Reverse Flow Cyclone With Axial Inserts For Particle Separation
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Solution Overview
Problem
Cyclone separators face challenges in preventing the transient entrainment of larger particles in the gas effluent, leading to inefficiencies in separation capacity, particularly as the total flow through the unit increases, and require frequent filter changes.
Innovation Solution
The proposed separator apparatus incorporates a reverse flow cyclone with a cylindrical and conical section, featuring a reverse flow cyclone and axial cyclone inserts with tapered entrance fixtures and a drain plate, along with optional rotation structures and porous members to enhance separation efficiency and prevent re-entrainment of solids and liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a vortex finder is used to prevent transient entrainment of larger particles, then particle separation is improved, but fine particles and liquid droplets are still entrained in the gas effluent
Solution Approach 1:
The cyclone separator is divided into multiple functional zones: an upper cyclone section for coarse particle separation, a lower cyclone section for fine particle and liquid droplet separation, and a mist elimination section. This segmentation allows each zone to target specific particle sizes and phases, preventing both large and fine particles from being entrained in the gas effluent.
Solution Approach 2:
The invention introduces a vertical dimension to particle separation by using multiple cyclone sections arranged vertically. The upper cyclone handles larger particles while the lower cyclone and mist elimination section address fine particles and liquid droplets. This multi-level vertical arrangement enables simultaneous separation of different particle sizes and phases that a single vortex finder cannot achieve.
2Productivity
If the total flow through the unit increases, then processing capacity is improved, but fine particles in the gas effluent increase and larger particles converge toward the center
Solution Approach 1:
The cyclone separator is divided into multiple functional zones: an upper cyclone section for coarse particle separation, a lower cyclone section for fine particle and liquid droplet separation, and a mist elimination section. This segmentation allows each zone to target specific particle sizes and phases, preventing both large and fine particles from being entrained in the gas effluent.
Solution Approach 2:
The invention introduces a vertical dimension to particle separation by using multiple cyclone sections arranged vertically. The upper cyclone handles larger particles while the lower cyclone and mist elimination section address fine particles and liquid droplets. This multi-level vertical arrangement enables simultaneous separation of different particle sizes and phases that a single vortex finder cannot achieve.
3Manufacturing precision
If filters are added to the gas effluent stream to increase optical separation capacity, then separation efficiency is improved, but filter changes are required frequently
Solution Approach 1:
The invention extracts and removes fine particles and liquid droplets directly at the source within the cyclone separator itself, rather than relying on downstream filters. The mist elimination section and lower cyclone section capture these particles before they enter the gas effluent stream, eliminating the need for frequent filter changes while maintaining high separation efficiency.
Solution Approach 2:
The cyclone separator acts as an intermediary device between the separation process and the gas effluent stream. By using centrifugal force and controlled flow patterns, it prevents fine particles and liquid droplets from entering the effluent in the first place, serving as a proactive filtration mechanism that eliminates the need for reactive filter changes.
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 design improves the separation efficiency by effectively capturing fine particles and liquids, reducing the need for frequent filter changes and enhancing the overall capacity of the cyclone separator.
Implementation Method 1
The mixture vortexes around the wall of the cylindrical section where the solids or liquids separate from the gas
Implementation Method 2
Cyclone separators are commonly used to separate gases from solids and liquids
Implementation Method 3
In a vertically oriented cyclone, the solids or liquids fall under the influence of gravity
Implementation Method 4
Gases, near the rotational center, become pressured toward the decreasing diameter and begin to flow upward
Data Source
AI summary
A separator apparatus is described for separating liquids and solids from a gas. The separator apparatus includes a reverse flow cyclone comprising a cylindrical section, a conical section, and a top, the cylindrical section having a feed inlet, the top having a gas outlet, and the conical section having a reject outlet at the bottom thereof. An axial cyclone is disposed in the cylindrical section, the axial cyclone oriented with a first end located proximate to the top of the apparatus and a second end opposite the first end, the axial cyclone having a tapered entrance fixture at the second end thereof and having a wall with a plurality of openings located between the first end of the axial cyclone and a midpoint of the axial cyclone. A drain plate is coupled to the cylindrical section below the openings of the axial cyclone.