Patent Grant
6860042
Numerous types of pumps have been developed for moving matter from one location to another. Typically, the physical and/or chemical nature of the material being moved by the pump plays an important role in pump efficacy. For example, the dredging industry commonly utilizes large centrifugal pumps for suction and movement of slurry material, i.e., water or other liquid in admixture with solid particulate matter, e.g., sand or gravel. Because of the abrasive characteristics of particles within such slurry material, these pumps typically suffer wear and tear and significant downtime to repair equipment components, especially moving parts which come into direct contact with the particulate matter.
Another dredging technique involves the use of air to induce an upward flow of water. This technique has typically involved compressed air or gas, requiring expensive compression equipment. In addition, the combination of gas, water and solids has contributed to process instability in the mixing chamber of the device, as discussed in U.S. Pat. No. 4,681,372.
Other hydraulic pumps employed in dredging and deep sea mining operations employ jet eduction systems, in which water is forced through piping configurations to cause an upward flow that pulls the water and solid material from the desired location. However, many jet eductor systems are flawed in that their high pressure water jets, while effective at removing high volumes of slurry material, cause severe cavitation in the throat and mixing regions of the eductor conduit, and result in lowered efficiency and extremely short equipment life, as discussed in, e.g., U.S. Pat. No. 4,165,571.
Other jet eduction systems have used atmospheric air for the purpose of creating air bubbles for separation processes, as in U.S. Pat. No. 5,811,013. These systems are not designed to increase pump efficiency, prevent pump cavitation or increase pump flow as disclosed by the present invention. However, U.S. Pat. No. 5,993,167 does disclose a jet eduction system which permits air to form a layer surrounding a high pressure flow of liquid, which is directed through a space and into a tube, thereby forming a vacuum in the space. Yet, this system does not produce vacuum sufficient for many commercial operations, and does not provide for control of the weight percentage of solids in pumped slurries.
Thus a need continues to exist for a commercially viable jet eduction system which moves large volumes of matter with very little wear and tear on the system. A need also exists for systems which enabling users to achieve greater pumping efficiency. A need also exists for excavation systems employing vacuum pumps to enable handling of heavy or agglomerated material which is not readily suctioned without agitation.
The present invention overcomes the shortcoming of prior developments by providing, among other things, a pumping system which can (a) increase the quantity of material moved, relative to previously developed pumps, without an increase in energy consumption, (b) move solid materials with minimal wear on component parts, (c) overcome the problems associated with traditional venturi effect pumps, (d) include specific component parts which are designed to wear and which can be easily changed, (e) produce a vacuum for suctioning material with little or no cavitation, and/or (f) enable the control of the solid to liquid ratio of the material being pumped to drastically increase the pumping efficiency. Moreover, the present invention provides an efficient mixing system which employs a jet pump of this invention and enables users to rapidly form a liquid and solid material mixture, preferably one in which the mixture is substantially homogeneous, to control the weight percent of solids in the resulting mixture, and to efficiently transport the mixture downstream from the jet pump to a desired location.
Thus, in one embodiment of the present invention, an improved liquid jet pump is provided. The liquid jet pump is comprised of a nozzle assembly that pulls in atmospheric air. The liquid jet created by passage of liquid through the nozzle assembly has minimal deflection as it exits because of an atmospheric air bearing surrounding the liquid jet. Consequently, the liquid jet pump has improved efficiency and capacity. The liquid jet pump is configured to define a suction chamber and further comprises a suction pipe. The suction pipe pulls in the material to be pumped as the liquid jet from the nozzle assembly passes through the suction chamber. The liquid jet pump further comprises a target tube that receives the liquid jet combined with material to be pumped which enters the suction chamber after traveling through the suction pipe. The target tube is comprised of a housing support detachable from the suction chamber and a wear plate of abrasion-resistant material.
In another embodiment, this invention provides apparatus which is comprised of (a) a nozzle assembly which is sized and configured to (i) receive a pressurized liquid and a gas, and (ii) eject the pressurized liquid as a liquid flow while feeding the gas into proximity with the periphery of the liquid flow; (b) a housing defining a suction chamber into which the nozzle assembly may eject the liquid flow, the housing also defining a suction inlet and a suction outlet; (c) an outlet pipe extending from the suction outlet away from the suction chamber housing, said outlet pipe being configured for liquid communication with the suction chamber and being disposed to receive the liquid flow; the outlet pipe defining at least a first inner diameter along a portion of its length and a second inner diameter along another portion of its length, the second inner diameter being less than the first inner diameter; and (d) a suction pipe, a first end of the suction pipe opening into the suction chamber at the suction inlet, and a second end of the suction pipe opening into the surrounding environment; wherein the nozzle assembly extends into the suction chamber towards the suction outlet and into the imaginary line of flow of the suction pipe.
