Active wear-resistant self-cleaning elbow
By installing a gas distributor inside the bend to form an air cushion buffer and implementing self-cleaning measures with intelligent monitoring and adjustment, the wear and blockage problems of bends in the chemical and pharmaceutical industries have been solved, enabling efficient operation of the equipment and long-term continuous production.
Patent Information
- Application Number
- CN202510945307.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-07-09
- Publication Date
- 2025-11-25
AI Technical Summary
In the chemical and pharmaceutical industries, wear is a serious problem, especially at bends, during the transportation of powder and granular materials through pipelines. This leads to system shutdowns and material losses, and existing solutions are costly and difficult to maintain.
A gas distributor is installed inside the bend, supplying air to the central air chamber through the pipe opening. The gas distributor sprays air to form an air cushion, which buffers solid materials at the bend, preventing direct contact and collision. Residual materials are also cleaned by the airflow. Combined with intelligent devices, the gas source parameters are monitored and adjusted in real time to achieve self-cleaning.
It reduces wear on elbows, avoids blockages, increases the continuous operating time of the system, and reduces equipment maintenance costs and material losses.
Smart Images
Figure CN121007261A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of pneumatic conveying technology, and in particular to an active anti-wear self-cleaning elbow. Background Technology
[0002] In the chemical and pharmaceutical industries, processes such as coal gasification and polyolefin production often involve the pneumatic conveying of powdered and granular materials. Examples include pneumatic conveying of pulverized coal in pulverized coal gasification, pneumatic conveying of resin powder and granules in polyolefin production, and pharmaceutical conveying. These conveying processes typically involve high speeds, varying depending on the method. Dense-phase conveying generally operates at speeds of 2-10 m / s, while dilute-phase conveying typically operates at speeds of 25-40 m / s. High-speed material conveying often causes wear and tear on the pipelines, especially at bends, where wear can be severe, frequently leading to system shutdowns due to bend wear.
[0003] To maintain continuous and safe production, pipe linings, increased elbow thickness, or the use of high-strength, wear-resistant materials are commonly employed to manufacture elbows. This results in higher elbow prices and greater maintenance difficulties. Furthermore, the strength of thickened elbows often exceeds that of the conveyed material. When the material collides with the elbow during high-speed transport, it causes damage to the material's appearance, increasing material loss. Summary of the Invention
[0004] This invention provides an active anti-wear self-cleaning elbow to solve the technical problems mentioned in the background section.
[0005] To solve the above-mentioned technical problems, the present invention discloses an active anti-wear self-cleaning elbow, comprising:
[0006] The bend and the gas distributor are located inside the bend, forming an air chamber between the gas distributor and the side wall of the bend. The outer wall of the bend has a pipe opening for connecting to an external gas supply facility.
[0007] Preferably, flanges are installed at the air inlet and air outlet of the bend.
[0008] Preferably, the outlet cross-sectional shape of the gas distributor is any one of circular, square, triangular, polygonal, or strip-shaped.
[0009] Preferably, the outlet angle of the gas distributor is set to any angle within a range of - degrees; the outlet size of the gas distributor is set according to the particle size of the conveyed material, and the outlet diameter is smaller than the particle size of the material.
[0010] Preferably, the connecting pipe port interface is connected to the pipe port by any one of flange connection, welding, or threaded connection, and the connecting pipe port interface is used to connect to external gas supply facilities.
[0011] Preferably, the gas supply facility includes: an air compressor, the air outlet of which is connected to one end of a gas source pipeline, the other end of which is connected to the pipe opening, and a pressure gauge, a thermometer, and a flow meter are installed on the gas source pipeline.
[0012] Preferably, the intermediate air chamber is also connected to an exhaust pipe, which is connected to a purge exhaust valve.
[0013] Preferably, the external gas supply facility is electrically connected to the intelligent device, which includes:
[0014] First acquisition module: used to acquire the first information of the current material, the first information of the current material includes: particle size, conveying speed, angle of repose and density of the current material;
[0015] The second acquisition module is used to acquire the second information of the current material, which includes the conveying mass flow rate, conveying pressure, and impact angle of the current material on the bend.
[0016] First calculation module: used to calculate the impact energy parameters of the current material based on the first acquisition module and the second acquisition module;
[0017] The first early warning module is used to issue an early warning when the impact energy parameter of the current material is greater than or equal to a preset value.
[0018] Preferably, the smart device further includes:
[0019] The third acquisition module: acquires the reference gas pressure and gas flow rate in the gas source pipeline for the current material transportation;
[0020] First control module: used to control the operation of external gas supply facilities for a first set duration based on the parameters obtained by the third acquisition module;
[0021] The fourth acquisition module is used to acquire the average actual gas pressure and the average actual gas mass flow rate within the gas source pipeline during the first set time period.
