Cyclone separator apparatus and methods of production

Abstract

There is provided a method of forming a hydrocyclone body including assembling sintered alumina blocks (27) against a form (37), holding the blocks (27) in place with tape (40), locating a hydrocyclone housing over the blocks (27), filling a space between them with settable epoxy/ceramic composite to secure the blocks (27) to the casing, and removing the form (37), resulting in a substantially continuous, wear resistant surface.

Claims

1. A method of forming a wear resistant minerals processing body including the steps of: assembling wear resistant elements to form a substantially continuous wear resistant surface against an outer surface of a form; locating a casing over the wear resistant elements with a space therebetween; filling the space with a settable adhesive material; allowing the settable adhesive material to set in order to secure the wear resistant elements relative to the casing; and removing the form wherein the wear resistant minerals processing body is selected from a cyclone separator body assembly and a cyclone separator lower cone and spigot assembly.

2. The method according to claim 1, wherein the wear resistant elements comprise isostatically pressed sintered ceramic material.

3. The method according to claim 2, wherein the ceramic material is alumina.

4. The method according to claim 1, wherein the wear resistant elements comprise specifically shaped elements adapted to form, in close abutment, a frusto-conical surface comprising said substantially continuous wear resistant surface.

5. The method according to claim 1, wherein the form comprises a substantially truncated-conical outer surface against which the wear resistant elements are assembled.

6. The method according to claim 1, wherein the casing is of steel and provided with one or more end flanges.

7. The method according to claim 1, wherein the settable adhesive material is selected from a resilient material and a thermoset resin material.

8. The method according to claim 7, wherein the settable adhesive material is selected from mineral-filled epoxy grouting materials.

9. The method according to claim 8, wherein the mineral-filled epoxy grouting materials comprise ceramic beads.

10. The method according to claim 1, including providing monitoring means in the space between the wear resistant elements and the casing.

11. The method according to claim 10, wherein the monitoring means includes one or more transducers connected to an interface external of the casing.

12. The method according to claim 10, wherein the monitoring means comprises one or more conductors each forming a continuity testing circuit element having an interface external of the casing.

Description

DESCRIPTION OF THE FIGURES

(1) The accompanying drawings facilitate an understanding of the various embodiments.

(2) FIG. 1 is a perspective view of a crated cyclone separator assembly;

(3) FIG. 2 is a portion of a cyclone assembly, in accordance with one embodiment of the present disclosure;

(4) FIG. 3 is a portion of a cyclone assembly, in accordance with a another embodiment of the present disclosure;

(5) FIG. 4 is a perspective view of a partially-assembled wear resistant lining on a form, in accordance with one embodiment of the apparatus and of one embodiment of the method of the present disclosure;

(6) FIG. 5 is a cyclone body outer casing suitable for use in conjunction with the liner of FIG. 6;

(7) FIG. 6 is a half-sectional view of a wear resistant cyclone body in accordance with an embodiment of the present disclosure;

(8) FIG. 7 is a perspective view of an assembled wear resistant liner assembly in accordance with an embodiment of the present disclosure, which suitable for use with the cyclone body of FIG. 4; and

(9) FIG. 8 is a conductor lead-in detail of the cyclone body of FIG. 4.

DETAILED DESCRIPTION

(10) Referring to FIG. 1, there is provided a cyclone assembly 10 consisting of an inlet assembly 11 and a lower cone and spigot assembly 12, separated by a cyclone body assembly 13, the latter secured to each of the inlet assembly 11 and the lower cone and spigot assembly 12 by respective flange abutments 14, 15. The inlet assembly has a tangential or cycloidal inlet 16 to, and an in use upper axial outflow from a ceramic-lined inlet portion 20.

(11) The lower cone and spigot assembly 12 includes a ceramic lined, lower cone 21 defining a separation zone in use for relatively large and/or dense particles of a feed slurry material during a cyclone separation operation, and an underflow outlet spigot 22 via which the separated particles pass in use during discharge.

(12) As shown in FIGS. 2 and 6, the cyclone body assembly 13 includes a steel outer frusto-conical housing 23 having an in use upper inlet flange 24 and a lower underflow flange 25. A wear resistant liner assembly 26 comprising closely abutting, isostatically pressed, sintered alumina blocks 27 of both axially tapered and circumferentially curved form, is arranged in serried circumferential rows 30, the joins 31 between adjacent blocks 27 in a row being offset from the joins 31 in the rows axially adjacent.

(13) As can be seen in FIG. 2, and in the detail shown in FIG. 8, a conductive wire insulated by LINATEX? rubber 32 forms an axially aligned zigzag pattern with radiused apices on the outer surface of the liner assembly 26. The wire insulated by LINATEX? rubber is 5-stranded, multifilament wire wherein each filament comprises 0.38 mm brass coated crimped steel, the strands being twisted to form a bundle within the insulation cover. The conductive wire 32 is terminated by lead-outs 34 passing through the wall of the housing 23 via ceramic insulators 35. The liner assembly 26 is spaced from the housing 23 by a 5-25 mm deep space 36. The liner assembly 26, conductive wire 32, lead-outs 34 and insulators 35 are all encapsulated by and secured to the interior wall of the frusto-conical housing 23 by mineral filled epoxy resin encapsulant adhesive filler occupying the space 36. LINATEX? is a registered trademark of Linatex Limited, a Weir Group PLC affiliate company.

