Multi-stage vessel and separator/coalescer filter element

• US 6,168,647 B1
• Filed: 01/26/1999
• Issued: 01/02/2001
• Est. Priority Date: 01/26/1999
• Status: Expired due to Term

• Current Assignee: PECOFacet (US), Inc.
• Original Assignee: Perry Equipment Corp. (Parker-Hannifin Corporation)
• Inventors: Burns, David J., von Phul, Stephen A., Krogue, John A., Perry, Marney Dunman Jr.
• Primary Examiner(s): Simmons, David A.
• Assistant Examiner(s): PHAM, MINH CHAU THI
• Application Number:
  US09/237,446
• Time in Patent Office: 707 Days
• Field of Search: 95/19, 95/24, 952/68, 952/86, 964/09, 964/14, 964/21, 553/19, 553/18, 553/21, 553/24, 554/23, 554/84, 555/02
• US Class Current: 95/19
• CPC Class Codes: B01D 2271/027 Radial sealings
• CPC Class Codes: B01D 45/02 by utilising gravity
• CPC Class Codes: B01D 46/2414 End caps including additional functions or special forms
• CPC Class Codes: B01D 46/64 arranged concentrically or coaxially
• CPC Class Codes: B01D 50/20 Combinations of devices covered by groups B01D45/00 and B01D46/00

Abstract

The present invention relates to an apparatus for separating liquids and solids from a gas stream and simultaneously coalescing liquids from the gas stream. The apparatus includes a closed vessel having a longitudinally extending length, an initially open interior, an input port at an extent and an output port at an opposite extent thereof. There is a partition located within the vessel interior that divides the vessel interior into a first stage and a second stage. There is at least one opening in the partition. A separator/coalescer filter element is disposed within the vessel to sealingly extend from within the first stage through the opening into the second stage. There is a chevron-type seal or an O-ring seal between the filter element and the opening. The input port, vessel interior, separator/coalescer filter element and output port together define a flow passage within the apparatus, whereby the gas stream flows into the first stage through the input port and through the filter element hollow core, thereby filtering solids out of the gas stream, separating liquids from the gas stream, and pre-coalescing liquids in the gas stream. The gas stream then flows along the hollow core past the partition and back through the filter element into the second stage through a louvered impingement baffle, thereby coalescing liquids out of the gas stream, the gas stream then exiting the second stage through the outlet port. The louvered impingement baffle conditions the gas stream to create a scrubbing effect on any fine mist exiting the separator/coalescer filter element.

Claims

1. An apparatus for simultaneously filtering solids from a gas stream, separating liquids from the gas stream, pre-coalescing liquids from the gas stream, and coalescing liquids from the gas stream, the apparatus comprising:

a closed vessel having a length and an initially open interior;

a partition disposed within the vessel interior, the partition dividing the vessel interior into a first stage and a second stage;

at least one opening in the partition;

an inlet port in fluid communication with the first stage;

an outlet port in fluid communication with the second stage;

at least one tubular separator/coalescer filter element having a filter wall and a hollow core, each tubular separator/coalescer filter element being disposed within the vessel to sealingly extend from within the first stage through one of the openings into the second stage;

an annular seal holder permanently affixed around each tubular separator/coalescer filter element, the annular seal holder being selectively located along the extent of the tubular separator/coalescer filter element; and

an annular seal disposed between each annular seal holder and each tubular filter guide to prevent the gas stream from flowing from the first stage into the second stage without flowing through the tubular separator/coalescer filter element.

2. The apparatus according to claim 1, further comprising:

a tubular filter guide coupled to the partition and aligned with each opening, each tubular filter guide extending into the first stage, each tubular filter guide facilitating disposal of one of the tubular separator/coalescer filter elements through one of the openings, each tubular filter guide being disposed in the first stage such that the gas stream from the inlet port impinges thereupon, thereby causing free liquids in the gas stream to fall out.

3. The apparatus according to claim 1, wherein the input port, the vessel interior, the tubular separator/coalescer filter element, and the output port together defining a flow passage within the apparatus, whereby the gas stream flows into the first stage through the input port and through the filter wall, thereby separating solids out of the gas stream, separating liquids from the gas stream, and pre-coalescing liquids in the gas stream, whereby the gas stream then flows along the hollow core past the partition and back through the filter wall into the second stage, thereby coalescing liquids out of the gas stream, and whereby the gas stream then flows out of the second stage through the outlet port.

