CA2583076C - A system for separating an entrained liquid component from a gas stream - Google Patents

Abstract

A system for separating an entrained immiscible liquid component from a gas stream employing a vessel having a wet gas inlet, a gas outlet and a liquid outlet. At least one vortex tube is supported within the vessel and has a liquid outlet end and a wet gas inlet tangential to its sidewall and arranged so that wet gas rotates within the vortex tube to cause the liquid components to be forced against the interior wall surface by centrifugal action. An orifice plate closes the vortex tube first end and has a concentric gas outlet opening therein. A vortex finder tube is axed to the orifice plate in communication with the gas outlet opening and extends concentrically within the vortex tube, the vortex finder tube providing an annular area between itself and the vortex tube internal wall. A gas deflector positioned within the annular area, the gas deflector having a downwardly spiraled surface that diverts wet gas downwardly away from the wet gas inlet. One embodiment may include at least one free-fall preventer within the vortex tube positioned below the tangential inlet and having a plurality of spaced apart radially arranged flow diverting vanes positioned in a plane perpendicular to a longitudinal axis of the vortex tube and serving to augment the rotation of liquid as it traverses towards the outlet end of the vortex tube.

Description

A SYSTEM FOIt SEP -A.P-A.TiNG A:K E?ti'~'R~~L~ED LIQ ViD
CONIYUNENT FROM A GAS STRLA~2 This is a divisional of Application Serial Number 2.448,25-5 filed June 13, 2002.

Background of the Invention This cusclosure is to an improved vortex tube for use in separatinJ an immiscible Iiquid component from aga:s stream and more particularly for a system and a method of 15 operating a systemfor separafing liquid components from a gas.stream. 'An-example of an appiication of the invention is for separ.ating entrained water from a naiural gas str-eam:

The subject of the invention generally relates to gas!liquid separators or gas/liquid/solid separators. Separators of this type are typically process vessels tilatmay 20 be at atmospheric or above atmospheric pressures. The main function of the separator system-is to-segregate irnmiscible phases of the process stream,such as when the process stream islhe foimi of a gas, such- as natural Ras that carries witlz it an immiscible liquid component. The function of th'e separator of tbis invention is to separate out the liquid cornponent to provide at the output of the separator a gas stream that is relatively :Eree 25 fiFom entrained liquids.

Separators for separating liquid components from a gas stream are commonly utilized in the oil and gas industry, specifically in oil and gas production, oil refining and gas processing. While very commonly utilized in the oil and gas industry, separators of this type are also used in the niining industry, chemical plants, water treatment facilities, pulp and paper plants and pharmaceutical manufacturing facilities. Separators can be designed to separate a two-phase stream - that is, a vapor/liquid stream or a three-phase stream - that is, a vapor/organic liquid/aqueous stream or a four-phase stream - that is, a vapor/organic liquid/aqueous liquid/solids stream.

Separation of inuniscible components of the stream usually and ultimately depend on the force of gravity. Gravity can be either natural gravity - that is, the pull of objects towards the center of the earth or created gravitational forces such as represeiited by, centrifugal separators. Natural gravity is usually used by flowing a stream having immiscible components into a vessel which provides a quiescent zone - that is, a relatively undisturbed environiuent that allows gravity to act on heavier components of the stream and move them into a downward part of the vessel. This movement has the counteraction of the lighter components of the stream migrating to aiz upward part of the vessel. In this way, the heavier components - that is, liquids, can be withdrawn from the lower part of the vessel and the lighter components - tl-iat is, gases, withdrawn from an upper part of the vessel.

Another type of gravitational separator utilizes artificial gravity attained by centrifugal force. One way of generating artificial gravity is by tlie use of a vortex tube.
A vortex tube is typically an elongated tube having a cylindrical intez-ior wall that is preferably vertically mounted or at lease nlounted with a verticatly downward tangent.
Adjacent an upper end of the vessel is an inlet opening into the vortex tube, the inlet being arranged so that fluids flowing therein tangentially intersect the i.nterior wall of the vortex tube and flow around the interior wall thereby creating centrifugal force that is applied to the components, the centrifugal force serving to move the heavier component-that is, the liquid coinponent, towards the wall of the vortex tube while the lighter component is forced towards the interior of the vortex tube. In a typical vortex tube the gas is withdrawn from an upper central vortex opening while the liquid component is withdrawn from a liquid outlet in the bottom portion of the vortex tube. The invention herein pertains to improvements to vortex tubes and to metllods of using the improved vortex tubes for separation of immiscible components of a gas stream.

