HOPPER FOR FEEDING BULK MATERIAL

Abstract

There is herein described an apparatus and method for feeding bulk material. More particularly, there is described an apparatus and method for feeding bulk material such as bulk solids which provides a constant and reliable feed of material.

Claims

1. A hopper for feeding bulk material, the hopper comprising: a main body having an upper portion and a lower portion; an inlet located on an upper surface of the upper portion of the main body for bulk material to enter the hopper; and an outlet located on a lower surface of the lower portion of the main body for bulk material to exit the hopper, wherein the main body defines a substantially vertical passageway for bulk material to pass from the inlet down and substantially vertically through the outlet of the hopper, wherein the upper portion of the main body has at least one or a plurality of substantially planar panel surfaces that are inclined outwards from a centrally positioned substantially vertical axis passing through the center of the hopper from the inlet to the outlet in a direction of travel of the bulk material, wherein the lower portion of the main body has at least one or a plurality of substantially planar panel surfaces that are inclined inwards towards the substantial vertical axis passing through the center of the hopper from the inlet to the outlet in the direction of travel of the bulk material, and wherein the hopper provides a substantially constant feed of bulk material through the outlet.

2. The hopper for feeding bulk material according to claim 1, wherein on the upper portion of the main body of the hopper there is at least one or a series of flat or substantially flat planar panels which extend outwards and away from a central vertical axis of the hopper as the bulk material travels from the inlet through and out of the outlet.

3. The hopper for feeding bulk material according to claim 1, wherein the majority of the panels forming the upper portion of the hopper extend outwards and away from a central vertical axis of the hopper as the bulk material travels from the inlet through and out of the outlet.

4. The hopper for feeding bulk material according to claim 1, wherein the panels forming the upper portion of the hopper are substantially flat polygon shapes.

5. The hopper for feeding bulk material according to claim 1, wherein the upper portion of the hopper comprises two larger six-sided flat panels and two smaller triangular flat panels which are inclined outwards from the central axis of the hopper as the bulk material travels from the inlet through and out of the outlet.

6. The hopper for feeding bulk material according to claim 1, wherein the panels forming the upper portion of the hopper and extending outwards and away from a central axis of the hopper are inclined outwards in a range from about 2 degrees to about 45 degrees.

7. The hopper for feeding bulk material according to claim 1, wherein the at least one or a plurality of substantially planar panel surfaces forming the lower portion extend inwardly towards the central axis in the direction of travel of the bulk material to thereby assist the transportation of the bulk material.

8. The hopper for feeding bulk material according to claim 1, wherein the upper portion of the hopper is longer in height extending down the central vertical axis of the hopper than the lower portion of the hopper.

9. The hopper for feeding bulk material according to claim 1, wherein the upper portion of the hopper is about 1 to 5 times or 2 to 5 times the height of the lower portion of the hopper.

10. The hopper for feeding bulk material according to claim 1, wherein on the lower portion of the hopper there is at least one or a plurality of agitators capable of providing stirring and/or pulsing and/or vibration and/or disrupting and/or wiping and/or scraping to the lower portion of the hopper which facilitates the flow of material to the outlet of the hopper.

11. The hopper for feeding bulk material according to claim 1, wherein there are two or more agitators located on opposite sides of the lower portion of the hopper.

12. The hopper for feeding bulk material according to claim 1, wherein at least one or the majority or all of the panels forming the lower portion of the hopper are inclined in towards the central axis of the hopper and therefore extend inwardly towards the central axis in the direction of travel of the bulk material.

13. The hopper for feeding bulk material according to claim 11, wherein a degree of inclination of the panels forming the lower portion ranges from about 10 degrees to about 45 degrees.

14. The hopper for feeding bulk material according to claim 1, wherein the agitators on the lower portion of the hopper are located on panels forming the lower portion which are inclined in towards the central axis of the hopper and are therefore located on panels which extend inwardly towards the central axis in the direction of travel of the bulk material.

15. The hopper for feeding bulk material according to claim 14, wherein the degree of inclination of the panels in towards from a vertical central axis ranges from about 10 degrees to about 45 degrees.

