A drain gate assembly

Abstract

A drain gate assembly (100) comprise of a housing (102) defining a first passage (206) between a first opening (202) and a second opening (204), and a second passage (208) exposed to the first passage (206). A gate plate (104) is accommodated within the housing (102). The first passage (206) receives material through the first opening (202) and allows the material to exit the first passage (206) through the second opening (204). The gate plate (104) operably moves between a first position and a second position, wherein in the first position, the gate plate (104) obstructs the first passage (206), and in the second position, the gate plate (104) opens the first passage (206). The gate plate (104) is operable to travel within the first passage (206) and the second passage (208) to move along a path between the first position and the second position.

Description

A DRAIN GATE ASSEMBLYBACKGROUNDField of the invention

[0001] The present invention relates to drain gates, specifically to an improved design of drain gate mechanism for controlling the discharge of material in systems, such as, fluidized bed systems for processing fuel by combustion or pyrolysis.Brief statement of the prior art

[0002] Conventional drain gate systems in fluidized bed system operations face several significant drawbacks that impact the process's efficiency, safety, and environmental compliance. One major issue is their inability to withstand the high temperatures typical of combustion and pyrolysis processes, which leads to material degradation and mechanical failures. This susceptibility to high heat can compromise the entire system, necessitating frequent maintenance and replacements that cause operational downtimes and increase costs.

[0003] Another critical challenge is the inadequate handling of the diverse range of particle sizes present during fuel processing. Very fine particles (0 to 100 microns) often consolidate causing clogging restricting movement of movable parts, while larger particles (1 to 100mm) may not be discharged effectively and may prevent intended movement of moveable parts. This inconsistency can result in blockages and inefficient clearing of the system, affecting the overall throughput and effectiveness of the fuel processing process. Furthermore, many existing drain gates have poor sealing capabilities, which is crucial to prevent unintentional leaks of materials and gases. Inadequate sealing can lead to the loss of valuable materials and the release of potentially toxic gases and dust into the environment, posing significant health and environmental risks. Additionally, it can disrupt the controlled internal environment necessary for optimal fuel processing operations, further affecting process outcomes.

[0004] Operational reliability is also a concern with current systems, which often lack features to manage and relieve blockages easily, making maintenance difficult and hazardous. The inability to address operational issues quickly and safely leads to increased downtime and operational costs. Moreover, systems that are not user-friendly in terms of maintenance can pose significant safety risks to personnel. Another limitation of current drain gates is their limited process control functionality, which restricts the ability to adapt to varying operational conditions or to handle emergencies and abnormal situations effectively. This lack of advanced control features hampers the flexibility of the combustion or pyrolysis process and prevents operators from responding swiftly to changes in the system's performance or external demands.

[0005] The safety risks associated with drain gates are particularly concerning. Failure to close properly can lead to severe consequences, including the risk of materials accidentally entering critical process components, e.g. the rotary kiln at a cement plant.

[0006] In light of the foregoing, there is a need for an improved and efficient drain gate design that aims to provide a more reliable, efficient, and environmentally safe solution for fluidized bed systems, significantly improving the overall stability and performance of the process.OBJECT OF THE INVENTIONIt is an object of the present invention to overcome or at least alleviate one or more of the above problems of the prior art and / or provide the user with a useful or commercial choice.It is an object of the present invention to provide a drain gate assembly.It is a further object of the present invention to provide an alternative to the prior art.SUMMARY OF THE INVENTION

[0007] In an embodiment, a drain gate assembly is disclosed, wherein the drain gate assembly comprises a housing with a gate plate accommodated within the housing. The housing defines a first opening and a second opening. The housing defines a first passage between the first opening and the second opening, wherein the first passage is configured to receive material through the first opening and allow the material to exit the first passage through the second opening. The gate plate is configured to operatively move between a first position and a second position, wherein in the first position, the gate plate is configured to obstruct the first passage thereby preventing the material entering through the first opening from exiting through the second opening, and in the second position, the gate plate is configured to open the first passage thereby permitting the material entering through the first opening to exit through the second opening. The gate plate is configured with a second passage defined by the housing and exposed to the first passage, where the gate plate is operable to travel within the first passage and the second passage.BRIEF DESCRIPTION OF DRAWINGS

[0008] Embodiments are illustrated, by way of example and not limitation, in the figures of the accompanying drawings, in which like references indicate similar elements and in which:

[0009] FIG. 1A illustrates a portion of a fluidized bed fuel processing setup with a drain gate assembly 100 arranged at multiple locations of the fuel processing setup, in accordance with an embodiment.

[0010] FIG. IB illustrates a perspective view of the drain gate assembly 100 along with a cover 106, in accordance with an embodiment.

[0011] FIG. 2 A illustrates a cross-sectional view of the drain gate assembly 100 with a gate plate 104 in a first position, in accordance with an embodiment.

[0012] FIG. 2B illustrates a cross-sectional view of the drain gate assembly 100 with the gate plate 104 in a second position, in accordance with an embodiment.

[0013] FIG. 2C illustrates a perspective cross-sectional view of the drain gate assembly 100 with the gate plate 104, in accordance with and embodiment.

[0014] FIG. 2D illustrates a cross-sectional view of the drain gate assembly 100 with the gate plate 104 and the frame plate 236, in accordance with and embodiment.

[0015] FIG. 2E illustrates a detailed cross-sectional view of the drain gate assembly 100 with the gate plate 104 having one or more holes 238, in accordance with and embodiment.

[0016] FIG. 2F illustrates a cross-sectional view of a first structural configuration of the drain gate assembly 100 with the gate plate 104 and the frame plate 236, in accordance with and embodiment.

