System for capture, separation, transport, compaction and reincorporation

Abstract

The present invention relates to a system for capturing, separating, transporting, compacting and reincorporating dry particulate material in mining processes. The system comprises a collection module designed to suction air containing particulate material from a mining process area, a multicyclone module that includes a plurality of cyclones disposed in one or more separation stages for treating different granulometric fractions, and internal surfaces designed to induce triboelectric interaction by means of contact and friction with the particulate material, promoting the separation thereof. In a preferred embodiment, at least one of the cyclones has a double-case configuration, wherein the first case includes internal geometries such as helical channels and distributed openings that allow fine fractions to pass to a second case, improving fine and ultrafine particle separation. The system also comprises at least one chamber for receiving the separated particulate material; an internal conveyor system, preferably based on an endless screw; and a compaction module, preferably based on briquetting rollers, designed to densify the particulate material to form compacted units. The system is designed to operate in a continuous and integrated manner, such that the captured particulate material is separated, carried and compacted within a single operation line, without requiring external transport between the main stages, enabling the compacted material to be reincorporated into the mining process.

Description

[0001] DESCRIPTIVE MEMORANDUM

[0002] Title of the invention

[0003] System for the capture, separation, transfer, compaction and reincorporation of particulate matter in mining processes

[0004] 1. Technical field of the invention

[0005] The present invention falls within the field of mining engineering, particularly in systems for the control, capture, separation, treatment, compaction, recovery, valorization and reincorporation of particulate matter generated in mining processes, such as underground mining, open pit mining, crushing plants, grinding, mineral transfer, tunnels, chutes, pits, conveyor belts, unloading points and areas of accumulation or emission of fine and ultrafine dust.

[0006] In complementary embodiments, the invention can be applied in other industrial installations where there is generation of dry particulate matter of analogous behavior, provided that this does not alter the essential technical principle described in this document.

[0007] 2. Technical problem to be solved

[0008] In mining processes, the generation of fine and ultrafine particulate matter is a critical problem from operational, environmental, and health perspectives. This material can disperse into the environment, reduce operational visibility, affect occupational health conditions, contaminate equipment, structures, and transit areas, increase cleaning and maintenance efforts, generate losses of valuable materials, and require removal, transport, storage, or external disposal systems.

[0009] Existing solutions have limitations, such as:

[0010] low efficiency in capturing fine and ultrafine particles;

[0011] need for external transport of the captured material;

[0012] generation of waste material without direct recovery;

[0013] High operational costs are associated with logistics, maintenance, cleaning, transportation, and disposal. Additionally, solutions such as suction systems and transport using specialized trucks involve significant costs in man-hours, fuel consumption, use of infrastructure for storage, occupation of operational space, and risk of recontamination or loss of continuity between the capture of the material and its eventual valorization.

[0014] Conventional systems, such as bag filters, electrostatic precipitators, wet suppression, directed ventilation, and traditional cyclones, do not provide an integrated solution for the capture, enhanced separation, continuous transfer, compaction, and reincorporation of particulate matter in a single operating line.

[0015] Therefore, there is a need for a system that allows not only the capture of particulate matter, but also its processing and reincorporation into the production process in a continuous and integrated manner, reducing or eliminating the need for external transport between the main stages of treatment.

[0016] 3. Object of the invention

[0017] The present invention relates to an integrated, modular and scalable system intended for the capture, separation, conveyance, controlled storage, transfer, compaction and reincorporation of dry particulate material, especially fine and ultrafine dust generated in mining processes.

[0018] The system is characterized by combining, in the same continuous operating line: a) an air intake and suction module loaded with particulate matter; b) a multicyclone module arranged in one or more separation stages;

[0019] c) internal surfaces configured to induce triboelectric interaction between the particulate matter and the internal walls of the system;

[0020] d) a specialized geometric configuration, in at least one cyclone, comprising a double casing, helical grooves and distributed openings;

[0021] e) one or more chambers for receiving and controlled storage of the separated material;

[0022] f) an internal transport system, preferably using a screw conveyor or Archimedes screw;

[0023] g) a mechanical compaction module, preferably using briquetting rollers; h) a discharge outlet for the compacted material for its reincorporation into the mining process;

[0024] i) a supplementary filtration system upstream of suction motors; and

[0025] j) a system of sensors, monitoring, control and self-cleaning.

