Key information

Title: A filter device, and method of assembly
Application number: 20181546
Case type: National
Status: 12.10.2020 Patent meddelt (B1)
Filed: 30.11.2018
Effective date: 30.11.2018
Publicly available: 01.06.2020
Next annual fee due: 30.11.2026
Applicant: AKER SOLUTIONS AS (NO)
Owner: Aker Carbon Capture Norway AS (NO)
Inventor: Pål Helge Nøkleby (NO) et al.
Agent: ZACCO NORWAY AS (NO)
Granted: 12.10.2020
Patent number: 345138
Expiry date: 30.11.2038

Abstract and drawing

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content.

A filter device comprises two or more membrane filter units (108), each having an inlet opening for a fluid flow (F) to be processed, a first outlet opening for at least one portion (R) of said fluid flow and second outlet port for at least a remaining portion (P) of said fluid flow. The respective inlet openings of each membrane filter unit (108) are fluidly connected to a common inlet manifold (101; 203) and the respective first outlet openings of each membrane filter unit (108) are fluidly connected to a common outlet manifold (100; 200): The manifolds are structurally interconnected by connection means (109; 126, 127) to form a unitary membrane filter cartridge (120; 120’; 210).

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Date

Date	Doc. No.	Process	Case number	In/Out	Journal description	To/from
18.06.2021	02-01	Endring av fullmektig	2021/08135	UT	GH Forespørsel	ZACCO NORWAY AS
11.06.2021	03-01	Overdragelse av søknad/rettighet	2021/05575	UT	GH Forespørsel	ZACCO NORWAY AS
09.06.2021	04-03	Overdragelse av søknad/rettighet	2021/05575	INN	NO Patents Zacco
09.06.2021	04-02	Overdragelse av søknad/rettighet	2021/05575	INN	2021-05-25 General POA - signed
09.06.2021	04-01	Overdragelse av søknad/rettighet	2021/05575	INN	Korrespondanse (Hovedbrev inn)
01.06.2021	01-02	Endring av fullmektig	2021/08135	INN	Power of Attorney NO	ZACCO NORWAY AS
01.06.2021	01-01	Endring av fullmektig	2021/08135	INN	Generell henvendelse	ZACCO NORWAY AS
29.04.2021	02-01	Overdragelse av søknad/rettighet	2021/05575	UT	GH Forespørsel	ZACCO NORWAY AS
13.04.2021	01-07	Overdragelse av søknad/rettighet	2021/05575	INN	List of Cases - NO 104381	ZACCO NORWAY AS
13.04.2021	01-06	Overdragelse av søknad/rettighet	2021/05575	INN	5- Clean Carbon to Aker Engineering and Technology 104382	ZACCO NORWAY AS
13.04.2021	01-05	Overdragelse av søknad/rettighet	2021/05575	INN	4- Aker Solutions AS_merger confirmation 104386	ZACCO NORWAY AS
13.04.2021	01-04	Overdragelse av søknad/rettighet	2021/05575	INN	- Certificate of Registration - ACC 104385	ZACCO NORWAY AS
13.04.2021	01-03	Overdragelse av søknad/rettighet	2021/05575	INN	- Withdrawal of name registration 104384	ZACCO NORWAY AS
13.04.2021	01-02	Overdragelse av søknad/rettighet	2021/05575	INN	- ACC APA - EXECUTION VERSION (Signed) only pages related to ransfer of IP 104383	ZACCO NORWAY AS
13.04.2021	01-01	Overdragelse av søknad/rettighet	2021/05575	INN	Generell henvendelse	ZACCO NORWAY AS
16.10.2020	12-01	Saksbehandling	20181546(345138)	UT	PT Registreringsbrev Nasjonal Patent (15) (PT20181546)
06.10.2020	11-01	Saksbehandling	20181546(345138)	UT	PT Varsel om betaling av første årsavgift (3317) (PT20181546)
29.07.2020	10-01	Saksbehandling	20181546	UT	Intention to grant	ZACCO NORWAY AS
19.05.2020	09-04	Saksbehandling	20181546	INN	Beskrivelse merket	ZACCO NORWAY AS
19.05.2020	09-03	Saksbehandling	20181546	INN	Beskrivelse ren	ZACCO NORWAY AS
19.05.2020	09-02	Saksbehandling	20181546	INN	Hovedbrev	ZACCO NORWAY AS
19.05.2020	09-01	Saksbehandling	20181546	INN	Korrespondanse (Hovedbrev inn)	ZACCO NORWAY AS
25.03.2020	08-01	Saksbehandling	20181546	UT	Realitet patent	ZACCO NORWAY AS
01.11.2019	06-04	Saksbehandling	20181546	INN	Beskrivelse	ZACCO NORWAY AS
01.11.2019	06-03	Saksbehandling	20181546	INN	Beskrivelse med sporing	ZACCO NORWAY AS
01.11.2019	06-02	Saksbehandling	20181546	INN	Hovedbrev	ZACCO NORWAY AS
01.11.2019	06-01	Saksbehandling	20181546	INN	Korrespondanse (Hovedbrev inn)	ZACCO NORWAY AS
31.10.2019	07-01	Saksbehandling	20181546	INN	Korrespondanse (Hovedbrev inn)	ZACCO NORWAY AS
06.06.2019	05-02	Saksbehandling	20181546	UT	PT_report 10:19:58
06.06.2019	05-01	Saksbehandling	20181546	UT	Realitet patent	ZACCO NORWAY AS
12.02.2019	04-02	Saksbehandling	20181546	INN	Erklæring Søkers rett til oppfinnelse	ZACCO NORWAY AS
12.02.2019	04-01	Saksbehandling	20181546	INN	Korrespondanse (Hovedbrev inn)	ZACCO NORWAY AS
05.12.2018	03-01	Saksbehandling	20181546	UT	Formal Examination 1	ZACCO NORWAY AS
05.12.2018	02-01	Saksbehandling	20181546	UT	Infobrev til oppfinner	ZACCO NORWAY AS
30.11.2018	01-04	Saksbehandling	20181546	INN	Fullmakt	ZACCO NORWAY AS
30.11.2018	01-03	Saksbehandling	20181546	INN	Beskrivelse	ZACCO NORWAY AS
30.11.2018	01-02	Saksbehandling	20181546	INN	Patenttegninger	ZACCO NORWAY AS
30.11.2018	01-01	Saksbehandling	20181546	INN	Søknadsskjema Patent	ZACCO NORWAY AS