[0017] FIG. 2G illustrates a cross-sectional view of a second structural configuration of the drain gate assembly 100 with the gate plate 104 and the frame plate 236, in accordance with and embodiment.

[0018] FIG. 3 illustrates another perspective view of the drain gate assembly 100 with an actuator assembly 234, in accordance with an embodiment.

[0019] FIG. 4 illustrates a detailed perspective view of sealing member 320, in accordance with an embodiment.

[0020] FIG. 5 illustrates a plan view of the drain gate assembly 100 with a first fluid port 222 among a pair of first fluid ports, a second fluid port 224 among a pair of second fluid ports and a third fluid port 226 among a pair of third fluid ports, in accordance with an embodiment.

[0021] FIG. 6 illustrates a plan view of the drain gate assembly 100 with a first spring 602, in accordance with an embodiment.DETAILED DESCRIPTION

[0022] Referring to FIG. 1 A a fluidized bed fuel processing system setup is disclosed with a drain gate assembly 100 provided for lower sealing and controlled removal of fine and / or coarse particles (material) within the fluidized bed fuel processing system setup. The drain gate assembly 100 may be configured to be detachably engaged to, but not limited to, a fluidized bed fuel processing system setup. The two drain gates positioned vertically over each other are configured to sluice out batches of solid fluidized material from a fluidized bed. As a consequence, the upper gate is exposed to the static pressure of the fluidized meal bed above it when open, and the upper gate needs to close through a static bed of solid material with fine and / or coarse particles when operating in sluice configuration.

[0023] FIG. IB illustrates a perspective view of the drain gate assembly 100 with a cover 106.

[0024] Referring to FIGs. 2A-2C and 3, the drain gate assembly 100 comprises of a housing 102 with a gate plate 104. The drain gate assembly 100 further comprises of an actuator assembly 234(refer FIGs. 2A-2C and 3), wherein the actuator assembly 234 may be configured to be encompassed within the cover 106. The housing 102 may be provided with a first opening 202 and a second opening 204, wherein the first opening 202 may be disposed opposite to the second opening 204. The housing 102 may define a first passage 206, wherein the first passage 206 may extend at least in a portion between the first opening 202 and the second opening 204. The first passage 206 may be configured to enable receiving of material through the first opening 202 and allow the material to exit the first passage 206 through the second opening 204.

[0025] In an embodiment, the housing 102 may define a second passage 208, wherein the second passage 208 may be exposed to the first passage 206. The second passage 208 may extend from the first passage 206 within the housing 102.

[0026] In an embodiment, the gate plate 104 may be configured to be accommodated within the housing 102 of the drain gate assembly 100. The gate plate 104 may be accommodated within the housing 102 of the drain gate assembly 100 in a manner that the gate plate 104 may be configured to operationally travel within the first passage 206 and the second passage 208. The gate plate 104 may be configured to be extended into the first passage 206 to move into a first position, and the gate plate 104 may be configured to be retracted into the second passage 208 to move into a second position.

[0027] The housing 102 may define a sealing space 210, wherein the sealing space 210 may be provided opposite to the second passage 208 and may extend from the first passage 206 into the housing 102. The sealing space 210 may be configured to operationally receive at least a portion of the gate plate 104 during operation.

[0028] In an embodiment, at least a portion of the sealing space 210 may define a profile that compliments at least a portion of the gate plate 104, wherein at least portions of the gate plate 104 and the sealing space 210 interface with each other to thereby establish sealing between the gate plate 104 and the sealing space 210.

[0029] In an embodiment, the gate plate 104 may be configured to be operationally moved between the first position and the second position, wherein in the first position, the gate plate 104 may be configured to obstruct the first passage 206 thereby preventing material entering through the first opening 202 from exiting through the second opening 204 (refer FIG. 2A), and in the second position, the gate plate 104 may be configured to open the first passage 206 thereby permitting the material entering through the first opening 202 to exit through the second opening 204 (refer FIG. 2B).

[0030] In an embodiment, the gate plate 104 may be configured to move along a path between the first position and the second position, wherein the path may be angled relative to a direction of the material passing through the first passage 206 and the path may be inclined towards the secondopening 204.

[0031] In an embodiment, the drain gate assembly 100 comprises a first supporting member 232 and a second supporting member (not shown in the figures, however the second supporting member is identical to the first supporting member), wherein the first supporting member 232 and the second supporting member may be configured to provide support to the gate plate 104 as the gate plate 104 moves in and out of the first passage 206. The first supporting members 232 and the second supporting members may be provided in a manner that at least a first portion of the first supporting member 232 and the second supporting member may be disposed in the first passage 206, and at least a second portion of the first supporting member 232 and the second supporting member may extend into the second passage 208.

[0032] In an embodiment, the first portion of the first supporting member 232 and the second supporting member may define a curved path towards an end of the first portions disposed towards the sealing space 210 defined by the housing 102. The curved path defined by the first portions of the first supporting member 232 and the second supporting member may be configured to enable pressing of the gate plate 104 against at least a portion of the sealing space 210, as the gate plate 104 moves into the first position, thereby establishing sealing between the gate plate 104 and the sealing space 210.

[0033] In an embodiment, the first supporting members 232 comprise a first set of projections that may extend laterally into the housing 102, and similarly the second supporting members comprise a second set of projections that may extend laterally into the housing 102. The first supporting member 232 and the second supporting member may be disposed on opposite sides within the housing 102.

