Horizontal Coalescing Filter Reducing Vertical Footprint
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Solution Overview
Problem
Vertically oriented gas coalescers require large vertical space due to their tall design, which is inefficient in terms of space usage and height requirements for separating liquid condensates from gas in fracking operations.
Innovation Solution
A horizontal gas coalescing filter unit with a first housing oriented horizontally and a second housing oriented vertically, featuring a vane separator and a pleated coalescing filter, where the gas flow direction is altered by an impingement head and tuyere to facilitate centrifugal separation, and the separated liquids are collected via gravity, reducing overall height and vertical footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vertically oriented coalescers are used to efficiently separate liquid condensates from gas, then separation efficiency is improved, but vertical space requirements increase
Solution Approach 1:
The patent transitions from a vertical coalescer configuration to a horizontal configuration, changing the primary dimension of separation from vertical to horizontal. This allows the separation process to occur along the length of the housing rather than the height, thereby reducing vertical footprint while maintaining separation efficiency through the same coalescing mechanisms.
Solution Approach 2:
The horizontal coalescer is divided into distinct functional sections: an impingement section for initial liquid removal, a coalescing section with filter elements for further separation, and a drainage section. This segmentation allows each component to perform its specific function efficiently within the horizontal orientation, maintaining overall separation performance.
2Productivity
If multiple gas coalescing filters are positioned vertically one above another, then separation capacity is improved, but liquid condensates accumulate and drop onto lower filters
Solution Approach 1:
The patent extracts the drainage function from the vertical stacking arrangement and implements a dedicated drainage system with drains positioned at the lowest point of the horizontal housing. This separate drainage pathway prevents liquid accumulation from affecting the separation capacity of the coalescing elements.
Solution Approach 2:
By positioning drains at the lowest horizontal point rather than vertically below filters, the system uses horizontal positioning to achieve gravitational drainage, eliminating the harmful effect of liquid dropping onto lower filters while maintaining separation capacity.
3Area of stationary object
If a horizontal configuration is used to reduce vertical footprint, then space efficiency is improved, but separation efficiency may be compromised
Solution Approach 1:
The patent merges multiple separation mechanisms into a single horizontal housing: impingement separation, coalescing through filter elements, and gravitational drainage all occur within the same horizontal structure. This integration maintains separation efficiency while achieving compact vertical footprint.
Solution Approach 2:
Different sections of the horizontal housing are optimized for specific functions: the impingement section for high-velocity liquid removal, the coalescing section with pleated filter elements for fine separation, and the drainage section for liquid collection. This localized optimization ensures high separation efficiency throughout the horizontal configuration.
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 horizontal configuration effectively reduces the vertical footprint of the filter unit while maintaining high efficiency in removing liquid condensates, allowing for a compact design without compromising separation efficiency, with the ability to handle gases with high liquid content like those from the Marcellus/Utica Shale industry.
Implementation Method 1
The impingement head changes the flow direction of the gas
Implementation Method 2
the tuyere forces the gas outwardly in a centrifugal manner
Implementation Method 3
The vane separator is configured for removing the liquid condensates from the gas
Implementation Method 4
Coalescing is the process where liquid aerosols in a compressed gas/air system are forced to join together into large droplets
Implementation Method 5
These combined droplets then can be drained away by gravity
Data Source
AI summary
A horizontal gas coalescing filter unit having a reduced vertical footprint includes a first housing including an inlet and an outlet, the inlet being configured for receiving a gas, including liquid condensates, under pressure. The filter unit includes an impingement head, a tuyere, and a vane separator to cause liquid condensates to separate from the gas. A second housing is positioned in fluid communication with the horizontal housing and contains a coalescing filter for receiving the gas exiting the vane separator and for further removing the liquid condensates from the gas. A gas outlet is associated with the second housing for allowing the separated, dry gas to exit the filter unit. A method for separating liquid condensates from the gas is also provided.