Patent ID: 12214381

DETAILED DESCRIPTION

Portable Particulate Grader

In one aspect, embodiments disclosed herein relate to a portable particulate grader.FIG.1Ais a perspective view of the portable particulate grader according to one or more embodiments. The portable particulate grader (“grader”)100includes a grader body assembly (“body assembly”)110and a grader tray assembly (“tray assembly”)150. The grader100has a first side102, a second side104, a third side106and a fourth side108. In the present disclosure, the first side102refers to the side of the grader100where residual material is retrieved. The second side104is the opposite side of the first side102and is the side of the grader100where the filtered material is retrieved. The third side106is the right side of the grader100when the grader100is viewed from the first side102. The fourth side108is the opposite side of the third side106and the left side of the grader100when the grader100is viewed from the first side102.

In the present disclosure, “a first side102” of the tray assembly150and “a first side102” of the body assembly110refer to the same side as “a first side102” of the grader100when the tray assembly150is placed on the body assembly110as intended to be placed. In other words, the first side102of the tray assembly150, body assembly110, the grader100refer to the same side when the tray assembly150is placed on the body assembly110to have an upper chute156(which is described in detail in the subsequent sections) lower than the side without the upper chute156. The same definition applies to the second side104, third side106and fourth side108of the tray assembly150, body assembly110and grader100.

“Toward a first side102” and “toward a second side104” are interpreted to be “in the direction of” the first side102/second side104, respectively. For example, “hold a grader tray assembly in a descending angle toward a first side” means that the grader tray assembly is held to have the first side of the grader tray assembly lower than second side of the grader tray assembly such that the grader tray assembly has a descending slope when viewed from the second side in the direction of the first side.

FIGS.1B-Care side and perspective views of the body assembly110included in the grader100. The body assembly110includes an upper housing112including side portions112ahaving an upper edge112band a lower edge112c. The body assembly110includes a plurality of springs122disposed on an inner portion of the upper housing112. The “inner portion of the upper housing112” refers to a space within the side portions112a, a plane defined by the upper edge112band a plane defined by the lower edge112cof the side portions112aof the upper housing112. The body assembly110also includes a lower chute114including a bottom portion114aand side portions114b, wheels118disposed on the body assembly110, and a dust control gate120provided on the second side104of the body assembly110. The wheels118may be disposed on a plurality of support116that is disposed on the body assembly110.

FIG.1Dis a perspective view of the tray assembly150included in the grader100. The tray assembly150has a first side102, a second side104, a third side106and a fourth side108, which correspond to respective sides of the body assembly110when the tray assembly150is placed on the body assembly110as intended to be placed (i.e, the tray assembly150placed such that the side with the upper chute156is lower than the side without the upper chute156). The tray assembly150includes a grader tray frame (“tray frame”)152, a detachable mesh (“mesh”)154disposed on the tray frame152, an upper chute156provided on the first side102of the tray assembly150, and a residual material control gate (“residual control gate”)158located between the mesh154and the upper chute156. The tray assembly150is configured to be detachable from the body assembly110. The upper housing112, lower chute114and tray assembly150are configured to provide an enclosed space such that the emission of the filtered material to the outside of the grader100is prevented or reduced. Such prevention of filtered material emission reduces or eliminates worker exposure to the filtered material, improving the safety of the work environment. The tray assembly150may include handles160disposed on the tray frame152.

Input Material

An input material to be graded by the grader100is generally in a form of particulates or powders. The particles of the input material may have various shapes. Examples of the input material shape include, but are not limited to, sphere, ovoid, cylinder, cuboid, prism, pyramid, random shape, or combinations thereof. A filtered material refers to a portion of the input material that passes through the mesh154upon grading/filtering of the input material, and a residual material refers to a portion of the input material that does not pass through the mesh154. Any material in a form of particulates or powders may be graded with the grader100. In one or more embodiments, the input material includes a catalyst, a desiccant, an activated carbon, a multimedia filter material, ceramic balls, industrial chemicals, absorbents in granular forms, air dryers, silica particles and combinations thereof.

