Patent Publication Number: US-2019179299-A1

Title: Hydrocyclone Wear Maintenance Control System

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is an International Application which claims the benefit of U.S. Provisional Patent Application No. 62/373,229, filed 10 Aug. 2016, the contents of which are hereby incorporated by reference, in its entirety, for any and all purposes, as if fully set forth herein. 
    
    
     FIELD OF THE INVENTION 
     This invention pertains generally to the use of hydrocyclone separators for liquid/solid separation in the minerals processing, power and coal industries. In particular, it pertains to a control system and method including computer hardware, wear sensors, valve timers, process operation data and proprietary control software algorithms for automatically activating and deactivating individual or groups of hydrocyclone separators for actively controlling the wear of such hydrocyclone separators to produce a desired wear pattern for matching planned maintenance schedules. 
     BACKGROUND OF THE INVENTION 
     Hydrocyclones used in the minerals processing, power and coal industries are exposed to flowing liquid/solid slurries that cause abrasive wear on interior wall surfaces of the separation chamber and inlet/outlet ports. Excessive amounts of wear can result in unacceptably high circulation loads within the separation circuit, and which can result in poor separation efficiency. For these reasons, hydrocyclones require periodic maintenance to repair and/or replace components subject to wear, including both individual hydrocyclone sections and applied interior surface wear liners. The need for such maintenance results in downtime for individual hydrocyclone units and manifold systems comprising groups of individual hydrocyclone units, which can slow or stop the desired production process. When this maintenance can be performed on a planned schedule, the downtime, inconvenience, effort and cost associated with the maintenance is reduced, time and cost budgeting and predictability are improved, overall process visibility is enhanced and the maintenance can take advantage of available rebuild programs. Also, performing such maintenance at a time before wear is considered unacceptably high tends to reduce process upset conditions and prevent costly premature or unscheduled maintenance activities. In addition, having the ability to plan the maintenance of hydrocyclone groups is advantageous for further reducing the downtime, inconvenience, effort and cost associated with the maintenance, as well as for further improving time and cost budgeting and predictability, overall process visibility, and taking advantage of available rebuild programs. 
     Many facilities in the minerals processing, power and coal industries have manifold systems comprising groups of individual hydrocyclone units, so that some individual units or groups of units can be activated or deactivated at any given time with remotely actuated valves operated via dedicated computer workstation from a control room, or manual valves, based on separation process and maintenance requirements. Accordingly, at any given time, a facility may operate with less than all of its total hydrocyclone units active, some units being in a standby or maintenance condition, while still satisfying current separation process requirements. In addition to activate or deactivate, other parameters (discussed below) can be adjusted to control the operation, performance and wear of individual or groups of hydrocyclones, again based on separation process requirements. 
     Wear in hydrocyclones is typically detected and monitored in two ways: (1) through the use of timers, such as valve timers, that directly measure the amount of time a given hydrocyclone has been in operation, and (2) through the use of wear sensors embedded within liners of the cyclone walls or in areas of anticipated wear. The wear sensors communicate signals reporting the slow abrasion of the liner material during operation to corresponding node units for each cyclone via waterproof cables connecting the sensors to each cyclone&#39;s corresponding node control box. The node units, in turn, feed operating data to manifold controllers via suitable cable, where signal data is accumulated and transmitted at regular intervals to a dedicated control room computer workstation, as shown and described in Applicant&#39;s prior U.S. Pat. No. 6,945,098, and as reproduced in  FIG. 1 . 
     While timers and wear sensors do provide hydrocyclone operators with some degree of actual wear estimation in hydrocyclones individually, they do not provide an accurate estimate of hydrocyclone wear among hydrocyclone groups, nor are they used, either individually or in groups, for controlling wear among hydrocyclone groups, especially in an optimized manner. Accordingly, the present devices and methods do not provide much capability for controlling wear as needed for maintenance planning purposes; nor do they allow for customizable plans for wear maintenance based on the needs of a particular facility. This is especially true when considering groups of hydrocyclones within a manifold, wherein each individual unit might have different operating characteristics and history, such as different slurry compositions (including based on the material characteristics of the ore), different amounts of runtime, different introduced water dilution compositions, different operating pressures and different flowrates. For these reasons, it would be advantageous to have a better mechanism for actively estimating individual unit wear within a hydrocyclone group during its operation, to provide operators with the ability to actively, and preferably in an optimized manner, activate or deactivate individual or groups of hydrocyclones within a manifold to improve and plan wear distribution within the manifold, either more evenly or on an uneven basis to coincide with specific and preferred maintenance schedules. 
