Inlet Device for Gravity Separator Using Axial Cyclones
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Solution Overview
Problem
Current inlet devices in gas scrubbers, particularly those using vane diffusers, are inefficient in removing low liquid content from gas streams, leading to operational problems and malfunctions in downstream equipment, as they rely solely on gravity forces and have limitations in gas velocities, especially in vertical scrubbers with liquid fractions below 3 vol %.
Innovation Solution
The development of an inlet device that utilizes centrifugal forces in addition to gravity, featuring an inlet distribution chamber with swirl-inducing elements and axial flow cyclones to pre-separate liquid from gas, achieving over 99% liquid removal efficiency by distributing the mixture into cyclones where centrifugal forces separate liquid towards the walls, and the gas exits at a different end, minimizing liquid carryover and pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vane diffuser inlet device is used, then device complexity is reduced and ease of manufacture is improved, but liquid removal efficiency deteriorates and reliability of downstream equipment worsens
Solution Approach 1:
The inlet device is segmented into multiple functional components: a distribution chamber that divides the gas stream into multiple sub-streams, multiple inlet cyclones that process each sub-stream, and a liquid collection chamber. This segmentation allows each component to be optimized for its specific function, improving overall liquid removal efficiency while maintaining manufacturing feasibility through modular construction.
Solution Approach 2:
The distribution chamber performs preliminary action by distributing the incoming gas stream into multiple smaller streams before they enter the cyclones. This pre-distribution optimizes the flow characteristics entering each cyclone, enhancing liquid separation efficiency before the main separation process occurs in the cyclones.
2Device complexity
If gravity force alone is used for liquid separation, then device complexity is minimized, but liquid removal efficiency deteriorates and gas velocity limitations increase
Solution Approach 1:
The patent replaces the purely gravitational separation mechanism with a cyclonic separation mechanism that utilizes centrifugal force. The inlet cyclones generate rotational flow that creates centrifugal forces much stronger than gravity, enabling effective liquid removal at higher gas velocities. This mechanical substitution dramatically improves productivity while the modular design keeps complexity manageable.
Solution Approach 2:
The invention changes the separation parameter from gravity-based (low acceleration) to centrifugal force-based (high acceleration). By transforming the gas stream into rotational flow within the cyclones, the separation force parameter is increased by orders of magnitude, enabling efficient liquid removal at high gas velocities that would be impossible with gravity alone.
3Reliability
If cyclone inlet device is used, then liquid removal efficiency is improved, but pressure drop increases
Solution Approach 1:
The gas stream is segmented into multiple smaller streams that pass through multiple parallel cyclones rather than one large cyclone. This segmentation reduces the pressure drop in each individual cyclone while maintaining high overall liquid removal efficiency. The distribution chamber plays a key role in creating this segmented flow pattern.
Solution Approach 2:
The distribution chamber performs partial separation action before the gas enters the cyclones by distributing the flow into multiple streams. This preliminary partial action reduces the liquid load on each cyclone, allowing them to operate at lower pressure drops while still achieving the required overall liquid removal efficiency.
4Productivity
If gas velocity is increased to improve productivity, then productivity is improved, but liquid carryover to demisting equipment increases
Solution Approach 1:
The distribution chamber and inlet cyclones perform preliminary liquid removal action before the gas reaches the demisting equipment. By removing the bulk of the liquid in this preliminary stage using centrifugal forces, the gas stream entering the demisting equipment has significantly reduced liquid content, allowing higher gas velocities without excessive liquid carryover to the demisting section.
Solution Approach 2:
The patent replaces the gravity-based separation mechanism with centrifugal force-based separation in the inlet cyclones. This mechanical substitution enables effective liquid removal at high gas velocities, breaking the limitation that previously forced a trade-off between gas velocity and liquid carryover. The centrifugal forces remain effective even at high velocities where gravity alone would fail.
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
This solution significantly improves gas quality by removing the bulk of liquid at the inlet stage, reducing liquid entrainment and allowing higher gas velocities, thus enhancing the overall efficiency and reducing operational issues in gas scrubbers, especially in vertical configurations.
Implementation Method 1
The gas is set in rotation by a swirl-inducing element located close to the inlet section and exits at the opposite end of the cyclone tube. The liquid separated by the axial flow cyclone is drained through the inlet device
Implementation Method 2
distributing the mixture into cyclones where centrifugal forces separate liquid towards the walls
Implementation Method 3
The gas is set in rotation by a swirl-inducing element located close to the inlet section
Implementation Method 4
the separated liquid is normally drained down to the liquid reservoir through a said drainpipe, whose lower end is submerged in the liquid reservoir
Data Source
AI summary
An inlet device (17) for a separator (18) for separating a fluid mixture including gas and liquid. The inlet device (17) includes an inlet nozzle (1) for the fluid mixture, a distribution chamber (2) connected to the inlet nozzle for distributing the fluid mixture to one or more axial cyclones (3) constituting an integral part of the inlet device (17) and being connected to the distribution chamber (2). The axial cyclones (3) are provided with an outlet opening (9) for the gas rich fluid stream, a swirl inducing element (21), one or more openings (24) to allow the liquid-rich stream exiting the openings (24) of the axial cyclones (3) as well as liquid separating from a gas-rich stream exiting the outlet opening (9) to be drained to a level below the inlet device (17).