CN109847490B - Rigid gas-liquid coalescent filter element, preparation method and device thereof - Google Patents

Abstract

The invention provides a rigid gas-liquid coalescence filter element, a preparation method and a device thereof, wherein the filter element comprises: a coalescing layer surrounding the outside of the central inlet channel for coalescing and separating droplets in the gas flowing in through the inlet channel; the liquid draining layer surrounds the outer side of the aggregation layer and is used for providing a liquid draining channel for the coalesced liquid drops; the gas-liquid coalescent filter element comprises a first flexible material, a second flexible material, a liquid drainage layer, a first adhesive-containing flexible material, a second adhesive-containing flexible material, a first adhesive-containing flexible material and a second adhesive-containing flexible material, wherein the first flexible material and the second flexible material are formed by drying and solidifying the first adhesive-containing flexible material, and the adhesive solution is obtained by passing through the first flexible material and the second flexible material through vacuum suction.

Description

A rigid gas-liquid coalescing filter element, preparation method and device thereof

Technical Field

The invention relates to the technical field of gas-liquid filtration, and in particular to a rigid gas-liquid coalescing filter element, and a preparation method and device thereof.

Background technique

Natural gas, coalbed methane and other process gases and dry gas sealing gases usually contain liquid impurities, which will affect the safe operation of downstream related instruments and equipment. Therefore, it is necessary to filter the droplets in the gas. The filtration is usually carried out under high pressure conditions (for example, natural gas needs to be pressurized at a compressor station before transportation, and the pressure in the West-East Gas Transmission Line 3 is 12MPa). For droplets with a particle size of 0.1 to 1μm, a coalescing filter is generally used for filtration. The coalescing filter is usually used downstream of a blade separator, a mist collector and a filter separator. The large droplets in the gas are removed by the blade separator, the mist collector and the filter separator, and the small droplets are removed by the coalescing filter.

The existing coalescing filter is composed of an inner skeleton and a fiber filter layer. The inner skeleton is usually formed by processing metal materials and is a porous tubular structure, which can provide support for the fiber filter layer. The fiber filter layer includes a coalescing layer and a drainage layer. The coalescing layer and the drainage layer can filter the droplets, and both are in the form of multi-layer winding. The current coalescing layer is usually made of glass fiber material, and the drainage layer is usually made of needle-punched felt material. The coalescing layer has a coalescing effect on small droplets in the incoming gas. After the small droplets collide with the fibers, they gradually coalesce into large droplets under the action of inertia, diffusion and interception effects. The function of the drainage layer is to provide a drainage channel for the liquid, so that the coalesced liquid can be smoothly discharged from the filter element under the action of gravity, reducing the occurrence of secondary entrainment.

At present, the commonly used coalescing filters are all made of flexible materials. Flexible materials have no compressive strength and will be compressed and deformed under high pressure. The internal structure of the filter material will be severely deformed, resulting in changes in the pore structure, affecting the coalescence and drainage process, resulting in unsatisfactory filtration effect. In addition, under high pressure conditions, the gas density increases significantly, and the buoyancy of the droplets increases accordingly, resulting in a relatively slow discharge rate of the liquid in the drainage layer. Liquid accumulation will form in the drainage layer. The amount of liquid accumulation increases, the gas flow area decreases, and the gas velocity flowing through the drainage layer will increase, resulting in an increase in the scouring effect of the gas on the liquid in the drainage layer. When the amount of liquid accumulation reaches a certain level, that is, the saturated liquid accumulation, it will cause serious secondary entrainment. In addition, the material of the inner skeleton is usually metal. If the gas and droplets contain corrosive components, it is easy to cause the skeleton to be damaged, thereby causing the filter to fail.

Summary of the invention

One object of the present invention is to provide a rigid gas-liquid coalescing filter element to improve the strength of the gas-liquid coalescing filter element to meet the requirements of high-pressure working conditions. Another object of the present invention is to provide a method for preparing a rigid gas-liquid coalescing filter element. Another object of the present invention is to provide a device for preparing a rigid gas-liquid coalescing filter element.

