Cyclone Separator With Pulsating Media for Density-Based Waste Sorting

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Solution Overview

Problem

Current methods for sorting waste materials, particularly non-ferrous metals and non-metallic materials from waste streams like automobile shredder residue and electronic components, are inefficient and costly, lacking effective cost-effective systems for revenue recovery and landfill reduction.

Innovation Solution

A four-dimensional separation system using a cyclone with an impeller or paddle, feed distributors, and media with specific gravity between 1.1 and 3, employing centrifugal, vertical, and pulsating motions to separate materials based on density, with a centrifugal motion generated by the impeller and media flow.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual sorting by laborers is used, then recyclable materials can be sorted, but labor costs are too high and the approach is not sustainable

Engineering Contradiction:

Improvesorting efficiencyVSAvoidlabor cost

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces manual mechanical sorting by laborers with an automated hydraulic classification system that uses density-based separation. The system employs a classification tank with hydraulic flow to automatically separate recyclable materials by density, eliminating the need for manual labor while maintaining high sorting efficiency for diverse waste streams including non-ferrous metals and plastics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention uses hydraulic flow through a classification tank to create density-based separation. Media with specific gravity between 1.1 and 3.0 is circulated through the tank, causing materials to stratify based on their density. This hydraulic classification mechanism automates the sorting process and provides cost-effective separation without requiring manual intervention.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Productivity

If traditional separation methods are used, then some materials can be recovered, but separation efficiency is insufficient for diverse waste streams containing non-ferrous metals and non-metallic materials

Engineering Contradiction:

Improvematerial recovery rateVSAvoidseparation efficiency

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent changes the separation parameter from simple gravity settling to controlled hydraulic flow with adjustable media specific gravity (1.1 to 3.0). By adjusting the media density and flow rate, the system can effectively separate a wide range of materials including non-ferrous metals, plastics, and other non-metallic materials from diverse waste streams, significantly improving both recovery rate and separation efficiency.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The system uses composite media with specific gravity between 1.1 and 3.0 to enhance separation capability. This media composition allows simultaneous effective separation of multiple material types with different densities, including non-ferrous metals and non-metallic materials, providing reliable and efficient separation for complex waste streams.

Inventive Principle:

Principle #40Composite materials

3Ease of manufacture

If no cost-effective separation system is used, then waste materials can be disposed of, but revenue recovery from recyclables is lost and landfill strain increases

Engineering Contradiction:

Improvecost-effectivenessVSAvoidrecyclable material loss

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The hydraulic classification system operates as a self-service automated process that continuously separates recyclable materials without requiring external intervention. The system recovers valuable materials including non-ferrous metals and plastics, converting waste into revenue-generating resources while reducing landfill disposal requirements, thereby achieving cost-effective waste management.

Inventive Principle:

Principle #25Self-service

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

Enhances separation efficiency, reduces landfill waste, and facilitates cost-effective recovery of recyclable materials by effectively sorting and recovering non-ferrous metals and non-metallic materials with higher throughput and reduced labor costs.

Implementation Method 1

The impeller rotates in a first direction about an axis in the cyclone... The impeller generates a centrifugal motion

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

The media can have a specific gravity between about 1.1 and 3.0... generating a downward and outward flow within the cyclone

Methodology Applied

Scientific EffectBuoyancy: Archimedes' Principle (Buoyancy)

Data Source

PatentUS20250360514A1System and method for four dimensionally separating materials

Publication Date: 2025.11.27 VALERIO THOMAS A

AI summary

This application discloses a separator for separating and recovering materials from a waste stream. The separator has a cyclone having a top section and a bottom section, an impeller within the cyclone, a media inlet for accepting a flow of media or a pulsating flow of the media operatively connected to the impeller in which media or fluid flows through the impeller into the separator; a first discharge passage for a collecting a light fraction, and a second discharge passage for collecting a heavy fraction.