Description, claims and drawings

Disclaimer: This text has been machine-scanned and may contain errors – please refer to "Publications" for legally binding content.

Description

A filter device, and method of assembly

Field of the invention

The invention concerns the field of fluid processing, and more precisely filtration of fluids using a plurality of membrane filters. More specifically, the invention concerns a filter device, a membrane filter unit, and an associated method of installation, as set out by the preambles of claims 1 and 11.

Background of the invention

A membrane filter comprises one or more membranes (thin sheets or films) having specific pore sizes. When a fluid (e.g. a gas or a liquid) is forced against the membrane, particles larger than the pore size are retained, while the remaining fluid particles are allowed to permeate through the membrane pores. The retained particles may be for example microbiological particles, molecules, or ions, depending on the pore size.

Examples of membrane filter types, defined by their pore size, are microfilters, ultrafilters, and nanofilters.

Membrane filters are used in various technical fields (e.g. water purification and gas purification) and industries (e.g. public utility services, oil and gas exploration). For example, one type of membrane filter is used for removing water from hydrocarbon wellstreams, while another membrane filter type is used for removing unwanted constituents from a natural gas. Membrane filters for land-based applications generally comprise several membranes filters which are assembled as individual vessels and interconnected with small pipework. For such applications, the filters are placed horizontally or vertically and may be grouped in many hundreds of membrane vessels in one installation. This is a well-known configuration for municipal water treatment plants, and often cover large areas. However, for subsea use this configuration is impractical and in many cases impossible due to the footprint taken up by so many units. Furthermore, the weight would be too great and the entire system would be prone to be damaged during handling at offshore installations.

The prior art includes US 6017 451 A, which describes a spider fitting for a multimodule filtration system. A multi-arm spider fitting comprises a central hub from which individual arms radiate. The arms are adapted at their extremities for coupling with filter modules, so that multiple filter modules can be secured to a single spider fitting, spaced around the central hub circumference. The multi-arm spider fitting and filter modules are arranged inside a movable cart. The prior art also comprises CN 104226120 A, WO 00/62908 A1, WO 2016/108697 A1, and JP 2004/136173 A, which all describe membrane filter units.

A trend in the oil and gas industry is that hydrocarbons produced from subterranean subsea wells are processed by subsea equipment before further export to onshore plants or topsides facilities. It is therefore necessary to adapt existing designs such that they may be used in the harsh environment that is found subsea and may be safely handled by the applicable and available equipment for subsea installation and intervention.

WO 2016/108697 A1 (to Aker Subsea AS) describes a process system in which a gaseous stream containing a mixture of hydrocarbon gases, CO2 and water vapour is fed into a membrane separator. The membrane generally comprises a polymer material such as PEEK (polyether ether ketone), and allows permeation of CO2 gas and inorganic compounds while retaining the typical hydrocarbon gas components. Thus, exiting from the membrane separator are a retentate stream of enriched hydrocarbon gas and a permeate stream comprising CO2 gas and inorganic compounds. Because the pressure drops across the membrane, the permeate stream pressure is lower than the gas feed stream pressure and the retentate stream pressure.

When membrane filters are used for processing well fluids from subterranean hydrocarbon reservoirs, particularly at subsea (seabed) locations, weight and size of the membrane separator units are crucial parameters. Units with low weights, low heights and small footprint are preferred, due to weight and space constraints for the installation vessels, as well as for interface with other seabed components when installed.

There are today several designs for multiple membrane filters and filter packaging. These are, however, based on multiple membrane filters arranged between two plates, one each at the end of a vessel, with the inlet and outlets of two of the membrane ends terminating in each of the two ends. This allows for only one level of membranes with the vessel internal diameter, none of the solutions allow for more than one level of membrane filters. The assemblies are also built up of complicated end seals and retaining plates for sealing the flows from each other at each end of the vessel.

To accommodate more membrane filters, these vessels are increased in diameter to sizes up to 3 meters or more. There are normally no high pressures involved, so the vessel wall material thicknesses and body flange sizes are within normal manufacturing possibilities.

For prior art designs suitable for subsea use, any pressure vessel with a body flange should not exceed 42 inches in diameter; this is the present-day (prior art) maximum high pressure flange available in the form of a compact flange approved for subsea use. In the prior art, API flanges do not normally go to sizes more than 12 inches, it is therefore considered that the largest pressure vessel for subsea use, with a full body flange, shall be no greater than the maximum available compact flange diameter as used subsea and as specified by ISO 27509 (first edition, 2012-12-15).