In another embodiment, this invention provides a pumping system comprising: (a) a nozzle assembly which is sized and configured to (i) receive a pressurized liquid and a gas, and (ii) eject the pressurized liquid as a liquid flow while feeding the gas into proximity with the periphery of the liquid flow; (b) a housing defining a suction chamber into which the nozzle assembly may eject the liquid flow, the housing further defining a suction inlet and a suction outlet; (c) an inlet pipe for providing pressurized liquid to the nozzle assembly; (d) a gas conduit for providing the gas to the nozzle assembly; (e) an outlet pipe extending from the suction outlet away from the suction chamber, the outlet pipe being configured for liquid communication with the suction chamber and being disposed to receive the liquid flow; the outlet pipe defining at least a first inner diameter along a portion of its length and a second inner diameter along another portion of its length, the second inner diameter being less than the first inner diameter; and (f) a suction pipe, a first end of the suction pipe opening into the suction chamber at the suction inlet, and a second end of the suction pipe opening into the surrounding environment. This invention also provides a system for dredging matter from the bottom of a body of water, the system comprising: (a) a pumping system as described above in this paragraph, (b) a buoyant platform equipped to raise and lower at least a portion of the pumping system relative to the bottom of the body of water, and (c) a first pump for providing the pressurized liquid to the nozzle assembly.
In yet another embodiment of the present invention, a method of moving, from one location to another, a slurry comprised of a solid and a liquid, is provided. The method comprises:
In another embodiment, this invention provides an excavation system comprising:(1) a bucket which defines an outlet at its base,(2) a suction tube in fluid communication with a jet pump and with the bucket outlet, and (3) a guard substantially covering the bucket outlet, wherein the jet pump is comprised of a nozzle assembly which is sized and configured to (i) receive a pressurized liquid and a gas, and (ii) eject the pressurized liquid as a liquid flow while feeding the gas into proximity with the periphery of the liquid flow, so that when the jet pump creates a vacuum in the suction tube, material in the bucket which can pass though the guard is suctioned through the outlet. Preferably the jet pump further comprises a housing defining a suction chamber into which the nozzle assembly may eject the liquid flow, the housing further defining a suction inlet and a suction outlet; and an outlet pipe extending from the suction outlet away from the suction chamber, the outlet pipe being configured for fluid communication with the suction chamber and being disposed to receive the liquid flow; the outlet pipe defining at least a first inner diameter along a portion of its length and a second inner diameter along another portion of its length, the second inner diameter being less than the first inner diameter. Preferably the bucket is pivotally attached to the end of an excavator arm or alternatively comprises a hopper.
In another embodiment of the present invention, a method of excavating material is provided. The method comprises: (1) loading excavation material into a bucket which defines an outlet at its base, (2) sizing the excavation material by sieving action of a guard substantially covering the bucket outlet, (3) suctioning the sized material though the bucket outlet using a vacuum created by (a) injecting a pressurized liquid into a nozzle assembly of a jet pump in fluid communication with the bucket outlet to produce a flow of pressurized liquid, (b) providing a gas to the nozzle assembly to surround the flow of pressurized liquid with the gas, (c) directing the flow of pressurized liquid surrounded by the gas into a suction chamber of the jet pump in fluid communication with a suction pipe and an outlet pipe of the jet pump, the outlet pipe defining a venturi-like inner surface, and (d) directing the flow of pressurized liquid surrounded by the gas toward the outlet pipe to produce a vacuum at the end of the suction pipe which suction pipe defines a passageway in fluid communication with the outlet of the bucket. Preferably, the method further comprises positioning the nozzle assembly so that it extends into the suction chamber towards the suction outlet and into the imaginary line of flow of the suction pipe.
These and other embodiments, objects, advantages, and features of this invention will be apparent from the following description, accompanying drawings and appended claims.
FIG. 7 and
In each of the above figures, like numerals or letters are used to refer to like or functionally like parts among the several figures.
It will now be appreciated that, while specific embodiments are described hereinafter, several other applications of the presently described invention may be contemplated by those of skill in the art in view of this disclosure. For example, while the accompanying drawings illustrate the pumping system of this invention as used for dredging operations, the system may be used for virtually any application in which solid particulate matter, e.g., or a slurry comprised of such matter, must be moved from one location to another. The system also may be employed to remove liquids from each slurry mixtures, thereby permitting solid particulate matter to be rapidly separated from the liquid and dried, if desired. In each of the above examples, small batch operations as well as large commercial batch, semi-continuous and continuous operations are possible using pumping methods and systems of this invention.
The gas employed in the pumping systems and methods of this invention will preferably be under no more than atmospheric pressure, to reduce risk of operations and cost. The gas preferably will be an inert gas, e.g., nitrogen or argon, when the liquid or other material being pumped could be volatile in the presence of certain atmospheric gases, e.g., oxygen. When such volatility is not an issue, the gas employed will be most conveniently atmospheric air.
Turning now to the drawings,
A discharge (or “inlet”) pipe 103 feeds water or other liquid pumped by a pump 104 to jet pump 107. Pump 104 is typically a centrifugal pump, but can be any kind of pumping means, such as a positive displacement pump or even another jet pump. Pump 104 can be contained in a pump housing 105. Discharge pipe 103 also feeds water or other liquid to a supplemental jet nozzle assembly, illustrated here as a jet nozzle 106, upstream from jet pump 107 and suction pipe 102. Jet nozzle 106 is sized and configured to project a pressurized liquid flow into the surrounding environment, to thereby break up solid material to facilitate its incorporation into the material pumped by jet pump 107.
Although suction pipe 102 is shown in
The depiction of the preferred embodiment of this invention for use in the dredging industry reflected in
Water or other fluid supplied by a pumping means passes through discharge (or “inlet”) pipe 103, fluid nozzle 201, and air injection nozzle 202 into a housing 200 which defines a suction chamber 205. In suction chamber 205, the fluid in the form of a liquid flow combines with material entering chamber 205 from suction pipe 102 via a suction inlet 109, and the combined stream enters a target tube 206 disposed within an outlet pipe 207 through a suction outlet 110 of chamber 205. The combined stream then passes through target tube 206 into outlet pipe 207.
In a preferred embodiment jet nozzle 106 extends from discharge (or “inlet”) pipe 103, allowing a portion of the forced fluid supplied by pumping means to pass through jet nozzle 106. In a similar manner to the configuration for jet pump 107, jet nozzle 106 contains a venturi 208 at its end opposite the end connected to discharge pipe 103. Venturi 208 is equipped with air hose 210 to allow entry of atmospheric air at aperture 209 when jet pump 107 is submerged.
Jet nozzle 106 extends approximately the same length as suction pipe 102 and, as depicted in
Although jet nozzle 106 is shown in
Referring to
Fluid nozzle 201 is attached to air injection nozzle 202 by means of nozzle housing 203. Nozzle housing 203 is a flanged pipe with air intake 211 drilled into the pipe circumference. Although nozzle housing 203 is depicted with one air intake 211, those skilled in the art would know that multiple air intakes can be provided.
Air injection nozzle 202 is provided with one or more air holes 304. In a preferred embodiment depicted in
When air injection nozzle 202 and fluid nozzle 201 are assembled, one of air holes 304 can align with air intake 211. Alignment however is not necessary, as air injection nozzle 202 further defines an annular trough 602 in its outer surface into which air holes 304 open, thereby providing a path for air flow around the circumference of nozzle 202 and into each of holes 304.
Air hole 304 and air intake 211 allow the entry of atmospheric air to fill air gap 302. The forced delivery of liquid through constricted throat 301 creates a vacuum in air gap 302 that pulls in atmospheric air. Varying the amount of air entering air hole 304 creates an increased suction effect in air gap 302.
In one embodiment, vacuum in air gap 302 measured 29 inches Hg when air intake 211 was 10% open, compared to 10 inches Hg when air intake 211 was 100% open. Restriction of air though air intake 211 can be accomplished by any mechanical valve means, e.g., such as that depicted as valve 212.
Without being bound to theory, it is believed that entry of a gas (e.g., air) into air gap 302 creates a gas bearing effect. The air surrounds the flow of fluid leaving constricted throat 301 and the combined fluid jet with surrounding air passes through air injection nozzle 202.
Referring to
As illustrated approximately in
Air bearing 501 around the liquid jet minimizes deflection, and thus, cavitation in suction chamber 205. Less cavitation reduces wear and the need to replace component parts, and increases flow through suction chamber 205 into target tube 206 with the liquid jet stream.
Referring to
Suction pipe 102 entering at an angle avoids the problem common to many eductor nozzles suffering excessive wear and corrosion by being placed in the flow of solid material. Although this configuration is a preferred embodiment to maximize the entry of slurry material with minimal abrasive effect, those skilled in the art would know that alternate angles greater than 0° and less than 180° can be utilized.
In the embodiment depicted, suction chamber 205 measures 24¾ inches at A. The distance between nozzle opening 303 and one end of target tube 206 is 13¾ inches at B.
As the liquid jet passes through target tube 206, a suction effect is created in suction chamber 205. The suction effect pulls in any material located at open end of suction pipe 102. The section effect increases the overall quantity of material driven by pump 104. The following Table 1 illustrates the ratio of total material exiting target tube 206 to pumped liquid entering fluid nozzle 201:
The specific gravity of the material pumped, i.e. water, versus sand or gravel, will affect the optimum inches vacuum in air gap 302 and the discharge pressure of pump 104. During testing of jet pump 107, vacuum in air gap 302 measured 29 inches Hg when suctioning water, 24 inches Hg when suctioning slurry material containing sand, and 18 inches Hg when suctioning material containing gravel.
The suction effect created by target tube 206 allows the movement of larger quantities of material without any concurrent increase in horsepower to operate pump 104 providing the liquid flow. For example, testing has demonstrated movement of material containing 60-65% by weight of sand, as compared to the 18-20% of solids using conventional methods such as centrifugal pumps at the same flow rate or discharge pressure.
Target tube 206 constitutes a segment of the outlet pipe in the form of a detachable wear plate in the preferred embodiment illustrated. The outlet pipe segment defines an inner surface, at least a portion of which in turn defines the second inner diameter of the outlet pipe. The target tube can be detached from outlet pipe 207 and suction chamber 205. The majority of wear from abrasive material occurs in target tube 206, not suction chamber 205, because of reduced cavitation from the air bearing effect on the liquid jet and the design of suction chamber 205.
In
In an alternative embodiment, target tube 206 may be fixably attached at one end to a connecting means such as a split locking flange. The split locking flange could then hold target tube 206 in place at one end by connecting between outlet pipe 207 or suction chamber 205 and target tube housing 306. The opposite end of target tube 206 could then rest on target tube housing 306 using notches or other means to prevent axial or radial movement.
A centrifugal dredge pump 108, as shown in
Target tube 206 can vary in both length and diameter. Diameter will most often be determined by the particle size of the material conveyed. Length and diameter of target tube 206 will effect the distance and head pressure that jet pump 107 can generate.
In a preferred embodiment shown in
As shown in
In a preferred embodiment, the nozzle elements of
Air injection nozzle 202 is 12⅞ inches in length. At one end, air injection nozzle 202 is 10 inches in diameter on outside surface 703, and 8.01 inches in diameter on inside surface 704. Outside surface 703 remains 10 inches in diameter axially for a length of 5 inches, then drops radially to a diameter of 7 inches, and angles inward radially to a diameter of 4 inches for the remaining length. In a preferred embodiment, air injection nozzle 202 has an angle of 102° between the smallest diameter at angled end in the vertical plane and angled edge.
Inside surface 704 of air injection nozzle 202 remains 8.01 inches axially for a length of 4{fraction (3/16)} inches, then drops radially to a diameter of 2½ inches for the remainder of the length.
Air hole 304 is ½ inch in diameter equally spaced along the circumference of outside surface 703 located 2 inches from the end of air injection nozzle 202 that has a 10 inch diameter.
In a preferred embodiment, nozzle housing 203 measures 13½ inches at flanged end 705 connected to fluid nozzle 201. At flanged end 706 connected to suction chamber 205, the outer diameter measures 19 inches. Flanged end 705 has an inner diameter measuring 7.0625 inches, sufficient to allow passage of air injection nozzle 202 at its angled end. Flanged end 705 has an inner diameter for the remaining length of 10.01 inches to accommodate air injection nozzle 202 at its largest point. Nozzle housing 203 has a 1 inch NPT connection in air intake 211.
It will also be appreciated from
To further illustrate the present invention, a pump incorporating the features of that illustrated in
The settings during sampling and the results achieved are set forth in Table 2.
It is believed that, heretofore, production of 18-20 wt % solids was the best that could be expected from conventional deck mounted dredging pumps. However, as can be seen from the data presented in Table 2, percentages at or above 40 wt % solids, and more preferably at or above 50 wt % solids, in the pumped material are routinely achieved. Such results are most readily achieved in particularly preferred embodiments of this invention by controlling gas flow so as to maintain gas entering the nozzle assembly under a vacuum in the range of about 18 inches Hg to about 26 inches Hg, and operating the dredge pump at an intake pressure/vacuum in the range of about 5 inches Hg to about 5 psia. Pumping systems of this invention operated under these conditions enable particularly drastic and surprising improvements in pumping efficiency.
While it is understood that at least one preferred jet pump described herein is characterized by the entry of atmospheric air and a detachable outlet pipe segment forming a wear plate, it is apparent that the foregoing description of specific embodiments can be readily adapted for various applications without departing from the general concept or spirit of this invention. Thus, for example, the inner surface of the outlet pipe (which provides the venturi effect feature of the outlet pipe) alternatively can be defined by the pipe itself, rather than a detachable wear plate, and/or the gas entering the nozzle assembly can be an inert gas, e.g., nitrogen. In addition, an efficient mixing system and method are provided by this invention, whereby the jet pump described herein is employed to mix a liquid with solid or slurry material to form a mixture, wherein the weight percent of solids in the mixture is controlled by controlling the air intake vacuum and the dredge pump intake pressure/vacuum as described above. Such mixing systems facilitate mixing volatile materials by simply using an inert gas for the gas intake at the nozzle assembly. Mixtures made in accordance with this system are particularly uniform and can be substantially homogenous, presumably on account of the forces applied to the liquid and solid material in, for example, the suction chamber of jet pumps of this invention.
These and other adaptions and modifications are intended to be comprehended within the range of equivalents of the presently disclosed embodiments. Terminology used herein is for the purpose of description and not limitation.
The present invention can be used in any application requiring significant suction effect of solid material in a liquid or gaseous environment. Those skilled in the art would know that the invention can also be used for suction in gaseous or liquid environments without solids present, and maintain a significant suction effect. Thus, as noted earlier, the invention can also be used in closed loop de-watering applications to remove excess water or moisture from material.
The dimensions of the various component parts of devices of this invention may vary depending upon the circumstances in which the device will be employed, so long as the dimensions permit the components to function as described herein. Except where specifically noted otherwise herein, the component parts may be fabricated from a wide variety of materials, the selection of which will depend again upon the circumstances in which the device will be employed. Preferably, metals, metal alloys or resilient plastics, for example, will be employed to insure that points of mechanical contact or abrasive wear in the systems and pumps will be resilient enough to withstand the forces placed upon them during pump operation.
An excavation system 800 is provided in a preferred embodiment of this invention as shown in
In the embodiment of the invention as shown in
Each and every patent, patent application and printed publication referred to above is incorporated herein by reference in toto to the fullest extent permitted as a matter of law.
This invention is susceptible to considerable variation in its practice. Therefore, the foregoing description is not intended to limit, and should not be construed as limiting, the invention to the particular exemplifications presented hereinabove. Rather, what is intended to be covered is as set forth in the ensuing claims and the equivalents thereof permitted as a matter of law. As used in this specification, means-plus-function clauses are intended to cover the structures described herein as performing the cited function and not only structural equivalents but also equivalent structures.
This application may be considered to have subject matter related to that of commonly owned U.S. patent application Ser. No. 09/711,499 filed on Nov. 13, 2000 now U.S. Pat. No. 6,450,775 B1, issued on Sep. 12, 2002, which is a continuation-in-part of U.S. patent application Ser. No. 09/482,995 now U.S. Pat. No. 6,322,327 B1, issued on Nov. 27, 2001, to commonly owned and co-pending U.S. patent application Ser. No. 10/199,777 filed on Jul. 19, 2002 and to commonly owned and co-pending U.S. patent application Ser. No. 10/199,763 filed on Jul. 19, 2002.
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