[0034] In an embodiment, the projections among the first set of projections may be spaced apart. Similarly, projections among the second set of projections may be spaced apart. The spacing between projections among the first set of projections and the second set of projections respectively, avoid accumulation of material. Furthermore, support for the gate plate 104 by the first supporting member 232 and the second supporting member helps maintain alignment of the gate plate 104 and contact with the sealing space 210, when the gate plate 104 is in the first position, to thereby ensure effective sealing and preventing material leakage.

[0035] In an alternate embodiment, the first supporting member 232 and the second supporting member may be provided in the form of channels that may enable gliding of the gate plate 104 over the first supporting member 232 and the second supporting member while providing support to the gate plate 104.

[0036] In an embodiment, also referring to FIGs. 2A-2C, the gate plate 104 comprises a top surface 212 and a bottom structure 214, wherein the top surface 212 may be exposed to the first opening202, and the bottom structure 214 which may be exposed to the second opening 204 is formed so that it facilitates smooth gliding on the first and second set of projections and, ensure that the top surface 212 is maintained substantially plane under thermal and mechanical stress. The top surface 212 of the gate plate 104 may define a plane surface area suitable for sealing against the opening above while the bottom surface 214 may be a combination of stiffener plates, side support surfaces and fixation points for operating plungers 316. The bottom structure 214 of the gate plate 104 may be configured to interface with at least a portion of the first supporting member 232 and the second supporting member, wherein the first supporting member 232 and the second supporting member may be configured to provide support to the gate plate 104, as the gate plate 104 moves in and out of the first passage 206.

[0037] In an embodiment, the gate plate 104 further comprises of at least a portion towards its sides cross section perpendicular to its movement direction being small (i.e. sharp front) so that it cuts through particles rather than consolidating them. The gate plate 104 may not have surfaces towards the front part on which materials can accumulate and surfaces are formed so that they are accessible to fluid ports for cleaning. The front comers on each side are retracted from the leading portion of the gate plate 104 to avoid material consolidation in comers of the sealing space 210

[0038] This structural configuration of the gate plate 104 not only enables upward sealing, avoidance of material consolidation, access to cleaning by fluid ports, smooth and easy operation of the gate plate 104, but also enables reduction in the overall weight of the gate plate 104.

[0039] In an embodiment, the gate plate 104, the first supporting member 232 and the second supporting member, and the sealing space 210 defined by the housing 102 may be provided at an inclination of angle greater than or equal to 45 degrees relative to a longitudinal axis 216, wherein the longitudinal axis 216 may be along the vertical plane (refer FIG. 2A) passing through centres of the first opening 202 and the second opening 204 (most preferably greater than 60 degrees).

[0040] In an embodiment, the drain gate assembly 100 comprises the actuator assembly 234, wherein the actuator assembly 234 may be disposed, but not limited to, external to the housing 102 of the drain gate assembly 100. The actuator assembly 234 may be configured to be coupled with the gate plate 104, wherein the actuator assembly 234 may be configured to enable movement of the gate plate 104 between the first position and the second position.

[0041] In an embodiment, referring to FIG. 3, the actuator assembly 234 comprises a gear motor 302, a shaft 304, a first sprocket 306, a second sprocket 308, a first pin rack 310, a second pin rack 312, a connecting member 314 and at least one operating plunger 316.

[0042] In an embodiment, the gear motor 302 may be configured to be disposed, but not limited to, external onto the housing 102 of the drain gate assembly 100. The gear motor 302 may either be fixed speed motor or a Variable Frequency Drive motor.

[0043] In an embodiment, the shaft 304 may be disposed on one side of the housing 102 in a manner that the shaft 304 is parallelly disposed to at least one surface of the housing 102. The shaft 304 may be engaged onto the housing 102 by way of, but not limited to, a pair of first bearings 318a, 318b, wherein the pair of first bearings 318a, 318b may be engaged to the housing 102 and the pair of first bearings 318a, 318b may be configured to operably receive at least a portion of the shaft 304. The pair of first bearings 318a, 318b may be configured to enable rotation of the shaft 304 within the pair of first bearings 318a, 318b.

[0044] In an embodiment, one end of the shaft 304 may be configured to be connected to the gear motor 302, wherein the gear motor 302 may be configured to rotate the shaft 304.

[0045] In and embodiment, the first sprocket 306 and the second sprocket 308 may be disposed on the shaft 304, wherein the first sprocket 306 may be disposed on one end of the shaft 304 and the second sprocket 308 may be disposed on another end of the shaft 304. The first sprocket 306 and the second sprocket 308 may be, but not limited to, disposed on opposite ends of the shaft 304.

[0046] In an alternate embodiment, the drain gate assembly 100 may be provided with plurality of sprockets that may be disposed on the shaft 304, wherein the sprockets may be spaced apart from each other.

[0047] In an embodiment, the first pin rack 310 may be configured to be operably engaged with the first sprocket 306, and the second pin rack 312 may be configured to be operably engaged with the second sprocket 308. The first pin rack 310 and the second pin rack 312 may be configured to move within respective guide channels that may be provided on the housing 102 of the drain gate assembly 100.

[0048] In an embodiment, each of the first pin rack 310 and the second pin rack 312 may comprise a plurality of pins provided along a length of a plate, wherein the plurality of pins may project from both sides of the plate, and wherein the plurality of pins may be spaced apart.

[0049] In an embodiment, the connecting member 314 may be configured to be connected on at least one end of the first pin rack 310 and the second pin rack 312, in a manner that one end of the connecting member 314 may be coupled with one end of the first pin rack 310, and another end of the connecting member 314 may be coupled with one end of the second pin rack 312. The coupling of the connecting member 314 with the first pin rack 310 and the second pin rack 312 may be by way of, but not limited to, a pair of second bearings. The connecting member 314 establishes connection between the first pin rack 310 and the second pin rack 312 on one of their sides.

