Concave Top Head Cyclone Reducing Vortex Void
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-pressure cyclonic separation processes face inefficiencies due to the failure of traditional top head and tangential inlet designs under elevated pressures and temperatures, leading to reduced separation efficiency and structural integrity issues.
Innovation Solution
A cyclone design featuring a concave top head with a refractory roof and a tangentially disposed inlet nozzle that transitions from a cylindrical to an elliptical shape, combined with an erosion-resistant and insulating layer, to withstand high pressures and maintain process efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a semi-spherical convex top head is used to withstand elevated pressures, then structural integrity is improved, but a void area is created between the tangential inlet and top head that disturbs the vortex and reduces separation efficiency
Solution Approach 1:
The patent inverts the conventional convex top head design to a concave top head configuration. This inversion eliminates the void area between the tangential inlet and top head that disturbs the vortex, while the concave shape still provides structural integrity under elevated pressures by directing forces toward the cyclone body.
Solution Approach 2:
The patent introduces a head space reduction component that extends axially into the cyclone body, creating a multi-dimensional structure. This component fills the void area and redirects the vortex flow, improving separation efficiency without compromising the structural integrity provided by the concave top head.
2Ease of manufacture
If a flat top head is used near the inlet entrance, then manufacturing is simplified, but joints and edges have a significant propensity to fail under elevated pressures and temperatures
Solution Approach 1:
The patent employs a concave top head with curved surfaces instead of flat surfaces. The curved geometry eliminates stress concentration at sharp edges and joints, significantly improving resistance to elevated pressures and temperatures while remaining manufacturable through standard forming processes.
3Strength
If the inlet nozzle is shifted into direct alignment with the centrally-located vortex output tube to avoid square features, then structural integrity is improved, but particulate matter is injected directly at the output tube causing premature erosion and disturbing the vortex
Solution Approach 1:
The patent segments the inlet system by introducing a head space reduction component that is offset from the central axis. This component creates a separate flow path that directs the vortex away from the output tube, preventing direct injection of particulate matter while maintaining structural integrity through the offset configuration.
4Object-affected harmful factors
If a bend is introduced in the output tube to place it off-center from the vortex, then erosion and vortex disturbance are reduced, but the efficiency of the separation process is significantly reduced
Solution Approach 1:
The patent extracts the flow direction-changing function from the output tube itself and relocates it to a dedicated head space reduction component positioned at the inlet. This allows the output tube to remain straight and centrally located for optimal vortex extraction, while the separate component handles the flow redirection to prevent erosion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enhances structural integrity and separation efficiency by eliminating voids between the inlet and top head, reducing the risk of premature erosion and improving overall process performance while reducing material costs.
Implementation Method 1
separating a mixture of two or more phases, for example, fluid-particulate suspensions wherein one or more solid particulates are suspended in a carrier fluid, under a centrifugal force generated by centripetal motion
Implementation Method 2
a tangentially disposed inlet nozzle that transitions from a cylindrical to an elliptical shape, combined with an erosion-resistant and insulating layer
Data Source
AI summary
A pressure cyclone is disclosed having a concave top head, wherein the concave top head has a substantially flat roof disposed in the interior of the cyclone vessel. An inlet is tangentially-coupled to the vessel and has an inlet nozzle disposed therein and configured to smoothly transition into the cyclone vessel to create a vortex that separates solid particulates from an incoming particulate-fluid suspension. In particular, the one surface of the inlet nozzle is tangent to the inner surface of cyclone vessel and another surface of the inlet nozzle is parallel and continuous with the substantially flat roof. An inlet casing is disposed around a length of the inlet nozzle and configured to transition from a circular casing to an elliptical casing along the length of the inlet nozzle, and couple to the vessel with the elliptical casing.