[0026] The invention allows the capture of fugitive or accumulated dust, the separation of different fractions of particulate material, the conveyance of the retained material to a compaction stage, and the generation of a solid, compact, and manageable by-product suitable for direct or controlled reincorporation into the mining production circuit.

[0027] In a preferred embodiment, the invention is oriented towards recovering dust with valuable mineral content, transforming it into a compact by-product capable of being reintegrated into subsequent processes, such as belt transport, crushing, grinding, flotation, leaching or other mining operations.

[0028] 4. State of the art

[0029] In previous technology, there are various solutions for the control or handling of particulate matter in mining.

[0030] Bag filters allow the retention of fine particles, but they operate mainly as filtration and dust accumulation systems, requiring cleaning, maintenance and subsequent handling of the retained material.

[0031] Electrostatic precipitators allow the capture of small particles, although they usually require more complex operating configurations, and the captured material is not necessarily continuously integrated into a compaction and reincorporation stage within the same line.

[0032] Wet suppression reduces dust dispersion in certain applications, but it alters the state of the material and can be inconvenient in processes where it is necessary to keep the particulate matter dry.

[0033] Directed ventilation or localized extraction systems move particulate matter out of a critical area, but do not necessarily involve separation, recovery, compaction or reincorporation of the captured dust.

[0034] Traditional cyclones are robust and relatively low-maintenance equipment, but they have limitations in the efficient capture of fine and ultrafine particles, and on their own, they do not solve the problem of continuous valorization of the separated material. Likewise, there are partial solutions that use mobile suction equipment to remove accumulated dust from operating areas, but these solutions usually discharge the collected material in another location, without transforming it within an integrated line for separation, compaction, and immediate return to the process.

[0035] Consequently, the state of the art does not directly solve an architecture oriented towards mining processes that combines, in the same continuous and functionally cooperative line:

[0036] i) multi-cyclone stage separation;

[0037] ii) internal surfaces configured to induce triboelectric interaction by contact and friction;

[0038] iii) in at least one cyclone, a double-shell configuration with helical slots and distributed openings for fine fraction transfer;

[0039] iv) continuous internal transfer of the separated material towards compaction; and v) reincorporation of the compacted material into the mining process.

[0040] 5. Brief description of the figure

[0041] complete

[0042] finuHi

[0043] 3 multicyclonic

[0044] Vauimedes

[0045] etchers —

[0046]

[0047]

[0048] Figure 1: General schematic view of the system that is the subject of the invention, showing: (1) collection and suction module;

[0049] (1.1), (1.2), (1.3) and (1.4) complementary chambers or filters prior to the engines;

[0050] (2) multicyclone module;

[0051] (2.1) main system input;

[0052] (3) primary storage chamber;

[0053] (4.4) secondary storage chamber or pre-hopper;

[0054] (4.1) worm screw or Archimedes screw;

[0055] (4.2) briquetting roller compaction module;

[0056] (4.3) controlled release of compacted material; and

[0057] (5) sensors and monitoring / control system.

[0058] 6. General description of the invention

[0059] The present invention proposes an integrated system that allows the capture, separation, transfer and compaction of dry particulate material, enabling its reincorporation into the mining process as a useful by-product.

[0060] The invention corresponds to a multicyclonic dust capture and valorization system, composed of integrated functional modules arranged to operate sequentially, continuously and in a coordinated manner.

[0061] In general terms, the system comprises: an air capture module with particulate matter;

[0062] a multicyclonic module configured in one or more separation stages; internal surfaces configured to induce triboelectric interaction;

[0063] one or more receiving chambers for the separated material;

[0064] an internal transport system;

[0065] a compaction module;

[0066] a system for unloading the compacted material;

[0067] a supplementary filtration system;

[0068] a system of sensors, monitoring and control; and

[0069] a self-cleaning system.

[0070] The system operates continuously and in an integrated manner, avoiding the need for external transport between stages.

[0071] The system can be installed in a fixed or mobile manner, and can be mounted on a frame, chassis, skid or transportable cart.

