Slurry Hopper System

Abstract

A low profile hopper for mixing a granular solid product, such as coal, with water to form a slurry. The hopper consists of an open-topped tank having low side walls and a bottom. One end has a slurry pump inlet, and the other end contains a water inlet system. The tank is designed to direct the slurry and gravity feed the slurry to the pump inlet. A water level maintenance system is provided which is mounted in the tank and communicates with the water inlet means for controlling the level of the water, regardless of the amount of product being dumped into the hopper. Baffles are also included to reduce surface turbulence in the vicinity of the water level maintenance system.

Parent Case Text

CROSS REFERENCES TO RELATED APPLICATIONS

This is a continuation of applicants' co-pending application of the same title, Ser. No. 298,118 filed Oct. 16, 1972. Related subject matter is disclosed in the co-pending application of Reichl et al, Ser. No. 294,720 filed Oct. 3, 1972 and entitled "A Mobile Slurry Handling System."

Description

BACKGROUND OF THE INVENTION

This invention relates to improvements in apparatus for forming a slurry from a granular solid and water, and more particularly, but not by way of limitation, to such apparatus particularly useful in coal mining.

The best prior art relating to the above system is found in U.S. Pat. No. 3,260,548, entitled "Method and Apparatus for Continuous Mining and Transporting Coal" by E. H. Reichl. In addition to disclosing a basic slurry system this patent discloses a slurry hopper operating on the centrifuge principle. The hopper consists of a funnel-shaped retaining means having a pump inlet at the apex. Water inlet means are provided around the periphery at the top. The product is moved by conveyor and dumped into the top along with water to form a slurry. The hopper system in the Reichl patent does not disclose an effective way for maintaining the water level at a predetermined height so that the pump system can, for this reason, overfill or cavitate. Secondly, a centrifugal-type hopper as in the Reichl patent tends to cause the water to spiral, permitting air to pass directly into the pump and the slurry hose. Entrained air, among other things, tends to cause the pump to become inefficient and reduces the product pumped into the line, all of which tends to be detrimental to the proper operation of this system. Further, a centrifugal type hopper requires excessive head room which is at a premium in a coal mine.

BRIEF DESCRIPTION OF THE INVENTION

This invention discloses a hopper assembly including a tank which has shallow sides and a bottom which is tapered to the pump inlet. A plurality of baffles extends into the water slurry mixture, reducing surface turbulence, thereby allowing entrapped air to escape before entering the pump. The baffles also provide a reduction in water turbulence so that the water level can be properly determined and adjusted. The water inlet means injects water into the hopper along the bottom of the hopper. Water entering in this manner causes a directed stream of water which mixes with the product being dumped into the hopper, resulting in the flow and mixing of product with water as it moves toward the pump inlet. The overall design of this system permits large bariations in the quantity of the product being dumped into the hopper without causing overflow of the hopper or without causing air to enter the slurry hoses or pump. The hopper assembly has a low profile, making it particularly useful in restricted spaces, such as in coal mining.

BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a schematic layout of a hose hauling system which may be used with this invention and its interconnection with the slurry hopper system of this invention;

FIG. 2 is a side view, partially schematic, of the slurry hopper system showing the location of the pump, the product conveyor, and water level control; and

FIG. 3 is a perspective view of the hopper.

GENERAL DESCRIPTION OF THE INVENTION

The same numbers will be used throughout the specification for the same or similar parts.

Referring to all of the drawings, but in particular to FIG. 1, reference character 10 designates a mine digging machine which mines the product, such as coal, and feeds the product onto a conveyor 11. The product 12 is dropped into a crusher 13, which may be any usual type crusher such as a roll crusher or jaw crusher, and may include means for separating the material that does not need to be crushed and crushing only the larger material. Crushers are well known and will not be further discussed. The material from the crusher is dropped or conveyed into the tank of a hopper system 14 which contains water. A water level control 15 applies a continuous signal through line 16 to a valve 17 which is connected to a water line 18. Another water line 19 is connected to valve 17 and through a plurality of slots (not shown) communicates with the interior of the tank of the hopper system.

A slurry pump 20 has its inlet connected to the outlet 21 of the hopper system 14. Slurry pump 20 has an outlet 22 connected to a slurry hose 23. Another hose 24 is connected to water line 18. Both hoses 23 and 24 are supported upon a slurry transportation system which essentially comprises a plurality of carts 25 connected by linkage 26. A conveyor mechanism 27 controls the movement of the carts, linkage and pipe assembly around a 180.degree. turn 28. The termination of the slurry hose 23 and water hose 24 is at a remote terminal 29. A surface separator 30 may be connected to remote terminal 29 through any well known system 31 such as a pipe line.

