Magnetic Separator

Abstract

A pneumatically operated magnetic separator captures magnetic contaminants from process fluids that are used in many industrial operations for a variety of purposes. The pneumatically operated magnetic separator may include a housing wall, a first flange plate assembly, a second flange plate assembly, a main fluid passageway, a tube, and a shuttle. The first and second flange plate assemblies may each include a pair of flange plates. The tube extends between the first and second flange plate assemblies, and the shuttles are disposed within the tube. Each of the shuttles includes one or more magnets. In one example, during use, the shuttles move longitudinally within the tube in response to activation and deactivation of air pressure. A weldment attaches the tube and the first and second flange plate assemblies together.

Description

[Technical field]

[0001] (introduction) The present disclosure relates generally to the separation of magnetic contaminants from process fluids in industrial applications, and more specifically to pneumatically operated magnetic separators employed to separate and remove magnetic contaminants from process fluids. [Background technology]

[0002] Process fluids are used in many industrial operations. Fluids include machining coolants, cleaning solutions, degreasing solutions, and quenching fluids, among many others. Industries such as automotive and heavy truck, steel, and industrial HVAC (heating, ventilation, and air conditioning) employ the use of process fluids for machining, honing, grinding, parts cleaning, induction hardening and quenching, paint pretreatment, steel rolling, and other applications. Metal contaminants are routinely introduced into the process fluids during operations. Magnetic filtration systems can be installed downstream to capture and remove metal contaminants from the process fluid. Summary of the Invention [Means for solving the problem]

[0003] (overview) In one embodiment, the pneumatically operated magnetic separator may include a housing wall, a first flange plate assembly, a second flange plate assembly, a primary fluid passageway, a plurality of tubes, a plurality of shuttles, and a plurality of weldments. The first flange plate assembly is located near an end of the housing wall. The first flange plate assembly includes a first flange plate and a second flange plate. A plurality of first openings are established in the second flange plate. The second flange plate assembly is located near another end of the housing wall. The second flange plate assembly includes a third flange plate and a fourth flange plate. A plurality of second openings are established in the fourth flange plate. The primary fluid passageway is established in part by the housing wall, by the first flange plate assembly, and by the second flange plate assembly. The tubes extend between the first flange plate assembly and the second flange plate assembly. The tubes are received in the first openings and in the second openings. Each of the tubes defines a bore. The shuttles are disposed within the tubes. Each of the shuttles includes one or more magnets. The shuttle is capable of moving longitudinally within the bore of the tube. A first weldment attaches the tube and the first flange plate assembly together. A second weldment attaches the tube and the second flange plate assembly together.

[0004] In one embodiment, a pneumatically operated magnetic separator may include a housing wall, a first flange plate, a second flange plate, a primary fluid passageway, a plurality of tubes, a plurality of shuttles, and a plurality of first weldments. The first flange plate is located near the housing wall. The first flange plate has a plurality of first openings. The first openings extend entirely through the first flange plate. Each of the first openings has a first open edge in a first surface of the first flange plate. The second flange plate is located near the housing wall and opposite the first flange plate. The primary fluid passageway is established in part or more by the housing wall. The primary fluid passageway extends between the first and second flange plates. The tubes extend between the first and second flange plates. The tubes are inserted into the first openings. Each of the tubes has a tube wall. The tube walls each have a first end edge. The shuttles are located within the tubes. Each of the shuttles includes one or more magnets. A first weldment attaches the first flange plate and the pipe together. The first weldment is established at the first open edge and at the first end edge.

[0005] In one embodiment, the pneumatically operated magnetic separator may include a housing wall, a first flange plate assembly, a second flange plate assembly, a primary fluid passageway, a plurality of tubes, a plurality of shuttles, a plurality of first weldments, and a plurality of second weldments. The first flange plate assembly is located near an end of the housing wall. The first flange plate assembly includes a first flange plate and a second flange plate. A plurality of first openings are located in the second flange plate. The first openings extend entirely through the second flange plate. Each of the first openings has a first open edge. The second flange plate assembly is located near another end of the housing wall. The second flange plate assembly includes a third flange plate and a fourth flange plate. A plurality of second openings are located in the fourth flange plate. The second openings extend entirely through the fourth flange plate. Each of the second openings has a second open edge. The primary fluid passageway is established in part by the housing wall, by the first flange plate assembly, and by the second flange plate assembly. The tubes extend between the first flange plate assembly and the second flange plate assembly. The tubes are received in the first opening of the second flange plate and in the second opening of the fourth flange plate. Each of the tubes has a tube wall. The tube walls each have a first end edge and a second end edge. A shuttle is disposed within the tube. Each of the shuttles includes one or more magnets. A first weldment attaches the second flange plate and the tube together. The first weldment is established at the first open edge and at the first end edge. The first weldment is a continuous weld extending around the entire extent of the first open edge and the first end edge. A second weldment attaches the fourth flange plate and the tube together. The second weldment is established at the second open edge and at the second end edge. The second weldment is a continuous weld extending around the entire extent of the second open edge and the second end edge.

