| What is claimed is: 1. A device for sorting contaminants from minerals, the device comprising: a mineral feeding arrangement configured to feed the minerals for sorting the contaminants, the mineral feeding arrangement capable of feeding a predetermined size range of the minerals with minimum joyriding thereof; an elongated chute member configured to the mineral feeding arrangement in an inclined position with respect to the mineral feeding arrangement, the elongated chute member receives the minerals from the mineral feeding arrangement for enabling free falling of the minerals in a detection zone; an X-ray generating member capable of generating at least two collimated X- rays, first, a low energy collimated X-rays, and, second, a high energy collimated X- rays, at a point near to the elongated chute member in such a manner that the collimated X-rays passes from the free falling minerals in the detection zone for being partially absorbed by the minerals or the contaminants; a multi-energy X-rays sensors array configured to sense at least one of residual low energy X-rays and residual high energy X-rays passing through the free falling minerals, and sending a data signal; an electronic module configured to gather the signal data from the multi-energy X-rays sensors array to generate a comparative valve to determine the contaminants from the free falling minerals to be sorted based on a stored threshold valve, and send a process signal; and a manifold arrangement configured to the electronic module, the manifold arrangement comprising a plurality of ejectors, the manifold arrangement capable generating pneumatic-pressure based on the process signal to actuate required numbers of the ejectors of the plurality of ejectors for sorting contaminants from the minerals. 2. The device as claimed in claim 1, wherein the mineral feeding arrangement comprises, a bunker member having a discharge opening, the discharge opening configuring a screen mesh sheet disposed thereon to allow to pass the minerals of the predetermined size range, and a feeder member configured to the bunker member for receiving the discharged minerals to minimize the joyriding of the minerals. 3. The device as claimed in claim 2, wherein the feeder member is an electromagnetic feeder capable of controlling mineral flow with low amplitude and high frequency and minimizing joyriding of the minerals on the elongated chute member. 4. The device as claimed in claim 2, wherein the feeder member is an electromagnetic screen having plurality of fins configured thereon, the electromagnetic screen is capable of eliminating a predetermined size range of the contaminants from the minerals. 5. The device as claimed in claim 1, wherein the elongated chute member comprises, at least one vibrator member disposed underside, opposite to the side receiving the minerals, thereof; and at least one heating system disposed underside of the elongated chute member near to the at least one vibrator member, the at least one heating system is capable of heating the elongated chute member for preventing sticking of the minerals having wet characteristics. 6. The device as claimed in claim 1, wherein the elongated chute member is a flat tray composed of stainless steel material disposed with respect to the mineral feeding arrangement at the inclined position having a range varying between about 0 degree to 90 degrees. 7. The device as claimed in claim 1, wherein the X-ray generating member is an X-ray generator configured to provide the at least two collimated X- rays for uniform exposure across the multi-energy X-rays sensors array. 8. The device as claimed in claim 1, wherein the multi-energy X-rays sensors array comprises, a low energy detector sensor for detecting the residual low energy X-rays, a high energy detector sensor for detecting the residual high energy X-rays, and a copper filler disposed between the low energy detector sensor and the high energy detector sensor, thereby configuring the multi-energy X-rays sensors array. 9. The device as claimed in claim 1, wherein the electronic module comprises, an amplifier for amplifying the signal data based on the sensed output data from the multi-energy X-rays sensors array, a multiplexor configured to the amplifier for receiving the amplified signal data from the amplifier, a data acquisition system configured to the multiplexor to receive the signal date and convert thereto into digital value for processing, and a control electronic configured to the data acquisition system to receive the digital value and send thereto to an image generation software configured therein, the image generation software is capable of converting the digital values of residual low energy X-rays and residual high energy X-rays into the comparative value for comparing thereto with the stored threshold valve to determine the contaminants from the free falling minerals to be sorted, and sending the process signal through a solenoid control circuitry to the manifold arrangement generating desired pneumatic- pressure. 10. The device as claimed in claim 1, wherein each of the plurality of ejectors of the manifold arrangement is a pneumatic solenoid activated valve. 11. The device as claimed in claim 1, wherein the distance between the detection zone and an ejection point of the plurality of ejector is about two times the distance of the maximum mineral size being analyzed. 12. The device as claimed in claim 11, wherein the plurality of ejector is capable of being adjusted to shift the ejection point. 13. The device as claimed in claim 1 further comprising a compressor for air to be utilized by the X-ray generating member for enabling the X-ray generating member generate at least two collimated X-rays, wherein the compressor is capable compressing air and supplying thereto to the manifold arrangement. 14. The device as claimed in claim 13 further comprising an air surge tank configured to the compressor for storing the compressed air. 15. The device as claimed in claim 1 further comprising a V-shaped chute member configure below the detection zone between the X-ray generating member and the multi-energy X-rays sensors array for sorting the contaminants from minerals. 