In order to achieve the above objectives, the present invention discloses a rigid gas-liquid coalescing filter element, comprising:

a coalescing layer, surrounding the outer side of the central air inlet passage, for coalescing and separating liquid droplets in the gas flowing in through the air inlet passage; and

A drainage layer, surrounding the outer side of the coalescence layer, for providing a drainage channel for the coalesced droplets;

The coalescence layer is formed by drying and consolidating a first flexible material containing a binder, and the drainage layer is formed by drying and consolidating a second flexible material containing a binder, wherein the first flexible material containing a binder and the second flexible material containing a binder are obtained by passing a binder solution through the first flexible material and the second flexible material by vacuum suction.

Preferably, the filter element further comprises a pre-separation layer arranged on a side of the coalescing layer close to the air inlet passage.

Preferably, the pre-separation layer is formed by drying and consolidating a third flexible material containing a binder, and the third flexible material containing a binder is obtained by passing a binder solution through the third flexible material through vacuum suction.

Preferably, the pre-separation layer is in a multi-layer winding form or a folded and wrapped form.

Preferably, the third flexible material is ceramic fiber or non-woven fabric.

Preferably, the coalescing layer and/or the drainage layer is in a multi-layer winding form or a folded and wrapped form.

Preferably, the material of the coalescing layer is glass fiber, polyester fiber or polypropylene fiber.

Preferably, the material of the liquid drainage layer is needle-punched felt.

Preferably, the binder is one or more of silica sol, water glass, aluminum sol, polyvinyl alcohol or polyethylene glycol.

Another aspect of the present invention discloses a method for preparing a rigid gas-liquid coalescing filter element, comprising:

The first flexible material and the second flexible material are sequentially fixed around the porous mold;

Connecting one end of the porous mold opening to a liquid storage tank;

Connecting the liquid storage tank to a vacuum pump;

placing the porous mold in a binder solution so that at least a portion of the first flexible material and the second flexible material on the porous mold are immersed in the binder solution;

Starting the vacuum pump to suck so that the binder solution passes through the second flexible material and the first flexible material in sequence and enters the liquid storage tank through the through holes on the porous mold to obtain the first flexible material containing the binder and the second flexible material containing the binder;

removing the porous mold from the binder solution and continuing to draw suction through the vacuum pump;

The first flexible material containing a binder and the second flexible material containing a binder on the porous mold are dried and solidified, and the dried and solidified first flexible material and second flexible material are removed from the porous mold to obtain the rigid gas-liquid coalescing filter element.

Preferably, the method further comprises fixing a third flexible material around the porous mold before fixing the first flexible material and the second flexible material around the porous mold in sequence.

Preferably, placing the porous mold in a binder solution so that at least part of the first flexible material and the second flexible material on the porous mold are immersed in the binder solution specifically comprises:

When the porous mold is placed in a binder solution so that parts of the first and second flexible materials are immersed in the binder solution, the porous mold is rotated so that parts of the flexible materials not immersed in the binder solution are immersed in the binder solution in sequence.

The present invention also discloses a preparation device for a rigid gas-liquid coalescing filter element, comprising:

A solution tank, used for containing a binder solution;

a porous mold for supporting a flexible material for forming the filter element;

A liquid storage tank connected to the porous mold through a pipeline;

A vacuum pump is connected to the liquid storage tank through a pipeline.

Preferably, the device further comprises a rotating device;

The rotating device is used to rotate the porous mold.

