Flow-altering refiner segment

BACKGROUND

Unless otherwise indicated herein, the materials described in this section are not prior art to the claims in this application and are not admitted to be prior art by inclusion in this section.

Conical mechanical refiners for treating fibrous material typically include two elements substantially opposite to one another. One of the refiner elements, the rotor, is arranged to move with respect to a stationary refiner element, the stator. Between the rotor and the stator, a refiner gap is created into which the fibrous material to be refined is fed. The refiner elements include the refining surfaces that carry out the actual refining. The refining surfaces may be one integral structure or they may consist of a plurality of refining surface segments arranged adjacent to one another forming the refining surface.

FIG. 1 is a simplified diagram illustrating a conical mechanical refiner 100. The conical mechanical refiner 100 may include a conical rotor 110, and a conical stator 120. Rotation of the conical rotor 110 around an axis of rotation “R” may be caused by a motor 130 via a shaft 135. Rotor refining plates 115 may be disposed on the surface of the conical rotor 110 and may rotate with the conical rotor 110, and stator refining plates 125 may be disposed on the surface of the conical stator 120 and may be stationary. A refining gap 140 may be formed between the conical rotor 110, and the conical stator 120.

In the case of a conical mechanical refiner 100 shown in FIG. 1, feedstock 150 such as wood pulp or cellulose is fed into the internal portion of the conical rotor 110 and into the refining gap 140 via a large number of substantially homogeneously distributed openings 117 cut across the rotor refining plates 115 or rotor refining cone. The feedstock 150 travels across the rotor refining plates 115 and stator refining plates 125. The stator refining plates 125 or stator cone also have similar openings 127 that are substantially homogeneously distributed over their surface through which the refined feedstock 155 flows out of the conical mechanical refiner 100. On the remaining surface of both rotor and stator plate segments or cones (the surface that surrounds all the openings), an array of bars and grooves is disposed and provides the refining treatment, as the rotor turns against the stator.

It has been observed in practice that pulp treated with the type of refiner and plate designs illustrated in FIG. 1 show that a significant proportion of fibers are either untreated or very lightly treated by the refining action, indicating that there is a significant amount of stock that possibly travels directly or almost directly through rotor openings directly into stator openings, hence being barely treated in the refining gap. There is a need to improve the flow pattern of pulp stock in this type of refiner construction in order to provide a more homogenous fiber treatment and ensure a better overall pulp development.

SUMMARY

Apparatuses for improving the flow pattern of pulp stock in a conical mechanical refiner are provided.

According to various aspects there is provided refiner plate elements for a conical mechanical refiner. In some aspects, the refiner plate elements may include: a rotor plate element including at least one rotor plate segment having at least one feedstock inlet opening disposed at a first end of the at least one rotor plate segment; and a rotor plate segment refining area disposed between the at least one feedstock inlet opening and a second end of the at least one rotor plate segment. The refiner plate elements may further include: a stator plate element including at least one stator plate segment having a stator plate segment refining area; a first attaching rail configured to couple to the at least one stator plate segment at a first edge portion of the at least one stator plate segment; and a second attaching rail configured to couple to the at least one stator plate segment at a second edge portion of the at least one stator plate segment opposite the first edge portion.

The first attaching rail and the second attaching rail may be configured to attach the at least one stator plate segment to a stator support frame of the conical mechanical refiner. A separation between the first attaching rail and the second attaching rail that is not covered by the at least one stator plate segment is configured to form at least one feedstock outlet opening.

According to various aspects there is provided refiner plate elements for a conical mechanical refiner. In some aspects, the refiner plate elements may include: a stator plate element including at least one stator plate segment having a stator plate segment refining area; a first attaching rail configured to couple to the at least one stator plate segment at a first edge portion of the at least one stator plate segment; and a second attaching rail configured to couple to the at least one stator plate segment at a second edge portion of the at least one stator plate segment opposite the first edge portion of the at least one stator plate segment. The first attaching rail and the second attaching rail are configured to attach the at least one stator plate segment to a stator support frame of the conical mechanical refiner.

The refiner plate elements may further include: a rotor plate element including: at least one rotor plate segment having a rotor plate segment refining area; a third attaching rail configured to couple to the at least one rotor plate segment at a first edge portion of the at least one rotor plate segment; and a fourth attaching rail configured to couple to the at least one rotor plate segment at a second edge portion of the at least one rotor plate segment opposite the first edge portion of the at least one rotor plate segment.

The first attaching rail and the second attaching rail are configured to attach the at least one stator plate segment to a stator support frame of the conical mechanical refiner, and a separation between the first attaching rail and the second attaching rail is configured to form at least one feedstock outlet opening that is not covered by the at least one stator plate segment.

The third attaching rail and the fourth attaching rail are configured to attach the at least one rotor plate segment to a rotor support frame of the conical mechanical refiner, and a separation between the third attaching rail and the fourth attaching rail that is not covered by the at least one rotor plate segment is configured to form at least one feedstock inlet opening.

According to various aspects there is provided stator plate element for a conical mechanical refiner. In some aspects, the stator plate element may include: at least one stator plate segment having a stator plate segment refining area; a first attaching rail configured to couple to the at least one stator plate segment at a first edge portion of the at least one stator plate segment; and a second attaching rail configured to couple to the at least one stator plate segment at a second edge portion of the at least one stator plate segment opposite the first edge portion.

The first attaching rail and the second attaching rail are configured to attach the at least one stator plate segment to a conical stator support frame of the conical mechanical refiner, and a separation between the first attaching rail and the second attaching rail that is not covered by the at least one stator plate segment is configured to form at least one feedstock outlet opening.

According to various aspects there is provided rotor plate element for a conical mechanical refiner. In some aspects, the rotor plate element may include: at least one rotor plate segment having a rotor plate segment refining area; a first attaching rail configured to couple to the at least one rotor plate segment at a first edge portion of the at least one rotor plate segment; and a second attaching rail configured to couple to the at least one rotor plate segment at a second edge portion of the at least one rotor plate segment opposite the first edge portion of the at least one rotor plate segment.

