Cyclone Separator Distributor Curvature Reduces Erosion

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Solution Overview

Problem

Conventional cyclone clusters experience high erosion and efficiency losses due to recirculation flow patterns in distributor devices, which are prone to turbulence and wear from particulates.

Innovation Solution

A distributor device with a main body having a distribution chamber, a protrusion on the back wall, and flared inlet passage, along with delivery outlets that taper to increase discharge speed, reducing turbulence and recirculation losses.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional distributor devices with flat walls and direct flow paths are used, then the structure is simple and easy to manufacture, but high erosion and recirculation losses occur due to turbulence

Engineering Contradiction:

Improvestructural simplicityVSAvoidrecirculation losses

Core Design Contradiction:

Ease of manufactureVSLoss of energy

Solution Approach 1:

The distributor device replaces flat walls with curved surfaces, including a curved front wall, curved back wall, and curved side walls forming a substantially cylindrical distribution chamber. This curvature eliminates sharp corners and edges that cause flow separation and turbulence, thereby reducing recirculation losses while maintaining manufacturing feasibility through standard curvilinear forming processes

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The inlet passage is designed with a gradual curvature that changes the flow direction parameter progressively rather than abruptly. The curved geometry transforms the flow parameters (velocity distribution, flow direction) smoothly from the inlet through the distribution chamber to the outlets, minimizing turbulence and energy loss

Inventive Principle:

Principle #35Parameter changes

2Device complexity

If conventional distributor devices are used, then the design is straightforward, but significant erosion occurs from recirculation flow patterns

Engineering Contradiction:

Improvedesign simplicityVSAvoiderosion

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The curved cylindrical geometry of the distribution chamber eliminates sharp corners and edges where flow separation and recirculation zones form. The smooth curvilinear surfaces guide flow continuously from inlet to outlets without creating turbulent eddies that cause particulate erosion, thereby protecting the distributor structure

Inventive Principle:

Principle #14Spheroidality (Curvature)

Solution Approach 2:

The curved geometry converts what would be harmful flow separation and recirculation into beneficial smooth, continuous flow patterns. The curvature that might seem to increase path length actually reduces turbulence intensity and redirects flow constructively toward the outlets, transforming potential erosion zones into protected flow paths

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If flat-walled distributor devices are used, then manufacturing is easier, but turbulence and recirculation reduce efficiency

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidflow throughput efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The curved cylindrical distribution chamber maintains relatively simple manufacturing processes while dramatically improving flow efficiency. The curvature eliminates dead zones and recirculation areas where flow would stagnate, ensuring all fluid passes efficiently through the distribution system to the outlets, thereby increasing effective throughput

Inventive Principle:

Principle #14Spheroidality (Curvature)

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 solution effectively reduces erosion and maintains medium velocity flow at delivery outlets, minimizing turbulence and recirculation, thereby enhancing the efficiency and longevity of cyclone separator installations.

Implementation Method 1

by generating centrifugal forces within the hydrocyclone as the liquid passes through a conical shaped separating chamber

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

The delivery outlets are configured so as to increase the speed of fluid discharge from the distribution chamber

Methodology Applied

Scientific EffectVenturi effect: Venturi Effect

Data Source

PatentUS11318481B2Distributor device for cyclone separator apparatus

Publication Date: 2022.05.03 WEIR MINERALS AUSTRALIA LTD

AI summary

A distributor device for use with cyclone separator apparatus, the distributor device comprising, a main body having a distribution chamber therein, the main body including a back wall and a front wall which at least in part enclose the distribution chamber, the main body including a peripheral region between the front and back walls, the device comprising a plurality of delivery outlets arranged in spaced apart relation around the peripheral region the front wall having an inner face and a back wall having an inner face, the device further including a feed inlet to the distribution chamber in the front wall having a main axis extending in a direction between the front and back walls; the back wall having an inner face which includes main face section and a protrusion which extends from the main face section towards the inner face of the front wall.