16. The device as claimed in claim 15 further comprising at least two conveyer assemblies configured below the V-shaped chute member for carrying the contaminants through one of the conveyer assembly and minerals from another conveyer assembly. 17. A method for sorting contaminants from minerals, the method comprising : feeding the minerals of a predetermined size range with minimum joyriding for sorting the contaminants therefrom by a mineral feeding arrangement; receiving the fed minerals on an elongated chute member configured in an inclined manner to the mineral feeding arrangement for enabling free falling of the minerals in a detection zone; generating at least two collimated X-rays, first, a low energy collimated X-rays, and, second, a high energy collimated X-rays, by an X-ray generating member configured at a point near to the elongated chute member in such a manner that the collimated X-rays passes from the free falling minerals in the detection zone for being partially absorbed by the material or the contaminants; sensing at least one of residual low energy X-rays and residual high energy X- rays passing through the free falling minerals by a multi-energy X-rays sensors array to send a signal data; gathering the signal data by an electronic module based on the sensed output data from the multi-energy X-rays sensors array for generating a comparative valve to determine the contaminants from the free falling minerals to be sorted based on a stored threshold valve; sending a process signal based on the comparison of the comparative valve and the stored threshold valve; and generating pneumatic-pressure based on the process signal of the electronic module to actuate required numbers of ejectors of a plurality of ejectors configured in a manifold arrangement for sorting contaminants from the minerals. 18. The method as claimed in claim 17, wherein feeding the minerals by the mineral feeding arrangement comprises, passing the minerals of the predetermined size range from a bunker member having a discharge opening, the discharge opening configuring a screen mesh sheet disposed thereon to allow passing minerals of the predetermined size range, and receiving the discharged on a feeder member to minimize the joyriding of the minerals. 19. The method as claimed in claim 18, wherein feeding the minerals comprises controlling mineral flow with low amplitude and high frequency to minimize joyriding of the minerals on the elongated chute member, by the feeder member which is an electromagnetic feeder. 20. The method as claimed in claim 18, wherein feeding the minerals comprises eliminating a predetermined size range of the contaminants from the minerals by the feeder member which an electromagnetic screen having plurality of fins configured thereon. The method as claimed in claim 18, wherein receiving the minerals from the mineral feeding arrangement on an elongated chute for heating the minerals on the elongated chute member for preventing sticking of the minerals having wet characteristics. 21. The method as claimed in claim 17, wherein generating the at least two collimated X-rays further comprising exposing the at least two collimated X-rays uniformly across the multi-energy X-rays sensors array. 22. The method as claimed in claim 17, wherein sensing at least one of residual low energy X-rays and residual high energy X-rays passing through the free falling minerals by the multi-energy X-rays sensors array comprises, detecting the residual low energy X-rays by a low energy detector sensor of the multi-energy X-rays sensors array, detecting the residual high energy X-rays by a high energy detector sensor of the multi-energy X-rays sensors array, and sending the signal data of the residual low energy X-rays and the residual high energy X-rays. 23. The method as claimed in claim 17, wherein gathering the signal data and generating a comparative valve to determine the contaminants from the free falling minerals to be sorted by the electronic module comprises, amplifying the signal data based on the sensed output data from the multi- energy X-rays sensors array by an amplifier of the electronic module, receiving the amplified signal data from the amplifier by a multiplexor of the electronic module, receiving the signal date for converting thereto into digital value for processing by a data acquisition system of the electronic module, receiving the digital value by a control electronic of the electronic module, sending the digital value to an image generation software configured to the electronic module, the image generation software is capable of converting the digital values of residual low energy X-rays and residual high energy X-rays into the comparative value for comparing thereto with the stored threshold valve to determine the contaminants from the free falling minerals to be sorted, and sending the process signal through a solenoid control circuitry to the manifold arrangement generating desired pneumatic-pressure. 24. The method as claimed in claim 17 further comprising compressing air by a compressor, the compressed air being utilized by the X-ray generating member for enabling the X-ray generating member to generate at least two collimated X-rays. 25. The method as claimed in claim 29 further comprising supplying the compressed air to the manifold arrangement at about predetermined pressure range. 26. The method as claimed in claim 29 further comprising storing the compressed air in an air surge tank configured to the compressor. 27. The method as claimed in claim 17 further comprising sorting the contaminants from minerals by a V-shaped chute member configured below the detection zone between the X-ray generating member and the multi-energy X-rays sensors array. 28. The method as claimed in claim 17 further comprising carrying the contaminants through one of a conveyer assembly and minerals from another conveyer assembly of at least two conveyer assemblies configured below the V- shaped chute member. |
METHOD THEREOF
FIELD OF THE DISCLOSURE
The present disclosure relates to a device and a method for sorting materials, and, more particularly, relates to a device and a method for detecting and sorting contaminants from minerals, such as coarse coal, to improve the quality of the minerals.