The prior art includes the above mentioned WO 2016/108697 A1, which describes a subsea separation plant where a membrane separator is arranged in a pressure vessel adapted for subsea use. The pressure vessel comprises two housing parts interconnected by respective flanges, and has a gas inlet opening for receiving gas to be treated, a retentate outlet opening, and a permeate outlet opening. A membrane cartridge assembly is made up of a plurality of membrane cartridges. Each membrane cartridges comprises an outer sleeve which houses a substantially cylindrical membrane element. An opening in each sleeve allows gas to enter the cartridge and flow past the membrane element.

While the prior art membrane separators configured for subsea use are compact in comparison to land-based membrane separator systems, further improvements are still needed, to cope with increasing demands for compactness, retrievability, reliability and ability to withstand harsh conditions (including extreme external pressures).

The prior art also includes US 2013/0168307 (to Siemens AG), which describes a pressurized cylindrical filtration vessel, comprising a filter element made up of a plurality of filtration membrane modules (e.g. ultrafiltration membrane modules), a distributor connected to an inlet for distributing an input fluid to the filter element, and a collector connected to an outlet for collecting an output fluid from the filter element. Multiple membrane filters are arranged in a single level between two end plate arrangements. The collection/distribution region is the pressure vessels end, which is a flanged elliptical domed region retained by clamps or bolted in place. This prior art document shows a complex build-up of seal plates, seals and attachments required to isolate each end from the rest of the vessel. These types of designs often require two vessel body flanges which again add to the weight of the vessel. Furthermore, any problem with an individual membrane filter will require a complete dismantling of the assembly to access and remove or replace the membrane filter.

The installation and retrieval of a process unit to or from a seabed location can incur high costs and risk, it is important that this operation can be done efficiently with a minimum of down time. One major factor in reducing downtime, is to minimise the weight of the process unit being handled. During the recent years, interest has developed for more compact process units/modules, especially for operations in deep waters (e.g. to 3000 meters water depth) were the external pressures exerted on equipment requires extreme material strength which in turn adds to material being thicker and hence heavier (typically pressure vessels). In addition to the need for handling lighter units, their weather deployment operational window can be greatly increased.

Many removable subsea process units are heavy due to their surrounding structural supports and/or protection frame, together with the process unit vessel (e.g. outer body), connection devices, piping and valves etc. Most subsea intervention requirements for filtration equipment is for the internal components and would normally require renewal, reconfiguring or cleaning etc. In some cases, due to changes in well stream characteristics, the process unit could be better favoured with an alternative type or number of filter units.

Summary of the invention

The invention is set forth and characterized in the main claim, while the dependent claims describe other characteristics of the invention.

It is thus provided a filter device, comprising two or more membrane filter units, each having an inlet opening for a fluid flow to be processed, a first outlet opening for at least one portion of said fluid flow and second outlet port for at least a remaining portion of said fluid flow,and the respective inlet openings of each membrane filter unit are fluidly connected to a common inlet manifold and the respective first outlet openings of each membrane filter unit are fluidly connected to a common outlet manifold, characterized in that at least one membrane filter unit is arranged at a first position along a longitudinal axis and at least one membrane filter unit is arranged at a second position along the longitudinal axis, and the said two memberane filter units are not axially aligned.

In one embodiment, the manifolds are structurally interconnected by connection means, to form a unitary membrane filter cartridge.

In one embodiment, the membrane filter units are elongated members that are arranged along a longitudinal axis of the unitary membrane filter cartridge.

The inlet manifold and the outlet manifold of a plurality of membrane filter cartridges may be connected to a respective augmented inlet manifold and augmented outlet manifold, to form an augmented unitary membrane filter cartridge.

In one embodiment, the membrane filter units are arranged at different positions along a longitudinal axis of the unitary membrane cartridge. The unitary membrane filter cartridge and the augmented unitary membrane filter cartridge may each form unitary, elongated, bodies around a common longitudinal axis.

In one embodiment, the unitary membrane filter cartridge and the augmented unitary membrane filter cartridge are each configured to be inserted into a pressure-retaining device having a circular cross-section, such as a pressure vessel or pipe.

A plurality of unitary membrane filter cartridges may be fluidly and structurally interconnected in an end-to-end relationship, to form a cartridge string.

In one embodiment, the augmented unitary membrane filter cartridge may comprise connection means whereby the membrane filter cartridge may be connected to, and supported by, a first pressure vessel part as one single unit.

The structural connection means may comprise an interlocking member configured to provide structural integrity and to lock the membrane filter units and manifolds together. The interlocking member may be connected to the inlet manifold and to the outlet manifold.

It is also provided a membrane filter unit, characterized by the filter device according to the invention, arranged in a pressure vessel and being fluidly connected to an inlet port and an outlet port of the pressure vessel; the pressure vessel further comprising an opening through which filtered fluid may pass.

The filter device according to the invention may be used at a subsea location, where the one or more unitary membrane filter cartridges or one or more augmented unitary membrane filter cartridges are arranged in a pipe or a pressure vessel, and a hydrocarbon fluid is flowed into an inlet port of the device and a retentate is flowed out of an outlet port of the device. The device may be placed on a seabed location in an upright (substantially vertical) orientation or in a substantially horizontal orientation.

