Material Flow Amplifier

Abstract

To provide a novel material flow amplifier.SOLUTION: Material flow amplifiers disclosed herein overcome drawbacks associated with known adverse flow conditions (e.g., surface erosion and head losses) that arise from a flow of certain types of materials (e.g., fluid, slurry, particulates, flowable aggregate, and the like) through a material flow conduit. Such material flow amplifiers provide a flow of a flowable material within a flow passage of a material flow conduit (e.g., a portion of a pipeline, tubing or the like) to have a cyclonic flow (i.e., vortex or swirling) profile. Advantageously, the cyclonic flow profile centralizes a flow toward a central portion of the flow passage, thereby reducing the magnitude of a laminar flow. Such cyclonic flow profile provides a variety of other advantages compared to a parabolic flow profile (e.g., an increased flow rate, reduced inner pipeline wear, more uniform inner pipe wear, reduction in energy consumption, reduced or eliminated slugging, and the like).SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The disclosures made herein relate generally to structural devices used in the transport of flowable materials, and more specifically to devices used to enhance the flow attributes of materials in material flow conduits, such as pipelines or tubular flow members. [Background technology]

[0002] The need to flow materials (i.e., flowable materials) through material flow conduits is known. Examples of such materials include, but are not limited to, fluids, slurries, particles, flowable aggregates, etc. Examples of such material flow conduits include, but are not limited to, pipes, pipelines, conduits, tubular flow members, etc.

[0003] As shown in FIG. 1, a conventional low-flow material 5 within a flow passage 10 of a material flow conduit 15 has a flow profile characterized by laminar effects (i.e., laminar flow 20). The parabolic flow profile is a result of a laminar boundary layer along the surfaces of the material flow conduit 15 that define the flow passage 10. The flowable material at the surfaces of the flow passage 10 exhibits significant friction and zero flow velocity, thus slowing down the flowable material even at significant distances from the surfaces of the flow passage 10. In conjunction with this reduction in velocity, laminar effects (e.g., friction at the surfaces of the material flow conduit) are known to increase head loss and heating of the flowable material.

[0004] There are various known flow considerations that occur when abrasive materials flow through material flow conduits, such as pipelines. One such consideration is erosion (i.e., wear) of the material flow conduit. The transport and pumping of flowable materials with abrasive content, such as coal and sand slurries, wet sand, gravel, etc., can cause particularly high costs associated with component wear due to interactions between the flowable materials and the surfaces that define the passageways through which such materials flow. Additionally, erosion of piping systems, particularly uneven erosion of elbow fittings, is well known to lead to fitting failure or premature replacement of fittings, both of which are costly in materials, manpower, and downtime.

[0005] When a fluid or flowable material passes through an elbow fitting, the change in direction creates turbulent conditions, flow separation, and vortex shedding along the pipe wall inside the bend. This change in direction can also create non-flowing vortices, creating unfavorable flow conditions along the pipe wall of the elbow fitting. Generally, this condition causes the pipe wall of the elbow fitting along the outside of the bend to erode much faster than the pipe wall along the inside of the bend, as the flowable material directly impacts the wall along the outside of the bend as it enters the fitting and changes direction. In addition, centrifugal forces generally tend to throw heavier solids and heavier particles against the outside wall as the flowable material changes direction, causing it to continually scrape against the outside wall.

[0006] Similar non-uniform erosion effects often occur in long straight pipe runs. For example, the concentration of particles in the flowable material increases in the lower regions of the fluid in a long straight pipe run, making the bottom of the fluid flow more abrasive than the top. Additionally, in larger diameter piping systems, the weight of the flowable material is supported by the lower pipe wall sections, causing faster erosion.

[0007] Another known flow consideration that arises is head loss due to turbulence and flow separation at elbow fittings. To mitigate head loss due to such head loss, higher pump pressures may be utilized. However, higher pump pressures are generally implemented at the expense of higher energy consumption and associated costs. Additionally, implementing higher pump pressures often creates vibration and heating problems in the piping system.

[0008] Larger diameter elbow fittings and piping sections can reduce these adverse flow considerations. However, larger diameter fittings require more space than standard (i.e., smaller) radius fittings. Additionally, larger radius fittings are subject to accelerated erosion rates along the pipe walls along the outside of the bend as centrifugal forces throw heavier, more abrasive flowable material against the outside wall and are continually washed away by the ongoing flow of such flowable material.

[0009] Therefore, an apparatus that overcomes the drawbacks associated with known flow considerations resulting from the flow of abrasive material flowing through a material flow conduit would be beneficial, desirable and useful. Summary of the Invention

[0010] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention relates to an apparatus that overcomes the drawbacks (e.g., surface erosion, head loss, fluid cavitation, heating, etc.) associated with known adverse flow conditions in pipe structures via gravity flow systems or mechanical flow pumping apparatus. The drawbacks result from certain types of materials (e.g., fluids, slurries, particles, flowable aggregates, etc.) flowing through a material flow conduit. A material flow amplifier according to one or more embodiments of the present invention provides a flow of flowable material within a flow path of a material flow conduit (e.g., a portion of a pipeline, tube, etc.) to have a cyclonic (i.e., vortex or swirl) profile. Advantageously, such a vortex profile reduces the magnitude of laminar flow because it concentrates the flow toward a central portion of the flow path. Such a cyclonic flow profile provides various other advantages compared to the parabolic flow profile resulting from laminar flow (e.g., increased flow rate, reduced wear on the inside of the pipeline, more uniform wear on the inside of the pipe, reduced energy consumption, reduced or eliminated slugging, etc.).

[0011] In one or more embodiments of the invention, a material flow amplifier includes an amplifier body, at least one helical vane, and a centralizer tube. The amplifier body has a flow inlet structure, a flow expander, a vortex chamber, a flow mixer, and a flow outlet structure, all in fluid communication with one another to form a fluid flow path. The flow expander extends from the flow inlet structure, the vortex chamber extends from the flow expander, the flow mixer extends from the vortex chamber, and the flow outlet structure extends from the flow mixer. The at least one helical vane is within the vortex chamber and extends at least intermittently (or in some embodiments continuously) from a first helical vane end proximate the flow expander to a second helical vane end proximate the flow mixer. At least a portion of an outer edge portion of the at least one helical vane is attached to an inner surface of the amplifier body within the vortex chamber. The at least one helical vane includes a material impingement surface oriented at a predetermined angle of incidence with respect to the flowable material entering the vortex chamber from the flow expander. A centralizer tube is within the amplifier body and extends at least a portion of the length of the vortex chamber At least a portion of an inner edge portion of the at least one helical vane is attached to an outer surface of the centralizer tube.

