Bulk material continuous dedusting system

Abstract

The bulk material continuous dedusting system combines high-velocity, low-moment air or gas jets with vacuum technology to efficiently eliminate fine particles before the bulk material is loaded onto a bed. The system seeks to provide users with a system that may seamlessly integrate into material transport without affecting transfer rates. In order to accomplish this the system has a material feeding section wherein the target bulk material is introduced. Next, a vacuum section extracts the dust particles. Additionally, a separation section removes the dust particles from the bulk material. Then, the discharge section extracts the bulk material. Finally, the sweep section ensures the dust particles are removed from the bulk material.

Description

[0001] Bulk Material Continuous Dedusting System

[0002] FIELD OF THE INVENTION

[0003] The present invention relates generally to a continuous dust removal system. More specifically, the present invention is a system that removes dust during any stage of bulk material handling.

[0004] BACKGROUND OF THE INVENTION

[0005] Dust generated during the handling of bulk materials like catalyst pellets, grains, or similar particulate substances can pose several hazards and operational challenges. The generated dust poses health and safety hazards such as: respiratory issues wherein fine dust can become airborne and inhaled by workers, potentially causing respiratory problems, especially if the dust contains harmful or toxic materials like metal oxides in catalysts. Long-term exposure can lead to conditions such as pneumoconiosis or other occupational lung diseases; fire and explosion risks wherein dust, particularly in confined spaces, can be flammable or explosive. Certain materials, including organic or metallic powders, pose a risk of dust explosions when mixed with air in high enough concentrations and exposed to an ignition source; and slips and falls wherein dust accumulation on surfaces can create slippery conditions, increasing the risk of workplace accidents.

[0006] Further, the dust generated during the handling of bulk materials may cause operational and environmental challenges such as: dust contamination wherein dust can contaminate other nearby materials, leading to potential product quality issues. In catalyst handling, even small levels of contamination can affect the performance of the catalyst; equipment wear wherein dust particles can be abrasive, leading to increased wear and tear on handling equipment such as conveyors, valves, and filters. This can result in frequent maintenance and repairs, reducing operational efficiency; and environmental pollution wherein dust can disperse into the environment, causing air pollution that could lead to regulatory compliance issues, such asexceeding allowed particulate emissions. In some cases, water or soil contamination might occur if the dust is not properly contained.

[0007] Within the current industry dust generation is controlled by various systems and devices such as: a dust suppression systems that sprays water or uses chemical agents can suppress dust during material transfer. In certain operations, especially when dealing with catalysts, inert gas purging may be used to prevent dust exposure to oxygen; dust collection systems that install dust collectors, fdters, or vacuum systems can help capture and manage airborne dust during handling and transfer processes; personal protective equipment (PPE); and enclosed handling wherein people use enclosed systems such as conveyors, hoppers, and vacuum loaders can minimize dust generation. Airlocks or sealed transfer points can also be employed to prevent dust from escaping.

[0008] Many industries handling bulk materials must comply with regulations like OSHA’s permissible exposure limits (PELs) for dust and particulate matter or environmental regulations governing emissions. Proper dust control measures, coupled with regular monitoring, can help minimize the risks associated with dust in bulk material handling operations. Dust explosions during silo loading are a serious safety hazard in industries handling combustible bulk materials like grains, powders, catalyst pellets, or chemicals. Dust explosions occur when fine particles become airborne in a confined space (such as a silo) and are exposed to an ignition source. The explosion process generally involves five key elements, often referred to as the "Dust Explosion Pentagon":

[0009] Combustible Dust which are fine particles of material that can burn (e.g., grain, sugar, coal, metal dust); the air inside the silo provides enough oxygen to support combustion;

[0010] an ignition source such as sparks, friction, static electricity, hot surfaces, or electrical equipment can serve as ignition points; dispersion wherein the dust must be suspended in the air in sufficient concentration for an explosion to occur; and confinement wherein the dust cloud must be within a confined space like a silo or a closed transfer system to create the pressure buildup needed for an explosion. During silo loading, particularly when materials are transferred into the silo through pneumatic conveyors or augers, fine dust particles are generated and become suspended in the air, increasing the risk of an explosion if an ignition source is present.

[0011] Primary explosions occur when an ignition source ignites a localized dust cloud. This explosion can cause a pressure wave, dislodging more dust from surfaces inside the silo.Secondary explosions occur when the dislodged dust from the primary explosion becomes airborne, creating a larger dust cloud, which can ignite and cause a much larger secondary explosion. Secondary explosions are often more destructive than the primary one. Ignition during silo loading may happen due to static electricity, mechanical sparks, hot surfaces, and electrical malfunctions. These risks are increased with high dust concentration, fine dust particles, confined spaces, and low moisture content.

