Structure and performance influencing factors of vane separation components: The reviews

doi:10.16085/j.issn.1000-6613.2023-1133

Abstract

Abstract:

The vane separation element is a kind of element which mainly relies on inertia to separate gas and liquid. It is widely used in the field of gas and liquid separation because of its characteristics of high throughput, high separation efficiency and low pressure drop. In this paper, the separation mechanism, structure and performance factors of the blade separation element were investigated in detail. The research progress of the separation mechanism such as droplet inertia separation, droplet impact and secondary entrainment caused by liquid film rupture in the vane flow path was discussed. The main structural characteristics of the vane-type gas-liquid separation element were summarized, and the specific effects of structural parameters such as curvature number, bending angle, spacing and hydrophobic hook on the separation performance were analyzed. By comparing the advantages and disadvantages of different existing vane structures and their application situations, the optimization direction of increasing the interception area and opening up the drainage channel of vane structures was put forward. The application status of wave-plate separation element and static rotation element was analyzed, which provides reference for application selection and optimization of vane gas-liquid separation technology. The internal effects of air velocity, pressure and inlet humidity on the performance of the corrugated plate-vane separation element were summarized. Finally, combining the separation mechanism, structure research and performance influence law, the structural design and performance optimization direction of the wave-plate separation element were summarized and prospected.

Key words: vane type separation element, separation mechanism, performance optimization, structural research

摘要：

叶片式分离元件是一种主要依靠惯性进行气液分离的元件，因其高处理量、高分离效率和低压降的特点而广泛应用于气液分离领域。本文从叶片式分离元件分离机理、结构及性能影响因素两个方面进行了详细的调研。论述了叶片流道内的液滴惯性分离、液滴撞击以及液膜破裂导致的二次夹带问题等分离机理研究进展，从机理层面分析了二次夹带现象的成因并提出了抑制思路。归纳了叶片式气液分离元件的主要结构特征，分析了曲级数、弯折角度、间距以及疏水钩等结构参数对分离性能的具体影响。通过对比现有不同叶片结构的优缺点与适用场合，提出了增加拦截面积及开辟排液通道的叶片结构设计优化方向。分析了波形板叶片式分离元件及静态起旋转元件的应用现状，为叶片式气液分离技术应用选择及优化提供了参考。归纳了气流速度、压力以及入口湿度等操作工况对波形板叶片式分离元件性能的内在影响规律。最后，结合分离机理、结构研究与性能影响规律对波形板叶片式分离元件的结构设计与性能优化方向进行了总结与展望。

关键词: 叶片式分离元件, 分离机理, 性能优化, 结构研究

CLC Number:

TQ051.8

JIAO Wenlei, LIU Zhen, CHEN Junxian, ZHANG Tianyu, JI Zhongli. Structure and performance influencing factors of vane separation components: The reviews[J]. Chemical Industry and Engineering Progress, 2024, 43(8): 4187-4202.

焦文磊, 刘震, 陈俊先, 张天钰, 姬忠礼. 叶片式分离元件结构及性能影响因素研究进展[J]. 化工进展, 2024, 43(8): 4187-4202.

Figures/Tables 14

相关研究	液滴参数	撞击参数	壁面类型	研究参数
Chen等^[14]	乙醇；液滴直径1.95~2.05mm	接触角为15°~45°	不锈钢表面；液膜厚度为75~109µm	倾斜角度的增加有利于抑制飞溅；当倾角相同时，We对液滴扩散因子影响不大
Ru等^[18]	平均粒径224~600µm	入射速度1m/s	不锈钢表面	液滴最大扩散因子半经验公式： $D i m a x * = D i m a x d p = c o s a x [(W e + B o + 12) 3 (1 - c o s θ)] 0.5 b$
Tang等^[19]	水、癸烷、乙醇和十四烷；液滴直径1.9mm	雷诺数为858~4290	不锈钢表面；不同粗糙度（Ra=0.025~6.3µm）	最大归一化扩展直径： $β m a x = a (W e / O h) b$
Sikalo等^[20]	水、异丙醇（C₃H₈O）、甘油（85%溶液）；液滴直径1.8~3.3mm	接触角为0°~105° 雷诺数为27~8880	光滑玻璃、粗糙玻璃、光滑石蜡；干表面/湿表面、液膜厚度为40~100µm	在较低角度和光滑或湿润表面易发生反弹；低黏性液滴会反弹或沉积在光滑或湿润表面；高黏度液滴也可能分解出小液滴，具体取决于撞击角度
樊玉光等^[21]	水、甘油（70%）；液滴直径50~100µm	接触角为36°~90°	液膜厚度为2.5mm	入射角度30°~90°，飞溅的临界We增大