16. The hopper for feeding bulk material according to claim 1, wherein the outlet of the hopper is about 30% to 80% smaller than the cross-section of the area between the upper portion and the lower portion of the hopper.

17. The hopper for feeding bulk material according to claim 1, wherein the upper portion and lower portion of the hopper are made from panels that are flat or substantially flat and form a flat and/or smooth surface for the passageway passing through the hopper.

18. The hopper for feeding bulk material according to claim 1, wherein the at least one or a plurality of substantially flat panels forming the upper and/or lower portions are formed from sheet metal and/or composite material and/or alloy.

19. The hopper for feeding bulk material according to claim 1, wherein the at least one or a plurality of substantially flat panels forming the upper and/or lower portions form a smooth inner surface for material to pass through the hopper from the inlet to the outlet with the minimum amount of friction and/or resistance and to thereby prevent any blockages of bulk material.

20. The hopper for feeding bulk material according to claim 1, wherein there are at least one or a plurality of agitators located on the lower portion.

21. A method of providing a substantially constant feed of bulk material, the method comprising: providing a main body having an upper portion and a lower portion; providing an inlet located on an upper surface of the upper portion of the main body for bulk material to enter the hopper; and providing an outlet located on a lower surface of the lower portion of the main body for bulk material to exit the hopper, wherein the main body defines a substantially vertical passageway for bulk material to pass from the inlet down and substantially vertically through the outlet of the hopper; wherein the upper portion of the main body has at least one or a plurality of substantially planar panel surfaces that are inclined outwards from a centrally positioned substantially vertical axis passing through the center of the hopper from the inlet to the outlet in the direction of travel of the bulk material, and wherein the lower portion of the main body has at least one or a plurality of substantially planar panel surfaces that are inclined inwards towards the substantial vertical axis passing through the center of the hopper from the inlet to the outlet in the direction of travel of the bulk material.

22. A conveying system comprising a hopper according to claim 1.

23. The conveying system according to claim 22, wherein the conveying system is part of a mechanical conveying system such as conveying system for burning household and/or industrial waste.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0074] The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

[0075] FIG. 1 is a perspective view of a hopper according to an embodiment of the present invention;

[0076] FIG. 2 is a further perspective view of the hopper shown in FIG. 1 rotated 180° around a vertical axis according to an embodiment of the present invention;

[0077] FIG. 3 is a further perspective view of the hopper shown in FIGS. 1 and 2 according to an embodiment of the present invention;

[0078] FIG. 4 is a further view of the hopper shown in FIG. 3 rotated by 180° around a vertical axis according to an embodiment of the present invention;

[0079] FIG. 5 is a front view of the hopper shown in FIGS. 1 to 4 according to an embodiment of the present invention;

[0080] FIG. 6 is a view of the hopper shown in FIGS. 1 to 5 according to an embodiment of the present invention;

[0081] FIG. 7 is a side view of the hopper shown in FIGS. 1 to 6 according to an embodiment of the present invention;

[0082] FIG. 8 is a side view of the other side of the hopper shown in FIG. 7 according to an embodiment of the present invention;

[0083] FIG. 9 is a perspective bottom view of the hopper shown in FIGS. 1 to 8 according to an embodiment of the present invention;

[0084] FIG. 10 is a sectional view of the hopper shown in FIGS. 1 to 9 according to an embodiment of the present invention; and

[0085] FIG. 11 is a sectional side view of the hopper shown in FIGS. 1 to 10 attached to part of a conveying/feeding system according to a further embodiment of the present invention.

DETAILED DESCRIPTION

[0086] The present invention relates to an apparatus and method for feeding bulk material which provides a constant and reliable feed of bulk material. The bulk material may be any type of type of bulk and/or particulate material. In particular embodiments, the material being conveyed may be in the process of being sent for incineration such as household and/or industrial waste. Furthermore, the bulk material being transferred may be any type of solid fuel (e.g. coal) or any other solid material including powder or powder-like material. The bulk material may also include any type of foodstuff in a solid and/or powder form.

[0087] FIGS. 1 to 11 show a range of representations and views of a hopper generally designated 100 according to the present invention. The hopper 100 feeds bulk material and is intended to overcome any problems associated with prior art systems with potential bridging in the system causing permanent blockages in the transportation of the bulk material.

