream enters a separator vessel... using a helical separator with coaxial tubes and fins for impingement separation
Implementation Method 2
liquid injection to encapsulate particulate and facilitate hydraulic removal
Implementation Method 3
A flowing gas stream enters a separator vessel hydraulically connected to a waste liquid recovery tank
Data Source
AI summary
Systems and related methods for separating liquids and particulate from a flowing gas stream include a separation vessel containing a liquid injector, an impingement separator or a helical impingement separator, and a waste liquid recovery tank. Separated liquid and particulate collect in a sump, flow into a recovery tank, and may be filtered in a side stream duplex filter circuit for return into the recovery tank and re-injection into the separation vessel. The helical separator element has outwardly extending helical fins that form helical gas channels. The interior of the channels forms a rounded radius and opposing vertical edges of the channels include chamfers. The lower end of the helical separator element forms a concave, generally conical surface. The helical fins form a first impingement separator and the chamfers form a second vane-type impingement separator, such that particulate and liquids may be removed from the gas stream at varying flow rates and liquid/particulate densities.