Integrated Separator for Cement Plants
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Solution Overview
Problem
Cement plant separators, both static and dynamic, contribute significantly to the high construction costs due to their non-compact design and layout, leading to increased building height.
Innovation Solution
An integrated separator combining a static and dynamic separator with a compact layout, featuring a de-agglomeration cone, inverted frustum cones, and a main air supply duct, arranged to minimize height and eliminate unnecessary ducts, allowing for efficient particle separation while reducing the overall plant height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional static and dynamic separators are used separately, then separation function is provided, but building height increases and construction cost increases
Solution Approach 1:
The patent combines a static separator and a dynamic separator into a single integrated separator unit. The static separator section processes material first, then the fine particles are conveyed to the dynamic separator section above it. This merging of two separate separator functions into one compact unit reduces the overall building height and eliminates the need for separate separator structures, directly addressing the contradiction between providing separation function and minimizing construction cost and building height.
Solution Approach 2:
The dynamic separator is positioned in the uppermost part of the integrated separator, with the static separator below it. The conveying duct connects the bottom of the dynamic separator to the top of the static separator, creating a nested vertical arrangement. This nesting approach allows both separator types to occupy overlapping vertical space efficiently, minimizing the total building height while maintaining both separation functions.
2Ease of operation
If separators are arranged with necessary ducts and conveying systems, then material transport is enabled, but layout becomes non-compact and building height increases
Solution Approach 1:
The conveying duct is integrated directly into the integrated separator structure, connecting the static and dynamic separator sections. This merging of the conveying function into the separator body eliminates the need for external conveying systems and unnecessary ducts, simplifying the overall layout while maintaining material transport capability.
3Reliability
If separate static and dynamic separators are installed, then particle separation is achieved, but the layout height increases construction cost
Solution Approach 1:
The integrated separator merges static and dynamic separator functions into a single unit, maintaining the separation efficiency of both types while reducing construction cost through compact design. The static separator handles coarse separation, and the dynamic separator handles fine separation, with both functions integrated in one 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 compact integrated separator design reduces cement plant construction costs by minimizing building height without compromising separation efficiency, optimizing the layout and reducing duct lengths.
Implementation Method 1
a de-agglomeration cone (5) and a first inverted frustum cone (6)... the de-agglomeration cone being arranged adjacent to the first inverted frustum cone (6) by holding rods (18)
Implementation Method 2
a static separator (2)... the static separator (2) comprises an outer housing (11), a de-agglomeration cone (5) and a first inverted frustum cone (6)
Implementation Method 3
a main air supply duct (16) configured for supplying external air to the static separator (2)
Data Source
AI summary
The invention relates to an integrated separator (1) for separating coarse and fine particles in a cement making process, said integrated separator (1) comprising a static separator (2) and dynamic separator (3), said dynamic separator (3) being arranged in an uppermost position relative to said static separator (2) and said static separator (2) comprising an outer housing (11); a de-agglomeration cone (5) and a first inverted frustum cone (6), said de-agglomeration cone [5] arranged adjacent to said first inverted frustum cone (6) by holding rods (18), said holding rods (18) are connected to said inverted first frustum of cone (6).