[0072] 7. Detailed description of the invention

[0073] 7.1 Intake and suction module (1)

[0074] In a preferred embodiment, the system comprises a collection module (1) configured to draw air with particulate matter from a mining process area.

[0075] The system comprises one or more motors or suction / drive units configured to draw air containing particulate matter from an area of ​​interest. These motors can be three-phase or single-phase, with variable power, depending on the required flow rate and the system design.

[0076] Collection can be carried out by means of ducts, pipes, bells, suction mouths or inlets with helical geometry, intended to induce rotational flow and favor the entry of particulate matter.

[0077] 7.2 Supplementary filters prior to motors (1.1, 1.2, 1.3, 1.4) Before each motor, a supplementary filtration chamber may be provided, preferably with HEPA filters or equivalent, intended to protect the motor and improve the retention of remaining ultrafine material.

[0078] These cameras can incorporate saturation sensors, vibration mechanisms, pneumatic pulses, and programmed or automatic cleaning systems.

[0079] 7.3 Multicyclone Module (2)

[0080] The captured material is directed to a multicyclone module (2), which may comprise multiple cyclones arranged in series, in parallel or in combined configurations, forming one or more separation stages.

[0081] The system comprises a multicyclone module consisting of one or more cyclones arranged in one or more stages, configured to perform progressive separation of particulate matter according to size, mass, apparent density, aerodynamic behavior or interaction with internal surfaces.

[0082] In one particular embodiment, these stages are configured to treat different particle size fractions, including ranges of coarse, fine, and ultrafine particles.

[0083] In a preferred embodiment, the multicyclone module comprises:

[0084] a first stage focused on coarser fractions;

[0085] a second stage focused on intermediate fractions;

[0086] a third stage focused on fine fractions; and

[0087] a fourth stage focused on very fine or ultrafine fractions.

[0088] The number of stages may vary depending on the operational requirement.

[0089] 7.4 Internal surfaces and triboelectric interaction

[0090] The internal surfaces of the system, particularly in the multicyclone module and associated ducts, are configured to induce triboelectric interaction through contact and controlled friction, which modifies the aerodynamic behavior of the particles and improves their separation efficiency.

[0091] At least some of the internal surfaces of the cyclones, ducts, or conduits of the system may be lined with polymeric materials, polymeric composites, or technical coatings selected to induce triboelectric interaction resulting from contact and friction between the particulate matter and the internal walls. This interaction promotes the modification of the trajectory of fine particles, their temporary adhesion, deceleration, deflection, or separation from the main flow, contributing to improved capture of fine and ultrafine fractions.

[0092] 7.5 Cyclone with dual casing and specialized internal geometry

[0093] In a preferred embodiment, at least one of the cyclones has a double-shell configuration (2.1), where:

[0094] A first housing comprises internal geometries such as helical grooves, reliefs, or other configurations intended to modify the flow of particulate material;

[0095] said first casing further comprises distributed openings that allow the passage of fine fractions to a second casing; and

[0096] The second casing is configured to collect smaller particulate matter.

[0097] In certain embodiments, at least one of the cyclones in the multicyclone module has a double-shell configuration.

[0098] In this arrangement, a first casing receives the main flow and internally features helical grooves, ridges, channels, or reliefs, and additionally, distributed openings, preferably oval or elongated. A second casing receives the fine material that passes through these openings or is conveyed from the first casing.

[0099] This configuration cooperates with the multicyclonic effect and with the triboelectric interaction, allowing additional separation of fine or ultrafine fractions and their discharge towards the material reception zone.

[0100] In an exemplary, non-limiting embodiment, the openings can have lengths of up to approximately 1.5 cm and widths between approximately 3 mm and 5 mm.

[0101] 7.6 Primary Receiving and Storage Chamber (3)

[0102] The separated material is conveyed to a receiving chamber (3), from where it is transferred by means of an internal transport system. Under the multicyclone module there is a primary storage chamber or container, intended to receive the material captured and separated by the cyclones.

[0103] This chamber is designed to reduce obstructions, stabilize the discharge flow, and feed the next stage in a regulated manner.

