US20120204721A1 - System for reducing head space in a pressure cyclone - Google Patents
System for reducing head space in a pressure cyclone Download PDFInfo
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- US20120204721A1 US20120204721A1 US13/448,250 US201213448250A US2012204721A1 US 20120204721 A1 US20120204721 A1 US 20120204721A1 US 201213448250 A US201213448250 A US 201213448250A US 2012204721 A1 US2012204721 A1 US 2012204721A1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B04—CENTRIFUGAL APPARATUS OR MACHINES FOR CARRYING-OUT PHYSICAL OR CHEMICAL PROCESSES
- B04C—APPARATUS USING FREE VORTEX FLOW, e.g. CYCLONES
- B04C5/00—Apparatus in which the axial direction of the vortex is reversed
- B04C5/02—Construction of inlets by which the vortex flow is generated, e.g. tangential admission, the fluid flow being forced to follow a downward path by spirally wound bulkheads, or with slightly downwardly-directed tangential admission
- B04C5/04—Tangential inlets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D45/00—Separating dispersed particles from gases or vapours by gravity, inertia, or centrifugal forces
- B01D45/12—Separating dispersed particles from gases or vapours by gravity, inertia, or centrifugal forces by centrifugal forces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B04—CENTRIFUGAL APPARATUS OR MACHINES FOR CARRYING-OUT PHYSICAL OR CHEMICAL PROCESSES
- B04C—APPARATUS USING FREE VORTEX FLOW, e.g. CYCLONES
- B04C5/00—Apparatus in which the axial direction of the vortex is reversed
- B04C5/08—Vortex chamber constructions
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Definitions
- Embodiments of the present invention generally relate to cyclonic separation units. More particularly, embodiments of the present invention relate to high-pressure cyclones.
- Cyclonic separation involves separating a mixture of two or more phases, for example, fluid-particulate suspensions wherein one or more solid particulates are suspended in a carrier fluid, under a centrifugal force generated by centripetal motion.
- a cyclone separator is the mechanical device typically used to carry out cyclonic separation processes. In normal cyclone separator operation, a particulate suspension is introduced into the top of the cyclone separator via a tangential inlet where the solid particles tend to collect on the inner surface of the separator and its fluidic counterpart is entrained into a vortex. The solid particles gradually fall to the bottom of the separator vessel for further processing, while the fluidic counterpart is eventually drawn through a centrally-located output tube.
- Uses of cyclonic separation methods can include unit operations to purify a phase, to concentrate a phase, to terminate chemical and physical interactions between mixed phases, or combinations thereof.
- Pressure cyclones In applications exhibiting high and ultrahigh pressures, cyclonic separation operations are typically undertaken by a pressure cyclone separator.
- Pressure cyclones generally consist of a compression-proof vessel that is geometrically and structurally designed to resist elevated pressures and temperatures. However, it is nonetheless not unheard of to employ pressure cyclones in low-pressure environments. In practice, a pressure cyclone can be manufactured to almost any size or dimension to fit any particular separation application.
- At least one high-pressure application that is appropriate for a pressure cyclone includes hydrocarbon gasification processes, where carbonaceous materials, such as coal, petroleum, crude oil, tars, biofuel, or biomass, are converted into a “syngas,” such as carbon monoxide and hydrogen.
- a hydrocarbon gasification process can range from about 50 psi to about 1,000 psi, and even up to ultrahigh pressures of about 7,000 psi. Because of these potentially-extreme conditions, the structural design of pressure cyclones is a vital concern if it is to endure a long production life.
- the top head and tangential inlet of the pressure cyclone are key components in improving the overall efficiency of high-pressure cyclonic separation processes.
- the top head has been designed as a flat surface near the inlet entrance, thereby creating joints and edges reflecting a significant propensity to fail under elevated pressures and temperatures.
- Prior applications have implemented a semi-spherical, convex top head to take advantage of the structural integrity of an arced surface in order to withstand the elevated pressures.
- the convex top head design essentially creates a void area between the tangential inlet and the top head where the vortex can be significantly disturbed, thereby resulting in a significant reduction in efficiency of the separation process.
- the casing surrounding the tangential inlet has often been designed with square or rectangular features that also have a tendency to fail or crack under extreme conditions.
- the inlet nozzle is oftentimes required to be shifted into direct or semi-direct alignment with a centrally-located vortex output tube, thereby injecting particulate matter directly at the output tube which prematurely erodes its surface and disturbs the vortex.
- some designs have implemented a bend in the output tube, thereby placing it off-center from the vortex and effectively reducing the efficiency of the process.
- FIG. 1 depicts a side view of an exemplary cyclone, according to one or more embodiments of the disclosure.
- FIG. 2 depicts a top view of the exemplary cyclone of FIG. 1 , according to one or more embodiments of the disclosure.
- FIG. 3 depicts a portion of a top head as shown in FIG. 1 , according to one or more embodiments of the disclosure.
- FIG. 4 depicts a side view of the cyclone inlet, according to one or more embodiments of the disclosure.
- FIG. 5 depicts an end view of the cyclone inlet of FIG. 4 taken along the line 5 - 5 indicated in FIG. 4 , according to one or more embodiments of the disclosure.
- FIG. 6 depicts an opposing end view (with respect to the end view shown in FIG. 5 ) of the cyclone inlet of FIG. 4 taken along the line 6 - 6 indicated in FIG. 4 , according to one or more embodiments of the disclosure.
- FIG. 7 depicts a portion of the top head with an exemplary rain shield disposed thereon, according to one or more embodiments of the disclosure.
- FIG. 8 depicts a magnification of the cap portions indicated in FIG. 7 .
- FIGS. 1 and 2 depict an exemplary cyclone 100 , according to one or more embodiments of the present disclosure.
- FIG. 1 depicts a side view of the exemplary cyclone 100
- FIG. 2 depicts an end view of the same.
- the cyclone 100 can be configured as a pressure cyclone as used in high-pressure cyclonic separation applications.
- one high-pressure cyclonic separation application can include hydrocarbon gasification processing.
- the exemplary cyclone 100 can be equally effective in low-pressure applications, such as fluid catalytic cracking units where catalyst particles are cyclonically-separated from a hydrocarbon vapor suspension.
- the cyclone 100 can include a cyclone vessel 102 generally defining a cylindrical structure having an inlet 104 and an outlet 106 , where the outlet 106 includes an outlet tube 105 configured to sealingly penetrate a top head 107 .
- the cyclone vessel 102 can be configured as a pressure-vessel enabled to withstand elevated pressures and temperatures in cyclonic separation processes.
- the cyclone vessel 102 can include a vessel casing 108 , an erosion resistant layer 110 , and an insulating layer 112 interposed between the vessel casing 108 and the erosion resistant layer 110 .
- the vessel casing 108 can generally define the outside surface of the cyclone vessel 102
- the erosion resistant layer 110 generally defines an inner cylindrical surface 126 .
- the vessel casing 108 can be made of, for example, carbon steel, such as a low-alloy steel, but can also be manufactured of other materials having similar strength characteristics as carbon steel.
- the erosion resistant layer 110 can include a dense layer refractory material, either a pressed or monolithic refractory, configured to protect the adjacent insulating layer 112 and provide a surface 126 where solid particulate can collect, as will be described below.
- the erosion resistant layer 110 can be made of RESCO® RS-88 VC refractory material (Resco Products, Inc.), and can be installed by vibracasting techniques.
- the insulating layer 112 can serve as a back-up refractory layer, but more importantly can provide an insulating material for the cyclone vessel 102 .