The first attaching rail and the second attaching rail are configured to attach the at least one rotor plate segment to a rotor support frame of the conical mechanical refiner, and a separation between the first attaching rail and the second attaching rail that is not covered by the at least one rotor plate segment is configured to form at least one feedstock inlet opening.

BRIEF DESCRIPTION OF THE DRAWINGS

Aspects and features of the various embodiments will be more apparent by describing examples with reference to the accompanying drawings, in which:

FIG. 1 is a simplified diagram illustrating a conical mechanical refiner according to some aspects of the present disclosure;

FIG. 2 is a diagram illustrating the typical construction of rotor segments and stator segments used for a conical mechanical refiner of the type illustrated in FIG. 1;

FIG. 3A is a diagram illustrating an example of a rotor plate element according to some aspects of the present disclosure;

FIG. 3B is a perspective view of the rotor plate element of FIG. 3A according to some aspects of the present disclosure;

FIG. 4A is a diagram illustrating an example of a stator plate element according to some aspects of the present disclosure;

FIG. 4B is a perspective view of the stator plate element of FIG. 4A according to some aspects of the present disclosure;

FIG. 5 is a diagram illustrating attaching rails mounted to a stator support frame according to some aspects of the present disclosure;

FIG. 6A is a top perspective view of corresponding stator and rotor plate elements according to some aspects of the present disclosure;

FIG. 6B is a bottom perspective view of the corresponding stator and rotor plate elements illustrated in FIG. 6A according to some aspects of the present disclosure;

FIG. 7 is a diagram illustrating a simplified example of feedstock flow through refining zones of a conical refiner having the exemplary rotor plate segments and stator plate segments according to some aspects of the present disclosure;

FIG. 8 is a simplified diagram illustrating feedstock flow for examples of rotor and stator plate elements having a common outlet opening according to some aspects of the present disclosure;

FIG. 9 is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common inlet opening according to some aspects of the present disclosure;

FIG. 10 is a perspective view illustrating attaching rails mounted on a conical rotor support frame according to some aspects of the present disclosure;

FIG. 11 is a perspective view of a rotor plate element according to some aspects of the present disclosure;

FIG. 12 is a diagram illustrating a simplified example of feedstock flow through refining zones of a conical refiner 1200 having the exemplary rotor plate segments and stator plate segments according to some aspects of the present disclosure;

FIG. 13 is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common outlet opening according to some aspects of the present disclosure; and

FIG. 14 is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common inlet opening according to some aspects of the present disclosure.

DETAILED DESCRIPTION

While certain embodiments are described, these embodiments are presented by way of example only, and are not intended to limit the scope of protection. The apparatuses, methods, and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions, and changes in the form of the example methods and systems described herein may be made without departing from the scope of protection.

Conical mechanical refiners for treating fibrous material include a conical rotor that is arranged to move with respect to a stationary conical stator. A refiner gap is created between the conical rotor and the conical stator, into which the fibrous material to be refined is fed. The fibrous material may be fed into the middle of the conical rotor and into the refining gap through a large number of homogeneously distributed openings. The fibrous material may exit the conical mechanical refiner through similar openings that are homogeneously distributed over the surface of the conical stator. The conical rotor and the conical stator include the refining surfaces that perform the refining of the fibrous material.

FIG. 2 illustrates the typical construction of rotor segments 210a and 210b and stator segments 230a and 230b normally used for a conical mechanical refiner of the type illustrated in FIG. 1. The rotor segments 210a and 210b may be portions of the conical rotor 110 and the stator segments 230a and 230b may be portions of the conical stator 120. As shown in FIG. 2, inlet openings 220a, 220b in the rotor segments 210a, 210b for conducting feedstock in to the refining gap span the surface of the rotor refining areas 215a, 215b. Similarly, outlet openings 240a, 240b in the stator segments 230a, 230b for conducting refined feedstock out of the refining gap span the surface of the stator refining areas 235a, 235b. As the rotor rotates, portions of the inlet openings 220a, 220b of the rotor segments 210a, 210b can align with portions of the outlet openings 240a, 240b of the stator. Due to this geometry, the feedstock flow that enters through the inlet openings 220a, 220b in the rotor refining areas 215a, 215b can also exit through the outlet openings 240a, 240b in the stator refining areas 235a, 235b. Thus, a direct route for the feedstock in and out of the refining zone without being refined may be created when the opposing openings line up.

According to aspects of the present disclosure, the conical rotor and the conical stator may be made up of a plurality of refiner plate elements. Each of the refiner plate elements may include a plurality of segments that form the surfaces of the conical rotor and the conical stator. The rotor plate segments may include one or more inlet locations configured to conduct feedstock into the refining gap as well as one or more refining areas configured to refine the feedstock. The stator plate segments may include one or more refining areas configured to refine the feedstock, but may not include outlet openings to conduct refined feedstock out of the refining gap. Rather, the stator plate segments may be configured for mounting on attaching rails, and the attaching rails may be configured to mount the stator plate segments to provide outlet openings between the stator plate segments or at opposite ends of the stator plate segments to conduct refined feedstock out of the refining gap.

For each rotor plate segment, one or more inlet locations for feedstock may be defined outside of the refining areas such that the inlet locations are separated from the refining areas of the rotor plate segment. One or more outlet locations for the feedstock may be defined between the stator plate segments or at opposite ends of the stator plate segments based on the positioning of the stator plate segments on the attaching rails. The refined feedstock may flow through the outlet openings formed between the attaching rails adjacent to the ends of the stator plate segmentstator plate segments. In some implementations, the refined feedstock may flow through the outlet openings formed by the attaching rails at opposite ends of stator plate segmentstator plate segments.