The invention enables the packaging of multiple membrane filter units as a single unitary cartridge, or augmented cartridges, for installation into the confined space of a pressure retaining device, such as a pipe or a pressure vessel .

Brief description of the drawings

These and other characteristics of the invention will become clear from the following description of a preferential form of embodiment, given as a non-restrictive example, with reference to the attached drawings (not to scale), wherein:

Figure 1a is a side view of a typical membrane filter, whereas figure 1b illustrates an embodiment of a membrane filter unit, comprising a membrane filter, end cap and fittings;

Figure 2 is a schematic drawing of a first embodiment of a unitary membrane filter cartridge, comprising two membrane filter units connected to common manifolds and associated conduits;

Figure 3 is a schematic drawing of a second embodiment of a unitary membrane filter cartridge, comprising eight membrane filter units connected to common manifolds and associated conduits;

Figure 4 is a perspective drawing of the embodiment illustrated in figure 3, in a partly assembled state;

Figure 5 is a perspective drawing of the embodiment illustrated in figure 4, in an assembled state;

Figure 6 is an enlarged view of the area marked "A" in figure 4;

Figure 7 is an enlarged view of the area marked "B" in figure 4, however with certain parts removed for illustration purposes;

Figure 8 is a view from above, along the longitudinal axis, of the embodiment illustrated in figure 5;

Figure 9 is a view from below, along the longitudinal axis, of the embodiment illustrated in figure 5;

Figure 10 is a schematic drawing of a third embodiment of a unitary membrane filter cartridge, comprising three unitary membrane filter cartridges of the second embodiment connected to common manifolds and associated conduits;

Figure 11 is an exploded view of the embodiment illustrated in figure 10;

Figure 12 is a perspective drawing of the embodiment illustrated in figure 11, in an assembled state;

Figure 13 is an enlarged view of the area marked "C" in figure 12, however as a partly exploded view;

Figure 14 is an enlarged view of the area marked "D" in figure 12, however as a partly exploded view;

Figure 15 is a view from above, along the longitudinal axis, of the embodiment illustrated in figure 12;

Figure 16 is a sectional side view of the embodiment illustrated in figure 12, installed in a pressure vessel;

Figure 17 is a sectional side view of the embodiment illustrated in figure 12, connected to a first section of a pressure vessel and partly inserted into a second section of the pressure vessel;

Figure 18 corresponds to figure 17, but shows a reversed orientation,

Figure 19 is a sectional side view of a variant of the first section of the pressure vessel illustrated in figures 16-18;

Figure 20 is a sectional side view of a variant of the second section of the pressure vessel illustrated in figures 16-18;

Figure 21 is a schematic drawing of a fourth embodiment of a unitary membrane filter cartridge, comprising six membrane filter units connected to common manifolds and associated conduits;

Figure 22 is an exploded view of the embodiment illustrated in figure 21, less the membrane filter units;

Figure 23 is a perspective view of the embodiment illustrated in figure 21;

Figure 24 is a schematic drawing of a fifth embodiment of a unitary membrane filter cartridge, comprising three unitary membrane filter cartridges of the fourth embodiment connected to common manifolds and associated conduits;

Figure 25 is a side view of three unitary membrane filter cartridges according to the embodiment illustrated in figure 23, in a disassembled state;

Figure 26 correspond to figure 25, and shows the three unitary membrane filter cartridges in an assembled state, forming the fifth embodiment illustrated in figure 24;

Figure 27 is a perspective view of the unitary membrane filter cartridge illustrated in figure 26, installed in a pipe;

Figure 28 is a perspective view of the unitary membrane filter cartridge illustrated in figure 26, installed in a pipe; and

Figures 29 and 30 are perspective views comparing an embodiment of the invention to an example of the prior art.

Detailed description of embodiments of the invention

The following description may use terms such as “horizontal”, “vertical”, “lateral”, “back and forth”, “up and down”, ”upper”, “lower”, “inner”, “outer”, “forward”, “rear”, etc. These terms generally refer to the views and orientations as shown in the drawings and that are associated with a normal use of the invention. The terms are used for the reader’s convenience only and shall not be limiting.

The invention relates to the assembly of multiple (i.e. two or more) membrane filters to form a unitary cartridge for insertion into a pressure retaining device such as a cylindrical vessel or a pipe. In the embodiments described in the following, the membrane filter is an ultra-filtration unit, which is well known in the art. One example of such membrane filter 60 is shown in figure 1a. The membrane filter has generally one process flow into the filter, and two process flows out. The process flow into the filter is unfiltered, and one portion of the process flow passes through the membrane (the permeate), while the remaining portion of the process flow exits along the hollow fibres of the membrane (the retentate). In figure 1a, two flow scenarios are illustrated.

Reference sign Fa designates the unfiltered flow into the membrane filter, Ra designates the retentate, while Pa designates the permeate flow. In a reversed-flow process, unfiltered flow Fb is flowed towards the membrane, permeate Pb flows out of the membrane, while the retentate Rb does not pass through the membrane. The skilled person will understand that in a practical application, the membrane filter is encased by a vessel (not shown in figure 1a). Although the invention is applicable to both flow scenarios, it should be understood that the former is the most commonplace. It should be understood that the membrane filter can be orientated in either vertical or horizontal direction, and the flow pattern is commonly described relative to its orientation.

The membrane filter 60 can have many different forms at the filter ends. However, however whatever the form (whether plain or fitted with connections such as a pipe insert or flanged ends) the design would be modified to suit the connecting parts and does not deter from the form of the invention.