- the insulating layer 112 can include a thermal ceramic, such as KAOLITE® 2300 LI thermal ceramic (Thermal Ceramics, Inc.), and can be installed by casting techniques.
- the insulating layer 112 can be configured to withstand elevated temperatures of around 1800° F.
- the inlet 104 can be tangentially-disposed on the cyclone vessel 102 and include an inlet casing 116 , an inlet erosion resistant layer 118 , and an inlet insulating layer 120 interposed between the inlet casing 116 and the inlet erosion resistant layer 118 .
- the inlet casing 116 can be substantially cylindrical along its length, but gradually tapering or transitioning along its length into an elliptical or oval-like conduit as it eventually intersects the vessel casing 108 .
- the inlet 104 can be welded to the cyclone vessel 102 to ensure a pressure-tight interconnection.
- the inlet 104 can be mechanically coupled or otherwise attached to the cyclone vessel 102 , while maintaining a pressure-resistant interconnection.
- the inlet casing 116 can be made of carbon steel, such as low-alloy steel.
- the inlet erosion resistant layer 118 can include a dense layer refractory material, such as RESCO® RS-88VC refractory material, and can be installed by vibracasting techniques, as known in the art.
- the inlet insulating layer 120 can serve as a back-up refractory layer to the inlet erosion resistant layer 118 and also provide insulation along the length of the inlet 104 .
- the inlet insulating layer 120 can include a thermal ceramic, such as KAOLITE® 2500 LI (Thermal Ceramics, Inc.), and can be installed by gunning techniques, as known in the art.
- An inlet nozzle 122 can be defined in and generally centered along the length of the inlet 104 toward the cyclone vessel 102 .
- the inlet nozzle 122 can be rectangular in shape, having a first surface 124 substantially tangent to and continuous with the inner cylindrical surface 126 of the cyclone vessel 102 .
- the inlet nozzle 122 can have a second surface 128 substantially parallel and continuous with a cyclone roof 130 of the cyclone vessel 102 , wherein the cyclone roof 130 forms part of the top head 107 .
- first surface 124 and the second surface 128 can each provide a smooth transition for any incoming fluid-particulate suspension from the inlet nozzle 122 to the inner cylindrical surface 126 and cyclone roof 130 , respectively.
- other exemplary embodiments can include a substantially square-shaped inlet nozzle 122 having similar first and second surfaces 124 , 128 , without departing from the scope of the disclosure.
- a fluid-particulate suspension containing one or more solid particulates suspended in a fluid can enter the cyclone vessel 102 tangentially through the inlet nozzle 122 and swirl circumferentially against the inner cylindrical surface 126 , thereby creating a centrally-located vortex of reduced solids content.
- the fluid-particulate suspension can be introduced to the cyclone vessel 102 at elevated temperatures and pressures.
- the incident pressures Can range from a lower end of about zero psi, about 100 psi, about 200 psi, about 300 psi or about 400 psi to an upper end of about 500 psi, about 600 psi, about 700 psi, about 800 psi, about 900 psi or about 1000 psi. Further, the incident pressures can range from about 500 psi to about 900 psi, or from about 600 psi to about 800 psi, from about 700 psi to about 800 psi.
- the incident temperatures can range from a low end of about 100° F., about 200° F., about 300° F., about 400° F., about 500° F., about 600° F., about 700° F., about 800° F., about 900° F. or about 1000° F. to and upper end of about 1100° F., about 1200° F., about 1300° F., about 1400° F., about 1500° F., about 1600° F., about 1700° F., about 1800° F., about 1900° F. or about 2000° F. Further, that incident temperature can range from about 1500° F. to about 2000° F., about 1600° F. to about 1900° F., about 1700° F. to about 1800° F. or from about 1550° F.
- the pressure within the cyclone vessel can reach ultrahigh pressures of greater than 1000 psi, such as 2000 psi, 3000 psi, 4000 psi, 5000 psi, 6000 psi and even up to about 7000 psi or more.
- the suspended solid particulates can be immediately driven outward toward the inner cylindrical surface 126 by centrifugal forces.
- the disentrained particulates rapidly concentrate at the inner cylindrical surface 126 and gradually pass downward through the cyclone vessel 102 for downstream processing.
- the separated fluid phase of decreasing particulate loading can eventually form a centrally-located vortex. From the vortex, a solids-lean fluid, such as gas or fuel, can exit via the outlet tube 105 to the outlet 106 .
- the top head 107 can be circumferentially-disposed around and sealingly engaged with a portion of the outlet tube 105 .
- the top head 107 can include the cyclone roof 130 , as discussed above, a concave casing 302 , and a roof insulation layer 304 interposed therebetween.
- the cyclone roof 130 can include a dense layer refractory, such as RESCO® RS-88VC, and be configured to prevent erosion of the roof insulation layer 304 .
- the cyclone roof 130 can also be configured to provide a flat surface substantially parallel and continuous with the second surface 128 of the inlet nozzle 122 (see FIGS. 1 and 2 ).
- the cyclone roof 130 can include a series of pie-shaped refractory bricks, circumferentially-surrounding the outlet tube 105 and interconnected with each other through, for example, a tongue-and-groove or keyed joint.
- each pie-shaped refractory brick of the cyclone roof 130 may be coupled to and supported within the cyclone vessel 102 by one or more T-studs 306 a,b,c cast directly into the bricks of the cyclone roof 130 and attached or otherwise coupled to the concave casing 302 .
- a shoulder 308 of the erosion resistant layer 110 and a ring 310 , coupled or otherwise attached to the outlet tube 105 can provide further support for the cyclone roof 130 refractory bricks.
- the ring 310 can be disposed circumferentially about the outlet tube 105 and made of an alloy, such as HAYNES® HR-120® (Haynes International).
- the roof insulation layer 304 can serve as a back-up refractory layer to the cyclone roof 130 and further provide an insulating material.
- the roof insulating layer 304 can include a thermal ceramic, such as KAOLITE® 2300 LI thermal ceramic, and can be installed by casting techniques.
- the concave casing 302 can be inwardly-concave toward the interior of the cyclone vessel 102 but convex to the pressure, as typified by the Boiler and Pressure Vessel Code provided by ASME.
- the concave casing 302 can be welded, or otherwise attached by mechanical means, to the casing 108 of the cyclone vessel 102 .
- employing the inwardly-concave casing 302 to the top head 107 takes advantage of the resilient structural properties of an arced member for use in high-pressure applications, whereas similarly-situated non-arced members (e.g., a flat member) would be unable to withstand the elevated pressures and would ultimately fail.
- the concave casing 302 of the top head 107 can eliminate unneeded and process-inefficient voids created between the inlet 104 and the cyclone roof 130 . Eliminating the void between the inlet 104 and the cyclone roof 130 can not only improve overall process efficiency, but can also result in a substantial cost savings in materials needed to fill or seal the void.
- the inlet 104 can include a longitudinal axis 402 along which the inlet nozzle 122 concentrically extends into the cyclone vessel 102 .
- the inlet nozzle 122 can be rectangular, but other embodiments can include a square-shaped inlet nozzle 122 or other polygonal shapes without departing from the scope of the disclosure.
- the inlet nozzle 122 can at least be configured to direct any incoming fluid-particulate suspension away from and/or around the outlet tube 105 , thereby decreasing the potential of premature erosion on the surface of the outlet tube 105 .