[0012] In one or more embodiments of the invention, an elbow flow amplifier includes an amplifier body, a plurality of helical vanes, and a curved centralizer tube. The amplifier body has a flow inlet structure, a flow expander, a curved vortex chamber, a flow mixer, and a flow outlet structure, all in fluid communication with one another to form a fluid flow path. The flow expander extends from the flow inlet structure, the vortex chamber extends from the flow expander, the flow mixer extends from the vortex chamber, and the flow outlet structure extends from the flow mixer. The plurality of helical vanes are within the vortex chamber and extend from a helical vane first end proximate the flow expander to a helical vane second end proximate the flow mixer. An outer edge portion of each helical vane is attached to an inner surface of the amplifier body within the vortex chamber. Each helical vane includes a material impingement surface oriented at a predetermined angle of incidence with respect to the flowable material entering the vortex chamber from the flow expander. The curved centralizer tube is within the amplifier body and extends at least a portion of the length of the curved vortex chamber. An inner edge portion of each spiral vane is attached to an outer surface of a curved centralizer tube having a centerline axis extending along the centerline axis of the curved vortex chamber.

[0013] In one or more embodiments of the invention, the material flow amplifier includes a flow inlet structure, a flow expander, a vortex inducer, a flow mixer, and a flow outlet structure. The flow inlet structure defines a nominal cross-sectional flow area. The flow expander includes an upstream portion of the flow expander, the upstream portion being attached to and concentric with a downstream portion of the flow inlet structure. The flow expander includes a downstream portion of the flow expander, the downstream portion having a first expanded cross-sectional flow area relative to the nominal cross-sectional flow area. The vortex inducer includes an outer tubular body, a centralizer tube, and at least one at least one helical flow passage. The upstream portion of the outer tubular body is attached to and concentric with the downstream portion of the flow expander. The centralizer tube extends at least a portion of the length of the outer tubular body and has a cross-sectional flow area at least approximately the same along its entire length as the nominal cross-sectional flow area. The at least one helical flow passage extends between the outer tubular body and the centralizer tube and extends at least partially along the length of the centralizer tube. The at least one helical flow passage includes a material impingement surface oriented at a predetermined angle of incidence with respect to the flowable material entering the outer tubular body from the flow expander. The centerline axis of the centralizer tube extends along the centerline axis of the outer tubular body. The flow mixer includes an upstream portion of the flow mixer, the upstream portion having a second expanded cross-sectional flow area and attached to and concentric with a downstream portion of the outer tubular body. The second expanded cross-sectional flow area is smaller than the first expanded cross-sectional flow area. At least the upstream portion of the flow mixer is cylindrical. The flow outlet structure includes an upstream portion of the flow outlet structure, the upstream portion attached to and concentric with a downstream portion of the flow mixer. The flow outlet structure has a downstream portion having a cross-sectional flow area at least about the nominal cross-sectional flow area.

[0014] In one or more embodiments of the present invention, the material flow amplifier may include a plurality of helical vanes. In one or more embodiments, a first helical vane end of the one or more helical vanes may be disposed adjacent to or within the flow expander and a second helical vane end of the one or more helical vanes may be disposed within the vortex chamber.

[0015] In one or more embodiments, the centralizer pipe may have a cross-sectional flow area along its entire length that is at least about the same as the nominal cross-sectional flow area. In one or more embodiments, the length of the centralizer tube is less than the length of the vortex chamber.

[0016] In one or more embodiments, the flow inlet structure, the flow expander, the vortex chamber, the flow mixer, and the flow outlet structure may all be concentric with one another. In one or more embodiments, the centerline axis of the vortex chamber may be curved.

[0017] In one or more embodiments, the flow mixer may include a cylindrical portion extending from the vortex chamber and a converging portion extending from the cylindrical portion. In one or more embodiments, the converging section of the flow mixer may have a curved sidewall profile or a linearly tapered sidewall profile.

[0018] These and other objects, embodiments, advantages and / or distinctions of the present invention will become readily apparent upon further review of the following specification, the associated drawings, and the appended claims. [Brief description of the drawings]

[0019] [Figure 1] FIG. 1 is a schematic diagram illustrating laminar flow effects within a material flow conduit. [Diagram 2] FIG. 2 is a schematic diagram illustrating the conversion of a laminar flow effect to a rotational flow effect by a material flow amplifier constructed in accordance with one or more embodiments of the present invention. [Diagram 3] FIG. 3 is a perspective view of a linear material flow amplifier constructed in accordance with one or more embodiments of the present invention. [Figure 4] FIG. 4 is a cross-sectional view taken along line 4-4 of FIG. [Diagram 5] FIG. 5 is a cross-sectional view taken along line 4-4 of FIG. [Figure 6]FIG. 6 is a first ornamental perspective view of the amplifier body (i.e., cyclone flow includer) of the material flow amplifier shown in FIG. 3, with the dashed lines shown being included for purposes of illustrating subject matter that may be unclaimed part of the ornamental design. [Figure 7] FIG. 7 is a second ornamental perspective view of the amplifier body of the material flow amplifier shown in FIG. 3, the dashed lines shown being included for purposes of illustrating subject matter which may be unclaimed part of the ornamental design. [Figure 8] FIG. 8 is a decorative top view of the amplifier body of the material flow amplifier shown in FIG. 3, with the decorative bottom view, decorative left side view, and decorative right side view being identical to the decorative top view, and the dashed lines shown being included for the purpose of illustrating subject matter that may be an unclaimed part of the decorative design. [Figure 9] FIG. 9 is a decorative left end view of the amplifier body of the material flow amplifier shown in FIG. 3 , the dashed lines shown being included for purposes of illustrating subject matter which may be unclaimed part of the decorative design. [Figure 10] FIG. 10 is a decorative rear end view of the amplifier body of the material flow amplifier shown in FIG. 3, the dashed lines shown being included for purposes of illustrating subject matter which may be a non-claimed part of the decorative design. [Figure 11] FIG. 11 is a cross-sectional view of an elbow material flow amplifier constructed in accordance with one or more embodiments of the present invention. [Figure 12] 12 is a bottom perspective view showing a guide body lock of the physical reference device of the implanted article of FIG. 1. FIG. [Figure 13] FIG. 13 is a cross-sectional view taken along line 13-13 of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Embodiments of the present invention relate to material flow amplifiers that provide increased volumetric flow rates of flowable materials (e.g., fluids, slurries, particles, flowable aggregates, etc.) and reduced wear to material flow conduits through which such flowable materials pass. These material flow amplifiers induce a cyclonic (i.e., vortex or swirl) flow profile that advantageously overcomes the drawbacks associated with known adverse flow conditions (e.g., erosion of inner pipe walls, head loss, material heating) that can result from the flow of various flowable materials through a material flow conduit in a conventional manner (e.g., under laminar flow effects).