[0022] The second calculation module is used to calculate the current actual air cushion energy parameters based on the fourth acquisition module.
[0023] The third calculation module is used to calculate the current actual ratio of the impact energy parameter and air cushion energy parameter of the current material based on the first calculation module and the second calculation module.
[0024] The fifth acquisition module is used to acquire the ideal ratio fitting curve of the impact energy parameter and the air cushion energy parameter of the current material, and the ideal initial ratio of the impact energy parameter and the air cushion energy parameter of the current material based on the initially used elbow.
[0025] The fourth calculation module is used to calculate the target opening degree of the flow regulating valve in the gas source pipeline based on the third calculation module and the fifth acquisition module.
[0026] The second control module is used to control the actual opening degree of the flow regulating valve of the gas source pipeline to the target opening degree, so as to carry out the current conveying of the current type of material.
[0027] Preferably, the first calculation module calculates based on the following formula:
[0028]
[0029] Where W is the impact energy parameter of the current material; ρ is the density of the current material; A is the particle size of the current material; V is the conveying speed of the current material; Q is the mass flow rate of the current material; sin is the sine; α is the angle of repose of the current material; P is the conveying pressure of the current material; g is the acceleration due to gravity; tan is the sine; β is the current impact angle of the current material on the bend; R is the radius of curvature of the air chamber side in the bend setting; t is the unit time;
[0030] The second calculation module is based on the following formula:
[0031] E = tQ1kP1; where E is the current actual air cushion energy parameter; P1 and Q1 are the average actual gas pressure and average actual gas mass flow rate in the gas source pipeline within the first set time period, respectively; k is the correction coefficient.
[0032] Compared with the prior art, the beneficial effects of the present invention are as follows:
[0033] This invention supplies air to the air chamber through a pipe opening. The gas is then sprayed out through a gas distributor, forming an air cushion on the inner wall of the elbow. Solid material particles are transported in the pipeline and are buffered by the air cushion at the elbow, preventing the solid material from directly contacting and colliding with the elbow, thereby reducing the wear of the elbow.
[0034] This invention supplies air to the air chamber through a pipe opening. The gas is then sprayed out through a gas distributor, forming an air cushion on the inner wall of the elbow. Solid material particles are transported in the pipeline and are buffered by the air cushion at the elbow, preventing the solid material from directly contacting and colliding with the elbow, thereby reducing the wear of the elbow.
[0035] The airflow ejected by the gas distributor continuously washes the inner wall of the bend, which can clean up residual materials in real time (such as powder materials that are easy to stick to the bend, the airflow can break the adhesion), avoiding the dilemma of "long-term operation → blockage → manual disassembly and cleaning" in traditional conveying.
[0036] Reduced downtime: "Online self-cleaning" is achieved through air pressure purging, eliminating the need for frequent shutdowns to disassemble pipes and clean, thus increasing the continuous operating time of the system (especially valuable for continuous production scenarios such as chemical industry). Attached Figure Description
[0037] To more clearly illustrate the technical solutions in this invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0038] Figure 1 This is a schematic diagram of an active wear-resistant self-cleaning elbow according to the present invention. Figure 1 ;
[0039] Figure 2 This is a schematic diagram of an active wear-resistant self-cleaning elbow according to the present invention. Figure 2 .
[0040] 1. Bend; 2. Gas distributor; 21. Gas distributor outlet; 3. Pipe opening; 4. External gas supply facilities; 41. Compressor; 42. Gas source pipeline; 43. Pressure gauge; 44. Thermometer; 45. Flow meter; 5. Flange; 6. Discharge pipeline; 7. Purge and exhaust valve; 8. Medium air chamber. Detailed Implementation
[0041] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.
[0042] Example 1: This invention provides an active anti-wear self-cleaning elbow, such as... Figure 1 , Figure 2 As shown, it includes:
[0043] The bend 1 and the gas distributor 2 are located inside the bend 1. An air chamber 8 is formed between the gas distributor 2 and the side wall of the bend 1. The outer wall of the bend 1 is provided with a pipe opening 3, which is used to connect to an external gas supply facility 4.
[0044] Preferably, flanges 5 (welded or threaded connection optional) are provided at the air inlet and air outlet of the bend 1 respectively.
[0045] Preferably, the outlet cross-sectional shape of the gas distributor 2 is any one of a circle, square, triangle, polygon, or strip.
