Low-Shear Ball Valve With Helical Flow Paths for Foam Separation
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Solution Overview
Problem
Current flow control devices and separators are inefficient in handling fluids with mixed phases, leading to unwanted foam and emulsion formation due to inadequate control of kinetic energy and flow speed, which results in premature failure and inaccurate fluid separation, especially when upstream conditions change.
Innovation Solution
A ball-type flow control device with a cylindrical body and internal flow control body featuring helical fins that create a vortex chamber, allowing for controlled vorticity and rotational fluid flow to manage foam and emulsion separation effectively, with the ball element being pivotable to adjust fluid communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional flow control valves are used to control flow speed, then flow control is achieved, but excessive speed and turbulence cause unwanted foam and emulsion formation
Solution Approach 1:
The ball element with its spherical geometry and helical flow passages creates curved flow paths that reduce turbulence. The spherical shape naturally promotes laminar flow transitions, reducing the formation of foam and emulsion while maintaining effective flow control through the valve mechanism.
Solution Approach 2:
The valve changes flow parameters gradually through the helical flow passages rather than creating abrupt changes. This gradual parameter change reduces turbulence intensity and prevents the excessive agitation that leads to foam and emulsion formation, while still achieving the desired flow speed control.
2Ease of manufacture
If separators are designed based on predefined rules, then initial design is simplified, but they fail to adapt to changing upstream conditions and fluid composition
Solution Approach 1:
The flow control valve introduces dynamic adaptability to the separator system. By adjusting the ball element position, operators can change flow characteristics in real-time to match varying upstream conditions, making the separator adaptable without requiring complex redesign while maintaining simple operational control.
3Speed
If valves are positioned before the separator inlet to control flow, then flow control is achieved, but they create disturbances that reduce separator efficiency
Solution Approach 1:
The spherical ball element with helical flow passages creates smooth, curved flow transitions that minimize disturbances. This geometry allows flow control to be achieved without creating the turbulent disturbances that would reduce separator efficiency, as the curved paths naturally dampen flow irregularities before fluid enters the separator.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device achieves low shear control of fluids, effectively separating foam and emulsions by imparting variable g-forces and promoting rotational flow, enhancing the efficiency and accuracy of fluid separation across changing upstream conditions.
Implementation Method 1
A ball-type flow control device with a cylindrical body and internal flow control body featuring helical fins that create a vortex chamber, allowing for controlled vorticity and rotational fluid flow
Implementation Method 2
The device achieves low shear control of fluids, effectively separating foam and emulsions by imparting variable g-forces and promoting rotational flow
Data Source
AI summary
A flow control device includes a cylindrical body disposed about a primary axis. The cylindrical body includes a primary flow passage extending therethrough. A ball element having an inlet flow passage extending therethrough is pivotable relative to the cylindrical body between an open position and a closed position. In the open position, the inlet flow passage is in fluid communication with the primary flow passage, and in the closed position, the inlet flow passage is not in fluid communication with the primary flow passage. The flow control device further comprises an internal flow control body having a collar positioned within the cylindrical body about the primary axis. A plurality of outer helical fins extend outwardly from the collar and define a plurality of outer helical passageways, and a plurality of inner helical fins are positioned inwardly from the collar and define a plurality of inner helical passageways.