Compact Axial Flow Separator with Helical Channels
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Solution Overview
Problem
Existing systems for removing liquids and particulate from gas streams are inefficient, pose environmental hazards, and are costly to manufacture and operate.
Innovation Solution
A compact axial flow separator system that includes a separator vessel with an inlet flow conditioner, helical separators with a rounded nose portion, and a coaxial inner tube, which separates liquids and particulate through inertial and gravitational forces, and directs clean gas through a polishing chamber to minimize pressure drop and reduce equipment size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional separation systems are used to remove liquids and particulate from gas streams, then separation function is provided, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple separation functions into a single integrated device. The separator vessel integrates a cyclone separator for large liquid slugs, helical separators for smaller liquid flows and particulate, and a polishing chamber for final gas cleaning. This merging of functions reduces device complexity while maintaining high separation efficiency.
Solution Approach 2:
The separation process is divided into distinct stages within the single vessel: first stage cyclone separation for large liquid slugs, second stage helical separation for smaller liquids and particulate, and third stage polishing for final gas cleaning. This segmentation allows each stage to be optimized for its specific function while maintaining overall system simplicity.
2Reliability
If longer separation equipment is used to improve separation efficiency, then liquid removal performance increases, but equipment length and manufacturing cost increase
Solution Approach 1:
The helical separators are positioned within and near the top of an outer tube, with a coaxial inner tube positioned downstream. The inner tube provides a flow path for clean gas while the annular space between the outer tube and inner tube collects liquid and encapsulated particulate. This nested arrangement maximizes separation efficiency within a compact length.
Solution Approach 2:
The patent uses helical channels that wrap around the inner tube, creating three-dimensional flow paths that increase separation effectiveness without increasing equipment length. The helical geometry allows liquid and particulate to be separated from the gas stream in multiple dimensions as the gas flows axially through the vessel.
3Reliability
If helical separators with sharp edges are used to separate liquid, then separation efficiency increases, but liquid shatter and pressure drop increase
Solution Approach 1:
The helical separators feature a rounded or elliptical nose portion at their upstream end. This curved geometry reduces liquid shatter as the gas stream contacts the separators, minimizing droplet formation and reducing pressure drop while maintaining effective liquid 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 system effectively removes liquids and particulate from gas streams, reducing the length and cost of equipment, and achieving high efficiency with minimal liquid carryover, as demonstrated by less than 0.1 gallon per million standard cubic feet of gas flow under high liquid loading conditions.
Implementation Method 1
The liquid slug falls by gravity and inertia into the first sump
Implementation Method 2
The liquid slug falls by gravity and inertia into the first sump
Implementation Method 3
separate smaller liquid flows and particulate... Liquids and encapsulated particulate are separated from the flowing gas stream in the helical channels
Implementation Method 4
The nose portion reduces shatter of liquids in the flowing gas stream as the flowing gas stream contacts the upstream portion of each helical
Implementation Method 5
the liquid and encapsulated particulate falls into a second sump
Implementation Method 6
Gas communication between the first sump and the second sump tends to advantageously equalize the pressure between the first sump and the second sump
Data Source
AI summary
Systems are disclosed for separating and collecting liquid and particulate from a flowing gas stream. The systems may include a plurality of horizontally oriented helical separators positioned in a vessel between a gas stream inlet and a gas stream outlet. The helical separators form helical channels for the gas stream and may include an upstream conical portion. The vessel includes a first space upstream from the helical separators wherein the gas stream changes direction before entering the helical separators, such that the change in direction causes mechanical separation of liquids or solids from the gas stream. The vessel may also form a second space downstream from the helical separators for collecting liquid and particulate separated from the gas stream. The first and second spaces in the vessel may each include a drain which empties into a common sump, such that the first and second spaces are in fluid communication.