[0104] 7.7 Secondary storage chamber or pre-hopper (4.4)

[0105] In certain embodiments, the system incorporates a second chamber, hopper or pre-hopper that receives material from the primary chamber and allows the solid flow rate to be regulated before entering the transport or compaction system.

[0106] 7.8 Internal transport system (4.1)

[0107] The separated material is conveyed by an internal transport system (4), preferably a screw conveyor.

[0108] The separated material is conveyed by at least one screw conveyor or Archimedes screw from the primary chamber, or from the secondary chamber, to the compaction module.

[0109] The conveying system can be driven by an electric or hydraulic system, and in a preferred embodiment operates with variable speed control. The screw conveyor may incorporate speed control, thermal monitoring, load sensors, jamming sensors, and overload protection.

[0110] 7.9 Compaction modulus (4.2)

[0111] The transported material is conveyed to a compaction module, which preferably comprises at least two briquetting rollers configured to densify the particulate material and form compacted units.

[0112] In a preferred embodiment, the module comprises two opposing briquetting rollers capable of applying controlled pressure to the fed material. The rollers may have cavities, patterns, dies, or profiles designed to define the shape of the compacted product.

[0113] In a preferred embodiment, the system operates without the addition of binding agents, although their use may be considered in specific configurations.

[0114] In other embodiments, the use of binders may be permitted if the process requires it.7.10 Discharge outlet of the compacted material (4.3)

[0115] At the outlet of the compaction module, the system includes a controlled discharge zone for the generated byproduct, and this discharge can be directed to a conveyor belt, a hopper, a feeding point to another process, or an immediate reintegration stage.

[0116] 7.11 Sensors, monitoring and control (5)

[0117] The system can incorporate sensors to monitor variables such as pressure, flow rate, temperature, vibration, and material level, as well as an automated control system based on PLC, SCADA, or equivalent architectures.

[0118] The invention can incorporate sensors distributed in different areas of the system, intended to measure variables such as pressure, flow rate, dust saturation, temperature, humidity, vibration, motor load, filter status, internal accumulation of material and variables associated with triboelectric behavior.

[0119] These sensors can be integrated into a centralized platform, PLC, HMI, SCADA, IoT system, or equivalent monitoring and control architecture.

[0120] 7.12 Self-cleaning system

[0121] Additionally, the system can incorporate self-cleaning mechanisms, such as vibrators or air pulses.

[0122] The system can incorporate vibrators, pneumatic nozzles, air pulsators or equivalent mechanisms, suitable for reducing the deposition of material in cyclones, filters, ducts, chambers, hoppers and discharge lines.

[0123] 7.13 Structure and modularity

[0124] All components are mounted on a modular structure, which can be fixed, transportable, or mobile.

[0125] All the components described can be supported on a metal structure, frame or modular chassis, designed to maintain alignment, mechanical rigidity, maintenance access and scalability.

[0126] The structure can accommodate a fixed or mobile configuration.

[0127] 8. System Operation

[0128] 8.1 Air Intake: Particle-laden air is drawn from an area of ​​interest using the suction module. Intake can be achieved through an inlet configured to induce rotational movement.

[0129] 8.2 Primary and secondary separation

[0130] Once inside the multicyclone module, the airflow and particles undergo separation due to centrifugal force, internal geometry, and interaction with coated surfaces.

[0131] The larger particles are separated in the initial stages, while the finer fractions continue to later stages.

[0132] In double-shell cyclones, some of the fine material passes through the distributed openings into the secondary shell, from where it is conveyed to the collection system.

[0133] 8.3 Enhanced capture by triboelectric effect

[0134] During the circulation of the material through ducts, cyclones and internal lined surfaces, triboelectric interaction occurs between the particulate matter and the walls, favoring the retention or deflection of fine fractions that, in the absence of this phenomenon, could remain suspended in the main flow.

[0135] 8.4 Reception and storage of separated material

[0136] The separated material falls or is conveyed to the primary storage chamber and, where appropriate, to the secondary chamber or pre-hopper.

[0137] 8.5 Internal transport

[0138] The screw conveyor guides the material in a controlled manner towards the compaction module.

[0139] 8.6 Compaction

[0140] The material enters between the briquetting rollers and is subjected to compression, generating compacted bodies in a continuous or semi-continuous manner.

