SYSTEM FOR FILTERING LIQUIDS AND PARTICULATES FROM HYDROCARBONS

Abstract

This is a system for filtering liquids and particulates from hydrocarbons. The system starts with an intake where hydrocarbons from a source are placed into an oil circuit within the hydrocarbon filtering apparatus. The hydrocarbon that is passed through the elements of the hydrocarbon filtering apparatus has liquid, such as water removed, as well as particulates. The process is an improvement on existing machines and that the apparatus is able to run at an decreased temperature and reduced pressure as compared to the current state of the art. An improved diffuser element is made using a central tube that has a multiplicity of apertures interspersed along the shaft of the tube. The central tube has an attachment end and a closed end opposite from the attachment end. The tube is wrapped with a metal mesh and the mesh clamped in place.

Claims

1. An diffuser element for facilitating the separation of a liquid emulsified in a hydrocarbon from said hydrocarbon comprising: a core tube having an attachment end and a closed end opposite each other; wherein said core tube is hollow; said attachment end of said core tube having an opening; a multiplicity of holes along the length of said core tube; and a length of mesh wrapped about said core tube and said mesh secured by a closure piece.

2. The apparatus of claim 1, further comprising: a first spacer disc attached to said core tube near said attachment end; a second spacer disc attached to said core tube near said closed end; and wherein said wrap of mesh is positioned between said first spacer disc and said second spacer disc.

3. The apparatus of claim 1, wherein said holes are positioned in substantially the same orientation along said core tube.

4. The apparatus of claim 1, wherein said mesh is sized between size 10 mesh and 100 mesh.

5. The apparatus of claim 1, further comprising a large mesh sheets inserted between the mesh wraps wherein said large mesh has larger holes than said mesh.

6. The apparatus of claim 4, further comprising a large mesh sheets inserted between the mesh wraps wherein said large mesh has larger holes than said mesh.

7. The apparatus of claim 2, wherein said holes are positioned in substantially the same orientation along said core tube.

8. The apparatus of claim 7, wherein said mesh is sized between size 10 mesh and 100 mesh.

9. The apparatus of claim 7, further comprising a large mesh sheet inserted between the wraps of said mesh wherein said large mesh has larger holes than said mesh.

10. The apparatus of claim 8, further comprising a large mesh sheet inserted between the wraps of said mesh wherein said large mesh has larger holes than said mesh.

11. The apparatus of claim 1, wherein said attachment end is attachable inside an extraction chamber so as to be in operative communication with a hydrocarbon filtering apparatus.

12. The apparatus of claim 10, wherein said attachment end is attachable inside an extraction chamber so as to be in operative communication with a hydrocarbon filtering apparatus.

13. The apparatus of claim 2, wherein said holes are positioned between said first spacer disc and said second spacer disc.

14. The apparatus of claim 7, wherein said holes are positioned between said first spacer disc and said second spacer disc.

15. The apparatus of claim 10, wherein said holes are positioned between said first spacer disc and said second spacer disc.

16. The apparatus of claim 1, wherein said mesh has a multiplicity of hole sizes.

17. The apparatus of claim 10, wherein said mesh has a multiplicity of hole sizes.

18. The apparatus of claim 12, wherein said mesh has a multiplicity of hole sizes.

19. The apparatus of claim 15, wherein said mesh has a multiplicity of hole sizes.

20. The apparatus of claim 1, wherein said mesh is made from one of aluminum, stainless steel, or plastic.

21. The apparatus of claim 10, wherein said mesh is made from one of aluminum, stainless steel, or plastic.

22. The apparatus of claim 12, wherein said mesh is made from one of aluminum, stainless steel, or plastic.

23. The apparatus of claim 15, wherein said mesh is made from one of aluminum, stainless steel, or plastic.

24. The apparatus of claim 19, wherein said mesh is made from one of aluminum, stainless steel, or plastic.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] FIG. 1 is a front, perspective view of the hydrocarbon filtering apparatus.