For background information relating to the general subject matter of this invention reference may be had to the following previously issued United States patents:
PATENT NO. INVENTOR TITLE
1,836,004 Becker paratus for Treating Gas 2,808,897 Reinsch et al pparatus for Contacting iquid and Vaporous aterials 3,296,774 Hoogendorn et al Gas-Liquid Contactor with Wall Obstructions and Contacting Method 3,498,028 Trouw pparatus for Contacting iquids and Gases 3,581,467 Donnelly ethod and Apparatus for Vortical Liquid-Gas Movement 3,605,388 Zuidcrwg et al Apparatus for Contacting i uids a.nd Gases 3,662,521 Behar et al Device for Reaction Between Liquid Phase and Gaseous hase 3,930,816 Miczek Structure for a Gas and iquid Contacting Chamber in a Gas Effluent Processing System 4,128,406 Spevack Contact Apparatus for Multiphase Processing 4,486,203 Rooker Inlet Momentum Absorber for Fluid Separation 4,838,906 Kiselev Contact-and-Separating lement 4,880,451 Konijn Gas/Liquid Contacting Apparatus 5,145,612 Reay et al pparatus for Mi-xing Vapor ui a Countercurrent Column 5,683,629 Konijn orizontal Tray and Column or Contacting Gas and iquid 5,714,068 Brown nlet Device for Large Oil Field Separator -t Brief Summary of the Invention Separators are process vessels, commonly pressurized, which segregate inuniscible phases of a process stream. They are conunonly used in oil and gas production, oil refining, gas processing, nlining, chemical plants, waste water treatment, pulp and paper, and pharmaceutical plants. They separate two-phase streams (vapor/liquid), three-phase streams (vapor/organic liquid/aqueous liquid) or four-phase streains (vapor/organic liquid/aqueous liquid/solids). Separators commonly have an inlet momentum absorber or deflector intended to utilize or reduce fluid incoming momentum, and distribute liquid and gas. This energy reduction initiates phase separation inside the separator vessel. These inlet devices are then followed by various types of de-n-iisting, de-foaming, and/or liquid coalescing apparatus.

These inlet devices are then followed by various types of de-misting, de-foaming, and/or liquid coa.lescing apparatus. The most common separator inlet device is a "splash plate" -- that is, a flat, curved or dished impingenlent plate that intercepts the incoming flow stream. Fluids are allowed to rebound in a direction considered least destructive to the quiescence of the bulk phases residing in the vessel. Splash plates are characterized by relatively high rebouird turbulence. A diffusion inlet is another generic type of ii-ilet device. It typically divides the flow stream into multiple smaller streams and reduces momentuna by gradual ei-dargement of ihe flow areas of each strcain.

The invention herein relates to a"vortex tube" that is frequently utilized in a "vortex tube cluster". A vortex tube can be used as a momentuum dissipating ii-ilet device and can eliminate other phase separation elements as well. A vortex tube has an inlet through which fluids enter tangentially creating rotational flow. Centrifugal force separates phases within the tube, which then exit, gas from the top through a central gas orifice and liquids from the bottom through peripheral openings. A vortex is formed inside the tube. In a prefei7=ed embodinlent, the bottom of each tube is submcrged below the liquid surface to a depth that prevents the gas vortex from blowulg out the bottom.

An essential characteristic of a vortex tube is that it uses flow energy constructivcly to separate phases whereas in impingement and diffusion devices flow energy is counterproductive to separation, and so they seelc to dissipate flow energy as non-destructively as is practical. ("Destructive" refers to the tendency of hydraulic agitation to niix, rather than to separate phases). This invention herein includes. an improved vortex tube that is usually employed in a vortex tube cluster.

The disclosure herein covers a vortex tube system, which produces optimum perfornianee for a variety of proeess cireumstances and conditions.

One improvement described herein minimizes fluid shear by sl-uelding the axially flowing gas stream leaving the top of the tube from the feed stream as it enters the tube tangentially. It consists of a'vortex finder', which shields the vortex tube outlet stream from disturbatice by the inlet stream. It is comprised of a vertical tube the sanie size as the gas orifice and concentric with the vertical vortex tube and protrudes froni the orifice plate on top downward to below the lowest point of the vortea tube entry. This improvement also includes a method of diverting the fluid already rotating circtunferentially about the tube as it completes its first rotation from the entering stream.
'This is done by directing tlie inlet stream downward using a deflector at such an angle as to iniss the tube inlet after one revolution. The deflector diverts the incoming fluid streani downward at the necessary angle. A benefit of using this method is that a smaller amount of liquid rnist is carried out of the tube with the gas streain.

Occasionally the gas flow velocity inside a vortex tube may exceed the ideal design limits, either continuously or iiltermittently due to slugging. This excessive velocity re-entrains liquid mist, and causes the gas stream to spit coarse mist droplets out of the gas orifice. Uncontained, these droplets can result in separator liquid carryover. A

second iniprovement described herein is a method for diverting the gas outlet from the vortex tube downward so that any entrained liquid is directed toward the sta.iiding liquid phase. A curved outlet tube is installed on top of the gas orifice to catcli these large droplets and direct them harmlessly downward towards the standing liquid. The deflecting tube must arch down sufficiently to create this downward velocity component but does not need to point directly down. If space limits the curve oÃthe tube, it can be modified as shown in Figure 9. The benefit of this device is that it allows a smaller tube cluster, rnaking the unit more competitive and giving a greater flow turndown to the device without carryover.

