Steam Injection Boiler Dryness Raiser with Compressed Air Cooling
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Solution Overview
Problem
Existing steam injection boilers face issues such as poor fuel atomization at high pressures, flame flashback, equipment ablation due to high temperatures, and inadequate sealing and heat dissipation, leading to reduced efficiency and shortened apparatus lifespan.
Innovation Solution
The dryness raiser includes a front end head, cylinder, and rear end head with specific structures for compressed air and cooling medium circulation, heat dissipation, and internal mixing fuel nozzle design to enhance fuel atomization, prevent flame flashback, and improve sealing and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high pressure combustion is used to improve steam generation efficiency, then productivity increases, but fuel atomization deteriorates and flame flashback occurs
Solution Approach 1:
The fuel nozzle is divided into separate components: a replaceable nozzle tip and a main body. This segmentation allows the nozzle tip to be easily replaced when worn or damaged, preventing flame flashback and poor atomization while maintaining high-pressure combustion capability. The main body structure remains intact, reducing waste and maintenance costs.
Solution Approach 2:
The nozzle tip geometry and compression ratio are optimized for high-pressure operation. By changing the structural parameters of the nozzle (particularly the tip angle and compression chamber dimensions), the system achieves proper fuel atomization and prevents flashback even at high combustion pressures, thereby maintaining both productivity and reliability.
2Ease of manufacture
If integral structure of fuel nozzle and spray head is used to simplify manufacturing, then ease of manufacture improves, but reliability deteriorates due to ablation damage
Solution Approach 1:
The fuel nozzle assembly is segmented into a permanent spray head and a consumable nozzle tip. The nozzle tip, which is subject to ablation and wear, can be replaced independently without replacing the entire spray head. This resolves the contradiction by maintaining manufacturing simplicity while improving reliability through selective replacement of damaged components.
3Device complexity
If conventional sealing structures are used to reduce complexity, then device complexity decreases, but reliability deteriorates at high temperatures
Solution Approach 1:
The sealing structure uses composite materials including graphite extrusion and high-temperature resistant sealing rings. These composite materials maintain sealing effectiveness at high temperatures while keeping the overall structure relatively simple. The graphite extrusion provides conformal sealing that adapts to thermal expansion and maintains contact under high temperature conditions.
4Weight of moving object
If inadequate heat dissipation structures are used to reduce weight, then weight decreases, but durability deteriorates due to overheating
Solution Approach 1:
Heat dissipation structures are applied locally to critical components rather than uniformly across the entire apparatus. Cooling channels and heat sinks are concentrated in areas experiencing highest temperatures (nozzle, combustion chamber), reducing overall weight while ensuring adequate cooling where most needed to maintain durability.
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 solution effectively improves steam dryness, enhances fuel atomization and combustion stability, extends equipment lifespan by preventing ablation, and ensures reliable sealing and heat dissipation, leading to increased operational efficiency and cost savings.
Implementation Method 1
a plurality of compressed air circulation holes (1.8) perpendicular to the front end head (1) are provided in the middle of a flange bolt hole of the front end head (1) in a compressed air inlet passage (1.3)
Implementation Method 2
a plurality of compressed air heat dissipation holes (1.10) are provided in a front end face (1.9) of the front end head (1), the compressed air heat dissipation holes (1.10) are perpendicular to and are connected to the compressed air circulation holes (1.8)
Implementation Method 3
an internal mixing fuel nozzle (1.12) is disposed at a front end of the fuel pipe (1.5), the internal mixing fuel nozzle (1.12) and the fuel pipe (1.5) are an integral structure
Implementation Method 4
the internal mixing fuel nozzle (1.12) and a tail end of the fuel pipe passage (1.4) are sealed by graphite extrusion
Implementation Method 5
High-pressure combustion generates an ultra-high temperature to ablate equipment
Implementation Method 6
a cooling medium inlet (2.1), a cooling medium connecting pipe (2.2), and a cooling medium passage (2.3) are provided at a front end of the cylinder (2)
Data Source
AI summary
Provided are dryness raiser and method for improving steam dryness of a steam injection boiler. Technical solutions of the dryness raiser and the method are that: a plurality of compressed air circulation holes perpendicular to a front end head are provided in the middle of a flange bolt hole of the front end head in a compressed air inlet passage, and the compressed air inlet passage is connected to a fuel pipe passage by the compressed air circulation holes; and a plurality of compressed air heat dissipation holes are provided in a front end face of the front end head, and are perpendicular to and are connected to the compressed air circulation holes, air heat dissipation nozzles are disposed at tail ends of the compressed air heat dissipation holes, and a plurality of air heat dissipation jet orifices are evenly distributed on circumferences of the air heat dissipation nozzles.