[0012] Dust explosions during silo loading are a significant safety risk, but they can be managed through proper dust control, equipment maintenance, and preventive safety systems.

[0013] Understanding the specific risks related to the material being handled and implementing effective dust explosion protection measures can greatly reduce the chances of an incident.

[0014] An objective of the present invention is to provide users with an advanced dust removal system to separate and eliminate dust and fine particles that fall below a required process size or exceed an acceptable particle size limit. The present invention intends to maximize dust removal efficiency without compromising the properties or characteristics of the bulk material being processed. In order to accomplish that, a preferred embodiment of the present invention comprises a material feeding section 5, a vacuum section 31, a separation section 21, a sweep section 22, and a discharge section 41. Thus, the present invention is a bulk material continuous dedusting system that eliminates fine particles before a material is loaded onto a bed.

[0015] BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a top front perspective view of the present invention.

[0017] FIG. 2 is a bottom rear perspective view of the present invention.

[0018] FIG. 3 is a front view of the present invention.

[0019] FIG. 4 is a rear view of the present invention.

[0020] FIG. 5 is a right-side view of the present invention.

[0021] FIG. 6 is a left-side view of the present invention.

[0022] FIG. 7 is a top view of the present invention.

[0023] FIG. 8 is a bottom view of the present invention.

[0024] FIG. 9 is a cross-section view of the present invention taken along line 9-9 in FIG. 6.FIG. 10 is a cross-section view of the present invention taken along line 10-10 in FIG. 6.

[0025] FIG. 11 is an illustration of the orientation of the plurality of air slots.

[0026] FIG. 12 is an illustration of the separation section.

[0027] FIG. 13 is an illustration of air / gas and material interaction.

[0028] FIG. 14 is an illustration of multistage dedusting.

[0029] DETAILED DESCRIPTION OF THE INVENTION

[0030] All illustrations of the drawings are for the purpose of describing selected versions of the present invention and are not intended to limit the scope of the present invention.

[0031] The present invention is a system that combines high-velocity, low-moment air or gas jets with vacuum technology to efficiently eliminate fine particles before the material is loaded onto a bed as seen in FIG. 1-14. The present invention seeks to provide users with a system that may seamlessly integrate into material transport without affecting transfer rates. In order to accomplish this the present invention comprises a material feeding section 5 wherein the target bulk material is introduced. Further, the vacuum section 31 extracts the dust particles.

[0032] Additionally, the separation section 21 removes the dust particles from the bulk material.

[0033] Further, the discharge section 41 extracts the bulk material. Furthermore, the sweep section 22 ensures the dust particles are removed from the bulk material. Thus, the present invention is a bulk material continuous dedusting system that eliminates fine particles before a material is loaded onto a bed.

[0034] As shown in FIG. 1, the present invention is a bulk material continuous dedusting system. An objective of the present invention is to provide users with a system that preserves the integrity of the material being processed by preventing breakage, chipping, or attrition during the handling process. The present invention intends to provide users with a system that separates dust and particles from a target bulk material. To accomplish this the present invention comprises a material feeding section 5, a vacuum section 31, a separation section 21, a sweep section 22, and a discharge section 41. The present invention comprises a system housing 1 which further comprises a separation chamber 2, a top chamber 3, and a bottom chamber 4. The material feeding section 5 is positioned centrally within the present invention and traversespartially into a separation chamber 2 within the system housing 1. The sweep section 22 is positioned below and offset the material feeding section 5. The separation section 21 is positioned within the separation chamber 2 and adjacent to and above the sweep section 22. The sweep section 22 further comprises a sweep head 221 and a sparger 223. The vacuum section 31 is positioned above the separation section 21. Further, the discharge section 41 is positioned below the sweep section 22 along the bottom of the system housing 1. The discharge section 41 further comprises and air inlet 42. Thus, the present invention is a bulk material continuous dedusting system that eliminates fine particles before a material is loaded onto a bed.

[0035] The present invention comprises a system housing 1 which further comprises a separation chamber 2, a top chamber 3, a bottom chamber 4, and a material feeding section 5. The material feeding section 5 is a cylindrical hollow pipe wherein a bulk material can be introduced into the separation chamber 2. The material feeding section 5 further comprises a feeding section top opening 51 and a feeding section bottom opening 52. The feeding section top opening 51 may be connected to an external system or may manually receive a material. The feeding section bottom opening 52 is positioned along the bottom end of the material feeding section 5 opposite the feeding section top opening 51. As a result, the bulk material then falls down the material feeding section 5 and out of the feeding section bottom opening 52, positioned along the bottom end of the material feeding section 5, opposite the feeding section top opening 51 as seen in FIG.

[0036] 1. It should be further noted that, the material feeding section 5 and system housing 1 may be designed with various materials, shapes, and sizes while still staying within the scope of the present invention.

[0037] Once the material exits the material feeding section 5, the material enters the separation chamber 2. The separation chamber 2 is a cylindrical chamber that encompasses the bottom portion of the material feeding section 5. The separation chamber 2 further comprises a separation section 21, a sweep section 22, an airflow adjustment mechanism 23 and a plurality of holes 24. Thus, as the material exits the material feeding section 5, the material falls into the sweep section 22.

[0038] The sweep section 22 comprises a sweep head 221 and a sparger 223. The sweep head 221 is a dome shaped component positioned centrally within the separation chamber 2, and offset below the material feeding section 5. Consequently, the bulk material falls onto the sweep head 221 as the bulk material exits the material feeding section 5.The sweep head 221 further comprises a plurality of support wings 222. The plurality of support wings 222 is a support structure. The plurality of support wings 222 is tangentially secured along the bottom of the sweep head 221. Accordingly, this enables the sweep head 221 to be secured in place. The plurality of support wings 222 secures along the inner surface 25 of the separation chamber 2. So, the sweep head 221 does not move throughout the dedusting process.

[0039] The sweep section 22 further comprises a sparger 223. The sparger 223 integrates along the circumference of the sweep head 221. The sparger 223 further comprises a lip 224 and a plurality of air slots 225. The lip 224 is a ridge that traverses along the top edge of the sparger 223. Furthermore, the plurality of air slots 225 is integrated along the surface of the sparger 223, enabling the separation chamber 2 to be in fluid communication with the bottom chamber 4. The plurality of air slots 225 integrates along the surface of the sparger 223. As a result, when the material falls down the dome shaped sweep head 221, the material slides off the lip 224, suspending the material momentarily within the separation section 21, wherein the material is blasted by an air flow exiting the plurality of air slots 225. The plurality of air slots 225 is angled upwards and outwards at a slot angle 226. Consequently, the air flow then knocks off all dust and particles along the surface of the material and pushes the dust and particles upwards into the separation section 21. The material then falls downwards into the bottom chamber 4 as seen in FIG. 10. Small particles and dust are captured by the upward air and gas streams, with the lightest particles being transported all the way to the vacuum section 31. In contrast, larger and heavier particles fall back down toward the discharge section 41 of the present invention, ensuring effective separation and removal of unwanted materials while allowing the desired bulk material to continue through the system.

[0040] As seen in FIG. 10, the airflow adjustment mechanism 23 comprises a sealing wall 231 and a plurality of reciprocating barriers 232. The sealing wall 231 is a cylindrical wall that prevents air from flowing on one side of the sealing wall 231 to ensure the speed and force of the air flow may be affected as desired. The sealing wall 231 extends downwards within the separation chamber 2. The sealing wall 231 is offset the inner surface 25 of the separation chamber 2. As a result there is a gap between the sealing wall 231 and the inner surface 25 of the separation chamber 2 which is filled by the plurality of reciprocating barriers 232. The pluralityof reciprocating barriers 232 is positioned between the sealing wall 231 and the inner surface 25 of the separation chamber 2.

[0041] Furthermore, each of the plurality of reciprocating barriers 232 further comprises an adjustment arm 233 as seen in FIG. 10. The adjustment arm 233 is mechanically coupled to each of the plurality of reciprocating barriers 232. Consequently, this enables the adjustment arm 233 to move each of the plurality of reciprocating barriers 232 upwards and downwards within the separation chamber 2 as needed, in order to affect the airflow. The adjustment arm 233 extends upwards and traversing though the system housing 1, wherein a portion of the adjustment arm 233 is accessible outside of the system housing 1. The plurality of holes 24 traverses through the system housing 1. As a result, outside air may enter the separation chamber 2 to ensure make up the difference in air coming in from the sparger 223 and air leaving from the vacuum to ensure that the bulk material is not being vacuumed up from the lower section along with the dust particles. The plurality of holes 24 is positioned offset and tangential to the sparger 223.

