Double-Roller System for Non-Fibrous Solid Separation
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Solution Overview
Problem
Existing methods are inadequate for effectively separating liquids from non-fibrous solids, such as crushed ores and solid precipitates, as these materials do not interlock and form sheets, making it difficult to utilize traditional double-roller systems for solid-liquid separation.
Innovation Solution
A double-roller system is employed to compress non-fibrous solid particles, using rollers with interlocking teeth or concave pockets to agglomerate, clump, or sinter the solids, thereby expelling liquids from interstitial spaces, and separate the solids from the liquid phase, potentially using thickeners or filters with sealed elevated pressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional double-roller systems are used for solid-liquid separation, then fibrous materials can be effectively dehydrated, but non-fibrous solids cannot be separated because they do not interlock and form sheets
Solution Approach 1:
The invention changes the operating parameters of the double-roller system by applying high compression forces (up to 1000 psi) and controlling the rotational speed differential between rollers. This transforms the mechanism from a gentle squeezing action suitable for fabrics to a high-pressure compression action that forces non-fibrous solids to agglomerate and expel liquids, thereby expanding adaptability while maintaining reliability
Solution Approach 2:
The invention introduces dynamic elements including variable roller speeds, adjustable compression forces, and movable roller positions. The rollers can rotate at different speeds to create shearing motion that enhances agglomeration, and the compression force can be dynamically adjusted based on material properties, enabling effective separation of non-fibrous solids while preserving the core double-roller mechanism
2Productivity
If high compression is applied to non-fibrous solids to expel liquids, then separation efficiency improves, but energy consumption and equipment complexity increase
Solution Approach 1:
The invention applies compression force selectively and progressively rather than uniformly. The double-roller system applies partial compression in stages, with the first roller pre-compressing the slurry and the second roller completing the dewatering. This staged approach achieves high separation efficiency while reducing peak energy demands compared to single-stage high-pressure compression
Solution Approach 2:
The invention utilizes the self-weight of the slurry and the natural agglomeration tendency of non-fibrous solids under compression. The system is designed so that the material's own properties facilitate the separation process, reducing the need for excessive external energy input. The rollers simply provide the minimal compression needed to trigger the material's natural dewatering behavior
3Stress or pressure
If double-roller systems are designed with interlocking teeth for non-fibrous solids, then compression effectiveness improves, but device complexity increases
Solution Approach 1:
The invention segments the compression function across two separate rollers rather than requiring a single complex roller. Each roller can have simpler tooth patterns, and together they provide the cumulative compression effect. The slurry passes between the rollers, receiving compression from both surfaces, which achieves high pressure while keeping individual roller structures relatively simple
Solution Approach 2:
The double-roller system performs multiple functions with a relatively simple structure: the first roller provides pre-compression and alignment, the second roller provides final dewatering, and both rollers simultaneously convey the material through the system. This multi-functionality is achieved with minimal additional complexity compared to a single-roller design
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 system efficiently separates non-fibrous solids from liquids by compressing and agglomerating the solids, reducing the liquid content within the solids and producing a product stream with minimal residual liquid, suitable for various process fluids including water, hydrocarbons, and cryogenic liquids.
Implementation Method 1
A portion of the process fluid is compressed through the double-roller system to produce a compressed portion of the suspended solid
Implementation Method 2
The compressing step may further comprise agglomerating, clumping, fusing, sintering, pressing, or combinations thereof the suspended solid into larger particles
Implementation Method 3
The first roller and the second roller comprise partially-interlocking teeth, wherein the suspended solid is compressed between the teeth of one roller and an outer surface of another roller
Implementation Method 4
reducing the process liquid from becoming bound in the pores in the larger particles
Data Source
AI summary
A method for separating solids from liquids is disclosed. A double-roller system is provided. A process fluid is provided to the double-roller system. The process fluid comprises a suspended solid and a process liquid. The suspended solid comprises non-fibrous solid particles. A portion of the process fluid is compressed through the double-roller system to produce a compressed portion of the suspended solid. A product stream and a dilute fluid stream are separated. The product stream comprises a compressed portion of the suspended solid and a first portion of the process liquid. The dilute fluid stream comprises a second portion of the suspended solid and a second portion of the process liquid.