     For the above reasons, there exists a need for a hydrocyclone wear maintenance control system that is able to assist in the customizable activation and deactivation of individual or groups of hydrocyclones within a manifold, through detected timer, wear and other information, for facilitating a desired wear pattern among a hydrocyclone group and matching such wear pattern to a planned maintenance schedule for facilitating required wear maintenance. The subject matter disclosed herein at least partially satisfies this need. 
     SUMMARY OF THE INVENTION 
     It is, in general, an object of the invention to provide a new and improved control system for optimally activating and deactivating individual or groups of hydrocyclone separators for controlling the wear of such hydrocyclone separators to produce a desired wear pattern and to match planned maintenance schedules, along with a method for its use. Furthermore, the invention allows for continuous monitoring of cyclone wear through direct and discrete sensors, as well as indirect estimation of wear from timers and sensors within the circuit that monitor overall process conditions. Another object of the invention is to provide a hydrocyclone wear maintenance control system and method of the above character that overcomes the limitations and disadvantages of the prior art. 
     These and other objects are achieved in accordance with the invention by providing a hydrocyclone wear maintenance control system for managing wear maintenance among a plurality of hydrocyclone separators, and disposed in communication with an associated hydrocyclone control system operable for monitoring and controlling operation of said plurality of hydrocyclone separators. In a preferred form, the control system comprises one or more usage measurement devices disposed in communication with one or more hydrocyclone separators, and operable for measuring and reporting slurry flow time data for one or more hydrocyclone separators; and one or more electronic wear sensors disposed in communication with an internal wear region of one or more hydrocyclone separators, and operable for detecting a wear condition within said internal wear region of said at least one hydrocyclone separator, creating electronic data indicative of said wear condition and reporting said electronic data indicative of said wear condition. 
     In this form, the control system further comprises a computer algorithm operable for recognizing a predetermined hydrocyclone maintenance plan based on an end-user assessment and user inputs establishing optimal or preferred plant maintenance schedules, estimated wear, analyzing the slurry flow time data and the wear condition data for one or more hydrocyclone separators, calculating an estimated wear profile for one or more hydrocyclone separators based on the analysis, automatically directing the hydrocyclone control system to activate and deactivate one or more hydrocyclone separators as necessary to follow the predetermined hydrocyclone maintenance plan, calculating a subsequent estimated wear profile for one or more hydrocyclone separators based on further analysis, and automatically or manually performing adjustments to the predetermined hydrocyclone maintenance plan based on the subsequently estimated wear profile. 
     These and other objects are also achieved in accordance with the invention by providing a method for managing wear maintenance among a plurality of hydrocyclone separators. In a preferred form, the method includes the steps of providing at least one usage measurement device disposed in communication with at least one hydrocyclone separator (not shown), and operable for measuring and reporting slurry flow time data for one or more hydrocyclone separators; and providing one or more electronic wear sensors disposed in communication with an internal wear region of one or more hydrocyclone separators, and operable for detecting a wear condition within the internal wear region of one or more hydrocyclone separators, and creating electronic data indicative of the wear condition and reporting said electronic data indicative of the wear condition. 
     The method further includes providing a predetermined hydrocyclone maintenance plan based on user input (as described above), estimated wear; providing a computer algorithm operable for receiving the slurry flow time data and the electronic data indicative of the wear condition; employing the computer algorithm for analyzing the slurry flow time data and the wear condition data for each hydrocyclone separator; employing the computer algorithm for calculating an estimated wear profile for each hydrocyclone separator based on the analysis; employing the computer algorithm for directing the hydrocyclone control system to activate and deactivate each hydrocyclone separator as necessary to follow the predetermined hydrocyclone maintenance plan; employing the computer algorithm for calculating a subsequent estimated wear profile for each hydrocyclone separator based on further said analysis; and performing adjustments to the predetermined hydrocyclone maintenance plan based on the subsequently estimated wear profile. 
     These and other objects are also achieved in accordance with the invention by providing a method for managing wear maintenance among a plurality of hydrocyclone separators, wherein the steps of providing a predetermined hydrocyclone maintenance plan based on estimated wear; analyzing the slurry flow time data and the wear condition data for one or more hydrocyclone separators; calculating an estimated wear profile for one or more hydrocyclone separators based on the analysis; directing the hydrocyclone control system to activate and deactivate one or more hydrocyclone separators as necessary to follow the predetermined hydrocyclone maintenance plan; calculating a subsequent estimated wear profile for one or more hydrocyclone separators based on further analysis; and allowing adjustments to be made to the predetermined hydrocyclone maintenance plan based on the subsequently estimated wear profile are performed by a computer algorithm operable for recognizing the predetermined hydrocyclone maintenance plan and performing each of the steps. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic diagram showing the use of wired hydrocyclone wear sensors and their control environment according to the prior art. 
