Multistage separation system
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Solution Overview
Problem
Current compression systems require larger and more complex rotary separators to handle higher volumes of multiphase fluid streams, increasing costs and complexity due to the inefficiency of existing fluid separation systems in removing liquid phases before compression.
Innovation Solution
An integrated static and rotary separator system is introduced, where a static separator upstream coarsely separates liquids from the gas stream, reducing the liquid load on the rotary separator, allowing it to efficiently process higher volumes without significant power input and maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a larger rotary separator is used to handle higher volume liquid separation, then the separation capacity is improved, but the system complexity and cost increase
Solution Approach 1:
The separation system is divided into two distinct stages: a first rotary separator that performs initial coarse separation of liquid from gas, followed by a second rotary separator that performs final separation. This segmentation allows each separator to be smaller and simpler while collectively handling higher liquid volumes, resolving the contradiction between separation capacity and system complexity
Solution Approach 2:
The first rotary separator performs preliminary separation of the multiphase fluid stream before it enters the second rotary separator. By removing a portion of the liquid content in the first stage, the second separator only needs to handle the remaining liquid, allowing both separators to be smaller than a single large separator would require, thus reducing overall system complexity while maintaining high separation capacity
2Productivity
If a larger rotary separator is used to handle higher volume liquid separation, then the separation capacity is improved, but the equipment cost increases
Solution Approach 1:
The system uses two smaller rotary separators instead of one large separator. Each separator can be manufactured using standard, cost-effective designs and components, avoiding the need for custom-large equipment. This segmentation reduces overall equipment cost while achieving the required liquid separation capacity
Solution Approach 2:
The first rotary separator performs preliminary liquid removal, reducing the burden on the second separator. This allows both separators to be smaller, more standard-sized units that are less expensive to manufacture and install, resolving the contradiction between separation capacity and equipment cost
3Device complexity
If a single rotary separator is used for fluid separation, then the system design is simple, but it cannot effectively process high liquid volume streams
Solution Approach 1:
The single separator is segmented into two sequential rotary separators, each handling a portion of the liquid separation task. This maintains relative design simplicity while dramatically increasing the overall liquid processing volume capacity, as each separator operates within its optimal size range
4Productivity
If a larger rotary separator is used to handle higher volume liquid separation, then the separation capacity is improved, but the maintenance cost increases
Solution Approach 1:
The system segments the separation function across two smaller rotary separators. Each separator uses standard, off-the-shelf components and designs that are well-documented and easier to maintain. If one separator requires maintenance, the other can continue operating, reducing downtime and overall maintenance costs while maintaining high separation capacity
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 configuration enhances separation efficiency, reduces system complexity and costs by enabling smaller, less expensive rotary separators to handle higher liquid volumes effectively, while maintaining a compact and efficient fluid processing system.
Implementation Method 1
a rotating separator configured to separate the fluid stream into a substantially gaseous portion and a substantially liquid portion
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A "bolt on" static separator is disclosed for use in conjunction with a rotating separator to handle higher liquid volumes that are not able to be effectively separated by the rotating separator alone. The static separator may be positioned upstream of the rotating separator, generally right in front of the rotating separator, i.e., immediately ahead of the inlet to the rotating separator and generally attached directly to the front end of the rotary separator. The static separator may include a significant change in flow path direction that is sufficient to cause coarse fluid separation. The output of the static separator is in communication with the input of the rotating separator. Additionally, the drain of the static separator is in communication with the drain of the rotating separator and is at the same pressure.