[0046] Preferably, the outlet angle of the gas distributor 2 is set to any angle within the range of 0-180 degrees; the outlet size of the gas distributor 2 is set according to the particle size of the conveyed material, and the outlet diameter is smaller than the particle size of the material.
[0047] Preferably, the connecting pipe port interface and the pipe port 3 are connected by any one of flange connection, welding, or threaded connection, and the connecting pipe port interface is used to connect to the external gas supply facility 4.
[0048] Preferably, the gas supply facility includes: an air compressor 41, the air outlet of the air compressor 41 is connected to one end of a gas source pipe 42, the other end of the gas source pipe 42 is connected to the pipe port 3 (specifically, the connecting pipe port interface is connected), and a pressure gauge 43, a thermometer 44, and a flow meter 45 are installed on the gas source pipe 42.
[0049] Preferably, the intermediate air chamber 8 is also connected to an exhaust pipe 6, and the exhaust pipe 6 is connected to a purge exhaust valve 7.
[0050] Preferably, the outer wall of the bend can be provided with a port for connection to an external gas supply facility in any direction. Preferably, the outer wall of the bend can be provided with a discharge port, pipeline, and valve in any direction. Material entering the gas chamber can be discharged or purged through the discharge port.
[0051] Preferably, the elbow can be a square elbow or a spherical elbow.
[0052] This invention relates to an elbow equipped with active anti-wear features. This invention overcomes the wear issues of elbows in powder or granule conveying pipelines in the chemical or pharmaceutical industries, reduces the cost associated with using linings or high-strength wear-resistant materials in conventional wear-resistant elbows, and minimizes material loss due to elbow collisions and wear during conveying.
[0053] This invention pertains to the field of chemical and pharmaceutical production and is an active, self-cleaning, wear-resistant elbow device for conveying solid powders and granules.
[0054] The active anti-wear elbow is installed in the gas phase conveying pipeline of polyolefin resin particles. The gas distributor at the bend of the elbow is in the shape of a round hole. The round holes are evenly distributed on the distributor. The diameter of the round holes is 1 mm and the spacing between the round holes is 2 mm.
[0055] The air source is compressed air, which is introduced into the elbow air chamber (intermediate air chamber) through a compressor and related pipelines. The air is then ejected from the circular hole of the gas distributor 2, forming a uniform air cushion. The polyolefin resin particles have a particle size of 3-5mm. The particles are conveyed to the elbow by the conveying air, where they are buffered at the air cushion of the elbow distributor before being conveyed, avoiding direct contact with the elbow pipe wall. The air supply system is equipped with accessories such as pressure gauges, flow meters, and check valves to control the air source pressure within a suitable range.
[0056] The beneficial effects of the above technical solution are as follows:
[0057] This invention supplies air to the air chamber 8 through the pipe 3. The gas is sprayed out through the gas distributor 2 and forms an air cushion on the inner wall of the elbow. Solid material particles are transported in the pipeline and are buffered by the air cushion at the elbow (bend 1), which avoids direct contact and collision between the solid material and the elbow, thereby reducing the wear of the elbow.
[0058] The airflow ejected from the gas distributor 2 continuously washes the inner wall of the bend 1, which can clean up residual materials in real time (such as powder materials that are easy to stick to the bend, and the airflow can destroy the adhesion), avoiding the dilemma of "long-term operation → blockage → manual disassembly and cleaning" in traditional conveying.
[0059] Reduced downtime: "Online self-cleaning" is achieved through air pressure purging, eliminating the need for frequent shutdowns to disassemble pipes and clean, thus increasing the continuous operating time of the system (especially valuable for continuous production scenarios such as chemical industry).
[0060] This invention only demonstrates one type of active anti-wear elbow. Other types of elbows that adopt this active anti-wear measure are still within the scope of protection of this patent.
[0061] This invention only demonstrates one type of active anti-wear elbow. If the active anti-wear measures are applied to straight pipes, they still fall within the scope of protection of this patent.
[0062] Example 2, based on Example 1, involves an external gas supply facility 4 electrically connected to a smart device, which includes:
[0063] First acquisition module: used to acquire the first information of the current material, the first information of the current material includes: particle size, conveying speed, angle of repose and density of the current material;
[0064] The second acquisition module is used to acquire the second information of the current material, which includes the conveying mass flow rate, conveying pressure, and impact angle of the current material on the bend.
[0065] First calculation module: used to calculate the impact energy parameters of the current material based on the first acquisition module and the second acquisition module;
[0066] The first early warning module is used to issue an early warning when the impact energy parameter of the current material is greater than or equal to a preset value.