[0050] In an embodiment, the actuator assembly 234 may be provided with at least one operating plunger 316, wherein the operating plunger 316 may be provided between the connecting member 314 and the gate plate 104, wherein the operating plunger 316 may establish connection between the operating plunger 316 and the connecting member 314. One end of the operating plunger 316may be configured to be engaged to the connecting member 314 by any known mechanical coupling. Another end of the operating plunger 316 may be engaged to the gate plate 104 by any known mechanical coupling.

[0051] In an embodiment, during operation of the actuator assembly 234, the first sprocket 306 and the second sprocket 308 may be configured to be operationally engaged with the first pin rack 310 and the second pin rack 312, respectively in a manner that the pins of the first pin rack 310 and the second pin rack 312 may be configured to be received and interface between teeth of each of the first sprocket 306 and the second sprocket 308, respectively.

[0052] In an alternate embodiment, the first sprocket may comprise of a pair of first sprockets and the second sprocket may comprise of a pair of second sprockets, wherein the pair of first sprockets may be spaced apart and the pair of second sprockets are spaced apart.

[0053] In an embodiment, referring to FIGs. 3 and 4, the drain gate assembly 100 comprises at least one sealing member 320, wherein the sealing member 320 may be disposed on an external side of the housing 102. The housing 102 of the drain gate assembly 100 may define at least one through hole, wherein the sealing member 320 may be configured to be engaged onto the housing 102 at the through hole defined on the housing 102. The sealing member 320 may be configured to operably receive at least a portion of the operating plunger 316. The sealing member 320 may be engaged onto the housing 102, by any known mechanical coupling, in a manner that portion of the sealing member 320 receiving the operating plunger 316 aligns with the through hole. The operating plunger 316 may be configured to pass through the sealing member 320 and into the housing 102 of the drain gate assembly 100 via the through hole of the housing 102, and thereby engage with the gate plate 104. The sealing member 320 may be disposed on the same side of the housing 102 as the shaft 304.

[0054] In an embodiment, the at least one sealing member 320 may have, but not limited to, a unibody design. The sealing member 320 may be provided with a port 402, wherein the port 402 may be configured to receive sealant lubrication. The port 402 provided on the sealing member 320 may be such that the sealant lubrication received through the port 402 thereafter passes into the portion of the sealing member 320 receiving the operating plunger 316 to thereby lubricate the operating plunger 316 for smoother operations. The sealant lubrication employed may be, but not limited to, grease. The sealing member 320 is provided to limit and ideally stop the leak of gas and dust from the slide gates when the plunger(s) is / are moving and when the pressure in the drain gate exceeds ambient pressure. The sealant lubrication employed may offer sealing along with lubrication, wherein the sealant lubrication may be a solid sealing agent and a liquid sealing agent, wherein the solid sealing agent may be graphite rope and the liquid sealing agent may be grease.

[0055] In an embodiment, the sealant lubrication may be supplied / injected into the port 402 of thesealing member 320 at specific intervals for efficient sealing. The sealant lubrication may be supplied to the sealing members 320 via a centralized lubrication system or may be supplied manually. The lubrication system may be designed for continuous operation, providing a steady and controlled flow of sealant lubrication to the sealing members 320 to thereby maintain optimal lubrication levels at all times, contributing to creating a seal between plungers 316 and sealing members 320 despite slight varying gaps and movement, preventing wear and extending the life of the sealing members 320.

[0056] In an embodiment, the number of sealing members 320 may be proportional to the number of operating plungers 316 employed in the actuator assembly 234.

[0057] In an embodiment, the drain gate assembly 100 further comprises a first spring 602 and a second spring (not shown in the figures, however the second spring is identical to the first spring 602). The first spring 602 may be disposed under the first pin rack and the second spring may be disposed under the second pin rack. The first spring 602 and the second spring provided may be configured to offer tension onto the first pin rack 310 and the second pin rack 312, wherein the tension of the first spring 602 and the second spring may be configured to push the first pin rack 310 and the second pin rack 312, respectively, against gravity. The tension offers smoother operation of the actuator assembly 234 by preventing sagging of the first pin rack 310 and the second pin rack 312 which may occur from hanging of the first pin rack 310 and the second pin rack 312 from the housing 102, when the gate plate 104 may be in the second position.

[0058] In an embodiment, referring to FIGs. 2A-2C along with FIG. 5, the drain gate assembly 100 comprises of a plurality of fluid ports, wherein the plurality of fluid ports is provided at different portions of the drain gate assembly 100. The plurality of fluid ports comprises a pair of first fluid ports, a pair of second fluid ports and a pair of third fluid ports. The pair of fluid ports further comprises a first fluid port 222 among the pair of first fluid ports, a second fluid port 224 among the pair of second fluid ports and a third fluid port 226 among the pair of third fluid ports. The other of the first fluid port, the second fluid port and the third fluid port among the pair of first fluid ports, the second fluid ports and the third fluid ports respectively may be disposed, on the housing, on side opposite to the first fluid port 222, the second fluid port 224 and the third fluid port 226, (not shown in figures). The first fluid port 226 may be disposed in the first passage 206, towards the first opening 202 of the housing 102, in a manner that the first fluid port 222 may be disposed between the gate plate 104 and the first opening 202.

[0059] In an embodiment, the second fluid port 224 may be disposed in the second passage 208 below the path along which the gate plate 104 is configured to move between the first position and the second position.

