Two-Stage Gas Separation Unit with Integrated Housing
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Solution Overview
Problem
Traditional membrane-based gas separation systems require multiple module stages, leading to increased space and piping requirements, complex connections, and higher costs due to the need for multiple gas connection points and headers, especially in compact installations like offshore oil drilling platforms.
Innovation Solution
A two-stage membrane module is housed within a single casing, with an innovative piping and baffling arrangement that reduces fluid connections from six to three, allowing for efficient flow management and identical module design, which minimizes space and piping needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple membrane modules are arranged in series to achieve high purity gas separation, then the purity of the product gas is improved, but the number of gas connection points and piping requirements increase
Solution Approach 1:
The patent combines multiple membrane modules into a single integrated housing, merging what would traditionally be separate modules requiring multiple external connections into one unified device. The housing contains multiple stages of membrane elements with internal flow distribution, reducing the system from requiring six external stream connections to only three, while maintaining the series arrangement necessary for high purity gas separation
Solution Approach 2:
The single housing serves multiple functions simultaneously: it contains and supports multiple membrane modules, provides internal flow distribution and collection systems, houses the interconnection piping between stages, and maintains pressure differentials across all membrane elements. This multi-functional integration eliminates the need for separate external piping and connection points for each module
2Area of stationary object
If multiple membrane modules are stacked vertically to save space, then the footprint area is reduced, but the number of module housings and connection points increases
Solution Approach 1:
The patent merges multiple membrane modules that would traditionally require separate housings into a single integrated housing structure. The housing contains vertical or horizontal stacks of membrane elements with internal flow distribution, achieving compact vertical arrangement while eliminating the need for multiple external housings and their associated connection points
Solution Approach 2:
The patent implements a nested arrangement where multiple membrane elements are contained within concentric or stacked configurations inside a single housing. The hollow fiber membranes are arranged in bundles within the housing, with internal piping and flow distributors nested within the module structure, creating a compact nested architecture that minimizes both footprint and connection requirements
3Ease of repair
If traditional piping arrangements are used for multi-stage modules, then each module can be independently maintained, but the number of headers and spacers increases space requirements
Solution Approach 1:
The patent combines the housing, piping, and support structures into a single integrated unit, eliminating the need for separate external headers and spacers. The internal flow distribution system is built into the housing structure itself, reducing the space required for auxiliary components while maintaining the multi-stage separation functionality
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
This configuration reduces the number of gas connections, minimizes space and weight, simplifies installation and maintenance, and enhances the efficiency and cost-effectiveness of non-cryogenic gas separation by allowing two membrane modules to operate in series with reduced pressure drop and inter-stage piping.
Implementation Method 1
A polymer used in air separation, for example, will pass oxygen and nitrogen at different rates. The gas that preferentially flows through the membrane wall is called the 'permeate' gas
Implementation Method 2
The selectivity of the membrane is a measure of the degree to which the membrane allows one component, but not the other, to pass through
Data Source
AI summary
A two-stage gas-separation membrane system includes two identical membrane modules held within a single casing. A feed gas is directed into the first module, so as to produce permeate and retentate streams. One of the latter streams then becomes the feed gas for the second module, and reaches the second module through a core tube located within the module. The product of the second module is the product gas for the system. The gas streams entering the two modules flow in mutually opposite directions. This arrangement makes it feasible to provide a two-stage system while using only the number of ports that would be needed for a single stage.