In some implementations, the one or more inlet locations on the rotor plate segments may be covered or partially covered by the rotor plate segment refining areas. The inlet location and the outlet location may be separated from each other by a specified axial distance along a surface of the rotor plate segment and/or the surface of the stator plate segment. Refining areas of the stator plate segment and the rotor plate segment may be disposed on the surfaces of the segments in the areas between the inlet locations on the rotor plate segments and the outlet locations between the stator plate segments or at opposite ends of the stator plate segments. The feedstock thus can flow along the rotor and stator plate segments over the length of the refining zone in order to travel from the inlet location to the outlet location.

FIG. 3A is a diagram illustrating an example of a rotor plate element 300 according to some aspects of the present disclosure. A plurality of rotor plate elements 300 may be disposed around a conical rotor support frame to form the conical-shaped rotor 110 illustrated in FIG. 1. The rotor plate element 300 may include rotor plate segments 310a and 310b arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical-shaped rotor 110 illustrated in FIG. 1. A first end 312a of the rotor plate segment 310a may be disposed on the conical rotor support frame toward a smaller end of the cone. A second end 314a of the rotor plate segment 310a may be disposed adjacent a first end 312b of the rotor plate segment 310b at an intermediate point on the conical rotor support frame. A second end 314b of the rotor plate segment 310b may be disposed on the conical rotor support frame towards a larger end of the cone.

Each rotor plate segment 310a, 310b may include one or more inlet openings 320a, 320b and one or more rotor refining areas 315a, 315b. The one or more inlet openings 320a, 320b may be disposed at the first ends 312a, 312b of the rotor plate segments 310a, 310b. The one or more inlet openings 320a, 320b may enable feedstock to flow from a back side 305a, 305b of the rotor plate segments 310a, 310b to the front side 306a, 306b of the rotor plate segments 310a, 310b and then over the refining areas 315a, 315b. The rotor refining areas 315a, 315b may include patterns of bars and grooves and/or other features designed to refine the feedstock.

While one rotor refining area 315a, 315b is shown on each of the rotor plate segment 310a, 310b, the rotor plate segments may include more than one refining area and each refining area may have the same or different patterns of bars and grooves and/or other features configured to refine feedstock. In some implementations, one or more inlet openings may be provided in areas of the rotor plate segments between the more than one refining areas.

In some implementations, each rotor plate element may include two or more rotor plate segments arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical rotor. In some implementations, the conical mechanical refiner may accommodate only one rotor plate segment per rotor plate element. In such implementations, the rotor plate segment may include one inlet opening location having one or more inlet openings, or multiple inlet opening locations each including one or more inlet openings. FIG. 3B is a perspective view of the rotor plate element 300 of FIG. 3A according to some aspects of the present disclosure.

FIG. 4A is a diagram illustrating an example of a stator plate element 400 according to some aspects of the present disclosure. The stator plate element 400 may include stator plate segments 410a, 410b mounted on attaching rails 450a-450d. The attaching rails 450a, 450b may be coupled to first edge portions 411a, 411b of the stator plate segments 410a, 410b, respectively. The attaching rails 450c, 450d may be coupled to second edge portions 411c, 411d of the stator plate segments 410a, 410b, respectively. The first edge portions 411a, 411b of the stator plate segments 410a, 410b may be disposed opposite the second edge portions 411c, 411d. The stator plate element 400 may be mounted to a conical stator support frame via the attaching rails 450a-450d. FIG. 5 is a diagram illustrating attaching rails mounted to a stator support frame according to some aspects of the present disclosure. As shown in FIG. 5, the attaching rails 450a-450d may be mounted to the conical stator support frame 510. Stator plate segments (e.g., the stator plate segments 410a, 410b) may be attached to the attaching rails 450a-450d using appropriate fasteners. While only one set of attaching rails 450a-450d is illustrated in FIG. 5, a plurality of set of attaching rails may be disposed around the conical stator support frame 510. Further, while the attaching rails 450a, 450b and 450c, 450d are illustrated as two piece rails, in some implementations the attaching rail 450a, 450b may be formed as a single piece and the attaching rail 450c, 450d may be formed as a single piece.

A plurality of stator plate elements 400 may be disposed around a conical stator support frame to form the conical-shaped stator 110 illustrated in FIG. 1. Returning to FIG. 4A, the stator plate element 400 may be arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical rotor 120 illustrated in FIG. 1. A first end 412a of the stator plate segment 410a may be disposed on the attaching rails 450a, 450c mounted on the conical stator support frame toward a smaller end of the cone. A second end 412b of the stator plate segment 410a may be disposed on the attaching rails 450a, 450c facing a first end 414a of the stator plate segment 410b. The first end 414a of the stator plate segment 410b may be disposed on the attaching rails 450b, 450d at an intermediate point on the conical stator support frame. A second end 414b of the stator plate segment 410b may be disposed on the attaching rails 450b, 450d on the conical stator support frame towards a larger end of the cone.

Each stator plate segment 410a, 410b may include one or more stator refining areas 415a, 415b. The stator refining areas 415a, 415b may include patterns of bars and grooves and/or other features configured to refine the feedstock. Outlet openings 420a, 420b may be formed according to the positions in which the stator plate segments 410a, 410b are mounted on the attaching rails 450a-450d. In some implementations, the stator plate segments 410a, 410b may be mounted on the attaching rails 450a-450d such that the outlet openings are formed between the stator plate segments 410a, 410b and at the second end 414b of the stator plate segment 410b as illustrated in FIG. 4A. In some implementations, the stator plate segments 410a, 410b may be mounted on the attaching rails 450a-450d such that the outlet openings are formed at opposite ends of the stator plate segments. For example, the stator plate segment 410a may be mounted on the attaching rails 450a, 450b such that the second end 412b of the stator plate segment 410a abuts the first end 414a of the stator plate segment 410b, thereby providing outlet openings adjacent to the first end 412a of the stator plate segment 410a and adjacent to the second end 414b of the stator plate segment 410b.

