Abstract:
A separation housing houses a rotor with multiple suspension chambers. Each chamber has a radially extending web portion between two rotating discs. An orifice is provided through the radially extending web portion. Another web portion urges gas radially out of the rotor. Passages through the rotating disks permit entry of gas and solid particle mixtures into the suspension chambers at high speed traveling toward each other in a suspension adjacent to the orifice. The web portion that urges gas out of the chamber pulls gas away from the suspension zone. Gas moving through the aperture and into a clean gas chamber pulls gas in the opposite direction. The result is gas in the suspension zone being fixed relative to the rotor or changing direction. Centrifugal force moves solid particles radially out of the chamber.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of the filing date of U.S. Provisional Application No. 61/148,339, titled GAS SOLID MIXTURE SEPARATOR filed Jan. 29, 2009. 
    
    
     TECHNICAL FIELD 
     The separator separates solids such as dust from a gas such as air. 
     BACKGROUND OF THE INVENTION 
     Air and other gasses often need to be cleaned. Solids need to be separated from a gas at times for use in industrial applications or possibly as food. Solids can also be separated to keep a solid material out of the environment. 
     Cyclone separators are used to separate material such as flour from air. The cyclones can be relatively efficient if the solids are somewhat dense. 
     Filters are widely employed for separating solids from a gas. Some of these filters catch and hold solids until the filter is partially plugged. The plugged filter is then removed and destroyed or cleaned. Other filters are partially cleaned by short periods of gas back flow. 
     Filters generally require a large surface area and substantial space. Operations of many filter systems require a system shut down for filter cleaning or replacement. 
     Gasses, that need to be cleaned, may be at elevated temperatures. Gasses at high temperatures may destroy filters, cooling before filtering can be expensive. Gas scrubbing and cooling with water applied directly to the dirty air may create a toxic sludge that is difficult to contain. 
     SUMMARY OF THE INVENTION 
     The gas solid particle mixture separator includes a frame. A separator housing is attached to the frame and including a first side wall plate a second side wall plate, a wall secured to the first side wall plate, the second side wall plate and forming a rotor chamber. A hopper is secured to the first side wall plate, the second side wall plate and the wall and forming a lower portion of the separator housing. A valve assembly is attached to the hopper for closing the hopper and for opening the hopper to discharge solid particles received in the hopper. 
     A rotor support shaft is journaled on the frame and extends through a passage through the first side wall plate. A seal mounted on the first side wall plate receives the rotor support shaft. 
     An inlet passage directs gas and solid particles into the separator housing. 
     A rotor hub is mounted on the rotor support shaft inside the rotor chamber. A first disk, with a cylindrical outer edge is concentric with an axis of rotation of the rotor support shaft and spaced from the first side wall plate. A web is fixed to the first disk and extends from the first disk toward the second side wall plate. A second disk, with a cylindrical outer edge is concentric with the axis of rotation of the rotor support shaft. The second disk is attached to the web fixed to the first disk. The second disk is parallel to the first disk and spaced from the second side wall plate. 
     At least four suspension chambers are formed by the web between the first disk and the second disk. Each of the suspension chambers includes a radially extending portion which extends from the cylindrical outer edge of the first disk and the outer edge of the second disk and toward the axis of rotation. A central opening passes through the radially extending portion. An orifice plate is attached to the radially extending portion. An orifice in the orifice plate is in alignment with the central opening and provides a flow path for gas passage from the suspension chamber. A second web portion is normal to an inner end of the radially extending portion and extends away from an orifice plate side of the radially extending portion. A fourth web portion of the suspension chamber wall extends from the outer edges of the first disk and the second disk toward the radially extending portion at an angle. The angle results in the fourth web portion forcing gas through the radially facing open side of the suspension chamber. A web portion extends from the second web portion to the fourth web portion. 
     An arc portion of the web extends from the fourth web portion of one suspension chamber to the radially extending portion of an adjacent suspension chamber. 
     A passage extends through the first disk and into the suspension chamber. The passage is adjacent to the orifice plate. A flap adjacent to the passage extends inward from the first wall and toward the orifice at an angle. 
     A passage extends through the second disk and into the suspension chamber. The passage is adjacent to the orifice plate. A flap adjacent to the passage extends inward from the second wall and toward the orifice at an angle. 
     Gas passing through the first disk makes a ninety degree change in direction. Gas passing through the second disk makes a ninety degree change in direction. The gas passing through the second disk intersects the gas passing through the first disk moving in the opposite direction. The combined gas flow makes another change in direction of ninety degrees and moves in the direction of movement of the orifice plate and through the orifice and into a clean gas chamber. Centrifugal force moves solid particles out of the suspension chamber. 