In the operation of a vortex tube it is inlportant to control the flow of liquid as it is discharged from the tube bottom. This is done by, changing flow direction -that is, to direct the liquid discharge from the tube upward instead of outward by using a tube-on-tube device. This is important if ihere is any gas carryunder frorn the tube. Gas exiting the bottom of the tube, if allowed to radiate outward, can propel gas-laden liquid towards the liquid outlet, resulting in carryunder of gas from the separator vessel. The tube-on-tube desigli projects tliis flow upward so that gas more quiclkly reaches the gas-liquid surface. This tends to keep the gas entraimlient localizeci, allowing a quiet zone in the separator to be more gas-free. The benefit of the tube-on-tube design results in more gas-fiee liquid leaving the separator.

The liquid release pouit for a typical vortex tube is located well beneath the liquid surface. However, in low level situations or at start-up, the bottom of the tube may not be submerged. The tube-on-tube arrangement establishes tube-bottom submergence as soon as any liquid is produced. A resulting benefit of incorporatulg the tube-on-tube system is that during separator startup, or during low liquid level excursions, the vortex tube liquid discharge will remain submerged and will therefore fiuiction normally.
Another benefit of the tube-on-tube system is that it keeps disturbance of the oil-water interface nlore localized around the tube. In tluee-phase separators the top of the outer tube is typically located below the oil-water interface. An improvement to the tube-on-tube system is the deflector ring. If the liquid release of a tube-o.n-tube system is near the liquid or interface surface, the deflector ring deflects the upward momentum into a horizontal direction. By the time this deflection occurs, gas has been released and velocity has slowed by natural diffusion. This reduces surface disturbauce and phase re-entrainment. The benefit is a reduction in cross-containination between liquid phases leaving the separator.

To diffuse liquid discharged from a cluster of voilex tubes, a liquid energy absorber may be used that is in the foim of a box that surrotmds the entire bottom portion of a tube cluster. The box has sides, a top and a bottom, some or all of Nvhich are of perforated plate. A liquid energy absorber system reduces turbulent spots in separator liquid residence sections by diffusing vortex tube exit velocities and reduces channeling by iznproving fluid distribution.

In vertical separators or in large diazneter horizontal separators the vertical height of vorfex tubes can be significant, Wl.-ien this occurs, liquid sepEu=ated within the tubes znust fall a long distance down the tube wall. As it plunges, gravity accelerates its s velocity such that when it finally imuinCes on the standing iiquid, its inah m.oment'Jm re-ent ains Uas into i.he Iiqui.d phases. ConcurrenLl.~-, in tall vortex tubes, wall friction slows dom7r rotational liquid velocity cau;ing a loss of Centrifuaal sepaxation as the liquid pr. ogresses down the tube. Thus at tlie bottom oi the tube, the liquid velocity direction is nearly verticall), down.ward. To alleviate this problem, a system employing fxee-fall preventers is used. The bene.fit of the free-fall preventer system is that gas re-entrainment and zoaining are g7-catly minimized or eliminated, and a higlier averade g-force is maintained in the vorter, tubes to improve phase separation within the tubes.

The claims and the.specincation describe the invention presented and the terms that are employed in the claims draw their meaning from tbe us.e of such tez-m.s in the specification. The, sam.e terms employed in the,prior art may b-- broadcr in -meani,ng than specifically employed herein. Whenever there is a question between the broader defr.nition of such terms used i.n the prior art and the more specific use of the term,s her.ein, the more speci-Ec,meaning is,meant.

While the invention has bean.described, with a certain cliegree of particularity, itis maafest that maDy changes may be m.ade in the details of coustruction and the arrangement of coniponents, without departing fiom the spirit and scope of this disclosure. It is understood that tbe invention is not limited to the embodimen:ts set forth lierein for purpose;s of eõernplincation, but is to be linaited ouly by the scope of the attaclzed clain~ or claitzis, includ'v-ig tlze fiill range of equi-valency to which each clement thereof is cntitled.

In one broad aspect, there is provided a system for separating an entrained immiscible liquid component from a wet gas stream comprising: a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet; at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end and a wet gas tangential inlet in and tangential to said internal wall surface, the tangential inlet being spaced from said first end and arranged so that wet gas entering said tangential inlet rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action; an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein; a vortex finder tube in communication with said orifice plate gas outlet opening and extending concentrically within said vortex tube in the direction towards said vortex tube outlet end, the vortex finder tube being of external diameter less than the internal diameter of said vortex tube internal wall providing an annular space therebetween; and a fluid deflector positioned within said annular space, the deflector having a downwardly spiraled surface that diverts wet gas flowing through said tangential inlet downwardly in the direction towards said vortex tube outlet end.

In another broad aspect, there is provided a system for separating an entrained immiscible liquid component from a wet gas stream comprising: a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet; at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end and a wet gas tangential inlet in and tangential to said internal wall surface, the tangential wet gas inlet being 9a spaced from said first end and arranged so that wet gas entering therein rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action; an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein; and a curved outlet pipe affixed to said orifice plate exterior of said vortex tube and in communication with said vortex tube central opening and configured to divert gas passing out of said orifice plate gas outlet opening in a direction having a downward tangent.