In some implementations, the stator plate segment 410b may include a blocking portion 425 disposed at the first end 414a of the stator plate segment 410b. The blocking portion 425 may be configured to prevent feedstock that enters from inlet openings of the rotor from exiting through the outlet opening 420a without passing through the refining area 415b of the stator plate segment 410b.

FIG. 4B is a perspective view of the stator plate element 400 of FIG. 4A according to some aspects of the present disclosure. The stator plate segments 410a, 410b may have a thickness less than the thickness of the rotor plate segments to account for the thickness of the attaching rails 450a-450d on which the stator plate segments 410a, 410b are mounted.

FIG. 6A is a top perspective view of corresponding stator and rotor plate elements according to some aspects of the present disclosure. FIG. 6A illustrates a relative position of a rotor plate element 610 and a stator plate element 620 as they would appear when installed in a conical refiner. Referring to FIG. 6A, a rotor plate element 610 may include rotor plate segments 310a, 310b having refining areas 315a, 315b as illustrated in FIG. 3A. The rotor plate segments 310a, 310b may be mounted to a conical rotor support frame (not shown). The stator plate element 620 may include stator plate segments 410a, 410b and attaching rails 450a-450d of which only attaching rails 450a, 450c, and 450d are visible. The attaching rails 450a-450d may be mounted to a conical stator support frame (see FIG. 5). The stator plate segments 410a, 410b may include refining areas 415a, 415b as illustrated in FIG. 4A.

The rotor plate segment 310a may include an inlet opening 320a through which feedstock can be fed into a refining zone 630 formed between refining area 315a of the rotor plate segment 310a and the refining area 415a of the stator plate segment 410a. After passing through the refining zone 630, the refined feedstock may exit the conical refiner through an outlet opening 420a formed by a space between the attaching rails in an area between the longitudinally adjacent stator plate segments 410a, 410b. Similarly, the rotor plate segment 310b may include an inlet opening 320b through which feedstock can be fed into a refining zone 640 formed between refining area 315b of the rotor plate segment 310b and the refining area 415b of the stator plate segment 410b. After passing through the refining zone 640, the refined feedstock may exit the conical refiner through an outlet opening 420b formed by a space between the attaching rails in an area at a second end 414b of the stator plate segment 410b. The outlet opening 420b at the second end of the stator plate segment 410b formed by the space between the attaching rails is obscured by the rotor plate segment 310b in FIG. 6A. The feedstock inlet openings and feedstock outlet openings may be offset from each other in an axial direction with respect to the direction of rotation of the rotor in order to promote feedstock flow from the feedstock inlet openings, through the refining zones, and then out of the feedstock outlet openings. In some implementations, the stator plate segment 410b may include a blocking portion 425 to inhibit feedstock entering through inlet opening 320b in rotor plate segment 310b from passing directly out of outlet opening 420a without passing through the refining zone 640.

FIG. 6B is a bottom perspective view of the corresponding stator and rotor plate elements illustrated in FIG. 6A according to some aspects of the present disclosure. Referring to FIG. 6B, the stator plate segment 410a may be attached to attaching rails 450a, 450c. The stator plate segment 410b may be attached to attaching rails 450b, 450d. An outlet opening 420a may be formed by the separation between the attaching rails 450a, 450c in the area between the second end 412b of the stator plate segment 410a and the first end 414a of the stator plate segment 410b. A portion of the rotor plate segment 310a can be seen through the outlet opening 420a. Another outlet opening 420b may be formed by the separation between the attaching rails 450b, 450d in the area at the second end 414b of the stator plate segment 410b. A portion of the rotor plate segment 310b can be seen through the outlet opening 420b.

FIG. 7 is a diagram illustrating a simplified example of feedstock flow 705 through refining zones 730a, 730b of a conical refiner 700 having the exemplary rotor plate segments 710a, 710b and stator plate segments 720a, 720b according to some aspects of the present disclosure. As used herein, a “refining zone” 730a, 730b can be defined as the refining areas of a rotor plate segment and a stator plate segment forming a refining gap. The rotor plate segments 710a, 710b may be the rotor plate segments 310a, 310b illustrated in FIG. 3. The stator plate segments 720a, 720b may be the stator plate segments 410a, 410b illustrated in FIG. 4. The stator plate segments 720a, 720b may be coupled to attaching rails 723. The attaching rails 723 may be the attaching rails 450a-450d illustrated in FIG. 4. The combination of rotor plate segments 710a, 710b may be referred to herein as a rotor plate element 760, and the combination of stator plate segments 720a, 720b and attaching rails 723 may be referred to herein as a stator plate element 770. While FIG. 7 illustrates two rotor plate segments 710a, 710b forming the rotor plate element 760, a rotor plate element may be formed by one, two, or more than two rotor plate segments. Similarly, a stator plate element may be formed by one, two, or more than two stator plate segments.

The rotor plate segments 710a, 710b may include inlet openings 712a, 712b, and rotor plate segment refining areas 714a, 714b. In some implementation, the inlet openings 712a, 712b may not extend into the rotor plate segment refining areas 714a, 714b. In some implementations, the inlet openings 712a, 712b may extend partially or completely into the rotor plate segment refining areas 714a, 714b. The rotor plate segments 710a, 710b may be coupled to a conical rotor support frame 715. Multiple rotor plate segments may be coupled around the conical rotor support frame 715 forming a conical shape. The conical rotor support frame 715 and the rotor plate segments may rotate around an axis 716 driven by a motor (not shown).

