Lock Hopper Pressurization via Segmented Gas Injection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for pressurizing bulk material in lock hoppers require lengthy pressurizing times, lead to equipment dimensioning issues, and generate noise nuisances, especially when operating at high pressures.
Innovation Solution
A process and apparatus that control the pressurizing gas flow rate to a lock hopper at a constant preset volume flow rate, reducing pressurizing time by up to 70% and minimizing equipment wear and noise, while maintaining safe and efficient operation without compacting the bulk material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressurizing gas is supplied at high flow rate to reduce pressurizing time, then productivity is improved, but gas velocity increases causing bulk material compaction and equipment wear
Solution Approach 1:
The pressurizing gas supply is divided into multiple injection points distributed throughout the hopper volume. Instead of single high-velocity injection, gas is supplied at several locations simultaneously at reduced individual flow rates, achieving effective pressurization without excessive local gas velocities that would compact the bulk material.
Solution Approach 2:
Different regions of the hopper receive pressurizing gas at optimized local flow rates. The gas injection characteristics are tailored to local requirements, ensuring adequate pressurization throughout the bulk material volume while maintaining gas velocities below compaction thresholds at each specific injection point.
2Productivity
If pressurizing gas flow rate is increased to reduce pressurizing time, then productivity is improved, but equipment wear increases
Solution Approach 1:
The total pressurizing gas flow is segmented into multiple smaller streams injected at different locations. This distribution reduces the velocity and erosive impact at each injection point and along the gas supply lines, thereby minimizing equipment wear while maintaining effective pressurization speed through coordinated multi-point injection.
3Productivity
If pressurizing gas flow rate is increased to reduce pressurizing time, then productivity is improved, but noise levels increase
Solution Approach 1:
The pressurizing gas flow is divided into multiple lower-velocity streams injected simultaneously at different points. This segmentation reduces the noise generated by gas flow through the supply lines and injection devices, as noise level is related to gas velocity, while the combined effect of multiple injection points achieves the required pressurization speed.
4Object-affected harmful factors
If hopper volume is increased to maintain constant pressurizing gas flow rate, then gas velocity is reduced preventing compaction, but hopper size increases
Solution Approach 1:
Instead of increasing hopper volume, the solution segments the gas supply into multiple injection points distributed within the existing hopper volume. This allows maintaining constant or even reduced total gas flow while achieving effective pressurization throughout the bulk material without requiring a larger hopper.
Solution Approach 2:
The gas injection approach transitions from a single-point or limited-point injection to a distributed three-dimensional network of injection points throughout the hopper volume. This spatial distribution enables effective pressurization with lower individual and total gas flows, avoiding bulk material compaction without increasing hopper size.
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
Significantly reduces pressurizing time, decreases equipment wear, and lessens noise levels without increasing gas velocity or requiring re-dimensioning of existing components, ensuring continuous and efficient operation of lock hoppers.
Implementation Method 1
the opening position of said (controllable) valve is controlled to provide pressurizing gas to the lock hopper at a preset constant gas volume flow rate
Implementation Method 2
Pressurizing of the bulk material inside the lock hopper is performed by injecting pressurized process gas into the bulk material
Implementation Method 3
the process gas may be accumulated in a buffer vessel for pressurizing gas. The buffer vessel is continuously filled with pressurizing gas supplied from the supply main at a reduced flow rate, and then periodically, each time a lock hopper is to be pressurized, emptied at a large flow rate into the lock hopper
Data Source
Figure 1~2
Figure 3
AI summary
A process for pressurizing bulk material in a hopper; wherein the hopper is configured as a lock hopper (29) containing a bulk material, a source of pressurized gas, lines (22, 26, 28) to convey the pressurized gas from the source to one or more inlets (30) of the lock hopper, a valve arranged in the lines, wherein the opening position of said valve (34, 35) is controlled to provide pressurizing gas to the lock hopper at a preset constant gas volume flow rate.