     A clean gas discharge pipe is coaxial with the axis of rotation and is connected to the clean gas chamber. A gas outlet pipe is in communication with the clean gas discharge pipe and a passage through the second side wall plate. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The presently preferred embodiment of the invention is disclosed in the following description and in the following drawings, wherein: 
         FIG. 1  is an end elevational view of the gas and solid particles mixture separator with parts broken away; 
         FIG. 2  is a sectional view taken along line  2 - 2  in  FIG. 1 ; 
         FIG. 3  is a sectional view taken along line  3 - 3  in  FIG. 1 ; 
         FIG. 4  is an enlarged side elevational view of one suspension chamber, in the separation rotor assembly, with the second disk and half the web removed; 
         FIG. 5  is a perspective view of a modified driven rotor with the fixed housing removed; 
         FIG. 6  is an enlarged perspective view of the separation rotor assembly with parts broken away to show the suspension chamber; and 
         FIG. 7  is an enlarged sectional view taken along line  7 - 7  in  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The gas solid mixture separator  10 , shown in  FIG. 2  includes a support frame  12 , a separator housing  14  supported by the support frame, a rotor support shaft  16 , a drive motor  18  and a separation rotor assembly  20 . Dirty gas is supplied to the separator housing  14  by a supply pipe  22 . Clean gas is discharged from the separation rotor assembly  20  through a discharge pipe  24 . The clean gas may be air or other gasses that need to be cleaned. Solids separated from the gas are collected in a lower portion  26  of the separator housing  14  and discharged into a container  28  for use or disposal. 
     Dirty gas may be forced into the supply pipe  22  by a blower  30 . Clean gas may be sucked from the discharge pipe  24  by a clean gas fan  32 . The clean gas fan  32  may be replaced by a stack if the gas to be separated is at an elevated temperature. The blower  30  may be eliminated thereby permitting the clean gas fan  32  to suck dirty gas from the supply pipe  22  and into the housing  14 . Alternatively the clean gas fan  32  can be eliminated thereby permitting the blower  30  to force clean air through the clean gas discharge pipe  24 . 
     The rotor support shaft  16  is journaled in two spaced apart bearings  34  and  36  that are attached to and supported by the support frame  12 . The motor  18  is mounted on the support frame  12 . The motor output shaft  38  is connected to the rotor support shaft  16  by a shaft coupler  40 . The rotor support shaft  16  passes into the separator housing  14  as explained below. 
     The separator housing  14  includes a first side wall plate  42  that is fixed to the support frame  12  and perpendicular to the axis of rotation  44  of the rotor support shaft  16 . A second side wall plate  46  is parallel to the first side wall plate  42  and spaced from the first side wall plate. A wall  48  is connected to the first side wall plate  42  and the second side wall plate  46  and encloses the top and both ends of the separator housing  14 . The bottom of the separator housing  14  is closed by a hopper  50  that forms the lower portion  26  of the separator housing  14 . The hopper  50  is connected to the first side wall plate  42  the wall  48 , the second side wall plate  46  and forms a substantially sealed rotor chamber  52 . A valve assembly  54  closes the bottom of the hopper  50 . The rotor support shaft  16  passes through a shaft seal  56  and a passage through the first side wall plate  42 . A clean gas outlet pipe  58  with a flange  60  is coaxial with the axis of rotation  44  and fixed to the second side wall plate  46 . The discharge pipe  24  is connected to the flange  60 . 
     The separation rotor assembly  20  includes a rotor hub  62  that is mounted on the rotor support shaft  16 . A first disk  64  is connected directly to the rotor hub  62 . The outer edge  66  of the disk  64  is a cylindrical surface that is concentric with the rotor axis  44 . A second disk  68  is parallel to and spaced from the first disk  64 . An outer edge  70  of the second disk  68  is a cylindrical surface that is concentric with the rotor axis  44 . The second disk  68  has a circular central passage  72 . A discharge pipe  74 , for clean gas is fixed to the second disk  68 . The pipe  74  rotates with the second disk  68  and extends from the second disk through a passage  76  in the second side wall plate and into the gas outlet pipe  58 . A seal  78  is provided to seal between the discharge pipe  74  and the second side wall plate  46 . 