         FIG. 2  is a process diagram showing the components and method steps of the present invention. 
         FIG. 3  is a contribution diagram showing the various sensor and detector inputs whose data may be evaluated by the present hydrocyclone wear maintenance control system in controlling hydrocyclone activity. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In accordance with the present invention, a hydrocyclone wear maintenance control system is provided that is capable of directing activation and deactivation, by an associated hydrocyclone control system, of individual or groups of hydrocyclone separators for controlling the wear of such hydrocyclone separators to produce a desired wear pattern and to match planned maintenance schedules, along with a method for its use. As shown in  FIG. 2 , the system  10  includes one or more usage measurement devices  12  disposed in communication with one or more hydrocyclone separators (not shown). The usage measurement devices  12  are capable of measuring and reporting slurry flow time data  14  through the hydrocyclone separator(s), either continuously or periodically during operation. Typical selections for the usage measurement devices  12  are valve timers and manifold valve position sensors, and these devices provide some estimation of internal hydrocyclone wear by directly measuring the amount of time a given hydrocyclone has been in operation. 
     The system  10  further includes one or more electronic wear sensors  16  disposed in communication with internal wear region(s) of one or more hydrocyclone separators (again, not shown). The electronic wear sensors  16  are capable of detecting a wear condition within the internal wear region(s) of the hydrocyclone separator(s), creating electronic data indicative of a wear condition  18  and reporting the electronic data indicative of a wear condition  18 . 
     The system  10  further includes a computer algorithm  20  operable for recognizing a predetermined hydrocyclone maintenance plan  22  based on estimated wear and maintenance needs of the particular facility involved. The predetermined hydrocyclone maintenance plan  22  may preferably include a schedule for downtime of selected individual or groups of hydrocyclones for replacement of individual hydrocyclone sections and/or applied interior surface wear liners of the type that are typically subjected to wear, along with any other hydrocyclone components that might require maintenance, including inflow and outflow ports, pumps, flow meters, sensors and other associated devices. Preferably, the hydrocyclone maintenance plan  22  includes a schedule for activating and deactivating individual or groups of hydrocyclones within a manifold to improve and plan wear distribution within the manifold, either more evenly or on an uneven, but planned, basis. Such a schedule provides the ability to plan the maintenance of hydrocyclone groups for reducing the downtime, inconvenience, effort and cost associated with required maintenance, as well as for improving time and cost budgeting and predictability, overall process visibility, and taking advantage of available rebuild programs. 
     Slurry flow time data  14  generated and provided by the usage measurement device(s)  12  for the hydrocyclone(s) is provided to, and analyzed by, the computer algorithm  20 . At the same time, wear condition data  18  generated and provided by the electronic wear sensor(s)  16  is also provided to, and analyzed by, the computer algorithm  20 . With this data, the computer algorithm  20  is able to calculate an estimated wear profile for each hydrocyclone separator under consideration, and automatically direct the associated hydrocyclone control system (not shown, but typically including a dedicated computer workstation), through instructions  24 , to activate and deactivate one or more hydrocyclone separators as necessary or desired to follow the predetermined hydrocyclone maintenance plan. The computer algorithm  20  is also able to calculate a subsequent estimated wear profile for one or more hydrocyclone separators based on this analysis, to allow manual or automatic adjustments to be made to the predetermined hydrocyclone maintenance plan  26  based on subsequently estimated wear profiles. 
     The predetermined hydrocyclone maintenance plan  22  may also take into account different operating characteristics and history, such as different slurry compositions, different amounts of runtime, different introduced water dilution compositions, different operating pressures and different flow rates, in directing activation or deactivation of one or more hydrocyclone separators, and also in developing adjustments to the predetermined hydrocyclone maintenance plan  26 . More specifically, as shown in  FIGS. 2 and 3 , the computer algorithm  20  can also be provided with additional sensor data  28 , representing either direct measurement or estimation of several process operation quantities associated with slurry flow through the hydrocyclone that may further assist the computer algorithm  20  in estimating wear conditions within individual or groups of hydrocyclone separators. This can be provided by one or more additional measurement devices that provide roping detection  30 , wear detection  32  (previously described), manifold valve position  34  (previously described in terms of valve timing), feed pump bearing temperature  36 , feed pump bearing vibration  38 , feed pump power draw  40 , water dilution sump level  42 , hydrocyclone feed or internal pressure  44 , hydrocyclone flow rate  46 , feed pump speed  48 , slurry particle size measurement  50 , hydrocyclone overflow density  52 , hydrocyclone overflow temperature  54 , and slurry feed density  56 . 
