Nested Flow-Redirection Separator for Reduced Liquid Carryover
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Solution Overview
Problem
Conventional venturi-ejector scrubbers face issues with high liquid/gas ratios leading to unstable flow, excessive liquid carryover, and the need for additional downstream separators, resulting in a large footprint and increased cost.
Innovation Solution
A separator design that redirects the effluent and entraining fluid flow multiple times, utilizing flow redirection structures and nested separation conduits to create a compact, efficient separation system, including a first flow redirection structure to redirect from axial to circumferential flow and a second structure to revert back to axial flow, enhancing separation efficiency while minimizing dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional venturi-ejector scrubbers use high liquid/gas ratios to improve contaminant capture, then separation efficiency is improved, but flow stability deteriorates and liquid carryover increases
Solution Approach 1:
The separator is divided into multiple distinct sections: a venturi-ejector scrubber section for contaminant capture and a separator section for liquid-gas separation. This segmentation allows each section to be optimized independently - the scrubber can use high liquid/gas ratios for effective contaminant capture while the separator section manages flow stability and liquid removal, preventing carryover issues.
Solution Approach 2:
A baffle plate is introduced as an intermediary element between the scrubber outlet and separator inlet. This baffle plate stabilizes the flow by breaking up turbulent patterns and redistributing the liquid-gas mixture evenly into the separator section, thereby improving flow stability without compromising the high liquid/gas ratio operation in the scrubber.
2Manufacturing precision
If additional downstream separators are added to reduce liquid carryover, then liquid separation is improved, but device footprint and cost increase
Solution Approach 1:
The separator integrates multiple functions into a single compact device: contaminant capture via the venturi-ejector scrubber, flow stabilization via the baffle plate, and liquid-gas separation in the integrated separator section. This merging of functions eliminates the need for separate downstream separators, reducing both footprint and complexity while maintaining effective liquid separation.
Solution Approach 2:
The separator section is nested within the overall separator housing, with the baffle plate and separation conduits arranged in a compact nested configuration. This nested design maximizes separation efficiency within a minimized footprint, avoiding the need for additional external separator apparatus.
3Volume of stationary object
If the separator is compacted to reduce footprint, then device size is reduced, but separation efficiency and dwell time decrease
Solution Approach 1:
The separator utilizes vertical space and three-dimensional arrangement of separation conduits and baffles to achieve effective separation within a compact footprint. By arranging flow paths in multiple dimensions and using vertical orientation where appropriate, the design maintains sufficient dwell time and path length for effective separation without requiring a large horizontal footprint.
Solution Approach 2:
The separator employs curved flow paths and rounded separation conduits that optimize fluid dynamics within a compact volume. The curved geometry enhances mixing and separation efficiency by creating beneficial flow patterns, allowing effective separation to occur in a smaller space compared to straight-line configurations.
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 design achieves improved separation of contaminants with reduced entraining fluid carryover, eliminating the need for additional downstream apparatus, thus reducing size and cost, and optimizing separation efficiency by increasing dwell time and path length.
Implementation Method 1
Venturi scrubbers have long been used as a method to turbulently mix multiple phases (gas-liquid, gas-particle-liquid) with the purpose of transferring materials from one phase to another
Implementation Method 2
the first flow redirection structure is configured to redirect flow of the effluent stream and the entraining fluid from an axial flow from the inlet conduit to a circumferential flow in a second major direction opposing the first major direction within the first separation conduit
Implementation Method 3
The exhaust of the scrubber discharges into a gas-liquid separator. This gas-liquid separator is generally in the form of a tank which permits gravitational settling of large liquid droplets
Data Source
AI summary
A separator for separating contaminants suspended within an effluent stream includes an inlet conduit configured to receive from an effluent stream containing contaminants flowing in a first major direction from a lower portion of said separator towards an upper portion of said separator; a spray nozzle configured to spray an entraining fluid within the inlet conduit in the first major direction to entrain the contaminants within the effluent stream; a first flow redirection structure located downstream of the inlet conduit; and a first separation conduit located downstream of the first flow redirection structure, wherein the first flow redirection structure is configured to redirect flow of the effluent stream and the entraining fluid from an axial flow from the inlet conduit to a circumferential flow in a second major direction opposing the first major direction within the first separation conduit.