Vertical cooler with liquid removal and mist eliminator

1. A method of intercooling gas between compressor stages in a multistage compressor comprising:

(a) providing a gas intercooler ( 10 ) with liquid removal and mist eliminator, the intercooler including:

(i) an elongated vertically oriented housing ( 12 ) provided with an inlet ( 14 ) at a first end portion ( 16 ) thereof and a side-draw outlet ( 18 ) at a second end portion ( 20 ) thereof on a first side ( 32 ) of said housing;

(ii) a plurality of cooling tubes ( 22 ) located adjacent the first end portion ( 16 ) of the housing;

(iii) a mist eliminator assembly ( 24 ) disposed between the cooling tubes ( 22 ) and the side-draw outlet ( 18 ) of the housing, the mist eliminator assembly ( 24 ) having a pair of spaced baffle plates including a first baffle plate ( 26 ) juxtaposed with a second side ( 34 ) of the housing and a second baffle plate ( 28 ) juxtaposed with said first side ( 32 ) of the housing which baffle plates position a mist eliminator medium ( 30 ) centrally therebetween within the housing and thereby define a tortuous serpentine channel extending sequentially from said first side ( 32 ) of the housing to the mist eliminator medium ( 30 ) to the second side of the housing ( 34 ) at an outlet ( 36 ) of the mist eliminator medium ( 30 ) and therefrom to the side draw outlet ( 18 ) on the first side ( 32 ) of the housing; and

(iv) the housing ( 12 ) further defining a disengaging space ( 25 ) between the mist eliminator assembly outlet ( 36 ) and side-draw outlet ( 18 ) of the housing;

(b) feeding compressed gas from a first compressor stage to the inlet ( 14 ) of the intercooler ( 10 );

(c) cooling the gas in the intercooler ( 10 ) and removing condensed liquid therefrom;

(d) withdrawing the cooled gas from the intercooler side draw outlet ( 18 ) and

(e) feeding the withdrawn gas to a second compressor stage of a multistage compressor.

2. The method of intercooling gas between compressor stages in a multistage compressor according to claim 1 , wherein the gas comprises hydrogen.

3. A gas cooler ( 10 ) with liquid removal and mist eliminator comprising:

(a) an elongated housing ( 12 ) provided with an inlet ( 14 ) at a first end portion ( 16 ) thereof and a side-draw outlet ( 18 ) at a second end portion ( 20 ) thereof on a first side ( 32 ) of said housing;

(b) a plurality of cooling tubes ( 22 ) located adjacent the first end portion ( 16 ) of the housing;

(c) a mist eliminator assembly ( 24 ) disposed between the cooling tubes ( 22 ) and the side-draw outlet ( 18 ) of the housing, the mist eliminator assembly ( 24 ) having a pair of spaced baffle plates including a first baffle plate ( 26 ) juxtaposed with a second side ( 34 ) of the housing and a second baffle plate ( 28 ) juxtaposed with said first side ( 32 ) of the housing which baffle plates position a mist eliminator medium ( 30 ) centrally therebetween within the housing and thereby define a tortuous serpentine channel extending sequentially from said first side ( 32 ) of the housing to the mist eliminator medium ( 30 ) to the second side of the housing ( 34 ) at an outlet ( 36 ) of the mist eliminator medium ( 30 ) and therefrom to the side draw outlet ( 18 ) on the first side ( 32 ) of the housing; and

(d) the housing ( 12 ) further defining a disengaging space ( 25 ) between the mist eliminator assembly outlet ( 36 ) and side-draw outlet ( 18 ) of the housing.

4. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the disengaging space ( 25 ) extends over a distance ( 37 ) of at least 3-4 inches (75-100 mm) and preferably 6 inches (150 mm) or more.

5. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 4 , wherein the disengaging space ( 25 ) extends over a distance ( 37 ) of at least 6 inches (150 mm) or more.

6. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the the first side of the housing ( 32 ) where the side draw outlet ( 18 ) is located is disposed opposite the second side of the housing ( 34 ) where the mist eliminator outlet ( 36 ) is located.

7. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the mist eliminator assembly ( 30 ) includes a drain pipe ( 38 ).

8. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the housing defines a sump ( 40 ) located outwardly with respect to the side-draw outlet ( 18 ) for collecting liquid removed from a cooled gas, and the sump includes a pair of sensor ports ( 40 , 42 ) for monitoring liquid level in the sump.

9. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the mist eliminator assembly includes a drain pipe and the drain pipe extends to a sump defined by the housing located outwardly with respect to the side-draw outlet.

10. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the mist eliminator assembly includes a mist eliminator medium selected from metal mesh, co-knit metal and glass mesh and combinations thereof.

11. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein said plurality of cooling tubes ( 22 ) comprises a U-tube bundle.

12. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 11 , wherein the U-tube bundle is a baffled ( 47 , 49 , 51 , 53 ) U-tube bundle.

13. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the housing ( 12 ) has a length ( 56 ) to diameter ( 58 ) ratio of from about 5 to about 30.

14. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the housing ( 12 ) has a length ( 56 ) to diameter ( 58 ) ratio of from about 8.5 to about 20.

15. The gas cooler ( 10 ) with liquid removal and mist eliminator according to claim 3 , wherein the housing ( 12 ) has a length ( 56 ) to diameter ( 58 ) ratio of from about 12.5 to about 17.5.