Slurry Pump Plunger Control for Debris Obstruction Prevention
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Solution Overview
Problem
Current pumping systems for feedstock materials, particularly in devolatilization reactors, face inefficiencies when handling lower volumes and are prone to obstructions due to debris, leading to complex and costly maintenance.
Innovation Solution
A pumping system incorporating a plunger, sensors, and a controller to pressurize and control the flow of slurry, with sensors monitoring pressure and plunger position to adjust the plunger mode and control valve operation, ensuring efficient flow and preventing obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional fluid type pumps with valves are used to pump feedstock material, then large volumes of feedstock can be pushed through, but pump efficiency reduces when pumping lower volumes and valves may jam or become obstructed by debris
Solution Approach 1:
The patent replaces traditional mechanical valves with a mechanical pig system that uses a scraper mechanism to clear debris from the pipe walls. The pig is propelled by pressure differential and mechanically scrapes the pipe interior, eliminating the need for valves that can jam or obstruct. This substitution of the valve mechanism with a pig-based clearing system resolves the contradiction by maintaining flow capability while preventing obstruction.
Solution Approach 2:
The patent introduces a mechanical pig as an intermediary device between the feedstock flow and the pipe walls. The pig acts as a mediator that interacts with debris and pipe surfaces to clear obstructions, rather than allowing debris to directly block the flow path as would occur with valve-based systems. This intermediary mechanism enables continuous flow while preventing the jamming issues associated with traditional valves.
2Ease of operation
If valves are used to control feedstock flow, then flow direction can be controlled, but valves require removal or disassembly to clear debris, increasing maintenance complexity
Solution Approach 1:
The mechanical pig system is self-actuating and propels itself through pressure differential without requiring external control mechanisms or manual intervention for operation. The pig automatically clears debris through its scraping action and is removed from the system when its function is complete, eliminating the need for complex valve maintenance and disassembly procedures.
Solution Approach 2:
The patent extracts the debris clearing function from the flow control mechanism. Instead of using valves that require disassembly for maintenance, the system uses a separate, removable pig that is inserted to perform the clearing function and then extracted from the system. This separation of functions simplifies maintenance as the pig can be easily removed and replaced without complex disassembly.
3Device complexity
If traditional pumping systems are used, then simple structure is maintained, but operation and maintenance become expensive and complex due to valve obstructions
Solution Approach 1:
The mechanical pig system enables continuous operation by preventing debris accumulation that would otherwise cause valve obstructions and flow interruptions. The pig continuously scrapes the pipe walls during feedstock transport, eliminating the need for shutdowns and maintenance interventions, thereby reducing operational costs while maintaining relatively simple system structure.
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 system enhances pumping efficiency by effectively handling varying slurry volumes and reducing maintenance costs through controlled pressure and flow management, preventing debris accumulation and ensuring continuous operation.
Implementation Method 1
The plunger is configured to pressurize the slurry to a first pressure prior to the slurry entering the device
Implementation Method 2
The first sensor is configured to sense a second pressure of the slurry entering the device
Implementation Method 3
The second sensor is configured to sense the position of the plunger
Data Source
AI summary
The present disclosure relates to a system and method for pumping a feedstock slurry through a device. The system includes a pressure pump, a first sensor, a second sensor, a controller, and a control valve. The pressure pump includes a plunger configured to pressurize the slurry to a first pressure prior to the slurry entering the device. The first sensor is configured to sense a second pressure of the slurry entering the device. The second sensor is configured to sense the position of the plunger. The controller is configured to determine a change of position of the plunger based on the sensed position of the plunger and to control the movement of the plunger by setting a plunger mode based on the second pressure of the slurry and the change of position of the plunger. The control valve is configured to control the flow rate of the slurry through the device.