[0021] As discussed above with reference to FIG. 1, a conventional flowable material 5 in the flow passage 10 of a material flow conduit 15 has a flow profile characterized by laminar flow effects (i.e., laminar flow 20). Advantageously, however, a material flow amplifier 1 according to one or more embodiments of the present invention is configured to convert the conventional flow from a flow profile characterized by laminar flow effects to a flow profile characterized by cyclonic flow effects (i.e., vortex flow 25). The vortex flow effect is a result of the rotational motion, also known as vortex motion, of the flowable material 5 about the longitudinal axis L1 of the material flow conduit 15, as generated by the material flow amplifier 1. As one skilled in the art will appreciate (e.g., as shown in FIGS. 1 and 2), cyclonic flow provides a greater average flow velocity and volumetric flow than laminar flow for a given material flow conduit. Additionally, cyclonic flow reduces adverse interactions between the surfaces of the material flow conduit and the flowable material. These advantageous aspects of cyclonic flow result from a cyclonic flow profile that accelerates and concentrates the flow of flowable material toward a central portion of the flow path 10, thus mitigating associated adverse flow conditions and increasing flow magnitude. The vortices created within the amplifier create a siphon effect at the inlet, creating a "push-pull" effect of the fluid. Such cyclonic flow profiles created by material flow amplifier 1 provide various other advantages compared to laminar flow profiles (e.g., increased flow rates, reduced wear on the inside of the pipeline, more uniform wear on the inside of the pipe, reduced energy consumption, reduced or eliminated slugging, etc.).

[0022] The generation of a cyclonic flow profile is generated by a siphoning (e.g., push-pull) effect occurring at the upstream portion of the material flow amplifier 1. The upstream side of the flow amplifier (i.e., upstream of the flow expander) defines its suction side, and the downstream side of the output side of the flow amplifier (i.e., downstream of the flow mixer) defines its suction side. The rotational flow creates a siphoning action at the suction side of the material flow amplifier, which can contribute up to about 20% or more of the total flow increase. The siphoning effect creates momentum in the material flow that aids in the movement of the flowable material. One such beneficial aspect of the transfer of flowable materials is that the amount of fluid transfer is greatly increased because pumping energy is not used to overcome sidewall resistance associated with laminar flow. In contrast, this pumping energy is advantageously used to generate greater flow velocities and volumetric flows.

[0023] As will become apparent from the disclosure made herein, the material flow amplifier according to embodiments of the present invention advantageously drives the flow of the flowable material toward a focal point along the centerline axis of the material flow conduit. Without this focusing function, the flow of the material exiting the flow amplifier would be centrifugal flow; that is, the material would be undesirably accelerated and driven toward the inner surface of the material flow conduit. In contrast, by moving the flowable material toward the centerline axis of the material flow conduit, the amount of flowable material at the inner surface of the material flow conduit is significantly reduced compared to laminar or centrifugal flow. Furthermore, by moving the flow of the flowable material toward the focal point of the material flow amplifier, a portion of the flowable material (i.e., the flowable material that is not substantially rotating) is trapped between the inner surface of the material flow conduit (e.g., pipeline) and the outer boundary of the flowable material that is rotating and therefore becomes the interface material of the flowable material that is rotating and helps to reduce the effective friction coefficient that occurs at the outer boundary of the flowable material that is rotating and flowing (i.e., the flowable material flows over a similar material rather than the material of the material flow conduit).

[0024] Thus, by considering that the material flow is moved toward the centerline axis of the material flow conduit (i.e., toward the focal point of the material flow amplifier), the rotational flow profile provided by the flow amplifier according to embodiments of the present invention propagates, dramatically reducing pipe wear (e.g., due to significantly reduced sidewall resistance).

[0025] To maintain the beneficial effects of the cyclonic flow, one or more additional material flow amplifiers may be provided downstream of the first material flow amplifier. The distance between amplifiers is proportional to system attributes, such as, for example, pipe size, required flow rate of fluid, pipeline layout, topography (e.g., degree of elevation), etc. The purpose of the placement and configuration of material flow amplifiers is to increase flow rate and maximize the potential of the flow cross-sectional area of ​​the material flow conduit by reducing sidewall resistance.

[0026] In conventional pipe construction, uneven wear occurs inside the pipe due to the concentration of wear particles rubbing against the lowest region of the pipe. In conventional piping systems, the heavier particles fall and drag along the bottom of the pipe construction. The vortex action (swirl) condition keeps the particles suspended. At every change in flow direction, such as in an elbow pipe, the same particles are thrown outward as in a centrifuge. In contrast, the cyclonic flow provided by the material flow amplifier according to one or more embodiments of the present invention acts to focus the flowable material flow more uniformly across the centerline and cross-sectional portion of the material flow conduit with less boundary layer contact. Thus, uneven wear and erosion in the material flow conduit can be mitigated by the use of one or more material flow amplifiers according to one or more embodiments of the present invention.