BACKGROUND OF THE DISCLOSURE
Qualities of minerals, such as coal, determine the efficiency and economics of operation wherever utilized. In nature, minerals are found in a wide array of forms, chemistry and compositions generally interwoven with a number of contaminants that tend to affect the quality thereof. In order to remove contaminants from the minerals and to improve the quality thereof, various conventional technologies, such as wet beneficiation technologies, and dry beneficiation technologies etc. are widely used.
In the wet beneficiation technologies, the minerals are crushed to appropriate sizes, and are subjected to separation in a liquid medium based on specific gravity differentials between the minerals and the contaminant particles. However, the wet beneficiation technologies are generally expensive as the techniques use plenty of water, and have a serious adverse impact on the environment, both, in terms of using water, a scarce resource, and polluting the environment in the form of effluents. Further, as water is being used for sorting contaminant also adds moisture to minerals, which may affect the efficiency of the minerals in terms of heat value.
Accordingly, nowadays dry benefication technologies are evolving, which offset many of the drawbacks of the conventional wet beneficiation technologies. Limitations of the dry beneficiation technologies in existence that may be till date are that the technologies are based on mechanical properties, which may reduces accuracy levels from what are required.
One of the dry beneficiation technologies utilizes a system for on-line evaluation of minerals quality and its acceptance or rejection. Such state of the art technologies in practice include non-destructive methods of identification of impurities on-line, and removal of the unwanted material, such as contaminants, from the minerals. On-line detection of the contaminants from the bulk minerals while transporting on conveyors may be done through applied radiometric measurements, such as a gamma ray transmission technique integrated with ultrasonic measurement sensors, for compensation of loading height of the materials. Once the contaminants are detected, removal of such contaminants from the bulk flow of the minerals by an appropriate technique is followed.
In line with the above, a conventional process and a device are known for mechanically detecting over-sized contaminants in respect of determination of its depth. For such detection, a conducting system in the device is utilized for receiving the waste material bulk flow at a delivery point under observation of the belt speed, in such a manner that the contaminants drop on a collecting point. Such conventional process and device generally result, unsuccessful separation of such contaminants having a size which were identical with the pieces of the useful minerals.
Another conventional technique is disclosed in German Patent Document bearing No. DE3312586, (hereinafter disclosed "DE'586"). DE'586 discloses a determination of a radiation of radio-active material with the help of a detection unit and a logic unit. The logic unit evaluates the average value of the radiation from the mineral being transported and causes an effect on the distribution of the material flow, when there is a fluctuation from a predetermined normal value. The disclosed device may be generally useful only for self-emitting radiating material or material under consideration having some components which emit radiation. Detection and subsequent elimination of the impurities from the useful mineral flows, such as coal in power plants and cement plants etc, may generally not be possible with the help of system disclosed in DE'586.
Further, another United State Patent Document bearing No. US3655964 (hereinafter referred to as "US'964") discloses detection of impurities in a useful mineral flow, where s effect of varying weakening of the radioactive emission through materials of different chemical composition is used. However, this method is applicable only when the useful mineral is transported with a constant loading height and bulk density. Further, this method may be insensible in the determination of stones in ash-containing raw coals, because the chemical components are more or less the same, and particularly in cases where both are near density material. The ' same is appropriate in cases of homogeneous stone of larger dimension in pyrites flow. Hence, this technique is applicable generally for such useful mineral flows, where the chemical composition of the undesired impurities is strongly different from that of the useful materials. The influence of the naturally available random value (stochastic) of the impulse rates of the individual measurements become larger with the reduction in the measuring time, so that the accuracy of the representative process or the device working decreases with increasing reduction of the measuring cycles. This is because the data obtained is finally used for differentiated control of the material flow, a large error is unavoidable.
