IP Verse

Modular Cyclone

Patent No. US11839883 (titled "Modular Cyclone") was filed by Pnc Bank Na on Feb 23, 2021.

What is this patent about?

’883 is related to the field of cyclone separators , specifically those used to remove solids, such as sand, from fluids extracted from wells. Traditional cyclone separators are often replaced entirely when fluid properties like flow rate, viscosity, or particle size change, leading to downtime and expense. The patent addresses the need for a more adaptable solution that can be modified in situ to accommodate changing well conditions.

The underlying idea behind ’883 is to create a modular cyclone separator where key internal components can be easily swapped out to optimize performance for different fluid characteristics. Instead of replacing the entire cyclone, the operator can select from a kit of inserts with varying geometries to fine-tune the separation process. This allows for a more flexible and cost-effective approach to solids removal in well operations.

The claims of ’883 focus on a cyclone sand separator kit comprising a cyclone body and a plurality of cyclone inserts with different geometries, including variations in inner diameter, length, conical section angles, underflow outlet sizes, and vortex finder placements. The claims also cover a method for assembling such a separator by selecting appropriate inserts based on well flow conditions and a modular cyclone separator with removable inlet, cyclone, and cyclone starter inserts.

In practice, the operator first determines the volumetric flow rate, target velocity, and other relevant parameters of the fluid coming from the well. Based on these measurements, they select an appropriate inlet insert to achieve the desired fluid velocity entering the cyclone body. Then, they choose a cyclone starter insert and a cyclone insert with specific dimensions to optimize the vortical flow and dwell time within the cyclone, maximizing the separation of solids from the fluid.

This modular design differentiates itself from traditional cyclones by allowing for on-site adjustments to optimize performance without requiring complete replacement. The use of removable inserts with varying geometries enables fine-tuning of the separation process to match changing well conditions, reducing downtime and costs associated with traditional cyclone replacement. The design also incorporates features like a suspended sand hopper for accurate measurement of collected solids and a blow-down nozzle for easy removal of accumulated sand.

How does this patent fit in bigger picture?

Technical landscape at the time

In the late 2010s when ’883 was filed, systems commonly relied on computational fluid dynamics (CFD) simulations to optimize cyclone separator designs, at a time when hardware or software constraints made real-time adjustments to cyclone geometry non-trivial. At that time, cyclone separators were typically implemented using fixed geometries optimized for specific flow conditions, when systems commonly relied on fixed configurations rather than adaptive designs.

Novelty and Inventive Step

The application was subject to a final rejection. Claims were rejected for obviousness-type double patenting and obviousness over prior art. The applicant amended the claims and presented arguments, but the examiner found the arguments unpersuasive. The prosecution record describes claim changes and the examiner's technical reasoning for the rejections.

Claims

This patent includes 19 claims, with independent claims 1, 13, and 18. Independent claims focus on a cyclone sand separator kit, a method for assembling a cyclone separator, and a modular cyclone separator, respectively. The dependent claims generally elaborate on the features, components, and steps of the independent claims.

Key Claim Terms New

Definitions of key terms used in the patent claims.

Term (Source)Support for SpecificationInterpretation
Cyclone insert
(Claim 1, Claim 13, Claim 18)		“The kit also includes a plurality of cyclone inserts configured to be positioned in the cyclone body, at least partially between the inlet and the solids outlet and at least partially between the fluids outlet and the solids outlet. The cyclone inserts each define a vortical section configured to induce inertial separation of the mixed fluid, and include different geometries including different inner diameters, different lengths for respective cylindrical sections thereof, different angles for respective conical sections thereof, different underflow outlet sizes, different vortex finder placements, or a combination thereof.”A component configured to be positioned within the cyclone body, defining a vortical section for inertial separation of mixed fluid. These inserts have varying geometries.
Cyclone starter insert
(Claim 13, Claim 18)		“The separator further includes a cyclone starter insert removably coupled to the cyclone insert and positioned in the cyclone body, wherein the cyclone starter insert is received at least partially in the cyclone insert, and wherein the cyclone starter insert is configured to induce a vortical flow in the mixed fluid received through the inlet insert.”A component removably coupled to the cyclone insert and positioned in the cyclone body, configured to induce a vortical flow in the mixed fluid received through the inlet insert.
Inlet insert
(Claim 1, Claim 13, Claim 18)		“The separator also includes an inlet insert removably positioned in inlet and coupled to an outside of the cyclone body, the inlet insert having a bore and a nozzle configured to direct the mixed fluid generally tangent to an interior surface of the cyclone body, at least a portion of the bore decreasing in diameter as proceeding to a tip of the nozzle.”A component configured to be positioned at least partially in the inlet of the cyclone body. The inlet inserts are selectable depending on a well flow condition. The inlet inserts are rigid and configured to be fixed in place at least partially in the inlet, such that the inlet inserts do not move with respect to the inlet, and wherein the inlet inserts each include a flange for removable connection of the inlet inserts into the inlet.
Underflow outlet
(Claim 18)		“The separator also includes an inlet insert removably positioned in inlet and coupled to an outside of the cyclone body, the inlet insert having a bore and a nozzle configured to direct the mixed fluid generally tangent to an interior surface of the cyclone body, at least a portion of the bore decreasing in diameter as proceeding to a tip of the nozzle.”An outlet of the cyclone body to which the underflow, separated from the mixed fluid, is directed.
Vortical section
(Claim 1, Claim 13)		“The kit also includes a plurality of cyclone inserts configured to be positioned in the cyclone body, at least partially between the inlet and the solids outlet and at least partially between the fluids outlet and the solids outlet. The cyclone inserts each define a vortical section configured to induce inertial separation of the mixed fluid, and include different geometries including different inner diameters, different lengths for respective cylindrical sections thereof, different angles for respective conical sections thereof, different underflow outlet sizes, different vortex finder placements, or a combination thereof.”A section within the cyclone insert that is configured to induce inertial separation of the mixed fluid.

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US11839883

PNC BANK NA
Application Number
US17182803
Filing Date
Feb 23, 2021
Status
Granted
Expiry Date
Jul 1, 2039
External Links
Slate, USPTO, Google Patents