In still another broad aspect, there is provided a system for separating an entrained immiscible liquid component from a wet gas stream comprising: a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet; at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end, and a wet gas tangential inlet in and tangential to said internal wall surface, the tangential wet gas inlet being spaced from said first end and arranged so that wet gas entering therein rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action; an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein; and a liquid discharge deflector tube secured in relationship to an external portion of said vortex tube and encompassing said vortex tube outlet end, the deflector tube being of internal diameter greater than the external diameter of said vortex tube at said outlet end providing an external annular area, the deflector tube having a bottom end; and an end plate at least substantially closing said bottom end of said deflector tube to thereby deflect liquid flowing out of said 9b vortex tube outlet end into an upward direction through said external annular area.

In yet another broad aspect, there is provided a system for separating an entrained immiscible liquid component from a wet gas stream comprising: a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet; at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end and a wet gas tangential inlet in and tangential to said sidewall, the tangential wet gas inlet being spaced from said first end and arranged so that wet gas entering therein rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action; an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein; and an energy absorbing housing providing a quiescent inducing cavity surrounding said outlet end of said vortex tube, liquid flowing out said outlet end of said vortex tube flowing into said quiescent inducing cavity provided by said energy absorbing housing, said energy absorbing housing having cavity walls defining said quiescent inducing cavity, said cavity walls having small diameter openings therethrough which liquid passes into the interior of said vessel.

A better understanding of the invention will be obtained from the following detailed description of the preferred embodiments taken in conjunction with the attached drawings.

9c Description of the Drawinbs Figure 1 shows a cluster of vortex tubes or a vortex tube assembly positioned within a separator vessel. The separator vessel is shown very diagrammatically to show a fluid inlet, a gas outlet and a liquid outlet to show very generally the environn7ent in which the vortex tube assembly of Figure 1 is enlployed.

Figure 2 is a horizontal cross-sectional view taken along the line 2-2 of Figure 1 and sliowing the nlaimer in which wet gas is introduced from the horizontal irilet tube into the vertically arranged vortex tubes.

Figure 3 is an elevational cross-sectional view of one of the vortex tubes as talcen along the line 3-3 of Figure 3.

Figure 4 is a fragmentary cross-sectional view of the upper portion of a vortex tube as shown enlarged.

Figure 5 is a cross-sectional view of the upper portion of a vortex tube showing one inlprovement of the invention herein that includes a short length vertical tubular vortex finder that serves to separate the incoming fluid stream from the gas outlet stream.

Figure 6 is an isometric view of the upper portion of a vortex tube having a short length vortex finder as shown in Figure 5 and fiirther, having a downward flow diverter so that gas tzngentially entering the vortex tube is immediately directed in a downward spiral tangent.

Figure 7 is an isometric view of a vortex tube showing a gas flow diverter that is in conullunication wit11 the vortex tube gas outlet on the top of the vortex tube, and that serves to direct the outlet gas in a dovnward tangent.

Figure 8 is a side view of a gas flow diverter extending from the upper end of a vortex tube and sliowing a more U-shaped flow diverter to provide an increased downward tangent for gas passing out of the vortex tube. This is the norrnal configuration.

Figure 9 is a view similar to Figure 8 except it shows the wall of a cylindrical vessel in which the vortex tube is positioned and showing the vortex tube adjacent the wall and specifically, the gas flow diverter as being positioned adjacent the vessel cylindrical wall and shows the use of a shield to direct exhaust gas away from the vessel sidewall. This configuration is used instead of that in Figure 8 when available space does not pemlit the Figure 8 design.

Figure 10 shows in cross-section the bottom end portion of a vortex tube, the vortex tube extending below a liquid level established witlun a vessel. A
portion of the vessel is shown. Spaced from the lower end of the vortex tube is a bottom diverter plate that serves to spread the flow of liquid exiting from the vortex tube. The bottom diverter plate also serves to decrease the possibility that the gas vortex formed within the diverter tube can elongate to ea-tend out the lower end of the vortex tube.

Figure 11 is a view of the bottom portion of a vortex tube as in Figure 10 but showing the use of a tube-on-tube attachnient that provides a short length annular space at the lower end of the vortex tube through which liquids passing out of the vortex tube travels. The tube-on-tube arrangement of Figure 11 decreases the turbulence of the fluid flowing from the vortex tube aild furtlier decreases the possibility that the gas vortex foimed within the tube can extend out the lower end thereof.

Figure 12 is like Figures 10 and 11 in that it shows the lower end portion of a vortex tube. In these figures, the liquid accumulation within the bottorn of the separator vessel is shown as being a two-phase airangeincnt - that is, with a lowen ccavier phase, such as water and aii upper lighter liquid phase such as oil with gas in the vessel being above the Iighter liquid or oil phase. In Fib tre 11, the upper end of the tube-oia-tube attacluneilt discharges into the denser liquid phase whereas in the arrangement ofFib re 12, the length of the tube-on-tube attachment is such that the upper end is above the liquid level of the lightest liquid phase so that liquid passing theretlirough is distributed on top of the upper liquid phase.

