Fluid Separator Methods and Systems

Abstract

A method and system for separating multicomponent fluids into components having different buoyancies. A flow shaping member has a helical channel that imparts a helical motion to the fluid, and a separation chamber for separating the moving fluid into a helically moving heavier flow portion and a more buoyant portion along the central axis. A flow receiving member has a first collection horn with a mouth arranged to collect the higher buoyancy fluid and direct the fluid to an outlet. At least one other fluid passageway for carrying lower buoyancy fluid has an inlet surrounding of the collection horn, and directs the fluid to a separate outlet at an end of the separator. Additional collection horns can be arranged concentrically around the first collection horn to collect intermediate buoyancy flows. Cascaded fluid separators can concentrate the higher buoyancy fluid or the denser fluid.

What is claimed as new and desired to be protected by Letters Patent of the United States is: 
     
         1 . A fluid separation system for separating a multicomponent fluid into two or more flow channels, each containing components with different buoyancy, comprising:
 a housing having a fluid inlet at an inlet end, a fluid outlet for less buoyant fluid at an outlet end opposite the inlet end, and at least one other fluid outlet for more buoyant fluid;   a flow forming member configured to fit within the housing at the inlet end of the housing and having at least one helical channel in an outer cylindrical surface that directs the fluid into a helical flow direction near the outer circumference of the flow forming member as the fluid exits the flow forming member; and   a flow receiving member configured to fit within the housing at an opposite end of the housing,   the flow receiving member having a first fluid passageway with an inlet positioned at the central axis of the separator to receive higher buoyancy fluid, the first fluid passageway extending to the other fluid outlet for more buoyant fluid,   the flow receiving member having a second fluid passageway with an inlet positioned radially outward of the first fluid passageway to receive lower buoyancy fluid, the second fluid passageway extending to the fluid outlet for less buoyant fluid; wherein a separation chamber is formed between a face of the flow forming member and the flow receiving member.   
     
     
         2 . The system according to  claim 1 , wherein in operation, helical flow enters the separation chamber, and more buoyant portions of the flow move toward the central axis of the chamber and enter the inlet of the first fluid passageway, and more buoyant portions of the flow continue in a helical path near the outer part of the chamber, bypass the inlet of the first fluid passageway and exit the system through the second fluid passageway. 
     
     
         3 . The system according to  claim 1 , wherein the other fluid outlet for more buoyant fluid is located at the cylindrical surface of the housing. 
     
     
         4 . The system according to  claim 1 , wherein the inlet of the first fluid passageway increases in diameter in an upstream direction. 
     
     
         5 . The system according to  claim 1 , wherein the flow receiving member includes a third fluid passageway having an inlet concentrically surrounding the inlet of the first fluid passageway, the third fluid passageway extending to a third fluid outlet. 
     
     
         6 . The system according to  claim 1 , wherein the flow receiving member includes an exit flow adapter module with a cylindrical outer surface that fits closely within the housing. 
     
     
         7 . The system according to  claim 6 , wherein the flow receiving member includes at least one strut connecting a wall of the first fluid passageway to the exit flow adapter module. 
     
     
         8 . The system according to  claim 7 , wherein the at least one support strut has an oval or airfoil shape. 
     
     
         9 . The system according to  claim 6 , wherein the exit flow adapter module has an inner diameter that decreases in a downstream direction toward the outlet end of the housing. 
     
     
         10 . The fluid separation system according to  claim 1 , in combination with at least one other fluid separation system, wherein at least one of the fluid outlets is coupled to an inlet of the at least one other fluid separation system. 
     
     
         11 . The fluid separation system in accordance with  claim 1 , wherein each of the housing, the flow forming member, and the flow receiving member is formed separately and subsequently assembled. 
     
     
         12 . The fluid separation system in accordance with  claim 1 , wherein the housing, the flow forming member, and the flow receiving member are formed as an integral unit. 
     
     
         13 . The fluid separation system in accordance with  claim 1 , wherein at least one of the housing, the flow forming member, and the flow receiving member are formed by at least one of bonding separately formed pieces together, casting, forging, machining, and an additive manufacturing process. 
     
     
         14 . The fluid separation system according to  claim 13 , wherein the additive manufacturing process is a three-dimensional printing process. 
     
     
         15 . A method for separating a multicomponent fluid into two or more flow portions by buoyancy using a fluid separator having a housing, a flow forming member positioned within the housing at an inlet end, and a flow receiving member positioned within the housing at an outlet end, the method comprising:
 introducing a pressurized fluid into a fluid inlet at an inlet end of the housing, the housing having a fluid outlet for less buoyant fluid at an outlet end opposite the inlet end, and the housing having at least one other fluid outlet for more buoyant fluid;   the fluid pressure moving the fluid into at least one helical channel in an outer cylindrical surface of the flow forming member such that the channel imparts a helical flow direction to the fluid;   the fluid having a helical flow direction passing into a separation chamber arranged between the flow forming member and a flow receiving member;   a more buoyant portion of the fluid entering an inlet of a first fluid passageway at the central axis of the separator and continuing out of the separator through the other fluid outlet for more buoyant fluid; and   a less buoyant portion of the fluid entering a second fluid passageway inlet positioned concentrically around the first fluid passageway inlet and continuing out of the separator through the fluid outlet for less buoyant fluid.   
     
     
         16 . The method according to  claim 15 , wherein in operation, helical flow enters the separation chamber, and more buoyant portions of the flow move toward the central axis of the chamber and enter the inlet of the first fluid passageway, and less buoyant portions of the flow continue in a helical path near the outer part of the chamber, bypass the inlet of the first fluid passageway and exit through the second fluid passageway. 
     
     
         17 . The method according to  claim 15 , wherein the other fluid outlet for more buoyant fluid is located at the cylindrical surface of the housing. 
     
     
         18 . The method according to  claim 15 , wherein the inlet of the first fluid passageway increases in diameter in an upstream direction. 
     
     
         19 . The method according to  claim 15 , further comprising:
 another portion of the flow entering an inlet of a third fluid passageway in the flow receiving member that concentrically surrounds the inlet of the first fluid passageway, and passing out of the separator through an outlet of third passageway.   
     
     
         20 . The method according to  claim 15 , wherein the flow receiving member includes an exit flow adapter module with a cylindrical outer surface that fits closely within the housing. 
     
     
         21 . The method according to  claim 20 , wherein the flow receiving member includes at least one strut connecting a wall of the first fluid passageway to the exit flow adapter module. 
     
     
         22 . The method according to  claim 21 , wherein the at least one support strut has an oval or airfoil shape. 
     
     
         23 . The method according to  claim 20 , wherein the exit flow adapter module has an inner diameter that decreases in a downstream direction toward the outlet end of the housing. 
     
     
         24 . The method according to  claim 15 , further comprising:
 passing the less buoyant fluid portion directly from the heavier flow fluid outlet into an inlet of another fluid separation system.   
     
     
         25 . The method according to  claim 24 , wherein the less buoyant fluid portion is passed into the inlet of another fluid separation system without pumping.