Figure 1b illustrates how the membrane filter 60, in a practical application, is furnished with an end cup 62 (at the retentate R end) and a pipe fitting 61 at the process inflow F end. The end cup 62 is furnished with a flange 63 for firm connection to further pipework, and the end cup 62 is fitted to the retentate end of the membrane filter 60 via an O-ring 65 in order to seal the retentate end to the end cup. This secure and flanged connection is necessary, as there is normally a large pressure drop across this end of the membrane filter. The pipe fitting 61 is furnished with an O-ring seal 64, which is configured for sealingly engage with a socket (not shown in figure 1b), which is described below. This end of the membrane filter has normally very little pressure difference, and does therefore not require to be a flanged end.

The membrane filter 60 and end fittings 61, 62 will in the following generally be referred to as a membrane filter unit 108. It should be noted, however, that the illustrated flanged end cup and O-ring seals are only one example of many possible connection means. For example, other connections could be welded, clamped or screwed. Such connection means are well known to the skilled person, and need therefore not be described in further detail.

Referring now to figure 2, the invented apparatus comprises in its most basic form a plurality (i.e. two or more) membrane filter units 108 arranged in parallel and connected to common manifolds 100, 101, which in turn are connected to respective inlet conduit 111 and outlet conduit 112. In the illustrated embodiment, one membrane filter unit 108 is fluidly connected to the manifolds via respective conduits 103, 105 and the other membrane filter unit 108 is fluidly connected to the manifolds via respective conduits 102, 104. This assembly of membrane filter units 108 thus forms a unitary membrane filter cartridge 120, i.e. cartridge that may be handled as one entity.

Referring now to figures 3 to 9, another embodiment of the unitary membrane filter cartridge 120’ will be described. In this embodiment, the unitary membrane filter cartridge 120’ comprises eight membrane filter units 108, and each membrane filter units 108 is fluidly connected at a first end to a first manifold 100 and at a second end to a second manifold 101. The manifolds comprise internal chambers and are fitted with a number of pipes common at one end to the chamber. The first manifold 100 comprise pipes 104, 105 furnished with flanges 107, configured for connection to the flange 63 (see figure 1b) on a respective membrane filter unit 108. The second manifold 101 comprise pipes 102, 103 furnished with sockets 106, configured for connection to the inflow end pipe 61 (see figure 1b) on a respective membrane filter unit 108. During the assembly procedure, the pipe fitting 61 with O-ring 64 is inserted into respective socket 106, whereupon the flange 63 is attached to a corresponding flanged termination 107.

For use in a subsea environment, modules for installation onto the seabed are restricted to a height of around 8 meters as this suit the service vessels installation module handling lifting equipment. Therefore, any pressure vessel housing the membrane filter should preferably be within the subsea module height, and this will normally limit the number of membrane filter cartridges in a pressure vessel to two, one above the other. . Other forms of the same idea can be used in multiple stacks for insertion into long pipe, this is described later.

In the illustrated embodiment, the membrane filter units 108 are therefore grouped in two levels L1, L2 (lower and upper, if the cartridge 120’ is arranged in an upright position, as shown in figure 5). Thus, the retentate end of a membrane filter unit in a first level L1 is connected to the first manifold 100 via a pipe 104 which is longer than the membrane filter unit. The inflow end of a membrane filter unit in the first level L1 is connected to second manifold 101 via a shorter pipe 102. Correspondingly, the retentate end of a membrane filter unit in a second level L2 is connected to the first manifold 100 via a shorter pipe 105, while the inflow end is connected to the second manifold 101 via a pipe 103 which is longer than the membrane filter unit. This configuration allows the membrane filter units 108 to be brought closer together (towards the longitudinal axis x1), whereby the circumference may be reduced. This is illustrated in figures 8 and 9, where the circumference Ø is indicated in figure 9.

As illustrated in figure 4, the upper and lower manifolds 100, 101 are joined together by a connecting bar 109, bolted to corresponding connection members. The connection member 110 on the second (lower) manifold is illustrated in figure 7. The connecting bar serves as a structural member to hold the first (upper) and second (lower) manifolds together and thus lock the membrane filter units 108 in place, such that the unitary membrane filter cartridge 120’ may be handled as one structural entity.

It will be understood that the membrane filter cartridge 120’ can be used as a single cartridge in a small diameter vessel or as a combination of a plurality of cartridges joined together to form a larger cartridge for installation into a large diameter vessel.

The latter is indicated schematically in figure 10, where a plurality of (i.e. three) unitary membrane filter cartridges 120’ are interconnected to form an augmented unitary membrane filter cartridge 150.

Figures 11 to 15 illustrate a corresponding embodiment, where a plurality of (i.e. five) unitary membrane filter cartridges 120’ are interconnected to form an augmented unitary membrane filter cartridge 150’. This configuration is useful when a large numbers of membrane filter units are to be installed in a subsea pressure vessel with a height restriction. The individual membrane filter cartridges 120’ are connected at their process inflow F ends (via respective second manifolds 101) to a first augmented manifold 122 and at their retentate outflow R ends (via respective first manifolds 100) to a second augmented manifold 121. Reference number 125 (see figure 13) denotes a flange on the second (upper) first augmented manifold, while reference number 124 (see figure 14) denotes an O-ring on the first (lower) augmented manifold. Each manifold comprises an internal distribution chamber, which is well known in the art. The first (lower) augmented manifold comprises a centring guide 123, to aid alignment with the pipe or pressure vessel during installation (described below).