The stator plate segments 720a, 720b may include stator plate segment refining areas 724a, 724b. The stator plate segments 720a, 720b may be coupled to the attaching rails 723, and the attaching rails 723 coupled to a conical stator support frame 725. Outlet openings 722a, 722b may be formed by the separation between the attaching rails at ends of the stator plate segments 720a, 720b as can be seen, for example, as outlet openings 420a and 420b in FIGS. 4B and 6B. In some implementations, at least one of the stator plate segments 720a, 720b may include a blocking portion 735 configured to inhibit feedstock entering through an inlet opening in a rotor plate segment from passing directly out of an outlet opening without passing through a refining zone. For example, referring to FIG. 7, the blocking portion 735 may inhibit feedstock entering through inlet opening 712b from passing directly out of outlet opening 722a without passing through the refining zone 730b.

Multiple stator plate segments may be coupled around the conical stator support frame 725 forming a conical shape disposed around the conical shape formed by the rotor plate segments. In some implementations, the conical stator support frame 725 and stator plate segments may be stationary. In some implementations, the conical stator support frame 725 and stator plate segments may rotate around the axis 716 in a direction opposite the direction of rotation of the conical rotor support frame 715 and the rotor plate segments.

In some implementations, each rotor plate segment and stator plate segment may form multiple refining zones. For each refining zone, one or more feedstock inlet openings in the rotor plate segment may be disposed at one end of the rotor plate segment refining area, and one or more feedstock outlet openings in the stator plate segment may be disposed at an opposite end of the stator plate segment refining area. In some implementations, the rotor plate segments and stator plate segments may form a single refining zone having one inlet and one outlet. For example, referring to FIG. 7, for each pair of rotor plate segments 710a, 710b (e.g., rotor plate element 760), only one inlet opening 712a may be provided, and only one outlet opening 722b may be provided for the corresponding pair of stator plate segments 720a, 720b (e.g., stator plate element 770).

In some implementations, the refining zones may not span the entire length of the rotor and stator plate segments. For example, rotor plate segments 710a, 710b may each include two refining areas (e.g., each refining area 714a, 714b may be split to form two refining areas for each segment) with inlet openings 712a, 712b plus additional inlet openings in the middle of the segments between the refining areas. The corresponding stator plate elements may then include four stator plate segments having outlet openings formed by the separation between the attaching rails with the outlet openings being disposed between adjacent stator plate segments and/or disposed adjacent to the ends of the stator plate segments.

The area between the inlet openings and the outlet openings of a refining zone is substantially covered by a pattern of bars and grooves. Typically, the refining areas of the rotor plate segments and the stator plate segments are covered by a relatively continuous design of bars and grooves that run substantially parallel in configurations that may be straight, curved, bent, or a combination of the configurations. Each refining areas of the rotor plate segments and stator plate segments can be continuous with a constant design of bars and grooves, can be separated in sections, can have different patterns of bars and grooves, such as a coarser zone and a finer zone, and/or can have different bar heights, different bar angles, etc.

As shown in FIG. 7, pressurized feedstock 705 may be conducted through the inlet openings 712a, 712b in the rotor. The feed stock pressure, the effect of angles on the rotor bars and/or centrifugal force produced by the rotating rotor plate elements 760 may cause the feedstock 705 to pass through the refining zones 730a, 730b formed between the rotor plate segment refining areas 714a, 714b and the stator plate segment refining areas 724a, 724b where the feedstock 705 is refined.

The combined feeding forces may cause the refined feedstock 706 to be conducted out of the conical refiner via the outlet openings 722a, 722b between the stator plate segments 720a, 720b and adjacent to the end of the stator plate segment 720b. Thus, the positioning of the inlet openings 712a, 712b and the outlet openings 722a, 722b at opposite ends of the refining zones 730a, 730b causes the feedstock entering the conical refiner to pass through the refining zones 730a, 730b before exiting the conical refiner, thereby ensuring that feedstock is unlikely to pass through the conical refiner without treatment.

The inlet opening locations for each refining zone may be defined on the rotor plate segments and may be at a defined location along the length of the rotor plate segments. In some implementations, the conical-shaped rotor may have the same number of inlet openings as the number of rotor plate segments (e.g., one inlet opening per rotor plate segment). In some implementations, each rotor plate segment may have multiple inlet openings. In some implementations, less than all of the rotor plate segments may have one or more inlet openings. The size and number of the inlet openings that create an inlet location may depend on the required feedstock flow that needs to pass through the defined refining zone that will be fed by that inlet location.

The outlet opening locations for each refining zone may be defined with respect to the positions of the stator plate segments. The refined feedstock may flow through the outlet openings formed between the attaching rails between the stator plate segments or adjacent to the ends of the stator plate segments. In some implementations, the refined feedstock may flow through the outlet openings formed by the attaching rails at opposite ends of stator plate segments. The outlet opening locations may be offset relative to the rotor inlet openings by at least a distance across a refining zone. Thus, as the feedstock enters through the inlet openings in the rotor plate segment, the feedstock will travel some distance along the refining gap created between the rotor refining area and the stator refining area (e.g., the refining zone) before it reaches the outlet openings.

The distance between the inlet openings and outlet openings along the refining gap may be, for example, 50 mm, 300 mm or another distance. In some implementations, multiple refining zones may be disposed along the length of a gap between the rotor and stator plate segments, and each refining zone may have its own inlet and outlet location with the rotor and stator refining areas spanning between them.

In some implementations, two or more refining zones may have a common outlet opening or inlet opening, for example, at a mid-point between two rotor plate segments or two stator plate segments, when the feedstock flow travel towards or away from each segment, respectively. FIG. 8 is a simplified diagram illustrating feedstock flow for examples of rotor and stator plate elements having a common outlet opening according to some aspects of the present disclosure. Referring to FIG. 8, the rotor plate element 860 may include rotor plate segments 810a, 810b. The rotor plate element 860 may be coupled to the conical rotor support frame 815. The stator plate element 870 may include stator plate segments 820a, 820b and attaching rails 823. The stator plate segments 820a, 820b may be coupled to attaching rails 823 and the attaching rails 823 may be coupled to the conical stator support frame 825.

