Liquid Separator Segmentation with Non-Return Valve
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional liquid separators in compressed air lines of oil-injected compressors are large, expensive, and subject to stringent inspection, leading to high costs and reduced lifespan due to foam formation and mechanical loading during pressure relief, which results in excessive oil consumption and reduced efficiency.
Innovation Solution
A liquid separator design featuring a centrifugal separator with a non-return valve isolating it from a fine separator, allowing fluid flow only from the centrifugal to the fine separator, eliminating the flow-through element from the centrifugal separator's internal space, enabling smaller and cheaper construction, reducing mechanical loading, and maintaining pressure in the fine separator during compressor transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a flow-through element is provided in the housing of the centrifugal separator, then liquid particles can be separated from compressed air, but the separator becomes relatively sizeable and expensive
Solution Approach 1:
The separator is divided into two independent functional units: a centrifugal separator for removing large liquid particles and a fine separator for removing smaller particles. Each unit operates independently with its own housing, allowing the system to achieve comprehensive separation without requiring one large integrated separator. This segmentation enables each component to be optimized for its specific function while reducing overall complexity and cost.
2Reliability
If the separator is made larger to improve separation performance, then separation efficiency increases, but inspection costs increase due to stringent inspection category
Solution Approach 1:
By dividing the separator into two smaller independent units (centrifugal separator and fine separator), each unit falls into a less stringent inspection category compared to one large integrated separator. This segmentation reduces inspection costs while maintaining comprehensive separation performance through the combined functionality of both units.
3Productivity
If gas volume is blown off quickly during compressor transition from loaded to unloaded condition, then equilibrium pressure is reached faster, but foam formation increases and deteriorates fine separator operation
Solution Approach 1:
The centrifugal separator and fine separator are divided into independent units with separate pressure management. The non-return valve allows the centrifugal separator to equalize pressure with the compressor discharge, while the fine separator maintains its own pressure independently. This segmentation prevents foam from the rapid pressure equalization in the centrifugal separator from entering and damaging the fine separator.
Solution Approach 2:
The non-return valve acts as an intermediary mechanism between the centrifugal separator and fine separator. It controls the flow direction and pressure equalization process, allowing the centrifugal separator to rapidly equalize pressure with the compressor while preventing this rapid pressure change and associated foam from affecting the fine separator's operation.
4Productivity
If gas is blown off rapidly during compressor transition, then pressure equilibrium is reached faster, but mechanical loading on flow-through element increases reducing its lifespan
Solution Approach 1:
By separating the centrifugal separator and fine separator into independent units with different pressure management strategies, the flow-through element in the fine separator is protected from the high-velocity gas flow and mechanical loading that occurs during rapid pressure equalization in the centrifugal separator. Each unit experiences different operational conditions optimized for its function.
Solution Approach 2:
The non-return valve serves as an intermediary that decouples the pressure equalization process in the centrifugal separator from the fine separator. It allows the centrifugal separator to rapidly equalize pressure with the compressor discharge while preventing this rapid pressure change and associated high gas velocities from mechanically loading the flow-through element in the fine separator, thereby extending its lifespan.
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 design results in a smaller, less expensive separator with reduced inspection costs, extended lifespan, minimized foam formation, and lower energy losses during gas blowing off, as the gas volume is smaller and pressure relief is gradual, reducing mechanical stress and pressure energy loss.
Implementation Method 1
the incoming mixture of gas and liquid, as is known, is subjected to a whirling motion, whereby a pre-separation occurs since, due to the centrifugal effect, the relatively heavy liquid particles are swung against the inner side of the cylindrical wall
Implementation Method 2
carried off along said wall to the bottom of the liquid separator due to the gravitational force
Implementation Method 3
through the flow-through element in order to separate the smaller liquid particles which are still present in the gas flow
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Liquid separator which is provided with a centrifugal separator (2) and a fine separator (10) through which a gas to be purified can flow, whereby the centrifugal separator (2) consists of a cylindrical housing (3) with a tangential inlet (6) and an axial outlet (7), characterised in that the fine separator (10) comprises a housing (11) defining a space (12) which is isolated from the inner space (8) of the centrifugal separator (2) by means of a non- return valve (13).