     A web  80  is secured to the first disk  64  and the second disk  68 . The web  80  has four radially extending portions  82 ,  84 ,  86  and  88  that extend radially inward from the outer edge  66  of the first disk  64  and the outer edge  70  of the second disk  68 . Each radially extending portion  82 ,  84 ,  86  and  88  extends almost half the distance from the outer edges  66  and  70  to the rotor axis  44 . The radially extending portions  82 ,  84 ,  86  and  88  are spaced ninety degrees apart about the rotor axis  44  from each other as shown in  FIG. 1 . Second web portions  90  extend from an inner end of each radially extending portion  82 ,  84   86  and  88  in a clock wise direction as shown in  FIG. 1 . Each web portion  90  is normal to the radially extending portion  82 ,  84 ,  86  or  88  it is integral with and extends from. A web portion  92  is integral with an end  94  of each web portion  90  and extends away from the rotor axis  44  at an angle of about thirty degrees from the web portion  88 ,  84 ,  86  or  88  which it is adjacent to. A fourth web portion  96  extends from an integral end  98  of the web portion  92  to an arc portion  100  of the web  80 . Each arc portion  100  has a radius from the rotor axis  44  that is equal to the radius of the outer edges  66  and  70  of the first disk  64  and the second disk  68 . Each of the four arc portions  100  extend about forty five degrees about the rotor axis  44  and have an end that is integral with an end  102  of the adjacent forth web portion  96  and an end  104  that is connected to the radially outer end of one of the web portions  82 ,  84 ,  86  and  88 . The web  80  is preferably made from one strip of material and has only one end joint. The continuous web  80  creates a clean gas chamber  106  in the center of the rotor  20 . The continuous web  80  could be fabricated from two or more separate parts if desired. The continuous web  80  also creates four suspension chambers  110 . Each suspension chamber  110  has a radially facing open side  112 . The open side  112  is encircled by the one of the radially extending portions  82 ,  84 ,  86  or  88 , a first disk  64 , and end  102  of a forth web portion  96  and the second disk  68 . The suspension chambers  110  are defined by a forth web portion  96 , a web portion  92  a second web portion  90 , a radially extending portion  82 ,  84 ,  86  or  88 , a first disk  64  and a second disk  68 . 
     Each of the radially extending portions  82 ,  84 ,  86  and  88  of the web  80  has a central opening  114 . An orifice plate  116  is fixed to the side, of each radially extending portion  82 ,  84 ,  86  and  88  of the web  80  facing a suspension chamber  110 . The orifice plate  116  includes an orifice  118  that is smaller than the central opening  114 . The orifice  118  has beveled edges  120 . The beveled surfaces  120  provide a passage that increases in cross section area from the suspension chamber  110  side to the clean gas chamber  106  side. The beveled surfaces  120  form a sharp edge  122  encircling the orifice  118  and reduce flow restriction. The orifice plate  116  includes a flat surface  124  that faces the suspension chamber  110 . This surface  124  includes a surface portion  126  that extends from the second disk  68  to the orifice  118 , a surface portion  128  that extends from the first disk  64  to the orifice, a surface portion  130  that extends from outer edge  66  of the first disk and the outer edge  70  of the second disk to the orifice, and a surface portion  132  that extends radially outward from the second web portion  90  to the orifice. The orifice plate  116  is a separate member as described above. As a separate member, the orifice plate  116  can be replaced from time to time if there is excessive wear. However, the orifice  118  can be formed in the radially extending portions  82 ,  84 ,  86  and  88  of the web  80 . If the orifice  118  is formed directly in the web  80 , the orifice plate  116  and the central opening  114  are eliminated. 
     Passages  140  are provided in the first disk  64  for the passage of gas and solids into each suspension chamber  110 . The passages  140  are formed by making a radial cut  142  adjacent to each of the flat surface  124  around each orifice  118 . Short cuts  144  and  146  that extend away from the flat surface  124  are made at each end of the radial cut  142  to form a flap  148 . The flap  148  is bent inwardly toward the second disk  68  to open the passage  140  and to direct gas and solids passing through the passage toward the surface portion  128 . The flap  148  is bent to an angle θ of about sixty degrees from the vertical first disk  64 . 
     Passages  150  are provided in the second disk  68  for the passage of gas and solids into each suspension chamber  110 . The passages  150  are formed by making a radial cut  152  adjacent to each of the flat surfaces  124  around each orifice  118 . Short cuts  154  and  156  that extend away from the flat surface  124  are made at each end of the radial cut  152  to form a flap  158 . The flap  158  is bent inward toward the first disk  64  to open the passage  150  and to direct gas and solids passing through the passage toward the surface portion  126 . The flap  158  is bent to an angle θ of about sixty degrees from the vertical second disk  68 . 
       FIG. 5  shows flaps  160  that are adjustable to change the size of the passage  162  through the first disk  64 . Adjustable flaps  160  are generally not needed. 