Furthermore, other conventional technique to separate contaminants from minerals includes use of X-rays on a belt conveyor. Such conventional technique may not be useful due to the interference of the belt and its varying condition over a period of time, in the measurement and the controlled speed at which the belt had to be operated to prevent "hazing" of the analysis. Moreover, higher belt speed to achieve higher capacities cause differential trajectories at the discharge end, which render inefficient ejection.
Accordingly, there exists a need for a technique which may effectively separate smaller sizes as well as large sizes the contaminant particles from the minerals. There is also need of effective ejection of the contaminants from the minerals, irrespective of the size the contaminants. Further, there exists a need for rapid method to preclude particle by particle analysis that slow down the separation method of contaminants from the minerals and makes the conventional technologies unviable in any commercial application.
SUMMARY OF THE DISCLOSURE
In view of the forgoing disadvantages inherent in the prior-art, the general purpose of the present disclosure is to provide a device and a method for sorting contaminants from minerals that is configured to include all advantages of the prior art, and to overcome the drawbacks inherent in the prior art.
An object of the present disclosure is to provide a device, with the help of which, impurities in the useful mineral are detected depending upon the level of contamination in each individual particle, and remove the same effectively.
Another object of the present disclosure is to provide a method that precludes particle by particle analysis for separation method of contaminants from the minerals and provides effective commercial application.
To achieve the above objectives, in an aspect of the present disclosure, a device for sorting contaminants from minerals, (e.g. ash content in coal), is provided. The device may be located on a main mineral processing/handling plant or may be a separate unit designed for processing minerals. The device comprises a mineral feeding arrangement, an elongated chute member, an X-ray generating member, a multi-energy X-rays sensors array, an electronic module and a manifold arrangement. The mineral feeding arrangement is configured feed the minerals for sorting the contaminants therefrom. The mineral feeding arrangement is capable of feeding a predetermined size range of the minerals with minimum joyriding thereof. The elongated chute member is configured to the mineral feeding arrangement in an inclined position with respect to the mineral feeding arrangement. The elongated chute member receives the minerals from the mineral feeding arrangement for enabling the free falling of the minerals in a detection zone for sorting the contaminants. The X-ray generating member is capable of generating at least two collimated X-rays, first, a low energy collimated X-rays, and, second, a high energy collimated X-rays, at a point near to the elongated chute member in such a manner that the collimated X-rays passes from the free falling minerals in the detection zone for being partially absorbed by the minerals or the contaminants. The multi-energy X-rays sensors array is configured to sense at least one of residual low energy X-rays and residual high energy X-rays passing through the free falling minerals to send a signal data. The electronic module is configured to gather the signal data based on the sensed output data from the multi-energy X-rays sensors array to generate a comparative valve for determining the contaminants from the free falling minerals to be sorted based on a stored threshold valve, and send a process signal. Further, the manifold arrangement is configured to the electronic module, and comprises a plurality of ejectors. The manifold arrangement is capable generating pneumatic- pressure based on the process signal of the electronic module to actuate required numbers of the ejectors of the plurality of ejectors for sorting contaminants from the minerals.
Further, in another aspect of the present disclosure, a method for sorting contaminants from minerals is provided. The method comprises feeding the minerals of a predetermined size range with minimum joyriding for sorting the contaminants therefrom by a mineral feeding arrangement. Further, the method comprises receiving the minerals from the mineral feeding arrangement on an elongated chute member configured in an inclined manner to the mineral feeding arrangement for enabling free falling of the minerals in a detection zone for sorting the contaminants therefrom. Method further comprises generating at least two collimated X-rays, first, a low energy collimated X-rays, and, second, a high energy collimated X-rays, by an X-ray generating member configured at a point near to the elongated chute member in such a manner that the collimated X-rays passes from the free falling minerals in the detection zone for being partially absorbed by the material or the contaminants. Furthermore, the method comprises sensing at least one of residual low energy X- rays and residual high energy X-rays passing through the free falling minerals by a multi-energy X-rays sensors array to send a signal data. The method further comprises gathering the signal data by an electronic module based on the sensed output data from the multi-energy X-rays sensors array for generating a comparative valve to determine the contaminants from the free falling minerals to be sorted based on a stored threshold valve. Moreover, the method further comprises sending a process signal based on the comparison of the comparative valve and the stored threshold valve, and generating pneumatic-pressure based on the process signal of the electronic module to actuate required numbers of ejectors of a plurality of ejectors configured in a manifold arrangement for sorting contaminants from the minerals.