- the inlet nozzle 122 can include a first surface 124 and a second surface 128 , wherein each surface 124 , 128 provides a smooth transition from the inlet nozzle 122 to the inner cylindrical surface 126 and cyclone roof 130 , respectively.
- the inlet nozzle 122 can include a third surface 404 and a fourth surface 406 , where the third surface 404 faces the first surface 124 and the fourth surface 406 faces the second surface 128 .
- the third surface 404 can be configured to help direct the incoming stream of fluid-particulate suspension away from and/or around the centrally-located outlet tube 105 .
- the shape of the inlet nozzle 122 defined by its surfaces 124 , 128 , 404 , 406 can remain substantially constant along the length of longitudinal axis 402 .
- surfaces 124 , 128 , 404 , 406 may merge together to form a substantially circular cross-sectional shape.
- FIG. 5 depicts a view from a first end of the inlet 104 distal to the cyclone vessel 102 , taken along line 5 - 5 as indicated in FIG. 4 , and shows the inlet nozzle 122 encased by the inlet erosion resistant layer 118 , the inlet insulating layer 120 , and the inlet casing 116 .
- FIG. 6 depicts a view from a second end of the inlet 104 proximal the cyclone vessel 102 , taken along line 6 - 6 as indicated in FIG. 4 , where the inlet 104 can be coupled to or otherwise attached to the cyclone vessel 102 .
- the inlet casing 116 can be generally circular in cross-section ( FIG.
- the transformation of the inlet casing 116 from a generally circular shape into a generally elliptical shape along the longitudinal axis 402 can provide a tapered connection point configured to smoothly transition into the outer surface of the cyclone vessel 102 .
- the tapering transition of the inlet casing 116 can prove advantageous over applications employing a uniformly-cylindrical inlet casing which is difficult to smoothly transition to the cyclone vessel 102 for attachment without shifting the longitudinal axis 402 into the path of the downwardly-extending outlet tube 105 .
- Such a shift in the longitudinal axis 402 would result in the direct impact of incoming particulates on the outlet tube 105 , thereby prematurely eroding its surface, or would necessitate a repositioning of the outlet tube 105 within the cyclone vessel 102 to avoid direct particulate contact.
- Repositioning the centrally-located outlet tube 105 can have adverse effects on vortex efficiency and overall process efficiency.
- the rain shield 700 can be circumferentially-disposed around the outlet 106 of the cyclone 100 ( FIG. 1 ) to prevent rainwater accumulation on the exterior of the top head 107 where the concave casing 302 is located.
- the rain shield 700 can include a series of cap portions 702 horizontally-disposed from the outlet 106 at varying points along the length of the outlet 102 .
- cap portions 702 are illustrated herein, it is understood that such is merely by way of example, and not intended to limit the scope of the subsequently presented claims. Indeed, a greater or lesser number of cap portions 702 can be implemented to fit a particular application, without departing from the scope of the disclosure.
- each cap portion 702 can be configured to extend at least partially around the outlet 106 at a given point along its length with respect to the outlet 106 . After extending partially around the outlet 106 , the cap portion 702 can there be coupled or otherwise attached to another cap portion 702 , and so on until the cap portions 702 extend completely around the outlet 106 at the given point. The same process can be undertaken at each elevation, as shown in FIG. 7 .
- the cap portion 702 can include two half-circle cap portions 702 that interconnect halfway around the outlet 106 , thereby providing a full circular cap portion 702 at a given point.
- the cap portion 702 can include a single circular length configured to extend completely around the circumference of the outlet 106 .
- the cap portions 702 can all generally be supported by a series of support plates 704 (only one shown), each support plate 704 being circumferentially-disposed around the exterior of the outlet 106 . Although only one cap portion 702 at a given point may actually be coupled to a support plate 704 , each cap portion 702 can be supported thereby through the internal support structure between each cap portion 702 , as will be described below. In at least one embodiment, there can be about eight support plate(s) 704 coupled or otherwise attached to the exterior of the outlet 106 . In one or more embodiments, the support plate(s) 704 can be welded to the exterior of the outlet 106 . In other exemplary embodiments, the support plate(s) 704 can be mechanically or otherwise attached to the exterior of the outlet 106 .
- a finish cap 706 Also coupled to the support plate(s) 704 can be a finish cap 706 . Similar to the construction of the cap portions 702 , the finish cap 706 can include one or more portions configured to extend at least partially around the outlet 106 and there be coupled or otherwise attached to another portion of the finish cap 706 , and so on until the finish cap 706 extends completely around the outlet 106 . In at least one embodiment, the finish cap 706 can include two half-circle finish cap 706 portions that interconnect halfway around the outlet 106 , thereby providing a full circular finish cap 706 . In other embodiments, the finish cap 706 can include a single portion that extends completely around the circumference of the outlet 106 .
- the finish cap 706 can also be coupled to a series of finish support plates 708 (only one shown), which can be coupled to or otherwise attached to the vessel casing 108 .
- the finish support plates 708 can be circumferentially-disposed around the vessel casing 108 and either welded or mechanically or otherwise attached thereto.
- each cap portion 702 can be supported by rigid straps 710 coupled at an end distal to the outlet 106 , and also supported by rigid straps 711 coupled at an end proximal to the outlet 106 .
- the rigid straps 710 , 711 can be bent or otherwise shaped to be coupled to the bottom of one cap portion 702 and to the top of the subsequent cap portion 702 , in a generally descending direction.
- At least one rigid strap 710 can be coupled to the bottom of the bottom-most cap portion 702 and also to the top of the finish cap 706 (not shown).
- the rigid straps 710 , 711 can include a thin strip of rigid material, such as a strip of stainless steel or aluminum, but can also include a strip of other rigid materials, such as plastics or other metals.
- the rigid straps 710 , 711 can be about one inch in width, but other exemplary embodiments can include rigid straps 710 , 711 of varying widths to suit a particular application.
- a plurality of the rigid straps 710 , 711 can be spaced equidistantly around the outlet 106 , thereby providing support to the several cap portions 702 .
- the rigid straps 710 , 711 can be spaced on about six inch centers at the periphery of the cap portions 702 around the outlet 106 . As illustrated, the rigid straps 710 , 711 can be coupled to the cap portions 702 and finish cap 706 by mechanical means, such as self-tapping screws 712 . One of skill in the art would, however, appreciate that the rigid straps 710 , 711 may be coupled by any available means without departing from the scope of the invention.
- portions of a screen material 714 can also be disposed around the outlet 106 to prevent the influx of animal life, such as birds and other foreign matter, into the exterior of the top head 107 where the concave casing 302 is located.
- the screen material 714 can be a wire mesh, but can also be made of other materials, such as plastics.
- the screen material 714 can be interposed between the cap portions 702 and the rigid straps 711 , and coupled or attached thereto by a coupling means, such as the self-tapping screws 712 . As shown in FIG.
- the screen material 714 can also be used in conjunction with the interconnection of the finish cap 706 and the finish support plated 708 , thereby providing a barrier configured to prevent the influx of animals and other foreign matter up through the bottom of the finish cap 706 .
- At least some of the cap portions 702 can include a lip section 716 configured to prevent the influx of rain into the exterior of the top head 107 .
- the lip sections 716 can be configured to stop blowing rain, which may enter at a substantially 90 ° angle with respect to horizontal.
- the remaining portion of the cap portions 702 can be generally disposed at a decline with respect to horizontal, thereby allowing any accumulated precipitation to drain from the rain shield 700 .
- the rain shield 700 can also provide a heat-dissipative effect for the cyclone vessel 102 .