[0027] 3-10, certain aspects of a linear material flow amplifier 100 according to one or more embodiments of the present invention will be described. The linear material flow amplifier 100 includes a flow inlet structure 102, a flow expander 104, a vortex inducer 106, a flow mixer 108, and a flow outlet structure 110. The flow inlet structure 102, the flow expander 104, the vortex inducer 106, the flow mixer 108, and the flow outlet structure 110 are all in fluid communication with one another to form a fluid flow path along a longitudinal axis L2 of the linear material flow amplifier 100. In a preferred embodiment, as shown, the flow inlet structure 102, the flow expander 104, the vortex inducer 106, the flow mixer 108, and the flow outlet structure 110 are concentric with one another (e.g., have aligned longitudinal axes and a common cross-sectional shape).

[0028] The flow inlet structure 102 includes an upstream portion 112 and a downstream portion 114. In a preferred embodiment, the upstream portion 112 and the downstream portion 114 of the flow inlet structure 102 are the same shape and size. However, in other embodiments, the shapes and / or sizes of the upstream portion 112 and the downstream portion 114 of the flow inlet structure 102 may differ. The flow inlet structure 102 defines a nominal flow cross-sectional area, which may be more specifically defined by dimensional attributes of the upstream portion 112 or the downstream portion 114 of the flow inlet structure 102. For example, if the flow portions 112 and the downstream portion 114 of the flow inlet structure 102 have the same size and shape (e.g., a round shape of a given diameter), the nominal flow cross-sectional area is the area of ​​a circle given in magnitude.

[0029] The flow expander 104 includes an upstream portion 116 and a downstream portion 118. The upstream portion 116 of the flow expander 104 is attached to the downstream portion 114 of the flow inlet structure 102. The downstream portion 118 of the flow expander 104 has a first expanded cross-sectional flow area relative to a nominal cross-sectional flow area. In a preferred embodiment, the first expanded cross-sectional flow area of ​​the flow expander 104 is established by the flow expander transitioning from a diameter of the upstream portion 116 approximately equal to a diameter of the downstream portion of the flow inlet structure 102 to a diameter larger than the diameter of the downstream portion of the flow inlet structure 102.

[0030] Together, the flow inlet structure 102 and the flow expander 104 form an inverted funnel-like profile (i.e., expanding the material flow rather than converging it). This inverted funnel profile causes the flowable material moving through the flow expander 104 to slow down and, as a result, exhibit a decrease in density. This decrease in velocity and decrease in density causes an associated increase in volume. In this regard, the flow volume is expanded as compared to the flow volume at the upstream portion 116 of the flow expander 104.

[0031] The vortex inducer 106 includes an outer tubular body 120, a centralizer tube 122, a plurality of helical vanes 124, and a plurality of helical flow passages 126. The flow inlet structure 102, the flow expander 104, the outer tubular body 120, the flow mixer 108, and the flow outlet structure 110 together define an amplifier body 119. The outer tubular body 120 includes an upstream portion 126 and a downstream portion 128. The upstream portion 126 of the outer tubular body 120 is attached to the downstream portion 118 of the flow expander 104. The centralizer tube 122 is disposed within the outer tubular body 120 and may preferably have a cross-sectional flow area along its entire length that is approximately the same (e.g., the same nominal pipe or tube size) as the nominal cross-sectional flow area of ​​the flow inlet structure 102. Each of the helical vanes 124 extends along at least a portion of the length of the outer tubular body 120. All or a portion of an outer edge portion of each helical vane 124 is attached to the outer tubular body 120 and all or a portion of an inner edge portion of each helical vane 124 is attached to the centralizer tube 122, thereby forming a respective one of the helical flow passages 126. Each of the helical vanes 124, and thus each of the helical flow passages 126, includes a material impingement surface 130 oriented at a predetermined angle of incidence with respect to the flowable material entering the outer tubular body 120 from the flow expander 104.

[0032] The helical vanes 124 may extend substantially the entire length of the outer tubular body 120. In some embodiments, a first helical vane end of one or more of the helical vanes 124 may be disposed adjacent to or within the flow expander 104, and a second helical vane end of one or more of the helical vanes 124 may be disposed within the vortex chamber 106. In a preferred embodiment, the first helical vane ends of all of the helical vanes 124 may be disposed at a location within the outer tubular body 120 that represents at least about 75% of the first expanded cross-sectional flow area of ​​the upstream portion of the outer tubular body 120 (i.e., the upstream portion of the vortex chamber 106), and a second helical vane end of all of the helical vanes 124 may be disposed within the vortex chamber 106 proximate the trailing edge of the centralizer tube 122.

[0033] Each of the helical vanes 124 extends helically along the length of the vortex chamber 106. The helical vanes 124 are preferably disposed equidistant from one another, but may be non-equidistantly spaced from one another. In one or more embodiments, the helical pitch of each of the helical vanes 124 is such that each of the helical vanes 124 rotates an angle of about 90 degrees to about 360 degrees around the interior of the vortex chamber 106 (e.g., as measured around the longitudinal axis L2 of the linear material flow amplifier 100). In one or more embodiments, the helical pitch of each of the helical vanes 124 is such that each of the helical vanes 124 rotates an angle of about 120 degrees to about 270 degrees around the interior of the vortex chamber 106. In a preferred embodiment, each of the helical flow chambers 126 exhibits a decrease in cross-sectional area along the length of the helical flow chamber 126 through the helical wrapping, resulting in amplification and acceleration of the fluid. In one or more embodiments, the helical pitch of each of the helical vanes 124 is such that each of the helical vanes 124 rotates greater than about 360 degrees or greater than about 540 degrees around the interior of the vortex chamber 106. In general, the overall length of the helical vanes 124 and the length and volume of the helical flow passage 126 are proportional to the overall size (i.e., strength) of the cyclonic flow.

[0034] The centralizer tube 122 extends at least a portion of the length of the outer tubular body 120 and has a cross-sectional flow area along its entire length that is at least approximately the same as the nominal cross-sectional flow area as defined by the inlet flow structure 102. In one or more embodiments, the centralizer tube 122 and the outer tubular body 120 may have a common center axis that is the longitudinal axis L2 of the linear material flow amplifier 100.

