SLURRY FLOW DIVIDER

RELATED APPLICATION

[01] This application claims priority to U.S. provisional application, serial number

60/871,055, which was filed on December 20, 2006, and which is hereby incorporated by reference, in its entirety.

FIELD OF THE INVENTION

[02] The present disclosure pertains to controlling the flow of slurries and more particularly to dividing a relatively large slurry stream into smaller constituent slurry streams.

BACKGROUND

[03] Slurry streams comprising particulates suspended in a transport fluid are found in many industries. For example, the manufacture of plastics typically involves extruding raw, melted plastic material from an extruder and then forming the raw plastic into particles. The plastic particles are entrained in a cooling transport fluid, which is typically water, to form a slurry. The water then carries the particulates to other locations in the plastics manufacturing plant for further processing, including but not limited to removal of undesirable materials (e.g., agglomerates) and dewatering, that is, removal of some portion of the transport fluid from the slurry. After dewatering, the plastic particles are transported to a dryer to remove moisture.

SUMMARY OF THE INVENTION

[04] Embodiments of the invention include a slurry dividing apparatus useful for dividing a slurry stream into two or more constituent slurry streams. In some embodiments, the apparatus includes a main flow channel with a slurry inlet opening and an inlet zone in fluid communication with, and extending from, the inlet opening. A deceleration zone may be provided in fluid communication with, and extending upward from, the inlet zone toward an upper end of the main flow channel. A flow divider terminating the upper end of the main flow channel may be provided to divide the slurry stream into two or more branch flow channels. In certain embodiments, a

weir extends across an upper portion of each of the branch flow channels to equalize the pressure in each of the branch flow channels. Embodiments of the invention also include an apparatus having such a flow divider in combination with an agglomerate removal and dewatering units and methods of separating a slurry stream.

BRIEF DESCRIPTION OF THE DRAWINGS

[05] The following drawings are illustrative of particular embodiments of the invention and therefore do not limit the scope of the invention. The drawings are not to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

[06] Figure IA is a perspective view of a slurry dividing apparatus in accordance with some embodiments of the present invention.

[07] Figure IB is a frontal elevation view of the slurry dividing apparatus shown in Figure IA.

[08] Figure 1C is a perspective view of a portion of the slurry dividing apparatus shown in Figure IA.

[09] Figure ID is a side section view through the slurry dividing apparatus shown in Figure IA.

[10] FIG. 2A is a frontal elevation schematic view of an apparatus in accordance with some embodiments of the invention.

[11] FIG. 2B is a side cross-sectional schematic view of an apparatus in accordance with some embodiments of the invention.

[12] FIG. 2C is a side cross-sectional view of an apparatus in accordance with some embodiments of the invention.

DETAILED DESCRIPTION

[13] The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides practical illustrations for implementing exemplary embodiments of the invention.

[14] Figure IA is a perspective view of a slurry dividing apparatus 500, according to some embodiments of the present invention; and Figure IB is a frontal elevation view of dividing apparatus 500. Figures IA-B illustrate apparatus 500 including a main flow channel 550 extending upward, preferably vertically, a flow divider 540 terminating an upper end of main flow channel 550, and a pair of branch flow channels 531, 532 in fluid communication with main flow channel 550 and extending upward, preferably vertically, from flow divider 540. Accordingly, slurry encountering slurry divider 540 will be split as it is traveling in an upward, vertical direction. The flow divider 540 is useful for separating a slurry stream into two or more constituent parts. As shown, the flow divider 540 comprises the inner walls of branch flow channels 531, 532. In other embodiments, flow divider 540 may comprise a single vertically oriented planar member.

[15] Branch flow channels 531, 532 may be provided in any relative cross -sectional sizes. For example, if a slurry stream is to be split into roughly two equivalent streams, the cross-sectional area of branch flow channels 531, 532 may be approximately equal. Other stream split ratios and corresponding branch flow channel cross-sectional areas (e.g., 60/40, 70/30) may be provided as desired.

[16] Figures IA-B further illustrate main flow channel 550 including a slurry inlet opening 510, an inlet zone 515, which extends upward from the opening 510, and a deceleration zone 505 extending upward from inlet zone 515 toward flow divider 540; an increasing cross-sectional area of deceleration zone 505 decelerates slurry flow for division into constituent slurry streams flowing within branch channels 531, 532. According to the illustrated embodiment, opposing sidewalls 55 of deceleration zone 505 expand outward with increasing elevation in order to reduce slurry flow velocity, at flow divider 540, to a value just above that which would maintain the solids of the slurry in suspension, for a minimum anticipated slurry flow rate at inlet opening 510. Without intending to be bound by theory, the density difference between the suspended particles and the transporting fluid of the slurry will generally determine the minimum velocity required to maintain the solids of the slurry in suspension. Further, the height of the deceleration zone may depend on both the anticipated inlet velocity and the ideal reduced velocity at the top of the deceleration zone. In general, embodiments of the flow divider will work within a large range of inlet velocities.

For example, for pellet slurry applications, inlet velocities may generally be between about 10 to about 20 feet per second and the velocity in the deceleration zone could be reduced by a factor of about 10 to 1. Other slurry applications could deviate significantly from this range.

[17] In some embodiments, each of branch flow channels 531, 532 has a cross-sectional area of approximately one half of this maximum cross-sectional area of the deceleration zone. With further reference to Figure IB, it may be appreciated that sidewalls 55 gradually taper outward, in a linear fashion, at an angle A, which is preferably less than or equal to approximately 10 degrees, in order to prevent boundary layer separation between inlet zone 515 and deceleration zone 505 which can lead to turbulent flow that may cause separation of the solids suspended in the slurry. In some embodiments, the slurry stream is decelerated in deceleration zone 505 until it reaches laminar flow. In certain embodiments, the deceleration zone 505 is sized and shaped to decelerate the slurry stream to the minimum velocity that maintains particle suspension.

[18] Figure IA further illustrates slurry dividing apparatus 500 including a pair of discharge flow channels 541, 542. According to the illustrated embodiment, each of discharge flow channels 541, 542 is in fluid communication with a corresponding branch flow channel 531, 532, and, with reference to Figure 1C, it may be appreciated that the constituent slurry streams flowing upward within each of branch channels

531, 532, when reaching an upper portion thereof, will spill over a weir 503 and into discharge channels 541, 542, respectively. In some embodiments, weir 503 may be included in separate sections corresponding with each branch flow channel. With reference back to Figure IA, an optional observation window 565 may provide a view of the flow of the slurry streams over weirs 503. Weirs 503 are preferably horizontally plumb and located at approximately the same elevation such that each slurry stream flows at the same depth over the corresponding weir 503, and an approximately equivalent head pressure is maintained across branch channels 531,

532. Such equivalent head pressure allows the slurry stream to be split according to the relative cross-sectional area of the branch channels 531, 532, as discussed above. In some embodiments, the slurry has been decelerated in the deceleration zone 505 to

such an extent that the constituent slurry streams are in laminar flow when they encounter weirs 503.

[19] With further reference to Figure 1C, in conjunction with Figure ID, which is a side section view through apparatus 500, optional bypass flow channels 570 are shown extending between each of branch flow channels 531, 532 and the corresponding discharge flow channel 541, 542. Although only one is shown in Figure ID, a valve 575 is provided for each of optional bypass flow channels 570; when valve 575 is opened the corresponding optional bypass channel 570 provides a flow pathway from the corresponding branch flow channel 531, 532 to the corresponding discharge flow channel 541, 542, which bypasses the corresponding weir 503. According to the illustrated embodiment one of valves 575 may be opened to short circuit one of the constituent slurry streams, which is flowing upward in the corresponding branch channel 531, 532, directly to the corresponding discharge flow channel 541, 542 and thereby increase a flow rate thereof.

[20] With further reference to Figure IA, each of discharge flow channels 541, 542 is shown including an acceleration zone 509 extending downward, preferably vertically, toward a corresponding slurry outlet opening 519. According to the illustrated embodiment, acceleration zones 509 have cross-sectional areas that decrease with decreasing elevation in order to accelerate flow back to a velocity which provides for efficient transporting of the constituent streams out from outlets 519 to subsequent processing stations.