相关研究	液滴参数	撞击参数	壁面类型	研究参数
Chen等^[14]	乙醇；液滴直径1.95~2.05mm	接触角为15°~45°	不锈钢表面；液膜厚度为75~109µm	倾斜角度的增加有利于抑制飞溅；当倾角相同时，We对液滴扩散因子影响不大
Ru等^[18]	平均粒径224~600µm	入射速度1m/s	不锈钢表面	液滴最大扩散因子半经验公式： $D i m a x * = D i m a x d p = c o s a x [(W e + B o + 12) 3 (1 - c o s θ)] 0.5 b$
Tang等^[19]	水、癸烷、乙醇和十四烷；液滴直径1.9mm	雷诺数为858~4290	不锈钢表面；不同粗糙度（Ra=0.025~6.3µm）	最大归一化扩展直径： $β m a x = a (W e / O h) b$
Sikalo等^[20]	水、异丙醇（C₃H₈O）、甘油（85%溶液）；液滴直径1.8~3.3mm	接触角为0°~105° 雷诺数为27~8880	光滑玻璃、粗糙玻璃、光滑石蜡；干表面/湿表面、液膜厚度为40~100µm	在较低角度和光滑或湿润表面易发生反弹；低黏性液滴会反弹或沉积在光滑或湿润表面；高黏度液滴也可能分解出小液滴，具体取决于撞击角度
樊玉光等^[21]	水、甘油（70%）；液滴直径50~100µm	接触角为36°~90°	液膜厚度为2.5mm	入射角度30°~90°，飞溅的临界We增大

相关研究	液膜材料	液膜破裂及二次液滴描述		适用范围
Samenfink等^[13]	蒸馏水	沉积质量分数： $η c = 1.0 - 0.0866 (s c d - 1.0) 0.3188 α i D 0.1223 h * - 0.9585$	二次液滴角度： $α s D = 2.154 s c d 1.0946 α i D 0.03389 h * - 0.1589$ 直径分布： $σ g, D s D = 0.3696 s c d - 0.1772 α i D 0.09163 h * 0.03177$	1.0<s_d<5.0 $5000 < L a < 20000$ 0.3<h^* <3.0 $5 ∘ < x i D < 90 ∘$
Mao等^[29]	含有荧光剂的水	厚度与气流速度关系： $u i n = 1.895 l c o s 3 θ μ l 2 σ ρ l ρ g μ g 1 / 3 1 h$	液膜厚度半经验公式： $h = 0.304 R e l 0.644 v 2 / g 1 / 3 H $ $H = e - (0.784 R e 0.248 H w)$	基于三个固定测量位置（46mm、60mm、80mm）
Wang等^[25]	含有荧光剂的水	水膜击穿的量纲为1临界条件： $R e l = 4.564 R L R e g 0.5 (δ + R) δ 1 W e a$	液膜雷诺数与气流韦伯数： $R e l = ρ l δ μ l U$ ； $W e a = ρ g u g 2 σ 1 L$	水膜厚度0.574~1.64mm以上
Wang等^[30]	水	水膜破裂临界气流速度： $u g f = 1.6554 μ g 2 σ d c o s θ μ g ρ g ρ l R + δ 12 δ 2 - δ R + R 2 × l n R + g R 12 = 1.6554 μ l 2 σ μ g ρ g ρ l 13 d c o s θ 1 R + δ 12 δ 2 - δ R + R 2 × l n R + δ R 12$ 水膜厚度半经验公式： $h = 0.0465 R e 0.8193 v 2 g 13$		Re<4055 忽略重力
Wang等^[31]	水	临界气流速度： $u g = 2.4 (d c o s θ (σ 1 - σ 2) μ l 2 ρ l ρ g μ g) 13 1 h$		层流
Wang等^[22]	含有荧光剂的水	液膜破裂相对高度： $H' = 0.081 R e 0.851 v 2 g 13 - 0.063 R e 1.702 v 2 g L 3 t a n 3 2 θ 23 3.318 d c o s θ Δ σ μ l 2 ρ l ρ g μ g 44 1 u 0 c o s 2 θ$	二次液滴粒径： $r = k 1 k 2 k 3 2$ $k 1 = 0.0196 ρ l ρ g μ g h 2 H u 0 c o s 2 θ 3 d c o s θ Δ σ μ l 2 π t a n 2 θ 3$ $k 2 = 2.4 (d c o s θ Δ σ μ 12 ρ l ρ g μ g) 13 1 u 0 c o s 2 θ - 0.0465 R e 0.8193 (v 2 g) 13 + 0.00216 R e 1.6386 v 2 g L 3 t a n 3 2 θ 23 23$ $k 3 = 0.081 R e 0.851 v 2 g 13 - 0.063 R e 1.702 v 2 g L 3 t a n 3 2 θ 23 3$	Re<2788 中小雷诺数区域
Wang等^[32]	含有荧光剂的水	条形液膜夹角经验公式： $α π = 1 - 0.084 R e 0.901 v 2 g 13 - 0.061 R e 1.802 v 2 g L 3 t a n 3 2 θ 23 / 3.320 d c o s θ Δ σ μ l 2 ρ l ρ g μ g 13 1 u 0 c o s 2 θ$		Re=1997~4055
Zeng等^[33]	水	液膜临界破裂速度： $u l c = 1.3139 ρ l h ¯ g - μ l 2 σ / ρ l R + h ¯ 12 h ¯ 2 - R h ¯ + R 2 l n R + h ¯ R 12 23 h ¯ c o s θ μ l ρ l 13$		Re=8640~25900