     The separator housing  14  has an inside width between the first side wall plate  42  and the second side wall plate  46  that is about twice the outside width of the separation rotor assembly  20 . There are therefore substantial areas  166  and  168  between the rotor assembly  20  and both side wall plates  42  and  46 . A wall  48  of the separator housing  14  extends from plate  42  to plate  46 . The wall  48  is a substantial distance from the outer edges  66  and  70  of the first disk  64  and the second disk  68  of separation rotor assembly  20 . There is therefore a substantial gas and solids passage  170  and connected areas  166  and  168  which gas and solids can pass through. 
     The separation rotor assembly  20 , shown in the Drawing Figures, works well between seven hundred and fourteen hundred revolutions per minute. The number of suspension chambers  110  can be increased or decreased if desired. Increases in the number of suspension chambers  110  can be accommodated by reducing the length of arc portions  100  of the web  80  to provide additional space for the suspension chambers  110 . Additional suspension chambers  110  can also be added by increasing the diameter of the separation rotor  20 . Increasing the rotor diameter will change the dynamics and the forces on the solids. A larger diameter separation rotor assembly  20  may rotate slower. Capacity can also be increased by adding additional rotor assemblies. 
     During operation of the gas and solids mixture separator  10 , the separation rotor assembly  20  is driven in a counter clockwise direction, as shown in  FIG. 1 , by the motor  18  through the rotor support shaft  16 . A mixture of gas and solids enters the separator housing  14  through an inlet pipe  190 . The inlet pipe  190  receives the mixture of gas and solids from supply pipe  22  attached to a flange  192  on the inlet pipe  190 . The mixture of gas and solids enters the separator housing tangentially to an inside surface to an arcuate portion of the wall  48  secured to the first side wall plate  42  and the second side wall plate  46 . While moving through the passage  170 , solids mixed with gas tend to move radially outward toward the wall  48  and then into the lower portion  26  of the separator housing  14 . The solids collect in the lower portion  26  and are held until the valve assembly  54  is opened. 
     The mixture of gas with a reduced quantity of solids moves radially toward the axis of rotation  44  and into areas  166  and  168  adjacent to outside surfaces of the first disk  64  and the second disk  68 . The mixture of gas and solids in engagement with the first disk  64  and the second disk  68  tends to move with the disks. The solids in the gas will be moving with the outer surfaces of the first disk  64  and the second disk  68  and will be moved radially outward due to centrifugal force. Gas and some mixed solid in area  166  will move close to one of the passages  140  and will make a ninety degree change in direction of movement and pass through the passages and into a suspension chamber  110 . Some solid particles will not make the ninety degree direction change and will be collected in the lower portion  26  of the housing  14 . Gas and some mixed solids in area  168  will move close to one of the passages  150  and will make a ninety degree change in direction of movement and pass through the passages and into a suspension chamber  110 . Some solid particles will not make the ninety degree direction change and will be collected in the lower portion  26  of the housing  14 . 
     The gas and mixed solids that pass through the passage  140  are directed by the flap  148  toward the surface  128  of the orifice plate  116 . The gas and mixed solids that pass through the passage  150  are directed by the flap  158  toward the surface  126  of the orifice plate  116 . 
     The passages  140  and  150  are offset radially toward the axis of rotation  44  of the separation rotor assembly  20 . The flow of gas and mixed solids through the passages  140  and  150  is fast. However, this flow is cancelled out when the two flows meet on the suspension chamber  110  near the orifice  118  in the orifice plate  116 . The passages  140  and  150  are offset, as explained above, so that the suspension zone where the gas flows from both passages meet is substantially centered over the orifice  118 . Centrifugal force shifts the location of intersection of the gas flows from passages  140  and  150  radially outward from the location of the passages. The passages  140  and  150  are positioned radially inward toward the axis  44  relative to the orifice  118  to accommodate the shift. 
     The floor of the suspension chamber  110  including the fourth web portion  96  tends to move gas out of the suspension chamber and away from the orifice  118  in the orifice plate  116 . The suction of gas through the orifice  118  by the clean gas fan  32  balances the force of the floor of the suspension chamber  110  and suspends gas directly over the orifice. When the fixed suspension zone is created in alignment with the orifice  118  indicating no flow relative to the rotor  20 , and spaced from the orifice, centrifugal force discharges solids through the radially facing open side and cleaned gas passes through the orifice plate  116 . The centrifugal force is relative strong due to the high density of solids relative to the density of air. The gas in the suspension zone adjacent to the orifice  118  appears to be stationary. It is believed that gas molecules may be moving in random directions. 
     Use of the clean gas fan  32  is preferred for changing the direction of flow of cleaned gas toward and through the orifice  118 .