Figure 13 is a cross-sectional view of a lower portion of a vortex tube, having a "tube-on-tube" flow diverter as in Figure 11 with tlie addition of a horizontal deflector ring. Figure 13 shows a flat diverter ring on the left side of the vortex tube - that is, a diverter ring in a horizontal plane, and on the right side of the vortex tube a curved deflector ring.

Figure 14 is an isometric view of a cluster of vertically oriented vortex tubes fed by an inlet manifold tube and showing the lower end portions of each of the vortex tubes mal:ing up the cluster as encompassed witlun a liquid energy absorber. The liquid energy absorber is formed of an enclosure that can be rectangular as illustrated and that is highly perforated to let fluid freely flow out but in a way to diffuse the fluid flow and thereby miiumize turbulence.

Figure 15 is an elevational view of a vertically-oriented vortex tube fed by an inlet conduit and showing the enlployinent of spaced apart free-fall preventerswithin the vortex tube. In Figure 15 two free-fall prevcnters are illustrated.

Figure 16 is an isoiuetric view of a free-fall preventer of the type positioned within the vortex tube as illustrated in Figure 1S.

Detailed Description of the Preferred Embodiments Referring to Figure 1, a system for separating entrained liquid components from a gas stream is diagrammaticaIly illustrated. Generally speakiulg, the system of this invention employs one or more vortex tubes and the invention is specifically concerned with the constn.iction of vortex tubes. Figure 1 is more or less representative of the state of the prior art to which the principles of this invention apply with the iuatent of providing vortex tube systems to attau7 more effective separation of entrained inuniscible liquid components from a gas stream. Figure 1 illustrates diagranmiatically a vessel 10 which can be, as an example, a horizontal cylindrical vessel or a verrtical cylindrical vessel or any other type of vessel that provides a quiescent internal zone 12, a wet gas inlet 14, a liquid outlet 16 and a gas outlet 18. In the typical operation of a separator as shown in Figure 1, a liquid Ieve120 is established within a lower portion of the vessel, the liquid being drawn off at a rate to approximately maintain the liquid level 20 while gas is removed from an upper portion of the vessel through an upper gas outlet 18. In the typical operation of the system of Figure I, a liquid level control means (not shown) is used to control the rate of liquid discharge so as to maintain a liquid level 20.

Figure 2 is a horizontal cross-sectional view of Figure 1 showing a fluid injection conduit 22 that receives the wet gas from wet gas inlet 14 of the vessel of Figure 1, and showing a plurality of vertically positioned vortex tubes 24. Each vortex tube has a wet gas inlet 26 in the vertical sidewall thereof Wet gas under pressure flows through an opening 26 in eacli of the vortex tztbes and enters the vortex tube tangcntially - that is, at a tangent to the interior sidewall 28 of each of the vortex tubes. Figure 3 is a cross-sectional view of a single vortex tube 24 that is representative of the other tirortex tubes shown in the cluster. The upper end of each vortex thtbe is closed with atop plate 30 having a concentric gas outlet opening 32 therein. As seen in Figure 3, the bottom cnd 34 of each vortex tube 24 is open to admit the free-flow of liquid out of the lower bottom end. A horizontally positioned bottom diverter plate is supported to the vortex tube sidewal124 and spaced fiom the bottom 34 of the voitex tube to allow a circumferential liquid outlet passageway 38. Bottom diverter plate is typically supported to vortex tube 24 by spaeed apart stauld-offs that are not shown but can be in the form of short-lengtli metal rods welded to the interior or exterior surface of the cylindrical wall of the voi-tex tube.

A vortex tube functions to separate an immiscible liquid coznponent from a wet gas stream by utilizing artificially created gravity - that is, centrifu.gal force. Inlet fluids enter the fluids injection tube 22 and flows through opening 26 into the interior of the vortex tube tangentially so that the fluids swirl at a rapid rate within the vortex tube as illustrated by the dotted lines in Figure 3. The swirl'u1g gas causes entrained liquids to be expelled and to encounter the vortex tube internal cylindrical wall 28 where the liquids accunlulate and fa11 downwardly by gravity to ultimately flow out of the vortex tube through the liquid outlet passageway 38. The swirling gas coinponent of the fluid stream having substaiitially less density than the entrained liquid component migrates to the axial center of each vortex tube 24 and flows out tln=ough the upper concentric gas outlet 26. The swirling gas is in the form of a gas vortex that takes the geometrical pattein as shown by the vortex botmdaiy 48.

Thus Figures 1, 2 and 3 are represenlative of tlie state of the at-l to which this disclosure applies to provide the iniprovements to obtain more effective separation of an entrained iimniscible liquid coniponent frotn a wet gas streain. Systems can operate with one vortex tube which is typically oriented vertically but that can operate as long as it has a vertical downward tangent however, a vertical operation is preferred. A
vessel can include a single vortex tube or a cluster of vortex tubes as shown in Figure 1 or a plurality of clusters of vortex tubes depending on the volume of wet gas being treated and the arrangement of the vessel 10. The length of vortex tubes can vary in length; where long length vortex tubes are employed a vertically oriented vessel may be preferred but where shorter length vortex tubes are employed typically a horizontal vessel offers the most economic housing for the separation systeni.