[0060] In an embodiment, the third fluid port 226 may be disposed in the first passage 206 belowthe path along which the gate plate 104 is configured to move between the first position and the second position. The plurality of fluid ports may further comprise of a fourth fluid port 228 and a fifth fluid port 230, wherein the fourth fluid port 228 may be provided towards a front side of the drain gate assembly 100, and the fifth fluid port 230 may be provided towards a back side of the drain gate assembly 100. The fourth fluid port 228 and the fifth fluid port 230 may also be employed in cleaning.

[0061] In an embodiment, the first fluid port 222 may be provided to supply clean air for the purposes of aerating the material entering from the first opening 202 and passing through the first passage 206 or aerating non-flowing material contained in the volume encompassed by openings 202 and 204. In the event that flow of material through opening 204 is prevented, fine and / or coarse particles consolidate when exposed to the static pressure from a fluidized bed above it, which may cause the material to “bridge” whereby the cross-section is blocked, The first fluid port 222 may also be configured to supply, but not limited to, air to enhance the passing of material through the first passage 206 of the drain gate assembly 100.

[0062] In an embodiment, the second fluid port 224 and the third fluid port 226 may be provided under the gate plate 104 for cleaning of any debris of the material that may get accumulated under the drain gate within the housing 102 of the drain gate assembly 100 with regular material supply.

[0063] In an embodiment, the the first fluid port 222, second fluid port 224 and the third fluid port 226 for the gate plate 104 at various positions may be configured to operate in a specific synchronized sequence. This sequence prevents unnecessary overpressure, minimizes the consumption of fluid used for cleaning, and ensures effective cleaning.

[0064] The purpose of the first fluid port 222, second fluid port 224 and the third fluid port 226 are to facilitate the opening and closing of the gate plate 104, thereby reducing the risk of the gate plate 104 failing to close properly. Additionally, the provision of the first fluid port 222, second fluid port 224 and the third fluid port 226 decrease the likelihood of gate plate 104 malfunctions in environments having material with fine or coarse particles or a combination. This is crucial for preventing material buildup behind the gate plate 104, which could cause it to become stuck before fully opening. Furthermore, the positioning of the first fluid port 222, second fluid port 224 and the third fluid port 226 offers better cleaning efficiency.

[0065] In an embodiment, referring to FIG. 2C, one or more frame plates 236 may be provided that may surround the gate plate 104, wherein one or more frame plates 236 may be engaged to the first supporting member 232 and the second supporting member which may be configured to provide support for the gate plate 104. The one or more frame plates 236 are configured to be positioned above the gate plate 104, and may be configured to function as sealing surface towards which the gate plate 104 can be raised. This unique sandwich-like construction may be configuredto shield the (brittle) refractory lining from damage and wear caused by the forces experienced during opening and closing. Additionally, it ensures precise control over the gate's position and alignment.

[0066] In an embodiment, the frame plate 236 may be constructed with a rectangular cross-section with an open bottom as illustrated in FIG. 2D. The rectangular cross-section of the frame plate 236 offers several benefits for sealing of the gate plate 104. One of the disadvantages of having an open bottom is that the distance between either end (towards the first supporting member and the second supporting member) of the frame plate 236 annotated as “dl” can reduce overtime as the gate is exposed to varying temperatures and cyclical exposure to hot particulate material under pressure during filling followed by emptying and cooling by air as described in the foregoing. The frame plate 236 may therefore warp as a result of thermal stresses and or particulate material consolidating in the space between the frame plate and the refractory walls. If the dimension “dl” becomes smaller than the distance between two lateral walls of the gate plate 104, annotated as “d2”, at any position across the cross-section during operation, the gate plate 104 movement will be restricted and ultimately the gate plate 104 may get stuck. This in turn may cause wear, deformations, extra load on the driving mechanism, motor failure and breaking of the gate plate 104 and operating plunger 316 connection, which in turn would cause operating stoppages and / or additional costs for maintenance and repair.

[0067] A specifically designed frame plate 236 is therefore designed, in order to reduce the risk and frequency of the distance “dl” becoming smaller than “d2”, which are now described in greater detail.

[0068] In an embodiment, a front portion (adjacent to the sealing space 210 shown in FIG. 2 A) which may be stiffened by a front plate may extend across the whole of front section providing a stiff connection between both side plates at least over a fraction of the side plate height, but adapted to other requirements, for example, providing a chamfered front of the cross-section. The front portion may be provided with one or more holes 238 for facilitating cleaning fluid (air) through them (refer FIG. 2E).

[0069] In an embodiment, a rear outer stiffening flange may be provided configured to be connected around both sides and the top of the frame plate 236. This outer stiffening flange may be projected into the refractory lining not only in the top portion, but also in both the sides. The outer stiffening flange reduces the risk and frequency of deformations wherein “dl” will be reduced across any cross section over the length of the frame plate 236, particularly at rear end.

[0070] In an embodiment, the sides walls of the frame plate 236 may be restrained by one or more structural configurations (shown in FIG. 2F and FIG. 2G), wherein the movement may be restrained at one or more points on either side.

[0071] Referring to FIG. 2F, a first structural configuration for restraining the movement of the side walls of the frame plate 236 is disclosed, in accordance with an embodiment. The first structural configuration comprises a bracket 240 configured to be fixed to the outer shell, wherein the bracket 240 is configured to protrude through the refractory lining and into which the frame plate 236 can be slid into from above during assembly or maintenance. The first structural configuration offers advantages in terms of maintenance, as the frame plate 236 may only be locked in place when fully assembled, however, can be readily pulled up and replaced during maintenance when the flange is opened.

