Hydrocyclone Process for Slurry Concentration
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Solution Overview
Problem
Current methods for combining streams, solutions, and slurries often result in dilution effects or require expensive drying processes, and hydrocyclones are inefficient in concentrating suspended and dissolved particles effectively.
Innovation Solution
A process utilizing hydrocyclone equipment to combine solutions and slurries, resulting in a collected slurry with a higher total dry matter concentration of suspended and dissolved particles than the initial combined streams, with at least 90% of suspended particles and 10% of dissolved particles being recovered, and optionally using multiple hydrocyclone stages for enhanced concentration and clarification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If hydrocyclones are used to remove impurities from slurries, then contaminants are separated, but the dry matter concentration of the treated slurry decreases due to dilution
Solution Approach 1:
The patent combines a hydrocyclone for contaminant removal with a separate concentration unit (such as a membrane filter or centrifuge) to simultaneously achieve both contaminant separation and dry matter concentration enhancement. The treated slurry from the hydrocyclone is fed into the concentration unit which removes excess liquid and returns concentrated slurry, thereby merging two functions that normally produce conflicting outcomes.
2Quantity of substance
If conventional drying methods are applied to concentrate slurries, then dry matter concentration increases, but energy consumption and costs increase significantly
Solution Approach 1:
The patent employs mechanical separation methods such as membrane filtration or centrifugal separation instead of thermal drying. These hydraulic/mechanical methods use pressure gradients or centrifugal forces to separate liquid from solid particles, achieving concentration without the high energy input required by evaporative drying processes.
3Loss of substance
If multiple hydrocyclone stages are arranged in series for continuous countercurrent washing, then contaminant removal efficiency improves, but process complexity and equipment requirements increase
Solution Approach 1:
The patent implements a countercurrent washing system where the liquid stream is reused across multiple stages. The liquid exiting one hydrocyclone stage is fed into the previous stage, creating a cascading effect that enhances contaminant removal efficiency while minimizing fresh liquid consumption and reducing overall process complexity compared to parallel stage arrangements.
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 process effectively concentrates the dry matter content of the collected slurry, achieving a concentration up to 50% higher than simple mixing, reducing waste, and allowing for the reuse of dissolved particles and reaction aids, thereby improving efficiency and reducing costs.
Implementation Method 1
use is made of a plurality of hydrocyclone stages arranged in series or cascade for performing a continuous countercurrent washing process
Implementation Method 2
the collected slurry (B'') has a total dry matter concentration of the suspended particles (B') and dissolved particles (A') that is higher than the combined dry matter concentration of solution (A) and slurry (B)
Data Source
AI summary
The present invention concerns a process for preparing of slurries containing suspended and dissolved particles and a solution as well as a slurry are provided onto a hydrocyclone equipment, disk centrifuge or nozzle centrifuge equipment. The dry matter concentration in the collected slurry is higher than the concentration of the mixture of the slurry and the solution as such. The use of a hydrocyclone stage for this specific purpose is disclosed as well.