Figure 16 illustrates the augmented cartridge 150’ installed in a pressure vessel 151. The pressure vessel comprises two (first and second) sections 151a,b, in the views shown in figures 16 and 17 referred as upper and lower sections, interconnected via releasable flanges 161a,b. The cartridge top flange 125 (typically the retentate end) is connected to a flange inside the pressure vessel top head section 151a, which in turn is connected to a nozzle 153 (for connection to further pipework). The O-ring seal 124 on the first (lower) augmented manifold 122 is configured connection into a stab nozzle 154 in the bottom of the pressure vessel lower section 151b. As the skilled person will understand, this connection (typically process flow inlet) is suitable with an O-ring seal as the connection is exposed to only a small pressure difference. Reference number 160 designates the permeate outlet. It should be understood that required valves and piping to operate the membrane filters are not illustrated, as such parts and devices are well known in the art.

One advantage with all of the embodiments of the invention, is that the individual membrane filter units 108 are connected to form a unitary membrane filter cartridge 120; 120’ or an augmented unitary membrane filter cartridge 150; 150’. Thus, each membrane filter cartridge may be pre-assembled (e.g. at an onshore location) and easily and quickly be installed (inserted) into its designated pressure vessel (e.g. at an offshore location). One such installation method is illustrated in figure 17, where the augmented unitary membrane filter cartridge 150’ has been connected to the pressure vessel first section 151a and is in the process of being inserted into the second pressure vessel section 151b (cranes and lifting gear not shown). A reverse procedure may be used for removing the cartridge.

In figure 18, the assembled cartridge 150’ and first section 151a are placed in an upright orientation, and the second pressure vessel section 151b is lowered over the cartridge. In this variant, the first section 151a comprises the permeate outlet 160. The variant shown in figure 18 is useful in certain instances where for large assemblies it is advantageous for the cartridge to be mounted into a pressure vessel lower end. This allows for the assembly to be built-up in a workshop ground floor and not have the cartridge assembly hanging in a crane. There are also possibilities for all connections in and out of the pressure vessel to be mounted in the lower and only, this allows for the top body shell to be only a pressure retaining cover. For subsea modules this can be an advantage reducing the amount of external piping.

Figures 19 and 20 show alternative positions for the flow nozzles in the pressure vessel. Reference number 158 denotes a lateral outflow (retentate) port, whereas reference number 159 denotes a lateral inflow (unfiltered process flow) port. Any combination of these may be used, and an advantage of using such side entry for the flow into the cartridge is that the outflow from the membranes is into the vessel inner volume (e.g. permeate) may pass through the vessel bottom, which allows for a self-draining of the whole assembly.

Figures 21 to 23 illustrate yet another embodiment of a unitary membrane filter cartridge, denoted 210. Here, six membrane filter units 108 are arranged in parallel and connected to common manifolds (or headers) 202, 203 via respective flowpipes. A first manifold 202 is connected to the upper (retentate) end of the membrane filter units, and a second manifold 203 is connected to the lower (process inflow) end of the membrane filter units. A first transport pipe 200 is connected to the first manifold 202, and is in the illustrated embodiment configured for transporting retentate R. A second transport pipe 201 is connected to the second manifold 203, and is in the illustrated embodiment configured for transporting unfiltered process inflow F. Referring additionally to figures 24 to 26, the transport pipes 200, 201 are interconnected (e.g. via flanges 204) to similar transport pipes of corresponding unitary membrane filter cartridges 210, to form an augmented unitary membrane filter cartridge 220, in the following also referred to as a cartridge string 220. The assembly process in indicated in figure 25, and a completed cartridge string 220 comprising three membrane filter cartridges 210 is illustrated in figure 26. The transport pipes are connected to termination pipes 221a,b. It should be understood that one such string 220 may comprise two or more membrane filter cartridges 210.

The cartridge string 220, or a single membrane filter cartridge 210, may be inserted into a pipe 230, as illustrated in figure 27. Also a cartridge string 220, or a single membrane filter cartridge 210, may be inserted into a pressure vessel 231, as illustrated in figure 28. Here, an array of nine pressure vessels 231 (three by three) contains a total of 436 membrane filter units (9 x 48). This is an example of how many membrane filter units that can be installed in a confined space using pipe units as the pressure retaining vessel.

For a subsea environment for process equipment, it is critical that both size and weight are minimised due to handling, especially in bad weather or rough sea states. Therefore, a compact design maximising on the capacity of process equipment is of prime importance.

As an illustration of some of the advantages of the invention compared to other methods of packaging membrane filters, figure 29 illustrates a typical conventional array of membrane filter in individual vessels interconnected by external piping 251. Here, a total of 160 membrane filter vessels occupy a large area of approx.8 x 15 meters in plan and 8 meters high, whereas four multi-membrane vessels according to the invention, having a similar number of membrane filter units, occupies only a plan area of 6 x 8 meters, and 8 meters height. The total weight of the conventional vessel membrane filters is approximately 150 tonnes, whereas the total weight of the four multi membrane vessels according to the invention is approximately 80 tonnes (20 tonnes each).