[0141] 8.7 Unloading and reintegration

[0142] The compacted material is discharged in a controlled manner and can be directly reincorporated into the mining process or diverted to a later stage.

[0143] 8.8 Monitoring and self-cleaning During operation, sensors monitor critical variables and the system can activate self-cleaning routines or operational correction.

[0144] 9. Technical advantages of the invention

[0145] The system described allows:

[0146] improve the efficiency of capturing fine and ultrafine particles;

[0147] eliminate or reduce the need for external transport of particulate matter; reduce operational costs associated with logistics and storage;

[0148] to reduce exposure to particulate matter, improving occupational health conditions;

[0149] reincorporate the particulate matter into the production process.

[0150] The invention presents, among others, the following additional technical advantages: continuous integration of capture, separation, transfer, compaction and reincorporation within the same operational architecture;

[0151] improvement of fine and ultrafine particle separation through combination of multicyclonic effect, internal geometry and triboelectric interaction;

[0152] reduction or elimination of external stages of transport and intermediate disposal of captured dust;

[0153] possibility of converting dry particulate material into a compact and manageable byproduct;

[0154] reduced dust accumulation in critical areas of the process;

[0155] reduction of corrective maintenance associated with dust dispersion; modular and scalable operation;

[0156] compatibility with fixed or mobile configurations; and

[0157] possibility of integration with advanced control systems.

[0158] 10. Implementation methods and scalability

[0159] The invention can be implemented in different scales and configurations, while maintaining the same fundamental technical principle.

[0160] In a first embodiment, the system corresponds to a unit for direct connection to a critical dust generation point. In a second embodiment, the system can be expanded by increasing the number of cyclones, motors, chambers, conveyor screws, and compaction modules.

[0161] In a third embodiment, the system can be configured as a stationary plant with greater capacity.

[0162] In a fourth embodiment, the system can be configured as a receiving module for material discharged from an external suction system.

[0163] 11. Mining applications

[0164] The invention can be applied in transfer chutes, conveyor belts, chutes, ore drop points, areas under belts, crushing plants, grinding plants, tunnels, loading faces, blasting areas and dust accumulation areas.

[0165] 12. Final considerations

[0166] This specification describes preferred embodiments of the invention. A person skilled in the art will understand that modifications to the shape, dimensions, materials, number of stages, arrangement of components, drive systems, sensors, and structure may be introduced without departing from the essential technical scope of the invention, which is defined by the corresponding claims.

Claims

1. CLAIMS AND DEMANDS 1. Main independent claim 1. System for the capture, separation, transfer, compaction and reincorporation of dry particulate matter in industrial environments, characterized in that it comprises: a collection module configured to draw air containing particulate matter from a mining process area; a multicyclone module comprising a plurality of cyclones arranged in one or more separation stages to treat different particle size fractions; internal surfaces arranged within the multicyclone module and / or in associated ducts, configured to induce triboelectric interaction by contact and friction with the particulate material, favoring its separation; at least one receiving chamber for the separated particulate matter; an internal transport system configured to continuously convey particulate material from said receiving chamber; a compaction module configured to densify the transported particulate material and form compacted units; and a discharge outlet for the compacted material, where the system is configured to operate continuously and in an integrated manner, so that the captured particulate material is separated, conveyed and compacted within the same operating line, without requiring external transport of the material between the separation and compaction stages, allowing the reincorporation of the compacted material into the mining process.

2. Secondary independent claim for the multicyclone module 2. Multicyclone module for separating dry particulate matter in mining processes, characterized in that it comprises: a plurality of cyclones arranged in one or more stages; at least one cyclone with a double-shell configuration; a first casing comprising internal surfaces with helical geometry, grooves, reliefs or equivalent configurations; openings distributed in said first casing configured to allow the passage of fine fractions to a second casing; and internal surfaces configured to induce triboelectric interaction with the particulate material, where the cooperation between internal geometry, distributed apertures and triboelectric interaction is intended to improve the separation of fine and ultrafine particles compared to a conventional cyclone.

