Lock Hopper Material Transfer for Pressurized Systems
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Solution Overview
Problem
Existing methods for supplying materials to pressurized systems, particularly those with multiple receiving units, are inefficient in maintaining consistent pressure and flow, leading to suboptimal material distribution and processing.
Innovation Solution
A system and method utilizing two or more lock hoppers and a circulation loop to pressurize and transfer solid materials from a low-pressure zone to a high-pressure zone, allowing for simultaneous or staggered operation of lock hoppers to maintain continuous or semi-continuous material flow to multiple receiving units, with fluid management and vapor venting to control pressure and facilitate discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single lock hopper is used to supply material to a pressurized system, then the system structure is simple, but the material flow continuity and throughput are insufficient
Solution Approach 1:
The system divides the material supply function into multiple lock hoppers (first lock hopper, second lock hopper) that operate in parallel or sequence. Each lock hopper independently processes and pressurizes material batches, enabling continuous material flow to multiple receiving units while maintaining manageable individual unit complexity
Solution Approach 2:
The circulation loop serves multiple functions: it receives pressurized material from any lock hopper, distributes material to multiple receiving units (first receiving unit, second receiving unit), and maintains system pressure. This multi-functional component enables the system to handle multiple material streams efficiently
2Duration of action of moving object
If multiple lock hoppers operate simultaneously to increase throughput, then material flow continuity improves, but pressure control and fluid management become more complex
Solution Approach 1:
The system maintains continuous material flow by coordinating multiple lock hoppers to operate in overlapping cycles. While one lock hopper is pressurizing material, another is discharging to the circulation loop, ensuring uninterrupted supply to receiving units and eliminating idle time in the material flow process
Solution Approach 2:
The system uses pressure sensors and control valves to monitor and adjust pressure in real-time within the circulation loop and each lock hopper. This feedback mechanism automatically balances pressure across multiple operating units, maintaining stable operation without manual intervention despite the complexity of simultaneous pressurization events
3Speed
If rapid pressurization is applied to increase material discharge speed, then throughput improves, but pressure fluctuations and material distribution uniformity deteriorate
Solution Approach 1:
The system applies pressurization in controlled periodic cycles rather than continuous rapid pressure increases. Each lock hopper follows a standardized pressurization-discharge cycle with controlled timing, allowing pressure to stabilize at target levels before discharge begins, ensuring consistent material concentration while maintaining high throughput through coordinated cycling of multiple hoppers
Solution Approach 2:
The circulation loop is pre-filled with fluid and pressurized to the target operating pressure before material discharge begins. This preliminary pressurization ensures that when material is discharged from lock hoppers, it enters a already-pressurized environment, preventing pressure fluctuations and maintaining uniform material concentration throughout the system
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
This approach ensures efficient and consistent pressurization and transfer of materials to pressurized systems, reducing fluctuations in material concentration and enabling continuous or semi-continuous operation with improved throughput and pressure management.
Implementation Method 1
transferring material from a low pressure zone to a high pressure zone
Implementation Method 2
allowing vapor to enter the first lock hopper to facilitate the releasing of fluid and depressurization of the first lock hopper
Data Source
AI summary
Methods and systems for transferring feed materials between zones having substantially different pressures, where the transfer can be continuous or semi-continuous. The methods and systems include a plurality of lock hoppers to receive feed material from a low pressure zone and pressurize it with fluid to a pressure of a high pressure zone. The pressurized material can be discharged to a circulation loop, which carries the pressurized material to one or more receiving unit(s) of a pressurized system. At least some feed material remains in the receiving unit(s) and at least a portion of the fluid exits to become part of the circulation loop. After discharge, the lock hoppers can be depressurized so the next pressurization cycle can begin with additional feed material. The lock hoppers can be operated in a time-staggered manner to provide continuous or semi-continuous transfer of material.