Impact-Wall Separator Layout for Abrasion-Free Pneumatic Conveying
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Solution Overview
Problem
Conveying systems experience significant abrasion damage due to high conveying speeds, particularly when handling plastics with glass fiber proportions, leading to rapid wear of components like ceramic or glass inserts, especially in cyclone-based separations.
Innovation Solution
A separator design featuring an impact wall and cover wall configuration within a housing, forming a conveyed material cushion that absorbs kinetic energy, minimizing material impact and preventing abrasion, while ensuring reliable separation of conveyed material from the conveying medium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high conveying speeds are used to increase productivity, then material transport efficiency is improved, but abrasion damage to line sections and separator components increases significantly
Solution Approach 1:
The patent applies beforehand cushioning by introducing a protective layer of conveyed material that accumulates on the impact wall before the actual high-speed material flow arrives. This cushion layer absorbs the kinetic energy of incoming material, preventing direct impact and abrasion on the impact wall and separator components. The cushion is maintained continuously during operation to ensure ongoing protection against wear damage.
2Reliability
If cyclone action is used to separate conveyed material from conveying medium, then separation efficiency is improved, but abrasion damage at line sections increases due to high conveying speeds
Solution Approach 1:
The patent introduces an intermediary protective layer consisting of conveyed material itself that accumulates on the impact wall. This intermediary layer acts as a buffer between the high-speed conveyed material and the separator components, reducing direct contact and abrasion. The cushion layer maintains separation efficiency while protecting the cyclone separator and line sections from wear damage caused by high conveying speeds.
3Device complexity
If the impact wall is directly exposed to the conveying medium/conveyed material mixture, then separation function is simplified, but abrasion damages occur rapidly even with high quality materials
Solution Approach 1:
The patent implements self-service by using the conveyed material itself to create and maintain the protective cushion on the impact wall. The system automatically generates its own protection mechanism without requiring external intervention or complex additional components. The conveyed material continuously replenishes the cushion layer, ensuring ongoing protection of the impact wall while maintaining the simplicity of the separator structure.
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 effectively reduces or eliminates abrasion damage by allowing the conveyed material to form a cushion that covers the impact wall, maintaining separation efficiency even at high conveying speeds, thus protecting components and ensuring minimal wear.
Implementation Method 1
The conveyed material which is conveyed via the feed line into the container impacts on the impact wall so that the kinetic energy of the conveyed material is squelched
Implementation Method 2
The separation of conveying medium and conveyed material in case of suction conveyance can also be achieved by means of a cyclone action in which the feed line is provided tangentially in a housing of the separator
Implementation Method 3
The separator has a filter or screen through which the conveying medium can pass but the conveyed material is retained however
Data Source
AI summary
The invention relates to a separator for separating a conveyed medium, preferably air, from a conveyed material (4). Said separator comprises a container (1) which has at least one feed line (3) for the conveyed medium/conveyed material mixture, at least one outlet for the conveyed material (4), and at least one outlet (8) for the conveyed medium. In order to avoid abrasion damage at high conveying speeds or to ensure that said abrasion damage occurs at most only to a small extent, while nevertheless ensuring that the conveying medium and conveying material are reliably separated, an impact wall (14), which adjoins a cover wall (15) at an angle thereto, is located in the housing (1) opposite and at a distance from the outlet end (10) of the feed line (3) in the inflow direction (13) of the conveyed medium/conveyed material mixture. Said impact wall covers the inflow path of the conveyed medium/conveyed material mixture, blocking it from the outlet (8) for the conveyed medium. The conveyed material (4) hits the impact wall (14), which causes the kinetic energy of the conveyed medium to dissipate. The speed of the conveyed medium reduces very quickly after exiting the feed line (13), meaning that it cannot entrain any conveyed material.