Cyclone Separator Re-entrant Flow Channel Design
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Solution Overview
Problem
Cyclone separators face issues with the re-entrainment of solid particles at the conical-shaped bottom outlet, leading to accumulation and erosion, as well as difficulties in the downward flow of solid particles due to adverse upward fluid flow, which results in incomplete separation and potential carryover of solids into the cleaned fluid outlet.
Innovation Solution
The implementation of a cyclone separator design featuring a re-entrant fluid flow channel and opening that redirects a portion of the fluid exiting the separator back into the system upstream of the fluid entrance, creating a differential pressure to facilitate the downward flow of solid particles and prevent re-entrainment, while maintaining a substantially unrestricted bottom opening to prevent particle accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conical-shaped bottom outlet is used in the cyclone separator, then the structure provides a defined flow path for fluid, but solid particles accumulate at the bottom outlet leading to re-entrainment and erosion
Solution Approach 1:
The patent extracts the problematic conical bottom outlet structure from the cyclone separator body. By removing the conical shape that causes particle accumulation, the design eliminates the re-entrainment issue while maintaining separation efficiency through alternative geometric configurations of the separator body.
Solution Approach 2:
Instead of using a conical bottom outlet that directs flow upward and causes particle re-entrainment, the patent inverts the approach by designing a flat bottom outlet with downward-directed flow. This reversal of flow direction prevents particles from being lifted back into the separation zone, eliminating erosion and re-entrainment problems.
2Quantity of substance
If the bottom outlet is designed to allow fluid flow, then fluid can exit the separator, but upward fluid flow creates adverse pressure gradient that hinders solid particle downward flow
Solution Approach 1:
The patent inverts the conventional upward flow direction at the bottom outlet by designing the outlet to direct fluid flow downward. This reversal creates a favorable pressure gradient that assists solid particle discharge while maintaining necessary fluid flow through the separator, eliminating the adverse pressure gradient problem.
Solution Approach 2:
The patent changes the flow direction parameter at the bottom outlet from upward to downward. This parameter change transforms the adverse pressure gradient into a favorable one, enabling both continuous fluid flow and efficient solid particle discharge without interference between the two processes.
3Productivity
If solid particles are continuously separated and discharged, then separation efficiency is maintained, but particle buildup at the bottom outlet causes enhanced erosion of the outer wall
Solution Approach 1:
The patent extracts and removes the conical bottom outlet structure that causes particle accumulation and subsequent erosion. By eliminating this geometric feature, continuous particle separation can proceed without particles building up at the outlet, thereby preventing wall erosion while maintaining productivity.
Solution Approach 2:
The patent inverts the flow direction at the bottom outlet from upward to downward, preventing particles from accumulating against the wall. This inversion ensures that separated particles are continuously discharged without buildup, eliminating the erosion mechanism while maintaining continuous separation productivity.
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
This design effectively reduces the re-entrainment of solid particles, enhances the separation efficiency, and minimizes erosion by ensuring that solid particles are directed into the accumulation chamber without hindrance, resulting in a cleaner fluid outlet and reduced wear on the cyclone components.
Implementation Method 1
As the rotating fluid flows downward through the vanes, centrifugal forces acting on the rotating fluid cause some of the solid particles (and liquid if present) to be pushed toward the inner surface of the outer wall of the cyclone separator.
Implementation Method 2
From the bottom of the cyclone, the displaced solid particles are typically simply allowed to fall (due to gravity) into the accumulation section of the vessel.
Data Source
AI summary
One illustrative cyclone separator disclosed herein includes an outer body, an inner body positioned at least partially within the outer body, an internal flow path within the inner body, the internal flow path having a fluid entrance and a fluid outlet, a first fluid flow channel between the inner body and the outer body, and a re-entrant fluid opening that extends through the outer body and is in fluid communication with the fluid flow channel, wherein the re-entrant fluid opening is positioned at a location upstream of the fluid entrance of the internal flow path in the inner body.