- heat rising from the cyclone vessel 102 in the direction of arrow A ( FIG. 8 ) can be emitted via the open spaces between vertically-adjacent cap portions 702 in the direction of arrows B by means of convection.
- the cap portions 702 can be vertically-offset from each other by progressively smaller distances corresponding to the vertical point of the outlet 106 . In other words, the higher the vertical position on the outlet 106 , the smaller the outlet between adjacent cap portions 702 .
- progressively smaller outlet paths can force more heat out the lower and larger outlet paths by means of convective air currents, thereby allowing a greater amount of heat to escape with little or no restriction.
- a rain shield for a cyclone comprising: one or more cap portions circumferentially-disposed around an outlet of the cyclone and having an end distal to the outlet and an end proximal to the outlet; a series of support plates coupled to the one or more cap portions and also coupled to the outlet; a finish cap circumferentially-disposed around the outlet of the pressure cyclone, the finish cap being coupled to the series of support plates and also coupled to a series of finish support plates, wherein the finish support plates are coupled to a vessel casing of the pressure cyclone; a first plurality of rigid straps coupled to the one or more cap portions at the end distal to the outlet; a second plurality of rigid straps coupled to the one or more cap portions at the end proximal to the outlet; and a screen material coupled to the one or more cap portions at the end proximal the outlet and also coupled to the second plurality of rigid straps.
- the one or more cap portions further comprises a lip section disposed at the end proximal the outlet for preventing an influx of rain.
- the one or more cap portions comprises at least three cap portions, and wherein the adjacent cap portions are offset from each other by a progressively smaller distance corresponding to the length along the outlet.
- the cyclone comprises: a cyclone vessel having an inlet coupled thereto, the inlet configured to receive a particulate-fluid suspension comprising a fluid and at least one solid particulate suspended therein, and wherein the outlet of the cyclone is configured to remove the fluid separated from the particulate-fluid suspension separated fluids from the cyclone vessel; and a concave top head coupled to the cyclone vessel and circumferentially-disposed about the outlet tube, the concave top head comprising a substantially flat cyclone roof disposed in an interior of the cyclone vessel.
- the cyclone further comprises an inlet nozzle disposed within the inlet and having a first surface and a second surface, and wherein the first surface transitions to an inner cylindrical surface of the interior of the cyclone vessel and the second surface transitions to the substantially flat cyclone roof.
- a rain shield comprising: two or more cap portions circumferentially-disposed around an outlet of a cyclone having a concave top head and having an end distal to the outlet and an end proximal to the outlet, wherein the two or more cap portions are disposed at a decline with respect to horizontal and are offset from each other along a length of the outlet; a series of support plates coupled to the one or more cap portions and also coupled to the outlet; a finish cap circumferentially-disposed around the outlet of the pressure cyclone, the finish cap being coupled to the series of support plates and also coupled to a series of finish support plates, wherein the finish support plates are coupled to a vessel casing of the pressure cyclone; a first plurality of rigid straps coupled to the two or more cap portions at the end distal to the outlet and configured to support and join adjacent cap portions; a second plurality of rigid straps coupled to the two or more cap portions at the end proximal to the outlet and configured to support and join the adjacent cap portions; and a screen material coupled to the
- a method of separating solid particulates from a particulate-fluid suspension comprising: introducing the particulate-fluid suspension into a cyclone vessel via an inlet coupled thereto, and wherein the cyclone vessel comprises a roof and a top head having a rain shield disposed thereon, the rain shield comprising: one or more cap portions circumferentially-disposed around an outlet of the cyclone and having an end distal to the outlet and an end proximal to the outlet; a series of support plates coupled to the one or more cap portions and also coupled to the outlet; a finish cap circumferentially-disposed around the outlet of the pressure cyclone, the finish cap being coupled to the series of support plates and also coupled to a series of finish support plates, wherein the finish support plates are coupled to a vessel casing of the pressure cyclone; a first plurality of rigid straps coupled to the one or more cap portions at the end distal to the outlet; a second plurality of rigid straps coupled to the one or more cap portions at the end a
- the inlet comprises a rectangular inlet nozzle having a first surface tangent to an inner cylindrical surface of the cyclone vessel and a second surface substantially parallel to and continuous with a cyclone roof of a concave top head.
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Abstract
Description
- This application is a continuation of co-pending U.S. patent application Ser. No. 12/773,206, filed on May 4, 2010, which is incorporated by reference herein.
- 1. Field of the Invention
- Embodiments of the present invention generally relate to cyclonic separation units. More particularly, embodiments of the present invention relate to high-pressure cyclones.
- 2. Description of the Related Art
- Cyclonic separation involves separating a mixture of two or more phases, for example, fluid-particulate suspensions wherein one or more solid particulates are suspended in a carrier fluid, under a centrifugal force generated by centripetal motion. A cyclone separator is the mechanical device typically used to carry out cyclonic separation processes. In normal cyclone separator operation, a particulate suspension is introduced into the top of the cyclone separator via a tangential inlet where the solid particles tend to collect on the inner surface of the separator and its fluidic counterpart is entrained into a vortex. The solid particles gradually fall to the bottom of the separator vessel for further processing, while the fluidic counterpart is eventually drawn through a centrally-located output tube. Uses of cyclonic separation methods can include unit operations to purify a phase, to concentrate a phase, to terminate chemical and physical interactions between mixed phases, or combinations thereof.
- In applications exhibiting high and ultrahigh pressures, cyclonic separation operations are typically undertaken by a pressure cyclone separator. Pressure cyclones generally consist of a compression-proof vessel that is geometrically and structurally designed to resist elevated pressures and temperatures. However, it is nonetheless not unheard of to employ pressure cyclones in low-pressure environments. In practice, a pressure cyclone can be manufactured to almost any size or dimension to fit any particular separation application.
- At least one high-pressure application that is appropriate for a pressure cyclone includes hydrocarbon gasification processes, where carbonaceous materials, such as coal, petroleum, crude oil, tars, biofuel, or biomass, are converted into a “syngas,” such as carbon monoxide and hydrogen. Depending on the hydrocarbon used and the conversion process employed, pressures in a hydrocarbon gasification process can range from about 50 psi to about 1,000 psi, and even up to ultrahigh pressures of about 7,000 psi. Because of these potentially-extreme conditions, the structural design of pressure cyclones is a vital concern if it is to endure a long production life.
- The top head and tangential inlet of the pressure cyclone are key components in improving the overall efficiency of high-pressure cyclonic separation processes. In prior applications, the top head has been designed as a flat surface near the inlet entrance, thereby creating joints and edges reflecting a significant propensity to fail under elevated pressures and temperatures. Prior applications have implemented a semi-spherical, convex top head to take advantage of the structural integrity of an arced surface in order to withstand the elevated pressures. However, the convex top head design essentially creates a void area between the tangential inlet and the top head where the vortex can be significantly disturbed, thereby resulting in a significant reduction in efficiency of the separation process.
- Likewise, the casing surrounding the tangential inlet has often been designed with square or rectangular features that also have a tendency to fail or crack under extreme conditions. In applications using a continuously-circular inlet casing, the inlet nozzle is oftentimes required to be shifted into direct or semi-direct alignment with a centrally-located vortex output tube, thereby injecting particulate matter directly at the output tube which prematurely erodes its surface and disturbs the vortex. To remedy this, some designs have implemented a bend in the output tube, thereby placing it off-center from the vortex and effectively reducing the efficiency of the process.