This together with the other aspects of the present disclosure, along with the various features of novelty that characterized the present disclosure, is pointed out with particularity in the description and claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present disclosure will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawing and claims, wherein like elements are identified with like symbols, and in which :
FIG. 1 illustrates a device in accordance with an exemplary embodiment of the present disclosure;
FIG. 2 illustrates a block diagram of the device of FIG. 1, in accordance with an exemplary embodiment of the present disclosure;
FIG. 3 illustrates a top view of a bunker member of the device of FIG. 1, in accordance with an exemplary embodiment of the present disclosure;
FIG. 4 illustrates a side view of an electromagnetic screen, in accordance with an exemplary embodiment of the present disclosure;
FIG. 5 illustrates side view of an elongated chute member of the device of FIG. 1, in accordance with an exemplary embodiment of the present disclosure;
FIG. 6 illustrates an enlarged view of a multi-energy X-rays sensors array of the device of FIG. 1, in accordance with an exemplary embodiment of the present disclosure;
FIG. 7 illustrates a block diagram of an electronic module of the device of FIG. 1, in accordance with an exemplary embodiment of the present disclosure; FIG. 8 illustrates a manifold arrangement of the device of FIG. 1, in accordance with an exemplary embodiment of the present disclosure; and
FIG. 9 illustrates a flow diagram of a method, in accordance with an exemplary embodiment of the present disclosure.
Like reference numerals refer to like parts throughout the description of several views of the drawings.
DETAILED DESCRIPTION OF THE DISCLOSURE
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting . Further, reference herein to "one embodiment" or "an embodiment" means that a particular feature, characteristic, or function described in connection with the embodiment is included in at least one embodiment of the invention .
The term "top," "bottom," "first," "second," and the like, herein do not denote any order, elevation or importance, but rather are used to distinguish placement of one element over another. Further, the terms "a" and "an" herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The term "minerals" and "materials" used herein are interchangeably used, and refer to same thing, that is minerals from which the contaminants are to be sorted.
Referring now to FIGS. 1 and 2, a device (1000) for sorting contaminants from minerals is illustrated, in accordance with exemplary embodiment of the present disclosure. Specifically, FIG. 1 illustrates a front view of the device (1000), and FIG. 2 illustrates a block diagram of the device (1000) of FIG. 1. The device (1000) includes a mineral feeding arrangement (100) configured to feed minerals, such as coarse coal, for sorting contaminants therefrom. The mineral feeding arrangement (100) is capable of feeding a predetermined size range of the minerals with minimum joyriding. Specifically, the mineral feeding arrangement (100) includes a bunker member (102) and a feeder member (104). In one form the bunker member ( 102), without departing from the scope of the present disclosure, may be made of a steel material.
FIG. 3 illustrates a top view of the bunker member (102) and is described herein in conjunction of FIGS. 1 and 2. As shown in FIG. 3, the bunker member (102) includes a top opening (102a), and a discharge opening ( 102b) opposite to the top opening (102a). The discharge opening (102b) includes a screen mesh sheet (102c) disposed thereon. The bunker member (102) is capable of receiving minerals that are needed to be analyzed for making thereto free from the contaminants. The materials are fed into the bunker member (102) and passes through the screen mesh sheet (102c) of the discharge opening (102b). The screen mesh sheet (102c) allows the minerals with contaminants of predetermined size range to pass therefrom for analysis thereof. The predetermined size range of the minerals with contaminants that passes from the screen mesh sheet (102c) may be as per standards of coarse coal. Size and shape of the bunker member (102) may be manufactured depending upon specific requirement of the application demand.
Referring back to FIGS. 1 and 2, the feeder member (104) of the mineral feeding arrangement (100) is configured to the bunker member ( 102) to receive the minerals discharged from the discharge opening (102b) for sorting the contaminants to minimize the joyriding of the minerals. In one embodiment, the feeder member (104) is an electromagnetic feeder. The electromagnetic feeder may be provided to control the mineral flow with low amplitude and high frequency and minimize joyriding of minerals. In another embodiment of the present disclosure, the feeder member (104) may be an electromagnetic screen (105) as shown in FIG. 4. The electromagnetic screen (105) having plurality of fins (105a) configured thereon. The electromagnetic screen (105) is capable of eliminating a predetermined size range of the contaminants from the minerals. The electromagnetic screen (105) may be capable of eliminating the predetermined size range of the contaminants particles of about 6mm from the minerals.
