Conveyors: fluid current – Intake to fluid current conveyor – Load receptacle type
Reexamination Certificate
2001-01-30
2002-07-09
Ellis, Christopher P. (Department: 3651)
Conveyors: fluid current
Intake to fluid current conveyor
Load receptacle type
C406S052000, C198S550010, C198S550200, C198S642000, C222S410000, C222S342000
Reexamination Certificate
active
06416261
ABSTRACT:
TECHNICAL FIELD OF THE INVENTION
The present invention relates generally to solids handling and in particular to feeder valves, having little or no air loss, used in pneumatic conveying systems.
BACKGROUND OF THE INVENTION
In pneumatic conveying solid materials (powder, sand, gravel, coal, and the like as well as agricultural products such as seed and foodstuffs) must be moved from a storage facility be it a silo, a bin, a bunker, or similar, into a pneumatic conveying system. The storage facility is generally at atmospheric pressure; whereas, the conveying system is at a different pressure. Generally, the pneumatic system is at a higher pressure, but there are some vacuum pneumatic conveying systems. The conveying system pressure must be isolated from the storage hopper (bin, silo, etc.), and an airlock type valve is generally used for this purpose.
The airlock valve can take several forms. In some systems, the valve can be a simple gate or ball valve, which opens when the conveying system is de-pressured. This allows material to enter the conveying system. The valve is closed, the system pressured, and the material conveyed. This type of system is a batch process system and cannot deliver material at continuous rate.
In order to deliver material at a continuous rate, the conveying system must remain pressured at all times. Thus, in a continuous system, the airlock valve must be capable of delivering material from the hopper and into the system while maintaining system pressure. Finally, in continuous systems, the operator generally wishes to deliver a certain rate of material over time. Thus, the airlock valve should be capable of “metering” the material from the hopper.
The past art has generally employed a “star-valve” that obtains its name from the valve internals, which are shaped like a star. The star is formed about a shaft and is rotated within a circular valve body. The valve internals are a series of circular open sectors starting at the shaft and extending towards the circular wall of the valve body. The width of the sectors is set by the width of the valve body. The valve is placed between the hopper and the pneumatic conveying system. Material enters at the top of the valve and exits at the bottom of the valve. Essentially, material falls, under gravity, from the hopper into a sector, the sector rotates, and the material falls into the conveying system. Each sector within the star feeder valve acts like an airlock. The rate of material injection into the conveying system is determined by the speed of rotation of the star valve.
In order to create “airlock” properties, the stars (or open sectors) must have extremely tight clearances to and between the internal valve body. Basically, the sectors rub against the valve body walls at all times. Because the sectors rub against the walls, material within the sectors experiences grinding or damage. Furthermore, abrasive materials, such as sand, alumna, and the like, will grind the sectors eventually reducing the airlock properties of the valve. Unfortunately, some materials are capable of packing or clumping when exposed to work as exerted by a rotating star valve. These materials often seize a star valve causing damage to the drive motor and valve internals.
Finally, even though the star valve has ‘airlock’ properties, it is not an efficient airlock. Each sector, as it rotates from the conveying side pressure to the atmospheric side pressure, must equalize in pressure. Thus, air is transferred from the conveying system to the atmosphere (in a pressure system) or from the atmosphere to the conveying system (in a vacuum system). In fact, many star valves incorporate a special venting system, which allows such transfer to occur externally to the valve.
Rotary plate valves may also be used to transfer material from a hopper to a process and are well known in the art. These valves do not grind the material, nor do they suffer the drawbacks of abrasion or binding found in the star feeder. The rotary plate valve consists of a rotating plate upon which material falls, under gravity, and a plow or scrapper. The plow moves across the plate and scraps material from the plate into a discharge port or opening within the valve. The depth of the plow and the speed of the rotating plate control the rate of transfer through the valve. However, the current art in rotary plate valves does not extend to pressure conveying systems. There are some rotary plate feeder valves that may be used under pressure, but as will be seen these are somewhat limited in their application. Specific examples of the prior art may be found in the following series of U.S. patents.
Bonnot, U.S. Pat. No. 1,679,398, discloses a Disk Feeder for use in the coal industry and is probably one of the earlier disk feeders. Coal (or a similar material) is fed from an offset hopper onto a rotating disk and a scrapper blade removes the coal from the disk. The offset hopper barely touches the rotating disk and has a hole cut on one side of the hopper that allows material to fall onto the disk. A rotary sleeve valve rotates about the hopper and adjusts the amount of material falling onto the hopper. The scrapper blade is fixed. This early apparatus was designed solely for use in an atmospheric pressure environment.
Scholz, U.S. Pat. No. 1,993,249, discloses a Fine Coal Feeder that is a variation of Bonnot. Scholz places a hopper over a rotating disk, and the eccentricity of the hopper may be varied from zero eccentricity (i.e., over the center of the disk) to maximum eccentricity (at the edge of the disk). The eccentricity adjustment provides adjustment of “feed” to the system. Coal is then scrapped from the disk into a down-comer and into the place of use (in this case a boiler). Again, this device was designed for use at atmospheric pressure.
Wheldon, U.S. Pat. No. 2,213,508, discloses a Feeder for Pulverulent Material. Wheldon places a hopper over the center of a rotating disk. The hopper has an opening in the side next to the rotating disk, and an adjustable “scrapper” extends through the opening. The scrapper is hinged at one end and may swing into the hopper or line up against the wall of the hopper. In the later position, no material feeds from the system. As the scrapper is positioned into the hopper, material is caused to flow from the hopper, across the disk and onto a conveyor belt. Once more this device was designed for atmospheric pressure.
Shallock, U.S. Pat. No. 2,329,948, discloses a Feeder Means that is similar to Wheldon in that a hopper is placed over the center of the rotating disk. The means for controlling the removal of material is quite different and uses a triangular shaped extension inside the hopper that is in contact with the disk. The extension serves to hold a wedge valve that allows material to flow from the hopper onto the disk and serves also scrap the material from the disk. (Essentially the triangular extension serves two consecutive purposes. Material then follows the extension and drops from the disk into the process. This device was also designed for atmospheric pressure.
Weiste, U.S. Pat. No. 3,820,688, discloses a Material Dosaging Apparatus that is designed for use in pneumatic systems. The apparatus is designed to mix different amounts of material (up to four) into a common stream for conveying. Weiste uses a modified disk in the form of a tub with an outside wall and a center conical section with an opening. An ejector is placed immediately above the opening through which pneumatic conveying air is passed. The ejector causes a partial vacuum, which draws material from the rotating tub into the conveying system. Material falls onto the tub from circular supply hoppers through a form of gate valve. The gate valves regulate the quantity of material falling onto the rotating tub and consequently into the conveying system. The individual hoppers are vented to atmospheric pressure and atmospheric air is permitted to flow through the hoppers to assure movement of material from the hopper. It is apparent that the design requires the supply
Alworth C. W.
Dillon, Jr. Joe
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