[0006] BRIEF DESCRIPTION OF THE DRAWINGS One or more aspects of the present disclosure are described below in conjunction with the accompanying drawings, in which like reference numbers refer to like elements. [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a cross-sectional view of one embodiment of a magnetic separator. [Diagram 2] FIG. 2 is a close-up view of one embodiment of a magnetic separator weldment. [Figure 2A] FIG. 2A is another enlarged view of the weldment. [Diagram 3] FIG. 3 is a perspective view of a shuttle that may be used with the magnetic separator. [Figure 4] FIG. 4 is a cross-sectional view of the shuttle. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] (Detailed Description) With reference to the figures, one embodiment of a pneumatically operated magnetic separator 10 is presented for separating and removing magnetic contaminants from a process fluid. The magnetic separator 10 may be installed in filtration equipment employed in many industries, including, but not limited to, automotive and heavy truck, steel, and industrial HVAC (heating, ventilation, and air conditioning). The process fluids themselves may be varied and may include machining coolants, cleaning solutions, degreasing solutions, and quenching fluids. Process fluids are used in all kinds of applications, such as machining, honing, grinding, parts cleaning, induction hardening and quenching, paint pre-treatment, and steel rolling. Unlike conventional devices, the magnetic separator 10 has its flange plates and tubes attached together via weldments, and may lack O-ring seals and gaskets between and near the attachment points. This construction of the magnetic separator 10 provides greater robustness and flexibility in the use of the magnetic separator 10. The magnetic separator 10 may be employed in applications that are less permanent than large production facilities, and may be adapted for use in field applications, such as those perhaps most common in the oil and gas industry, environmental remediation, and the like. Additionally, the magnetic separator 10 may be employed in applications having process fluids that more aggressively degrade O-ring seals and gaskets, such as those in the oil and gas industry, environmental remediation, and the like. The magnetic separator 10 thus exhibits a level of maneuverability in its use not previously demonstrated. Additionally, seal and gasket failure, as may occur under certain circumstances in embodiments without O-ring seals and gaskets, is entirely avoided.

[0009] It should be noted that, unless otherwise specified, the terms radial, axial, and circumferential, and their grammatical variations, refer to directions relative to the generally circular and cylindrical shape of the magnetic separator 10 and its components as shown in the figures.

[0010] The magnetic separator 10 is in-line with respect to the fluid flow moving therethrough, and depending on its size, in certain instances may handle fluid flow rates ranging from 1 gallon per minute (GPM) to 250 GPM, although other fluid flow rates may be possible in other instances. The magnetic separator 10 may be part of a larger filtration installation, for example, where multiple individual magnetic separators are arranged parallel to one another and fed process fluid from a common manifold. The magnetic contaminants captured by the magnetic separator 10 may be particles, fine powders, or other objects, depending on the application and process, and may be composed of ferrous metal materials. It should be noted that the magnetic contaminants to be removed do not necessarily have magnetic properties themselves, and do not necessarily have a ferrous metal composition. For example, the magnetic contaminants to be removed may initially be non-magnetic particles, fine powders, or other objects, and may then be induced to associate with magnetic particles, which render the magnetic contaminants susceptible to the effects of a magnetic field. In the water and wastewater treatment example, certain coagulants, such as ferric chloride, ferrous chloride, alum, aluminum sulfate, or other soluble materials, may be added to the fluid, such as water, to agglomerate small particles. Calcium in the form of calcium hydroxide or calcium oxide may be employed to enhance particle removal, and certain polymeric materials, sometimes referred to as flocculants, may be added to the fluid to add strength to the particle agglomeration or increase its size. Finally, in this water and wastewater treatment example, magnetic materials, such as iron powder, magnetite powder, hematite powder, etc., may be added to the fluid to give the particles magnetic properties. Still, there are additional examples in which particles, fines, or other objects that are initially non-magnetic are made susceptible to magnetic fields. The term magnetic contaminants is used broadly here and is intended to include all of these possibilities. It should be noted that the size of the magnetic contaminants to be captured may vary and may be greater than or equal to one micron or even sub-micron in size. Separation and removal is accomplished by the magnetic separator 10 without harming the process fluid in which the magnetic contaminants are saturated.The magnetic separator 10 may have a variety of designs, constructions, and components in different embodiments, defined at least in part by the particular application and the particular contaminants. In the embodiment of Figures 1-4, the magnetic separator 10 is pneumatically operated and actuated and generally includes a housing wall 12, a first flange plate assembly 14, a second flange plate assembly 16, a plurality of tubes 18, and a plurality of shuttles 20.

[0011] With particular reference to FIG. 1 , the housing wall 12 forms the outer structure of the magnetic separator 10. The housing wall 12 has a cylindrical shape and is constructed of a metallic material, such as stainless steel. The housing wall 12 extends from a first end 22 at the first flange plate assembly 14 to a second end 24 at the second flange plate assembly 16. A main passageway 26 is established within the housing wall 12, with the first and second flange plate assemblies 14, 16 also contributing to the establishment of the main passageway 26. Process fluid is provided through the main passageway 26 from an inlet conduit 28 to an outlet conduit 30, or the process fluid may be reversed in certain applications and flow in the opposite direction from the conduit indicated by reference numeral 30 to the conduit indicated by reference numeral 28. The inlet conduit 28 is disposed within the first flange plate assembly 14 and is in fluid communication with the main passageway 26. Similarly, the outlet conduit 30 is disposed within the second flange plate assembly 16 and is in fluid communication with the main passageway 26. Inlet and outlet conduits 28, 30 are centrally disposed with respect to the main passage 26 and with respect to the first and second flange plate assemblies 14, 16. The main passage 26 extends between the first and second ends 22, 24 and between the first and second flange plate assemblies 14, 16. Process fluid with magnetic contaminants enters the magnetic separator 10 via the inlet conduit 28, and process fluid with less or no magnetic contaminants exits the magnetic separator 10 via the outlet conduit 30. A pair of two-way valves or a three-way valve may be provided downstream of the outlet conduit 30 to direct the flow of the process fluid based on the operating mode of the magnetic separator 10.