Inlet openings 812a, 812b may be disposed at locations at opposite ends of the rotor plate element 810 in each of rotor plate segments 810a, 810b. Outlet openings 822a may be disposed at a location at an intermediate point between the stator plate segments 820a, 820b. As illustrated in FIG. 8A, the feedstock 805 may be conducted into the inlet opening 812a and travel through the refining zone 830a toward the mid-point between the rotor plate segments 810a, 810b and the stator plate segments 820a, 820b. Concurrently, feedstock 805 may be conducted into the inlet opening 812b at the opposite end of the rotor plate element 810 and travel in an opposite direction through the refining zone 830b toward the mid-point between the rotor plate segments 810a, 810b and the stator plate segments 820a, 820b. Refined feedstock 806 from refining zones 830a, 830b may exit the conical refiner via the common outlet opening 822 between the stator plate segments 820a, 820b. The common outlet opening 822 may be formed by the separation between the attaching rails 823 in the area between adjacent ends of the stator plate segments 820a, 820b.

FIG. 9 is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common inlet opening according to some aspects of the present disclosure. Referring to FIG. 9, the rotor plate element 960 may include rotor plate segments 910a, 910b. The rotor plate element 960 may be coupled to the conical rotor support frame 915. The stator element 970 may include stator plate segments 920a, 920b and attaching rails 923. The stator plate segments 920a, 920b may be coupled to attaching rails 923 and the attaching rails 923 may be coupled to the conical stator support frame 925. The feedstock 905 may be conducted into the common inlet opening 912 disposed at a location at an intermediate point between the rotor plate segments 910a, 910b.

As illustrated in FIG. 9, the feedstock 905 may travel in one direction through the refining zone 930a toward an end of the rotor plate segment 910a and a corresponding end of the stator plate segment 920a through the refining zone 930a. Concurrently, the feedstock 905 may travel in an opposite direction through the refining zone 930b toward an end opposite of the rotor plate segment 910b and a corresponding end of the stator plate segment 920b through the refining zone 930b. Refined feedstock 906 from refining zones 930a may exit the conical refiner via outlet opening 922a in the stator plate segment 920a and refined feedstock 906 from refining zones 930b may exit the conical refiner via outlet opening 922b in the stator plate segment 920b.

In some implementations, feedstock may flow from the smaller end of the conical shape towards the larger end of the conical shape in all refining zones. In some implementations, the feedstock may flow from the larger end of the conical shape towards the smaller end of the conical shape in all refining zones. In some implementations, feedstock may flow from the smaller end of the conical shape towards the larger end of the conical shape in some refining zones, while feedstock may flow from the larger end of the conical shape towards the smaller end of the conical shape in other refining zones.

According to some aspects of the present disclosure, the rotor plate element may alternatively or additionally include attaching rails. FIG. 10 is a perspective view illustrating attaching rails 1050a-1050d mounted on a conical rotor support frame 1010 according to some aspects of the present disclosure. The attaching rails 1050a-1050d mounted on the conical rotor support frame 1010 with appropriate fasteners.

FIG. 11 is a perspective view of a rotor plate element 1100 according to some aspects of the present disclosure. The rotor plate element 1100 may include rotor plate segments 1110a, 1110b and attaching rails 1050a-1050d. The attaching rails 1050a-1050b may be coupled to first edge portions 1111a, 1111b of the rotor plate segments 1110a, 1110b, respectively. The attaching rails 1050c-1050d may be coupled to second edge portions 1111c, 1111d of the rotor plate segments 1110a, 1110b, respectively. The first edge portions 1111a, 1111b of the rotor plate segments 1110a, 1110b may be disposed opposite the second edge portions 1111c, 1111d. The rotor plate element 1100 may be mounted to the conical rotor support frame 1010 via the attaching rails 1050a-1050d. The rotor plate segments may be attached to the attaching rails 450a-450d using appropriate fasteners. The rotor plate segments 1110a, 1110b may have a thickness less than the thickness of rotor plate segments used without attaching rails to account for the thickness of the attaching rails 1050a-1050d on which the rotor plate segments 1110a, 1110b are mounted. While only one set of attaching rails 1050a-1050d is illustrated in FIG. 11, a plurality of sets of attaching rails may be disposed around the conical rotor support frame 1010. Further, while the attaching rails 1050a, 1050c and 1050b, 1050d are illustrated as two piece rails, in some implementations the attaching rail 1050a, 1050c may be formed as a single piece and the attaching rail 1050a, 1050c may be formed as a single piece.

A plurality of rotor plate elements 1100 may be disposed around a conical rotor support frame to form the conical rotor 110 illustrated in FIG. 1. Returning to FIG. 11, the rotor plate element 1100 may be arranged in a longitudinal direction with respect to an axis of rotation “R” of the conical rotor 110 illustrated in FIG. 1. A first end 1112a of the rotor plate segment 1110a may be disposed on the attaching rails 1150a, 1150c mounted on the conical rotor support frame toward a smaller end of the cone. A second end 1112b of the rotor plate segment 1110a may be disposed on the attaching rails 1150a, 1150c facing a first end 1114a of the rotor plate segment 1110b. The first end 1114a of the rotor plate segment 1110b may be disposed on the attaching rails 1150b, 1150d at an intermediate point on the conical rotor support frame. A second end 1114b of the stator plate segment 1110b may be disposed on the attaching rails 1150b, 1150d on the conical stator support frame towards a larger end of the cone.