相关研究	液膜材料	液膜破裂及二次液滴描述		适用范围
Samenfink等^[13]	蒸馏水	沉积质量分数： $η c = 1.0 - 0.0866 (s c d - 1.0) 0.3188 α i D 0.1223 h * - 0.9585$	二次液滴角度： $α s D = 2.154 s c d 1.0946 α i D 0.03389 h * - 0.1589$ 直径分布： $σ g, D s D = 0.3696 s c d - 0.1772 α i D 0.09163 h * 0.03177$	1.0<s_d<5.0 $5000 < L a < 20000$ 0.3<h^* <3.0 $5 ∘ < x i D < 90 ∘$
Mao等^[29]	含有荧光剂的水	厚度与气流速度关系： $u i n = 1.895 l c o s 3 θ μ l 2 σ ρ l ρ g μ g 1 / 3 1 h$	液膜厚度半经验公式： $h = 0.304 R e l 0.644 v 2 / g 1 / 3 H $ $H = e - (0.784 R e 0.248 H w)$	基于三个固定测量位置（46mm、60mm、80mm）
Wang等^[25]	含有荧光剂的水	水膜击穿的量纲为1临界条件： $R e l = 4.564 R L R e g 0.5 (δ + R) δ 1 W e a$	液膜雷诺数与气流韦伯数： $R e l = ρ l δ μ l U$ ； $W e a = ρ g u g 2 σ 1 L$	水膜厚度0.574~1.64mm以上
Wang等^[30]	水	水膜破裂临界气流速度： $u g f = 1.6554 μ g 2 σ d c o s θ μ g ρ g ρ l R + δ 12 δ 2 - δ R + R 2 × l n R + g R 12 = 1.6554 μ l 2 σ μ g ρ g ρ l 13 d c o s θ 1 R + δ 12 δ 2 - δ R + R 2 × l n R + δ R 12$ 水膜厚度半经验公式： $h = 0.0465 R e 0.8193 v 2 g 13$		Re<4055 忽略重力
Wang等^[31]	水	临界气流速度： $u g = 2.4 (d c o s θ (σ 1 - σ 2) μ l 2 ρ l ρ g μ g) 13 1 h$		层流
Wang等^[22]	含有荧光剂的水	液膜破裂相对高度： $H' = 0.081 R e 0.851 v 2 g 13 - 0.063 R e 1.702 v 2 g L 3 t a n 3 2 θ 23 3.318 d c o s θ Δ σ μ l 2 ρ l ρ g μ g 44 1 u 0 c o s 2 θ$	二次液滴粒径： $r = k 1 k 2 k 3 2$ $k 1 = 0.0196 ρ l ρ g μ g h 2 H u 0 c o s 2 θ 3 d c o s θ Δ σ μ l 2 π t a n 2 θ 3$ $k 2 = 2.4 (d c o s θ Δ σ μ 12 ρ l ρ g μ g) 13 1 u 0 c o s 2 θ - 0.0465 R e 0.8193 (v 2 g) 13 + 0.00216 R e 1.6386 v 2 g L 3 t a n 3 2 θ 23 23$ $k 3 = 0.081 R e 0.851 v 2 g 13 - 0.063 R e 1.702 v 2 g L 3 t a n 3 2 θ 23 3$	Re<2788 中小雷诺数区域
Wang等^[32]	含有荧光剂的水	条形液膜夹角经验公式： $α π = 1 - 0.084 R e 0.901 v 2 g 13 - 0.061 R e 1.802 v 2 g L 3 t a n 3 2 θ 23 / 3.320 d c o s θ Δ σ μ l 2 ρ l ρ g μ g 13 1 u 0 c o s 2 θ$		Re=1997~4055
Zeng等^[33]	水	液膜临界破裂速度： $u l c = 1.3139 ρ l h ¯ g - μ l 2 σ / ρ l R + h ¯ 12 h ¯ 2 - R h ¯ + R 2 l n R + h ¯ R 12 23 h ¯ c o s θ μ l ρ l 13$		Re=8640~25900