[0012] It should be noted that in the embodiment shown, the internal baffle body 32 is located within the interior of the housing wall and within the main passageway 26. The internal baffle body 32 serves to divert the flow of the process fluid outwardly towards the tubes 18 and shuttle 20. A more direct and straight fluid flow path between the inlet conduit 28 and the outlet conduit 30 is blocked by the internal baffle body 32. The process fluid and magnetic contaminants therein are forced to flow closer to the tubes 18 and shuttle 20, optimizing capture of the magnetic contaminants. In the depicted embodiment, the internal baffle body 32 occupies the lower half of the interior of the housing wall. The upper half of the interior of the housing wall is free of the internal baffle body 32. The spacing provided in the upper half facilitates extraction of larger obstructions in the process fluid that find their way into the magnetic separator 10 during use. It should be noted that in other embodiments, the internal baffle body 32 may occupy both the upper and lower halves of the interior of the housing wall. The internal baffle body 32 is a hollow cylinder of metallic material with one or more closed ends 34. The internal baffle body 32 is mounted within the main passageway 26 via a peg 36, which may be welded to the second flange plate assembly 16. The closed end 34 faces the outlet conduit 30 across the gap. Also, in the embodiment shown, an internal baffle plate 38 is located within the housing wall and within the main passageway 26. The internal baffle plate 38 serves to support the extension of the tubes 18 between the first and second flange plate assemblies 14, 16. The internal baffle plate 38 also divides the main passageway 26 into two half sections, a first or upper section 40 and a second or lower section 42. The internal baffle body 32 is located in the lower section 42 in this embodiment. The internal baffle plate 38 extends laterally and radially across the main passageway 26 and is mounted in place via welding to the internal baffle body 32. An opening in the internal baffle plate 38 accommodates the passage of the tubes 18 through the structure. A recess 39 may be present around the periphery of the interior baffle plate 38 to permit process fluid flow to proceed from the upper section 40 to the lower section 42. The recess 39 establishes a fluid flow path between the interior baffle plate 38 and an interior surface 44 of the housing wall 12.

[0013] Still referring to FIG. 1, the first flange plate assembly 14 constitutes the upper end of the magnetic separator 10. The first flange plate assembly 14 may have different designs and constructions and components. In this embodiment, the first flange plate assembly 14 includes a first flange plate 46 and a second flange plate 48. The first and second flange plates 46, 48 are connected to each other via bolts 50. They are both disk-shaped and may be constructed of a metallic material such as stainless steel. A somewhat large central opening in both the first and second flange plates 46, 48 accommodates receipt of the inlet conduit 28. Now referring to the enlarged view of FIG. 2, the first flange plate 46 has a first, inboard surface 52 and a second, outboard surface 54. And the second flange plate 48 has a first, inboard surface 56 and a second, outboard surface 58. The first surfaces 52, 56 directly face each other. A first gap 60 is between the first and second flange plates 46, 48 and the opposing first surfaces 52, 56 for communicating and distributing air pressure to the tubes 18 and shuttle 20 during use of the magnetic separator 10. The first gap 60 is established in part by an annular passage 62 defined in the first flange plate 46. The annular passage 62 runs circumferentially around the first flange plate 46 for communication with all of the tubes 18 and shuttle 20, which are also positioned circumferentially around the magnetic separator 10. A pair of O-rings 64 of different diameters are mounted on the inner and outer circumferences of the first gap 60 to form a seal at their respective locations. The O-rings 64 are sandwiched between the first and second flange plates 46, 48. Additionally, an air fitting 66 is provided in the first flange plate 46 and communicates with the first gap 60 for connection to a source of air pressure operation.

[0014] 1 and 2, the second flange plate 48 has a plurality of first openings 68 located within its structure for receiving the insertion of the ends of the tubes 18 during assembly. There are as many first openings 68 as there are tubes 18. A single first opening 68 is provided for each tube 18. As best shown in FIG. 2, the first opening 68 has a diameter slightly larger than that of the tube 18 for a tight fit between the first opening 68 and the tube 18 upon insertion. Each first opening 68 extends entirely through the second flange plate 48 between the first surface 56 and the second surface 58, and spans between a first open edge 70 at the first surface 56 and a second open edge 72 at the second surface 58.

