U.S. patent application number 13/448250 was filed with the patent office on 2012-08-16 for system for reducing head space in a pressure cyclone.
This patent application is currently assigned to KELLOGG BROWN & ROOT LLC. Invention is credited to William E. Phillips.
Application Number | 20120204721 13/448250 |
Document ID | / |
Family ID | 44901050 |
Filed Date | 2012-08-16 |
United States Patent
Application |
20120204721 |
Kind Code |
A1 |
Phillips; William E. |
August 16, 2012 |
SYSTEM FOR REDUCING HEAD SPACE IN A PRESSURE CYCLONE
Abstract
A pressure cyclone is disclosed having a concave top head,
wherein the concave top head has a substantially flat roof disposed
in the interior of the cyclone vessel. An inlet is
tangentially-coupled to the vessel and has an inlet nozzle disposed
therein and configured to smoothly transition into the cyclone
vessel to create a vortex that separates solid particulates from an
incoming particulate-fluid suspension. In particular, the one
surface of the inlet nozzle is tangent to the inner surface of
cyclone vessel and another surface of the inlet nozzle is parallel
and continuous with the substantially flat roof. An inlet casing is
disposed around a length of the inlet nozzle and configured to
transition from a circular casing to an elliptical casing along the
length of the inlet nozzle, and couple to the vessel with the
elliptical casing.
Inventors: |
Phillips; William E.;
(Houston, TX) |
Assignee: |
KELLOGG BROWN & ROOT
LLC
Houston
TX
|
Family ID: |
44901050 |
Appl. No.: |
13/448250 |
Filed: |
April 16, 2012 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
12773206 |
May 4, 2010 |
8157895 |
|
|
13448250 |
|
|
|
|
Current U.S.
Class: |
95/268 ;
55/385.7 |
Current CPC
Class: |
B04C 5/081 20130101;
B01D 45/12 20130101; B04C 5/04 20130101 |
Class at
Publication: |
95/268 ;
55/385.7 |
International
Class: |
B01D 45/16 20060101
B01D045/16; B01D 50/00 20060101 B01D050/00 |
Claims
1. A rain shield for a cyclone, comprising: at least a first sloped
tray and a second sloped tray vertically disposed with respect to
one another about a longitudinal axis, each tray having an aperture
formed therethrough; at least one support member coupled to at
least one of the first and second trays and extending toward the
longitudinal axis; at least one support body coupled to at least
one of the first and second trays and extending toward the
longitudinal axis; a first plurality of straps coupled to an outer
edge of the first and second trays; a second plurality of straps
coupled to an inner edge of the first and second trays; and a
screen at least partially disposed between the first and second
trays.
2. The rain shield of claim 1, wherein at least one of the first
and second trays comprises a plurality of segments that together
form the at least one of the first and second sloped trays.
3. The rain shield of claim 1, wherein the first and second trays
each have a frusto-conical shape, and wherein each aperture of each
tray is axially aligned with one another about the longitudinal
axis.
4. The rain shield of claim 1, wherein an outlet of a cyclone is
disposed through the apertures of the first and second trays such
that the first and second trays are circumferentially-disposed
about the outlet of the cyclone.
5. The rain shield of claim 4, wherein the cyclone comprises a
concave top head.
6. The rain shield of claim 1, wherein the first and second trays
are offset from each other along the longitudinal axis.
7. The rain shield of claim 1, wherein the first plurality of
straps and the second plurality of straps are configured to support
and join the first and second trays in fixed positions relative to
one another.
8. The rain shield of claim 7, wherein an outlet of a cyclone is
disposed through the apertures of the first and second trays such
that the first and second trays are circumferentially-disposed
about the outlet of the cyclone, and wherein the first and second
trays dissipate heat from the cyclone via one or more open spaces
defined between the first and second trays.
9. The rain shield of claim 7, further comprising at least three
sloped trays, wherein the adjacent trays are offset from each other
by a progressively smaller distance corresponding to a length along
the longitudinal axis.