[0035] In a preferred embodiment, as shown in FIG. 4 , the centralizer tubes 122 and the helical vanes 124 each have a length such that a leading edge of the centralizer tube 122 is spaced from the downstream portion 116 of the flow expander 104, a first helical vane end of one or more of the helical vanes 124 is disposed adjacent to or within the flow expander 104, and a second helical vane end of all of the helical vanes 124 and a trailing edge of the centralizer tube 122 are disposed adjacent to or within the flow expander 104. This relationship is desirable because it allows the flowable material entering the vortex inducer 106 from the flow expander 104 to follow the path of least resistance, either into the centralizer tube 122 or along the material impingement surface 130 of one of the helical vanes 124 into a corresponding one of the helical passages 126, and allows these individual streams of flowable material to enter the flow mixer 108 while minimizing mixing within the vortex chamber 106. Preferably, the outer tubular body 120, the centralizer tube 122 and the helical vanes 124 are configured together (e.g., the length of the vortex chamber, the taper of the vortex chamber, the length of the centralizer tube, the location of the leading edge of the centralizer tube, the pitch and length of the helical vanes, the surface area of ​​the helical vanes, and the volume of the material flow path) so that at least about 65% of the flowable material entering the vortex chamber 106 collectively flows through the helical flow path 126, with the remainder of such flowable material flowing through the centralizer tube 122.

[0036] Referring to the relationship between the outer tubular body 120, the centralizer tubes 122, and the helical vanes 124, in one or more embodiments, the helical vane first ends of all the helical vanes 124 represent at least about 75% of the first expanded cross-sectional flow area of ​​the upstream portion of the outer tubular body 120 and are disposed at a position within the outer tubular body 120. Each of the helical vanes 124 extends along at least about 60% of the total length of the vortex chamber 106 while rotating at an angle of about 90 degrees to about 360 degrees around the interior of the outer tubular body 120. The centralizer tubes 122 have a length that is at least about 40% of the length of the helical vanes 124. The centralizer tubes 122 have a cross-sectional flow area along their entire length that is equal to or greater than the nominal cross-sectional flow area of ​​the flow inlet structure 102. Both the centralizer tube 122 and all of the helical vanes 124 (e.g., their inner edges) terminate within the outer tubular body 120. In a preferred embodiment, the helical vane first ends of all of the helical vanes 124 represent at least about 90% of the first expanded cross-sectional flow area of ​​the upstream portion of the outer tubular body 120 and are disposed at a position within the outer tubular body 120. Each of the helical vanes 124 extends along about 80% of the entire length of the outer tubular body 120, rotating at an angle of about 120 degrees to about 270 degrees around the interior of the outer tubular body 120. The centralizer tube 122 has a length of at least about 50% to about 75% of the length of the helical vanes 124. The centralizer tube 122 has a cross-sectional flow area along its entire length that is approximately the same as the nominal cross-sectional flow area of ​​the flow inlet structure 102. Both the centralizer tube 122 and all of the helical vanes 124 terminate within the outer tubular body 120 .

[0037] Thus, the material flow amplifier according to one or more embodiments of the present invention advantageously provides for the generation of a material flow having a cyclonic flow. Even with the use of spiral vanes that are enclosed (e.g., sidewalls defined by the outer tubular body, the centralizer tube, and adjacent spiral vanes) and arranged (e.g., sized and evenly spaced) to provide spiral flow passages of preferably the same size and volume, the resulting cyclonic flow of flowable material flowing through the material flow amplifier according to one or more embodiments of the present invention is controlled and balanced. In contrast to material flow amplifiers that do not include enclosed spiral flow passages, the material flow amplifier according to one or more embodiments of the present invention exhibits negligible flow interaction of flowable material from one spiral flow space to another, or no overflow or other flow interaction. This flow separation mitigates flow imbalances that cause flow turbulence and produce adverse flow conditions (e.g., vibration of the material flow conduit, pulsation of the material flow, eddy currents in the material flow, etc.) that can induce structural damage and limit material flow efficiency.

[0038] The flow mixer 108 includes an upstream portion 132 and a downstream portion 134. The upstream portion 132 of the flow mixer 108 is attached to the downstream portion 128 of the outer tubular body 120. The upstream portion 132 of the flow mixer 108 has a second expanded cross-sectional flow area that is smaller than the first expanded cross-sectional flow area of ​​the flow expander 104. The minimum cross-sectional flow area of ​​the outer tubular body 120 is generally located at the point where the upstream portion 132 of the flow mixer 108 is attached to the downstream portion 128 of the outer tubular body 120, such that the second expanded cross-sectional flow area is approximately the same as the minimum cross-sectional flow area of ​​the outer tubular body 120. Thus, in a preferred embodiment in which the outer tubular body 120 has a round cross-sectional shape, the second expanded flow area, which is smaller than the first expanded flow area, corresponds to a conical outer tubular body 120 in which the helical channels 126 are tapered (i.e., wider upstream and narrower downstream) along their length.

[0039] 3 and 4, in a preferred embodiment, the flow mixer 108 may preferably include a cylindrical portion 136 that defines the upstream portion 132 of the flow mixer 108 and a converging portion 138 that defines the downstream portion 134 of the flow mixer 108. The converging portion 138 may have an inwardly curved sidewall profile (e.g., a parabolic shape) or a linearly tapered sidewall profile. The cylindrical portion 136 may extend over a portion of the entire length of the flow mixer 108, and the converging portion 138 may extend over the remaining portion of the entire length of the flow mixer 108. In some embodiments, the cylindrical portion 136 may be omitted such that the flow mixer 108 consists entirely of the converging portion 138.

[0040] The flow mixer 108 provides a volumetric space where the material flows through the helical flow passage 126 and the centralizer tube 122 can merge together. In contrast to a material flow amplifier with a flow mixer that does not include a cylindrical portion, the cylindrical portion 136 of the flow mixer 108 of a material flow amplifier according to one or more embodiments of the present invention (e.g., the linear material flow amplifier 100) provides a volumetric space where the material flows joining from the vortex inducer 106 can join before undergoing convergent compression by the converging portion 138 of the flow mixer 108. The tapered profile of the converging portion 138 of the flow mixer 108 creates a focal point of the cyclonic flow of the flowable material. In a preferred embodiment, the focal point of the cyclonic flow of the flowable material is located before the outlet structure 110. Thus, in view of the disclosure herein, one skilled in the art will understand that the duration of the intensity of the cyclonic flow downstream of the material flow amplifier is defined by the dimensions and structural attributes of the flow expander 104, the vortex inducer 106 and the flow mixer 108.