[0015] The second flange plate assembly 16 may have a similar design and structure as the first flange assembly 14. Referring to FIG. 1, the second flange plate assembly 16 constitutes the lower end of the magnetic separator 10. In this embodiment, the second flange plate assembly 16 has a third flange plate 74 and a fourth flange plate 76. The third and fourth flange plates 74, 76 are connected to each other via bolts 78. They are both disk-shaped and may be constructed of a metallic material such as stainless steel. A somewhat larger central opening in both the third and fourth flange plates 74, 76 is adapted to receive the outlet conduit 30. The third flange plate 74 has a first, inboard surface 80 and a second, outboard surface 82. And the fourth flange plate 76 has a first, inboard surface 84 and a second, outboard surface 86. The first surfaces 80, 84 face each other directly. A second gap 88 is between the third and fourth flange plates 74, 76 and the opposing first surfaces 80, 84 for transmitting and distributing air pressure to the tubes 18 and shuttle 20 during use of the magnetic separator 10. The second gap 88 is established in part by an annular passage 90 defined in the third flange plate 74. The annular passage 90 runs circumferentially around the third flange plate 74 for communication with all of the tubes 18 and shuttle 20. A pair of O-rings 92 of different diameters are mounted on the inner and outer peripheries of the second gap 88 to form a seal at their respective locations. The O-rings 92 are sandwiched between the third and fourth flange plates 74, 76. Additionally, an air fitting (not shown) may be provided in the third flange plate 74 and communicate with the second gap 88 for connection to a source of air pressure operation.

[0016] The fourth flange plate 76 has a plurality of second openings 94 located within its structure for receiving the insertion of the ends of the tubes 18 during assembly. There are as many second openings 94 as there are tubes 18. A single second opening 94 is provided for each tube 18. The second opening 94 has a diameter slightly larger than the diameter of the tube 18 for a tight fit between the second opening 94 and the tube 18 upon insertion. Each second opening 94 extends entirely through the fourth flange plate 76 between the first surface 84 and the second surface 86 and spans between a first open edge 96 (shown in FIGS. 2, 2A) at the first surface 84 and a second open edge 98 (shown in FIG. 2) at the second surface 86.

[0017] The tubes 18 are located within the housing wall and in the main passage 26 and extend completely between the first and second flange plate assemblies 14, 16. The tubes 18 extend through the first and second sections 40, 42 of the main passage 26. In the main passage 26, the tubes 18 have direct exposure to the process fluid flowing through the magnetic separator 10. The process fluid flows around the tubes 18 to make its way from the inlet conduit 28 and to the outlet conduit 30. A single shuttle 20 is received inside each tube 18. The tubes 18 guide the shuttle 20 for its length and upward and downward movement during use of the magnetic separator 10. Each tube 18 is cylindrical in shape and may be constructed of a metallic material such as stainless steel. As depicted in FIG. 1, the tubes 18 are circumferentially arranged around the main passage 26 and are offset and spaced apart from one another. The arrangement may be somewhat uniform to balance the magnetic attractive forces and those generated by shuttle magnets (described later) held within the tubes 18. The exact amount of tubes 18 may vary. In one example, there are a total of 26 tubes 18 and 26 associated shuttles 20 provided, with other amounts being contemplated in other examples. With particular reference to FIG. 2, each tube 18 has a tube wall 100. The tube wall 100 has an outer surface 102 and an inner surface 104. A bore 106 is defined within the hollow interior of each tube 18. A first open end 108 is defined at one free end of each tube 18, and similarly a second open end 110 (depicted in FIGS. 2, 2A) is defined at the opposite free end of each tube 18. Additionally, a first terminal edge 112 is defined at the first open end 108, and in a similar manner, a second terminal edge 114 (depicted in FIGS. 2, 2A) is defined at the second open end 110. The first and second terminal edges 112, 114 extend completely around the circumference of the first and second open ends 108, 110, respectively.

[0018] The shuttle 20 serves to attract magnetic contaminants against the tube wall 100 when the shuttle 20 is placed in the tube 18 and is in a position to capture the magnetic contaminants. The magnetic contaminants are held against and accumulate in the tube wall 100 as a result of the attraction. The shuttle 20 is received in a bore 106 in the tube 18 and can move lengthwise and up and down therein in response to pneumatic actuation. The shuttle 20 is generally cylindrical in shape. The overall length of each individual shuttle 20 from end to end corresponds approximately to the axial length of the first section 40 and to the axial length of the second section 42. The diameter of each individual shuttle 20 is slightly smaller than the diameter of the bore 106 so that the shuttle 20 can move therethrough. The shuttle 20 can have different designs and constructions and components. 3 and 4, in this embodiment, each shuttle 20 includes a spindle 116, a first end cap 118, a second end cap 120, an O-ring 122, a plurality of magnets 124, and a plurality of pole pieces 126.

[0019] The spindle 116 supports the other components of the shuttle 20. First and second end caps 118, 120 connect to opposing free ends of the spindle 116 and hold the magnets 124 and pole pieces 126 together. The connection between the spindle 116 and the first and second end caps 118, 120 is via threads therebetween. The first and second end caps 118, 120 are threaded onto the respective free ends of the spindle 116. A thread locking fluid may be applied to the threads. The first and second end faces 128, 130 of the first and second end caps 118, 120 are planar and receive pressure from pressurized air during use of the magnetic separator 10. The first and second end faces 128, 130 establish first and second closed ends 129, 131 thereon of the shuttle 20. In conventional shuttles, the spindle extends through an opening in the end cap at such surface, and an internal O-ring is provided between the spindle and the end cap due to the opening in conventional shuttles. In the illustrated embodiment, the spindle 116 does not extend through the first and second end caps 118, 120. Rather, the first and second closed ends 129, 131 at the first and second end faces 128, 130 thus eliminate the need for an internal O-ring, which is omitted in the shuttle 20 and in the spindle 116. The potential drawback of an internal O-ring has been eliminated in the illustrated embodiment.