[0067] Preferably, the smart device further includes:
[0068] The third acquisition module: acquires the gas pressure and gas flow rate in the reference gas source pipeline 42 for the current material transportation (based on the ideal initial ratio of the impact energy parameter and air cushion energy parameter of the current material, the corresponding gas pressure and gas flow rate in the gas source pipeline 42 can be obtained based on experiments).
[0069] First control module: used to control the external gas supply facility 4 to operate for a first set duration based on the parameters obtained by the third acquisition module;
[0070] The fourth acquisition module is used to acquire the average actual gas pressure and the average actual gas mass flow rate within the gas source pipeline 42 within a first set time period.
[0071] The second calculation module is used to calculate the current actual air cushion energy parameters based on the fourth acquisition module.
[0072] The third calculation module is used to calculate the current actual ratio of the impact energy parameter and air cushion energy parameter of the current material based on the first calculation module and the second calculation module.
[0073] The fifth acquisition module is used to acquire the ideal ratio fitting curve of the impact energy parameter and the air cushion energy parameter of the current material, and the ideal initial ratio of the impact energy parameter and the air cushion energy parameter of the current material based on the initially used elbow.
[0074] The fourth calculation module is used to calculate the target opening degree of the flow regulating valve of the gas source pipeline 42 based on the third calculation module and the fifth acquisition module.
[0075] The second control module is used to control the actual opening degree of the flow regulating valve of the gas source pipeline 42 to the target opening degree, so as to carry out the current conveying of the current type of material.
[0076] Preferably, the first calculation module calculates based on the following formula:
[0077]
[0078] Where W is the impact energy parameter of the current material; ρ is the density of the current material; A is the particle size of the current material; V is the conveying speed of the current material; Q is the mass flow rate of the current material; sin is the sine; α is the angle of repose of the current material; P is the conveying pressure of the current material; g is the acceleration due to gravity; tan is the sine; β is the current impact angle of the current material on the bend; R is the radius of curvature of the air chamber 8 side in the setting of bend 1; t is the unit time;
[0079] The second calculation module is based on the following formula:
[0080] E = tQ1kP1; where E is the current actual air cushion energy parameter; P1 and Q1 are the average actual gas pressure and average actual gas mass flow rate in the gas source pipeline 42 within the first set time period, respectively; k is the correction coefficient (the correction coefficient k is used to compensate for the influence of gas characteristics, pipeline resistance, operating condition deviation and other factors on the air cushion energy, based on test calibration);
[0081] The fourth calculation module is based on the following formula:
[0082]
[0083] K2 is the ideal initial ratio of the impact energy parameter and air cushion energy parameter of the current material, based on the initially used elbow (the initially used elbow corresponding to the current material); K0 is the current actual ratio of the impact energy parameter and air cushion energy parameter of the current material; H0 is the valve opening corresponding to the gas pressure and gas flow rate in the reference air source pipeline 42 for conveying the current material; H is the target valve opening. These are adjustment weight one and adjustment weight two (determined based on experimental fitting).
[0084] The beneficial effects of the above technical solution are as follows:
[0085] Multi-field coupling modeling: By integrating the kinematic and mechanical parameters of materials with the pressure energy parameters of gases, a multi-field coupling energy model of "material impact energy - gas cushion energy" is constructed, breaking through the limitations of traditional "single parameter control" (such as controlling only gas pressure or material flow rate).
[0086] By acquiring full-dimensional parameters of materials (particle size, velocity, density, etc.) and gases (pressure, flow rate) through multiple modules, dynamic balance control of "material impact energy - gas cushion energy" is achieved, solving the problems of increased wear and frequent blockages caused by coarse parameters in traditional conveying systems.
[0087] Closed-loop adaptive regulation: A closed loop is formed from "parameter acquisition → energy calculation → ratio correction → valve control", which can automatically adapt to different materials (such as granules and powders) and operating conditions (such as conveying volume fluctuations), improving the system's versatility and stability.
[0088] Impact Energy Early Warning: The first early warning module monitors impact energy parameters (which can be monitored periodically). When the threshold is exceeded, an early warning is issued proactively to avoid accidents such as excessive wear of bends and pipe rupture, thereby reducing equipment operation and maintenance costs.
[0089] Cross-module data twin: Data from each module (such as material parameters of the first module and gas reference parameters of the third module) form a "material-gas" data twin in the intelligent device, which can simulate the energy balance state under different working conditions and provide a "virtual calculation" basis for valve opening adjustment (such as predicting the impact energy change when the material particle size increases and adjusting the air cushion energy in advance).
[0090] Full lifecycle adaptation: By comparing the parameters of the "initial elbow" and "actual operation" (such as the baseline parameters of the third acquisition module), it covers the entire lifecycle of the equipment from new commissioning to the later stage of wear, extending the service life of elbows and pipelines.
