High-Pressure Separator with Nested Centrifugal Unit

Solution Overview

Problem

Conventional high-pressure separators are not 100% efficient in separating liquids from gases, leading to entrainment of liquids in the gas stream, which causes fouling, increased maintenance, and reduced operating rates in downstream equipment and processes.

Innovation Solution

A dual-separator system comprising a gravity separator and a centrifugal separator that imparts a helical flow to the mixture, reducing liquid entrainment by coalescing droplets into larger pools before discharge, thereby enhancing separation efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional gravity separator is used to separate gas and liquid phases, then the separation process is simple and device complexity is low, but liquid entrainment in the gas stream occurs leading to poor separation efficiency

Engineering Contradiction:

Improveseparation efficiencyVSAvoidseparator structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The centrifugal separator is nested inside the gravity separator, creating a compact dual-stage separation system. The centrifugal separator components (inlet conduit, separation chamber, outlet conduit) are positioned within the gravity separator vessel, allowing both separation mechanisms to function in sequence without requiring separate vessels.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The separation process is divided into two distinct stages: first, the gravity separator performs coarse separation of gas and liquid phases; second, the centrifugal separator performs fine separation to remove remaining liquid entrainment. This segmentation allows each stage to be optimized for its specific function.

Inventive Principle:

Principle #1Segmentation

2Reliability

If the separator vessel size is increased to improve separation efficiency, then more liquid can be separated from the gas stream, but the equipment cost and footprint increase

Engineering Contradiction:

Improveseparation efficiencyVSAvoidseparator vessel volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The centrifugal separator is nested inside the gravity separator, creating a compact dual-stage separation system. The centrifugal separator components (inlet conduit, separation chamber, outlet conduit) are positioned within the gravity separator vessel, allowing both separation mechanisms to function in sequence without requiring separate vessels.

Inventive Principle:

Principle #7Nested doll (Nesting)

Solution Approach 2:

The system utilizes the kinetic energy and pressure of the incoming gas-liquid mixture to drive the centrifugal separation process. The inwardly directed inlet conduit creates a swirl flow pattern that generates centrifugal force, eliminating the need for external mechanical drivers or large vessel volumes.

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Object-affected harmful factors

If liquid entrainment is reduced to minimize fouling of downstream equipment, then maintenance frequency decreases, but separation efficiency must be significantly improved requiring more complex equipment

Engineering Contradiction:

Improvefouling of downstream equipmentVSAvoidseparator structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The separation process is divided into two distinct stages: first, the gravity separator performs coarse separation of gas and liquid phases; second, the centrifugal separator performs fine separation to remove remaining liquid entrainment. This segmentation allows each stage to be optimized for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system converts the kinetic energy and momentum of the incoming high-velocity gas-liquid mixture, which would normally cause turbulence and poor separation, into a beneficial centrifugal force. The inwardly directed inlet conduit creates a swirl flow that generates centrifugal acceleration, causing liquid droplets to migrate outward and coalesce on the chamber walls for removal.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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-separator system significantly reduces liquid entrainment in the gas stream, minimizing fouling and maintenance, improving process yields, and increasing operating rates and efficiency.

Implementation Method 1

a centrifugal separator located inside of the gravity separator for imparting a helical flow to the mixture

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

a gravity separator for expanding and separating the mixture into a gas phase and a liquid phase

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS7740674B2High-pressure separator

Publication Date: 2010.06.22 WESTLAKE LONGVIEW CORP

AI summary

A high-pressure separator with improved efficiency is provided. The separator comprises a centrifugal separator located inside of a gravity separator. The centrifugal separator has an enclosed upper portion and desirably comprises a single cylinder. The high-pressure separator is particularly suitable for use in the production of low-density polyethylene under high pressure.