Turning Vane Gas-Liquid Separator for Low Inertia Droplet Removal
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Solution Overview
Problem
Existing gas-liquid separators in chemical processes are inefficient in removing liquid droplets with low inertia, leading to valuable reactants or products being lost and causing pressure drops and plugging issues, especially in large and inflexible conduit systems.
Innovation Solution
A gas-liquid separation enhancer with a bent conduit section and longitudinally extending turning vanes that redirect the gas stream and collect liquid droplets, allowing them to be returned to the original vessel, utilizing a central spine and peripheral return channels for efficient liquid collection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inertial separators are used to remove liquid droplets from gas streams, then droplets with large inertia are effectively captured, but droplets with low inertia are not efficiently removed
Solution Approach 1:
The patent changes the flow direction parameter by introducing a bent conduit section that redirects gas flow from a first average direction to a second average direction. This directional change causes liquid droplets to impinge on the conduit walls or collecting surfaces due to their inertia, while the gas stream follows the bend. The turning vanes further modify flow parameters to enhance droplet separation efficiency.
Solution Approach 2:
The bent conduit section introduces curvature to the flow path, causing the gas stream to turn while liquid droplets with inertia continue in their original direction and impinge on the outer wall of the bend. This curved geometry creates centrifugal effects that enhance separation without requiring additional energy input or complex mechanisms.
2Reliability
If packed columns are used to efficiently remove liquid droplets, then separation efficiency is improved, but pressure drop increases severely and plugging occurs
Solution Approach 1:
The patent extracts the separation function from complex packed column structures and implements it using the inherent inertia of liquid droplets in a bent conduit. By removing the need for packed materials and complex internal structures, the design eliminates the associated pressure drop and plugging problems while maintaining effective liquid droplet removal through simple geometric redirection of the gas stream.
3Reliability
If cyclone separators are used to separate liquid from gas, then separation is achieved through centrifugal forces, but the device complexity increases
Solution Approach 1:
The bent conduit section utilizes the natural inertia and flow characteristics of the gas-liquid stream itself to achieve separation. The system serves itself by using the existing kinetic energy and directional flow of the gas stream to cause liquid droplets to impinge on walls, eliminating the need for external centrifugal forces, rotating components, or complex cyclone geometries.
4Reliability
If large surface area serpentine paths are created to reduce pressure drop, then liquid removal efficiency improves, but the device size increases and capital cost increases
Solution Approach 1:
The bent conduit section performs the separation action preliminarily within the existing conduit infrastructure. By integrating the separation function into the natural flow path redirection that already occurs in the system, the design achieves liquid droplet removal without requiring additional large-volume separator vessels or extended serpentine paths, thereby reducing overall device size and capital costs.
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 achieves improved collection efficiency with reduced pressure drop, effectively removing liquid droplets of various sizes and returning them to the original vessel, minimizing losses and maintenance needs.
Implementation Method 1
Inertial separators or traps make use of the fact that a flowing gas can easily make turns that droplets with large inertia cannot. The droplets that cannot turn with the gas stream because of their inertia strike or impact a target or collecting surface
Implementation Method 2
U.S. Patent No. 5,510,017 discloses a gas-liquid separator involving two sets of concentric, radially arranged vanes, which cause a swirling flow of liquid-containing gas directed therethrough. The centrifugal forces generated cause liquid droplets to impinge upon the walls of the pipe section containing the separator
Data Source
Figure 1
Figure 2
Figure 3A~3B
AI summary
A gas-liquid separation enhancer includes a plurality of longitudinally extending turning vanes distributed within a bent conduit section. At least a portion of the vanes have a bend that redirects a portion of a flowing gas stream from an initial direction to a final direction. Each of the vanes have a first end and a second end and are positioned in the bent conduit section to direct a portion of any liquid contacting the vanes to either the first end or the second end when the gas-liquid separation enhancer is incorporated into an outlet conduit. The separation is positioned in an outlet conduit such that captured liquid droplets are returned to the vessel from which they originate.