The improvements of the invention are illustrated in Figures 5 through 16 as will now be described.

Figure 5 illustrates an improvenlent of the basic concept of a vortex tube separator in the form of a tubular vortex finder 42 having an upper end connected with top plate 30 and an internal tubular wall 44 that conmlunicates with concentric gas outlet 32. Vortex finder 42 mininiizes fluid shear by shielding the axially flowing gas stream that leaves the top of the vortex tube froni the feed streain as it enters the vortex tube through tangential iiilet opening 26. Stated another way, vortex finder 42 shields the vortex tube outlet stream from disturbance by the inlet stream. The lower end 46 of vortex finder 42 should preferably extend below the lowest point of the vortex tube entry -tliat is, below the lowest point of tangential inlet opening 26.

Figure 6 is an isometric view of a portion of a vortex tube 24 tliat includes the improvements of Figure 5 - that is, a sliort lengl:h tubular vortex fnlder 42 but in additioil iiicludes a sloped deflector 48. Deflcctor 48 fits in the aiuZular area 50 exterior of vortex finder 42 and within vortex tube internal cyliridrical sidewall 28 and is spirally sloped downwardly so that tlie inconzing gas streain that enters the vortex tube tlu-ough opeiung 26 (seen in Figure 5 bitt not seen in Figure 6) is spirally deflected downwardly by the 1 s sloped deflector 48. The sloped deflector diverts the incoming wet gas stream dovsmward at the necessary angle. A benefit of using the sloped deflector 48 is that it minimizes liquid droplet brealc-up caused by shearing as the rotating stream intersects the incozning stream. As a result of a smaller amount of liquid mist is carried out of the tube with the gas stream that passes upwardly through vortex finder 42.

4ccasionaly the gas 'flow velocity 'inside a voi-textube may exeeed the ideal design Limits either continuously, or intermittently due to slugging.
Excess'flow velocity of gas re-entrains liquid mist and causes the gas stream to spit course niist droplets out of the gas orifice, that is out of the orifice 32 as in Figure 4 or out of the vortex finrler 42 in the erribodimeirt'of Figure 5 and 6. Uncontained; these droplets can result in separator . ,.
liquid carry=over = that is; the liquid that is contained in the rapidly d.ise}iarged' gas 'is carri-ed -upwardly into -the vessel into the compartment where gas'is -intended to accumulate iustead of downwardly into the area where the liquid should aecuinulate. To overcome fhis problem, a method of divert.in.g the gas outlet frorri tlie' vorfex tube downwarclly so that any entrained liquid is directed towardthe standing Iiquid phase is illustrated in Figures 7, 8 and 9. Figure 7 shows the vortex tube 24 withtop plate 3.0, the vortex tube' extending from and receiving the inlet of gas 'from wet gas inj ector conduit 22. Affixed to top plate 30 is a gas flow diverter 52 that is a bcnt tubli.lar nieinber having an in.let end 54 connected to tlie concentric dry gas outlet in a top plate 30, 'fhe two being curved so that its outlet end 56 is directed in a downward tangent that is, gas 'ilow tlirough gas flow divertez 52 iualces a transition of more than 90 . By the down,,arard diversion of the gas passing out of the vortex tube, any entrained droplets are directed do-wnwardly towaid the liquid that collects ul the bottoni of the vessel, such as the liquid shown in the bottom of vessel 10 that has a Iiquid level 20.

Figure 8 is an elevational view of the top portion only of the vortex tube 24 showing the tubular dry gas flow diverter in which the outlet end 46 has a more downward inclination. It can be seen that, if desired, the tubular gas flow diverter 52 could include a bend of 180 so that the gas is directed vertically downwardly if desired however, any downward direction iunparted to droplets that pass out with the gas is very beneficial in preventing re-entrainment of the liquid with the exiting gas stream.

Figure 9 shows a special application of the gas diverter of Figures 7 and 8 where the outlet end 56 of the tubular gas diverter is closely spaced to the ulternal wa11 surface 58 of a vessel 10 in an arrangement that does not permit sufficient space to provide a fully arcuate downwardly directed bent tubular gas flow diverter 52 as shown in Figure 8.
In this predicament, downward diversion of any fluid droplets carried by the gas stream exiting vortex tube 24 can be deflected by use of an angular diversion shield 60 welded or otherwise attached to tubular gas diverter 52.