[0088] A specific feature of the present invention is to use what is called ‘negative angles’ on main surfaces of the hopper 100. This has been found to reduce the torque demands on agitators used to facilitate the flow of material and to also maximize the usable volume of the hopper 100. These are specific technical advantages over the prior art devices which use vertical straight walls and conical bottoms for their hopper designs. Such prior art designs have been found to lead to permanent blockages in the flow of bulk material and to also lead to exerting excessive torque demands on the agitators. By using negative angles in the design of the hopper of the present invention has been found to reduce the torque demands by up to about 70% in the operation of the hopper and agitators.

[0089] Referring to FIGS. 1 to 11 a hopper 100 is shown to have an inlet 110 located on an upper surface of the hopper 100 and an outlet 130 located on a lower surface of the hopper 100. Bulk material will therefore be fed into inlet 110 and pass through a central passageway 111 down and out through the outlet 130. The central passageway 111 is clearly shown in the cross-sectional view of FIG. 10. FIGS. 5 to 8 and 10 also clearly show a central vertical axis ‘Y’ extending through the center of the hopper 100.

[0090] The hopper 100 as clearly shown in FIGS. 5 to 8 and 11 has an upper portion identified by reference numeral CA′ and a lower portion identified by reference numeral CB′. The upper portion ‘A’ is longer in height extending down the central vertical ‘Y’ axis of the hopper 100 than the lower portion CB′. The upper portion CA′ is, for example, about 1-5 times or about 2-5 times the height of the lower portion CB′ and typically at least about double or at least three times the height of the lower portion CB′.

[0091] We now refer to the upper portion ‘A’ of the hopper 100.

[0092] In the upper portion ‘A’ of the hopper 100 is shown a series of flat or substantially flat panels. It is important to appreciate that a number of these panels are what is known in the art as being oriented with ‘negative angles’. By having ‘negative angles’ we mean that the panels extend outwards and away from a central axis ‘Y’ of the hopper 100 in the direction of travel as the bulk material travels from the inlet 110 through and out of the outlet 130. The panels therefore extend outwards and point away from the exit outlet 130 of the hopper 100 in the direction of travel of the bulk material.

[0093] FIG. 1 shows that in the upper portion CA′ of the hopper 100 there is a negatively inclined flat or substantially flat panel 112 which points outwards and away from the central axis ‘Y’ in the direction of travel of the bulk material. The panel 112 therefore points outwards and away from the exit outlet 130 in the direction of travel of the bulk material. The flat panel 112 is also clearly shown in FIG. 5.

[0094] The flat panel 112 comprises six sides 112a, 112b, 112c, 112d, 112e, 112f. As shown in FIGS. 1 and 5, side 192a extends along the upper surface of the hopper 100 and side 112f extends along the lower end of the upper portion ‘A’ of the hopper 100. Sides 112b, 112c are significantly shorter than sides 112d, 112e. Using sides 112d, 112e the flat panel 112 tapers down and reduces from a wider length at side 112a down to a shorter length at side 112f. Importantly, the panel 112 is inclined outwards from the central axis ‘Y’ in the direction of travel of the bulk material. The degree of inclination outwards from the vertical axis ‘Y’ may range from about 2 degree—about 45 degrees. A preferred degree of inclination outwards is about 5 degrees—about 20 degrees.

[0095] FIGS. 1 and 5 also clearly show that there is an access hatch 160 located on the panel 112. The access hatch 160 is an optional feature and allows access to the inside of the hopper 100 for any form of routine maintenance.

[0096] FIGS. 1, 4 and 7 show a side of the hopper 100. The side of the hopper 100 is mainly made up of three triangular areas which are in a series of panels 114, 116, 118. It is important to note that panel 114 similar to panel 112 points outwards and away from the central axis ‘Y’ in the direction of travel of the bulk material.

[0097] Panel 114 comprises a side 114a located up towards the inlet 110 and two sides 114b, 114c extending and tapering down to a point 114d at the intersection between the upper portion ‘A’ and the lower portion ‘B’. There is also shown in the side a flat panel 190 extending along the side 114a of the triangular panel 114.