The present invention provides a rigid gas-liquid coalescing filter element. The coalescing layer and the drainage layer in the coalescing filter element of the present invention are dried and consolidated by a first flexible material and a second flexible material containing a binder to form a rigid gas-liquid coalescing filter element. A small amount of binder is attached to the flexible material forming the coalescing layer and the drainage layer by allowing a binder solution to pass through through vacuum suction, and the binder remains at the contact points between the fibers. After the binder is dried and consolidated, the fibers are consolidated together, thereby improving the rigidity of the flexible material, making the coalescing layer and the drainage layer have a certain compression strength, and maintaining the original pore structure of the flexible material, so that the rigid gas-liquid coalescing filter element can work normally under high-pressure conditions. In addition, the rigid gas-liquid coalescing filter element of the present invention itself is a rigid structure, so it can be self-supporting, and there is no need to set up an internal skeleton to provide support, which can reduce costs.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

FIG1 shows a front cross-sectional view of a specific embodiment of a rigid gas-liquid coalescing filter element of the present invention;

FIG2 is a top cross-sectional view showing a specific embodiment of a rigid gas-liquid coalescing filter element of the present invention;

FIG3 shows an enlarged view of the area A in FIG2 ;

FIG4 is a schematic diagram showing fibers in a flexible material in a rigid gas-liquid coalescing filter element of the present invention after consolidation;

FIG5 is a magnified view of the solidified fibers in the flexible material of a rigid gas-liquid coalescing filter element of the present invention;

FIG6 shows one of the flow charts of a specific embodiment of a method for preparing a rigid gas-liquid coalescing filter element of the present invention;

FIG. 7 shows a second flow chart of a specific embodiment of a method for preparing a rigid gas-liquid coalescing filter element according to the present invention;

FIG8 is a schematic diagram showing a device for preparing a rigid gas-liquid coalescing filter element according to the present invention.

Detailed ways

The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

According to one aspect of the present invention, this embodiment discloses a rigid gas-liquid coalescing filter element. As shown in Figures 1 to 3, in this embodiment, the rigid gas-liquid coalescing filter element includes a coalescing layer 20 and a drainage layer 30. The coalescing layer 20 surrounds the outside of the central air inlet channel and is used to coalesce and separate liquid droplets in the gas flowing through the air inlet channel, and the drainage layer 30 surrounds the outside of the coalescing layer 20 and is used to provide a drainage channel for the liquid droplets formed by coalescence after the gas passes through the coalescing layer 20.

The coalescing layer 20 is formed by drying and consolidating a first flexible material containing a binder, and the drainage layer 30 is formed by drying and consolidating a second flexible material containing a binder, wherein the first flexible material containing a binder and the second flexible material containing a binder are obtained by passing a binder solution 1 through the first flexible material and the second flexible material by vacuum suction.

The present invention provides a rigid gas-liquid coalescing filter element. The coalescing layer 20 and the drainage layer 30 in the coalescing filter element of the present invention are dried and consolidated by a first flexible material and a second flexible material containing a binder to form a rigid gas-liquid coalescing filter element. The flexible material forming the coalescing layer 20 and the drainage layer 30 is subjected to vacuum suction to allow a binder solution 1 to pass through and a small amount of binder is attached, and the binder is retained at the contact point 50 between the fibers 40 and the fibers 40. After the binder is dried and consolidated, the fibers 40 and the fibers 40 are consolidated together, as shown in Figures 4 and 5. By attaching and consolidating the binder at the contact point 50 between the fibers 40 and the fibers 40, the rigidity of the flexible material can be improved, so that the coalescing layer 20 and the drainage layer 30 have a certain compressive strength, and at the same time, the pore structure of the original flexible material can be maintained, so that the rigid gas-liquid coalescing filter element can work normally under high-pressure conditions. In addition, the coalescing layer 20 and the drainage layer 30 of the rigid gas-liquid coalescing filter element of the present invention have a certain rigidity, can be self-supporting, and no internal skeleton is required to provide support, which can reduce costs.