[0041] The flow outlet structure 110 includes an upstream portion 140 and a downstream portion 142. In a preferred embodiment, the upstream portion 140 and the downstream portion 142 of the flow outlet structure 110 are the same shape and size and may have the same or approximately the same cross-sectional flow area (e.g., a nominal cross-sectional flow area) as the inlet flow structure 102. However, in other embodiments, the shapes and / or sizes of the upstream portion 140 and the downstream portion 142 of the flow outlet structure 110 may be different.

[0042] A material flow amplifier according to one or more embodiments of the present invention can have a vortex chamber with a curved centerline axis (i.e., an elbow material flow amplifier). The centerline axis of the vortex chamber and its sidewalls are curved and contoured at a compound angle. Such a curved centerline axis provides a material flow amplifier in the form commonly referred to as a "pipe elbow." Pipe elbows are well known to have a curvature or curvatures ranging from about 15 degrees from straight to up to 90 degrees from straight. It is also well known that conventional pipe elbows exhibit unbalanced flow. When flowable material is directed around the curvature of the pipe elbow, centrifugal forces push the flowable material towards the outer diameter of the pipe elbow, thereby causing flow resistance, friction, and premature wear of the pipe walls. Advantageously, the structure of an elbow material flow amplifier configured according to one or more embodiments of the present invention promotes cyclonic flow therethrough and therefore helps promote balanced fluid flow therethrough (i.e., flowing uniformly along the centerline axis).

[0043] An elbow material flow amplifier 200 according to one embodiment of the present invention is shown in Figure 11. As shown, the elbow material flow amplifier 200 has a general structure similar to that of the straight material flow amplifier 100 described above with reference to Figures 3-10. Aspects of the elbow material flow amplifier 200 that differ significantly from that of the straight material flow amplifier 100 will now be described.

[0044] The elbow material flow amplifier 200 provides an amplifier body including a number of amplifier segments (inlet section 229, flow expander section 231, vortex inducer section 233, flow mixer section 235, and flow outlet section 237). Together, each of these sections 229-237 provide the same functionality as the corresponding section of the straight material flow amplifier 100 described above with reference to Figures 3-10. As shown, the vortex inducer section 233 may have a first helical vane segment 224A extending from adjacent the flow expander section 231. The first helical vane segment 224A terminates adjacent to where the curvature of the centralizer tube 222 of the vortex inducer section 233 begins. The vortex inducer section 233 may have a second helical vane segment 224B extending from adjacent to where the curvature of the centralizer tube 222 of the vortex inducer section 233 ends. The second helical vane segment 224B terminates near the flow mixer section 235. The outer tubular body 220 of the vortex inducer section 233, the first helical vane segment 224A, the second helical vane segment 224B, and the centralizer tube 222 may collectively define an upstream helical flow passage 226A, a downstream helical flow passage 226B, and an intermediate flow passage 226C extending therebetween. Preferably, the intermediate flow passage 226C is free of vanes or other internal structures and maintains a uniform cross-sectional area along its length, thereby allowing the rotational flow from within the upstream helical flow passage 226A to continue indefinitely within the intermediate flow passage 226C. In this regard, the helical vanes 224A, 224B and the helical flow passages 226A, 226B, 226C extend intermittently along the length of the outer tubular body 220. In one or more other embodiments, the length of the intermediate flow passage 226C may be substantially longer than shown, the length of the intermediate flow passage 226C may be substantially shorter than shown, the intermediate flow passage 226C may have a cross-sectional area that decreases along its length, and / or the intermediate flow passage 226C may be omitted such that one or more helical flow passages extend continuously along at least a portion of the length of the centralizer tube 222.

[0045] As shown, the centralizer tube 222 has a terminus at a location after the curvature of the centralizer tube 222 ends. Such a configuration provides that the downstream spiral flow passage 226B is linear rather than having a curvature. The linear portion of the downstream spiral flow passage 226B (or the downstream portion of an adjacent spiral flow passage) utilizes the natural centrifugal force of the material flowing through the curved portion of the vortex inducer section 233 to further promote rotational flow. In a preferred embodiment, the length of such linear portion of the downstream spiral flow passage 226B (or the downstream portion of an adjacent spiral flow passage) is at least about 10% of the length of the curved portion of the centralizer tube 122 (as measured along the centerline), and preferably is at least about 25% of the length of the curved portion of the centralizer tube 122.

[0046] Material flow amplifiers according to embodiments of the present invention can be manufactured utilizing a variety of known and yet to be discovered materials and manufacturing techniques. Examples of useful material classes include, but are not limited to, metallic materials (e.g., metal alloys), concrete (i.e., cement-based materials), and polymeric materials (e.g., plastics). Examples of useful manufacturing techniques include, but are not limited to, casting forging, welding, etc. for metallic materials, and casting, molding, 3D printing, etc. for polymeric materials.

[0047] As shown in Figures 12-13, in one particular implementation of a manufacturing technique, a material flow amplifier according to one or more embodiments of the present invention can have a "clamshell" configuration (i.e., clamshell material flow amplifier 300). As shown, the clamshell material flow amplifier 300 has an overall structure similar to that of the linear material flow amplifier 100 described above with reference to Figures 3-10. Aspects of the clamshell material flow amplifier 300 that differ significantly from that of the linear material flow amplifier 100 are described. It is also disclosed herein that such a clamshell configuration is equally applicable to conventional material flow amplifiers (e.g., those that do not include a centralizer tube).

[0048] The clamshell material flow amplifier 300 includes opposed amplifier bodies 302A, 302B. The amplifier bodies 301A, 301B collectively define an amplifier body that includes a centralizer tube 322, a plurality of helical vanes 324, and a helical passage 326 (or a single helical passage corresponding to a single helical vane). The amplifier body includes a plurality of amplifier segments (inlet section 329, flow expander section 331, vortex inducer section 333, flow mixer section 335, and flow outlet section 337). Together, each of these sections 329-337 provides the same functionality as the corresponding section of the linear material flow amplifier 100 described above with reference to Figures 3-10.

