Hydrocyclone Underflow Nozzle with Sensor-Controlled Water Injection
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Solution Overview
Problem
Existing hydrocyclone systems face challenges in accurately separating solid particles by size, leading to incorrect discharge of coarse grains into the underflow and fine grains into the overflow, due to physical limitations and inefficiencies in water supply methods which cause dilution and disrupt separation processes.
Innovation Solution
A hydrocyclone arrangement with a tangentially oriented underflow nozzle and a sensor system for monitoring jet shape, featuring a controlled supply of additional water through nozzle-like bores with radial and axial angles of attack, which generates a counter-flow classification to enhance separation by reducing fine grain discharge and improving coarse grain separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If additional water is supplied into the conical part of the hydrocyclone, then the dilution effect reduces fine grain concentration in the underflow, but the coarse grain separation is disrupted and more coarse grains are pushed into the upper reaches
Solution Approach 1:
The patent applies local quality by introducing additional water at a specific location (transition area from conical to cylindrical part) rather than uniformly throughout the conical part. The nozzle-like bores are positioned to deliver water precisely where it can dilute fine grains without disrupting the centrifugal separation of coarse grains, creating a localized modification that benefits one aspect without harming another
Solution Approach 2:
The patent employs preliminary action by stabilizing the discharge jet shape through controlled water supply before the final separation occurs. The sensor system detects jet shape changes and adjusts water supply in advance to maintain optimal separation conditions, preventing incorrect discharge before it happens rather than correcting it afterward
2Quantity of substance
If the discharge jet shape changes from strand to screen, then the solids content in the underflow increases, but coarse grain is incorrectly discharged into the fine grain discharge
Solution Approach 1:
The patent implements feedback by using a sensor system to continuously monitor the discharge jet shape and adjust the additional water supply accordingly. When the jet shape deviates from the optimal strand form, the sensor detects this change and modifies water supply to restore proper separation, creating a closed-loop control system that maintains both high solids content and high separation precision
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the flow rate and distribution of additional water based on detected jet shape parameters. The control system modifies water supply parameters (flow rate, distribution pattern) to maintain the discharge jet in the optimal strand shape regime, thereby simultaneously achieving high solids content and accurate separation
3Productivity
If multiple hydrocyclones are coupled together, then the overall capacity is increased, but the structural outlay increases
Solution Approach 1:
The patent applies merging by combining multiple hydrocyclone units into a battery arrangement where they share common infrastructure (inlet distribution system, overflow collection chamber, underflow collection system). This allows the system to achieve increased overall capacity while minimizing structural outlay through shared components rather than duplicating entire hydrocyclone assemblies
4Manufacturing precision
If a cylindrical spacer with tangential washing water feeding is inserted, then fine particle concentration is reduced through dilution, but the dilution occurs in an undesired manner and coarse grain separation is affected
Solution Approach 1:
The patent applies local quality by positioning nozzle-like bores at the specific transition area from conical to cylindrical part of the underflow nozzle. This localized water introduction point ensures dilution occurs precisely where fine grains are concentrated without interfering with the centrifugal separation zone, achieving selective dilution that reduces fine particle discharge while preserving coarse grain separation
Solution Approach 2:
The patent employs copying by using nozzle-like bores that replicate the beneficial dilution effect of the cylindrical spacer approach while avoiding its harmful side effects. The bores are designed to introduce water in a controlled manner that mimics the successful dilution principle but eliminates the unwanted disruption to coarse grain separation that occurred with the full cylindrical spacer
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 solution achieves improved separation efficiency by stabilizing the discharge jet shape and reducing incorrect grain discharge, allowing for better product yields and quality control with minimal modifications to existing systems and reduced operational effort.
Implementation Method 1
Known hydrocyclones have a tangential inlet of the feed pulp into a cylindrical-conical process space and two discharges of the separation products into a fine-grain upper course and a coarse-grain lower course
Implementation Method 2
a sensor system for detecting the jet shape or the jet change at the coarse grain discharge
Implementation Method 3
a controlled supply of additional water through nozzle-like bores with radial and axial angles of attack, which generates a counter-flow classification to enhance separation
Data Source
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AI summary
The invention relates to a hydrocyclone arrangement comprising an especially tangential infeed of the feed pulp, an overflow (19) for discharging fine grains, a conical/cylindrical underflow (1) for discharging coarse grains, and a sensor system (4, 11) for detecting the jet shape or the change in shape of the jet at the coarse-grained discharge end. According to the invention, means (3) for feeding additional water in a directed manner are provided in the area of the transition from the conical part of the underflow to the cylindrical part of the underflow. Furthermore, a throttle valve (7) is optionally formed on the overflow in order to influence the solid flow to the underflow in such a way that a single-jet discharge state approaching the state where the jet is dispersed in different directions is set when a transition from the single-jet discharge (5.1) to the dispersed-jet discharge (5.2) is detected at the underflow after the additional water feeding process has been activated.