4. The apparatus according to claim 1, wherein the annular seal is a chevron seal having an annular base portion adapted to be received by the annular seal holder, and a frusto-conical portion having a small-diameter end and an opposing large-diameter end, the small-diameter end being connected to the annular base portion, the large-diameter end extending in the direction of the first stage.

5. The apparatus according to claim 1, wherein the annular seal is an O-ring.

6. The apparatus according to claim 1, further comprising:

a first end cap sealingly coupled to a first-stage end of the tubular separator/coalescer filter element, the first-stage end being located within the first stage; and

a second end cap sealingly coupled to a second-stage end of the tubular separator/coalescer filter element, the second-stage end being located within the second stage;

the first end cap and the second end cap each having an axial guide stem protruding longitudinally outward from the tubular separator/coalescer filter element.

7. The apparatus according to claim 1, further comprising:

a removable first-stage support strap disposed in the first stage opposite the partition, the first-stage support member being adapted to receive and spatially support the tubular separator/coalescer filter elements without the need for additional fasteners; and

a second-stage support member disposed in the second stage opposite the partition, the second-stage support member being adapted to receive and spatially support the tubular separator/coalescer filter elements without the need for additional fasteners.

8. The apparatus according to claim 1, further comprising:

a first-stage sump in fluid communication with the first stage; and

a second-stage sump in fluid communication with the second stage;

the first-stage sump and the second-stage sump collecting the filter solids, the separated liquids, the pre-coalesced liquids, and the coalesced liquids.

9. The apparatus according to claim 1, further comprising:

an impingement baffle disposed in the second stage about the tubular separator/coalescer filter element, the louvered impingement baffle facilitating further coalescing of the coalesced liquids.

10. The apparatus according to claim 9, wherein the impingement baffle is removable through the filter guide.

11. The apparatus according to claim 9, wherein the impingement baffle is annularly louvered.

12. The apparatus according to claim 9, wherein the impingement baffle comprises:

a tubular body portion having transverse louvers; and

a cap portion coupled to the tubular body portion, the cap portion having a plurality of exhaust ports through which the gas stream flows from the separator/coalescer filter element into the second stage.

13. The apparatus according to claim 1, further comprising:

a screen member disposed in the second stage, the screen member being adapted to prevent the coalesced liquids from being re-entrained into the gas stream.

14. The apparatus according to claim 1, further comprising:

a first-stage gauge in fluid communication with the first-stage sump for monitoring a level of the separated solids, the separated liquids, and the pre-coalesced liquids; and

a second-stage gauge in fluid communication with the second-stage sump for monitoring a level of the coalesced liquids.

15. The apparatus according to claim 1, wherein the tubular separator/coalescer filter element consists of multi-overlapped layers of non-woven fabric strips.

16. The apparatus according to claim 4, wherein the chevron seal is made of an elastomer.

17. The apparatus according to claim 1, further comprising:

an annular collar aligned with the outlet port, the annular collar projecting into the second stage, thereby preventing liquids from escaping the second stage.

18. The apparatus according to claim 1, wherein the annular seal holder is made of polyester.

19. A tubular separator/coalescer filter element for simultaneously filtering solids, separating liquids, pre-coalescing liquids, and coalescing liquids from a gas stream in a multi-stage vessel having a first stage and a second stage, the first stage being separated from the second stage by a partition having at least one opening, the separator/coalescer filter element comprising:

a filter wall having a plurality of overlapped layers of non-woven fabric strips;

a hollow core;

a seal holder permanently disposed on the filter wall; and

a seal removably carried by the seal holder, the seal forming a fluid-tight seal between the seal holder and the opening, such that the gas stream flows through the filter wall into the hollow core in the first stage and the gas stream flows out of the hollow core and back through the filter wall in the second stage.

