Cyclonic Separator with Adjustable Bleed Opening

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Solution Overview

Problem

Cyclone separators often entrain larger particles in the overflow stream, which can cause damage downstream and require additional processing, increasing costs and reducing efficiency, and it is time-consuming to adjust the proportion of particles in the overflow relative to the underflow.

Innovation Solution

A cyclonic separator with a vortex finder featuring an adjustable bleed opening between its upstream and downstream portions, allowing for the removal of oversized particles from the overflow stream, with the upstream and downstream portions being axially displaceable to adjust the size of the bleed opening, and an automatic control system to optimize this process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a conventional cyclone separator is used to separate particles, then the separation into coarse and fine fractions is achieved, but larger particles are entrained in the overflow stream causing downstream equipment damage and requiring additional processing

Engineering Contradiction:

Improveparticle size separation precisionVSAvoidoversized particles in overflow stream

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The overflow stream is segmented into two separate streams: a fine fraction stream and a coarse fraction stream. The bleed opening diverts a portion of the overflow stream containing larger particles away from the main overflow discharge, effectively segmenting the particle size distribution between two outlet streams and preventing oversized particles from entering downstream equipment.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Larger particles are extracted from the overflow stream through the bleed opening. The bleed opening selectively removes oversized particles that would otherwise be discharged with the fine fraction, extracting the harmful component before it can cause downstream equipment damage.

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If the vortex finder configuration is fixed, then the separator structure is simple, but it is time-consuming to adjust the proportion of particles delivered to overflow relative to underflow

Engineering Contradiction:

Improveadjustment speed of particle proportionVSAvoidvortex finder structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The vortex finder structure incorporates movable components that allow dynamic adjustment of the bleed opening size. The second end of the vortex finder can move axially relative to the first end, enabling real-time adjustment of particle proportion distribution between overflow and underflow streams without requiring shutdown or complex reconfiguration.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The vortex finder employs a nested structure where one tubular portion is positioned within another tubular portion. This nested arrangement allows for compact design while enabling relative axial movement between the nested tubes to adjust the bleed opening, achieving adjustable functionality without significant increase in overall structural complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

3Reliability

If additional processing equipment is added to remove oversized particles, then downstream equipment damage is prevented, but costs and processing time increase

Engineering Contradiction:

Improvedownstream equipment protectionVSAvoidnumber of processing equipment

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The bleed opening performs preliminary removal of oversized particles from the overflow stream before the stream is discharged to downstream equipment. By pre-removing harmful particles at the source, the need for additional downstream processing equipment is eliminated, protecting downstream equipment while avoiding increased system complexity.

Inventive Principle:

Principle #10Preliminary action

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 solution effectively reduces the number of oversized particles in the fine fraction, minimizing downstream damage and processing needs, while allowing for precise adjustment of particle proportions, thereby enhancing efficiency and reducing costs.

Implementation Method 1

By virtue of the configuration of the body the fluid and the particles entrained therein are subjected inter alia to centripetal and gravitational forces. This causes a separation of the particles based on particle size, weight and/or specific gravity, such that larger, heavier more dense particles move radially outwardly in the outer vortex

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

Methodology Applied

Scientific EffectGravitation: Gravitation

Data Source

PatentUS11806731B2Cyclonic separator

Publication Date: 2023.11.07 WEIR MINERALS AFRICA (PROPRIETARY) LIMITED

AI summary

A cyclonic separator (10) comprises a separation chamber (14), a feed inlet (16) leading into the separation chamber and an underflow discharge (18) leading from the separation chamber. The cyclonic separator further comprises a vortex finder which has an inlet end positioned in the separation chamber, an outlet end defining an overflow discharge, and a bleed opening (48) defined by the inlet and outlet ends of the vortex finder and through which a portion of an overflow stream can be bled from the vortex finder to remove oversized particles from the overflow stream.