[0049] Advantageously, the clamshell material flow amplifier 300 decouples the manufacture of the amplifier body from the internal components disposed therein. The amplifier bodies 301A, 301B may be manufactured by any suitable manufacturing technique (e.g., casting, forging, hydroforming, machining, 3D printing, etc.) and of any suitable material (e.g., metallic, polymeric, ceramic, etc.). Separately, each of the internal components may be manufactured independently from any suitable material (e.g., metallic, polymeric, ceramic, etc.) using a respective suitable manufacturing technique (e.g., molding, casting, forging, hydroforming, machining, 3D printing, etc.) and then assembled (e.g., via welding, bonding, etc.) to form the vortex chamber insert 339 including the centralizer tube 322 and the helical vanes 324 to manufacture the vortex chamber insert 339. Alternatively, the vortex chamber insert 339 may be integrally formed by using any suitable manufacturing technique (e.g., casting, forging, hydroforming, machining, 3D printing, etc.) and using any suitable material (e.g., metallic material, polymeric material, ceramic material, etc.).

[0050] The vortex chamber insert 339 is disposed within an interior space of a first amplifier body (e.g., amplifier body 301A) of the plurality of amplifier bodies, and then a second amplifier body (e.g., amplifier body 301B) of the plurality of amplifier bodies is disposed to matingly engage with the first amplifier body of the plurality of amplifier bodies. Thus, the interior configuration of the clamshell material flow amplifier 300 may be generally the same as a material flow amplifier having a unitary structure (e.g., a cast structure) as described above with respect to the linear material flow amplifier 100 of FIGS. 3-10. The amplifier bodies 301A, 301B may then be permanently attached to each other, for example, by welding, ultrasonic bonding, adhesives, etc. Optionally, the vortex chamber insert 339 may be secured to at least one of the amplifier bodies 302A, 301B by an appropriate technique (e.g., the same technique used to attach the amplifier bodies to each other) to prevent or limit relative movement therebetween. In one or more embodiments, all or a portion of an outer edge of one or more helical vanes 324 may be attached (e.g., via a continuous or tack weld, directly or through an access window) to at least one of the amplifier bodies 302A, 301B. In yet another manufacturing approach, after the amplifier bodies 301A, 301B are engaged with one another, all or a portion of each of the helical vanes 324 may be formed in combination with a corresponding one of the amplifier bodies 302A, 301B and a centralizer tube disposed within a centralizer tube receiving space defined by the helical vane. All or a portion of an inner edge of one or more helical vanes 324 may be attached (e.g., via a continuous or tack weld, a bonding material such as an adhesive, etc.) to the centralizer tube 322.

[0051] Various advantageous aspects of the material flow amplifier according to embodiments of the present invention will now be described. One such advantageous aspect is that the incorporation of a centralizer tube and the resulting helical flow path provide a cyclonic flow. Such a cyclonic flow is characterized by a "top" or head generated by the flow expander and the upstream portion of the vortex chamber, and an omnidirectional flow (i.e., approximately equal flow in all directions perpendicular to the axis of rotation). Each of the helical flow paths then uses kinetic energy (i.e., energy from motion) and flow velocity to generate several stream vanes (i.e., helical lower streams) of material flow that merge with each other in the flow mixer and with the material flow of the centralized flow (i.e., the centralizer tube flow). These material flows are then focused by the flow mixer to the centerline of the material flow amplifier, thereby forming the "tail end" of the cyclonic flow. Beneficially, the flow mixer further enhances the cyclonic flow and distributes a uniform (i.e., balanced) cyclonic flow profile around the centerline of the material flow amplifier. Advantageously, the condition of the inner wall of the material flow conduit (e.g., pipeline) downstream of the material flow amplifier has little effect on the cyclonic flow. Although there is significant energy loss from fluid passing through certain disruptive material flow attributes of the material flow conduit (e.g., turbulence caused by passing fluid through valves, fittings, or from one pipe size to another), by providing a concentration of material flow along the centerline of the material flow conduit downstream of the material flow amplifier, the cyclonic flow reduces losses from such disruptive material flow attributes of the material flow conduit and reduces sidewall drag and flow resistance.

[0052] Another advantageous aspect of the material flow amplifier according to one or more embodiments of the present invention is to provide a "soft backflow." In such soft backflow, when a backflow surge is present in a system including one or more material flow amplifiers according to one or more embodiments of the present invention, the material flow amplifier functions to reduce backflow (i.e., flow in an upstream direction) by at least about 50% compared to the absence of the material flow amplifier. Such soft backflow does not completely suppress backflow, which creates shock waves that are harmful to the structure of the material flow conduit and the pumping equipment. In gravity flow systems, this is particularly beneficial when tidewater or floodwaters may backflow in conventional pipeline systems. More specifically, in a backflow scenario, the flowable material enters the helical flow path from the flow mixer, and then the dead head enters the "funnel" of the flow expander, which creates a controlled flow disturbance (i.e., a controlled funnel flow). In this regard, soft backflow is enabled by the inclusion of a material flow path defined between the outer tubular body and the centralizer tube.

[0053] Yet another advantageous aspect of material flow amplifiers according to embodiments of the present invention is that they are fully "piggable" as required by the American Petroleum Institute certified according to API-570 inspection process. The oil and petroleum industry requires components of pipeline structures to be piggable. This includes, but is not limited to, cleaning and inspecting the interior of the pipeline by deploying a "pigging device" that travels within the pipeline. To this end, material flow amplifiers according to embodiments of the present invention allow the pigging device to travel unobtrusively through whatever type of section the pipeline contains (e.g., straight, small elbow, large elbow, Y-joint, side of the pipeline, elliptical, and semi-elliptical cross sections).