基础结构	增强结构的主要功能			性能表现	参考文献
基础结构	增强捕集	降低压损	增强疏水	性能表现	参考文献
折线形	—	—	—	压降较低	[39]
	—	开孔/槽	双层叶片	对粒径10μm液滴具有较高的捕集效率	[40]
	凹槽	—	—	可以提高粒径小于20μm液滴的去除效率，压降较高	[37]
	单疏水钩	—	—	对于粒径8μm以上的液滴去除效率可以达到90%以上，压降在37~415Pa	[41-46]
	单疏水钩	开孔/槽	疏水钩	降低压损、提高捕集效率。气速5.5m/s效率最高，可达到90%以上	[38, 47]
	双疏水钩	—	—	对于粒径8μm液滴可以达到90%的分离效率	[1-2，16，48-50]
	双疏水钩	开孔/槽	疏水钩	保证捕集面积的同时减少压损，保证排液，减少二次夹带
	多孔材料	—	—	可以提高临界气速度（4~5m/s），减少二次夹带	[51]
	疏水钩	—	表面改性	气速超过5m/s后壁面液膜厚度减小，分离效率下降程度减小	[52]
流线形	—	—	—	粒径25μm液滴的分离效率80%以上，压降10~30Pa（2.5~6m/s）	[53-54]
	单疏水钩	—	疏水钩	对粒径10μm液滴分离效率为65%，粒径20μm液滴分离效率可以达到90%以上	[55-59]
	双疏水钩	—	疏水钩	压降10~150Pa（1~6m/s），临界气速度较无钩型提高28%（3~4m/s与4~5m/s）	[60]
	—	—	降膜流动	接触角越小，浸润面积越大	[61-62]
梯形	—	—	—	压降10~90Pa（2~7m/s），气速为2m/s时，粒径26μm的液滴100%收集	[65]
梯形	双疏水钩	—	疏水钩	减少二次夹带，增强排液，增大气体容量
Ω形	—	—	—	20~320Pa（2~8m/s），叶片间距18.2mm时，平均效率在90%以上	[66]