Grader Body Assembly

In one or more embodiments, the grader100includes a body assembly110. The body assembly110includes an upper housing112which includes side portions112a. The side portions112amay be a vertical plate or substantially vertical plate located at the first side102, second side104, third side106and fourth side108. A “vertical plate” refers to a plate oriented at 90 degrees (°) with respect to a horizontal plane. A “substantially vertical plate” refers to a plate oriented at an angle in a range of from about 70° to about 1100 with respect to the horizontal plane, such as in a range of from a lower limit selected from any one of 70°, 75°, 80°, 85°, 86°, 87°, 88°, 89° to an upper limit selected from any one of 91°, 92°, 93°, 94°, 95°, 100°, 105° and 110°, where any lower limit may be paired with any upper limit. The side portions112amay be fastened or welded to each other by a suitable method available in the art to eliminate any gaps between the side portions112a.

The side portions112aof the upper housing112may include an upper edge112band a lower edge112c. A space defined by the plates of the side portions112a, a plane defined by the upper edge112bof the side portions112a, and a plane defined by the lower edge112cof the side portions112ais referred to an inner portion of the upper housing112.

In one or more embodiments, the third side106and fourth side108of the side portions112aof the upper housing112have an upper edge112bin the same descending angle, or substantially the same descending angle, toward the first side102, as the descending angle of the tray assembly150that is placed on the body assembly110. An upper edge112bhaving a “substantially the same descending angle” as the descending angle of the tray assembly150means that the descending angle of the upper edge112bis within 5° of the descending angle of the tray assembly150, such as within an angle in a range of about 0.1° to about 5°, or in a range having a lower limit selected from any one of 0.10, 0.2°, 0.3°, 0.4°, 0.5° and1, to an upper limit selected from any one of 3°, 4°, and 5°, where any lower limit may be paired with any upper limit. Such configuration may minimize or eliminate the gap between the upper housing112and the tray assembly150, reducing or eliminating filtered material emission from the grader100.

The upper housing112may be made of suitable materials used in the art, and may include, for example, metals, composites, wood and polymers. The side portions112aof the upper housing112may be made of a metallic material and may include a non-metallic protection layer on the surface of the side portions112athat is facing the inner portion of the upper housing to prevent the reaction of the metallic material with the input material being graded. The non-metallic protection layer may include a polymeric protection layer, such as a polyolefin layer, epoxy layer, polyurethane layer or combinations thereof. An exemplary polymeric protection layer may include an epoxy mastic with polyurethane topcoat layer.

The upper housing112may further include reinforcement beams124in various locations within the inner portion of the upper housing112, external portion of the upper housing112, or combinations thereof. The upper housing112may include the reinforcement beams124in parallel with the lower edge112cof the side portions112a, as shown inFIG.1C.

In one or more embodiments, a plurality of springs (“springs”)122is disposed on an inner portion of the upper housing112included in the body assembly110. The springs122are configured to hold a tray assembly150in a descending angle toward the first side102.

The descending angle of the tray assembly150toward the first side102may be in a range of from about 5° to about 450 from the horizontal plane, such as in a range of from a lower limit selected from any one of 5°, 10°, 15°, 20°, 25°, 28° and300to an upper limit selected from any one of 20°, 25°, 30°, 35°, 400 and 45°, where any lower limit may be paired with any mathematically compatible upper limit. In one or more embodiments, the descending angle of the tray assembly150is in a range of from about 280 to about 45°, which provides sufficient slope to overcome the friction between the particles of the input material and provides free flow of the input material. In one or more embodiments, the descending angle is 30°.

The springs122are configured to provide vibrations to the tray assembly150by oscillatory movement provided to the grader100. Because the tray assembly150is held by the springs122, the oscillatory movement provided to the grader100vibrates the tray assembly150and filters the input material placed on the mesh154in an efficient manner. The vibrations, or oscillatory movement may be provided non-electrically. For example, the oscillatory movement may be provided manually by an operator, or by using a pneumatic or mechanically-operated vibration device.