[0020] In assembly, a first spring 132 (FIG. 1) is disposed at a first end face 128 relative to the first end cap 118, and similarly a second spring 134 (FIG. 1) is disposed at a second end face 130 relative to the second end cap 120. Like the shuttle 20, the first and second springs 132, 134 are received in the bore 106 of the tube 18. The first and second springs 132, 134 serve to cushion and absorb shocks exerted as the shuttle 20 moves lengthwise and up and down in response to pneumatic actuation. The first and second springs 132, 134 may also serve as spacers to position the shuttle 20 in longitudinal alignment and relative to the first and second compartments 40, 42 in different operating modes of the magnetic separator 10. The longitudinal extent of the first spring 132 may be slightly greater than the axial extent of the first opening 68, and similarly the longitudinal extent of the second spring 134 may be slightly greater than the axial extent of the second opening 94. Referring again to Figures 3 and 4, one O-ring 122 is mounted in a groove 136 in the first end cap 118, and another O-ring 122 is mounted in another groove 138 in the second end cap 120. The O-rings 122 form an airtight seal with the inner surface 104 of the tube wall 100 at their respective locations.

[0021] The magnets 124 are supported by the spindle 116 between the first and second end caps 118, 120. The magnets 124 are permanent magnets in this embodiment. They generate a magnetic field that attracts and pulls magnetic contaminants towards and against the tube wall 100. The exact quantity of magnets 124 can vary. In this embodiment, there are a total of eight full magnets (F) and two half magnets (H), with other quantities being contemplated in other examples. The magnets 124 are cylindrical in shape with a central opening for insertion onto the spindle 116. A variety of materials can be used as the composition of the magnets 124. In one example, the magnets 124 are constructed of neodymium-iron-boron (NIB), with other materials being contemplated in other examples. Together, the magnets 124 can generate magnetic fields of different magnitudes depending on the application. In one example, the magnets 124 generate a magnetic flux density greater than 10,000 Gauss (G), with other magnitudes being contemplated in other examples. Finally, the pole pieces 126 are supported by the spindle 116 and are disposed intermediate the magnets 124. The pole pieces 126 direct the generated magnetic field radially outward. The exact amount of pole pieces 126 may vary and depend on the amount and arrangement of the magnets 124. In this embodiment, there are a total of nine pole pieces 126, with other amounts being contemplated in other examples. The pole pieces 126 are disc-shaped with a central opening for insertion onto the spindle 116. Note that in one example, the north poles of the consecutively arranged magnets 124 may face each other across the intervening pole pieces 126, and similarly, the south poles of the consecutively arranged magnets 124 may face each other across the intervening pole pieces 126. It has been discovered that this arrangement may produce a higher strength magnetic field.

[0022] It has been determined that the interrelationship between the flange plate and the tube should be sealed to prevent air and liquid leakage. Conventionally, O-ring seals were placed at the interface between the flange plate and the tube; a first O-ring seal for air and a second O-ring seal for the process fluid. The first and second O-ring seals were spaced apart from each other and mounted in a groove on the inside of an opening in the flange plate. The tube was then partially inserted into the opening with its outer surface abutting the first and second O-ring seals. The tube was removable from the flange plate for subsequent repair and replacement of the O-ring seal. Since the two O-ring seals had different sealing purposes, i.e., a first purpose for air and a second purpose for the process fluid, they were constructed by different materials with respect to each other. Furthermore, the material selected for the second O-ring seal was often dictated by the process fluid that was the subject of separation and removal of contaminants in the associated magnetic separator. One material may be suitable for preventing degradation for one type of process fluid, but not for another type of process fluid, which may result in faster degradation. Over time and with extensive use, it has been found that in some cases the O-ring seals will fail and require replacement. The failure may be due to degradation or other factors. Once a failure occurs, the conventional magnetic separator must be removed and disassembled, the tubes removed, the O-ring seal removed and replaced, and the parts reassembled and reinstalled. The possibility of failure in certain situations has been found to hinder the usefulness of conventional magnetic separators and can hinder their readiness for use in field applications and other more mobile applications, as well as in applications having process fluids that are more aggressive in nature in terms of being prone to degrading the O-ring seals.