Each rotor plate segment 1110a, 1110b may include one or more rotor refining areas 1115a, 1115b. The rotor refining areas 1115a, 1115b may include patterns of bars and grooves and/or other features configured to refine the feedstock. Inlet openings 1120a, 1120b may be formed according to the positions in which the rotor plate segments 1110a, 1110b are mounted on the attaching rails 1050a-1050d. In some implementations, the rotor plate segments 1110a, 1110b may be mounted on the attaching rails 1050a-1050d such that the inlet openings 1120a, 1120b are formed between the rotor plate segments 1110a, 1110b and adjacent to the first end 1112a of the rotor plate segment 1110a as illustrated in FIG. 11. In some implementations, the rotor plate segments 1110a, 1110b may be mounted on the attaching rails 1050a-1050d such that the inlet openings are formed at opposite ends of the rotor plate segments. For example, the rotor plate segment 1110b may be mounted on the attaching rails 1050a-1050d such that the second end 1112b of the rotor plate segment 1110a abuts the first end 1114a of the rotor plate segment 1110b, thereby providing inlet openings adjacent to the first end 1112a of the rotor plate segment 1110a and adjacent to the second end 1114b of the rotor plate segment 1110b.

The inlet opening 1120a may be formed by a space between the attaching rails 1050a-1050c in an area adjacent to a first end 1112a of the rotor plate segment 1110a. The inlet opening 1120b may be formed by a space between the attaching rails in an area between the rotor plate segments 1110a, 1110b. In some implementations, the rotor plate segment 1110b may include a blocking portion 1125 disposed at the first end 1114a of the rotor plate segment 1110b. The blocking portion 1125 may be configured to prevent feedstock that enters from inlet opening 1120b of the rotor from exiting through the outlet opening without passing through the refining area 1115b of the rotor plate segment 1110b.

FIG. 12 is a diagram illustrating a simplified example of feedstock flow 1205 through refining zones 1230a, 1230b of a conical refiner 1200 having the exemplary rotor plate segments 1110a, 1110b and stator plate segments 720a, 720b according to some aspects of the present disclosure. As used herein, a “refining zone” 1230a, 1230b can be defined as the refining areas of a rotor plate segment and a stator plate segment forming a refining gap. The rotor plate segments 1110a, 1110b may be coupled to attaching rails 1221. The attaching rails 1221 may be the attaching rails 1050a-1050d illustrated in FIG. 11. The stator plate segments 720a, 720b may be the stator plate segments 410a, 410b illustrated in FIG. 4. The stator plate segments 720a, 720b may be coupled to attaching rails 1223. The attaching rails 1223 may be the attaching rails 450a-450d illustrated in FIG. 4.

The combination of rotor plate segments 1110a, 1110b may be referred to herein as a rotor plate element 1260, and the combination of stator plate segments 720a, 720b and attaching rails 723 may be referred to herein as a stator element 1270. While FIG. 12 illustrates two rotor plate segments 1110a, 1110b forming the rotor plate element 1260, a rotor plate element may be formed by one, two, or more than two rotor plate segments. Similarly, a stator element may be formed by one, two, or more than two stator plate segments.

The rotor plate segments 1110a, 1110b may be attached to the attaching rails 1221, and the attaching rails 1221 may be coupled to a conical rotor support frame 1215. Multiple rotor plate segments may be coupled around the conical rotor support frame 1215 forming a conical shape. The conical rotor support frame 1215 and the rotor plate segments may rotate around an axis 1216 driven by a motor (not shown). The rotor plate segments 1110a, 1110b may be mounted on the attaching rails 1221 such that the inlet openings 1220a, 1220b are formed between the rotor plate segments 1110a, 1110b and adjacent to the first end of the rotor plate segment 1110a (see FIG. 11).

The stator plate segments 720a, 720b may include stator plate segment refining areas 715a, 715b. The stator plate segments 720a, 720b may be coupled to the attaching rails 1223, and the attaching rails 1223 may be coupled to a conical stator support frame 1225. Outlet openings 1222a, 1222b may be formed by the separation between the attaching rails at ends of the stator plate segments 720a, 720b as can be seen, for example, as outlet openings 420a and 420b in FIGS. 4B and 6B. In some implementations, at least one of the stator plate segments 720a, 720b may include a blocking portion 735 configured to inhibit feedstock entering through an inlet opening in a rotor plate segment from passing directly out of an outlet opening without passing through a refining zone. For example, referring to FIG. 12, the blocking portion 735 may inhibit feedstock entering through inlet opening 1220b from passing directly out of outlet opening 1222a without passing through the refining zone 1230a.

Multiple stator plate segments may be coupled around the conical stator support frame 1225 forming a conical shape disposed around the conical shape formed by the rotor plate segments. In some implementations, the conical stator support frame 1225 and stator plate segments may be stationary. In some implementations, the conical stator support frame 1225 and stator plate segments may rotate around the axis 1216 in a direction opposite the direction of rotation of the conical rotor support frame 1215 and the rotor plate segments.

In some implementations, each rotor plate segment and stator plate segment may form multiple refining zones. For each refining zone, one or more feedstock inlet openings may be formed by the separation between the attaching rails for the rotor plate segment and may be disposed adjacent to one end of the rotor plate segment, and one or more feedstock outlet openings may be formed by the separation between the attaching rails for the stator plate segment and may be disposed at an opposite end of the stator plate segment refining area. In some implementations, the rotor plate segments and stator plate segments may form a single refining zone having one inlet opening location and one outlet opening location. For example, referring to FIG. 11, for each pair of rotor plate segments 1110a, 1110b (e.g., rotor plate element 1260), only one inlet opening location may be provided, and only one outlet opening location may be provided for the corresponding pair of stator plate segments 720a, 720b (e.g., stator element 1270).

As shown in FIG. 12, pressurized feedstock 1205 may be conducted through the inlet openings 1220a, 1220b formed by the attaching rails 1221 in the rotor plate element 1260. The feed stock pressure, the effect of angles on the rotor bars and/or centrifugal force produced by the rotating rotor plate elements 1260 may cause the feedstock 1205 to pass through the refining zones 1230a, 1230b formed between the rotor plate segment refining areas 1115a, 1115b and the stator plate segment refining areas 715a, 715b where the feedstock 705 is refined.