结构类型	结构参数	分离性能的影响	参考文献
折线形/单钩型	疏水钩、叶片间距	沿程液滴尺寸有减小的趋势，当加入疏水钩时减小的速率更大，当叶片间距变大时减小变得更慢；气速分别为2.96m/s、4.14m/s、6m/s、8m/s时，折线形入口和出口之间的液滴尺寸减小8%、14%、22%、28%，而带疏水钩的分别减小50%、57%、64%和69%	[41, 68]
折线形、单钩型、双钩型	疏水钩数量叶片间距12mm、14mm、16mm、18mm、20mm	分离效率随着间距的增加而减小，间距相同时单钩效率最高，折线形最低；随着间距增加，压降减小，但达到某一值后下降幅度不明显；带疏水钩结构比无疏水钩结构下降幅度更大	[48]
流线形/单钩型	疏水钩横向间距30mm、20mm	带有疏水钩结构在相同条件下效率高于无疏水钩结构，压降也会更高；较小的间距分离效率和压力损失较高	[55]
带排液槽结构叶片	排液槽高度260mm、200mm 挡板数量1、3	挡板数量相同时，排液槽高度越高，分离性能反而下降；排液挡板数量的增加会使得临界分离气速升高；挡板数量增加会使得压降增大，排液槽高度对压降影响不大	[69]
单钩型	钩板高度1~15mm、长度 0~9mm、夹角-9°~9°	分离效率随钩板高度的增加而增加；β>0时，分离效率随钩板长度的增加而减小；β=0时，分离效率随钩板长度的增加而先增加后减小；β<0时，分离效率随着钩板长度的增加而增加；压降随着钩板高度的增加而增加，随着钩板长度的增加而减小，随着角度的增加而减小	[44]
流线形/单钩型	弯曲级数；弯曲波长	弯曲级数增加，液滴去除效率增加，压降增大；具有较小弯曲波长的叶片（λ/s=2.37）比更大的波长分离效率、压降更高，大波长（λ/s>7.11）叶片，量纲为1的波长增加对分离效率和压降影响不大	[45, 70]
单钩型	弯折曲率	在一定折角曲率条件下，有助于减少带疏水钩结构叶片的压力损失	[39]
带孔板结构	穿孔板间距、数量、厚度、孔隙率、安装角、孔板高度	孔板数较少时，捕集效率较高但压损大，随着孔板数量增加，会形成滞流区；板间距较大（15mm）时，捕集能力减弱；孔板厚度对分离效率影响较小，增加厚度，去除效率略微提升，但压损增大；随着孔间距增加（孔隙率降低），整体收集效率提高；压降先增大后减小；随着孔板率增加，效率降低，压降减小并逐渐达到平衡；捕集效率和压降随着安装角度的增大而不断减小，捕集效率随孔板高度的增加而小幅增加	[38, 47]

结构类型	结构参数	分离性能的影响	参考文献
折线形/单钩型	疏水钩、叶片间距	沿程液滴尺寸有减小的趋势，当加入疏水钩时减小的速率更大，当叶片间距变大时减小变得更慢；气速分别为2.96m/s、4.14m/s、6m/s、8m/s时，折线形入口和出口之间的液滴尺寸减小8%、14%、22%、28%，而带疏水钩的分别减小50%、57%、64%和69%	[41, 68]
折线形、单钩型、双钩型	疏水钩数量叶片间距12mm、14mm、16mm、18mm、20mm	分离效率随着间距的增加而减小，间距相同时单钩效率最高，折线形最低；随着间距增加，压降减小，但达到某一值后下降幅度不明显；带疏水钩结构比无疏水钩结构下降幅度更大	[48]
流线形/单钩型	疏水钩横向间距30mm、20mm	带有疏水钩结构在相同条件下效率高于无疏水钩结构，压降也会更高；较小的间距分离效率和压力损失较高	[55]
带排液槽结构叶片	排液槽高度260mm、200mm 挡板数量1、3	挡板数量相同时，排液槽高度越高，分离性能反而下降；排液挡板数量的增加会使得临界分离气速升高；挡板数量增加会使得压降增大，排液槽高度对压降影响不大	[69]
单钩型	钩板高度1~15mm、长度 0~9mm、夹角-9°~9°	分离效率随钩板高度的增加而增加；β>0时，分离效率随钩板长度的增加而减小；β=0时，分离效率随钩板长度的增加而先增加后减小；β<0时，分离效率随着钩板长度的增加而增加；压降随着钩板高度的增加而增加，随着钩板长度的增加而减小，随着角度的增加而减小	[44]
流线形/单钩型	弯曲级数；弯曲波长	弯曲级数增加，液滴去除效率增加，压降增大；具有较小弯曲波长的叶片（λ/s=2.37）比更大的波长分离效率、压降更高，大波长（λ/s>7.11）叶片，量纲为1的波长增加对分离效率和压降影响不大	[45, 70]
单钩型	弯折曲率	在一定折角曲率条件下，有助于减少带疏水钩结构叶片的压力损失	[39]
带孔板结构	穿孔板间距、数量、厚度、孔隙率、安装角、孔板高度	孔板数较少时，捕集效率较高但压损大，随着孔板数量增加，会形成滞流区；板间距较大（15mm）时，捕集能力减弱；孔板厚度对分离效率影响较小，增加厚度，去除效率略微提升，但压损增大；随着孔间距增加（孔隙率降低），整体收集效率提高；压降先增大后减小；随着孔板率增加，效率降低，压降减小并逐渐达到平衡；捕集效率和压降随着安装角度的增大而不断减小，捕集效率随孔板高度的增加而小幅增加	[38, 47]