In a preferred embodiment, the filter element further includes a pre-separation layer 10 disposed on the side of the coalescence layer 20 close to the air inlet channel. During the gas-liquid coalescence process, the droplets already captured by the filter element re-enter the downstream airflow due to the flushing effect of the airflow to form a secondary entrainment phenomenon, thereby causing an increase in the concentration of droplets in the downstream airflow, resulting in a decrease in filtration efficiency. This phenomenon is very easy to occur in micron-sized droplets. By providing the pre-separation layer 10, large droplets in the airflow of the air inlet channel can be initially separated, and the amount of liquid accumulated in the coalescence layer 20 and the drainage layer 30 can be reduced, thereby reducing the secondary entrainment phenomenon of the filter element.

In a preferred embodiment, the pre-separation layer 10 is formed by drying and consolidating a third flexible material containing a binder, and the third flexible material containing a binder is obtained by passing a binder solution 1 through the third flexible material by vacuum suction. The binder solution 1 is vacuum suctioned to pass through the third flexible material, and then dried and consolidated to form the pre-separation layer 10, so that the pre-separation layer 10 has a certain rigidity. The pre-separation layer 10 can provide a certain support for the coalescence layer 20 and the drainage layer 30, thereby replacing the internal skeleton in the existing filter element, and can effectively prevent the filter element from being damaged by liquid corrosion.

In a preferred embodiment, the coalescing layer 20 surrounds the air inlet channel, and the drainage layer 30 surrounds the outside of the coalescing layer 20. There are two types of surrounding forms, namely, a multi-layer winding form and a folded surrounding form. The coalescing layer 20 and the drainage layer 30 can adopt any one of the two surrounding forms, namely, the multi-layer winding form and the folded surrounding form. That is, the coalescing layer 20 in the form of multi-layer winding can be formed by winding the first flexible material around the air inlet channel, or the coalescing layer 20 in the form of folded surrounding can be formed by folding the first flexible material first, and then the folded first flexible material is wrapped around the coalescing layer 20, as shown in Figure 3. Similarly, the drainage layer 30 and the pre-separation layer 10 can adopt a multi-layer winding form or a folded surrounding form. The setting form can be selected according to actual conditions, and the present invention does not limit this.

In a preferred embodiment, the first flexible material can be glass fiber 40, polyester fiber 40 or polypropylene fiber 40. The thickness of the first flexible material is preferably between 0.3 and 1 mm, and the average pore size is preferably between 1 and 20 μm.

The second flexible material may be needle felt, such as aramid needle felt, polyester needle felt or polypropylene needle felt, etc. The thickness of the first flexible material is preferably 1-3 mm, and the average pore size is preferably 20-100 μm.

The third flexible material may be ceramic fiber 40 or non-woven fabric. The thickness of the third flexible material is preferably 0.5-3 mm, and the average pore size is preferably 20-150 μm.

The pore sizes of the flexible materials of the pre-separation layer 10, the coalescence layer 20 and the drainage layer 30 are different, among which the pores of the coalescence layer 20 are relatively small, and the pores of the pre-separation layer 10 and the drainage layer 30 are relatively large. The pre-separation layer 10 plays a pre-separation role, and the larger pores of the pre-separation layer 10 can separate larger droplets in the gas; the pores of the coalescence layer 20 are relatively small, and the small droplets in the gas are coalesced into large droplets when penetrating under the obstruction of the smaller pores; the drainage layer 30 has a relatively large pore size, and the addition of the drainage layer 30 is conducive to the smooth drainage of the coalesced large droplets under the action of gravity without increasing the pressure drop of the filter element.

In a preferred embodiment, the binder can be selected from one or more of silica sol, water glass, aluminum sol, polyvinyl alcohol or polyethylene glycol and other similar binders. The selected binder curing methods are all drying and dehydration curing, the drying temperature can be selected from 80 to 150°C, and the drying time can be selected from 5 to 12 hours. Preferably, the drying method can be selected from microwave drying, which can shorten the drying time to 10 to 20 minutes, and can also inhibit the migration of the bonding solution to the surface of the filter element under the action of heat and capillary action before solidification during the ordinary drying process, causing the problem of uneven distribution of the binder. Of course, in practical applications, other binders that can improve the rigidity of flexible materials can also be used and the corresponding drying temperature and time can be selected, and the present invention is not limited to this.