Figure 30 shows yet another comparison between the invention and the prior art. Two prior art membrane filter pressure vessels 253 are required to accommodate the same number of membrane filter units as the augmented unitary membrane filter cartridge 150’ according to the invention. To equal the same number of membrane filter units as in the augmented unitary membrane filter cartridge 150’ according to the invention, two of the prior are vessels 253 are needed or, alternatively, a larger prior art vessel 254 containing the same number of membrane filter units can be used. However, these alternatives have major consequences. Firstly there is the weight difference as on single multi membrane vessel with two levels of filters as described by the invention weight is 20 tonnes, whereas the single membrane level vessel weight is 14 tons but two are needed therefor weighing 28 tons. The larger vessel 254 (having the same number of membrane filter units) has a total weight of 37 tonnes. These weights are examples, and are for each case calculated by industry standard pressure vessel design for a subsea installation (internal pressure: 100 bar, water depth: 300 meters).

The following remarks apply to all of the embodiments described above:

Although the invention has been described in relation to the use of membrane filter separation of hydrocarbons in a subsea environment, it should be understood that the invention is equally applicable to any other conventional applications normally referred to as ultra-filtration membrane technology processes, such as (but not necessarily limited to) air separation, nitrogen generation, carbon dioxide removal, hydrogen purification, fuel filtering, water cleansing, sulphates.

Although flanges have been described as a suitable connection means, it should be understand that other connection means may be equally applicable; for example threaded connections, press-fitted connections, glued connections, or similar.

Although the invention has been described and illustrated with certain numbers of membrane filter units and membrane filter cartridges, the invention shall not be limited to the numbers illustrated. However, a unitary membrane filter cartridge comprises a plurality (two or more) membrane filter units. The invented cartridge-type filter assembly may be a part of a stand-alone process unit, or be an integral part of any other process equipment subsea, topsides or on land. It may be a pre-process unit or a postprocess unit for other process equipment.

Claims

1. A filter device, comprising two or more membrane filter units (108), each having an inlet opening for a fluid flow (F) to be processed, a first outlet opening for at least one portion (R) of said fluid flow and second outlet port for at least a remaining portion (P) of said fluid flow, and the respective inlet openings of each membrane filter unit (108) are fluidly connected to a common inlet manifold (101; 203) and the respective first outlet openings of each membrane filter unit (108) are fluidly connected to a common outlet manifold (100; 200), characterized in that

at least one membrane filter unit (108) is arranged at a first position (L1) along a longitudinal axis (x1) and at least one membrane filter unit (108) is arranged at a second position (L2) along the longitudinal axis (x1), and the said two membrane filter units (108) are not axially aligned.

2. The filter device of claim 1, wherein the manifolds are structurally interconnected by structural connection means (109; 126, 127), to form a unitary membrane filter cartridge (120; 120’; 210).

3. The filter device of claim 1 or claim 2, wherein the membrane filter units (108) are elongated members that are arranged along a longitudinal axis (x1) of the unitary membrane filter cartridge.

4. The filter device of any one of claims 1-3, wherein the inlet manifold (101) and the outlet manifold (100) of a plurality of membrane filter cartridges (120’; 210) are connected to a respective augmented inlet manifold (122) and augmented outlet manifold (121), to form an augmented unitary membrane filter cartridge (150’; 220).

5. The filter device of any one of claims 1-4, wherein the unitary membrane filter cartridge (120; 120’; 210) and the augmented unitary membrane filter cartridge (150’; 220) each form unitary, elongated, bodies around a common longitudinal axis (x2).

6. The filter device of claim 5, wherein the unitary membrane filter cartridge (120; 120’; 210) and the augmented unitary membrane filter cartridge (150’; 220) each are configured to be inserted into a pressure-retaining device having a circular crosssection, such as a pressure vessel (231) or pipe (230).

7. The filter device of any one of claims 1-6, wherein a plurality of unitary membrane filter cartridges (210) are fluidly and structurally interconnected in an end-toend relationship, to form a cartridge string (220).

8. The filter device of any one of claims 1-6, wherein the augmented unitary membrane filter cartridge (150’) comprises connection means (125) whereby the membrane filter cartridge may be connected to, and supported by, a first pressure vessel part (151a) as one single unit.

9. The filter device of claim 2, wherein the structural connection means comprises an interlocking member (109) configured to provide structural integrity and to lock the membrane filter units (108) and manifolds (101, 100) together.

10. The filter device of claim 9, wherein the interlocking member (109) is connected to the inlet manifold and to the outlet manifold.

11. A membrane filter unit, characterized by the filter device of any one claims 1-10, arranged in a pressure vessel (151; 230; 231) and being fluidly connected to an inlet port (154) and an outlet port (153) of the pressure vessel; the pressure vessel further comprising an opening (160) through which filtered fluid (P) may pass.

12. Use of the filter device of any one of claims 1-10 at a subsea location, where the one or more unitary membrane filter cartridges or one or more augmented unitary membrane filter cartridges are arranged in a pipe or a pressure vessel, and a hydrocarbon fluid (F) is flowed into an inlet port of the device and a retentate (R) is flowed out of an outlet port of the device.

13. Use of the filter device of any one of claims 1-10, where the device is placed on a seabed location in an upright (substantially vertical) orientation or in a substantially horizontal orientation.