The device ( 1000) further includes an elongated chute member (106). The elongated chute member (106) is described with reference to FIG. 5 in conjunction with FIGS. 1 and 2. The elongated chute member (106) is configured to the mineral feeding arrangement (100) in an inclined position with respect to the mineral feeding arrangement (100). The elongated chute member (106) receives the minerals from the mineral feeding arrangement (100) for enabling free falling of the minerals in a detection zone (D) for sorting the contaminants therefrom. The material from the bunker member (102) may be feed into the feeder member (104) and from there to the elongated chute member (106). The elongated chute member ( 106) may be a flat tray composed of stainless steel material with appropriate at least one vibrator, such as vibrators (106a) located underside, opposite to the side receiving the minerals, along with at least one heating system, such as heating systems (106b) to prevent sticking of materials with wet characteristic and obstructing the flow of the mineral particles on the elongated chute member ( 106). Further, the elongated chute member (106) may have width varying between about 960 mm to 1920 mm and is inclined at a predetermined angle with respect to the mineral feeding arrangement (100). The elongated chute member (106) is in inclined position with respect to the mineral feeding arrangement (100), specifically, with respect to the feeder member ( 104), at an angle having a range varying between about 0 degree to 90 degrees.
The device (1000) further includes an X-ray generating member (108) and a multi-energy X-rays sensors array (110), (hereinafter referred to as "sensors array ( 110)"). The material from the elongated chute member (106) passes from the X-ray generating member (108) and the sensors array (110). Specifically, the X-ray generating member (108) is capable of emitting at least two collimated X-rays, first, a low energy collimated X-rays, and, second, a high energy collimated X-rays, at a point near to the elongated chute member ( 106) in such a manner that the collimated X-rays passes from the free falling minerals in the detection zone (D) for being partially absorbed by the minerals or the contaminants. The X-ray generating member (108) is an X-ray generator. Further, the sensors array (110) may be placed in front and proximate to the X-ray generating member (108). The sensors array (110) may include multi-energy X-ray sensors for sensing the low and high energy X- rays. Specifically, as shown in FIG.6 the sensors array (110) includes a low energy detector sensor (112) for detecting the residual low energy X-rays, and a high energy detector sensor (114) for detecting the residual high energy X-rays, and send a signal data. Further, a copper filler (116) is disposed between the low energy detector sensor (112) and the high energy detector sensor (114), thereby configuring the sensors array (110) with pitch varying between about 1.2 mm to 1.8mm .
The collimation of the X-rays from the X-ray generating member (108) is such that there is uniform exposure across all the sensors, such as the low energy detector sensor (112) and the high energy detector sensor (114), of the sensors array (110). The X-ray radiation absorption of the material is governed by the energy level of the X-rays emitted by the X-ray generating member ( 108) and the composition of the material. Since two energies are used - high and low - the differential attenuation between these as measured by the sensors array (110) yield the composition of material independent of bulk or height of the material being evaluated. The evaluation equation may be as follows:
I = I 0 e - μχ
Where:
"I" is the measured value of the residual X-ray detected by the sensor after passing through material;
"I 0 " is the initial value measured by the sensor in the absence of material;
"μ" is the linear absorption co-efficient of the material; and
"X" is the height or thickness of the material.
The X-ray analysis is done at the start of the free-falling material in the detection zone (D) of the particle from the elongated chute member (106) as shown in FIG. 1. This design enables the uninterrupted evaluation of the particle not affected by any other material such as belt or steel plate etc.
Further, the device (1000) includes an electronic module (117). Block diagram of the electronic module (117) is illustrated in FIG. 7 and is described herein in conjunction with FIGS. 1 and 2. The electronic module (117) is configured to gather the signal data based on the sensed output data from the sensors array (110) to generate a comparative valve to determine the contaminants from the free falling minerals to be sorted based on a stored threshold valve, and send a process signal. The electronic module (117) includes an amplifier (118), a multiplexor (120), a data acquisition system (122) and a control electronic (124). The amplifier (118) is capable for amplifying the signal data based on the sensed output data from the sensors array (110). Further, the multiplexor (120) is configured to the amplifier (118) for receiving the amplified signal data therefrom. Furthermore, the data acquisition system (122) is configured to the multiplexor (120) to receive the signal date and convert thereto into digital value for processing. Moreover, the control electronic (124) is configured to the data acquisition system (122), which may receive the digital value and send thereto to an image generation software configured therein. The image generation software is capable of converting the digital values of residual low energy X-rays and residual high energy X-rays into the comparative value for comparing thereto with the stored threshold valve to determine the contaminants from the free falling minerals to be sorted, and sending the process signal through a solenoid control circuitry (SCC) ( 128) forward.