The springs122may be directly mounted onto the upper housing112, such as the side portions112aof the upper housing112, or may be mounted onto a support, such as a rod, which is located on the reinforcement beams124disposed on the upper housing112, as shown inFIG.1C. The springs122may be mounted with a method and material known in the art, such as welding, fasteners such as bolts and nuts, and adhesives, for example. The springs122may be made of suitable materials used in the art, and may include, for example, alloy steel, carbon steel, stainless steel, copper alloys, nickel alloys, titanium and cobalt-nickel. The springs122may be made of an alloy of iron and carbon including about 0.7 to about 0.8 wt % of carbon, about 0.5 to about 0.8 wt % of manganese, about 0.03 wt % or less of phosphorus, about 0.035 wt % or less of sulfur, and balance of iron. The number of springs122may be adjusted appropriately based on the requirements of each operation. In one or more embodiments, the body assembly110includes four springs122. The body assembly110may include more than four springs122depending on the size of the grader100.

In one or more embodiments, the body assembly110includes a lower chute114including a bottom portion114aand side portions114b. The lower chute114is located immediately below the upper housing112such that the lower chute114and the upper housing112provide a continuous structure together. The lower chute114includes side portions114bat the first side102, the second side104, the third side106and the fourth side108. The side portions114bof the lower chute114may adjoin with the side portions112aof the upper housing112, and the side portions114band the side portions112amay be bonded together to eliminate or minimize the gap between the lower chute114and the upper housing112.

The lower chute114may be made of suitable materials used in the art, and may include, for example, metals, composites, wood and polymers. The lower chute114may be made of a metallic material and may include a non-metallic protection layer on the surface of the lower chute114that is facing inside to prevent the reaction of the metallic material with the input material being graded. The non-metallic protection layer may include a polymeric protection layer, such as polyolefin layer, epoxy layer, polyurethane layer or combinations thereof. An exemplary polymeric protection layer may include an epoxy mastic with polyurethane topcoat layer.

In one or more embodiments, each side of the side portions114band the side portions112ais manufactured from a single, continuous sheet such that no bonding is necessary between each side of the side portions114band the side portions112a. Furthermore, the entirety of the side portions114band the side portions112amay be produced from a single, continuous sheet. The entirety of the side portions114band the side portions112amay be produced by cutting the sheet to appropriate shape and bending the sheet to provide all sides of the side portions114band side portions112a, or may be formed as a single structure with a process such as injection molding.

In one or more embodiments, the bottom portion114aof the lower chute114has a descending angle toward a second side104. Such configuration allows the filtered material to be transferred toward the second side104by gravity for easy retrieval of the filtered material. A grader100having a bottom portion114aof the lower chute114with a descending angle toward the second side104, and a tray assembly150with a descending angle toward the first side102allows simultaneous retrieval of the filtered material and residual materials without the risk of unintentionally mixing the filtered and residual materials. Such configuration also allows placement of collection vessels for the filtered and residual materials without interference. In one or more embodiments, the descending angle of the bottom portion114ais in a range of from about 5° to about 60°, such as in a range of from a lower limit selected from any one of 5°, 10°, 15°, 20° 30°, and 35°, to an upper limit selected from any one of 35°, 40°, 45°, 50°, 55°, and 60° where any lower limit may be paired with any mathematically compatible upper limit. In one or more embodiments, the descending angle of the bottom portion114ais in a range of about 35° to about 45°, which provides sufficient slope to overcome the friction between the particles of the filtered material and provides free flow of the filtered material. In one or more embodiments, the descending angle of the bottom portion114ais 40°.

In one or more embodiments, the body assembly110includes a dust control gate120. The dust control gate120may be provided on the second side104of the side portions114bof the lower chute114. The dust control gate120may include a hinge and may be configured to open outwardly. The hinge may be located at any side of the dust control gate120, such as at the top side of the dust control gate120. The dust control gate120may have a single-door configuration, or a multi-door configuration, such as a two-door configuration. The dust control gate120may also have a sliding-door configuration, and may be configured to slide in any directions including sliding upward.

The dust control gate120may be made of suitable materials used in the art, and may include, for example, metals, composites, wood and polymers. The dust control gate120may be made of a metallic material and may include a non-metallic protection layer on the surface of the dust control gate120that is facing inside to prevent the reaction of the metallic material with the input material being graded. The non-metallic protection layer may include a polymeric protection layer, such as polyolefin layer, epoxy layer, polyurethane layer or combinations thereof. An exemplary polymeric protection layer may include an epoxy mastic with polyurethane topcoat layer.

In one or more embodiments, the body assembly110includes wheels118disposed on the body assembly110, such that the grader100is made portable and may be easily transported to various locations. The wheels118may be directly disposed on the bottom portion of the lower chute114, or may be disposed on a support116, such as legs, as shown inFIGS.1A-C, which are disposed on the body assembly110.

Grader Tray Assembly

In one or more embodiments, the grader100includes a tray assembly150. The tray assembly150includes a grader tray frame (“tray frame”)152, and a detachable mesh (“mesh”)154disposed on the tray frame152to filter an input material. The springs122are configured to hold a tray assembly150in a descending angle toward a first side102. The tray assembly150is held by the springs122of the body assembly110such that the descending angle toward the first side102may be in a range of from about 5° to about 450 from the horizontal plane, such as in a range of from a lower limit selected from any one of 5°, 10°, 15°, 20°, 25°, 28° and300to an upper limit selected from any one of 20°, 25°, 30°, 35°, 400 and 45°, where any lower limit may be paired with any mathematically compatible upper limit. In one or more embodiments, the descending angle of the tray assembly150is in a range of from about 280 to about 45°. In one or more embodiments, the descending angle of the tray assembly150is 30°. A tray assembly150having a descending angle in the above range allows proper flow of the residual material toward the upper chute156.

The tray frame152is designed to allow secure placement of the tray assembly150on the springs122. The tray frame152is also designed to hold the mesh154without obstruction and in a gap-free manner to prevent any input material to pass through unfiltered. Handles160(as shown inFIG.1D) may be disposed on the tray frame152for ease of attaching and detaching the tray assembly150to the body assembly110.

The mesh154separates the input material into a filtered material and a residual material based on the particle size. The mesh154may have a mesh size (size of each opening) in a range of about 0.0625 inches (1.59 mm) to about 1 inches (25.4 mm). However, the mesh size may be smaller or larger than the aforementioned range depending on the requirement of each application. In one or more embodiments, the mesh size is in a range from a lower limit selected from any one of 0.0625, 0.075, 0.1 and 0.125 inches to an upper limit selected from any one of 0.5, 0.75 and 1 inches, where any lower limit may be paired with any upper limit. In one or more embodiments, the mesh size is 0.0625, 0.125, 0.25, 0.5, 0.75 or 1 inches. The shape of the mesh opening may include any shapes available in the art. Examples of the mesh opening shape may include, but are not limited to, circular, triangular, quadrangular, oval, hexagonal, random-shape and combinations thereof. The mesh154may be made of any suitable material known in the art, and may include metals, composites, polymers, ceramics, artificial fibers, natural fibers, and combinations thereof.

The tray assembly150further includes an upper chute156located on a first side102of the tray assembly150. The upper chute156may be disposed on the tray frame152such that the residual material may be transferred from the mesh154to the upper chute156and retrieved. The retrieval of the residual material may be conducted by placing a container or a bag at the end of the upper chute156. The upper chute156may have any shape provided that the upper chute156allows the transfer of the residual material and retrieval. In one or more embodiments, the upper chute156is a conduit, a channel, or a tube.

The tray assembly150further includes a residual control gate158located between the mesh154and the upper chute156. The residual control gate158may be located where the upper chute156abuts the tray frame152, as shown inFIG.1D. The residual control gate158is provided to allow the inspection of the residual material prior to the retrieval such that the quality of the residual material, including the particle size and size distribution of the residual material, can be properly assessed prior to the retrieval and collection. The residual control gate158may include a hinge and may be configured to open outwardly. The hinge may be located at any side of the residual control gate158, such as at the bottom side of the residual control gate158. The residual control gate158may be at its closed position while the input material is being graded, and may be transitioned to the open position by the weight of the residual control gate158. The residual control gate158may have a single-door configuration, or a multi-door configuration, such as a two-door configuration. The residual control gate158may also have a sliding-door configuration, and may be configured to slide in any directions including sliding sideways.

The dimensions of the grader100and all components may be appropriately determined based on the requirements of each application.

