Hydrocyclone Reject Slurry Dilution to Prevent Outlet Plugging

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Solution Overview

Problem

Hydrocyclonic cleaners are susceptible to plugging at the reject outlet due to high slurry consistency and concentration of solid debris, leading to re-introduction of contaminants into the cleaner system, which reduces separation efficiency and causes disruptions in downstream processes.

Innovation Solution

A cleaner system with a dilution device that includes a dilution water hydrocyclone and a flow director to establish a cyclonic flow pattern before mixing with the reject slurry, reducing turbulence and preventing the reintroduction of solid debris and contaminants.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If dilution water is added to the reject slurry proximate the underflow outlet of the hydrocyclone, then plugging at the underflow outlet is reduced, but turbulent mixing causes solid debris and contaminants to reverse flow back up into the hydrocyclone cleaner

Engineering Contradiction:

Improveplugging preventionVSAvoidre-introduction of contaminants

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

A flow director is introduced as an intermediary component between the dilution water inlet and the reject slurry inlet. This flow director establishes a controlled cyclonic flow pattern for the dilution water before it contacts the reject slurry, thereby mediating the mixing process to reduce turbulence and prevent contaminant re-introduction while still achieving effective dilution to prevent plugging.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The flow director is designed to establish a cyclonic flow pattern of the dilution water before the dilution water contacts the reject slurry. This preliminary action of creating controlled flow ensures that when mixing occurs, it is done in a controlled manner that prevents turbulent reverse flow of contaminants back into the hydrocyclone cleaner.

Inventive Principle:

Principle #10Preliminary action

2Object-generated harmful factors

If the flow director restricts flow of dilution water directly from the dilution water inlet to the reject slurry inlet, then contact between dilution water and reject slurry is spaced apart, but flow restriction may reduce dilution effectiveness

Engineering Contradiction:

Improvecontaminant re-introduction preventionVSAvoiddilution water mixing efficiency

Core Design Contradiction:

Object-generated harmful factorsVSQuantity of substance

Solution Approach 1:

The flow director utilizes the dimensional space within the hydrocyclone by creating a cyclonic flow pattern that moves dilution water along a curved path before it reaches the reject slurry inlet. This dimensional approach allows the dilution water to travel a longer effective path and mix more thoroughly with the reject slurry while still being spaced apart from the inlet, thus preventing contaminant re-introduction without compromising dilution effectiveness.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 effectively prevents plugging and re-introduction of contaminants, maintaining cleaner efficiency and reducing disruptions in downstream processes.

Implementation Method 1

The flow director may direct the dilution water to establish a cyclonic flow pattern before contacting the dilution water with the reject slurry

Methodology Applied

Scientific EffectCyclonic flow: Cyclone Separation

Implementation Method 2

The cyclonic fluid flow produced by the hydrocyclone can cause greater-density solid contaminants and debris to flow outward through centrifugal forces to the outer wall of the hydrocyclone while the lesser-density cleaned slurry migrates towards the center

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Data Source

PatentUS12421661B2Slurry cleaner systems with cleaner dilution devices and methods of cleaning slurries therewith

Publication Date: 2025.09.23 KADANT BLACK CLAWSON LLC

AI summary

A cleaner system for removing solid debris and contaminants from a feed slurry includes a cleaner operable to separate a feed slurry into an accepted slurry and a reject slurry, the reject slurry including the solid debris and contaminants. The cleaner system further includes a dilution device fluidly coupled to a reject outlet of the cleaner. The dilution device includes a dilution water hydrocyclone having a dilution water inlet, a cyclonic flow section, an underflow outlet at a downstream end of the cyclonic flow section, and a reject slurry inlet in a top of the dilution water hydrocyclone. The dilution water hydrocyclone further includes a flow director disposed between the dilution water inlet and the reject slurry inlet and operable to direct the flow of dilution water from the dilution water inlet in at least an axial direction towards the cyclonic flow section.