Specifically, conversion of dual energy X-rays signals into composite density image and collation of the information on the basis of pixels to obtain composite contamination value or Ash content. Thereafter, the image generation software sends appropriate instructions to switching transistors to switch on particular sets of ejectors of a plurality of ejectors of a manifold arrangement for generating desired pneumatic-pressure. The manifold arrangement with the plurality of ejectors will be described herein afterwards. The device (1000) may be configured to a PC/FG (126) with relation to the electronic module (117).
Further, the solenoid control circuitry (128) specifically enables solenoids to operate at high speed and less consumption of power without damaging a coil. The solenoid control circuitry (128) may be a special driver circuit that has been designed to enable the solenoids to switch on rapidly at high voltage but it is kept open at low voltages to enable the current consumption to be minimized while optimizing the speed of operations.
The device (1000) further include a manifold arrangement (130) configured to the electronic module (117) via the solenoid control circuitry (128), as mentioned above. The manifold arrangement ( 130) includes a plurality of ejectors (132). FIG. 8 illustrates the manifold arrangement (130) in accordance with an exemplary embodiment of the present disclosure, and is described in conjunction with FIGS. 1 and 2. The manifold arrangement (130) is capable generating pneumatic-pressure based on the process signal of the electronic module (117) to actuate required numbers of the ejectors of the plurality of ejectors (132) for sorting contaminants from the minerals in the detection zone (D).
Each of the plurality of ejectors (132) of the manifold arrangement (130) is a pneumatic solenoid activated valve. The plurality of pneumatic solenoid activated valves with a footprint of about less than 10 mm arranged in the manifold arrangement (130) such that pitch between each nozzle of the valves of the ejectors (132) is below about 5 mm. Further, the distance between the detection zone and an ejection point of the plurality of ejectors (132) is about two times the distance of the maximum mineral size being analyzed. The plurality of ejectors (132) is capable of being adjusted to shift the ejection point. The manifold arrangement (130) may be of aluminum or engineering plastics with provision for easy fixing and removal of the pneumatic solenoid activated valves for maintenance purposes. The X rays generated by the X-ray generating member (108) may be allowed to pass through the plurality of ejectors (132) and the manifold arrangement (130) for analyzing the materials falling from the elongated chute member (106) and categorizing thereto to fall onto a V-shaped chute member (134) depending upon the parameters set. The V-shaped chute member (134) is hereinafter referred to as "V-chute (134)," and will be described herein afterwards.
The device (1000) further includes a compressor (136) and an air surge tank
( 138). The compressor (136) and the air surge tank (138) are configured to the X- ray generating member (108) for, respectively, compressing and storing the air for being used by the X-ray generating member ( 108). The compressor (136) may be capable of supplying compressed air at about 4 to 10 bar to targeted location. Further, the air surge tank (138) may be capable of storing the compressed air at a capacity of about 300 to 500 liters. However, the capacity of the air surge tank ( 138) may be increased or decreased depending upon the requirement of the user.
The V-chute (134) as mentioned above may be capable of categorizing contaminants and the material or the minerals from each other for obtaining high quality minerals or materials. The V-chute (134) enables the categorizing of the contaminants and the material from each other for accumulating thereto on to at least two conveyer assemblies (140) and (142), which may be capable of transporting the rejected minerals or contaminants and high quality minerals from one place to another. More particularly, the conveyer assemblies (140) and (142) may be capable of evacuating the clean coals and rejected coals, respectively. In another form, separate conveyor belts may also be located at the ejection point to evacuate the clean and reject coal.
In utility, based on the above equation and deceive (100) as shown in FIGS. 1 and 2, whenever an impure material composite is detected upon falling from the elongated chute member (106) to between the sensors array ( 110) and the X-ray generating member (108), the time frame in which it reaches the ejection point is pre-determined since it is in the free-falling zone. The detected material is diverted from the main path of material flow with the help of high response pneumatic jets fitted in the manifold arrangement (130) . Since the sensors (112) and (114) pitches are small, viz. 1.2 - 1.6 mm, it is necessary to have a relatively small footprint for the ejectors (132) also. But at the same time, it is also necessary to have sufficient force to eject the particle from the normal path. Hence, for purposes of simplicity of design, the two sensors (112) and (114) are linked to one ejector, such as the ejectors (132) which implies that each ejector, such as the ejectors (132) needs to have a pitch twice that of the sensors (112) and (114).
When an impure material (contaminants) is detected, the ejection signals are given to the high speed pneumatic valves to blow the particle away. This is achieved by a highly synchronized operation of the timing cycles and the rate of fall of the material. Each set of the device (1000) operate as individual channels but are interconnected to the measurement of the neighboring channels. The detected material is blown out by the respective pneumatic ejector nozzle once a command is given to reject the material. The blow time duration and time of blow is synchronized with the time cycles of measurement for the particular piece and the blow is affected when the piece is in its free-falling trajectory path after the material leaves the elongated chute member (106).