20. The separator/coalescer filter element according to claim 19, wherein the seal holder is polyester.

21. The separator/coalescer filter element according to claim 19, wherein the seal is a chevron seal.

22. The separator/coalescer filter element according to claim 21, wherein the chevron seal is made of an elastomer.

23. The separator/coalescer filter element according to claim 19, wherein the seal is an O-ring.

24. An apparatus for simultaneously filtering solids from a gas stream, separating liquids from the gas stream, pre-coalescing liquids from the gas stream, and coalescing liquids from the gas stream, the apparatus comprising:

a closed vessel having a generally vertically extending length and an initially open interior;

a partition disposed within the vessel interior, the partition dividing the vessel interior into a first stage and a second stage;

at least one opening in the partition;

an inlet port in fluid communication with the first stage;

an outlet port in fluid communication with the second stage;

at least one tubular separator/coalescer filter element having a filter wall and a hollow core, each tubular separator/coalescer filter element being disposed within the vessel to sealingly extend from within the first stage through one of the openings into the second stage;

a tubular filter guide coupled to the partition and aligned with each opening, each tubular filter guide extending into the second stage, each tubular filter guide facilitating disposal of one of the tubular separator/coalescer filter elements through one of the openings;

an annular seal holder sealingly disposed around each tubular separator/coalescer filter element, the annular seal holder being selectively located along the extent of the tubular separator/coalescer filter element; and

an annular seal disposed between each annular seal holder and each tubular guide member to prevent the gas stream from flowing from the first stage into the second stage without flowing through the tubular separator/coalescer filter element;

the input port, the vessel interior, the tubular separator/coalescer filter element, and the output port together defining a flow passage within the apparatus, whereby the gas stream flows into the first stage through the input port and through the filter wall, thereby separating solids out of the gas stream, separating liquids from the gas stream, and pre-coalescing liquids in the gas stream, whereby the gas stream then flows along the hollow core past the partition and back through the filter wall into the second stage, thereby coalescing liquids out of the gas stream, and whereby the gas stream then flows out of the second stage through the outlet port.

25. The apparatus according to claim 24, wherein the annular seal is a chevron-type seal having an annular base portion adapted to be received by the annular seal guide, and a frusto-conical portion having a small-diameter end and an opposing large-diameter end, the small-diameter end being connected to the annular base portion, the large-diameter end extending in the direction of the first stage.

26. The apparatus according to claim 24, wherein the annular seal is an O-ring.

27. The apparatus according to claim 24, further comprising:

a first end cap sealingly coupled to a first-stage end of the tubular separator/coalescer filter element, the first-stage end being located within the first stage; and

a second end cap sealingly coupled to a second-stage end of the tubular separator/coalescer filter element, the second-stage end being located within the second stage;

the first end cap and the second end cap each having an axial guide stem protruding longitudinally outward from the tubular separator/coalescer filter element.

28. The apparatus according to claim 24, further comprising:

a first-stage support member disposed in the first stage opposite the partition, the first-stage support member being adapted to receive and spatially support the tubular separator/coalescer filter elements without the need for additional fasteners; and

a second-stage support member disposed in the second stage opposite the partition, the second-stage support member being adapted to receive and spatially support the tubular separator/coalescer filter elements without the need for additional fasteners.

29. The apparatus according to claim 24, further comprising:

a second-stage sump in fluid communication with the second stage;

the second-stage sump collecting the separated liquids, the separated solids, the pre-coalesced liquids, and the coalesced liquids.

30. The apparatus according to claim 24, further comprising:

a tubular flow diffuser disposed in the second stage concentrically about the tubular separator/coalescer filter element, the tubular flow diffuser to facilitate further coalescing of the coalesced liquids.

31. The apparatus according to claim 30, wherein the tubular flow diffuser is removable.

32. The apparatus according to claim 30, wherein the tubular flow diffuser is annularly louvered.

33. The apparatus according to claim 30, wherein the tubular flow diffuser comprises:

a louvered body portion; and

a cup portion coupled to the louvered body portion, the cup portion having a plurality of exhaust ports through which the gas stream flows from the separator/coalescer filter element into the second stage.

34. The apparatus according to claim 30, wherein the tubular flow diffuser is configured such that it is a liquid scrubbing device for removing micro-fine droplets of liquid in the gas stream.

35. The apparatus according to claim 24, wherein the tubular separator/coalescer filter element consists of multi-overlapped layers of non-woven fabric strips.

36. The apparatus according to claim 25, wherein the chevron seal is made of an elastomer.

37. The apparatus according to claim 24, wherein the annular seal holder is made of polyester.

38. The apparatus according to claim 24, further comprising:

an annular collar aligned with the outlet port, the annular collar projecting into the second stage, thereby preventing liquids from escaping the second stage.