[0091] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.
Claims
1. An active anti-wear self-cleaning elbow, characterized in that, include: The bend (1) and the gas distributor (2) are located inside the bend (1). An air chamber (8) is formed between the gas distributor (2) and the side wall of the bend (1). The outer wall of the bend (1) is provided with a pipe opening (3), which is used to connect to an external gas supply facility (4).
2. The active anti-wear self-cleaning elbow according to claim 1, characterized in that, Flanges (5) are installed at the air inlet and air outlet of the bend (1).
3. The active anti-wear self-cleaning elbow according to claim 1, characterized in that, The outlet cross-sectional shape of the gas distributor (2) can be any one of the following: circular, square, triangular, polygonal, or strip-shaped.
4. The active anti-wear self-cleaning elbow according to claim 1, characterized in that, The outlet angle of the gas distributor (2) is set to any angle within the range of 0-180 degrees; the outlet size of the gas distributor (2) is set according to the particle size of the conveyed material, and the outlet diameter is smaller than the particle size of the material.
5. The active anti-wear self-cleaning elbow according to claim 1, characterized in that, The connecting pipe port interface and the pipe port (3) are connected by any one of flange connection, welding or threaded connection, and the connecting pipe port interface is used to connect with the external gas supply facility (4).
6. The active anti-wear self-cleaning elbow according to claim 1, characterized in that, The gas supply facility includes an air compressor (41), the outlet of which is connected to one end of a gas source pipe (42), the other end of which is connected to the pipe opening (3), and a pressure gauge (43), a thermometer (44), and a flow meter (45) are installed on the gas source pipe (42).
7. The active anti-wear self-cleaning elbow according to claim 1, characterized in that, The intermediate air chamber (8) is also connected to an exhaust pipe (6), which is connected to a purge exhaust valve (7).
8. The active anti-wear self-cleaning elbow according to claim 1, characterized in that, An external gas supply facility (4) is electrically connected to a smart device, the smart device comprising: First acquisition module: used to acquire the first information of the current material, the first information of the current material includes: particle size, conveying speed, angle of repose and density of the current material; The second acquisition module is used to acquire the second information of the current material, which includes the conveying mass flow rate, conveying pressure, and impact angle of the current material on the bend. First calculation module: used to calculate the impact energy parameters of the current material based on the first acquisition module and the second acquisition module; The first early warning module is used to issue an early warning when the impact energy parameter of the current material is greater than or equal to a preset value.
9. The active anti-wear self-cleaning elbow according to claim 8, characterized in that, The intelligent device also includes: The third acquisition module: acquires the gas pressure and gas flow rate in the reference gas source pipeline (42) for the current material transportation; First control module: used to control the external gas supply facility (4) to work for the first set duration based on the parameters obtained by the third acquisition module; The fourth acquisition module is used to acquire the average actual gas pressure and the average actual gas mass flow rate within the gas source pipeline (42) within the first set time period. The second calculation module is used to calculate the current actual air cushion energy parameters based on the fourth acquisition module. The third calculation module is used to calculate the current actual ratio of the impact energy parameter and air cushion energy parameter of the current material based on the first calculation module and the second calculation module. The fifth acquisition module is used to acquire the ideal ratio fitting curve of the impact energy parameter and the air cushion energy parameter of the current material, and the ideal initial ratio of the impact energy parameter and the air cushion energy parameter of the current material based on the initially used elbow. The fourth calculation module is used to calculate the target opening degree of the flow regulating valve of the gas source pipeline (42) based on the third calculation module and the fifth acquisition module; The second control module is used to control the actual opening degree of the flow regulating valve of the gas source pipeline (42) to the target opening degree, and to carry out the current conveying of the current type of material.
10. The active anti-wear self-cleaning elbow according to claim 9, characterized in that, The first calculation module is based on the following formula: Where W is the impact energy parameter of the current material; ρ is the density of the current material; A is the particle size of the current material; V is the conveying speed of the current material; Q is the mass flow rate of the current material; sin is sine; α is the angle of repose of the current material; P is the conveying pressure of the current material; g is the gravitational acceleration; tan is sine; β is the current impact angle of the current material on the bend; R is the radius of curvature of the air chamber (8) side in the bend (1); t is the unit time; The second calculation module is based on the following formula: E = tQ1kP1; where E is the current actual air cushion energy parameter; P1 and Q1 are the average actual gas pressure and average actual gas mass flow rate in the gas source pipeline (42) within the first set time period, respectively; k is the correction coefficient.