Referring now to FIG. 9, a flow diagram of a method (200) is illustrated, in accordance with an exemplary embodiment of the present disclosure. The method (200) is described herein in conjunction to FIGS. 1 and 2. For the sake brevity of the description, repetition of earlier described matter is precluded herein, and in anyway may not consider being limiting and insufficient. The method starts at (210). At (220), the minerals of a predetermined size range with minimum joyriding for sorting the contaminants therefrom may be fed by the mineral feeding arrangement ( 100), in a same manner as described above.
Further, at (230), the minerals may be received from the mineral feeding arrangement (100) on the elongated chute member (106) configured in the inclined manner to the mineral feeding arrangement (100) for enabling free falling of the minerals in the detection zone (D) for sorting the contaminants therefrom.
At (240), at least two collimated X-rays, first, a low energy collimated X-rays, and, second, a high energy collimated X-rays, is generated by the X-ray generating member (108) configured at the point near to the elongated chute member (106) in such a manner that the collimated X-rays passes from the free falling minerals in the detection zone (D) for being partially absorbed by the material or the contaminants. Further at (250), at least one of residual low energy X-rays and residual high energy X-rays are sensed while passing through the free falling minerals by a sensors array (110) to -send a signal data. On-line measurement of material composition in respect of its contamination level for each individual particle in the flow may be done in the following manner: (a) in short time cycles of 100 - 1000 microseconds, (b) comparing the signals of the neighboring channels, (c) comparing preceding and succeeding signals. The signal data of X-ray radiation absorption from the low and high energy detector sensors (112) and (114) may be transmitted to the electronic module (117).
At (260), the signal data may be gathered by the electronic module (117) based on the sensed output data from the sensors array (110) for generating a comparative valve to determine the contaminants from the free falling minerals to be sorted based on a stored threshold valve. Further at (270), a process signal is sensed based on the comparison of the comparative valve and the stored threshold valve to the manifold arrangement (130). Specifically, the electronic module (117) may process the data signal for removing the noise, amplifying the signal to the required level and converting thereto from analog to digital form .
Furthermore at (280) pneumatic-pressure is generated based on the process signal of the electronic module (117) to actuate required numbers of ejectors of the plurality of ejectors (132) configured in a manifold arrangement (130) for sorting contaminants from the minerals in the detection zone (D).
Without limiting at steps (260) to (280), following operation may be carried on. The signal data may be processed in control software to generate on-line evaluation of contamination composition/ash content in composite material.
The computed composite contamination may be calculated for the whole particle by aggregating the information for the particle pixel by pixel. The contamination composition/ash content of each particle in terms of this composite value is compared with an adjustable representative mean value of useful mineral defined as control set value. The comparison takes place in a continuous manner and the same may be compared with that of a set value which acts as a threshold limit. The crossing of this limit by the computed value may trigger an output signal through high response interposing relays for the corresponding ejectors (132) to be activated . Based on output signal, impurities may be rejected by high speed and fast response pneumatic valves, the removal of impure particle on detection may be done by ejecting the material by blowing, through high pressure air jets specially designed for effective separation. A number of blow jets are arranged, corresponding to the number of measuring channels. The ejectors' jets (132) may be connected to the air surge tank (138), which maintains the pressure and flow requirements constant throughout the plant operation time. Each ejector (132) is designed to develop sufficient pressure for ejecting the reject material which varies according to particle sizes being handled in that module. The ejectors (132) is synchronized with the material flow speed and is effected when the material in its free-falling trajectory. The blow shall be affected only on the material to be separated while the useful material flow is left untouched to be delivered to the main flow of clean material. At (290), the method (200) stops.
The device (1000) and the method (200) may have following advantages along with several other advantages through out the disclosure. The time cycle for measurement may be fixed between 100 - 1000 microseconds and matched in respect of the ratio to one another such that the smallest size of the impurities (6 mm) can be detected. Further, high quality output may be achieved as measurement may be done particle by particle and all the contaminated particles above the set point are removed from the stream. Furthermore, an important feature in the design is the know-how related to changing the input parameters in the electronics to achieve high degrees of resolution in the output thereby increasing accuracy of measurement and the system. Yet further, the device (1000) has applications for a wide variety of minerals other than coal. Moreover, the method and the device (1000) is eco-friendly.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omission and substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but such are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention.