Energy Diffusion Sealing Ring for Hydrocyclone Wear

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Solution Overview

Problem

Hydrocyclones and slurry pumps face significant wear and erosion due to abrasive particles, particularly in areas with high velocities and pressures, leading to premature maintenance and reduced operational life, as conventional seals and gaskets fail to effectively prevent slurry escape and casing blowout.

Innovation Solution

An energy diffusion sealing ring is introduced, comprising a resilient suspension matrix with closely-spaced hard inserts, which diffuses the energy of abrasive slurry by allowing it to wear away the polymer or elastomer, creating interstices that slow down radial velocities and dissipate kinetic energy, thereby protecting less wear-resistant housing materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional seals and gaskets are used to prevent slurry escape, then sealing function is provided, but they fail under high velocities and pressures leading to premature wear and casing blowout

Engineering Contradiction:

Improvesealing effectivenessVSAvoidservice life

Core Design Contradiction:

ReliabilityVSDuration of action of stationary object

Solution Approach 1:

The patent changes the physical parameters of the sealing material by using a resilient matrix with embedded hard particles, transforming it from a homogeneous soft material to a composite structure that can withstand high-velocity abrasive slurry while maintaining sealing effectiveness under pressure

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a composite sealing ring comprising a resilient matrix material embedded with hard particles, combining the flexibility and sealing capability of soft materials with the wear resistance of hard materials to prevent both slurry escape and abrasive wear

Inventive Principle:

Principle #40Composite materials

2Strength

If ceramic liners are used to reduce abrasion, then wear resistance is improved, but gaps form at joints due to non-resilient nature causing slurry penetration and erosion

Engineering Contradiction:

Improveabrasion resistanceVSAvoidjoint sealing

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs a resilient sealing ring that can deform and conform to the joint surfaces, creating a flexible seal that accommodates manufacturing tolerances and thermal expansion while preventing slurry penetration at the joints between ceramic liners

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The sealing ring uses a composite structure with a resilient matrix and hard embedded particles, providing both the flexibility needed to seal gaps and the hard particles needed to resist abrasive wear from the slurry

Inventive Principle:

Principle #40Composite materials

3Reliability

If tight joint gap tolerances are enforced to prevent slurry escape, then sealing is improved, but manufacturing complexity and cost increase significantly

Engineering Contradiction:

Improvejoint sealingVSAvoidmanufacturing tolerance

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The resilient sealing ring acts as a compliant element that absorbs dimensional variations and manufacturing tolerances, allowing larger gap tolerances in the rigid ceramic liners while still achieving effective sealing through the flexible material's ability to deform and conform to the joint surfaces

Inventive Principle:

Principle #30Flexible shells and thin films

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 energy diffusion sealing ring significantly reduces wear and maintenance needs, extends equipment life, and enhances safety and performance by effectively arresting erosion in critical areas like the vortex finder and pump components, while being compatible with existing units and easy to refurbish.

Implementation Method 1

allowing it to wear away the polymer or elastomer

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 2

diffuses the energy of abrasive slurry by allowing it to wear away the polymer or elastomer, creating interstices that slow down radial velocities and dissipate kinetic energy

Methodology Applied

Scientific EffectEnergy diffusion:

Implementation Method 3

protecting less wear-resistant housing materials

Methodology Applied

Scientific EffectWear resistance: Wear

Data Source

PatentEP2742226B1Energy diffusing wear ring and methods thereof

Publication Date: 2016.06.08 F L SMIDTH & CO AS

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AI summary

An energy diffusion sealing ring for use with a hydrocyclone or pump is provided. The energy diffusion sealing ring comprises a sacrificial suspension matrix comprised of a polymer, elastomer, or combination thereof, and a number of packed inserts suspended in the matrix. The matrix serves as delivery means for the inserts into one or more recessed portions. The inserts comprise a hard material (e.g., ceramic or carbide) and form wear bodies which slow and dissipate kinetic energy of escaping slurry by way of creating paths of resistance. As the suspension matrix erodes over time, a plurality of interstices between the inserts are formed. Escaping slurry slows as it traverses three-dimensional serpentine paths defined by said interstices, thereby reducing its potential to wear surrounding components. Methods for manufacturing an energy diffusion sealing ring and for dissipating the energy of slurry are also disclosed.