The operation of the overall system functions as follows:

As the mining machine 10 removes product 12, it is carried by conveyer 11 and passed to crusher 13 where it is deposited in the tank of hopper system 14. Pump 20 pulls the slurry mixture from the hopper and passes it into hose 23, whereby it is eventually received at a remote terminal 29, pumped to the surface through pipe line 31, and separated by separator 30. As mining machine 10 works in and out of the coal seam, the slurry hose must follow these movements. Carts 25, through a servo mechanism, will follow the in and out movements of the mining machine. A portion of the slurry line between the conveyer 27 and the remote terminal 29 functions as a storage. Thus as additional length of hose is needed, conveyer 27 will move in the direction of arrow 32, shortening the amount in storage and lengthening the amount of slurry hose which can penetrate the mine room with the mining machine. In order to accomplish the above, however, conveyer 27 must move the carts 25, including the slurry hose supported by it, from the position in storage to a position where it can be utilized by the mining machine. Conveyer 27 accomplishes the transition from storage to active use by lifting the carts through 180.degree. while the conveyer itself is moving either in the direction of arrow 33 where additional storage is needed or arrow 32 where less storage is needed. The conveyer further restricts the hose to a definite radius, thereby preventing excess flexing or bending.

The hopper system 14 is shown in more detail in FIGS. 2 and 3. The system comprises an open topped tank 14a having overall dimensions such that the horizontal dimensions are greater than the vertical dimensions in order that the hopper may be most conveniently used in restricted spaces, such as in coal mines where the head room is extremely limited. The tank 14a has side walls 300 and 301 interconnected with end walls 302 and 303. The bottom 312 of the tank slopes downwardly from the end wall 302 toward the end wall 303, with the central portion 312a, the lowest portion of the bottom, being converged toward the central portion of the end wall 303 and the remaining portions of the bottom 312 being extended upwardly from the lower central portion to connect with the side walls 300 and 301, as well as the end wall 303. A plurality of vertical baffles 304 extend transversely across the tank between the side walls 300 and 301, with the lower edges of the baffles 304 being spaced upwardly from the bottom 312 of the tank.

A manifold 305 extends around the end wall 302 and the adjacent portions of the side walls 300 and 301 to form a water supply manifold. The manifold 305 communicates with the interior of the tank 14a through slots 306 formed through the end wall 302 and the adjacent portions of the side walls 300 and 301. The slots 306 are formed adjacent the bottom 312 of the tank below the baffles 304, such that water is fed into the tank below the baffles 304. The water pipe 19, previously mentioned, communicates with the manifold 305.

An outlet opening 307 is formed in the end wall 303 and is sized vertically to extend from the medial portion of the end wall 303 to the adjacent portion of the bottom 312 of the tank, in order that slurry formed in the tank will flow freely through the opening 307. The width of the opening 307 is such that the side edges of the opening are spaced from the adjacent side walls 300 and 301. Stated otherwise, the width of the opening 307 corresponds to the width of the respective end of the central portion 312a of the tank bottom, that being the lowest point at the bottom of the tank. A baffle 308 extends from one side edge of the opening 307 to the respective side wall 301 a distance from the end wall 303, and a similar baffle 310 extends from the opposite side of the opening 307 to the side wall 300 at a point spaced from the end wall 303. The baffles 308 and 310 form what may be considered a funnel to direct the slurry gravitating through the tank 14a out the outlet opening 307. Another baffle 309 may be extended from slightly above the opening 307 into the interior of the tank to further funnel the slurry out the opening 307. The outlet opening 307 is, of course, connected to the inlet of the slurry pump 20 as indicated in FIG. 2.

The level control 15, previously mentioned, has a level sensor 15a extending into the tank 14a at a point between the lower edges of the baffles 304 and the top of the walls of the tank and, as previously mentioned, the controller 15 controls the opening and closing of the water valve 17 to assure an adequate supply of water in the hopper system. The location of the sensor 15a assures an adequate supply of water in the hopper system to prevent cavitation at the outlet opening 307.

As previously indicated, the granular solid product is fed to the hopper system by a suitable conveyer either directly or indirectly from a crusher. Such a conveyer is schematically illustrated in FIG. 2 at reference character 45 to illustrate the positioning of the conveyer with respect to the tank 14a. The conveyer 45 extends over the tank 14a and terminates a short distance beyond the end wall 302 in order that the solid product 46 will be deposited into the open top of the tank at a point remote from the outlet opening 307.