It should be noted that, in this embodiment, the materials, thicknesses and pore sizes of the first flexible material, the second flexible material and the third flexible material are only given as examples. In practical applications, other flexible materials and thicknesses and pore sizes of the flexible materials may also be selected according to actual conditions, and the present invention is not limited to this.

According to another aspect of the present invention, this embodiment further discloses a method for preparing a rigid gas-liquid coalescing filter element. As shown in FIG6 , in this embodiment, the method comprises:

S100: The first flexible material and the second flexible material are sequentially wound and fixed on the porous mold 2. For example, when the coalescing layer 20 is in a multi-layer winding form, the first flexible material can be wound and fixed on the porous mold 2 layer by layer, preferably 4 to 8 layers.

When the drainage layer 30 is in a folded and wrapped form, the second flexible material can be folded first, and then the folded second flexible material is wrapped and fixed on the outer side of the coalescing layer 20 .

Preferably, the first flexible material and the second flexible material can be fixed to the outside of the porous mold 2 by gluing. More preferably, a point-jointed gluing method can be used, that is, glue is applied once at a preset distance to fix them by gluing. For example, the first flexible material can be fixed to the porous mold 2 by gluing, and a small amount of glue can be applied to the inside of the flexible material with a glue gun every 1 to 10 cm, and then pressed firmly to fix it. Then the folded length of the second flexible material can be folded every 5 to 30 mm, and can be folded 120 to 360 times a week. After being wrapped around the outside of the drainage layer 30, the head and tail of the second flexible material are glued together by gluing.

S200: Connect the open end of the porous mold 2 to the liquid storage tank 3. The porous mold 2 used includes an open end and a closed end, and the open end can be used to connect the liquid storage tank 3. A plurality of through holes are formed on the porous mold 2, and the through hole diameter is preferably 2 to 5 mm, and the through hole spacing is 10 to 50 mm. In a preferred embodiment, before the flexible material is wrapped and fixed on the porous mold 2, glycerin or other similar lubricating substances can be applied to the porous mold 2 to facilitate the smooth removal of the filter element from the porous mold 2 after drying.

S300: Connect the liquid storage tank 3 to the vacuum pump 4. The vacuum pump 4 can draw a vacuum to allow the binder solution 1 to pass through the flexible material.

S400: placing the porous mold 2 in a binder solution 1, so that at least part of the first flexible material and the second flexible material on the porous mold 2 are immersed in the binder solution 1. The binder can be one or more of silica sol, water glass, aluminum sol, polyvinyl alcohol or polyethylene glycol and the like. The binder solution 1 can be formed by mixing the binder with water in proportion.

S500: Start the vacuum pump 4 to suck so that the binder solution 1 passes through the second flexible material and the first flexible material in sequence and enters the liquid storage tank 3 through the through holes on the porous mold 2 to obtain the first flexible material containing the binder and the second flexible material containing the binder. During the suction process using the vacuum pump 4, the gas velocity of the gas flowing through the filter element can be controlled by using a mass flow controller, and the preferred gas velocity is controlled at 1 to 30 m/min.

S600: Take out the porous mold 2 from the binder solution 1 and continue to suck through the vacuum pump 4. The porous mold 2 is taken out from the binder solution 1. At this time, the flexible material contains a large amount of binder. Continuing to extract through the vacuum pump 4 can take away a large amount of binder, leaving only a small amount of binder at the contact point 50 between the fibers 40 and 40. The amount of binder remaining at the contact point 50 can be controlled by controlling the air velocity and the final suction time, so as to adjust the strength and pore size change of the filter element after curing. Preferably, the flexible material can be taken out after being rotated 5 to 30 times in the binder solution 1, and continue to be sucked for 5 to 60 seconds. The pore size of the filter element can be controlled by changing parameters such as the concentration of the binder solution 1, the suction air velocity, and the number of suctions.