公司单位	结构形式	分离参数	应用场景
CECO Peerless	单钩型	>8μm（100%）	小容量
Ensepatec	折线型&疏水槽	4.5m/s，气体处理量±30%	洗涤器、蒸发器
Ensepatec	单钩型/双钩型	8~20μm（99.9%）	液气比>30
Koch-Glitsch	梯型&底部排液孔	10~40μm；100~872Pa	黏性液体、高液体负载
	单钩型&疏水槽		高压、大容量
	双钩型		高压、大容量
Sulzer	梯型	K=0.17m/s；30~40μm	高黏度流体
	折线型	K=0.14m/s；25μm	高黏度流体
	单钩型	K=0.35m/s；25~30μm/35~40μm	高效气液分离、高黏度易结垢
	双钩型&疏水孔	K=0.17~0.45m/s；10~15μm	高效气液分离、高黏度易结垢
AMACS	梯型	20μm（90%），40μm（99.9%）；K=0.076~0.351m/s 77.7~1476.38Pa；气体处理范围30%~110%	丝网后端以提高液体容量、蒸馏塔
AMACS	梯型&双钩&疏水槽		丝网后端以提高液体容量、蒸馏塔

研究单位	结构形式	分离性能	应用场景
美国FMC Technologies公司管式相分离器^[76]	分流器、叶片、分离段、气体抽出口、气相及液相出口	单级分离，结构简单，但变工况时稳定性较差	入口含气率范围为0.5~0.9
挪威国家石油公司（Statoil） CompactSepTM系统^[77]	GLCC分离器、管式脱气器和（或）管式脱液器串联	分离效果较好，但控制复杂，且二级分离易受一级分离干扰	入口含气率范围为0.15~0.6
哈尔滨工程大学管式气液分离器^[78]	多级旋流元件串联、竖直方式	分离效率较高，但相同条件下处理液量较低	入口含气率范围0.05~0.9

相关研究	操作工况	研究结果
Tang等^[43]	2~4m/s；液滴尺寸3.4~13.5μm	在接近完全分离之前，随着液滴尺寸的增加，分离效率呈上升趋势
徐旭辉等^[49]	入口湿度30%~60% 雷诺数60000~180000 常温常压	出口湿度随入口湿度的增加和雷诺数的增加呈增长状态；当入口湿度和雷诺数较低时，出口湿度变化平缓；而当入口湿度和雷诺数较高时，出口湿度较高，变化幅度较大
Song等^[55]	2.5~6m/s；粒径分布；常压	当液滴直径小于4μm时，分级效率异常的高，发生“鱼钩”效应；小于5μm的液滴出口处液滴质量浓度高于入口，表明发生液滴再夹带
Li等^[85]	2~8m/s 0.101MPa，20℃（常温常压） 7MPa，286℃（高温高压）	分离效率随着气速先增加后减小；随着粒径增大，分级效率显著提高；临界分离粒径随着气速增加而减小。在高温、高压条件下，临界分离粒径增大。
Koopman等^[41]	1~19m/s；液体质量分数 2%~9%常温常压	带圆孔排液结构的叶片效率随着液滴质量分数的增加而提高，而压降受液滴质量分数的影响不大
Li等^[69]	4~12m/s；入口湿度6%、8%常温常压	入口湿度差在2%以内时对临界分离气速影响不明显；其他条件相同时，入口湿度越大，效率越高

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