- What is needed, therefore, is an improved top head design and tangential inlet for pressure cyclones that can withstand elevated pressures and maintain or increase process efficiency.
- So that the recited features of the present invention can be understood in detail, a more particular description of the invention may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
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FIG. 1 depicts a side view of an exemplary cyclone, according to one or more embodiments of the disclosure. -
FIG. 2 depicts a top view of the exemplary cyclone ofFIG. 1 , according to one or more embodiments of the disclosure. -
FIG. 3 depicts a portion of a top head as shown inFIG. 1 , according to one or more embodiments of the disclosure. -
FIG. 4 depicts a side view of the cyclone inlet, according to one or more embodiments of the disclosure. -
FIG. 5 depicts an end view of the cyclone inlet ofFIG. 4 taken along the line 5-5 indicated inFIG. 4 , according to one or more embodiments of the disclosure. -
FIG. 6 depicts an opposing end view (with respect to the end view shown inFIG. 5 ) of the cyclone inlet ofFIG. 4 taken along the line 6-6 indicated inFIG. 4 , according to one or more embodiments of the disclosure. -
FIG. 7 depicts a portion of the top head with an exemplary rain shield disposed thereon, according to one or more embodiments of the disclosure. -
FIG. 8 depicts a magnification of the cap portions indicated inFIG. 7 . - A detailed description will now be provided. Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the “invention” may in some cases refer to certain specific embodiments only. In other cases it will be recognized that references to the “invention” will refer to subject matter recited in one or more, but not necessarily all, of the claims. Each of the inventions will now be described in greater detail below, including specific embodiments, versions and examples, but the inventions are not limited to these embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the inventions, when the information in this patent is combined with publicly available information and technology.
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FIGS. 1 and 2 depict anexemplary cyclone 100, according to one or more embodiments of the present disclosure.FIG. 1 depicts a side view of theexemplary cyclone 100, whileFIG. 2 depicts an end view of the same. In an exemplary embodiment, thecyclone 100 can be configured as a pressure cyclone as used in high-pressure cyclonic separation applications. In at least one embodiment, one high-pressure cyclonic separation application can include hydrocarbon gasification processing. However, theexemplary cyclone 100 can be equally effective in low-pressure applications, such as fluid catalytic cracking units where catalyst particles are cyclonically-separated from a hydrocarbon vapor suspension. - As illustrated, the
cyclone 100 can include acyclone vessel 102 generally defining a cylindrical structure having aninlet 104 and anoutlet 106, where theoutlet 106 includes anoutlet tube 105 configured to sealingly penetrate atop head 107. In at least one embodiment, thecyclone vessel 102 can be configured as a pressure-vessel enabled to withstand elevated pressures and temperatures in cyclonic separation processes. Thecyclone vessel 102 can include avessel casing 108, an erosionresistant layer 110, and aninsulating layer 112 interposed between thevessel casing 108 and the erosionresistant layer 110. In one or more embodiments, thevessel casing 108 can generally define the outside surface of thecyclone vessel 102, while the erosionresistant layer 110 generally defines an innercylindrical surface 126. - The
vessel casing 108 can be made of, for example, carbon steel, such as a low-alloy steel, but can also be manufactured of other materials having similar strength characteristics as carbon steel. The erosionresistant layer 110 can include a dense layer refractory material, either a pressed or monolithic refractory, configured to protect the adjacentinsulating layer 112 and provide asurface 126 where solid particulate can collect, as will be described below. In at least one embodiment, the erosionresistant layer 110 can be made of RESCO® RS-88 VC refractory material (Resco Products, Inc.), and can be installed by vibracasting techniques. - The
insulating layer 112 can serve as a back-up refractory layer, but more importantly can provide an insulating material for thecyclone vessel 102. In at least one embodiment, theinsulating layer 112 can include a thermal ceramic, such as KAOLITE® 2300 LI thermal ceramic (Thermal Ceramics, Inc.), and can be installed by casting techniques. Theinsulating layer 112 can be configured to withstand elevated temperatures of around 1800° F. - As best illustrated in
FIG. 2 , theinlet 104 can be tangentially-disposed on thecyclone vessel 102 and include aninlet casing 116, an inlet erosionresistant layer 118, and aninlet insulating layer 120 interposed between theinlet casing 116 and the inlet erosionresistant layer 118. As will be described in more detail below, theinlet casing 116 can be substantially cylindrical along its length, but gradually tapering or transitioning along its length into an elliptical or oval-like conduit as it eventually intersects thevessel casing 108. In at least one embodiment, theinlet 104 can be welded to thecyclone vessel 102 to ensure a pressure-tight interconnection. In other exemplary embodiments, theinlet 104 can be mechanically coupled or otherwise attached to thecyclone vessel 102, while maintaining a pressure-resistant interconnection. - In an exemplary embodiment, the
inlet casing 116 can be made of carbon steel, such as low-alloy steel. Similar to the erosionresistant layer 110, the inlet erosionresistant layer 118 can include a dense layer refractory material, such as RESCO® RS-88VC refractory material, and can be installed by vibracasting techniques, as known in the art. Theinlet insulating layer 120 can serve as a back-up refractory layer to the inlet erosionresistant layer 118 and also provide insulation along the length of theinlet 104. In at least one embodiment, theinlet insulating layer 120 can include a thermal ceramic, such as KAOLITE® 2500 LI (Thermal Ceramics, Inc.), and can be installed by gunning techniques, as known in the art. - An
inlet nozzle 122 can be defined in and generally centered along the length of theinlet 104 toward thecyclone vessel 102. In at least one embodiment, theinlet nozzle 122 can be rectangular in shape, having afirst surface 124 substantially tangent to and continuous with the innercylindrical surface 126 of thecyclone vessel 102. Moreover, theinlet nozzle 122 can have asecond surface 128 substantially parallel and continuous with acyclone roof 130 of thecyclone vessel 102, wherein thecyclone roof 130 forms part of thetop head 107. Thus, thefirst surface 124 and thesecond surface 128 can each provide a smooth transition for any incoming fluid-particulate suspension from theinlet nozzle 122 to the innercylindrical surface 126 andcyclone roof 130, respectively. As can be appreciated, other exemplary embodiments can include a substantially square-shapedinlet nozzle 122 having similar first andsecond surfaces - In exemplary operation, a fluid-particulate suspension containing one or more solid particulates suspended in a fluid can enter the
cyclone vessel 102 tangentially through theinlet nozzle 122 and swirl circumferentially against the innercylindrical surface 126, thereby creating a centrally-located vortex of reduced solids content. In at least one embodiment, the fluid-particulate suspension can be introduced to thecyclone vessel 102 at elevated temperatures and pressures. For example, in one or more embodiments the incident pressures Can range from a lower end of about zero psi, about 100 psi, about 200 psi, about 300 psi or about 400 psi to an upper end of about 500 psi, about 600 psi, about 700 psi, about 800 psi, about 900 psi or about 1000 psi. Further, the incident pressures can range from about 500 psi to about 900 psi, or from about 600 psi to about 800 psi, from about 700 psi to about 800 psi. The incident temperatures can range from a low end of about 100° F., about 200° F., about 300° F., about 400° F., about 500° F., about 600° F., about 700° F., about 800° F., about 900° F. or about 1000° F. to and upper end of about 1100° F., about 1200° F., about 1300° F., about 1400° F., about 1500° F., about 1600° F., about 1700° F., about 1800° F., about 1900° F. or about 2000° F. Further, that incident temperature can range from about 1500° F. to about 2000° F., about 1600° F. to about 1900° F., about 1700° F. to about 1800° F. or from about 1550° F. to about 1850° F. In other exemplary embodiments, the pressure within the cyclone vessel can reach ultrahigh pressures of greater than 1000 psi, such as 2000 psi, 3000 psi, 4000 psi, 5000 psi, 6000 psi and even up to about 7000 psi or more. - Once injected into the
