Filterless Separator for Milling Gas Stream Particle Removal
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Solution Overview
Problem
Filters in milling machines become clogged quickly due to high dust loads, requiring frequent maintenance and large filter sizes, which is inefficient and costly.
Innovation Solution
A filterless separator system that uses a cyclone separator and a deflecting baffle to separate particles from the processing gas stream, with only a small portion being filtered and recirculated, extending maintenance intervals and allowing for smaller filter sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If large filters are applied to handle high dust loads, then the filter capacity is sufficient, but the device complexity and cost increase
Solution Approach 1:
The processing gas stream is divided into two separate streams: a first stream that is filtered and a second stream that bypasses the filter. This segmentation allows the filter to handle only a portion of the total dust load, reducing the required filter size and complexity while maintaining overall system effectiveness.
Solution Approach 2:
The invention extracts or removes a portion of the processing gas stream (the second stream) from the filtration path. By taking out this bypass stream that contains back-flushing gas, the system reduces the amount of gas and associated dust that must pass through the filter, thereby reducing filter size requirements.
2Reliability
If filters are used to remove all particles, then the gas is thoroughly cleaned, but the filters become clogged quickly requiring frequent maintenance
Solution Approach 1:
The gas stream is segmented into a first stream that undergoes filtration and a second stream that bypasses it. This segmentation ensures that the filter processes only a manageable portion of the total gas flow, reducing clogging speed and extending maintenance intervals while the combined streams maintain overall cleaning effectiveness.
Solution Approach 2:
Instead of filtering 100% of the processing gas stream, the system applies partial action by filtering only a portion (the first stream). This partial filtration approach is sufficient to maintain gas cleanliness standards while significantly reducing the burden on the filter and extending maintenance intervals.
3Reliability
If all processing gas is filtered, then maximum particle removal is achieved, but the filter size and cost increase significantly
Solution Approach 1:
The processing gas stream is divided into a first stream directed through the filter and a second stream that bypasses it. This segmentation allows the filter to be sized for only a portion of the total gas flow, significantly reducing filter size and cost while maintaining adequate particle removal efficiency for the overall system.
Solution Approach 2:
The system employs partial action by filtering only a fraction of the total processing gas stream rather than all of it. This approach achieves sufficient particle removal efficiency for operational requirements while avoiding the excessive cost and size associated with filtering the entire gas flow.
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
Significantly extends filter maintenance intervals and reduces the size of filters needed by filtering only the portion of the gas stream that requires it, minimizing clogging and operational costs.
Implementation Method 1
it comprises a filterless separator which reduces the particle content of the processing gas
Implementation Method 2
a filterless separator element for reducing the particle content of the processing gas
Data Source
AI summary
A separator for separating solid particles from a processing gas stream that has been fed repeatedly through a work machine, wherein the separator includes a processing gas inlet through which particle-laden processing gas emitted from the work machine is fed into the separator, and a filterless separator element to reduce the particle content of the processing gas and a processing gas outlet to discharge the processing gas with its reduced particle content to the work machine, the separator including a secondary stream filter, which filters a smaller portion of the processing gas, and a secondary outlet, connected thereto, which ejects the filtered secondary stream of processing gas.