[0072] Referring to FIG. 2G, a second structural configuration for restraining the movement of the side walls of the frame plate 236 is disclosed, in accordance with an embodiment. The second structural configuration is configured to fixate the side walls of the frame plate 236 by screwing bolts 242 through the outer wall and the refractory lining into the first supporting member 232 and the second supporting member, thereby locking it from the outside. This structural configuration is also configured to restrain “dl” from being reduced.

[0073] In an embodiment, the housing 102 of the drain gate assembly 100 is provided with lifting members 108 (refer FIG. IB and 3), wherein the lifting members 108 may be configured to enable lifting of the drain gate assembly 100 during installation or uninstallation of the drain gate assembly 100. The lifting members 108 may also be used during transportation of the drain gate assembly 100.

[0074] In an embodiment, the housing 102 may be provided with an insulating and wear protecting refractory lining. The refractory lining on the housing 102 enables the use of low-cost steel material instead of high-cost stainless steel.

[0075] The employment of the refractory lining offers exceptional heat resistance, ensuring long- lasting performance even under high temperature operating conditions. The refractory lining is designed to resist corrosion and chemical degradation, wherein the refractory lining maintains its integrity over time, thereby reducing the need for frequent replacements and minimizing downtime. Incorporating the refractory lining, the drain gate achieves superior drainage efficiency, ensuring smooth and reliable operation while minimizing the risk of blockages or obstructions. The refractory lining further offers robust protection against high temperatures and corrosive substances, wherein the refractory lining enhances safety for personnel and equipment, minimizing the risk of accidents or failures. With the exceptional durability and resistance to wear, the refractory lining significantly reduces maintenance and repair needs, resulting in lower lifecycle costs and improved operational efficiency.

[0076] In an alternate embodiment, multiple drain gate assemblies may be installed on the fluid bed system, wherein one drain gate assembly 100 may be coupled below another drain gateassembly 100. Such setup of providing drain gate assemblies in pairs limits the amount of material extracted during each opening of respective gate plates of the drain gate assemblies, thereby reducing process instability in connected processes.

[0077] In an embodiment, the angle of the gate plate 104, declined towards the second opening 204 of the housing 102, may be designed to facilitate material cleaning and prevent blockages, thereby reducing the likelihood of problems when opening the gate plate 104. A minimum of one fluid port (utilizing gas flow) may be added at the back of the gate plate 104 to facilitate removal of any accumulated material, particularly when the angle is not steep-ideally, greater than 45 degrees, and more preferably, 60 degrees with respect to a horizontal plane. Lower inclinations may reduce the height of drain gate assembly 100. Furthermore, proper inclination ensures that any material debris accumulating behind the gate plate 104 can flow away, assisted by gravity. If the inclination is absent or improper, material buildup can occur, leading to blockages and potential operational issues, such as the chamber behind the gate plate 104 or gate plate 104 filling up and preventing opening.

[0078] In an alternate embodiment, the gate plate 104 may be provided in a horizontal plane based on the requirements.

[0079] In an embodiment, the gate plate 104 may be provided with curved edges or chamfers towards the first side of the gate plate 104 which is configured to be received by the sealing space 210 of the housing 102. Similarly, at least a portion of entry of the sealing space 210 may be provided with curved edges or chamfers for smoother interface between the gate plate 104 and the sealing space 210, when the gate plate 104 is received within the sealing space 210. The provision of curved edges or chamfers on the gate plate 104 and the sealing space 210 is to reduce the likelihood of the gate plate 104 not closing properly by providing space for solids in front of the gate plate 104 to drain away, preventing consolidation and avoiding the need for tight tolerances or obstruction by larger particles.WORKING OF THE DRAIN GATE ASSEMBLY 100

[0080] Having described the components of the drain gate assembly 100 and their arrangement within the drain gate assembly 100, the working of the drain gate assembly 100 shall now be described in greater detail.

[0081] As described in the foregoing, the drain gate assembly 100 may be configured to be engaged onto a fluid bed system connected to other downstream process equipment.

[0082] In an embodiment, the actuator assembly 234 coupled to the gate plate 104 may be configured to move the gate plate 104 between the first position and the second position based on the requirement.

[0083] Referring to FIG. 2A, the first position of the gate plate 104 is depicted. In the first position,the gate plate 104 completely obstructs the first passage 206, thereby preventing the material entering through the first opening 202 from exiting through the second opening 204. In the first position of the gate plate 104, the connecting member 314 connecting the first pin rack 310 and the second pin rack 312 is positioned closer to the housing 102 of the drain gate assembly 100, wherein a larger portion of the operating plunger 316 is housed within the housing 102 of the drain gate assembly 100.

[0084] For the gate plate 104 to be moved from the first position to the second position, the gear motor 302 may be actuated, wherein upon actuation, the gear motor 302 may be configured to rotate the shaft 304 in a third direction, wherein the shaft 304 is coupled to the gear motor 302. The rotation of the shaft 304 in the third direction causes the first sprocket 306 and the second sprocket 308 disposed on the shaft 304 to also rotate in the third direction. As the first pin rack 310 is operably engaged with the first sprocket 306, and the second pin rack 312 is operably engaged with the second sprocket 308, rotation of the first sprocket 306 and second sprocket 308 in the third direction causes the connecting member 314 along with the operating plunger 316, and the first pin rack 310 and the second pin rack 312 to move away from the housing 102 of the drain gate assembly 100, which in turn causes the gate plate 104 to be moved from the first position to the second position in a second direction 220. In the second position of the gate plate 104, a larger portion of the operating plunger 316 remains outside the housing 102 of the drain gate assembly 100. The second position of the gate plate 104 is depicted in FIG. 2B.