In the operation of a vortex tube it is important to control the flow of liquid being discharged from the lower end of the tube and to prevent tl-ie gas vortex formed inside the tube from extending beyond the lower end of the tube and thereby into the liquid chamber in the bottonl of the separator vessel. For this purpose, a bottom diverter plate has been used such as shown in Figure 10 and that has previously been described with reference to Figure 1, the bottom diverterplate 36 having been described with reference to Figures 1 and 3.

lui improved metllod of controlling the fluid flow out the bottom end 34 of a vortex tube 24 is shown in Figures 11, 12 and 13. Each of these fibures show the lower end poi-tion of the vortex tube 24 positioned within a vessel having a vessel wall 10 with the vortex tube lower end 46 being below the level of liquid 20. In hibures 10 through 13, liquid leve120 is shown wherein the separated liquid is of two-phase. For instance, in separating liquid from a gas stream in the petroleum industry it is common that the separated liquid be co-mingled water and oil and preferably tliese liquids are separately removed from the interior of the separator vessel -- that is, a separator can be operated where all the separated liquids are discharged in a comtuon stream but in many applications it is desirable that if the liquid is of two-pllases, the two phases be separately discharged. As shown in Figures 10 tlirough 13, the liquid is in two-phase providing a water phase 20 having a liquid level 20A and on top of the water level an oil pliase that ha.s the top liquid level 20. In any event, in Figures 10 througl1 11, the lower end 38 extends into the bottom liquid phase - that is, below the intermediate liquid level 20A. If there is any possibility that a lugh liquid flow rate from vortex tube 24 can cause entrained gas to flow out the lower end 46, of vortex tube 24, if allowed to radiate outwardly, can propel gas-laden liquid toward the liquid outlet, resulting in a carryunder of gas from the separator vessel. To prevent this, a tube-on-tube arrangement is exceedingly useful, such as showii in Figures 11 through 13. This system requires a short length exterior tubular member 62 that has an internal wal164 of a diameter greater tha.n the external diameter of vortex tube 24 providing an annular area 66 therebetween. The lower etld of tubular member 62 is closed witll a bottom plate 68 so that all fluids exiting the lower end of the vortex tube pass upwardly through the annular area 66 and are dispersed around the exterior of vortex tube 24. In Figure 11, the top end 70 of tubular mcmbers 62 is below the intermediate liquid level 20A. Trz the embodiment in Figure 12, the top end 70 is above liquid level 20 so that fluid flows out on top of the level of liquid and is spread over the liquid contained in the bottom of the vessel. It can be secn that the length of tubular member 62 could be varied according to design requirements and, as aii example, could be of an intermediate length between that shown in Figures 11 and 12 so that the top end 70 is above the intermediate liquid level 20A but below the top liquid level 20.

Figure 13 shows an alternate arrangement wherein there is provided, in addition to the tube-on-tube method a horizontal distributor plate 72 that is positioned above the top end 70 of tubular member 62. This planar horizontal distributor plate 72 extends radially around vortex tube 24 for a full 360 in the practice of the invention. Instead of the circumferential distributor plate being horizontal as shown in element 62, the circumferential distributor plate can be arcuate as shown in the right side of vortex tube of Figure 13, the arcuate circumferential distributor plate being indicated by the numeral 74. Whether a horizontal circumferential distributor plate or an arcuate circumferential distributor plate 74, any disturbance of the oil/water interface caused by liquid exiting the lower end of the vortex tube 24 is more localized around the tube. If the liquid release of the tube-on-tube system is near the liquid interface surface, the deflector ring either 70 or 72 deflects the upper momentum of the flowing liquid into a horizontal direction. This reduces the surface disturbance either the surface 20A or the top liquid surface 20 to thereby reduce phase re-entrainment. The benefit of the system of Figure 13 is a reduction in cross-contamination between liquid phases leaving the separator.

Figure 14 shows a cluster of vortex tubes as seen in Figure 1 with the installation of a liquid energy absorber 76 which also may be referred to as a liquid energy diffuser. The energy absorber or diffuser is generally indicated by the numeral 76 and is in the form of a container having a top 78 and four sidewalls 80, only two of which are seen in Figure 14 and a bottom 82. The sidewalls are perforated at 84. If desired the top 78 and/or bottom 82 could, in like manner, be perforated. Liquid energy absorber 76 reduces 19a turbulent spots in the liquid collected in the bottom of the separator by diffusing the exits from the vortex tube and reduces charuieling of fluid flow by improved fluid distribution.
While in Figure 14, the liquid energy absorber is shown as a box enclosure that is, in a horizontal plane rectangular, the enclosure could be circular, spherical or any other shape the only requirement being that the liquid energy absorber provide a closed area encompassing the lower ends of each vortex tube making up a cluster of vortex tubes to diffuse and break up fluid channel flow paths that might otherwise be created within the fluid collected in the bottom of a separator vessel.

Figure 15 shows an alterna,.e embodiment of a vortex tube separator system in which there is positioned within the vortex tube one or more free-fall pxeventers, the free-fall preventers being generally indicated by the numeral 86. Figure 16 is an isometric view of a free-fall prevenLter that is preferably formed of a short length center tube 88 with an open tubular passageway 90 therethrough. Radially extending around the external circumference of center tube 88 are a plurality of vanes 92. These vanes extend out to contact the internal cylindrical wall of vortex tube 24.