[21] It should be noted that although each of inlet and outlet openings 510, 519 are shown having round cross-sections, which may be preferred for coupling with standard piping delivering slurries into and out from apparatus 500, the invention is not so limited and any suitable shape of cross-section may be employed for these openings. Furthermore, although main flow channel 550, branch flow channels 531, 532 and discharge flow channels 541, 542 are shown having rectangular cross-sections, again the invention is not so limited and any suitable shape of cross-section may be employed for these channels. Embodiments of the present invention may further include more than two branch flow channels and discharge flow channels to divide a slurry stream into more than two constituent streams.

[22] Embodiments of the invention also include methods of separating a slurry stream into two or more constituent parts. In some embodiments, the method includes the steps of causing the slurry to flow through a deceleration zone to decelerate the slurry stream and dividing the slurry into a first slurry stream and a second slurry stream with a flow divider. In some embodiments, each slurry stream enters independent agglomerate removal and dewatering units after the slurry divider.

[23] As shown in Figures 2A and 2B, in certain embodiments the independent agglomerate removal and dewatering units are provided within the same apparatus 500 as the slurry flow divider. In such embodiments, each slurry stream passing over weirs 503 (as described above) encounters a separate agglomerate removal and dewatering units 520, 525 in an agglomerate removal zone 527 and a dewatering zone 529. Each agglomerate removal unit and dewatering unit may be contained within a single housing, such as housing 528 shown in Figure 2A. Examples of agglomerate removal and dewatering units useful for utilization with some embodiments of the invention will be further described below. After traveling through the agglomerate removal and dewatering units, the particulates and transport fluid from each stream may exit the apparatus separately, such as at first stream fluid component exit 570, second stream fluid component exit 580, first stream particulate component exit 662, and second stream particulate component exit 660, as shown in Figure 2A. The particulates exiting at the first and second stream particulate component exits may then independently proceed to individual dryers for further moisture removal.

[24] The configuration of the agglomerate removal and dewatering units can take any suitable form useful for removing agglomerates and dewatering, respectively. An illustrative apparatus is described in commonly assigned U.S. Patent No. 6,063,296, entitled "Agglomerate Removal and Dewatering Apparatus," which is incorporated by reference herein.

[25] In the embodiment of Figure 2C, in such an apparatus the constituent slurry streams pass over weirs 503 and in to an agglomerate removal zone 527 and encounter a screening apparatus within the agglomerate removal zone. In some embodiments, screening apparatus comprises at least a first screen 600. Agglomerates present in the constituent slurry streams pass over the screen and out an agglomerate exit 610 while

the slurry transport fluid and desired particulates pass through the screen and flow on to the dewatering zone 529.

[26] Continuing with the embodiment shown in Figure 2C, apparatus 500 includes a dewatering unit in the dewatering zone 529. The dewatering unit includes a central tower 620 having a substantially cylindrical configuration. The central tower is surrounded by a substantially cylindrical screen 630 having a plurality of screening apertures sized to allow flow of the transport fluid through the screen but not the particulates entrained in the fluid. The screen includes a plurality of vertically spaced apart flanges 640 extending inwardly toward the tower. The tower includes a plurality of outwardly extending flanges 650. In operation, the fluid flow will enter the dewatering unit from the screen of the agglomerate removal unit. The particles will bounce back and forth between the flanges and the tower and screen, causing the transport fluid to separate from the particles. The fluid will largely flow through the screen while the particles will drop downwardly into a second stream particulate discharge exit 660. The fluid meanwhile, will exit the apparatus through second stream fluid component exit 580.

[27] Some embodiments of the invention include a method for removing agglomerates from a slurry comprising a transport fluid, particulates, and agglomerates formed from the particulates. In some embodiments, the method comprises the steps of causing the slurry to flow through a deceleration zone and past a flow divider to divide the slurry stream into a first slurry stream and a second slurry stream. Embodiments of the invention also include removing agglomerates from the first slurry stream by channeling the first slurry stream into the first agglomerate removal unit and removing agglomerates from the second slurry stream by channeling the second slurry stream into the second agglomerate removal unit. Other embodiments of the invention further include separating the slurry transport fluid from the slurry particles from the first and second slurry streams by channeling the first slurry stream into a first dewatering unit and by channeling the second slurry stream into a second dewatering unit.

[28] In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications

and changes can be made without departing from the scope of the invention as set forth in the appended claims.