Mechanically Induced Vortex Separator for Low-Pressure-Loss Air Streams
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Solution Overview
Problem
Existing cyclone separators require high inlet velocity and high pressure loss, limiting their efficiency and applicability to specific flow rates and pressure conditions.
Innovation Solution
A device utilizing a mechanically induced horizontal vortex within a vertical cylindrical or slightly conical body, where gases enter from the bottom and are subjected to centrifugal forces, allowing separation of particles regardless of flow speed and pressure conditions, with a horizontally rotating impeller generating the vortex.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high inlet velocity is used in conventional cyclones, then separation efficiency is improved, but pressure loss increases
Solution Approach 1:
The patent applies preliminary action by using a pre-vortex chamber that pre-rotates the gas stream before it enters the separation chamber. This preliminary vortex formation allows the main separation process to occur at lower inlet velocities, thereby maintaining separation efficiency while reducing pressure loss. The pre-vortex chamber prepares the gas stream in advance, reducing the energy penalty of the separation process.
Solution Approach 2:
The cyclone separator is segmented into distinct functional chambers: a pre-vortex chamber for initial rotation and a separation chamber for particle removal. This segmentation allows each chamber to be optimized for its specific function, with the pre-vortex chamber generating rotational flow at lower energy cost and the separation chamber operating under reduced pressure differential, thus resolving the contradiction between efficiency and pressure loss.
2Stability of the object's composition
If high inlet velocity is required for conventional cyclones, then a sufficiently strong vortex is generated, but the device cannot be applied at very low gas flow rates
Solution Approach 1:
The pre-vortex chamber performs the vortex generation function in advance, using a small driving motor to rotate the chamber and create the necessary centrifugal forces. This preliminary action decouples vortex strength from inlet gas velocity, allowing the system to maintain strong vortex conditions even at very low flow rates, thereby improving adaptability across different operating conditions.
Solution Approach 2:
The pre-vortex chamber is designed to generate its own rotational flow through a small driving motor that rotates the chamber itself, rather than relying on the kinetic energy of the incoming gas stream. This self-service approach ensures that vortex strength is maintained independently of gas flow rate, enabling the device to operate effectively from very low to high flow rates.
3Stability of the object's composition
If tangential inlet from outside is used in conventional cyclones, then vortex is generated, but pressure conditions must change before entering the device
Solution Approach 1:
The patent inverts the conventional cyclone configuration by using a pre-vortex chamber that rotates in the opposite direction to the gas flow, and by positioning the inlet at the bottom rather than the side. This inverted configuration allows the gas to enter axially from the bottom and be gradually rotated by the pre-vortex chamber, maintaining more stable pressure conditions while still generating the necessary vortex for separation.
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 device achieves efficient particle separation across varying flow rates and pressure conditions, including vacuum processes, without significant pressure changes, by utilizing the shape and speed of the rotating impeller, independent of inlet velocity.
Implementation Method 1
the deposition effect is based on the utilization of centrifugal forces
Implementation Method 2
a mechanically induced horizontal vortex within a vertical cylindrical or slightly conical body
Implementation Method 3
a vortex is produced by a horizontally rotating impeller
Implementation Method 4
They are decelerated through the contact with the inner wall of the cylindrical vortex chamber and then move downwards along the wall back into the process boiler, due to gravity
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3b
AI summary
Disclosed is an example of a device for separating solid and/or liquid particles from air or gas streams. The device is based on the effect of a mechanically induced horizontal vortex within a vertical cylindrical or slightly conical body, which is divided into two chambers. The mechanically induced vortex may be produced by a horizontally rotating impeller.