10. The rain shield of claim 1, wherein an outlet of a cyclone is
disposed through the apertures of the first and second trays such
that the first and second trays are circumferentially-disposed
about the outlet of the cyclone, and wherein the slope of the first
and second sloped trays allows precipitation to drain away from the
cyclone.
11. The rain shield of claim 1, wherein each of the first and
second trays further comprises a lip disposed about the outer
edge.
12. A rain shield for a cyclone, comprising: at least a first
sloped tray and a second sloped tray vertically disposed with
respect to one another about a longitudinal axis, each tray
circumferentially-disposed around an outlet of a cyclone having a
concave top head; at least one support member coupled to at least
one of the first and second trays and in contact with the outlet;
at least one support body coupled to at least one of the first and
second trays and in contact with a vessel casing of the cyclone; a
first plurality of straps coupled to an outer edge of the first and
second trays; a second plurality of straps coupled to an inner edge
of the first and second trays; and a screen at least partially
disposed between the first and second trays.
13. The rain shield of claim 12, wherein each of the first and
second trays further comprises a lip disposed about the outer
edge.
14. The rain shield of claim 12, wherein the concave top head
comprises a substantially flat roof disposed in an interior of the
cyclone.
15. A method of separating solid particulates from a
particulate-fluid suspension, comprising: introducing the
particulate-fluid suspension into a cyclone via an inlet coupled
thereto, wherein the cyclone comprises a roof and a top head having
a rain shield disposed thereon, the rain shield comprising: at
least a first sloped tray and a second sloped tray vertically
disposed with respect to one another about a longitudinal axis,
each tray having an aperture formed therethrough; at least one
support member coupled to at least one of the first and second
trays and extending toward the longitudinal axis; at least one
support body coupled to at least one of the first and second trays
and extending toward the longitudinal axis; a first plurality of
straps coupled to an outer edge of the first and second trays; a
second plurality of straps coupled to an inner edge of the first
and second trays; and a screen at least partially disposed between
the first and second trays; forming a vortex within the cyclone to
drive the solid particulates toward an inner cylindrical surface
and produce a reduced particulate loading particulate-fluid
suspension; and removing the reduced particulate loading
particulate-fluid suspension from the cyclone through the
outlet.
16. The method of claim 15, further comprising operating the
cyclone at a temperature of about 800.degree. C. to about
1,000.degree. C. and dissipating heat from the cyclone through the
rain shield and away from the cyclone.
17. The method of claim 15, wherein the inlet comprises a
rectangular inlet nozzle having a first surface tangent to an inner
cylindrical surface of the cyclone and a second surface
substantially parallel to and continuous with the roof of the
cyclone.
18. The method of claim 17, further comprising: disposing an inlet
casing around an external surface of the inlet nozzle and along a
length thereof; 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.
19. The method of claim 15, wherein the roof of the cyclone is
substantially flat.
20. The method of claim 19, wherein a series of pie-shaped
refractory bricks configured to circumferentially-surround the
outlet tube are disposed on the roof of the cyclone.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] 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.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to
cyclonic separation units. More particularly, embodiments of the
present invention relate to high-pressure cyclones.
[0004] 2. Description of the Related Art
[0005] 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.
[0006] 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.
[0007] 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.
[0008] 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.
[0009] 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.
[0010] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] 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.
[0012] FIG. 1 depicts a side view of an exemplary cyclone,
according to one or more embodiments of the disclosure.
[0013] FIG. 2 depicts a top view of the exemplary cyclone of FIG.
1, according to one or more embodiments of the disclosure.
[0014] FIG. 3 depicts a portion of a top head as shown in FIG. 1,
according to one or more embodiments of the disclosure.
[0015] FIG. 4 depicts a side view of the cyclone inlet, according
to one or more embodiments of the disclosure.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] FIG. 8 depicts a magnification of the cap portions indicated
in FIG. 7.
DETAILED DESCRIPTION
[0020] 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.