(14) As can be seen in the alternative embodiment of FIG. 3, the conductive wire 32 may be laid in a spiral on the outer surface of the liner assembly 26. In this embodiment the apertures 41 are located adjacent the respective flanges 24, 25.

(15) To illustrate the method of the example, reference can be made to FIGS. 3 and 7. The wear resistant liner assembly 26 is assembled from the isostatically pressed sintered alumina blocks 27 in the circumferential rows 30 by laying up the blocks 27 about a frusto-conical form, or mandrel 37. The layup is secured against collapse by strategic circumferential tie-wires or tape bands 40.

(16) After layup is complete, the conductive wire 32 is then laid up in either an axially aligned zigzag pattern (FIG. 2) or a circumferential spiral pattern (FIG. 3) on the outer surface of the liner assembly 26, and retained by occasional restraints (not shown). The lead-outs 34 are left long at this time.

(17) The frusto-conical housing 23 has apertures 41 to which are fitted the ceramic insulators 35. Each long lead-out 34 is passed through the housing 23 and out through a respective insulator 35. During assembly of the final product, the lead outs 34 are continuously eased through the insulators 35 while the housing 23 is lowered over the liner assembly 26.

(18) When the housing 23 is located completely over the liner 26, a ceramic-bead filled epoxy resin encapsulant adhesive filler is then injected into the 5-25 mm space 36, in order to encapsulate the inner assembly 26, the conductive wire 32, the lead-outs 34 and the insulators 35 and to bond the assembly thereof to the housing 23.

(19) After curing, the long lead-outs 34 may be trimmed and terminated, and the cyclone body assembly 13 assembled by mounting its upper inlet flange 24 and its lower underflow flange 25 to the inlet assembly 11 and to the lower cone and spigot assembly 12, respectively.

(20) The lower cone and spigot assembly 12 is formed in substantially the same way as described for the body assembly 13 of the cyclone.

(21) In use, the encapsulant adhesive filler comprises a secondary wear layer. The lead-outs 34 each form a terminal between which a continuity tester (in this case, a multimeter) may be connected. In the event that a discontinuity of the conductive wire 32 is detected, a worn state of the primary liner assembly 26 is inferred. Thereafter the operator may program a shut-down in an orderly fashion rather than in response to catastrophic failure. The secondary wear liner thus provides a management interval between an indication of failure and shut-down and replacement of the worn assembly.

(22) Apparatus and methods in accordance with the foregoing embodiment can reduce the labour required to manufacture cyclone components. The internal surface of cyclone component is relatively smoother than the prior art examples since the inner surface is prepared by being laid up on a smooth form or mandrel. This reduces the turbulence generated by the interaction of the outlet surface of the layer of tiles and the circulating fluid within the cyclone chamber.

(23) Labour can also be reduced as each individual tile does not have to be glued into its precise position, nor is it awkward for an operator to constantly need to reposition in order to place some tiles in specific locations down the inside wall of a cyclone housing, as is the known prior art methodology. In addition, the filled epoxy layer may accommodate any out-of-round shape of the fabricated housing while maintaining a regular conical substantially smooth wear surface.

(24) Using a multimeter (or alternative) across the two exposed ends of the conductive wire, the circuit can easily and rapidly be tested for integrity without disassembly or interruption of the operating process. Excess wear (which is evident if the circuit has been broken) warns the operator that the cyclone is operating with access to the secondary wear liner formed by the ceramic-bead filled epoxy, and that scheduled maintenance or replacement of the part is required. Catastrophic failure is therefore avoided with planned maintenance becoming predictable.

(25) Forming cyclone linings against a form can also accommodate the use of wear elements of varying thickness. This is a very useful alternative given that a vertically oriented cyclone typically wears more aggressively at the in use lower regions of the cyclone. It may therefore be beneficial to be able to use thicker linings in this region of the cyclone. This ability to easily accommodate different lining thickness offers cost and weight savings, which is something not economically achievable using the traditional tile laying method on the inside of the housing.

(26) In refurbishment, heating of the housing allows it to expand differentially from the epoxy/liner composite, allowing the word composite to drop out of the taper.

(27) In the foregoing description of preferred embodiments, specific terminology has been resorted to for the sake of clarity. However, the invention is not intended to be limited to the specific terms so selected, and it is to be understood that each specific term includes all technical equivalents which operate in a similar manner to accomplish a similar technical purpose. Terms such as front and rear, inner and outer, above, below, upper and lower and the like are used as words of convenience to provide reference points and are not to be construed as limiting terms.

(28) The reference in this specification to any prior publication (or information derived from it), or to any matter which is known, is not, and should not be taken as, an acknowledgement or admission or any form of suggestion that prior publication (or information derived from it) or known matter forms part of the common general knowledge in the field of endeavour to which this specification relates.

(29) In this specification, the word comprising is to be understood in its open sense, that is, in the sense of including, and thus not limited to its closed sense, that is the sense of consisting only of. A corresponding meaning is to be attributed to the corresponding words comprise, comprised and comprises where they appear.

(30) In addition, the foregoing describes only some embodiments of the invention(s), and alterations, modifications, additions and/or changes can be made thereto without departing from the scope and spirit of the disclosed embodiments, the embodiments being illustrative and not restrictive.

(31) Furthermore, invention(s) have been described in connection with what are presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention(s). Also, the various embodiments described above may be implemented in conjunction with other embodiments, for example, aspects of one embodiment may be combined with aspects of another embodiment to realize yet other embodiments. Further, each independent feature or component of any given assembly may constitute an additional embodiment.