Rotary Conveyor Mechanical Separator for Slurry
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Solution Overview
Problem
Conventional mechanical separation devices in corn milling processes face inefficiencies, including limited flow rates, high energy consumption, frequent maintenance needs, and emissions, particularly in separating solids from liquids, which increases operating and capital costs and greenhouse gas emissions.
Innovation Solution
A mechanical separation device featuring a cylindrical screen with a rotary conveyor system, including paddles and flingers, that enhances liquid-solid separation by conveying solids and liquids along an axial length, with adjustable orientation and bi-directional capability, and a raised discharge end for extended residence time, improving separation efficiency and reducing energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If pressure screen devices are used to separate solids from liquid medium, then separation can be achieved under pressure, but flow rates are limited and thick influent is required
Solution Approach 1:
The patent applies the dynamics principle by using a rotary conveyor system instead of a static screen. The rotary conveyor with paddles and flingers actively moves solids through the screen openings, dynamically adjusting the separation process to handle higher flow rates and thinner influent while maintaining separation efficiency. This dynamic approach resolves the contradiction between productivity and reliability.
2Reliability
If gravity screen devices are used to separate solids from liquid medium, then separation based on specific gravity difference occurs, but long residence times are required
Solution Approach 1:
The patent replaces the passive gravity-based mechanical system with an active rotary mechanical system. The rotary conveyor uses mechanical force from rotating paddles and flingers to propel solids through the screen, substituting gravity-dependent slow separation with mechanically-driven rapid separation. This reduces residence time while maintaining or improving separation efficiency.
3Reliability
If centrifuges are used to separate solids from liquid medium, then density-based separation occurs, but equipment cost and operating cost increase
Solution Approach 1:
The patent employs a simpler, more economical screen design that can be easily replaced rather than using expensive centrifuge equipment. The rotary conveyor system with screen and flingers provides effective separation at a fraction of the cost of centrifuges, accepting that the screen may need periodic replacement but avoiding the high capital and operating costs of centrifuge machinery.
4Reliability
If wedge-wire screens are used to separate solids from liquid medium, then filtration can be achieved, but components become clogged and wear occurs frequently
Solution Approach 1:
The patent uses a dynamic rotary conveyor system that continuously moves the screen and flingers, preventing solids from settling and clogging the screen openings. The motion keeps the screen surface active and self-cleaning, significantly extending screen life while maintaining filtration capability. This dynamic approach resolves the clogging and wear issues of static wedge-wire screens.
5Reliability
If conventional separation devices are used, then solids can be separated from liquid, but energy consumption is high and greenhouse gas emissions increase
Solution Approach 1:
The rotary conveyor system is designed to be self-propelling through the slurry flow itself. The paddles and flingers utilize the kinetic energy of the incoming slurry to rotate the conveyor, which then performs the separation work. This self-service mechanism minimizes external energy input while maintaining effective separation function, reducing both energy consumption and associated emissions.
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 improves separation efficiency, reduces energy consumption, lowers operating and capital costs, and decreases greenhouse gas emissions by effectively separating solids from liquids with a more efficient and cost-effective design.
Implementation Method 1
A rotary conveyor is positioned within the interior space to convey the solids and the liquid medium along an axial length of the interior space toward a discharge outlet
Implementation Method 2
a cylindrical screen positioned within the housing to separate at least a portion of the liquid medium from the solids, the cylindrical screen comprising a sheet of material formed into at least a portion of a cylinder having a central axis, the sheet of material comprising an inner screen surface that defines an interior space within the cylindrical screen and an outer screen surface with a plurality of openings formed through the sheet of material
Data Source
AI summary
A rotary tool for a mechanical separator, the tool can optionally comprise: a center shaft having a longitudinal axis; a plurality of longitudinal paddles coupled to the shaft, at least one paddle of the plurality of paddles having an inner edge and aligned radially relative to the longitudinal axis, wherein the at least one paddle has an elongate extent along the longitudinal axis with opposing lateral sides along the elongate extent; and a flange having a triangular shape in a radial cross-section, the flange affixed to the inner edge of the at least one paddle and having an apex radially inward of the at least one paddle. Other examples of the application include the rotary tool having a plurality of tools and the mechanical separator having the capability of being raised or lowered to alter a residence time of slurry within the mechanical separator.