S700: Dry and consolidate the first flexible material containing a binder and the second flexible material containing a binder on the porous mold and remove the dried and consolidated first flexible material and the second flexible material from the porous mold to obtain the rigid gas-liquid coalescing filter element. In a preferred embodiment, after drying, if you want to continue to improve the strength of the molded filter element and reduce the pore size of each layer of filter material, you can repeat steps S500-S700 until the rigidity requirements of the filter element are met.

In a preferred embodiment, as shown in FIG. 7 , the method further comprises, before the first flexible material and the second flexible material are sequentially fixed around the porous mold 2:

S000: The third flexible material is fixed around the porous mold 2. At this time, the first flexible material can be fixed to the porous mold 2 by being fixed on the third flexible material.

When the pre-separation layer 10 is provided in a multi-layer winding form, the third flexible material can be wound on the porous mold 2 in multiple layers. The third flexible material can be fixed on the porous mold 2 by gluing, and the gluing method can preferably be point-joined, that is, a small amount of glue is applied to the inner side of the end of the flexible material with a glue gun at a preset interval, and then pressed tightly to fix. The preset interval is preferably in the range of 1 to 10 cm.

Preferably, the first flexible material of the coalescing layer 20 can be seamlessly joined with the third flexible material of the pre-separation layer 10 .

In a preferred embodiment, in S400, when the porous mold 2 is placed in the binder solution 1 so that parts of the first flexible material and the second flexible material are immersed in the binder solution 1, the porous mold 2 is rotated so that parts of the flexible materials not immersed in the binder solution 1 are immersed in the binder solution 1 in sequence.

When the flexible material on the porous mold 2 is partially immersed in the binder solution 1, the porous mold 2 can be rotated to rotate the flexible material on the porous mold 2 and allow different parts of the flexible material to be immersed in the binder solution 1 in sequence, so that each part of the flexible material can retain the binder.

According to another aspect of the present invention, this embodiment further discloses a preparation device for a rigid gas-liquid coalescing filter element. As shown in FIG8 , in this embodiment, the preparation device comprises a solution tank, a porous mold 2 , a liquid storage tank 3 and a vacuum pump 4 .

Wherein, the solution pool is used to contain the binder solution 1.

The porous mold 2 is used to support the flexible material used to form the filter element.

The liquid storage tank 3 is connected to the porous mold 2 through a pipeline.

The vacuum pump 4 is connected to the liquid storage tank 3 through a pipeline.

In a preferred embodiment, the device further comprises a rotating device. The rotating device is used to rotate the porous mold 2. When the flexible material on the porous mold 2 is partially immersed in the binder solution 1, the porous mold 2 can be rotated by the rotating device, so that the flexible material on the porous mold 2 can be rotated and different parts of the flexible material are immersed in the binder solution 1 in sequence, so that each part of the flexible material can retain the binder. The arrow corresponding to the porous mold 2 in FIG8 is the rotation direction of the porous mold 2, and the other arrows are the flow direction of the binder solution.

The present invention is further described below by a specific example. In the specific example, the filter material of the pre-separation layer 10 is ceramic fiber 40, the filter material thickness is 1 mm, and the average pore size is 25 μm; the filter material of the coalescing layer 20 is glass fiber 40, the filter material thickness is 0.5 mm, and the average pore size is 3.7 μm; the filter material of the drainage layer 30 is needle felt, the filter material thickness is 3 mm, and the average pore size is 30 μm. The aperture of the openings on the porous mold 2 used is 3 mm, and the aperture spacing is 25 mm.