39. An apparatus for converting an existing single-stage vessel having an inlet port, and an outlet port, and a closure member into a multi-stage vessel having a first stage and a second stage, the apparatus comprising:

a partition having at least one opening, the partition being adapted to be inserted through the closure member and sealingly disposed within the existing single-stage vessel between the inlet port and the outlet port, the partition thereby converting the existing single-stage vessel into the multi-stage vessel in which the inlet port opens into the first stage and the outlet port opens into the second stage;

a tubular filter guide aligned with each opening, each tubular filter guide extending into the first stage;

a removable louvered impingement baffle configured to be inserted through the tubular filter guide, each louvered impingement baffle extending from the partition into the second stage;

a tubular separator/coalescer filter element having a filter wall, a hollow core, a seal holder bonded to the filter wall, and a seal carried by the seal holder, the separator/coalescer filter element being configured for insertion through the filter guide and into the louvered impingement baffle, such that a positive seal is created between the seal and the filter guide.

40. The apparatus according to claim 39, wherein the seal is a chevron seal.

41. The apparatus according to claim 40, wherein the chevron seal is made of an elastomer.

42. The apparatus according to claim 39, wherein the seal holder is made of polyester.

43. A method of filtering solids, separating liquids, and pre-coalescing liquids, and simultaneously coalescing liquids from a gas stream, the method comprising the steps of:

providing a multi-stage vessel having a first stage and a second stage, the first stage being separated from the second stage by a partition having at least one opening;

installing at least one replaceable separator/coalescer filter element within the multi-stage vessel, the separator/coalescer filter element being sealed within the opening in the partition by means of a permanent seal holder and a replaceable seal, the replaceable seal being adapted to form a seal with the opening;

filtering solids, separating liquids, and pre-coalescing liquids from the gas stream in the first stage; and

simultaneously coalescing liquids from the gas stream in the second stage.

44. The method according to claim 43, wherein the seal is a chevron seal.

45. The method according to claim 43, wherein the seal is an O-ring.

46. The method according to claim 43, further comprising the step of:

installing an impingement baffle around each separator/coalescer filter element in the second stage to prevent coalesced liquids from being re-entrained into the gas stream.

47. A method of maintaining a multi-stage vessel and separator/coalescer filter elements, the multistage vessel having a first stage and a second stage, the first stage being separated from the second stage by a partition having at least one opening through which the separator/coalescer filter elements are sealingly disposed, the method comprising the steps of:

opening the multi-stage vessel;

removing a filter support member;

removing at least one separator/coalescer filter element from the multi-stage vessel;

replacing the separator/coalescer filter element with a replacement separator/coalescer filter element;

creating a fluid-tight seal between the replacement separator/coalescer filter element and the opening;

replacing the filter support member; and

closing the multi-stage vessel.

48. The method according to claim 47, wherein the step of creating a fluid-tight seal between the replacement separator/coalescer filter element and the opening is achieved by using a chevron seal carried about the replacement separator/coalescer filter element.

49. The method according to claim 48, wherein the chevron seal is made of an elastomer.

50. The method according to claim 47, wherein the step of creating a fluid-tight seal between the replacement separator/coalescer filter element and the opening is achieved by using an O-ring.

51. A method of simultaneously filtering solids, separating liquids, pre-coalescing liquids, and coalescing liquids from a gas stream, the method comprising the steps of:

providing a closed vessel having an initially open interior, a partition located within the closed interior, the partition dividing the vessel into a first stage and a second stage, there being at least one opening in the partition;

providing an inlet port in the first stage and an outlet port in the second stage;

installing at least one replaceable tubular separator/coalescer filter element within the vessel, such that the tubular separator/coalescer filter element sealingly extends from within the first stage through one of the openings into the second stage, each tubular separator/coalescer filter element having a filter wall and a hollow core;

providing an annular seal guide sealingly disposed around each tubular separator/coalescer filter element, the annular seal guide being selectively located along the extent of the tubular separator/coalescer filter element;

providing a tubular guide member coupled to the partition and aligned with each opening, each tubular guide member extending into the first stage, each tubular guide member facilitating disposal of one of the tubular separator/coalescer filter elements through one of the openings, each tubular guide member being disposed in the first stage such that the gas stream from the inlet port impinges thereupon, thereby extracting free liquids from the gas stream;

providing an annular seal disposed between each annular seal guide and each tubular guide member to prevent the gas stream from flowing from the first stage into the second stage without flowing through the tubular separator/coalescer filter element;

directing the gas stream into the first stage through the input port;

impinging the gas stream upon the tubular guide members thereby extracting free liquids from the gas stream;

directing the gas stream through the filter element sidewalls into the hollow core, thereby filtering solids out of the gas stream, separating liquids from the gas stream, and pre-coalescing liquids in the gas stream;

directing the gas stream along the hollow core of the filter element past the partition;

directing the gas stream back through the filter element sidewalls into the vessel second stage, thereby coalescing liquids out of the gas stream; and

directing the gas stream out of the vessel second stage through the outlet port.