[0021] FIG. 2 is a first side, perspective view of the hydrocarbon filtering apparatus.

[0022] FIG. 3 is a second side, perspective view of the hydrocarbon filtering apparatus.

[0023] FIG. 4 is a rear, perspective view of the hydrocarbon filtering apparatus.

[0024] FIG. 5 is a side, perspective view of the diffuser element.

[0025] FIG. 6 is a side, cutaway view of the diffuser element.

[0026] FIG. 7 is a cross-sectional view of the diffuser element.

[0027] FIG. 8 is a diagram illustrating the oil circuit.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0028]

TABLE-US-00001 10 Hydrocarbon filtering apparatus 12 Inlet 14 Inlet valve 16 Vacuum pump 18 Knockout pot 20 Heater 22 Tower 24 Tower viewing port 26 Float valve 28 Float 30 Float arm 32 Tower viewing port shoulder 34 Tower viewing port connector 36a Tower viewing port outer gasket 36b Tower viewing port inner gasket 38 Tower viewing port cover 40 Extraction chamber 42 Diffuser element 44 Oil pump 46a First particulate filter 46b Second particulate filter 48 Outlet 50 Air intake 52 Air cooler 54 Knockout pot viewing port 56 Knockout pot viewing port connector 58 Knockout pot viewing port outer gasket 60 Knockout pot viewing port inner gasket 62 Knockout pot viewing port shoulder 64 Knockout pot viewing port cover 66 Vacuum pump vapor outlet 68 Vapor outlet inner pipe 70 Vapor outlet outer pipe 70a Vapor outlet outer pipe closed end 72 Control panel 74 Display 76 Roller 78 Base 80 Outer frame 82 Inner frame 84 Gauge 90 Diffuser core tube 92 End closure 94a Attachment end 94b Closed end 96 Mesh 98 Closure piece 100 Tube hole 102 Tube shaft 104 Large mesh 106 Tube opening 108 Tube interior 110 Spacer disc

[0029] Referring to the figures, FIGS. 1-4 illustrate one embodiment of the hydrocarbon filtering apparatus 10. The hydrocarbon filtering apparatus 10 can be manufactured in a generally self-contained unit. The components of the hydrocarbon filtering apparatus 10 can be installed on a base 78. In order to increase the mobility of the hydrocarbon filtering apparatus 10 the base can have rollers 76. In order to help protect and support the hydrocarbon filtering apparatus 10 unit, there may be an outer frame 80 attached to the base 78 and extending around the hydrocarbon filtering apparatus 10 in three (3) dimensions. An inner frame 82 may be connected to the base 78 or outer frame 80. The inner frame 82 provides a skeletal-like structure to which the components of the hydrocarbon filtering apparatus 10 can be attached. Gauges 84 can provide information to the user such as pressure, temperature, and humidity readings.

[0030] The hydrocarbon filtering apparatus 10 itself is a series of components that are operably connected to each other. The hydrocarbon filtering apparatus 10 is a closed system, or oil circuit, in which hydrocarbon travels from the source then from element to element within the hydrocarbon filtering apparatus 10 and finally back to the source. It is presumed that all of the elements of the hydrocarbon filtering apparatus 10 are in mechanical communication with each other such that hydrocarbon can flow, or be pumped, throughout the filtering apparatus 10. Hydrocarbon is pumped from the source or reservoir (not shown) and enters the hydrocarbon filtering apparatus 10 at the inlet 12. The inlet 12 is in mechanical communication with the source (not shown) via an inlet hose (not shown). When a hose is mentioned herein, it is assumed that the liquid conveyance device could be a hose, pipe or other apparatus commonly used to transport liquids. The hydrocarbon travels into the inlet 12 entering the hydrocarbon filtering apparatus 10.