First, evenly apply a small amount of glycerin on the surface of the porous mold 2. Then, wrap the pre-separation layer 10 filter material on the porous mold 2 in 2 layers, and fix the end by gluing. The gluing method is point connection, that is, apply a small amount of glue on the inner side of the end of the filter material with a glue gun every 3 cm, and then press it tightly to fix it. The head end of the coalescence layer 20 filter material is seamlessly connected to the end of the pre-separation layer 10, wrapped in 4 layers, and fixed by gluing at the end. The gluing method is point connection, that is, apply a small amount of glue on the inner side of the end of the filter material with a glue gun every 3 cm, and then press it tightly to fix it.

The drainage layer 30 is folded with a fold length of 15 mm and 240 folds, and is tightly wrapped around the coalescing layer 20 . The first section and the end section of the drainage layer 30 are bonded by gluing.

The whole structure was half immersed in the binder solution 1, the binder was water glass, and all filter materials were wetted by vacuum suction at a suction speed of 5 m/min. After rotating 20 times, it was taken out and suction was continued for 10 seconds.

The porous mold 2 and the filter element thereon are placed in a drying oven for drying at a temperature of 100°C for 10 hours. The dried and solidified first flexible material, second flexible material and third flexible material are removed from the porous mold to obtain a rigid gas-liquid coalescing filter element.

The rigid gas-liquid coalescing filter element prepared in this specific example has a compressive strength of 8.5 MPa. At a filtration gas velocity of 0.1 m/s at room temperature, the pressure drop is 0.96 kpa. Under a pressure of 5 MPa, the filter element does not undergo obvious deformation. The outlet droplet concentration is tested and is basically consistent with that under normal pressure, so there is basically no secondary entrainment caused by high pressure.

The present invention uses vacuum suction to adsorb a small amount of adhesive on the contact points 50 between the fibers 40 and the fibers 40 of the flexible material of the filter element, thereby fixing the fibers 40 and making the entire filter element rigid without substantially affecting the original pore structure of the filter element, thereby preventing deformation under high pressure and causing a decrease in filtering performance. It can also achieve self-support without the need for a metal inner or outer skeleton, thereby reducing the weight of the filter element and thus reducing the force on the tube sheet on which the filter element is loaded. In addition, the manufacturing cost of the rigid gas-liquid coalescing filter element is lower than that of a traditional filter element.

The drainage layer 30 is in a folded form, which can greatly increase the filtration area of the filter element. On the one hand, the increase in the filtration area relatively increases the saturated liquid accumulation in the drainage layer 30, allowing the liquid to have enough time to drain downward before the drainage layer 30 reaches the saturated liquid accumulation, which can effectively alleviate the serious secondary entrainment phenomenon caused by the slow drainage speed under high pressure. On the other hand, the filtration area increases and the apparent gas velocity decreases relatively, thereby reducing the scouring effect of the airflow on the large droplets in the drainage layer 30, and can also inhibit the occurrence of secondary entrainment. Each layer of the filter element of the present invention has a certain strength, so there is no need to set a metal inner skeleton to provide support, which effectively prevents the damage of the filter element due to corrosion. At the same time, the pre-separation layer can perform preliminary separation of large droplets in the gas, which can reduce the amount of liquid accumulation in the coalescence layer and the drainage layer, thereby reducing the secondary entrainment phenomenon.

Each embodiment in this specification is described in a progressive manner, and the same or similar parts between the embodiments can be referred to each other, and each embodiment focuses on the differences from other embodiments. In particular, for the system embodiment, since it is basically similar to the method embodiment, the description is relatively simple, and the relevant parts can be referred to the partial description of the method embodiment.

The above is only an embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various changes and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the scope of the claims of the present application.

