Spark Separator Flow Divider and Copper Baffles
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Solution Overview
Problem
Existing spark pre-separators are complex, expensive, heavy, and require significant space due to their intricate structure, posing a fire hazard when dealing with glowing particles and being unsuitable for pipeline installations.
Innovation Solution
A lightweight, inexpensive spark pre-separator with a simple structure featuring a V-shaped flow divider and parallel baffles that divert and slow the gas flow, separating heavy particles by gravity, and made from materials like copper to quickly dissipate heat and prevent fires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inertial separation spark separators are used, then sparks can be separated from gas flow, but the device becomes complex, expensive, heavy and space-consuming
Solution Approach 1:
The invention extracts only the essential function of spark separation from the complex traditional separator structure. By removing unnecessary components and retaining only the critical elements (housing, inlet, outlet, and flow division surfaces), the device achieves effective spark separation while dramatically reducing structural complexity, weight, and space requirements.
Solution Approach 2:
Instead of using complex rotating mechanisms or multiple stages to separate sparks, the invention inverts the approach by using simple flow division surfaces that guide the gas flow in a specific pattern. The separation is achieved through the inverted logic of letting gravity act on particles while the gas flows overhead, rather than trying to mechanically extract particles from the flow.
2Object-affected harmful factors
If traditional spark separators are used, then fire hazard can be reduced, but the device requires large installation space and high manufacturing cost
Solution Approach 1:
The invention employs simple, inexpensive flow division surfaces that can be easily manufactured and replaced if needed. These surfaces are designed to be functional rather than durable, reducing the need for expensive, heavily constructed separators. The simplicity of the design allows for cost-effective manufacturing while maintaining adequate protection against fire hazards from glowing particles.
3Reliability
If complex spark separator structures are used, then separation effectiveness is improved, but manufacturing cost and weight increase
Solution Approach 1:
The invention segments the separation function into distinct flow paths created by the flow division surfaces. Rather than using a single complex structure, the housing is divided into regions that guide gas flow in specific patterns, with each segment contributing to the overall separation effectiveness. This segmentation allows for lightweight construction while maintaining reliable particle 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
Effectively prevents sparks from entering the dedusting system, reduces fire risk, minimizes maintenance, and allows for compact installation, ensuring efficient separation of heavy particles while maintaining low operational costs.
Implementation Method 1
Known spark pre-separators are based on the principle of inertial separation, in which the air flow is set in rotation by swirl vanes, as a result of which the heavy particles are moved radially outwards and are then separated from the raw gas flow.
Implementation Method 2
The gas flow, including the sparks and particles it contains, is divided into two partial flows. These two partial flows are displaced laterally outwards towards the housing walls by the flow divider. Downstream of the flow divider, the two partial flows each meet one of the two slides arranged on the side. The baffles destroy the remaining kinetic energy of the sparks and particles so that they fall down and are thus separated from the gas flow.
Implementation Method 3
In a further embodiment of the proposed spark separator, the flow divider and the links are made of copper. As a result, so much heat is withdrawn from the heavy particles particularly quickly that they no longer pose a fire hazard, even if they were to get over the baffles.
Data Source
Figure 1~2
AI summary
The invention relates to a spark separator for separating a heavy particle fraction from a gas stream, comprising a housing bounded by housing walls with a gas stream inlet and a gas stream outlet arranged horizontally opposite the gas stream inlet, wherein a flow divider and two cams are arranged in the housing between the gas stream inlet and the gas stream outlet, the flow divider is arranged centrally with respect to a flow cross-section defined by the housing, covers a partial cross-section of this flow cross-section and is designed to divide the gas stream into two horizontally adjacent partial streams and to displace the partial streams laterally, and the two cams are arranged on both sides of the flow divider and downstream behind the flow divider and cover a residual cross-section of the flow cross-section not covered by the flow divider.as well as a dust extraction system with such a spark separator.