[0031] After entering the inlet 10 the hydrocarbon travels through the system to an inlet valve 14. When the inlet valve 14 is closed, it stops hydrocarbon from being gravity fed into the hydrocarbon filtering apparatus 10. For example, if the source (not shown) is above the hydrocarbon filtering apparatus 10 such that gravity would naturally cause the hydrocarbon to flow from the source into the hydrocarbon filtering apparatus 10, then the inlet valve 14when it is in a closed positionstops the flow of the hydrocarbon. Inadvertent flow of the hydrocarbon into the hydrocarbon filtering apparatus 10 could cause the hydrocarbon to fill into unintended portions of the hydrocarbon filtering apparatus 10 such as entering into the vacuum system and leaking out the vacuum pump 16. In such a situation, the hydrocarbon could unintentionally fill up the knockout pot 18 and spill over into the vacuum pump 16. This would cause the hydrocarbon to spill and could drain the source which would be undesirable and a potential problem. Therefore, it is desirable to have an inlet valve 14 that closes in order to stop such from happening.

[0032] The inlet valve 14 stays closed until the hydrocarbon filtering apparatus 10 reaches an internal vacuum which acts to pull the stop valve (not shown) of the inlet valve 14 to an open position.

[0033] After passing through the inlet valve 14, the oil enters into a heater 20. In order to boil water, the water temperature must be raised to 212 F. or 100 C. at 1 atm of pressure (see level). However, the boiling point of water depends on pressure (impurities in the water can also cause the water to boil at a different temperature) and water boils at a lower temperature as pressure decreases. Thus, as the vacuum within the hydrocarbon filtering apparatus 10 increases, the pressure decreases and water in the system will boil at a relatively lower temperature. For example, if the pressure in the system is lowered by about 25 inches of mercury then water in the system will boil at approximately 120 F.

[0034] After passing through the heater 20, the hydrocarbon continues up a tower 22. The tower 22 is generally anticipated to be a vertically oriented chamber that is likely to be cylindrical or ovoid. Inside the tower 22 is a float valve 26 that helps maintain the level of hydrocarbon in the tower 22. As the level of hydrocarbon and the tower 22 raises, a float 28 also raises. The float 28 is connected to the float valve 26 via a float arm 30 and movement of the float 28 consequently causes movement of the float valve 26. Raising the float 28 causes the float valve 26 to close the aperture that allows entry of the hydrocarbon into the tower 22. Conversely, as the level of hydrocarbon lowers in the tower 22, the float 28 also lowers causing the float valve 26 to open and allow more hydrocarbon into the tower 22. The level of hydrocarbon in the tower 22 can be monitored by a user through a tower viewing port 24. The tower viewing port 24 is comprised of an aperture into the tower 22 with a tower viewing port shoulder 32 extending from the aperture and generally perpendicularly from the tower 22. A tower viewing port cover 38 is attached to the shoulder 32 and closes the aperture from the environment. The tower viewing port cover 38 is made from a clear material with characteristics and sufficient strength to withstand the hydrocarbons, temperature, and pressures associated with the system. A clear tower viewing port cover 38 allows a user to see into the tower 22 and monitor hydrocarbon levels. The tower viewing port cover 38 is attached to the shoulder 32 via a multiplicity of power viewing port connectors 34 located interspersed around the shoulder 32 and generally a ring. It is generally anticipated that the connectors 34 will be a type of bolt or related device. In order to help resist leaking of the hydrocarbon from between the shoulder 32 and the cover 38 a tower viewing port gasket 36 is aligned around the edge of the shoulder 32 and between the shoulder 32 and the cover 38. In the illustrated embodiment, there are dual gaskets in between the shoulder 32 and the cover 38an outer gasket 36a between the outside edge of the shoulder 32 and the ring of connectors 34, and an inner gasket 36b between the inner edge of the shoulder 32 and the ring of connectors 34.

[0035] Hydrocarbon travels from the tower 22 into the extraction chamber 40. However, in order to enter the extraction chamber 40, the hydrocarbon is pushed through at least one diffuser element 42. Often, there is a multiplicity of diffuser element 42 in the extraction chamber 40. As illustrated in this embodiment (FIG. 1), there are five (5) diffuser elements 42. Hydrocarbon is pushed through the diffuser element 42 where contaminants in the hydrocarbon, particularly water, are separated from the hydrocarbon.