In one or more embodiments, the grader100does not include an electrically-operated component. A grader100free of an electrically-operated component does not produce electrical sparks, which may act as an ignition source to cause fire and/or explosion with a presence of flammable and/or explosive materials. Such a grader is suitable for use in a hazardous environment, such as in areas with the presence of hydrocarbon vapor, or airborne solvent, for example. As previously described, an oscillatory movement that provides vibrations to the tray assembly150may be provided manually, or by the use of pneumatic or mechanical vibration device.

Method for Grading Particulates

In one aspect, embodiments disclosed herein relate to a method for grading particulates. The method may be conducted using the portable particulate grader100as previously described.

In one or more embodiments, the method includes introducing an input material to the detachable mesh154of the grader100, providing vibrations non-electrically to the grader100to separate the input material into a filtered material and a residual material. The provided vibrations transfer the filtered material into the lower chute114and transfer the residual material toward the first side102of the grader tray assembly150. The method further includes opening the dust control gate120to retrieve the filtered material from the lower chute114, and opening the residual control gate158of the tray assembly150to transfer the residual material to the upper chute156of the tray assembly150.

In one or more embodiments, the introduction step of the input material to the mesh154is conducted by dispensing the input material onto the mesh154. The input material may be dispensed from, for example, a container or a bag, or from a hopper or a vessel.

In one or more embodiments, the provision of vibrations may be conducted non-electrically, such as providing oscillatory movement manually to the grader100or by using pneumatic or mechanical vibration device, to separate the input material to the filtered material and the residual material. Non-electrical provision of vibrations allows the method to be conducted safely in a hazardous environment, such as in an environment where flammable materials are present, because such method does not generate electrical sparks.

The vibrations cause the input material particles having an equal size as the mesh size or smaller than the mesh size of the mesh154transfer to the lower chute114, while the particles larger than the mesh size remain on the mesh154. Due to the vibrations and angled configurations of the tray assembly150and the bottom portion114aof the lower chute114as previously described, the filtered material may further transfer toward the second side104of the lower chute114, and the residual material may further transfer toward the first side102of the tray assembly150. The vibration may be provided for a duration in a range of from about 3 minutes to 5 minutes per batch of input material. The duration may be longer or shorter depending on the size of the batch or the grader100.

In one or more embodiments, the opening step of the dust control gate120is conducted to retrieve the filtered material. The filtered material may be placed in a container or a bag for storage or for the use in a downstream operation.

In one or more embodiments, the opening of the residual control gate158is conducted to allow the residual material to be transferred to the upper chute156. The residual material in the upper chute156is then retrieved for storage or for the use in a downstream operation. The residual material may be retrieved into a container or a bag directly attached to the upper chute156, such that the residual material flows into the container or a bag without additional assistance when the residual control gate158is opened. Such configuration allows the transfer of the residual material into the container or bag without additional contact to the material, minimizing contamination and possible health and safety hazard. The presence of the residual control gate158allows the residual material to remain on the mesh154such that the residual material may be inspected for its quality, such as particle sizes and particle size distribution, prior to opening the residual control gate158and transfer of the residual material to the upper chute156.

The retrieval of the filtered material from the lower chute114, transfer of the residual material to the upper chute156and retrieval of the residual material from the upper chute156may be conducted separately or simultaneously. The angled configuration of the tray assembly150and the bottom portion114aof the lower chute114(tray assembly150having a descending angle toward the first side102and the bottom portion114aof the lower chute114having a descending angle toward the second side104) allows the simultaneous retrieval of the filtered material and residual material.

The grader100of the present disclosure is portable, which may allow quick deployment in remote locations. The grader100is also designed to eliminate or minimize the emission of graded material, and is free of electric sparks and safe to use in an environment where flammable or explosive materials may be present. As a result, the grader may be suitable for use in various industries such as oil and gas industry, chemical industry, construction, water injection facilities and food industry. The grader may be suitable for separation of catalysts, sand and gravel, and multimedia separation. The grader requires minimal operator training, and the replacement of the mesh can be conducted quickly, which reduces down time. The grader does not require extensive maintenance and can be produced from commonly-available materials.

Although only a few example embodiments have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the example embodiments without materially departing from this invention. Accordingly, all such modifications are intended to be included within the scope of this disclosure as defined in the following claims. It is the express intention of the applicant not to invoke means-plus-function for any limitations of any of the claims herein, except for those in which the claim expressly uses the words ‘means for’ together with an associated function.