In operation, as previously indicated, water is supplied to the tank of the hopper system through the slots 306 and the solid product is supplied into the open upper end of the tank, such that the solid and the water will be thoroughly mixed as the water and product flow downwardly through the tank along the bottom 312 to form a slurry discharging through the opening 307. the baffles 304, being spaced above the bottom 312, do not interfere with the movement of the slurry along the bottom and through the outlet opening 307, but minimize the turbulence of water being fed into the tank when the system is operating at maximum capacity. In a typical form of the invention, the individual slots 306 may be 6 inches long and the tank may be sized to handle up to 11 tons of coal per minute. It should also be noted that the water level sensor 15a is positioned at a point remote from the entry of the water into the tank between the baffle 304 nearest the end wall 303 to be in the least turbulent area of the water moving through the tank, such that the sensor and controller 15 may perform the function of accurately maintaining an adequate supply of water in the tank.

It should be apparent from the foregoing that the present hopper system is particularly adapted for use in restricted spaces, such as in coal mining operations. The water level in the tank of the hopper may be accurately controlled and the invention will not be subjected to cavitation of the slurry pump.

Changes may be made in the combination and arrangement of parts or elements as heretofore set forth in the specification and shown in the drawings without departing from the spirit and scope of the invention as defined in the following claims.

Claims

What is claimed is:

1. A hopper assembly for forming a slurry of a granular solid product and water in restricted spaces for transportation by a slurry pump, comprising:

an open-topped tank having horizontal dimensions greater than vertical dimensions and having interconnected end walls and side walls and a bottom tapered downwardly toward one end wall;

means for feeding water into the tank adjacent the higher end of the bottom;

means for feeding the granular solid into the tank adjacent the higher end of the bottom;

means adjacent the lower end of the tank bottom forming an outlet for the slurry to the pump;

means in the tank limiting the flow of water through the upper portion of the tank to minimize turbulence; and

means for maintaining the water at a predetermined level in the tank.

2. The assembly defined in claim 1 wherein the means for feeding water into the tank comprises a manifold extending around the end wall at the higher end of the bottom and the adjacent portions of the side walls, and slots in said end wall and adjacent portions of the side walls at the bottom of the tank communicating with the manifold.

3. An assembly as defined in claim 2 wherein the means for limiting the flow of water through the tank comprises at least one baffle extending between the side walls above said slots.

4. The assembly defined in claim 1 wherein the means forming an outlet for the slurry to the pump comprises an opening in the respective end wall extending from a medial portion of the end wall to the bottom of the tank and having a width less than the width of the tank, and a baffle extending from adjacent each side of the opening to the respective side wall in spaced relation from the respective end wall to funnel the slurry through the opening.

5. The assembly defined in claim 4 wherein said means forming an outlet for the slurry further comprises a baffle extending from the top of the opening into the container.

6. The assembly defined in claim 4 wherein the means for maintaining the water at a pre-determined level includes level control sensing means in the tank adjacent the end of the tank associated with the outlet for the slurry and positioned above said opening.

7. The assembly defined in claim 1 wherein the means for feeding granular solid into the tank comprises a conveyer extending over the top of the tank and terminating adjacent the end of the tank associated with the higher end of the bottom to feed the solid into the tank remote from the outlet for the slurry.

8. A hopper assembly for forming a slurry of a granular solid product and water is restricted spaces for transportation by a slurry pump comprising:

an open-topped tank having horizontal dimensions greater than vertical dimensions and having interconnected end walls and side walls and a bottom tapered downwardly toward one end wall;

a water manifold extending around the lower portion of the end wall at the higher end of the bottom and around adjacent portions of the side walls communicating with the interior of the tank through slots formed in the respective end wall and adjacent portions of the side walls;

a water supply line connected to the manifold;

a control valve in the water supply line;

means for feeding the granular solid into the tank adjacent the higher end of the bottom;

the end wall at the lower end of the bottom having an outlet opening formed therein for discharge of slurry formed in the tank;

a plurality of vertical baffles extending between the side walls having the lower edges thereof positioned above the slots through which the water enters the tank;

a level control sensor positioned in the tank above said outlet opening; and

a level controller connected to the sensor and the control valve for maintaining the water level in the tank above said outlet opening.

9. The assembly defined in claim 8 wherein the sensor is positioned between the vertical baffle located nearest to the end wall having the outlet opening therein and said end wall.