Shaft-less Multi-phase Fluid Separator with Magnetic Spin-up
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Solution Overview
Problem
Existing multi-phase separators are voluminous and require large, heavy supporting structures, making them unsuitable for compact installations, and they struggle with effective interface level control due to emulsions, especially in high-pressure applications and offshore locations.
Innovation Solution
A shaft-less multi-phase fluid separator using a rotary spin-up device with permanent magnets and electromagnets to apply centrifugal forces for efficient phase separation, eliminating the need for heavy structures and reducing leakage risks through axle-free design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gravitational separation is used in prior art separators, then separation of fluid phases is achieved, but the separators become voluminous and require large supporting structures
Solution Approach 1:
The patent applies dynamic centrifugal separation by rotating the separator at controlled speeds to generate centrifugal forces that enhance phase separation efficiency. This dynamic approach replaces static gravitational separation, allowing for more compact separator design while maintaining or improving separation performance.
Solution Approach 2:
The patent changes the physical parameter of separation force from gravitational acceleration to centrifugal acceleration by rotating the separator. This parameter change enables much smaller separator volumes while achieving the same or better separation efficiency, directly resolving the contradiction between separation reliability and separator size.
2Reliability
If gravitational separation is used in prior art separators, then separation of fluid phases is achieved, but heavy supporting structures are required
Solution Approach 1:
By transitioning from static gravitational separation to dynamic centrifugal separation, the patent eliminates the need for heavy supporting structures that would be required to maintain large gravitational separation volumes. The centrifugal force is generated by rotation of the existing separator structure, eliminating the need for additional heavy support.
Solution Approach 2:
The patent substitutes the mechanical gravitational field with a rotational centrifugal field. This substitution allows phase separation to occur within a compact rotating chamber without requiring the large, heavy supporting structures necessary for gravitational separation systems.
3Speed
If shaft seals are used in high-pressure applications, then rotation is achieved, but leakage risks increase
Solution Approach 1:
The patent extracts and eliminates the shaft seal component entirely by using a magnetic coupling system that transfers rotational torque through magnetic fields rather than mechanical contact. This removal of the shaft seal eliminates the primary source of leakage in high-pressure rotating systems.
Solution Approach 2:
The patent replaces the mechanical shaft seal system with a magnetic coupling system. The magnetic field transmits rotational torque from the drive mechanism to the separator without requiring physical penetration of the pressure boundary, thereby eliminating leakage risks associated with shaft seals while maintaining high rotational speeds.
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 enables compact, efficient separation of multiple fluid phases with improved control and reduced maintenance, suitable for high-pressure applications and various fluid compositions, including those with emulsions, and can be adapted for different orientations and fluid types.
Implementation Method 1
A shaft-less multi-phase fluid separator using a rotary spin-up device with permanent magnets and electromagnets to apply centrifugal forces for efficient phase separation
Implementation Method 2
a magnetic coupling device, arranged between the stationary frame and the rotary frame, for magnetically coupling the rotor to the stationary frame
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
Multi-phase fluid separator (100) comprises an elongate housing(100') with a circular cross-section along its elongate axis (L). Multi-phase fluid (300) enters at inlet (101) and is set into rotation by a shaft-less spin-up device (400) which creates a highly centrifugal gravitational force that drives the heaviest liquid phases out to the wall of the separator (100) and the light phase along the longitudinal axis of the separator (100). The shaft-less permanent electromagnet motor (200) is driving vanes (401) mounted in a rotary frame (402). Contaminated heavy phase containing solids exits at outlet (105) where solids is prevented from further flow by weir (115). Non-contaminated heavy phase fluid (303) exits at outlet (104) and is prevented from further flow by weir (113). Intermediate weight phase fluid (302) exits at outlet (103), whereas the lightest fraction exits the separator (100) through a centrally arranged light phase outlet (102).