[0085] Similarly, for the gate plate 104 to be moved from the second position to the first position, the gear motor 302 may be actuated, wherein upon actuation, the gear motor 302 may be configured to rotate the shaft 304 in a fourth direction, wherein the shaft 304 is coupled to the gear motor 302. The rotation of the shaft 304 in the fourth direction causes the first sprocket 306 and the second sprocket 308 disposed on the shaft 304 to also rotate in the fourth direction. As the first pin rack 310 is operably engaged with the first sprocket 306, and the second pin rack 312 is operably engaged with the second sprocket 308, rotation of the first sprocket 306 and second sprocket 308 in the fourth direction causes the connecting member 314 along with the operating plunger 316, and the first pin rack 310 and the second pin rack 312 to move towards the housing 102 of the drain gate assembly 100, which in turn causes the gate plate 104 to be moved from the second position to the first position in a first direction 218. The movement of the first pin rack 310 and the second pin rack 312 is thereby translated into movement of the operating plunger 316 causing the gate plate 104 to move between the first position and the second position.

[0086] In an embodiment, the actuator assembly 234 comprises a control unit (not shown in the figures), wherein the control unit may be configured to enable the gate plate 104 to be positioned between the first position and the second position in a manner that at any instance, the gate plate104 enables partial opening of the first passage 206 thereby permitting the material entering through the first opening 202 to exit through the second opening 204. The positioning of the gate plate 104 between the first position and the second position may be determined by the control unit based on the requirements.

[0087] In an embodiment, the drain gate assembly 100 may be further provided with one or more position sensors to detect the position of the gate plate between the first position and the second position. The position sensors may comprise, but not limited to, a limit switch, length transducer and a ring magnet setup. The position sensors may be configured to communicate with the control unit to manage the movement of the gate plate between the first position and the second position.

[0088] The detailed description described in the foregoing includes references to the accompanying drawings, which form a part of the detailed description. The drawings show illustrations in accordance with example embodiments. These example embodiments, which may be herein also referred to as “examples” are described in enough detail to enable those skilled in the art to practice the present subject matter. However, it may be apparent to one with ordinary skill in the art that the present invention may be practised without these specific details. In other instances, well-known methods, procedures and components have not been described in detail so as not to unnecessarily obscure aspects of the embodiments. The embodiments can be combined, other embodiments can be utilized, or structural, logical, and design changes can be made without departing from the scope of the claims. The foregoing detailed description is, therefore, not to be taken in a limiting sense, and the scope is defined by the appended claims and their equivalents.

[0089] In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated.

[0090] Furthermore, the processes described above are described as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, or some steps may be performed simultaneously.

[0091] Although embodiments have been described with reference to specific example embodiments, it will be evident that various modifications and changes may be made to these embodiments without departing from the broader spirit and scope of the system and process or method described herein. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.

[0092] Many alterations and modifications of the present invention will no doubt become apparent to a person of ordinary skill in the art after having read the foregoing description. It is to beunderstood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. It is to be understood that the description above contains many specifications, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the personally preferred embodiments of this invention.Reference numbers100 - Drain gate assembly102 - Housing104 - Gate plate106 - Cover108 - Lifting members202 - First opening204 - Second opening206 - First passage208 - Second passage210 - Sealing space212 - Top surface214 - Bottom surface216 - Longitudinal axis218 - First direction220 - Second direction222 - First fluid port224 - Second fluid port226 - Third fluid port228 - Fourth fluid port230 - Fifth fluid port232 - First supporting member234 - Actuator assembly236 - Frame plate238 - Holes240 - Bracket242 - Bolt302 - Gear Motor304 - Shaft306 - First sprocket308 - Second sprocket310 - First pin rack312 - Second pin rack314 - Connecting member316 - Operating plunger318a, 318b - Pair of first bearings320 - Sealing member402 - Port 602 - First spring dl - distance between side walls of the frame plate d2 - distance between side walls of the gate plate

Claims

CLAIMS1. A drain gate assembly (100) comprising: a housing (102), wherein: the housing (102) defines a first opening (202) and a second opening (204); a first passage (206) is defined by the housing (102) between the first opening (202) and the second opening (204); and the first passage (206) is configured to receive material through the first opening (202) and allow the material to exit the first passage (206) through the second opening (204); a second passage (208) is defined by the housing (102), wherein the second passage (208) is exposed to the first passage (206); the housing is provided with a refractory lining; and a gate plate (104), wherein: the gate plate (104) is accommodated within the housing (102); the gate plate (104) is configured to move between a first position and a second position, wherein the gate plate (104) is operable to travel within the first passage (206) and the second passage (208); the gate plate (104) is extended into the first passage (206) to move into the first position, wherein, in the first position, the gate plate (104) obstructs the first passage (206), preventing the material entering through the first opening (202) from exiting through the second opening (204); the gate plate (104) is retracted into the second passage (208) to move into the second position, wherein, in the second position, the gate plate (104) opens the first passage (206), permitting the material entering through the first opening (202) to exit through the second opening (204).

2. The drain gate assembly (100) of claim 1, wherein the gate plate (104) is configured to move along a path between the first position and the second position, with the path angled relative to a direction of material passing through the first passage (206) and the path inclined towards the second opening (204).

3. The drain gate assembly (100) of claim 1, further comprising a first supporting member (232) and a second supporting member, providing support to the gate plate (104) as the gate plate (104) moves in and out of the first passage (206), wherein,a first portion of the first supporting member (232) and the second supporting member are disposed in the first passage (206); and a second portion of the first supporting member (232) and the second supporting member extend into the second passage (208).