[0021] 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, while FIG. 2 depicts an end
view of the same. In an exemplary embodiment, the cyclone 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, 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.
[0022] As illustrated, 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. In at least one
embodiment, 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. In one or more
embodiments, the vessel casing 108 can generally define the outside
surface of the cyclone vessel 102, while the erosion resistant
layer 110 generally defines an inner cylindrical surface 126.
[0023] 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. In at least one embodiment, the erosion resistant
layer 110 can be made of RESCO.RTM. RS-88 VC refractory material
(Resco Products, Inc.), and can be installed by vibracasting
techniques.
[0024] 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. In at least one embodiment, the insulating
layer 112 can include a thermal ceramic, such as KAOLITE.RTM. 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.degree. F.
[0025] As best illustrated in FIG. 2, 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. As will be described in
more detail below, 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. In at
least one embodiment, the inlet 104 can be welded to the cyclone
vessel 102 to ensure a pressure-tight interconnection. In other
exemplary embodiments, the inlet 104 can be mechanically coupled or
otherwise attached to the cyclone vessel 102, while maintaining a
pressure-resistant interconnection.
[0026] In an exemplary embodiment, the inlet casing 116 can be made
of carbon steel, such as low-alloy steel. Similar to the erosion
resistant layer 110, the inlet erosion resistant layer 118 can
include a dense layer refractory material, such as RESCO.RTM.
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. In at least one embodiment, the inlet insulating layer 120 can
include a thermal ceramic, such as KAOLITE.RTM. 2500 LI (Thermal
Ceramics, Inc.), and can be installed by gunning techniques, as
known in the art.
[0027] An inlet nozzle 122 can be defined in and generally centered
along the length of the inlet 104 toward the cyclone vessel 102. In
at least one embodiment, 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. Moreover, 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. Thus, the 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. As can be appreciated, 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.
[0028] 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 the inlet nozzle
122 and swirl circumferentially against the inner cylindrical
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 the cyclone 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.degree. F., about 200.degree. F., about 300.degree. F.,
about 400.degree. F., about 500.degree. F., about 600.degree. F.,
about 700.degree. F., about 800.degree. F., about 900.degree. F. or
about 1000.degree. F. to and upper end of about 1100.degree. F.,
about 1200.degree. F., about 1300.degree. F., about 1400.degree.
F., about 1500.degree. F., about 1600.degree. F., about
1700.degree. F., about 1800.degree. F., about 1900.degree. F. or
about 2000.degree. F. Further, that incident temperature can range
from about 1500.degree. F. to about 2000.degree. F., about
1600.degree. F. to about 1900.degree. F., about 1700.degree. F. to
about 1800.degree. F. or from about 1550.degree. F. to about
1850.degree. 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.
[0029] Once injected into the cyclone vessel 102, 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. 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 the outlet
tube 105 to the outlet 106.
[0030] Referring now to FIG. 3, illustrated is a portion of the top
head 107, as indicated in FIG. 1. According to one or more
embodiments of the present disclosure, the top head 107 can be
circumferentially-disposed around and sealingly engaged with a
portion of the outlet tube 105. In at least one embodiment, 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.RTM. RS-88VC, and be configured to
prevent erosion of the roof insulation layer 304. As described
above, 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).
[0031] In one or more embodiments, 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. In at least one embodiment, 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 306a,b,c cast directly into the bricks of the cyclone roof
130 and attached or otherwise coupled to the concave casing 302. In
other embodiments, 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. In at least one embodiment, the ring 310 can be
disposed circumferentially about the outlet tube 105 and made of an
alloy, such as HAYNES.RTM. HR-120.RTM. (Haynes International).
[0032] The roof insulation layer 304 can serve as a back-up
refractory layer to the cyclone roof 130 and further provide an
insulating material. In at least one embodiment, the roof
insulating layer 304 can include a thermal ceramic, such as
KAOLITE.RTM. 2300 LI thermal ceramic, and can be installed by
casting techniques.
