Spiral Scrubber Reducing Liquid Entrainment
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Solution Overview
Problem
Existing separation devices for liquids and gases face challenges in minimizing pressure loss and turbulence, leading to inefficient separation and high liquid entrainment, particularly for high viscosity fluids and gas flows.
Innovation Solution
A scrubber design featuring a tangentially oriented fluid inlet and a spiral fluid way within the scrubber, which directs fluid flow along the inner wall in a downwards spiral, minimizing turbulence and secondary flows, and allowing gas to escape inwardly, resulting in a laminar flow that enhances liquid-gas separation with reduced liquid entrainment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional separation devices are used, then separation function is provided, but pressure loss and turbulence are high
Solution Approach 1:
The patent employs a spiral fluid way with continuous curved geometry instead of straight or angular passages. This curved spiral path guides the fluid flow smoothly along the inner wall of the scrubber, minimizing abrupt changes in flow direction that cause turbulence and pressure loss. The spiral configuration allows the fluid to follow a natural curved trajectory, reducing kinetic energy losses while maintaining effective separation.
Solution Approach 2:
The patent utilizes pneumatic principles by designing a system where gas flow dynamically interacts with liquid flow through the spiral fluid way. The opening in the fluid way permits gas to escape inwardly to the center, creating a counterbalancing effect that reduces liquid entrainment. This pneumatic-hydraulic interaction optimizes the separation process by allowing the gas phase to move independently through the spiral path while the liquid phase is separated at the bottom outlet.
2Ease of operation
If conventional inlet designs are used, then fluid flow is introduced, but turbulence and secondary flows are generated
Solution Approach 1:
The tangentially oriented fluid inlet is positioned to introduce fluid flow that naturally follows the curved spiral path of the fluid way. This tangential entry point ensures that the fluid enters the spiral passage smoothly without creating abrupt directional changes or turbulence. The curved geometry of the spiral fluid way continues this smooth flow pattern, maintaining laminar conditions throughout the separation process.
Solution Approach 2:
The patent applies different flow characteristics to different regions: the inlet area uses tangential orientation to establish smooth entry, while the spiral fluid way maintains continuous curved flow. The opening in the fluid way is strategically positioned to allow gas escape only where needed, creating localized flow patterns that reduce liquid entrainment without disrupting overall laminar flow quality.
3Reliability
If high viscosity fluids are processed, then separation is achieved, but pressure loss increases
Solution Approach 1:
The spiral fluid way with its continuous curved geometry reduces flow resistance for high viscosity fluids by eliminating abrupt directional changes. The curved spiral path allows the viscous fluid to move smoothly along the inner wall, minimizing shear stress losses and pressure drops. This curved configuration is particularly beneficial for high viscosity fluids that require gentle flow guidance to maintain separation effectiveness.
Solution Approach 2:
The pneumatic interaction through the opening in the fluid way creates a counterbalancing effect that reduces the pressure loss impact of high viscosity liquids. The gas flow through the opening compensates for the higher pressure drops caused by viscous liquid flow, maintaining more favorable pressure gradients throughout the separation process and reducing overall energy losses.
4Reliability
If liquid-gas separation is performed, then separation occurs, but liquid entrainment in gas increases
Solution Approach 1:
The opening in the spiral fluid way creates a pneumatic counterbalancing effect where gas flow inwardly to the center counteracts the outward centrifugal force that causes liquid entrainment. This pneumatic interaction reduces the net centrifugal force acting on liquid droplets, preventing them from being carried into the gas outlet. The result is significantly reduced liquid entrainment in the separated gas stream.
Solution Approach 2:
The continuous curved spiral path of the fluid way allows liquid to separate smoothly along the curved surface rather than being abruptly deflected. This curved geometry reduces the likelihood of liquid droplets being thrown into the gas phase, as the gradual curvature allows for more controlled separation. The spiral configuration maintains stable flow patterns that prevent turbulent mixing and liquid entrainment.
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 scrubber achieves effective separation of liquids from gases with minimal turbulence and droplet entrainment, reducing liquid content in the gas by 50-75% compared to conventional designs, and is robust against variations in liquid fraction, improving downstream separation efficiency.
Implementation Method 1
separation of liquid from gas by use of a cyclone principle... the heavier constituents move to the outside of the curved fluid flow and are accumulated towards the inner wall of the vessel
Implementation Method 2
separation of liquid from gas by use of a cyclone principle... introduced fluid is directed tangentially horizontal or with a small downward slope along the inner wall of the scrubber, into and through a fluid way arranged as a downwards directed spiral
Implementation Method 3
the heavier constituents as a result of gravitation can be directed to a reservoir or outlet in the bottom of the vessel
Data Source
AI summary
A scrubber for separation of liquid phase and any other constituents from a fluid now that in substance includes a gas. The scrubber is formed as a standing vessel with round cross section, with an outlet for liquid from the bottom and an outlet for gas from the top. The scrubber is distinguished in includes a fluid inlet that either is tangentially oriented relative to the inner wall of the scrubber or equipped with a deflection plate, such that introduced fluid is directed tangentially horizontal or with a small downward slope along the inner wall of the scrubber, into and through a fluid way arranged as a downwards directed spiral within the scrubber, along the inner wall, from a level over or at the inlet to a level at or close to the outlet for liquid, with an opening for gas escape inwards toward the center of the scrubber. The scrubber according to the invention results in very low liquid entrainment.