Hydrocyclone separator

Abstract

A hydrocyclone separator and a system that includes a plurality of such hydrocyclone separators are presented. The hydrocyclone separator includes a head portion having an inlet conduit and an overflow discharge tube arranged in the head portion. The hydrocyclone separator further has an apex discharge port and a tapered separation portion arranged between the head portion and the apex discharge port. The tapered separation portion is tapering distally away from the head portion. Moreover, the head portion further includes an emptying port arranged in the head portion separately from the overflow discharge tube. Hereby, a hydrocyclone separator capable of achieving improved operational efficiency with reduced risk of coarse fraction being misplaced and left in the head portion is presented. This effectively reduces maintenance needs and prolongs the lifespan of the hydrocyclone.

Claims

1. A hydrocyclone separator for classifying solid material in liquid suspension, comprising: a head portion comprising an inlet conduit adapted to feed a suspension into the head portion; an overflow discharge tube arranged in the head portion; an underflow discharge port; a tapered separation portion arranged between the head portion and the underflow discharge port, the tapered separation portion having a proximal end facing the head portion and a distal end facing the underflow discharge port, and wherein said tapered separation portion tapers towards said distal end; wherein said head portion further comprises an emptying port arranged in the head portion separately from the overflow discharge tube.

2. The hydrocyclone separator according to claim 1, wherein said emptying port is provided with a closing arrangement for selectively opening and closing said emptying port.

3. The hydrocyclone separator according to claim 1, further comprising a set of fluid injection nozzles arranged in the head portion for injecting a secondary fluid into said head portion.

4. The hydrocyclone separator according to claim 1, wherein said emptying port comprises a settling pocket comprising an internal chamber for collecting residual coarse feed material.

5. The hydrocyclone separator according to claim 4, wherein said settling pocket comprises a closeable access port which is accessible externally from the hydrocyclone separator for removing collected residual coarse feed material from said internal chamber.

6. The hydrocyclone separator according to claim 1, wherein said emptying port is arranged at a lowest point of the head portion when said hydrocyclone separator is oriented such that said apex discharge port is at a vertically elevated position relative to the overflow discharge tube.

7. The hydrocyclone separator according to claim 1, wherein said head portion comprises: a disc-shaped end portion surrounding said overflow discharge tube; and wherein said emptying port is arranged in said disc-shaped end portion.

8. The hydrocyclone separator according to claim 7, wherein said emptying port is arranged at a peripheral end of said disc-shaped end portion.

9. The hydrocyclone separator according to claim 1, wherein said head portion comprises: a disc-shaped end portion surrounding said overflow discharge tube, and a substantially cylindrical wall portion; and wherein said emptying port is arranged in said substantially cylindrical wall portion, adjacent to the disc-shaped end portion.

10. The hydrocyclone separator according to claim 7, wherein a set of fluid injection nozzles are arranged in said disc-shaped end portion for injecting a secondary fluid into said head portion.

11. The hydrocyclone separator according to claim 7, wherein said disc-shaped end portion comprises an internal surface facing towards an interior of the hydrocyclone separator, said internal surface being slanted relative to a horizontal plane when said hydrocyclone separator is oriented such that said apex discharge port is at a vertically elevated position relative to the overflow discharge tube; and wherein said emptying port is arranged at a lowest end of said internal surface along a vertical direction relative to the horizontal plane when said hydrocyclone separator is oriented such that said apex discharge port is at the vertically elevated position relative to the overflow discharge tube.

12. The hydrocyclone separator according to claim 1, wherein said head portion comprises: an end portion surrounding said overflow discharge tube; and wherein said end portion comprises an internal surface facing towards an interior of the hydrocyclone separator, said internal surface having at least two surface portions arranged at different heights relative to a horizontal plane when said hydrocyclone separator is oriented such that said apex discharge port is at a vertically elevated position relative to the overflow discharge tube; and wherein said emptying port is arranged on a surface portion which is arranged a lowest height relative to the horizontal plane of the at least two surface portions when said hydrocyclone separator is oriented such that said apex discharge port is at the vertically elevated position relative to the overflow discharge tube.