[0042] The bottom chamber 4, positioned below the separation chamber 2, further comprises a discharge section 41 and an air inlet 42. Once dust and particles have been separated from the material, the material falls down into the discharge section 41. The discharge section 41 further comprises a material outlet 411. The material outlet 411 is a conical shaped section as seen in FIG. 2, that extracts the material once dust and particles have been removed from the material. The air inlet 42 traverses through the discharge section 41 and couples to the sparger 223 and the sweep head 221. Accordingly, the air inlet 42 is able to introduce a source of air flow into the sweep section 22, enabling an airflow to pass through the plurality of air slots 225, onto a material falling down within the sweep section 22, and then upwards into the separation section 21. This design enhances the efficiency of dust removal by maximizing the contact between the particles and the air / gas flow. This arrangement enables sweeping of the dust from the pellets / grains as well sweeping of the airborne dust. The plurality of air slots 225 along the sparger 223 are directed slightly upward, as seen in FIG. 11, to smoothly direct swept dust and chips upward and toward the separation section 21. Most pellets and granules of the bulk material, which are equal to or larger than the specified size, fall toward the discharge section 41. Meanwhile, dust and chips are captured by the air and gas streams, which transport them upward to the separation section 21. This efficient separation ensures that only on-spec material is discharged, while unwanted particles are effectively removed from the system.The top chamber 3 is positioned above the separation chamber 2. The top chamber 3 comprises a vacuum section 31 which further comprises a split baffle 311 and a dust outlet 312 as seen in FIG. 9. The vacuum section 31 is designed with a conical shape and receives the dust or particles knocked off of the material. The dust outlet 312 is a mechanical outlet that produces a suctional force to pull the dust or particles out of the vacuum section 31. The split baffle 311 is ring shaped filter that separates the separation section 21 from the vacuum section 31 ensuring only dust and particles enter the vacuum section 31. The split baffle 311 is concentrically positioned around the material feeding section 5 and ensures that any material carried by the air flow does not enter the vacuum section 31. With all the components working in tandem with each other it can be seen that the present invention is a bulk material continuous dedusting system that eliminates fine particles before a material is loaded onto a bed.

[0043] Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the invention as hereinafter claimed.

Claims

What is claimed is:

1. A bulk material continuous dedusting system comprising:a material feeding section, a vacuum section, a separation section, a sweep section, and a discharge section;a system housing which further comprises a separation chamber, a top chamber, and a bottom chamber;the material feeding section being positioned centrally;the material feeding section traversing partially into the separation chamber; the material feeding section further comprising a feeding section top opening and a feeding section bottom opening;the sweep section being positioned below and offset the material feeding section; the separation section being positioned within the separation chamber and adjacent to and above the sweep section;the vacuum section being positioned above the separation section;the discharge section being positioned below the sweep section along the bottom of the system housing;the discharge section further comprising an air inlet; andthe sweep section further comprising a sweep head and a sparger.

2. The bulk material continuous dedusting system as claimed in claim 1 comprising:the material feeding section being a cylindrical hollow pipe wherein bulk material is introduced to the system; andthe feeding section bottom opening being positioned along the bottom end of the material feeding section opposite the feeding section top opening.

3. The bulk material continuous dedusting system as claimed in claim 2 wherein the feeding section top opening being connected to an external system to receive a bulk material.

4. The bulk material continuous dedusting system as claimed in claim 2 wherein the feeding section top opening being manually fed a bulk material.

5. The bulk material continuous dedusting system as claimed in claim 1 comprising: the separation chamber being a cylindrical chamber;the separation chamber encompassing the bottom portion of the material feeding section; andthe separation chamber further comprising an airflow adjustment mechanism and a plurality of holes.

6. The bulk material continuous dedusting system as claimed in claim 5 comprising:the sweep head being dome shaped;the sweep head being positioned centrally within the separation chamber; and the sweep head being offset and below the material feeding section.

7. The bulk material continuous dedusting system as claimed in claim 6 comprising:the sweep head further comprising a plurality of support wings;the plurality of support wings being tangentially secured along the bottom of the sweep head; andthe plurality of support wings securing along the inner surface of the separation chamber.

8. The bulk material continuous dedusting system as claimed in claim 5 comprising:the sparger integrating along the circumference of the sweep head;the sparger further comprising a lip and a plurality of air slots;the lip traversing along the top edge of the sparger;the plurality of air slots integrating along the surface of the sparger; and the plurality of air slots being angled upwards and outwards at a slot angle.

9. The bulk material continuous dedusting system as claimed in claim 5 comprising:the airflow adjustment mechanism comprising a sealing wall and a plurality of reciprocating barriers;the sealing wall extending downwards within the separation chamber;the sealing wall being offset the inner surface of the separation chamber; and the plurality of reciprocating barriers being positioned between the sealing wall and the inner surface of the separation chamber.