[0036] Hydrocarbon drops from the diffuser elements 42 into the extraction chamber 40. The separated hydrocarbon then moves out of the extraction chamber. The oil pump 44 may then push the hydrocarbon through a particulate filter. In the illustrated embodiment there is a first particulate filter 46a and a second particulate filter 46b. While the diffuser elements 42 act to separate off liquid contaminants, such as water, from the hydrocarbon, the particulate filters 46a and 46b filter solid contaminants from the hydrocarbon. The separated and filtered hydrocarbon is then moved on through an outlet 48 and through an outlet hose (not shown) back to the source (not shown).

[0037] The vacuum circuit is another component of the hydrocarbon filtering apparatus 10. Air is allowed to enter the system through the air intake 50. However, the air intake 50 is restricting such that there is not a free flow of air into the system. It is anticipated that air intake will be limited such that pressure in the system will equalized at approximately a range of 15 inches of mercury to 35 inches of mercury. Like the oil circuit, the vacuum circuit is a system in which air is either evacuated from or travels from element to element. Also as above, it is presumed that all of the elements of the hydrocarbon filtering apparatus 10 are in mechanical communication with each other such that air can flow, the evacuated, or be pumped, throughout the components of the filtering apparatus 10.

[0038] Air that enters through the air intake 50 travels into the extraction chamber 40. From the extraction chamber 40 air travels into an air cooler 52. Mechanical communication from the extraction chamber 42 the air cooler 52 is through the top of the extraction chamber 42 so that it is less likely that hydrocarbons, which due to gravity will drop to the bottom of the extraction chamber 42, will enter into the air cooler 52. It is helpful to cool the air in the air cooler 52 because temperatures are elevated in the extraction chamber 42. Water vapor that has been extracted from the hydrocarbon travels with the heated air into the air cooler 52 where it condenses and then flows from the air cooler 52 into the knockout pot 18. It is desirable that the water flows into the knockout pot 18 so that it does not get into the vacuum pump 16. Like the tower 22, the knockout pot 18 has a knockout pot viewing port 54. The knockout pot viewing port 54 is comprised of a shoulder 62 and a cover 64. The cover 64 is attached to the shoulder 62 by a multiplicity of connectors 56 located around the circumference of the shoulder 62 and cover 64. The knockout pot viewing port 54 may have a single, or double, gasket between the shoulder 62 and cover 64. If it is a double gasket arrangement, it is anticipated that the inner gasket 60 will be between the ring of connectors 56 and the inner edge of the shoulder 62 or aperture and interior of the knockout pot 18, while the outer gasket 58 is positioned between the ring of connectors 56 and the outer edge of the shoulder 62. Unlike the tower 22, the knockout pot 18 will generally be a horizontally positioned cylindrical, or ovoid, chamber. Inside the knockout pot 18 is a float valve (not shown) that will shut off the system if liquid levels in the knockout pot 18 get too high and threatened to spill over into the vacuum pump 16. However, in practice, the vast majority of water in the system stays in a gaseous state as a water vapor and enters into the vacuum pump 16, and is expelled into the atmosphere from a vacuum pump vapor outlet 66. The vacuum pump vapor outlet 66 has an inner pipe 68 that comes from the vacuum pump 16 and points upwardly. An outer pipe 70 with a closed top end 70a fits down over the inner pipe 68 with space between the end of the inner pipe 68 and the end of the outer pipe closed and 70a, and space between the portion of the inner pipe 68 covered by the outer pipe 70 and the length outer pipe 70, so that air and gas can escape out the bottom of the outer pipe 70 but environmental liquids (such as rain) do not enter into the inner pipe 68.