4. The drain gate assembly (100) of claim 3, further comprising a sealing space (210) defined by the housing (102), opposite to the second passage (208), wherein, a part of the first portion of the first supporting member (232) and the second supporting member define a curved path disposed towards the sealing space (210); the curved path enables pressing of the gate plate (104) against at least a portion of the sealing space (210) as the gate plate (104) moves into the first position; and at least a portion of the sealing space (210) defines a profile complementing at least a portion of the gate plate (104), which interface with the sealing space (210), thereby establishing sealing between the gate plate (104) and the sealing space (210).

5. The drain gate assembly (100) of claim 3, wherein, the first supporting member (232) comprises a first set of projections laterally extending into the housing (102); and the second supporting member comprises a second set of projections laterally extending into the housing (102).

6. The drain gate assembly (100) of claim 1, wherein, the gate plate (104) comprises: a top surface (212) exposed to the first opening (202); and a bottom surface (214) exposed to the second opening (204); and the bottom surface (214) interfaces with a first supporting member (232) and a second supporting member, wherein the first supporting member (232) and the second supporting member provides support to the gate plate (104), as the gate plate (104) moves in and out of the first passage (206).

7. The drain gate assembly (100) of claim 1, further comprising an actuator assembly (234) coupled with the gate plate (104) for moving the gate plate (104) between the first position and the second position, wherein the actuator assembly (234) comprises: a gear motor (302); a shaft (304) coupled with the gear motor (302);a first sprocket (306) disposed on one end of the shaft (304); and a first pin rack (310), wherein: the gear motor (302) is configured to rotate the shaft (304); the first pin rack (310) is operably engaged to the first sprocket (306); and upon rotation of the shaft (304) via the gear motor (302), the fist pin rack is configured to move the gate plate (104) between the first position and the second position.

8. The drain gate assembly (100) of claim 7, wherein the actuator assembly (234) comprises: a second sprocket (308) disposed on another end of the shaft (304); a second pin rack (312) operably engaged with the second sprocket (308); and a connecting member (314) configured to connect at least one end of the first pin rack (310) and the second pin rack (312).

9. The drain gate assembly (100) of claim 8, wherein the actuator assembly (234) comprises at least one operating plunger (316), wherein: one end of the operating plunger (316) is engaged to the connecting member (314) and another end of the operating plunger (316) is engaged to the gate plate (104); and movement of the first pin rack (310) and the second pin rack (312) translates to the movement of the operating plunger (316), causing the gate plate (104) to move between the first position and the second position.

10. The drain gate assembly (100) of claim 9, further comprising a sealing member (320), wherein: the sealing member (320) is disposed on the housing (102); the sealing member (320) is configured to receive at least a portion of the operating plunger (316); the operating plunger (316) is configured to pass through the sealing member (320) into the housing (102) and engage with the gate plate (104) to operably move the gate plate (104) between the first position and the second position; and the sealing member (320) is provided with a port (402) for receiving lubricant sealant to facilitate sealing of the operating plunger (316).

11. The drain gate assembly (100) of claim 8, further comprising a first spring (602) and a second spring, wherein the first spring (602) and the second spring are disposed under the first pin rack (310) and the second pin rack (312), respectively, wherein the first spring (602) and thesecond spring push the first pin rack (310) and the second pin rack (312), respectively, against gravity.

12. The drain gate assembly (100) of claim 7, wherein the actuator assembly (234) comprises of a control unit, wherein the control unit is configured to enable the gate plate (104) to be positioned between the first position and the second position in a manner that the gate plate (104) partially opens the first passage (206), permitting the material entering through the first opening (202) to exit through the second opening (204).

13. The drain gate assembly (100) of claim 1, further comprising a pair of first fluid ports disposed between the first opening (202) and the gate plate (104), wherein the pair of first fluid ports are operable to aerate the material entering through the first opening (202).

14. The drain gate assembly (100) of claim 1, further comprising: a pair of second fluid ports disposed in the second passage (208) behind or below the path along which the gate plate (104) moves between the first position and the second position; a pair of third fluid ports disposed in the sealing space (210) towards front part of the path along which the gate plate (104) moves between the first position and the second position; a fourth fluid port (228) disposed on one side of the drain gate assembly (100); and a fifth fluid port (230) disposed on another side of the drain gate assembly (100), wherein, the pair of second fluid ports, the pair of third fluid ports, the fourth fluid port (228) and the fifth fluid port (230) are operated for cleaning debris of the material accumulated under the gate plate (104) within the housing (102) of the drain gate assembly (100).

15. The drain gate assembly (100) of claim 1, wherein the path defined by the gate plate (104) between the first position and the second position is provided at an angle greater than 45 degrees relative to a longitudinal axis (216) passing through centres of the first opening (202) and the second opening (204).

16. The drain gate assembly (100) of claim 1, further comprising a frame plate (236), wherein: the frame plate (236) is configured to surround the gate plate (104); the frame plate (236) is configured to be positioned above the gate plate (104); and the frame plate (236) is configured to be engaged to the first supporting member (232) and the second supporting member to hold the frame plate (236) in position.

17. A drain gate assembly of claims 1-16, for use in controlling the discharge of materials in systems, such as, fluidized bed fuel processing systems.

18. A drain gate assembly of claims 1-16, for use in controlling the discharge of materials in a cement plant.

19. A method for assembling a drain gate system, the method utilizing the drain gate assembly of claims 1-16.

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