[0023] To address some or all of these potential shortcomings, the magnetic separator 10 has a weldment established between the tube 18 and the first and second flange plate assemblies 14, 16. The weldment serves as a somewhat permanent fastener between the tube 18 and the first and second flange plate assemblies 14, 16, and at the same time serves as a permanent seal to prevent both air and process fluid leakage between the tube 18 and the first and second flange plate assemblies 14, 16. Since the seal is provided by the weldment itself, the O-ring seal of a conventional assembly may be unnecessary and may be avoided entirely, although in some embodiments, an O-ring seal may be provided as a back-up measure. The weldment provides a seal that does not degrade. The magnetic separator 10 is thus more useful and is suitable and ready for use in field applications such as the oil and gas industry, environmental remediation, and others, and in applications employing process fluids of a more aggressive nature. The weldment may take different forms in different embodiments. For each embodiment, one challenge encountered in providing a proper attachment and seal through the weldment was the thinness of the pipe wall 100. In one example, the pipe wall 100 has a thickness (i.e., from the outer surface 102 to the inner surface 104) of approximately 0.07 mils (thousandths of an inch, 0.000778 millimeters (mm)), with other thickness values ​​being contemplated in other examples. It has been discovered that the thinner the pipe wall 100, the more easily it can be scratched and distorted during welding, damaging the weld itself and damaging the seals intended to prevent leakage of air and process fluids.

[0024] 2A , in this embodiment, a first weldment 140 is established between each of the tubes 18 and the second flange plate 48, and in a similar manner, a second weldment 142 (depicted in FIG. 2A ) is established between each of the tubes 18 and the fourth flange plate 76. In assembly, the tubes 18 are inserted into the first openings 68 such that they are fully inserted, whereby the first end edge 112 is at the first open edge 70. The first open end 108 is generally flush with the first open edge 70 relative to the first surface 56 of the second flange plate 48. The first end edge 112 and the first open edge 70 are generally aligned with the plane defined by the first surface 56. The first weldment 140 is established between the first open end 108 and the first open edge 70, and between the first end edge 112 and the first open edge 70. Further, in one embodiment, a first weldment 140 may be formed between the outer surface 102 and the first surface 56. To provide attachment and a complete seal around the tube 18 and the first opening 68, the first weldment 140 may be formed continuously over the entire extent of the first interface between the first open edge 70 and the first end edge 112. The first weldment 140 extends continuously circumferentially around the tube 18 and the first opening 68. In one example, the first weldment 140 is prepared by a tungsten inert gas (TIG) welding process to create a TIG weldment. A first weldment filler 144 may be applied during the TIG welding process. However, other types of welding processes may be utilized to create the first weldment 140. To facilitate welding in certain embodiments and depending on the particular welding process being performed, a first beveled edge 148 may be provided at the first open edge 70. In the example of TIG welding, the first weldment filler 144 may then be secured at the first beveled edge 148 in the established spacing.

[0025] Similarly, in the fourth flange plate 76, the tube 18 is inserted into the second opening 94 such that it is fully inserted, whereby the second end edge 114 is at the first open edge 96. The second open end 110 is generally flush with the first open edge 96 relative to the first surface 84 of the fourth flange plate 76. The second end edge 114 and the first open edge 96 are generally aligned with the plane defined by the first surface 84. A second weld 142 is established between the second open end 110 and the first open edge 96, and between the second end edge 114 and the first open edge 96. Additionally, in one embodiment, the second weld 142 may be formed between the outer surface 102 and the first surface 84. The second weld 142 is formed continuously over the entire extent of the second interface between the first open edge 96 and the second end edge 114 to provide an attachment and complete seal around the tube 18 and around the second opening 94. The second weldment 142 extends continuously circumferentially around the tube 18 and around the second opening 94. In one example, the second weldment 142 is prepared by a tungsten inert gas (TIG) welding process to create a TIG weldment. The second weldment filler 146 may be provided during the TIG welding process. However, other types of welding processes may be utilized to create the second weldment 142. To facilitate welding in certain embodiments and depending on the particular welding process being performed, a second beveled edge 150 may be provided at the first open edge 96. In the example of TIG welding, the second weldment filler 146 may then be secured in a space provided at the second beveled edge 150.

[0026] The seal provided by the first and second weldments 140, 142 may replace the O-ring seal of a conventional assembly. The potential for undesired failure associated with an O-ring may therefore be avoided in certain embodiments. For example, an O-ring seal may be absent in an adjacent first proximate portion of the attachment between the tube 18 and the first flange plate assembly 14, specifically the second flange plate 48. More specifically, in the illustrated embodiment, an O-ring seal is not provided and is absent over a first lengthwise extent of the receiver 152 (FIG. 2) between the tube 18 and the first opening 68. Similarly, an O-ring seal may be absent in an adjacent second proximate portion of the attachment between the tube 18 and the second flange plate assembly 16, specifically the fourth flange plate 76. More specifically, in the illustrated embodiment, an O-ring seal is not provided and is absent over a second lengthwise extent of the receiver 154 (FIG. 2) between the tube 18 and the second opening 94.

