Cyclone Separator Dust Recycle Loop for Well Fluid Mixing
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Solution Overview
Problem
Portable well treating fluid mixing systems face challenges with dust generation during the pneumatic transfer of dry treating materials, as cyclone separators have limited capacity for solid collection, leading to clogging and interruptions in the transfer process.
Innovation Solution
A portable well treating fluid mixing system that includes a cyclone separator with a collection container and a pump to continuously convey solids back to the supply tank, preventing clogging and allowing continuous material transfer by using a pump powered by compressed air to recycle dust-laden air, ensuring clean air venting and uninterrupted operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a cyclone separator is used to separate dust from vented air in a portable mixing system, then dust separation is improved, but the system must be stopped periodically to empty the collection container when it fills up
Solution Approach 1:
The patent implements continuous operation by adding a pump that automatically transfers collected dust from the cyclone separator back to the supply tank. This creates a closed-loop system where the collection container is continuously emptied and reused, eliminating periodic shutdowns for maintenance while maintaining continuous dust separation functionality.
Solution Approach 2:
The system performs self-service by using the pump to automatically relocate collected dust back to the supply tank without requiring external intervention or system shutdown. The pump operates autonomously to maintain the cyclone separator's cleaning capability, allowing the system to service itself during continuous operation.
2Productivity
If the collection container capacity is increased to reduce emptying frequency, then continuous operation is improved, but the system portability and compactness deteriorate
Solution Approach 1:
Instead of increasing container size, the patent implements continuous operation through active management - the pump continuously transfers dust from the collection container back to the supply tank. This allows a smaller container to function indefinitely without filling up, achieving continuous operation without compromising portability or increasing volume.
Solution Approach 2:
The patent recovers collected dust by pumping it back to the supply tank rather than discarding it or storing it in a large container. This recovery approach allows the use of a small collection container that is continuously emptied and reused, maintaining both compactness and continuous operation capability.
3Volume of moving object
If the cyclone separator size is reduced for portability, then system portability is improved, but the dust collection capacity and separation efficiency deteriorate
Solution Approach 1:
The patent compensates for the small cyclone separator size by implementing continuous dust removal through the pump system. By continuously transferring collected dust back to the supply tank, the system prevents clogging and maintains optimal separation efficiency throughout operation, allowing a compact separator to perform effectively.
Solution Approach 2:
The pump creates a feedback loop where collected dust is continuously monitored and transferred back to the supply tank. This feedback mechanism prevents the small cyclone separator from becoming clogged, maintaining its separation efficiency despite its reduced size, and allowing the system to adapt to the separator's limited capacity.
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
Enables continuous and efficient transfer of dry treating materials into the supply tank, reducing dust discharge and maintaining system operation without interruptions, thereby supporting uninterrupted well treatment processes.
Implementation Method 1
a cyclone separator having an inlet coupled to the supply tank and receiving dust laden air from the supply tank, and having a first outlet venting clean air and having a second outlet venting solids
Implementation Method 2
a pump having an inlet coupled to the collection container outlet and a pump outlet coupled to the supply tank
Data Source
AI summary
A portable well treating fluid mixing system includes: a supply tank having an inlet receiving pneumatically conveyed dry treating material; a cyclone separator having an inlet coupled to the supply tank and receiving dust laden air from the supply tank, and having a first outlet venting clean air and having a second outlet venting solids; a collection container having a first inlet coupled to the cyclone separator second outlet and receiving solids from the cyclone separator and having an outlet; and, a pump having an inlet coupled to the collection container outlet and a pump outlet coupled to the supply tank. In operation, the system continuously conveys dust from the collection container back into the supply tank to maintain the separator in proper operating condition and minimizes venting of dust during the transfer of material to the supply tank.