52. The method according to claim 51, wherein the annular seal disposed between each annular seal guide and each tubular guide member is a chevron seal.

53. The method according to claim 51, wherein the annular seal disposed between each annular seal guide and each tubular guide member is an O-ring seal.

54. The method according to claim 51, further comprising the steps of:

sealingly coupling a first end cap having an axial guide stem protruding longitudinally outward from the tubular separator/coalescer filter element to a first-stage end of the tubular separator/coalescer filter element, the first-stage end being located within the first stage; and

sealingly coupling a second end cap having an axial guide stem protruding longitudinally outward from the tubular separator/coalescer filter element to a second-stage end of the tubular separator/coalescer filter element, the second-stage end being located within the second stage.

55. The method according to claim 51, further comprising the steps of:

locating a first-stage support member in the first stage opposite the partition, the first-stage support member being adapted to receive and spatially support the tubular separator/coalescer filter elements without the need for additional fasteners; and

locating a second-stage support member in the second stage opposite the partition, the second-stage support member being adapted to receive and spatially support the tubular separator/coalescer filter elements without the need for additional fasteners.

56. The method according to claim 51, further comprising the steps of:

providing a first-stage sump in fluid communication with the first stage;

providing a second-stage sump in fluid communication with the second stage; and

collecting the separated liquids, the separated solids, the pre-coalesced liquids, and the coalesced liquids with the first-stage sump and the second-stage sump.

57. The method according to claim 51, further comprising the step of:

installing an impingement baffle in the second stage about each tubular separator/coalescer filter element, such that the impingement baffle facilitates further coalescing of the liquids.

58. The method according to claim 57, wherein the impingement baffle is a removable, tubular flow diffuser.

59. The method according to claim 57, further comprising the step of:

providing a plurality of annular louvers along the extent of the impingement baffle.

60. The method according to claim 51, further comprising the step of:

disposing a screen member in the second stage, the screen member being adapted to prevent the separated liquids, the pre-coalesced liquids, and the coalesced liquids from being re-entrained into the gas stream.

61. The method according to claim 51, further comprising the steps of:

coupling a first-stage gauge in fluid communication with the first-stage sump for monitoring a level of the separated solids, the separated liquids, and the pre-coalesced liquids; and

coupling a second-stage gauge in fluid communication with the second-stage sump for monitoring a level of the separated liquids, the pre-coalesced liquids, and the coalesced liquids.

62. The method according to claim 51, wherein the step of providing tubular separator/coalescer filter elements consists of providing tubular separator/coalescer filter elements having multi-overlapped layers of non-woven fabric strips.

63. The method according to claim 51, wherein the annular seal is made of an elastomer.

64. The method according to claim 51, further comprising the step of:

providing an annular collar and aligning the annular collar with the outlet port, the annular collar projecting into the second stage, thereby preventing liquids from escaping the second stage.

65. The method according to claim 51, further comprising the steps of:

providing a pressure gauge in fluid communication with the first stage;

providing a pressure gauge in fluid communication with the second stage;

monitoring a pressure drop across the vessel by comparing the pressure in the first stage with the pressure in the second stage; and

replacing the filter element when the pressure drop reaches a selected amount.

66. The method according to claim 51, further comprising the steps of:

providing a sump in fluid communication with the vessel for collecting the filtered solids, the separated liquids, the pre-coalesced liquids, and the coalesced liquids;

providing a gauge for monitoring a level of the filtered solids, the separated liquids, the pre-coalesced liquids, and the coalesced liquids;

providing an outlet port in fluid communication with the sump for removing the filtered solids, the separated liquids, the pre-coalesced liquids, and the coalesced liquids; and

removing the filtered solids, the separated liquids, the pre-coalesced liquids, and the coalesced liquids when the level exceeds a selected amount.