cyclone vessel 102, the suspended solid particulates can be immediately driven outward toward the innercylindrical surface 126 by centrifugal forces. The disentrained particulates rapidly concentrate at the innercylindrical surface 126 and gradually pass downward through thecyclone vessel 102 for downstream processing. At the same time, the separated fluid phase of decreasing particulate loading can eventually form a centrally-located vortex. From the vortex, a solids-lean fluid, such as gas or fuel, can exit via theoutlet tube 105 to theoutlet 106. - Referring now to
FIG. 3 , illustrated is a portion of thetop head 107, as indicated inFIG. 1 . According to one or more embodiments of the present disclosure, thetop head 107 can be circumferentially-disposed around and sealingly engaged with a portion of theoutlet tube 105. In at least one embodiment, thetop head 107 can include thecyclone roof 130, as discussed above, aconcave casing 302, and aroof insulation layer 304 interposed therebetween. Thecyclone roof 130 can include a dense layer refractory, such as RESCO® RS-88VC, and be configured to prevent erosion of theroof insulation layer 304. As described above, thecyclone roof 130 can also be configured to provide a flat surface substantially parallel and continuous with thesecond surface 128 of the inlet nozzle 122 (seeFIGS. 1 and 2 ). - In one or more embodiments, the
cyclone roof 130 can include a series of pie-shaped refractory bricks, circumferentially-surrounding theoutlet tube 105 and interconnected with each other through, for example, a tongue-and-groove or keyed joint. In at least one embodiment, each pie-shaped refractory brick of thecyclone roof 130 may be coupled to and supported within thecyclone vessel 102 by one or more T-studs 306 a,b,c cast directly into the bricks of thecyclone roof 130 and attached or otherwise coupled to theconcave casing 302. In other embodiments, ashoulder 308 of the erosionresistant layer 110 and aring 310, coupled or otherwise attached to theoutlet tube 105, can provide further support for thecyclone roof 130 refractory bricks. In at least one embodiment, thering 310 can be disposed circumferentially about theoutlet tube 105 and made of an alloy, such as HAYNES® HR-120® (Haynes International). - The
roof insulation layer 304 can serve as a back-up refractory layer to thecyclone roof 130 and further provide an insulating material. In at least one embodiment, theroof insulating layer 304 can include a thermal ceramic, such as KAOLITE® 2300 LI thermal ceramic, and can be installed by casting techniques. - In illustrative embodiments, the
concave casing 302 can be inwardly-concave toward the interior of thecyclone vessel 102 but convex to the pressure, as typified by the Boiler and Pressure Vessel Code provided by ASME. Theconcave casing 302 can be welded, or otherwise attached by mechanical means, to thecasing 108 of thecyclone vessel 102. As can be appreciated, employing the inwardly-concave casing 302 to thetop head 107 takes advantage of the resilient structural properties of an arced member for use in high-pressure applications, whereas similarly-situated non-arced members (e.g., a flat member) would be unable to withstand the elevated pressures and would ultimately fail. Moreover, theconcave casing 302 of thetop head 107 can eliminate unneeded and process-inefficient voids created between theinlet 104 and thecyclone roof 130. Eliminating the void between theinlet 104 and thecyclone roof 130 can not only improve overall process efficiency, but can also result in a substantial cost savings in materials needed to fill or seal the void. - Referring now to
FIGS. 4-6 , depicted is theinlet 104 of thecyclone vessel 102 and an exemplary structural transformation of theinlet casing 116 along the length of theinlet 104. As illustrated, theinlet 104 can include alongitudinal axis 402 along which theinlet nozzle 122 concentrically extends into thecyclone vessel 102. In at least one embodiment, theinlet nozzle 122 can be rectangular, but other embodiments can include a square-shapedinlet nozzle 122 or other polygonal shapes without departing from the scope of the disclosure. Theinlet nozzle 122 can at least be configured to direct any incoming fluid-particulate suspension away from and/or around theoutlet tube 105, thereby decreasing the potential of premature erosion on the surface of theoutlet tube 105. - Furthermore, as described above with reference to
FIGS. 1 and 2 , theinlet nozzle 122 can include afirst surface 124 and asecond surface 128, wherein eachsurface inlet nozzle 122 to the innercylindrical surface 126 andcyclone roof 130, respectively. In addition, theinlet nozzle 122 can include athird surface 404 and afourth surface 406, where thethird surface 404 faces thefirst surface 124 and thefourth surface 406 faces thesecond surface 128. In at least one embodiment, thethird surface 404 can be configured to help direct the incoming stream of fluid-particulate suspension away from and/or around the centrally-locatedoutlet tube 105. In one or more embodiments, the shape of theinlet nozzle 122 defined by itssurfaces longitudinal axis 402. In at least one embodiment, surfaces 124, 128, 404, 406 may merge together to form a substantially circular cross-sectional shape. -
FIG. 5 depicts a view from a first end of theinlet 104 distal to thecyclone vessel 102, taken along line 5-5 as indicated inFIG. 4 , and shows theinlet nozzle 122 encased by the inlet erosionresistant layer 118, theinlet insulating layer 120, and theinlet casing 116.FIG. 6 depicts a view from a second end of theinlet 104 proximal thecyclone vessel 102, taken along line 6-6 as indicated inFIG. 4 , where theinlet 104 can be coupled to or otherwise attached to thecyclone vessel 102. In one or more embodiments, theinlet casing 116 can be generally circular in cross-section (FIG. 5 ) distal to thecyclone vessel 102, but may gradually transform in shape along the length of thelongitudinal axis 402 and eventually transition into a generally elliptical, or oval-like cross-section (FIG. 6 ) at or near thecyclone vessel 102. The transformation of the inlet casing 116 from a generally circular shape into a generally elliptical shape along thelongitudinal axis 402 can provide a tapered connection point configured to smoothly transition into the outer surface of thecyclone vessel 102. - As can be appreciated, the tapering transition of the
inlet casing 116 can prove advantageous over applications employing a uniformly-cylindrical inlet casing which is difficult to smoothly transition to thecyclone vessel 102 for attachment without shifting thelongitudinal axis 402 into the path of the downwardly-extendingoutlet tube 105. Such a shift in thelongitudinal axis 402 would result in the direct impact of incoming particulates on theoutlet tube 105, thereby prematurely eroding its surface, or would necessitate a repositioning of theoutlet tube 105 within thecyclone vessel 102 to avoid direct particulate contact. Repositioning the centrally-locatedoutlet tube 105, however, can have adverse effects on vortex efficiency and overall process efficiency. - Referring now to
FIGS. 7 and 8 , depicted is anexemplary rain shield 700 that can be circumferentially-disposed around theoutlet 106 of the cyclone 100 (FIG. 1 ) to prevent rainwater accumulation on the exterior of thetop head 107 where theconcave casing 302 is located. As illustrated inFIG. 7 , therain shield 700 can include a series ofcap portions 702 horizontally-disposed from theoutlet 106 at varying points along the length of theoutlet 102. Although a certain number ofcap portions 702 are illustrated herein, it is understood that such is merely by way of example, and not intended to limit the scope of the subsequently presented claims. Indeed, a greater or lesser number ofcap portions 702 can be implemented to fit a particular application, without departing from the scope of the disclosure. - In one or more embodiments, each