The combined feeding forces may cause the refined feedstock 1206 to be conducted out of the conical refiner via the outlet openings 1222a, 1222b between the stator plate segments 720a, 720b and adjacent to the end of the stator plate segment 720b. Thus, the positioning of the inlet openings 1220a, 1220b and the outlet openings 1222a, 1222b at opposite ends of the refining zones 1230a, 1230b causes the feedstock entering the conical refiner to pass through the refining zones 1230a, 1230b before exiting the conical refiner, thereby ensuring that feedstock is unlikely to pass through the conical refiner without treatment.

The inlet opening locations for each refining zone may be defined according to positions of the rotor plate segments on the attaching rails. The raw feedstock may flow through the inlet openings formed between the attaching rails between or adjacent to the ends of the rotor plate segments. In some implementations, the raw feedstock may flow through the inlet openings formed by the attaching rails at opposite ends of rotor plate segments.

The outlet opening locations for each refining zone may be defined with respect to the positions of the stator plate segments on the attaching rails. The refined feedstock may flow through the outlet openings formed between the attaching rails between or adjacent to the ends of the stator plate segments. In some implementations, the refined feedstock may flow through the outlet openings formed by the attaching rails at opposite ends of stator plate segments. The outlet opening locations may be offset relative to the rotor inlet openings by at least a distance across a refining zone. Thus, as the feedstock enters through the inlet openings of the rotor plate element, the feedstock will travel some distance along the refining gap created between the rotor refining area and the stator refining area (e.g., the refining zone) before it reaches the outlet openings in the stator element.

In some implementations, two or more refining zones may have a common outlet opening or inlet opening, for example, at a mid-point between two rotor plate segments or two stator plate segments, when the feedstock flow travel towards or away from each segment, respectively. FIG. 13 is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common outlet opening according to some aspects of the present disclosure. Referring to FIG. 13, the rotor plate element 1360 may include rotor plate segments 1110a, 1110b coupled to attaching rails 1321 and the attaching rails 1321 may be coupled to the conical rotor support frame 1315. The stator element 1370 may include stator plate segments 720a, 720b coupled to attaching rails 1323 and the attaching rails 1423 may be coupled to the conical stator support frame 1325.

Inlet openings 1320a, 1320b may be disposed at locations of the rotor plate element 1360 adjacent to opposite ends of rotor plate segments 1110a, 1110b. Outlet openings 1322a may be disposed at a location at an intermediate point between the stator plate segments 720a, 720b. As illustrated in FIG. 13, the feedstock 1305 may be conducted into the inlet opening 1320a and travel through the refining zone 1330a toward the mid-point between the rotor plate segments 1110a, 1110b and the stator plate segments 720a, 720b. Concurrently, feedstock 1305 may be conducted into the inlet opening 1320b at the opposite end of the rotor plate element 1360 and travel in an opposite direction through the refining zone 1330b toward the mid-point between the rotor plate segments 1110a, 1110b and the stator plate segments 720a, 720b. Refined feedstock 1306 from refining zones 1330a, 1330b may exit the conical refiner via the common outlet opening 1322 between the stator plate segments 720a, 720b. The common outlet opening 1322 may be formed by the separation between the attaching rails 723 in the area between adjacent ends of the stator plate segments 720a, 720b.

FIG. 14 is a simplified diagram illustrating feedstock flow for examples of rotor and stator elements having a common inlet opening according to some aspects of the present disclosure. Referring to FIG. 14, the rotor plate element 1360 may include rotor plate segments 1110a, 1110b coupled to attaching rails 1421. The stator element 1470 may include stator plate segments 770a, 770b coupled to attaching rails 1423 and the attaching rails 1421 may be coupled to the conical rotor support frame 1415. The stator plate segments 770a, 770b may be coupled to attaching rails 1423, and the attaching rails 1423 may be coupled to the conical stator support frame 1425. The feedstock 1405 may be conducted into the common inlet opening 1422 disposed at a location at an intermediate point between the rotor plate segments 1110a, 1110b.

As illustrated in FIG. 14, the feedstock 1405 may travel in one direction through the refining zone 1430a toward an end of the rotor plate segment 1110a and a corresponding end of the stator plate segment 720a. Concurrently, the feedstock 1405 may travel in an opposite direction through the refining zone 1430b toward an end opposite of the rotor plate segment 1110b and a corresponding end of the stator plate segment 720b. Refined feedstock 1406 from refining zones 1430a, 1430b may exit the conical refiner via outlet opening 1422a adjacent to the end of the stator plate segment 720a and refined feedstock 1406 from refining zones 1430b may exit the conical refiner via outlet opening 1422b adjacent to the end of the stator plate segment 720b.

The examples and embodiments described herein are for illustrative purposes only. Various modifications or changes in light thereof will be apparent to persons skilled in the art. These are to be included within the spirit and purview of this application, and the scope of the appended claims, which follow.

Number	Date	Country
2493678	Jul 2005	CA
2304101	Sep 2013	EP
3786357	Mar 2021	EP

Flow-altering refiner segment

Information

Patent Number

Date Filed

Date Issued

Inventors

Original Assignees

Examiners

Agents

CPC

Field of Search

US

CPC

International Classifications

Abstract

Description

Claims

CROSS-REFERENCE TO RELATED APPLICATIONS

US Referenced Citations (1)

Foreign Referenced Citations (3)

Non-Patent Literature Citations (2)

Related Publications (1)

Provisional Applications (1)

Entry
International Application No. PCT/US2022/018448, International Search Report and Written Opinion dated Jun. 7, 2022, 14 pages.
International Application No. PCT/US2022/018451, International Search Report and Written Opinion dated Jun. 3, 2022, 14 pages.