[0033] In illustrative embodiments, 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. As can be appreciated, 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. Moreover, 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.
[0034] Referring now to FIGS. 4-6, depicted is the inlet 104 of the
cyclone vessel 102 and an exemplary structural transformation of
the inlet casing 116 along the length of the inlet 104. As
illustrated, the inlet 104 can include a longitudinal axis 402
along which the inlet nozzle 122 concentrically extends into the
cyclone vessel 102. In at least one embodiment, 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.
[0035] Furthermore, as described above with reference to FIGS. 1
and 2, 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. In addition, 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. In at
least one embodiment, 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. In
one or more embodiments, the shape of the inlet nozzle 122 defined
by its surfaces 124, 128, 404, 406, whether it be rectangular,
square, or any other shape, can remain substantially constant along
the length of longitudinal axis 402. In at least one embodiment,
surfaces 124, 128, 404, 406 may merge together to form a
substantially circular cross-sectional shape.
[0036] 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. In one or more
embodiments, the inlet casing 116 can be generally circular in
cross-section (FIG. 5) distal to the cyclone vessel 102, but may
gradually transform in shape along the length of the longitudinal
axis 402 and eventually transition into a generally elliptical, or
oval-like cross-section (FIG. 6) at or near the cyclone vessel 102.
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.
[0037] 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 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,
however, can have adverse effects on vortex efficiency and overall
process efficiency.
[0038] Referring now to FIGS. 7 and 8, depicted is an exemplary
rain shield 700 that 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. As illustrated in FIG. 7, 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. Although a certain number of 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.
[0039] In one or more embodiments, 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. In at least one embodiment,
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. In another
exemplary embodiment, the cap portion 702 can include a single
circular length configured to extend completely around the
circumference of the outlet 106.
[0040] 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.
[0041] 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.
[0042] 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 the vessel casing
108. In one or more embodiments, the finish support plates 708 can
be circumferentially-disposed around the vessel casing 108 and
either welded or mechanically or otherwise attached thereto. In at
least one embodiment, there can be about sixteen finish support
plates 708 circumferentially-disposed around the exterior of the
vessel casing 108 and configured to provide support to the finish
cap 706.
[0043] Referring to FIG. 8, illustrated is a magnified view of a
section of the cap portions 702 as indicated in FIG. 7. In an
exemplary embodiment, 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. As illustrated, 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).
[0044] In an exemplary embodiment, 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. In at least one
embodiment, 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. In one
or more embodiments, 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. In at least one
embodiment, 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.
[0045] In an exemplary embodiment, 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. In at least one embodiment, the screen material 714 can be
a wire mesh, but can also be made of other materials, such as
plastics. As illustrated, 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. 7, 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.
[0046] 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. For example, the lip sections 716 can
be configured to stop blowing rain, which may enter at a
substantially 90.degree. 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.
[0047] In an exemplary embodiment, the rain shield 700 can also
provide a heat-dissipative effect for the cyclone vessel 102. In
exemplary operation, 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. To accomplish this in a more
efficient manner, 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. 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.
[0048] Embodiments of the present disclosure further relate to any
one or more of the following paragraphs:
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] 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.
[0056] 8. The rain shield according to any one of paragraphs 1-7,
wherein the cyclone comprises a concave top head.
[0057] 9. The rain shield of paragraph 8, wherein the concave top
head comprises a substantially flat roof disposed in an interior of
the cyclone.
[0058] 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.
[0059] 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.
[0060] 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.
[0061] 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.
[0062] 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.
[0063] 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.
[0064] 16. The method of paragraph 15, further comprising operating
the cyclone vessel at pressures ranging from about 50 psi to about
800 psi.
[0065] 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.
[0066] 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.
[0067] 19. The method according to any one of paragraphs 15-18,
wherein the cyclone roof is substantially flat.
[0068] 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.
[0069] 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.
[0070] 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.
[0071] 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.
* * * * *