[0039] After water is removed from the hydrocarbons in the extraction chamber 40, the hydrocarbons are pumped through one or more particulate filters 46. In the embodiment shown in FIG. 4, there is a first particulate filter 46a and a second particulate filter 46b. After passing through the particulate filters 46, the oil is pushed out through the outlet 48 and back to the source (not shown)

[0040] The power for the hydrocarbon filtering apparatus 10 is anticipated to be electrical. A control panel 72 provides various control input devices such as, but not limited to, knobs, switches, and dials, so that a user can operate the hydrocarbon filtering apparatus 10. The control panel 72 can also provide output information to inform the user about operational characteristics of the hydrocarbon filtering apparatus 10. A display 74 can display information about the hydrocarbon filtering apparatus 10 to the user, such as, but not limited to, temperatures and pressures within the system, and system on/off. Typical controls that are anticipated to be available on the control panel 72 include, but are not limited to, system on/off, variable power or speed, a heater control, and a vacuum control. It is also anticipated that these various controls could be located elsewhere on the hydrocarbon filtering apparatus 10, and that no central control panel 72 be present.

[0041] FIG. 5 is a side, perspective view of the diffuser element 42. The diffuser element 42 is made using a diffuser core tube 90 that has a multiplicity of tube holes 100 interspersed along the shaft 102 of the diffuser core tube 90. The diffuser core tube 90 has an attachment end 94a and a closed end 94b opposite from the attachment end 94a. The tube 90 is wrapped with a sheet of mesh 96 and the mesh 96 is held in place using a closure piece 98. The attachment end 94a may be threaded, have a quick release mechanism, or otherwise have a connection mechanism for putting the interior of the diffuser core tube 90 in operational communication with the remainder of the oil circuit of the hydrocarbon filtering apparatus 10.

[0042] FIG. 6 is a side, cut-away view of the diffuser element 42. This figure illustrates the diffuser element 42 and shows the diffuser core tube 90 at the center of the diffuser element 42. The diffuser core tube 90 is a hollow tube with an interior 108 and a shaft 102. At one end of the diffuser core tube 90 is the attachment end 94a. The attachment end 94a has a tube opening 106 through which hydrocarbons can pass while traveling through the oil circuit of the hydrocarbon filtering apparatus 10. Additionally, the attachment end 94a maybe threaded or otherwise the connectable with the circuit of the hydrocarbon filtering apparatus 10 such that when the diffuser element 42 is attached it is in operative communication with the hydrocarbon filtering apparatus 10. The end of the diffuser element 42 opposite the attachment end 94a is the closed end 94b. The closed end 94b as a closure piece 98 attached such that the aperture of the diffuser core tube 90 is plugged and hydrocarbon inside the tube interior 108 cannot exit through the closed end 94b of the diffuser core tube 90. Rather, there are a multiplicity of tube holes 100 interspersed along the shaft 102 of the tube 90. Hydrocarbons that flow into the diffuser core tube 90 through the tube opening 106 of the attachment end 94a and into the tube interior 108 exit through the tube holes 100.

[0043] Wrapped around the diffuser core tube 90 is a sheet of mesh 96. The mesh 96 is anticipated to be of size 10 mesh to 100 mesh, where the size is based upon the number of cross threads per inch. Attached near each and of the diffuser core tube 90 is a spacer disc 110. The spacer disc 110 helps keep the wraps of the mesh 96 stacked horizontally from the diffuser core tube 90. Additionally, because the wraps of mesh 96 are urged between the spacer disc 110, hydrocarbons that exit through the tube holes 100 don't simply flow out the end of the mesh 96 stack and are forced to travel through the system of holes in the mesh 96 stack.

[0044] Because the mesh 96 has relatively small holes, there is a potential that the wraps of mesh 96 may plug its own holes. In order to help alleviate this potential problem, one or more large mesh sheets 104 may be inserted into the mesh 96 wraps. The large mesh 104 has larger holes which open up the passages of travel for hydrocarbons in the mesh 96 stack. It is anticipated that the large mesh 104 pieces will be relatively short as compared to the mesh 96.