In vertical separators or in large diameter horizontal separators, the vertical height of vortex tube 24 can be sig7uficant. When this occurs, liquid separated within the tubes must fall a long distance dowii the tube wall. As the liquid plunges, gravity accelerates this velocity such that when it finally impinges on the standing liquid that would be approximately at the lieight of liquid level 20, its high monzenttun tends to re-entrain gas into the liquid phase. Concurrentlyõ in such tall vortex tubes wall friction slows down the rotational liquid velocity causing a loss of centrifugal separation as the liquid probresses do,ATn the tube. Thus, at the bottom of the tube the liquid velocity direction is nearly vertically downward. To alleviate this probleni the free-fall preventers 86 can be employed. The benefit of the use of free-fall preventers 86 is that gas re-entrainment and foaming are greatly miniunized or eliminated and a higher average centrifugal force is maintained in the liquids swirling within the vortex tube. Note that swirling gas that has not yet migrated to the center of the tube passes downwardly through the vanes and as it passes downwardly, additional swirling action is i.mparted. Gas that migrates toward the center of the vortex passes freely upwardly through the open passageway 90 in center tube 88 of each of the free=fall preventers and thus the gas can flow outwardly through the concentric gas outlet opening 32 and the top of each of the vortex tubes.

Figure 15 shows use of two spaced apart free-fall preventers but only one may' have been employed or more tliaii two may be employed according to the length of the vortex tube 24.

The improved separator system of this invention can be practiced employing various combinations of the improved vortex tube features as has been described herein according to design perameters dictated by the particular entrained liquid verses volume of gas in the wet gas stream, by the nature of the entrainment - that is, whether in relatively small or relatively large droplets, the nature of the liquid whether heavy such as water or relatively light such hydrocarbon condensate, and many other parameters.

The claims aud the specification describe the invention presented and the ternis that are employed in the claims draw their meauing from the use of such terms in the specification. The swne ter.tns employed in the prior art may be broader in 3neaning than specifically enlployed herein. Whenever there is a question between the broacler defirLition of such tcrms used in the prior art and the inore speciCc use of the terms herein, the more specific meaning is meant.

While the invention has been described with a ceiiain degree ofparticularity, it is manifest that many changes may be made in the details of construction and the arrangement of coniponents without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth.

herein for purposes of exeniplification, but is to be limited oiily by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.

Claims (4)

1. A system for separating an entrained immiscible liquid component from a wet gas stream comprising:

a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet;

at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end and a wet gas tangential inlet in and tangential to said internal wall surface, the tangential inlet being spaced from said first end and arranged so that wet gas entering said tangential inlet rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action;

an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein;

a vortex finder tube in communication with said orifice plate gas outlet opening and extending concentrically within said vortex tube in the direction towards said vortex tube outlet end, the vortex finder tube being of external diameter less than the internal diameter of said vortex tube internal wall providing an annular space therebetween; and a fluid deflector positioned within said annular space, the deflector having a downwardly spiraled surface that diverts wet gas flowing through said tangential inlet downwardly in the direction towards said vortex tube outlet end.

2. A system for separating an entrained immiscible liquid component from a wet gas stream comprising:

a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet;

at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end and a wet gas tangential inlet in and tangential to said internal wall surface, the tangential wet gas inlet being spaced from said first end and arranged so that wet gas entering therein rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action;

an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein; and a curved outlet pipe affixed to said orifice plate exterior of said vortex tube and in communication with said vortex tube central opening and configured to divert gas passing out of said orifice plate gas outlet opening in a direction having a downward tangent.

3. A system for separating an entrained immiscible liquid component from a wet gas stream comprising:

a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet;

at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end, and a wet gas tangential inlet in and tangential to said internal wall surface, the tangential wet gas inlet being spaced from said first end and arranged so that wet gas entering therein rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action;

an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein; and a liquid discharge deflector tube secured in relationship to an external portion of said vortex tube and encompassing said vortex tube outlet end, the deflector tube being of internal diameter greater than the external diameter of said vortex tube at said outlet end providing an external annular area, the deflector tube having a bottom end; and an end plate at least substantially closing said bottom end of said deflector tube to thereby deflect liquid flowing out of said vortex tube outlet end into an upward direction through said external annular area.

4. A system for separating an entrained immiscible liquid component from a wet gas stream comprising:

a vessel having an interior in communication with a wet gas inlet, a gas outlet and a liquid outlet;

at least one vortex tube supported within said vessel interior, the vortex tube having an internal wall surface, a first end, an outlet end and a wet gas tangential inlet in and tangential to said sidewall, the tangential wet gas inlet being spaced from said first end and arranged so that wet gas entering therein rotates within said vortex tube to cause at least some of the liquid components to be forced against said internal wall surface by centrifugal action;

an orifice plate closing said vortex tube first end and having a concentric gas outlet opening therein; and an energy absorbing housing providing a quiescent inducing cavity surrounding said outlet end of said vortex tube, liquid flowing out said outlet end of said vortex tube flowing into said quiescent inducing cavity provided by said energy absorbing housing, said energy absorbing housing having cavity walls defining said quiescent inducing cavity, said cavity walls having small diameter openings therethrough which liquid passes into the interior of said vessel.