[0098] The triangular panel 114 has a degree of inclination outwards from the central axis ‘Y’ in the direction of travel of the bulk material from about 2 degrees—about 45 degrees. A preferred degree of inclination outwards is about 5 degrees—about 20 degrees.

[0099] The panel 190 also extends outwardly away from the central axis ‘Y’ in the direction of travel of the bulk material. The degree of inclination outwards from the central axis ‘Y’ in the direction of travel of the bulk material ranges from about 2 degree—about 45 degrees. A preferred degree of inclination outwards is about 5 degrees—about 20 degrees.

[0100] The hopper 100 is highly symmetrical in shape and FIGS. 2, 4 and 6 show the other side. FIGS. 2, 4 and 6 clearly show that there is a panel 180 which is the same shape and size as panel 112. Panel 180 comprises six sides 180a, 180b, 180c, 180d, 180e, 180f. Side 180a extends along the upper surface of the hopper 100 and side 180f extends along the lower end of the upper portion ‘A’ of the hopper 100. Sides 180b, 180c are significantly shorter than sides 180d, 180e. Using sides 180d, 180e the flat panel 180 tapers down and reduces from a wider length at side 180a down to a shorter length at side 180f. Importantly, the panel 180 is inclined outwards from the central axis ‘Y’ in the direction of travel of the bulk material. The degree of inclination outwards from vertical axis ‘Y’ may range from about 2 degrees—about 45 degrees. A preferred degree of inclination outwards is about 5 degrees—about 20 degrees.

[0101] FIGS. 2 and 4 also clearly show that there is an access hatch 162 located on the panel 180. The access hatch 162 is an optional feature and allows access to the inside of the hopper 100.

[0102] FIGS. 2 and 8 clearly show a further side of the hopper 100. This side of the hopper 100 is mainly made up again of three triangular areas which are in a series of panels 120, 122, 124. It is important to note that panel 120 similar to panels 112, 114, 180 points outwards and away from the central axis ‘Y’ in the direction of travel of the bulk material. The degree of inclination outwards from the central axis ‘Y’ in the direction of travel of the bulk material ranges from about 2 degrees—about 45 degrees. A preferred degree of inclination outwards is about 5 degrees—about 20 degrees.

[0103] Panel 120 comprises a side 120a located up towards the inlet 110 and two sides 120b, 120c extending and tapering down to a point 120d at the intersection between the upper portion ‘A’ and the lower portion ‘B’. There is also shown in the side a flat panel 192 extending along the side 114a of the triangular panel 114. The panel 192 also extends outwardly away from the central axis ‘Y’ in the direction of travel of the bulk material.

[0104] The triangular panel 120 has a degree of inclination outwards from the central axis ‘Y’ in the direction of travel of the bulk material from about 2 degrees—about 45 degrees. A preferred degree of inclination outwards is about 5 degrees—about 20 degrees.

[0105] As shown above, in the upper portion ‘A’ of the hopper 100 the majority of the panels extend outwards and away from the central axis ‘Y’ in the direction of travel of the bulk material. As indicated above, this is known as having panels at a ‘negative angle’.

[0106] We now refer to the lower portion CB′ of the hopper 100.

[0107] The lower portion CB′ of the hopper 100 is shown in all the FIGS. 1 to 11. On opposite sides of the lower portion CB′ of the hopper 100 there are two agitators 140, 150. Any form of agitators may be used which are capable of providing stirring and/or disrupting and/or wiping (i.e. scraping) and/or vibrations to the inner sides of the hopper 100. In addition, although two agitators 140, 150 are shown any number or a plurality of agitators may be used which are located on the lower portion CB′ of the hopper 100.

[0108] In particular, we refer to FIGS. 1, 3, 4, 5, 7 and 8 which show that agitator 140 is located on a flat planar or substantially planar panel 142. In comparison to the majority of the panels in the upper portion ‘A’ of the hopper 100, panel 142 is inclined in towards the central axis ‘Y’ of the hopper 100 and is intended to feed material into the outlet 130. The panel 142 therefore extends inwardly towards the central axis ‘Y’ in the direction of travel of the bulk material.