13. A system comprising a plurality of hydrocyclone separators according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For exemplifying purposes, the invention will be described in closer detail in the following with reference to embodiments thereof illustrated in the attached drawings, wherein:

(2) FIG. 1 is a partial cut-through perspective view illustration of a hydrocyclone separator as known in the prior art;

(3) FIG. 2A is a partial cut-through perspective view illustration of a hydrocyclone separator in accordance with an embodiment of the present invention;

(4) FIG. 2B is an enlarged partial cut-through perspective view of the head portion of the hydrocyclone separator illustrated in FIG. 2A;

(5) FIG. 3 is a cross-sectional perspective view of a head portion of a hydrocyclone separator in accordance with an embodiment of the invention;

(6) FIG. 4 is a cross-sectional perspective view of a head portion of a hydrocyclone separator in accordance with another embodiment of the invention;

(7) FIG. 5A is a schematic side view illustration of a prior art hydrocyclone separator arranged in straight conventional (0°) orientation;

(8) FIG. 5B is a schematic side view illustration of a hydrocyclone separator arranged in an upside down (180°) orientation in accordance with an embodiment of the present invention;

(9) FIG. 5C is a schematic side view illustration of a hydrocyclone separator arranged in an upside down (225°) orientation in accordance with an embodiment of the present invention;

(10) FIG. 5D is a schematic side view illustration of a hydrocyclone separator arranged in an upside down (135°) orientation in accordance with an embodiment of the present invention.

DETAILED DESCRIPTION

(11) In the following detailed description, example embodiments of the present invention will be described. However, it is to be understood that features of the different embodiments are exchangeable between the embodiments and may be combined in different ways, unless anything else is specifically indicated. Even though in the following description, numerous specific details are set forth to provide a more thorough understanding of the present invention, it will be apparent to one skilled in the art that the present invention may be practiced without these specific details. In other instances, well known constructions or functions are not described in detail, so as not to obscure the present invention. Like reference characters refer to like elements throughout. Naturally the skilled reader understands that terms such as up, down, inwards or outwards are relative and in reference to the illustrated embodiments and should not be construed as limiting to the invention.

(12) FIG. 1 shows a schematic view of a prior art hydrocyclone separator 100. That hydrocyclone separator 100 (or simply “hydrocyclone”) comprises a cylindrical head portion 110. An inlet conduit 111 is arranged to feed a suspension of solid material into the cylindrical head portion 110, and an overflow discharge tube 112 is arranged axially through the top of the cylindrical head portion 110. The cylindrical head portion 110 is connected with a conically tapered separation part 120. The slurry is typically fed tangentially or in a volute path through the outer wall 113 of the head portion 110, thus creating a whirling motion 114 of the slurry which follows a path of gradually decreasing radius toward the point of the narrowest radius of the cone 120 and apex 115. As the spiral path approaches the apex 115 of the hydrocyclone 100, a portion 116 of it turns and begins to flow towards the opposite end, i.e. towards the head portion 110. Also this flow 116 is in a spiral path of radius smaller than the radius of the first spiral 114 while rotating in the same direction. Thus a vortex is generated within the hydrocyclone 100. The pressure will be lower along the central axis of the vortex and increase radially outwardly towards the outer wall 113 of the hydrocyclone 100. The hydrocyclone 100 will separate the particles of the slurry according to shape, size and specific gravity with faster settling particles moving towards the outer wall of the hydrocyclone 100 eventually leaving the hydrocyclone through the underflow 117. Slower settling particles will move towards the central axis and travel upwardly, eventually leaving the hydrocyclone through a discharge tube 112 (overflow). The discharge tube 112 is normally extending down into the head portion 110 such that a short circuiting of the feed is prevented (often referred to as a vortex finder, not shown). This separation according to shape, size and specific gravity can be denominated “stratification”.

(13) FIGS. 2A and 2B illustrate a partial cut-through perspective view of a hydrocyclone separator 1 suitable for classifying solid material in liquid suspension. The hydrocyclone separator 1 has a head portion 2 having an inlet conduit 3 adapted to feed a suspension into the head portion 2. The head portion 2 is here illustrated as being cylindrical. However, as is already apparent for the skilled reader, further shapes are feasible, such as e.g. a cone shape (having a cone angle in the range of 0 to 20 degrees) or a curved shape. Moreover, the hydrocyclone 1 has an overflow discharge tube 4, arranged axially in the head portion 2. However, the overflow discharge tube 4 may also be arranged in other orientations in the head portion 2 (e.g. slanted or off-center).