     Although measurement and estimation of these quantities does not necessarily predict hydrocyclone wear on its own, each operation quantity has a known or estimated influence of hydrocyclone wear, such that, when further combined together with wear condition and usage time data, can allow for more accurate predictions of actual hydrocyclone wear, its rate of wear, and its locations of wear. Accordingly, the inclusion of one or more of these additional data items may further assist the computer algorithm  20  in directing activation or deactivation of one or more hydrocyclone separators, and also in performing adjustments or allowing adjustments to be manually made to the predetermined hydrocyclone maintenance plan  26 . 
     Accordingly, this novel invention uses the combination of timer-based wear prediction with proprietary catastrophic wear detection sensors, along with the optional use of additional operational data, to provide an unparalleled, fully-automated, configurable wear management solution. This information is valuable for allowing operators to predict when excessive wear occurs in individual or groups of hydrocyclone separators, and the rate at which such wear occurs, so that maintenance activities to replace hydrocyclone separator sections and/or liners can be planned in advance. In addition, this information is valuable for allowing operators to track the amount of time each individual unit is in operation, and to use this information, in combination with the data received from the various sensors, usage timers and wear detection devices, to turn individual or groups of hydrocyclone separators in a manifold on or off to regulate individual cyclone wear, to regulate cyclone wear in groups, and to produce uniform or non-uniform, but planned, wear among a hydrocyclone separator group. This active selection of hydrocyclone separators based on perceived wear life, allows operators to optimize wear and produce predictable maintenance schedules even more efficiently. 
     Through the present invention, wear patterns in hydrocyclone separators can be customized to meet the maintenance preference of the site. As an example, an operator can activate or deactivate groups of two or more cyclones in any desired combination so that the ideal number wear out together to optimize maintenance outages. Accordingly, the computer algorithm  20  operates as a background process and can be consistently reverted to, in its original or adjusted forms, after any process perturbation such as roping. The catastrophic failure model, which represents a direct measurement of wear, relies on its specialized sensors to determine when wear points have been achieved, and can be used to immediately shut-off cyclones as needed to prevent damage. When supplemented by the timer-based predictive model, the computer algorithm  20  is better able to adjust estimated wear life. When further supplemented by additional operational process data, the computer algorithm  20  provides even more improved estimates of wear life. The combination of the two primary control models, their customizable nature, and the automation provided to hydrocyclone control circuits are all novel developments in the field. 
     The present invention also provides a method of managing wear maintenance among one or more hydrocyclone separators. In a preferred form, the method comprises the steps of providing at least one usage measurement device  12  disposed in communication with at least one hydrocyclone separator (not shown), and operable for measuring and reporting slurry flow time data  14  for one or more hydrocyclone separators; and providing one or more electronic wear sensors  16  disposed in communication with an internal wear region of one or more hydrocyclone separators, and operable for detecting a wear condition within the internal wear region of one or more hydrocyclone separators, and creating electronic data indicative of the wear condition  18  and reporting said electronic data indicative of the wear condition  18 . 
     The method further comprises providing a predetermined hydrocyclone maintenance plan  22  based on estimated wear; providing a computer algorithm  20  operable for receiving the slurry flow time data  14  and the electronic data indicative of the wear condition  18 ; employing the computer algorithm for analyzing the slurry flow time data  14  and the wear condition data  18  for each hydrocyclone separator; employing the computer algorithm  20  for calculating an estimated wear profile for each hydrocyclone separator based on the analysis; employing the computer algorithm  20  for directing the hydrocyclone control system to activate and deactivate each hydrocyclone separator as necessary to follow the predetermined hydrocyclone maintenance plan  22 ; employing the computer algorithm  20  for calculating a subsequent estimated wear profile for each hydrocyclone separator based on further said analysis; and allowing for adjustments to be made to the predetermined hydrocyclone maintenance plan  22  based on the subsequently estimated wear profile. 
     The disclosure of every patent, patent application, and publication cited herein is hereby incorporated herein by reference in its entirety. 
     While this subject matter has been disclosed with reference to specific embodiments, it is apparent that other embodiments and variations can be devised by others skilled in the art without departing from the true spirit and scope of the subject matter described herein. The appended claims include all such embodiments and equivalent variations.