Patentkrav

1. En filteranordning, omfattende to eller flere membranfilterenheter (108), hver med en innløpsåpning for en fluidstrøm (F) som skal prosesseres, en første utløpsåpning for i det minste én del (R) of nevnte fluidstrøm og andre utløpsåpning for i det minste en gjenværende del (P) av nevnte fluidstrøm, og de respektive innløpsåpninger i hver membranfilterenhet (108) er fluidforbundet til en felles innløpsmanifold (101; 203) og de respektive første utløpsåpninger i hver membranfilterenhet (108) er fluidforbundet til en felles utløpsmanifold (100; 200), karakterisert ved at

minst én membranfilterenhet (108) er arrangert i en første posisjon (L1) langs en lengdeakse (x1) og minst én membranfilterenhet (108) er arrangert i en andre posisjon (L2) langs lengdeaksen (x1), og de nevnte to membranfilterenhetene (108) er ikke aksialt innrettet.

2. Filteranordningen som angitt i krav 1, der manifoldene er strukturmessig sammenkoplet av strukturmessige koplingsmidler (109; 126, 127), for å danne enhetlig membranfilterinnsats (filter cartridge) (120; 120’; 210).

3. Filteranordningen som angitt i krav 1 eller krav 2, der membranfilterenhetene (108) er langstrakte elementer som er arrangert langs en lengdeakse (x1) til den enhetlige membranfilterinnsatsen.

4. Filteranordningen som angitt i et hvilket som helst av kravene 1-3, der innløpsmanifolden (101) and utløpsmanifolden (100) i et flertall membranfilterinnsatser (120’; 210) er tilkoplet a respektiv utvidet innløpsmanifold (122) og utvidet utløpsmanifold (121), for å danne en utvidet enhetlig membranfilterinnsats (150’; 220).

5. Filteranordningen som angitt i et hvilket som helst av kravene 1-4, der den enhetlige membranfilterinnsatsen (120; 120’; 210) og den utvidede enhetlige membranfilterinnsatsen (150’; 220) hver danner enhetlige, langstrakte, legemer rundt en felles lengdeakse (x2).

6. Filteranordningen som angitt i krav 5, der den enhetlig membranfilterinnsatsen (120; 120’; 210) og den utvidede enhetlige membranfilterinnsatsen (150’; 220) hver er konfigurert til å bli innført i en trykkholdende anordning som har et sirkelformet tverrsnitt, så som en trykkbeholder (231) eller rør (230).

7. Filteranordningen som angitt i et hvilket som helst av kravene 1-6, der et flertall enhetlige membranfilterinnsatser (210) er fluidforbundet og strukturelt sammenkoplet i et ende-mot-endeforhold, for å danne en streng (220) av innsatser.

8. Filteranordningen som angitt i et hvilket som helst av kravene 1-6, der de utvidede enhetlige membranfilterinnsatsene (150’) omfatter koplingsmidler (125) hvorved the membranfilterinnsatsen kan koples til, og bæres av, en første trykkbeholderdel (151a) som en singulær enhet.

9. Filteranordningen som angitt i krav 2, der de strukturmessige koplingsmidlene omfatter et sammenkoplingselement (109) konfigurert til å gi strukturell integritet og å låse membranfilterenhetene (108) og manifoldene (101, 100) sammen.

10. Filteranordningen som angitt i krav 9, der sammenkoplingselementet (109) er tilkoplet innløpsmanifolden og utløpsmanifolden.

11. En membranfilterenhet, karakterisert ved filteranordningen som angitt av et hvilket som helst av kravene 1-10, arrangert i en trykkbeholder (151; 230; 231) og fluidforbundet til en innløpsåpning (154) og en utløpsåpning (153) i trykkbeholderen; der trykkbeholderen videre omfatter en åpning (160) gjennom hvilken filtrert fluid (P) kan strømme.

12. Anvendelse av filteranordningen som angitt i et hvilket som helst av kravene 1-10 på en undervannslokasjon, der den ene eller flere enhetlige membranfilterinnsatsen eller en eller flere utvidede enhetlige membranfilterinnsatser er arrangert i et rør eller en trykkbeholder, og et hydrokarbonfluid (F) strømmes inn i en innløpsåpning på anordningen og et retentate (R) strømmes ut av en utløpsåpning på anordningen.

13. Anvendelse av filteranordningen som angitt i et hvilket som helst av kravene 1-10, der anordningen er plassert på en undervannslokasjon en stående ("upright") (hovedsakelig vertikal) orientering eller i en hovedsakelig horisontal orientering.

Drawings

Priority

No priority

Patent classes

IPC classes

B01D 63/04

E21B 43/36

CPC classes

B01D 63/04

B01D 2319/04

B01D 2313/08

B01D 2313/20

E21B 43/36

Citations

US 6017451 A (A)

CN 104226120 A (A)

WO 0062908 A1 (A1)

WO 2016108697 A1 (A1)

JP 2004136173 A (A)

Applicants, owners and inventors

Owners

Aker Carbon Capture Norway AS

Oksenøyveien 8

1366 LYSAKER

NO (BÆRUM Municipality, Akershus county)

Org. number: 925200654

Inventors

Pål Helge Nøkleby

Bergveien 19 C

3212 SANDEFJORD

NO (SANDEFJORD Municipality, Vestfold county)

Michael Hilditch

Bækenlia 29 A

3540 NESBYEN

NO (NESBYEN Municipality, Buskerud county)

Agent

ZACCO NORWAY AS

Postboks 488

0213 OSLO

NO (OSLO Municipality, Oslo county)

Org. number: 982702887

Reference: P61803754NO00

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Payment history

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Only events from 2024.03.04 and onwards are shown.