(14) Further, the hydrocyclone 1 has a tapered separation portion 5 with a proximal end 6 and a distal end 7. The proximal end 7 is connected to the head portion and the tapered separation portion 5 tapers towards the distal end 7. The head portion 2 is here shown as a removable or detachable part which is joined together with the tapered separation portion along a flange, however, other embodiments where the two parts are integrated in a single piece are feasible. Also, the hydrocyclone separator 1 may comprise an intermediate cylindrical (spacer) part arranged between the head portion 2 and the tapered separation portion 5 (not shown). Moreover, the tapered separation portion 5 may be a conically tapered separation portion, having a continuously decreasing cone angle, i.e. trumpet-shaped (as illustrated in FIG. 2A). Alternatively, the tapered separation portion 5 may have two or more tapered sections having different cone angles with larger cone angles close to the head portion 2 (at the proximal end 6) and smaller cone angles further away from the head portion 2 towards the distal end 7. In yet another embodiment (not shown) the conically tapered separation portion 5 may comprise one tapered section having a single cone angle. The hydrocyclone separator 1 further comprises an apex discharge port 8 (underflow) arranged at the distal end 7 of the tapered separation portion 5.

(15) The hydrocyclone 1 further includes an emptying port 9 arranged in the head portion 2, as illustrated in more detail in FIG. 2B. The emptying port 9 is arranged separately from the overflow discharge tube 4 (the protruding part of the overflow discharge tube has been removed from FIG. 2B in order to emphasize other parts of the head portion 2). Here, the emptying port 9 is arranged in the end portion 13 (may also be referred to as a cover), here being a disc-shaped end portion, which surrounds the overflow discharge tube 4. The emptying port 9 further comprises a settling pocket 11 which has an internal chamber for collecting residual coarse feed material that has become trapped within the head portion 2. The settling pocket 11 forms a type of intermediate storage for the trapped coarse particles during operation of the hydrocyclone separator 1, effectively reducing the time that the misplaced/trapped coarse particles are left swirling within the head portion. The settling pocket 11 is furthermore provided with a closeable access port 12 (schematically indicated as a valve in the drawing) which is accessible externally from the hydrocyclone separator in order to be able to remove collected residual coarse feed material from the internal chamber of the settling pocket 11.

(16) The head portion 2 further has a set of fluid nozzles 14 arranged in the disc-shaped end portion (cover) 13 for injecting a secondary fluid (e.g. water) into the head portion. The fluid nozzles 14 serve to facilitate cleaning of the head portion, and may be utilized to perform a flush through of the head portion 2 during e.g. a maintenance procedure.

(17) FIG. 3 illustrates a cross-sectional perspective view of a head portion 2 of a hydrocyclone separator in accordance with an embodiment of the invention. The cross-section being taken along an elongated central axis 50 of the hydrocyclone. The head portion comprises two emptying ports 9 having separate settling pockets 11 having internal chambers for collecting residual coarse feed material. The emptying ports 9 are arranged at the spatially lowest sections of the head portion 2 when the hydrocyclone separator is oriented such that the apex discharge port is at a vertically elevated position relative to the overflow discharge tube 4, i.e. in an upside down configuration/orientation. The head portion 2 has an end portion 13 (may be referred to as a cover) which surrounds the overflow discharge tube 4. The end portion 13 has an internal surface 16 facing towards an interior of the hydrocyclone separator, and having a slanted or conical structure. More specifically, the internal surface 16 is downwardly sloped inwards towards a central axis and towards the overflow discharge tube 4, when the hydrocyclone is in an upside down configuration.

(18) Stated differently, the internal surface 16 has two surface portions, an outer edge area proximal to the cylindrical wall 15 of the head portion, and an inner area proximal to the overflow discharge tube 4. The two surface portions are accordingly arranged at different heights relative to a horizontal plane (perpendicular to the axis 50) and the emptying ports 9 are arranged on the surface portion which is at the lowest height relative to the horizontal plane of the at least two surface portions, when the hydrocyclone is in the upside down configuration. This facilitates the collection of the residual coarse feed material which is stuck or trapped within the head portion 2 during operation, since it will gather at the lowest point within the head due to gravity. The head portion 2 further has a set of fluid nozzles 14 arranged in the “conical” end portion (cover) 13. The fluid nozzles 14 are configured to inject a secondary fluid (e.g. water) into the head portion. The fluid nozzles 14 facilitate cleaning of the head portion, and may be utilized to perform a flush through of the head portion 2 during e.g. a maintenance procedure.