cap portion 702 can be configured to extend at least partially around theoutlet 106 at a given point along its length with respect to theoutlet 106. After extending partially around theoutlet 106, thecap portion 702 can there be coupled or otherwise attached to anothercap portion 702, and so on until thecap portions 702 extend completely around theoutlet 106 at the given point. The same process can be undertaken at each elevation, as shown inFIG. 7 . In at least one embodiment, thecap portion 702 can include two half-circle cap portions 702 that interconnect halfway around theoutlet 106, thereby providing a fullcircular cap portion 702 at a given point. In another exemplary embodiment, thecap portion 702 can include a single circular length configured to extend completely around the circumference of theoutlet 106. - The
cap portions 702 can all generally be supported by a series of support plates 704 (only one shown), eachsupport plate 704 being circumferentially-disposed around the exterior of theoutlet 106. Although only onecap portion 702 at a given point may actually be coupled to asupport plate 704, eachcap portion 702 can be supported thereby through the internal support structure between eachcap portion 702, as will be described below. In at least one embodiment, there can be about eight support plate(s) 704 coupled or otherwise attached to the exterior of theoutlet 106. In one or more embodiments, the support plate(s) 704 can be welded to the exterior of theoutlet 106. In other exemplary embodiments, the support plate(s) 704 can be mechanically or otherwise attached to the exterior of theoutlet 106. - Also coupled to the support plate(s) 704 can be a
finish cap 706. Similar to the construction of thecap portions 702, thefinish cap 706 can include one or more portions configured to extend at least partially around theoutlet 106 and there be coupled or otherwise attached to another portion of thefinish cap 706, and so on until thefinish cap 706 extends completely around theoutlet 106. In at least one embodiment, thefinish cap 706 can include two half-circle finish cap 706 portions that interconnect halfway around theoutlet 106, thereby providing a fullcircular finish cap 706. In other embodiments, thefinish cap 706 can include a single portion that extends completely around the circumference of theoutlet 106. - In an exemplary embodiment, the
finish cap 706 can also be coupled to a series of finish support plates 708 (only one shown), which can be coupled to or otherwise attached to thevessel casing 108. In one or more embodiments, thefinish support plates 708 can be circumferentially-disposed around thevessel casing 108 and either welded or mechanically or otherwise attached thereto. In at least one embodiment, there can be about sixteenfinish support plates 708 circumferentially-disposed around the exterior of thevessel casing 108 and configured to provide support to thefinish cap 706. - Referring to
FIG. 8 , illustrated is a magnified view of a section of thecap portions 702 as indicated inFIG. 7 . In an exemplary embodiment, eachcap portion 702 can be supported byrigid straps 710 coupled at an end distal to theoutlet 106, and also supported byrigid straps 711 coupled at an end proximal to theoutlet 106. As illustrated, therigid straps cap portion 702 and to the top of thesubsequent cap portion 702, in a generally descending direction. At least onerigid strap 710 can be coupled to the bottom of thebottom-most cap portion 702 and also to the top of the finish cap 706 (not shown). - In an exemplary embodiment, the
rigid straps rigid straps rigid straps rigid straps outlet 106, thereby providing support to theseveral cap portions 702. In at least one embodiment, therigid straps cap portions 702 around theoutlet 106. As illustrated, therigid straps cap portions 702 andfinish cap 706 by mechanical means, such as self-tappingscrews 712. One of skill in the art would, however, appreciate that therigid straps - In an exemplary embodiment, portions of a
screen material 714 can also be disposed around theoutlet 106 to prevent the influx of animal life, such as birds and other foreign matter, into the exterior of thetop head 107 where theconcave casing 302 is located. In at least one embodiment, thescreen material 714 can be a wire mesh, but can also be made of other materials, such as plastics. As illustrated, thescreen material 714 can be interposed between thecap portions 702 and therigid straps 711, and coupled or attached thereto by a coupling means, such as the self-tappingscrews 712. As shown inFIG. 7 , thescreen material 714 can also be used in conjunction with the interconnection of thefinish cap 706 and the finish support plated 708, thereby providing a barrier configured to prevent the influx of animals and other foreign matter up through the bottom of thefinish cap 706. - At least some of the
cap portions 702 can include alip section 716 configured to prevent the influx of rain into the exterior of thetop head 107. For example, thelip sections 716 can be configured to stop blowing rain, which may enter at a substantially 90° angle with respect to horizontal. The remaining portion of thecap portions 702 can be generally disposed at a decline with respect to horizontal, thereby allowing any accumulated precipitation to drain from therain shield 700. - In an exemplary embodiment, the
rain shield 700 can also provide a heat-dissipative effect for thecyclone vessel 102. In exemplary operation, heat rising from thecyclone vessel 102 in the direction of arrow A (FIG. 8 ) can be emitted via the open spaces between vertically-adjacent cap portions 702 in the direction of arrows B by means of convection. To accomplish this in a more efficient manner, thecap portions 702 can be vertically-offset from each other by progressively smaller distances corresponding to the vertical point of theoutlet 106. In other words, the higher the vertical position on theoutlet 106, the smaller the outlet betweenadjacent cap portions 702. As can be appreciated, progressively smaller outlet paths can force more heat out the lower and larger outlet paths by means of convective air currents, thereby allowing a greater amount of heat to escape with little or no restriction. - Embodiments of the present disclosure further relate to any one or more of the following paragraphs:
- 1. A rain shield for a cyclone, comprising: one or more cap portions circumferentially-disposed around an outlet of the cyclone and having an end distal to the outlet and an end proximal to the outlet; a series of support plates coupled to the one or more cap portions and also coupled to the outlet; a finish cap circumferentially-disposed around the outlet of the pressure cyclone, the finish cap being coupled to the series of support plates and also coupled to a series of finish support plates, wherein the finish support plates are coupled to a vessel casing of the pressure cyclone; a first plurality of rigid straps coupled to the one or more cap portions at the end distal to the outlet; a second plurality of rigid straps coupled to the one or more cap portions at the end proximal to the outlet; and a screen material coupled to the one or more cap portions at the end proximal the outlet and also coupled to the second plurality of rigid straps.
- 2. The rain shield of paragraph 1, wherein the one or more cap portions further comprises a lip section disposed at the end proximal the outlet for preventing an influx of rain.
- 3. The rain shield of paragraphs 1 or 2, wherein the one or more cap portions comprises two or more cap portions offset from each other along a length of the outlet.
- 4. The rain shield according to any one of paragraphs 1-3, wherein the first plurality of rigid straps are coupled to two or more cap portions at the end distal to the outlet and configured to support and join adjacent cap portions and the second plurality of rigid straps are coupled to two or more cap portions at the end proximal to the outlet and configured to support and join the adjacent cap portions.
- 5. The rain shield according to any one of paragraphs 1-4, wherein the one or more cap portions dissipate heat from the pressure cyclone via open spaces defined between the adjacent cap portions.
- 6. The rain shield of paragraph 4, wherein the one or more cap portions comprises at least three cap portions, and wherein the adjacent cap portions are offset from each other by a progressively smaller distance corresponding to the length along the outlet.
- 7. The rain shield according to any one of paragraphs 1-6, wherein the one or more cap portions are disposed at a decline with respect to horizontal to drain precipitation away from the pressure cyclone.
- 8. The rain shield according to any one of paragraphs 1-7, wherein the cyclone comprises a concave top head.
