Rotating Vane Separator for Sulphuric Acid Gas
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Solution Overview
Problem
Sulphuric acid plants face issues with acid mist carryover leading to corrosion, equipment failure, and increased production costs due to inadequate separation of entrainment from process gas, which also results in premature maintenance and environmental concerns.
Innovation Solution
A separator device is integrated into the sulphuric acid plant process to remove entrainment from process gas with a minimal pressure drop, utilizing a vane-rotated gas flow mechanism that aligns with downstream equipment rotation, reducing fouling and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional entrainment eliminators (Chevron demisters, mesh-pad demisters, knock-out drums) are used to capture acid mist, then entrainment removal efficiency is improved, but pressure drop increases significantly (10-20 inches WC) and device complexity increases
Solution Approach 1:
The patent replaces conventional mechanical entrainment elimination devices (demisters, knock-out drums) with a centrifugal separation system that uses rotational mechanics. The rotating element creates centrifugal force to separate acid mist from gas, eliminating the need for large pressure drops associated with conventional mechanical filters while maintaining separation efficiency.
Solution Approach 2:
The patent changes the operating parameters by introducing rotation speed as a controllable variable. By adjusting the rotational speed of the centrifugal separator, the system can optimize separation efficiency while maintaining low pressure drop, unlike conventional devices where pressure drop is fixed by the device structure.
2Object-affected harmful factors
If conventional entrainment eliminators are installed to remove acid mist, then equipment corrosion is reduced, but device complexity and space requirements increase
Solution Approach 1:
The centrifugal separator is designed to perform multiple functions: it separates acid mist from gas, pre-conditions the gas for downstream equipment, and can be integrated into existing process flow without requiring separate dedicated equipment. This multi-functionality reduces overall system complexity while protecting downstream equipment from corrosion.
Solution Approach 2:
The rotating element in the centrifugal separator is designed to be self-cleaning, where the rotation prevents accumulation of corrosive materials on separation surfaces. This self-service capability reduces maintenance requirements and device complexity compared to conventional eliminators that require regular cleaning and maintenance.
3Reliability
If high-velocity direct contact scrubbers are used to remove entrainment, then acid mist capture is improved, but energy consumption and device complexity increase due to pumps and liquid recirculation
Solution Approach 1:
The patent extracts the liquid recirculation system (pumps, reservoirs, control systems) from the entrainment removal process. Instead of using liquid scrubbing with recirculation, the system uses a dry centrifugal separation method that achieves acid mist capture without requiring external energy input for liquid circulation, significantly reducing energy consumption.
Solution Approach 2:
The centrifugal separator operates autonomously using the kinetic energy already present in the process gas flow. The rotating element is driven by the gas flow itself or a low-power motor, and the separation process requires no external energy input for liquid recirculation, making the system self-sufficient and energy-efficient.
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 solution effectively separates entrainment with low pressure drop, extending equipment lifespan, reducing maintenance needs, and improving plant efficiency while minimizing environmental impact.
Implementation Method 1
Each passage comprises a vane extending longitudinally along the passage, wherein each vane rotates a process gas flowing through the separator
Data Source
AI summary
Sulphuric acid plants, separators for separating entrainment for process gas, and gas treatment processes for generating sulphuric acid are provided. The sulphuric acid plant comprises a source of process gas, an entrainment eliminator, a gas rotator located downstream of the gas-liquid contactor, and a separator located downstream of the entrainment eliminator and upstream of the gas rotator. The separator comprises a plurality of passages. Each passage comprises a vane extending longitudinally along the passage, wherein each vane rotates a process gas flowing through the separator. The process comprises transferring process gas from an entrainment eliminator to a separator located downstream of the entrainment eliminator, rotating the process gas through the separator to separate entrainment, and transferring the separated process gas from the separator to rotating equipment located downstream of the separator.