[0027] In operation, the magnetic separator 10 and its components work together to separate and remove magnetic contaminants from the process fluid. The magnetic separator 10 has at least two operating modes: a filtration mode and a purification mode. In the filtration mode, the shuttle 20 is positioned within the tube 18 in alignment with the second section 42. This mode and position is illustrated in FIG. 1. Air pressure via the air fitting 66 moves the shuttle 20 to a position within the tube 18 at the second section 42. Differential air pressure between the first and second end faces 128, 130 of the shuttle 20 results in the movement and positioning of the shuttle 20 in the tube 18. In the filtration mode, the process fluid enters the main passage 26 via the inlet conduit 28 and flows through the second section 42. Magnetic contaminants in the process fluid are attracted to the tube 18 by the shuttle's magnets 124 and held against the tube wall 100. The magnetic contaminants are captured and therefore do not exit the main passageway 26 through the outlet conduit 30 with the now purified process fluid. In the purification mode, meanwhile, the shuttle 20 is positioned in alignment with the first compartment 40. Air pressure via an air fitting at the second flange plate assembly 16 moves the shuttle 20 to a position in the pipe 18 at the first compartment 40. In the purification mode, the absence of positioning of the shuttle 20 at the second compartment 42 results in the previously captured magnetic contaminants being released into the second compartment 42. The main passageway 26 is purified, and the released magnetic contaminants are flushed and discharged out of the magnetic separator 10. Note that during the purification mode, magnetic contaminants from the newly entering process fluid may collect in the first compartment 40, so that the magnetic separator 10 operates in a continuous manner and process fluid is continuously provided to the magnetic separator 10.

[0028] The above should be understood as a description of one or more aspects of the present disclosure. The present disclosure is not limited to the specific embodiments disclosed herein, but rather is defined only by the following claims. Furthermore, statements contained in the above description should not be interpreted as limiting the scope of the present disclosure or the definition of the words or phrases used in the claims, unless the words or phrases are specifically defined above in relation to the specific embodiments. Various other embodiments and various changes and modifications to the disclosed embodiments will be apparent to those skilled in the art. All such other embodiments, changes and modifications are intended to fall within the scope of the appended claims.

[0029] As used in this specification and the claims, the words "eg," "for example," "for instance," "such as," and "like," as well as the verbs "comprising," "having," "including," and other verb forms thereof, when used in combination with a list of one or more components or other items, are each to be construed as open-ended, meaning that the list should not be considered as excluding other, additional components or items. Other words and phrases are to be construed using their broadest reasonable meaning unless used in a context that requires a different interpretation.

Claims

1. 1. A pneumatically operated magnetic separator comprising: A housing wall; a first flange plate assembly located adjacent an end of the housing wall, the first flange plate assembly including a first flange plate and a second flange plate, the second flange plate having a plurality of first openings located therein; a second flange plate assembly located adjacent another end of the housing wall, the second flange plate assembly including a third flange plate and a fourth flange plate, the fourth flange plate having a second plurality of openings located therein; a primary fluid passageway established partially by the housing wall, partially by the first flange plate assembly, and partially by the second flange plate assembly; a plurality of tubes extending between the first flange plate assembly and the second flange plate assembly, the plurality of tubes being received in the plurality of first openings of the second flange plate and in the plurality of second openings of the fourth flange plate, each of the plurality of tubes having a hole; a plurality of shuttles disposed in the bores of the plurality of tubes, each of the plurality of shuttles including at least one magnet, the plurality of shuttles being longitudinally movable within the bores; a first plurality of weldments attaching together said plurality of pipes and said first flange plate assembly, and a second plurality of weldments attaching together said plurality of pipes and said second flange plate assembly. the second flange plate has a first surface facing the first flange plate, each of the plurality of tubes has a first end, and the plurality of first weldments are established at the first surfaces and at the first ends; the fourth flange plate has a second surface facing the third flange plate, each of the plurality of tubes has a second end, and the plurality of second weldments are established at the second surface and at the second ends; the first weldments are a first TIG weldments (first tungsten inert gas weldments), and the second weldments are a second TIG weldments (second tungsten inert gas weldments); a first beveled edge is provided at a first open edge of each of the first plurality of openings, and the first plurality of TIG weldments are located at the first beveled edge; a second beveled edge is provided at a second open edge of each of said plurality of second openings, said plurality of second TIG weldments being located at said second beveled edges.

2. 2. The pneumatically operated magnetic separator of claim 1, wherein a first proximate portion of the fit between the plurality of tubes and the first flange plate assembly lacks an O-ring seal at that location, and a second proximate portion of the fit between the plurality of tubes and the second flange plate assembly lacks an O-ring seal at that location.

3. 2. The pneumatically operated magnetic separator of claim 1, wherein a first lengthwise extent of a receiver between said plurality of tubes and said plurality of first openings is absent of an O-ring seal, and a second lengthwise extent of a receiver between said plurality of tubes and said plurality of second openings is absent of an O-ring seal.

4. 2. The pneumatically operated magnetic separator of claim 1, wherein the first plurality of weldments are established between the plurality of pipes and the second flange plate, and the second plurality of weldments are established between the plurality of pipes and the fourth flange plate.

5. 2. The pneumatically operated magnetic separator of claim 1, wherein each of the plurality of first openings has a first open edge, each of the plurality of tubes has a first end edge, and the plurality of first weldments are established at the first open edges and the first end edges.

6. 6. The pneumatically operated magnetic separator of claim 5, wherein each of the plurality of second openings has a second open edge, each of the plurality of tubes has a second end edge, and the plurality of second weldments are established at the second open edges and the second end edges.

7. 7. The pneumatically operated magnetic separator of claim 6, wherein each of the plurality of first weldments is a continuous weld established across an entire extent of a first interface between a respective first open edge and a respective first end edge.

