Stacked-Plate Filter Radial Misalignment Reduces Pressure Drop
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Solution Overview
Problem
Conventional desanding devices in the oil and gas industry face challenges such as low pressure tolerance, clogging, and high pressure drop when filtering fine particulates, leading to equipment failure and contamination issues.
Innovation Solution
A stacked-plate filter apparatus with radially misaligned peripheral edges on adjacent filter plates, which reduces frictional jamming forces and maintains a consistent pressure drop, allowing for effective filtration of fine particulates without pleated outer edges, thereby preventing clogging and maintaining filter efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If filter plates are spaced very close together to filter fine particulates, then filtration effectiveness is improved, but pressure drop increases beyond theoretical models
Solution Approach 1:
The patent applies asymmetry by radially misaligning the peripheral edges of adjacent filter plates, creating offset gap interfaces that are not symmetrically positioned. This misalignment of 0.001 to 0.01 inches reduces frictional jamming forces and prevents capillary action, thereby reducing pressure drop while maintaining effective filtration of fine particulates through the closely spaced plates.
2Reliability
If conventional screen filters are used for desanding, then particulate removal is achieved, but devices collapse at low pressure and have low pressure tolerance
Solution Approach 1:
The patent segments the filtration system into multiple stacked filter plates with offset gap interfaces, creating a modular structure that distributes pressure loads. This segmented design allows the filter to maintain structural integrity at low pressures unlike conventional screen filters, while still achieving effective particulate removal through the stacked configuration.
Solution Approach 2:
The radial misalignment of peripheral edges creates asymmetric offset gap interfaces that prevent direct contact and frictional jamming between plates. This asymmetric design reduces pressure requirements for operation and prevents collapse at low pressures while maintaining filtration effectiveness.
3Manufacturing precision
If filter plates are spaced very close together, then fine particulate filtration is improved, but frictional jamming forces increase causing clogging
Solution Approach 1:
The patent radially misaligns the peripheral edges of adjacent filter plates by 0.001 to 0.01 inches, creating asymmetric offset gap interfaces. This misalignment prevents direct contact between plates, eliminating frictional jamming forces that would otherwise cause clogging. The asymmetric design allows fine particulates to be filtered effectively through the close spacing while preventing the plates from sticking together.
Solution Approach 2:
The patent introduces a radial dimension to the gap interface design by misaligning peripheral edges at different radial positions. This dimensional change from aligned to misaligned edges creates offset gap interfaces that reduce frictional contact, preventing jamming while maintaining the close spacing needed for fine particulate filtration.
4Ease of manufacture
If aligned peripheral edges are used in stacked-plate filters, then manufacturing is simplified, but pressure drop increases due to frictional jamming
Solution Approach 1:
The patent introduces radial misalignment of peripheral edges by 0.001 to 0.01 inches, creating asymmetric offset gap interfaces. This asymmetric design reduces frictional jamming forces and pressure drop. While it adds slight manufacturing complexity, the misalignment can be achieved through standard manufacturing tolerances and does not significantly complicate the manufacturing process.
Data Source
AI summary
Stacked-plate filters may include a plurality of stacked filter plates with small gaps therebetween. The present disclosure provides a stacked-plate filter apparatus comprising a plurality of filter plates stacked along a longitudinal axis with the filter plates substantially parallel. Each filter plate has a respective outer rim, first face and second face. Each of the filter plates defines a respective opening therethrough. The outer rim forms a first peripheral edge at the first face and a second peripheral edge at the second face. The first peripheral edge is radially misaligned from the second peripheral edge to form an offset gap interface for each adjacent pair of the filter plates. For each of the filter plates, the respective outer rim may be tapered from the first face to the second face to provide the radial misalignment.