[0109] The agitator 140 is substantially centrally located on the panel 142. However, the agitators of the present invention can be located on any outer or inner surface location of the lower portion CB′ of the hopper 100 which extend inwardly towards the central axis ‘Y’ in the direction of travel of the bulk material.

[0110] The panel 142 extends inwardly towards the central axis ‘Y’ in the direction of travel of the bulk material. The panel 142 therefore is inclined in towards and directs bulk material to the outlet 130. This may therefore be described as a ‘positive angle’. The degree of inclination in towards from a vertical central ‘Y’ axis may range from about 10 degrees—about 45 degrees. A preferred degree of inclination inwards is about 20 degrees—about 40 degrees.

[0111] On referring to FIGS. 2, 4, 6, 7 and 8 there is shown an agitator 150 opposite to the location of the agitator 140. The agitator 150 is located on the lower portion CB′ of the hopper 100. In particular, the agitator 150 is located on a panel 152 which is inclined in towards the central axis of the hopper 100 and is intended to feed material into the outlet 130. The panel 152 therefore extends inwardly towards the central axis ‘Y’ in the direction of travel of the bulk material. This may therefore be described as a ‘positive angle’. The degree of inclination in towards from a vertical central ‘Y’ axis may range from about 10 degrees—about 45 degrees. A preferred degree of inclination inwards is about 20 degrees—about 40 degrees.

[0112] It is an important feature of the present invention in that the agitators 140, 150 are located on inwardly inclined surfaces on the lower portion CB′ of the hopper 100. The agitators 140, 150 are typically located externally otherwise they would lead to internal blockages of the bulk material.

[0113] The agitators 140, 150 produce disturbance in material to prevent long-term blockages of the bulk material and aid the flow of the bulk material towards the outlet 130. The agitators 140, 150 are important in providing a constant and reliable feet of material through the outlet 130.

[0114] FIGS. 5 and 6 also show that there are also flat panels 172, 174 on the other sides of the lower portion CB′ of the hopper 100 which extend inwardly towards the central axis ‘Y’ in the direction of travel of the bulk material. The degree of inclination in towards from a vertical central ‘Y’ axis may range from about 10 degrees—about 45 degrees. A preferred degree of inclination inwards is about 20 degrees—about 40 degrees.

[0115] A further important feature of the hopper 100 is that due to the inclined inwardly pointing panel surfaces in the lower portion CB′ of the hopper 100, the outlet 130 is smaller than the cross-sectional area between the upper portion CA′ and the lower portion CB′ of the hopper 100. Typically, the outlet 130 is about 30%-80% smaller than the cross-section of the area between the upper portion ‘A’ and the lower portion ‘B’ of the hopper 100. The example shown in the hopper 100 is that the outlet 130 is about 50% smaller than the intersection between the upper portion ‘A’ which has a majority of outwardly directed panels and the lower portion ‘B’ which has inwardly directed panels.

[0116] The purpose of the inwardly directed panels on the lower portion CB′ not only facilitates the agitation process but also means that the bulk material is not perpendicular to the force of the agitators 140, 150. This means that the effectiveness of the agitation is increased and has been found to be significantly effective in preventing permanent blockages in the hopper 100.

[0117] A potential function of the hopper 100 is to act as a short-term storage or so-called buffer system to eliminate fluctuations in the amount/volume of material being fed and to avoid delays of any suitable type of feed system.

[0118] A further specific advantage of the hopper 100 described above is that by using a combination of the inwardly inclined and mainly outwardly directed panels in the upper portion ‘A’ and the inwardly directed panels in the lower portion ‘B’ this maximizes the volume capacity in relation to agitation requirements of the hopper 100 in comparison to hoppers with traditional and simple vertical sides. Moreover, due to the increase in volume capacity, this allows more efficient use of space on the conveying line and allows lower manufacturing costs.

[0119] A further advantage of the hopper 100 is that as shown in all of FIGS. 1 to 11 the panels on all sides are all flat or substantially flat which reduces manufacturing costs and also facilitates ease of manufacture. The flat surfaces are also highly effective in preventing blockages in the flow of the bulk material through the passageway 111.