8. 8. The pneumatically operated magnetic separator of claim 7, wherein each of the plurality of second weldments is a continuous weld established across an entire extent of a second interface between a respective second open edge and a respective second end edge.

9. 2. The pneumatically operated magnetic separator of claim 1, wherein a first gap is between the first flange plate and the second flange plate and a second gap is between the third flange plate and the fourth flange plate, the first gap and the second gap communicating with the holes in the plurality of tubes.

10. 10. The pneumatically operated magnetic separator of claim 9, wherein longitudinal movement of the plurality of shuttles within the bores of the plurality of tubes is effected by application and deapplication of pressurized gas in the first gap and the second gap.

11. 2. The pneumatically operated magnetic separator of claim 1, wherein each of the plurality of shuttles includes a spindle, a first end cap, and a second end cap, the spindle supporting the at least one magnet, the first end cap connected to the spindle and establishing a first closed end thereat, and the second end cap connected to the spindle and establishing a second closed end thereat.

12. 1. A pneumatically operated magnetic separator comprising: A housing wall; a first flange plate located adjacent to the housing wall, the first flange plate having a plurality of first openings extending entirely through the first flange plate, each of the plurality of first openings having a first open edge at a first surface of the first flange plate; a second flange plate located opposite the first flange plate and adjacent to the housing wall; a primary fluid passageway at least partially established by the housing wall and extending between the first flange plate and the second flange plate; a plurality of tubes extending between the first flange plate and the second flange plate, the plurality of tubes being inserted into the plurality of first openings, each of the plurality of tubes having a tube wall, the tube wall having a first terminal edge; a plurality of shuttles disposed in the plurality of tubes, each of the plurality of shuttles including at least one magnet; a plurality of first weldments attaching the first flange plate and the plurality of tubes together, the plurality of first weldments being established at the first open edge and the first end edge, the plurality of first weldments being a plurality of first tungsten inert gas weldments; a first beveled edge is provided on each of the first open ends and the plurality of first TIG weldments are located on the first beveled edges.

13. 13. The pneumatically operated magnetic separator of claim 12, wherein the second flange plate has a plurality of second openings, the plurality of second openings extending entirely through the second flange plate, each of the plurality of second openings having a second open edge at a second surface of the second flange plate, the plurality of tubes being inserted into the plurality of second openings, the tube wall having a second terminal edge, and the pneumatically operated magnetic separator further comprises a plurality of second weldments attaching the second flange plate and the plurality of tubes together, the plurality of second weldments being established at the second open edge and at the second terminal edge.

14. 13. The pneumatically operated magnetic separator of claim 12, wherein said first terminal edge is at said first open end edge and is generally aligned with a plane established by said first surface of said first flange plate.

15. 13. The pneumatically operated magnetic separator of claim 12, wherein the plurality of first weldments each comprise a weldment filler.

16. 13. The pneumatically operated magnetic separator of claim 12, wherein an O-ring seal is absent along a first longitudinal extent of a receiver between said plurality of tubes and said plurality of first openings.

17. 1. A pneumatically operated magnetic separator comprising: A housing wall; a first flange plate assembly located adjacent an end of the housing wall, the first flange plate assembly including a first flange plate and a second flange plate, a plurality of first openings located in the second flange plate, the plurality of first openings extending entirely through the second flange plate, each of the plurality of first openings having a first open edge, a first beveled edge being provided on each of the first open edges; a second flange plate assembly located adjacent another end of the housing wall, the second flange plate assembly including a third flange plate and a fourth flange plate, a plurality of second openings located in the fourth flange plate, the plurality of second openings extending entirely through the fourth flange plate, each of the plurality of second openings having a second open edge, a second beveled edge being provided on each of the second open edges; a primary fluid passageway established partially by the housing wall, partially by the first flange plate assembly, and partially by the second flange plate assembly; a plurality of tubes extending between the first flange plate assembly and the second flange plate assembly, the plurality of tubes being received in the first plurality of openings of the second flange plate and in the second plurality of openings of the fourth flange plate, each of the plurality of tubes having a tube wall, the tube wall having a first terminal edge and a second terminal edge; a plurality of shuttles disposed in the plurality of tubes, each of the plurality of shuttles including at least one magnet; a first plurality of TIG weldments (first tungsten inert gas weldments) attaching the second flange plate and the plurality of tubes together, the first plurality of TIG weldments being established at the first open edge and at the first end edge and located at the first beveled edge, the first plurality of TIG weldments being a continuous weldment extending around an entire extent of the first open edge and the first end edge; a second plurality of TIG weldments attaching the fourth flange plate and the plurality of tubes together, the second plurality of TIG weldments being established at the second open edge and at the second end edge and located at the second beveled edge, the second plurality of TIG weldments being a continuous weldment extending around the entire extent of the second open edge and the second end edge.

18. A pneumatically operated magnetic separator as described in claim 1, wherein the plurality of tubes have tube walls having a thickness dimension smaller than the thickness dimensions of the second flange plate and the fourth flange plate.

19. A pneumatically operated magnetic separator as described in claim 1, wherein the material of the plurality of pipes is within the first beveled edge and the second beveled edge at the time of establishment of the plurality of first TIG weldments and the plurality of second TIG weldments.

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