Claims (12)

1. A method for preparing a rigid gas-liquid coalescing filter element, characterized by comprising: The first flexible material and the second flexible material are sequentially fixed around the porous mold, wherein the first flexible material is wound around the air inlet channel to form a multi-layer winding coalescing layer, or the first flexible material is folded and then the folded first flexible material is wound around the coalescing layer to form a folded and wrapped coalescing layer; Connecting one end of the porous mold opening to a liquid storage tank; Connecting the liquid storage tank to a vacuum pump; placing the porous mold in a binder solution so that at least a portion of the first flexible material and the second flexible material on the porous mold are immersed in the binder solution; Starting the vacuum pump to suck so that the binder solution passes through the second flexible material and the first flexible material in sequence and enters the liquid storage tank through the through holes on the porous mold to obtain the first flexible material containing the binder and the second flexible material containing the binder; removing the porous mold from the binder solution and continuing to draw suction through the vacuum pump; The first flexible material containing a binder and the second flexible material containing a binder on the porous mold are dried and solidified, and the dried and solidified first flexible material and second flexible material are removed from the porous mold to obtain the rigid gas-liquid coalescing filter element. 2. The preparation method according to claim 1, characterized in that the method further comprises surrounding and fixing a third flexible material on the porous mold before surrounding and fixing the first flexible material and the second flexible material in sequence on the porous mold. 3. The preparation method according to claim 1, characterized in that the step of placing the porous mold in a binder solution so that at least part of the first flexible material and the second flexible material on the porous mold are immersed in the binder solution specifically comprises: When the porous mold is placed in a binder solution so that parts of the first and second flexible materials are immersed in the binder solution, the porous mold is rotated so that parts of the flexible materials not immersed in the binder solution are immersed in the binder solution in sequence. 4. A rigid gas-liquid coalescing filter element manufactured by the method according to any one of claims 1 to 3, characterized in that it comprises: a coalescing layer, surrounding the outer side of the central air inlet passage, for coalescing and separating liquid droplets in the gas flowing in through the air inlet passage; and A drainage layer, surrounding the outer side of the coalescence layer, for providing a drainage channel for the coalesced droplets; The coalescing layer is formed by drying and consolidating a first flexible material containing a binder, and the drainage layer is formed by drying and consolidating a second flexible material containing a binder, wherein the first flexible material containing a binder and the second flexible material containing a binder are obtained by passing a binder solution through the first flexible material and the second flexible material by vacuum suction; The thickness of the first flexible material is 0.3 mm to 1 mm, and the average pore size is 1 μm to 20 μm; the thickness of the second flexible material is 0.5 mm to 3 mm, and the average pore size is 20 μm to 100 μm. 5 . The rigid gas-liquid coalescing filter element according to claim 4 , characterized in that the filter element further comprises a pre-separation layer arranged on a side of the coalescing layer close to the air inlet channel. 6. The rigid gas-liquid coalescing filter element according to claim 5 is characterized in that the pre-separation layer is formed by drying and consolidating a third flexible material containing a binder, and the third flexible material containing a binder is obtained by allowing a binder solution to pass through the third flexible material through vacuum suction. 7. The rigid gas-liquid coalescing filter element according to claim 5 or 6, characterized in that the pre-separation layer is in a multi-layer winding form or a folded and wrapped form. 8. The rigid gas-liquid coalescing filter element according to claim 6, characterized in that the third flexible material is ceramic fiber or non-woven fabric. 9 . The rigid gas-liquid coalescing filter element according to claim 4 , wherein the coalescing layer and/or the drainage layer is in a multi-layer winding form or a folded and wrapped form. 10 . The rigid gas-liquid coalescing filter element according to claim 4 or 9 , wherein the coalescing layer is made of glass fiber, polyester fiber or polypropylene fiber. 11. The rigid gas-liquid coalescing filter element according to claim 4 or 9, characterized in that the material of the drainage layer is needle-punched felt. 12 . The rigid gas-liquid coalescing filter element according to claim 4 , wherein the binder is one or more of silica sol, water glass, aluminum sol, polyvinyl alcohol or polyethylene glycol.