[0120] Furthermore, by reducing the material pressure on the agitators 140, 150 with the inclined inwardly directed panel walls in the lower portion CB′ has been found to improve the lifetime of the agitators 140, 150 and has also been found to allow more efficient removal of bulk material from the hopper 100.

[0121] The hopper 100 is designed to provide sufficient volume for short time storage of bulk material in a range of feeding devices. For example, the amount of bulk material held may range from about 1 m.sup.3 to about 50 m.sup.3.

[0122] The hopper 100 has also been found to provide a constant and reliable feed and be highly effective in preventing blockages with the throughput of the bulk material from the inlet 110 down towards and out of the outlet 130.

[0123] FIG. 9 is a perspective view showing the bottom of the hopper 100. The outlet 130 is clearly shown. As mentioned above, the outlet 130 is smaller than the cross-sectional area between the upper portion CA′ and the lower portion CB′ of the hopper 100.

[0124] FIG. 10 is a sectional view of the hopper shown in FIGS. 1 to 9. FIG. 10 clearly shows that the material will enter through the inlet 110 and exit should outlet 130. FIG. 10 also shows that there is a central passageway 111 extending from the inlet 110 to the outlet 130. The shape of the central passageway 111 is defined by the direction of the panels in the upper portion CA′ and lower portion CB′.

[0125] It should be noted that all of the panels used in the construction of the hopper 100 are flat or substantially flat. FIG. 10 also clearly shows that the inside surface of the passageway 111 is smooth with the flat or substantially flat panel surfaces in both the upper portion CA′ and lower portion CB′. It is preferred that at least one, a majority or all the panel surfaces in the upper portion CA′ point outwards and away from the central axis ‘Y’ in the direction of travel of the bulk material. It is also preferred that at least one, a majority or all the panel surfaces in the lower portion CB′ point inwards and towards from the central axis ‘Y’ in the direction of travel of the bulk material.

[0126] The use of flat panels facilitates both manufacture and reduces cost.

[0127] The hopper 100 is also highly symmetrical meaning that this reduces the different number of different components required to manufacture the hopper 100.

[0128] Although any suitable material may be used for the construction of the panels sheet metal and/or composite material is a typically preferred option.

[0129] FIG. 11 is a representation of the hopper 100 where there is a device 200 used to extract the bulk material exiting the outlet 130 in controlled way. There is shown a series of transport screws 210, 212 which are driven by a motor 220. However, it should be noted that the hopper 100 as described herein is highly suitable as providing a constant and reliable feed for a range of systems including any form of mechanical feed systems.

[0130] In use, bulk material is initially fed into the inlet 110. As indicated above, any type of bulk material may be used. The bulk material then enters the upper portion ‘A’ of the hopper 100. As explained above, at least one or a majority of the panels in the upper portion ‘A’ of the hopper 100 extend and are inclined outwards from the central axis ‘Y’ in the direction of travel of the bulk material. This has been found to be an important feature in preventing potential bridges and blockages in the hopper 100.

[0131] The bulk material then passes to the lower portion CB′ where at least one or a majority of the panels extend inwardly towards the central axis ‘Y’ in the direction of travel of the bulk material. In combination with the material disturbance provided by the agitators 140, 150 such an arrangement has been found to be highly effective in preventing blockages and thereby providing a constant and reliable feed of bulk material.

[0132] A further advantage is that the load and torque exerted on the agitators 140, 150 is significantly reduced and by up to about 70% in comparison to hoppers with vertical straight sides. Such a system has also been found to maximize the available volume of material which can be fed into the hopper 100. By preventing any form of permanent blockage in the hopper this enables the time spent for bulk material in the hopper 100 to be kept to a minimum thereby increasing reliability and preventing forms of permanent blockage. Such a system also ensures a constant and reliable feed to subsequent, for example, any form of mechanical processing systems.

[0133] Whilst specific embodiments of the present invention have been described above, it will be appreciated that departures from the described embodiments may still fall within the scope of the present invention. For example, any suitable type of flat or substantially panels may be used in the construction of the hopper. Furthermore, the hopper may be used as part of a larger system such as a mechanical system for the supply of any form of material.

[0134] The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.