[0054] The pigging device comprises an elongated body having a peripheral seal at each of its ends. The peripheral seal is sized to maintain engagement with an inner diameter of the material flow conduit (e.g., pipeline) to assist in the pressure drop across the length of the pigging device. It is this pressure drop that helps propel the pigging device along the length of the material flow conduit. In this case, a material flow amplifier according to an embodiment of the invention is configured to maintain engagement between at least one of the peripheral seals and an inner diameter of the material flow conduit and / or the material flow amplifier. More specifically, the length of the centralizer tube of a material flow amplifier according to an embodiment of the invention has a length that provides such a seal with the pigging device as the pigging device enters and exits the material flow amplifier. As the pigging device passes through the material flow amplifier, at least one of the peripheral seals is located within a portion of the material flow conduit upstream or downstream of the material flow amplifier or is located within the centralizer tube. In some embodiments, the flow inlet structure and / or the flow outlet structure can be configured to provide such a seal with the pigging device as the pigging device enters and exits the material flow amplifier.

[0055] Material flow amplifiers according to embodiments of the present invention can be fitted with a remotely viewable flow monitor. Whether the material flow amplifier is underground or above ground, the flow monitor can include one or more monitoring devices (e.g., each monitoring device mounted within a corresponding portion of the amplifier body of the material flow amplifier) ​​from which a continuous display of data can be provided.

[0056] Material flow amplifiers according to embodiments of the present invention are useful in a variety of pipeline components such as, for example, straight sections, elbow sections, reduced sides, tees, etc. Material flow amplifiers according to embodiments of the present invention can be installed as fittings, retrofitted to a section of pipe, or installed in multiple sections of an operational pipeline. Material flow amplifiers according to embodiments of the present invention can be used in any right or left hand flow angle, including vertical up and vertical down applications. Material flow amplifiers according to embodiments of the present invention can be used in transport systems of various flowable materials (e.g., fluids, liquids, slurries, etc.) and various sizes (e.g., from about 2 inches (5.08 cm) in diameter to about 16 feet (4.877 meters) in diameter or larger).

[0057] Although the present invention has been described with reference to certain exemplary embodiments, it is understood that the words used are words of description and illustration, rather than words of limitation. Changes may be made within the purview of the appended claims, as presently described, as amended, without departing from the scope and spirit of the present invention in all its aspects. Although the present invention has been described with reference to particular means, materials, and embodiments, the invention is not intended to be limited to the particulars disclosed. Rather, the present invention extends to all functionally equivalent techniques, structures, methods, and uses, as fall within the scope of the appended claims.

Claims

1. A material flow amplifier, comprising: an amplifier body having a flow expander and an outer tubular body of a vortex chamber, the flow expander and the outer tubular body of the vortex chamber in fluid communication with each other to define a fluid flow path through the flow expander and the outer tubular body of the vortex chamber, the outer tubular body of the vortex chamber extending from the flow expander; a centralizer tube located within the amplifier body and extending at least a portion of the length of the outer tubular body of the vortex chamber; a plurality of helical vanes located within the outer tubular body of the vortex chamber, the vanes extending adjacently along a length of the centralizer tube and extending along an entire length of the centralizer tube; Equipped with the centralizer tube and the outer tubular body of the vortex chamber have a common substantially linear central axis; the plurality of helical vanes are disposed about the substantially linear central axis of the outer tubular body of the vortex chamber between the centralizer tube and the outer tubular body of the vortex chamber.

2. A material flow amplifier as described in claim 1, wherein each of the plurality of spiral vanes extends spirally along the length of the centralizer tube.

3. 2. The material flow amplifier of claim 1, wherein the helical pitch of each of the plurality of helical vanes is arranged such that each of the plurality of helical vanes has an angular rotation of between 90 degrees and 360 degrees when measured about a longitudinal axis of the material flow amplifier.

4. The material flow amplifier of claim 1 , wherein said plurality of helical vanes are equidistantly spaced from one another.

5. The material flow amplifier of claim 1 , wherein said plurality of helical vanes are non-equidistantly spaced from one another.

6. A material flow amplifier as claimed in claim 1, comprising: the amplifier body includes a flow mixer extending from the outer tubular body of the vortex chamber; The flow mixer is in fluid communication with the flow expander and the outer tubular body of the vortex chamber.

7. A material flow amplifier as claimed in claim 6, comprising: the centralizer tube terminates adjacent the flow mixer; A material flow amplifier, wherein the length of the centralizer tube is less than the length of the outer tubular body of the vortex chamber.

8. A material flow amplifier as claimed in claim 6, comprising: the flow mixer includes a cylindrical portion extending from the outer tubular body of the vortex chamber; the flow mixer includes a converging portion extending from the cylindrical portion; A material flow amplifier, wherein the converging portion of the flow mixer has one of a curved sidewall profile and a linearly tapered sidewall profile.

9. A material flow amplifier as described in claim 6, wherein the flow expander, the outer tubular body of the vortex chamber, and the flow mixer are all concentric with one another.

10. A material flow amplifier as described in claim 6, wherein each of a plurality of helical vanes within the outer tubular body of the vortex chamber extends from a first helical vane end adjacent the flow expander to a second helical vane end adjacent the flow mixer.

11. A material flow amplifier as described in claim 10, wherein the first ends of the plurality of spiral vanes are positioned at a position within the outer tubular body of the vortex chamber representing at least 75% of a first expanded flow cross-sectional area of ​​an upstream portion of the outer tubular body of the vortex chamber.

12. A material flow amplifier as claimed in claim 1, comprising: At least a portion of an outer edge portion of the plurality of helical vanes is attached to an inner surface of the amplifier body within the outer tubular body of the vortex chamber; At least a portion of an inner edge portion of the plurality of helical vanes is attached to an outer surface of the centralizer pipe.

13. A material flow amplifier as described in claim 1, wherein the centralizer tube has a flow cross-sectional area along the entire length of the centralizer tube that is at least as large as a flow cross-sectional area of ​​a flow inlet structure connected to the inlet portion of the flow expander.

14. A material flow amplifier as claimed in claim 1, comprising: the first helical vane ends of the plurality of helical vanes are disposed at a location within the outer tubular body of the vortex chamber that represents at least 75% of a first expanded cross-sectional flow area of ​​an upstream portion of the outer tubular body of the vortex chamber; a material flow amplifier, the helical vane second ends of the plurality of helical vanes being disposed within the outer tubular body of the vortex chamber.

Images