10. The bulk material continuous dedusting system as claimed in claim 9 comprising:each of the plurality of reciprocating barrier further comprising an adjustment arm;the adjustment arm being mechanically coupled to each of the plurality of reciprocating barriers; andthe adjustment arm extending upwards and traversing though the system housing, wherein a portion of the adjustment arm is accessible outside of the system housing.

11. The bulk material continuous dedusting system as claimed in claim 5 comprising:the plurality of holes traversing through the system housing; andthe plurality of holes being positioned offset and tangential to the sparger.

12. The bulk material continuous dedusting system as claimed in claim 1 comprising:the bottom chamber being positioned below the separation chamber; the discharge section further comprising a material outlet;the material outlet being a conical shaped;the air inlet traversing through the discharge section; andthe air inlet coupling to the sweep head and sparger.

13. The bulk material continuous dedusting system as claimed in claim 1 comprising:the top chamber being positioned above the separation chamber;the vacuum section further comprising a split baffle and a dust outlet; the vacuum section being a conical shape;the split baffle being a ring shaped filter;the split baffle separating the separation section from the vacuum section;the split baffle being concentrically positioned around the material feeding section; andthe separation chamber further comprising an airflow adjustment mechanism and a plurality of holes.

14. A bulk material continuous dedusting system comprising:a material feeding section, a vacuum section, a separation section, a sweep section, and a discharge section;a system housing which further comprises a separation chamber, a top chamber, and a bottom chamber;the material feeding section being positioned centrally;the material feeding section traversing partially into the separation chamber; the material feeding section further comprising a feeding section top opening and a feeding section bottom opening;the sweep section being positioned below and offset the material feeding section; the separation section being positioned within the separation chamber and adjacent to and above the sweep section;the vacuum section being positioned above the separation section;the discharge section being positioned below the sweep section along the bottom of the system housing;the discharge section further comprising an air inlet;the sweep section further comprising a sweep head and a sparger;the material feeding section being a cylindrical hollow pipe wherein bulk material is introduced to the system; andthe feeding section bottom opening being positioned along the bottom end of the material feeding section opposite the feeding section top opening.

15. The bulk material continuous dedusting system as claimed in claim 14 wherein the feeding section top opening being connected to an external system to receive a bulk material.

16. The bulk material continuous dedusting system as claimed in claim 14 wherein the feeding section top opening being manually fed a bulk material.

17. The bulk material continuous dedusting system as claimed in claim 14 comprising:the separation chamber being a cylindrical chamber;the separation chamber encompassing the bottom portion of the material feeding section;the sweep head being dome shaped;the sweep head being positioned centrally within the separation chamber; the sweep head being offset and below the material feeding section; the sweep head further comprising a plurality of support wings;the plurality of support wings being tangentially secured along the bottom of the sweep head; andthe plurality of support wings securing along the inner surface of the separation chamber.

18. The bulk material continuous dedusting system as claimed in claim 14 comprising:the sparger integrating along the circumference of the sweep head; the sparger further comprising a lip and a plurality of air slots;the lip traversing along the top edge of the sparger;the plurality of air slots integrating along the surface of the sparger; and the plurality of air slots being angled upwards and outwards at a slot angle.

19. The bulk material continuous dedusting system as claimed in claim 14 comprising:the airflow adjustment mechanism comprising a sealing wall and a plurality of reciprocating barriers;the sealing wall extending downwards within the separation chamber; the sealing wall being offset the inner surface of the separation chamber; the plurality of reciprocating barriers being positioned between the sealing wall and the inner surface of the separation chamber;each of the plurality of reciprocating barrier further comprising an adjustment arm;the adjustment arm being mechanically coupled to each of the plurality of reciprocating barriers;the adjustment arm extending upwards and traversing though the system housing, wherein a portion of the adjustment arm is accessible outside of the system housing; the plurality of holes traversing through the system housing; andthe plurality of holes being positioned offset and tangential to the sparger.

20. The bulk material continuous dedusting system as claimed in claim 14 comprising:the bottom chamber being positioned below the separation chamber; the discharge section further comprising a material outlet;the material outlet being a conical shaped;the air inlet traversing through the discharge section;the air inlet coupling to the sweep head and sparger;the top chamber being positioned above the separation chamber;the vacuum section further comprising a split baffle and a dust outlet; the vacuum section being a conical shape;the split baffle being a ring shaped filter;the split baffle separating the separation section from the vacuum section; and the split baffle being concentrically positioned around the material feeding section.

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