- 9. The rain shield of paragraph 8, wherein the concave top head comprises a substantially flat roof disposed in an interior of the cyclone.
- 10. The rain shield according to any one of paragraphs 1-9, wherein the cyclone comprises: a cyclone vessel having an inlet coupled thereto, the inlet configured to receive a particulate-fluid suspension comprising a fluid and at least one solid particulate suspended therein, and wherein the outlet of the cyclone is configured to remove the fluid separated from the particulate-fluid suspension separated fluids from the cyclone vessel; and a concave top head coupled to the cyclone vessel and circumferentially-disposed about the outlet tube, the concave top head comprising a substantially flat cyclone roof disposed in an interior of the cyclone vessel.
- 11. The rain shield of paragraph 10, wherein the cyclone further comprises an inlet nozzle disposed within the inlet and having a first surface and a second surface, and wherein the first surface transitions to an inner cylindrical surface of the interior of the cyclone vessel and the second surface transitions to the substantially flat cyclone roof.
- 12. A rain shield, comprising: two or more cap portions circumferentially-disposed around an outlet of a cyclone having a concave top head and having an end distal to the outlet and an end proximal to the outlet, wherein the two or more cap portions are disposed at a decline with respect to horizontal and are offset from each other along a length of the outlet; a series of support plates coupled to the one or more cap portions and also coupled to the outlet; a finish cap circumferentially-disposed around the outlet of the pressure cyclone, the finish cap being coupled to the series of support plates and also coupled to a series of finish support plates, wherein the finish support plates are coupled to a vessel casing of the pressure cyclone; a first plurality of rigid straps coupled to the two or more cap portions at the end distal to the outlet and configured to support and join adjacent cap portions; a second plurality of rigid straps coupled to the two or more cap portions at the end proximal to the outlet and configured to support and join the adjacent cap portions; and a screen material coupled to the two or more cap portions at the end proximal the outlet and also coupled to the second plurality of rigid straps.
- 13. The rain shield of paragraph 12, wherein the two or more cap portions further comprises a lip section disposed at the end proximal the outlet.
- 14. The rain shield of paragraphs 12 or 13, wherein the concave top head comprises a substantially flat roof disposed in an interior of the pressure cyclone.
- 15. A method of separating solid particulates from a particulate-fluid suspension, comprising: introducing the particulate-fluid suspension into a cyclone vessel via an inlet coupled thereto, and wherein the cyclone vessel comprises a roof and a top head having a rain shield disposed thereon, the rain shield comprising: one or more cap portions circumferentially-disposed around an outlet of the cyclone and having an end distal to the outlet and an end proximal to the outlet; a series of support plates coupled to the one or more cap portions and also coupled to the outlet; a finish cap circumferentially-disposed around the outlet of the pressure cyclone, the finish cap being coupled to the series of support plates and also coupled to a series of finish support plates, wherein the finish support plates are coupled to a vessel casing of the pressure cyclone; a first plurality of rigid straps coupled to the one or more cap portions at the end distal to the outlet; a second plurality of rigid straps coupled to the one or more cap portions at the end proximal to the outlet; and a screen material coupled to the one or more cap portions at the end proximal the outlet and also coupled to the second plurality of rigid straps; creating a vortex within the cyclone vessel to drive the solid particulates toward the inner cylindrical surface and produce a reduced particulate loading particulate-fluid suspension; and removing the reduced particulate loading particulate-fluid suspension from the cyclone vessel through the outlet.
- 16. The method of paragraph 15, further comprising operating the cyclone vessel at pressures ranging from about 50 psi to about 800 psi.
- 17. The method of paragraphs 15 or 16,wherein the inlet comprises a rectangular inlet nozzle having a first surface tangent to an inner cylindrical surface of the cyclone vessel and a second surface substantially parallel to and continuous with a cyclone roof of a concave top head.
- 18. The method of paragraph 17, further comprising: disposing an inlet casing around a length of the inlet nozzle; transitioning the inlet casing from a circular cross-section at a first end of the inlet casing to an elliptical cross-section at a second end of the inlet casing along the length of the inlet nozzle; and coupling the second end of inlet casing having the elliptical cross-section to the cyclone vessel.
- 19. The method according to any one of paragraphs 15-18, wherein the cyclone roof is substantially flat.
- 20. The method of paragraph 19, wherein the cyclone roof comprises a series of pie-shaped refractory bricks configured to circumferentially-surround the outlet tube.
- Certain embodiments and features have been described using a set of numerical upper limits and a set of numerical lower limits. It should be appreciated that ranges from any lower limit to any upper limit are contemplated unless otherwise indicated. Certain lower limits, upper limits and ranges appear in one or more claims below. All numerical values are “about” or “approximately” the indicated value, and take into account experimental error and variations that would be expected by a person having ordinary skill in the art.
- Various terms have been defined above. To the extent a term used in a claim is not defined above, it should be given the broadest definition persons in the pertinent art have given that term as reflected in at least one printed publication or issued patent. Furthermore, all patents, test procedures, and other documents cited in this application are fully incorporated by reference to the extent such disclosure is not inconsistent with this application and for all jurisdictions in which such incorporation is permitted.
- While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
Claims (20)
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US12/773,206 US8157895B2 (en) | 2010-05-04 | 2010-05-04 | System for reducing head space in a pressure cyclone |
US13/448,250 US8226749B1 (en) | 2010-05-04 | 2012-04-16 | System for reducing head space in a pressure cyclone |
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US13/448,250 Active US8226749B1 (en) | 2010-05-04 | 2012-04-16 | System for reducing head space in a pressure cyclone |
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AT511613B1 (en) * | 2012-01-24 | 2013-01-15 | Inteco Special Melting Technologies Gmbh | METHOD AND APPARATUS FOR EXHAUST GAS CLEANING IN VACUUM STEEL TREATMENT PROCESSES |
DE102012012727A1 (en) * | 2012-06-26 | 2014-01-02 | Hydac Process Technology Gmbh | Apparatus for conditioning gases |
DE202012009442U1 (en) * | 2012-10-02 | 2012-11-27 | Hirl Misch- und Anlagentechnik GmbH & Co. KG | Filling module for a silo |
AP2016009028A0 (en) | 2013-08-09 | 2016-02-29 | Weir Minerals Australia Ltd | Cyclone separator apparatus and methods of production |
FI126040B (en) * | 2014-07-09 | 2016-06-15 | Amec Foster Wheeler En Oy | Particle separator and fluidized bed reactor that can be connected to a fluidized bed reactor |
CN106959231B (en) * | 2017-05-05 | 2023-08-18 | 吉林大学 | Device for quickly preparing remolded soil |
CN107674714B (en) * | 2017-09-28 | 2020-04-28 | 上海化工研究院有限公司 | Continuous automatic material returning system of pulverized coal pressurized gasifier |
CN107520073A (en) * | 2017-09-28 | 2017-12-29 | 上海化工研究院有限公司 | A kind of coal gasification cyclone separator |
US11577258B2 (en) * | 2019-11-05 | 2023-02-14 | The Johns Hopkins University | Cyclone and methods of manufacture thereof |
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Also Published As
Publication number | Publication date |
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WO2011139836A1 (en) | 2011-11-10 |
CN103068702A (en) | 2013-04-24 |
US8157895B2 (en) | 2012-04-17 |
US20110271836A1 (en) | 2011-11-10 |
CN103068702B (en) | 2016-09-21 |
US8226749B1 (en) | 2012-07-24 |
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