3. Independent claim of method 3. Method for the capture, separation, transfer, compaction and reincorporation of dry particulate material in mining processes, comprising the stages of: draw in air containing particulate matter from a process area; introduce said material into a multi-cyclonic module arranged in multiple stages; induce triboelectric interaction between the particles and internal surfaces of the system; separate the particulate matter into different fractions; continuously convey the separated material to a compaction stage; compact the particulate material into densified units; and reincorporate the compacted material into the mining process.

4. System-dependent claims 4. System according to claim 1, wherein the cyclones are arranged in series, in parallel or in combined configurations.

5. System according to claim 1, wherein the multicyclone module comprises at least two separation stages.

6. System according to claim 1, wherein at least one of the cyclones has a double-shell configuration.

7. System according to claim 6, wherein a first housing comprises internal surfaces with helical geometry, grooves, reliefs or equivalent configurations intended to modify the flow of the particulate material.

8. System according to claim 6 or 7, wherein the first housing comprises distributed openings configured to allow the passage of fine fractions into a second housing.

9. System according to any of claims 6 to 8, wherein the second housing is configured to collect smaller particulate material.

10. System according to claim 1, wherein the triboelectric interaction is configured to increase the retention, deflection or separation of fine and ultrafine particles.

11. System according to claim 1 or 10, wherein the internal surfaces comprise polymeric materials, polymeric composites or technical coatings selected to induce triboelectric interaction.

12. System according to claim 1, wherein the collection module comprises one or more suction motors.

13. System according to claim 12, wherein each motor is associated with a complementary filtration chamber.

14. System according to claim 13, wherein the complementary filtration chamber comprises a HEPA filter or equivalent.

15. System according to claim 1, comprising a primary storage chamber for the separated material.

16. System according to claim 15, further comprising a secondary storage chamber or pre-hopper for flow regulation.

17. System according to claim 1, wherein the internal transport system comprises a worm screw or Archimedes screw.

18. System according to claim 17, wherein the worm gear is driven hydraulically, electrically or by an equivalent system.

19. System according to claim 17 or 18, wherein the transport system operates in a synchronized manner with the compaction module.

20. System according to claim 1, wherein the compaction module comprises at least two briquetting rollers.

21. System according to claim 20, wherein the rollers have cavities, dies or geometries intended to form briquettes.

22. System according to claim 1 or 20, wherein compaction is carried out without the addition of external agents.

23. System according to claim 1, wherein the discharge outlet of the compacted material is configured to discharge into a conveyor belt, a hopper or a subsequent stage of the mining process.

24. System according to claim 1, comprising sensors for monitoring one or more variables selected from pressure, flow rate, temperature, humidity, vibration, material saturation, internal accumulation, and filter status.

25. System according to claim 24, wherein said sensors are connected to an automated control platform.

26. System according to claim 25, wherein the control platform comprises PLC, HMI, SCADA, IoT system or equivalent architecture. I. System according to claim 1, comprising a self-cleaning system by means of vibration, pneumatic pulses or equivalent mechanisms.

28. System according to claim 1, wherein the components are mounted on a fixed or mobile modular structure.

29. System according to claim 28, wherein the structure comprises a frame, chassis, skid or transportable cart.

30. System according to claim 1, wherein the system is scalable by incorporating multiple multicyclonic, compaction or collection modules.

5. Claims dependent on the multicyclone module 31. Multicyclone module according to claim 2, wherein the cyclones are arranged in series, in parallel or in combined configurations.

32. Multicyclonic module according to claim 2, wherein the internal surfaces configured to induce triboelectric interaction comprise polymeric materials, polymeric composites or technical coatings.

33. Multicyclonic module according to claim 2, wherein the distributed openings have an oval or elongated geometry.

6. Method-dependent claims34. Method according to claim 3, wherein the separated particulate material is conveyed by a screw conveyor to the compaction stage.

35. Method according to claim 3 or 34, wherein compaction is carried out by briquetting rollers.

36. Method according to any of claims 3 to 35, wherein the compacted material is reincorporated into a conveyor belt or a later stage of the mining process.

7. Claims of use 37. Use of the system according to any of claims 1 to 30 for the capture, treatment and reincorporation of dry particulate matter in mining processes.

38. Use according to claim 37 in chutes, conveyor belts, chutes, tunnels, crushing plants, grinding plants, blasting areas or dust accumulation areas.

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