[0045] FIG. 7 is a cross-sectional view of the diffuser element. It illustrates the mesh 96 wrapped around the diffuser core tube 90. As shown in this cross-sectional view, the mesh 96 wraps around a portion of the tube shaft 102. Tube holes 100 are indicated in the tube shaft 102. The tube interior 108 can be seen in the center portion of the diffuser element 42. Within the wraps of the mesh 96 can be seen large mesh 104 wraps. In this embodiment, the large mesh 104 wraps are shown to be inserted in the complex every four (4) wraps of the mesh 96. Hydrocarbons would flow through the tube interior 108 and exit from the tube 90 through the tube holes 100, and then pass through the mesh 96 complex. Thus, the oil flow is from inside to out.

[0046] FIG. 8 is a diagram illustrating the oil circuit. This first embodiment illustrated and described in this figure while providing potential parts, is not intended to be limiting in regard to those parts and it is to be understood that many other parts with other specifications could be used to form different embodiments of the present invention. This first embodiment is for a 8 GPM (gallons per minute) oil purifier parts and instrumentation. It illustrates the flow of hydrocarbon through the filtration system.

[0047] The hydrocarbon is pumped from a source through an inlet hose 142 to a 304 stainless ball valve 120 with a 1 national pipe taper (NPT) (NPT is a common U.S. standard for pipe fittings. NPT fittings are measured on the internal diameter of the fitting.) The hydrocarbon continues through a 1 normally closed (NC) piston valve 122 and then through an inlet #4 bag filter 124 with 40 mesh (420 microns). The various parts are attached to and held in place by stainless steel tubing 126. The hydrocarbon is warmed with a 12 kW immersion heater 128 with a low watt density type K thermocouple on elements & process. The hydrocarbon continues into a tower 22 that has a level control valve 130 and a NPT horizontal float switch 132. The hydrocarbon is then pushed through five (5) 21 dispersion elements 136 inside a 12 304 stainless vacuum extraction chamber 134. The filtered hydrocarbon is transported through 1 pump feed pipe 138 made from schedule 10 304 stainless steel into a 1 oil pump Y-strainer 140 made from 20 mesh (840 micron). A Gorman Rupp or Viking 8 GPM gear pump 144 with a relief valve set at 80 PSI, 15 GPM at 1800 RPM with a 1.5 HP explosion proof oil pump motor 146 act to transport the hydrocarbon on through a 1 NPT stainless check valve 148. The hydrocarbon pressure inside the system is monitored by a 0 to 100 PSI glycerin filled pressure gauge 150 as the hydrocarbon is moved into a dual spin-on discharge filter housing 152. The hydrocarbon exits the system through a 1 NPT 304 stainless ball valve 158 while monitored by a 0-50 explosion proof differential pressure indicator 154 with a set point set at 35 PSID and filter alarm with upstream and downstream sample port valves, as well as a 1 NPT low flow indicator 156 with alarm contacts set between 1 to 2 GPM. The oil out is an outlet hose 190 in operative communication with the ball valve 158.

[0048] Air in 192 is through inlet air spin-on filter element 160. The air passes through a NPT gate valve 162 for tower vacuum control and a NPT check valve 164. A 30 HG to 0 PSI vacuum tower gauge 166 monitors the vacuum in the vacuum extraction chamber 134. Evaporated liquids extracted from the hydrocarbon pass through a 1 petroleum transfer hose 168 to an air cooled heat exchanger 170 with HP electric motor in an 8 diameter and into a condensate sump 172 made of 304 stainless steel. The condensate can be drained from the sump 172 through a NPT ball valve 174. Draining of sump is controlled by a NPT horizontal float switch 176. Air exits the sump 172 through a 1 petroleum transfer hose 178 with flow controlled by a NPT ball valve 180 used for vacuum pump rotor cleaning. The air is pushed on by a 40 CFM claw vacuum pump 182 with a 3 HP explosion proof vacuum pump motor 184, through a vacuum pump discharge diffuser 186 and out the air out 188.

[0049] Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention.