Boiler Water-Wall Outlet Structure for Balanced Flow Distribution
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Solution Overview
Problem
In vertical-tube furnaces, the pressure loss of internal fluid through orifices at furnace inlets is proportional to the square of the flow rate, making it difficult to achieve optimal flow-rate distribution across furnace walls from partial to rated loads, leading to unbalanced fluid distribution and potentially higher steam and metallic temperatures.
Innovation Solution
A boiler structure with a pressure-loss adjusting section in the outlet connection tube, which allows for flow-rate adjustment by varying the inner diameter, number, or length of tubular members or using fixed orifices, ensuring pressure loss is linearly proportional to the mass flow rate, facilitating balanced distribution across multiple furnace walls without moving parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If orifices are provided at furnace inlets to adjust flow rate according to rated load, then optimal flow-rate distribution is achieved at rated load, but pressure loss becomes excessive at partial load causing inability to achieve optimal flow-rate distribution
Solution Approach 1:
The patent replaces static orifices with dynamic flow rate control valves that can adjust their opening degree based on operating conditions. This allows the system to adapt the flow rate distribution dynamically between rated load and partial load conditions, resolving the contradiction by making the flow control mechanism responsive to changing operational requirements rather than fixed at design stage
Solution Approach 2:
The patent changes the control parameter from fixed orifice diameter to variable valve opening degree. By controlling the opening degree of the flow rate control valves, the system can adjust the flow rate characteristics to maintain optimal distribution across different load conditions, transforming a static parameter (orifice size) into a controllable variable parameter
2Ease of operation
If flow-rate distribution is adjusted using orifices at furnace inlets, then flow rate can be controlled, but the control mechanism requires moving parts and control valves increasing device complexity
Solution Approach 1:
The patent implements a control system that automatically adjusts flow rate distribution based on temperature feedback from the furnace walls. The control device receives temperature information and autonomously controls the flow rate control valves without requiring manual intervention, making the system self-regulating and reducing operational complexity while maintaining ease of operation
3Loss of energy
If orifice diameter is set for rated load optimization, then pressure loss is acceptable at rated load, but flow-rate distribution becomes unbalanced at partial load causing temperature fluctuations
Solution Approach 1:
The patent incorporates a feedback control mechanism where temperature detection devices monitor the outlet temperatures of furnace walls and provide this information to the control device. The control device uses this feedback to adjust the flow rate control valves, creating a closed-loop system that maintains stable flow-rate distribution and temperature balance across varying load conditions by continuously responding to actual system state
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
This configuration enables stable and balanced flow-rate distribution across furnace walls over a wide load range, maintaining appropriate steam and metallic temperatures, and eliminates the need for complex control mechanisms or valves.
Implementation Method 1
a loss of pressure occurring due to the internal fluid passing through the orifices (also referred to as 'pressure loss' hereinafter) is proportional to the square of the flow rate of the internal fluid
Data Source
AI summary
Provided is a boiler structure that allows for appropriate flow-rate distribution for each furnace wall by using a simple configuration without any moving parts in a wide thermal-load range of a furnace from a partial load to a rated load. In a boiler structure having a furnace water-wall formed of multiple boiler evaporation tubes and configured to generate steam by heating water inside the furnace when the water that is pressure-fed to the boiler evaporation tubes flows inside the tubes, the boiler structure includes a pressure-loss adjusting section, for an internal fluid, provided in an outlet connection tube that connects outlets of water walls obtained by dividing the furnace water-wall into multiple parts.