Boiler Tube Deposit Reducing Elements Using Exhaust Gas Pressure
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Solution Overview
Problem
Boilers face reduced thermal efficiency and increased fuel consumption due to soot deposits on tube surfaces, requiring cumbersome manual cleaning and frequent shutdowns.
Innovation Solution
The boiler incorporates deposit reducing elements that adjust based on exhaust gas pressure to control flow through tubes, increasing velocity and reducing deposit formation, while also allowing for automatic cleaning during operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If manual cleaning of tubes is performed to remove deposits, then thermal efficiency is improved, but boiler downtime increases and operation complexity increases
Solution Approach 1:
The deposit reducing element automatically adjusts tube flow distribution based on exhaust gas pressure, preventing deposit formation without requiring manual intervention. The system serves itself by using the existing exhaust gas pressure to drive the mechanism that prevents the problem (deposits), eliminating the need for external cleaning operations and associated downtime.
Solution Approach 2:
The deposit reducing element proactively prevents deposit formation by dynamically adjusting flow distribution before significant deposits can form. By continuously monitoring exhaust gas pressure and adjusting tube blockage accordingly, the system maintains optimal flow velocities to prevent deposit accumulation, avoiding the need for reactive cleaning operations.
2Loss of energy
If manual cleaning of tubes is performed to remove deposits, then thermal efficiency is improved, but operation complexity increases
Solution Approach 1:
The system automatically prevents deposit formation through the deposit reducing element that responds to exhaust gas pressure changes, eliminating the need for complex manual cleaning operations. The boiler manages its own maintenance needs through this self-regulating mechanism.
Solution Approach 2:
The manual mechanical cleaning operation is replaced by an automatic mechanical system (deposit reducing element) that uses exhaust gas pressure to adjust tube blockage dynamically. This substitution transforms a complex periodic manual task into a simple automatic process.
3Object-generated harmful factors
If deposit reducing elements block tubes at low exhaust gas pressure, then deposit formation is reduced, but exhaust gas flow resistance increases
Solution Approach 1:
The deposit reducing element dynamically adjusts the degree of tube blockage based on real-time exhaust gas pressure conditions. At low pressure, it blocks tubes to prevent deposits; at high pressure, it opens tubes to maintain flow. This dynamic adaptation resolves the contradiction by making the system responsive to changing conditions rather than statically blocked.
Solution Approach 2:
The system changes the flow distribution parameter (tube blockage degree) in response to exhaust gas pressure changes. When exhaust gas pressure increases, the deposit reducing element opens tubes to reduce flow resistance; when pressure decreases, it blocks tubes to prevent deposits, thus adapting the system parameters to resolve the contradiction.
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 solution minimizes manual cleaning needs, maintains thermal efficiency, and reduces downtime by preventing deposit buildup and allowing for automatic cleaning, thus optimizing boiler performance.
Implementation Method 1
be moved, by a sufficiently high exhaust gas pressure in said at least one of the tubes, to open said at least one of the tubes
Implementation Method 2
allow passage of exhaust gas having a sufficiently high exhaust gas pressure through said at least one of the tubes, to increase an exhaust gas velocity in the open tubes
Implementation Method 3
heat is transferred from the exhaust gas to the medium in the vessel
Implementation Method 4
exhaust gas from the burner is fed through the tubes, and a medium, such as water, is fed through the vessel and thus around the tubes
Data Source
Figure 1~2
Figure 3~4
Figure 5a~5b
AI summary
A boiler (2) comprising a first number of tubes (6, 34, 42) for conveying exhaust gas is provided. Each of the tubes (6, 34, 42) comprises an inlet (8) for receiving the exhaust gas and an outlet (10) for discharging the exhaust gas. Each of the tubes defines a respective longitudinal center axis (L). The boiler is characterized in that it further comprises a second number of deposit reducing elements (20, 44). Each of the deposit reducing elements (20, 44) is arranged to close at least one of the tubes (6, 34, 42), or be moved, by a sufficiently high exhaust gas pressure in said at least one of the tubes, to open said at least one of the tubes, to reduce formation of deposits inside the tubes.