(19) FIG. 4 illustrates a cross-sectional perspective view of a head portion 2 of a hydrocyclone separator in accordance with another embodiment of the invention. The cross-section being taken along an elongated central axis 50 of the hydrocyclone. The head portion 2 has an end portion 13 surrounding the overflow discharge tube 4, the end portion 13 having an internal surface 16 facing towards the interior of the head portion 2 and the overall hydrocyclone separator.

(20) Moreover, the head portion 2 has a cylindrical or tubular wall portion 15 and an emptying port 9 arranged in this cylindrical wall portion 15. The emptying port 9 is arranged or situated in the wall portion adjacent to the end portion 13. The end portion 13 is generally disc shaped with a slope forming a conical internal surface 16. Stated differently, the internal surface 16 is slanted relative to a horizontal plane (reference plane) when the hydrocyclone is arranged in an upside down orientation. Further, the head portion 2 has a set of fluid injection nozzles 14 arranged in the cylindrical wall portion 15, the fluid nozzles 14 being configured to inject a secondary fluid (e.g. water) into the head portion.

(21) FIG. 5A shows a schematic illustration of a prior art hydrocyclone separator 100 from a side view perspective. The hydrocyclone separator 100 is arranged in a conventional straight (0°) configuration. The elongated central axis 50 of the hydrocyclone 100 is aligned with a vertical axis 41 (y-axis), forming an angle of 0° between the vertical axis 41 (y-axis) and the elongated central axis 50.

(22) FIG. 5B shows a schematic illustration of a hydrocyclone separator 1 from a side view perspective, in accordance with an embodiment of the present invention. The hydrocyclone 1 is oriented in a straight upside down configuration (also known as an inverted configuration), where the elongated central axis 50 of the hydrocyclone 1 is rotated by 180° relative to the vertical axis 41 (rotated from a conventional straight configuration). In this orientation, shown in FIG. 5B, the head portion may be arranged as illustrated in FIG. 3 or FIG. 4 whereby the emptying port(s) would be arranged at a lowest end/point of the head portion, improving the probability of residual coarse material being collected in the settling pocket.

(23) FIG. 5C shows a schematic illustration of a hydrocyclone separator 1 from a side view perspective, in accordance with another embodiment of the present invention. Here, the hydrocyclone 1 is arranged in another upside down orientation/configuration (also known as a semi-inverted configuration), where the elongated central axis 50 of the hydrocyclone is rotated by approx. 225° relative to the vertical axis 41 (rotated from a conventional straight configuration). Here, the emptying port is arranged at a lowest point of the head portion. More specifically, the emptying port is arranged at an outer peripheral edge of the cover (disc-shaped end portion) of the head portion. Accordingly, by arranging the whole hydrocyclone in a “tilted” upside down orientation, the emptying port can be provided at the lowest point of the head portion.

(24) FIG. 5D shows a schematic illustration of a hydrocyclone separator 1 from a side view perspective, in accordance with yet another embodiment of the present invention. Here, the hydrocyclone 1 is arranged in another upside down orientation/configuration (also known as a semi-inverted configuration), where the elongated central axis 50 of the hydrocyclone is rotated by approx. 135° relative to the vertical axis 41 (rotated from a conventional straight configuration). Similarly, as in FIG. 5C, the emptying port is here, in FIG. 5D, arranged at a lowest point of the head portion. Even though only some specific examples were selected in FIGS. 5B-5D, the hydrocyclone separator may be oriented such that it is rotated by any number of degrees in the range of 91°-269° relative to a vertical axis, such as e.g. 100°, 110°, 125°, 170°, 235°, etc.

(25) Furthermore, the skilled person realizes that a number of modifications of the embodiments described herein are possible without departing from the scope of the invention, which is defined in the appended claims. For example, the separation part according to the invention need not necessarily be conical in a strict meaning. As long as the inner diameter is generally reduced from a top end towards a bottom end, it can have a plurality of different cone angles along its longitudinal axis and can also have more of a curved appearance, i.e. having a continuously changing cone angle. Moreover, the head portion may have various shapes and configurations in order to arrange the emptying port at a lowest point of the hydrocyclone when it is in an upside down orientation, as already apparent for the skilled reader. Variations to the disclosed embodiments can be understood and effected by the skilled addressee in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. Furthermore, in the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality.