Lock Hopper Pressurization Using Parallel Valves and Laval Tuyeres
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Solution Overview
Problem
In upstream pneumatic conveying lines, especially in dense phase conveying and against significant back-pressure, existing lock hoppers require long pressurizing times and are prone to material compacting, noise, and equipment dimensioning issues due to high initial gas velocities and pressure differences.
Innovation Solution
A process using a valve arrangement with at least two valves connected to downstream Laval tuyeres, allowing for controlled gas flow rates to reduce pressurizing time by up to 70% without compacting the material, achieved through a timed or pressure-based operating sequence, and optionally using differently sized Laval tuyeres for further adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single valve with Laval tuyere is used for pressurizing, then equipment complexity is reduced, but pressurizing time becomes excessively long and material compacting occurs
Solution Approach 1:
The single valve system is segmented into multiple parallel valves (at least two), each equipped with its own Laval tuyere. This segmentation allows simultaneous gas flow paths to operate in parallel, dramatically reducing pressurizing time while maintaining controlled gas velocities to prevent material compacting.
Solution Approach 2:
The patent employs multiple valves that can be opened partially or fully in a sequenced manner. By controlling the opening sequence and degree of opening for each valve, the system achieves excessive gas flow capacity when needed while maintaining precise control to avoid harmful effects like material compacting.
2Productivity
If high initial gas flow rate is used for rapid pressurizing, then pressurizing time is reduced, but material compacting occurs and flowability is lost
Solution Approach 1:
The valve arrangement enables dynamic control of gas flow rates during the pressurizing process. By opening multiple valves in a timed sequence and controlling their opening degrees, the system adapts gas flow rates to match the pressurizing stage, achieving high initial flow rates for rapid pressurizing then reducing flow rates to prevent material compacting.
Solution Approach 2:
The pressurizing process uses periodic action through sequenced valve opening. Different valves are opened at different times in a controlled sequence, creating periodic gas flow pulses that efficiently pressurize the material while allowing intervals that prevent excessive gas velocities and material compacting.
3Productivity
If high pressure difference is maintained for rapid pressurizing, then pressurizing efficiency increases, but noise levels increase and equipment dimensioning becomes problematic
Solution Approach 1:
The pressure difference is segmented across multiple parallel valve-Laval tuyere paths. Each path handles a portion of the total pressure differential, distributing the stress and noise generation across multiple controlled channels rather than concentrating it in a single high-stress path.
Solution Approach 2:
The system dynamically changes operating parameters including pressure differential and gas flow rate by controlling valve positions. By adjusting these parameters in real-time based on pressurizing stage, the system maintains high efficiency while preventing excessive noise and equipment stress that would result from continuously high pressure differences.
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 process significantly reduces pressurizing time, alleviates noise and equipment dimensioning issues, and maintains material flowability by controlling gas flow rates, allowing for efficient and rapid pressurization of bulk materials in lock hoppers.
Implementation Method 1
A valve arrangement with at least two valves connected to downstream Laval tuyeres, allowing for controlled gas flow rates
Implementation Method 2
The amount of process gas needed to pressurize the bulk material inside the hopper is conditioned by the inner volume of the hopper, the overpressure level to be achieved, the filling level of the bulk material and the void fraction of the bulk material
Data Source
AI summary
A process for pressurizing bulk material in an apparatus for pressurizing bulk material in a hopper; wherein the hopper is configured as a lock hopper containing a bulk material, wherein the apparatus comprises a source of pressurized gas, lines to convey the pressurized gas from the source of pressurized gas to one or more inlets of the lock hopper, a valve arrangement arranged in the lines, wherein the process is characterized in that said valve arrangement comprises at least two valves arranged in parallel, each valve being connected to a downstream Laval tuyere, and in that said valves are controlled to open in an operating sequence to provide pressurizing gas with an adjusted gas flow rate to the lock hopper.