Bulged Inlet Diffuser for Heat Recovery Boiler Misalignment
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Solution Overview
Problem
Misalignment between hot flue-gases sources and heat recovery boiler inlets leads to inefficient heat exchange, temperature inconsistencies, and increased risk of boiler damage and pollution due to non-homogeneous gas flow, especially when combined with afterburners.
Innovation Solution
A heat recovery boiler design featuring an inlet diffuser with bulges that increase and then decrease the passage section, creating a mixing zone to uniformize flue gas flow speed and temperature, allowing for efficient coupling regardless of alignment and reducing the risk of cracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the heat recovery boiler is connected to the hot flue-gases source in a non-linear configuration, then the installation flexibility is improved, but the heat exchange efficiency deteriorates and temperature uniformity worsens
Solution Approach 1:
The inlet diffuser is divided into multiple sections with varying passage areas, creating a segmented flow path that progressively mixes and uniformizes the flue gas flow, allowing non-linear installation while maintaining heat exchange efficiency
Solution Approach 2:
The passage section of the inlet diffuser is varied locally along the flow direction, with different areas at different positions to create optimal flow conditions for mixing and temperature uniformity, enabling flexible installation configurations
2Adaptability or versatility
If the hot flue-gases source is not aligned with the inlet of the heat recovery boiler, then the installation flexibility is improved, but the temperature uniformity of flue gases deteriorates
Solution Approach 1:
The inlet diffuser passage is segmented into zones with different cross-sectional areas, creating multiple flow regions that promote mixing and temperature uniformity even when the flue-gases source is misaligned with the boiler inlet
Solution Approach 2:
The passage section parameter of the inlet diffuser is changed along the flow direction to optimize flow patterns, creating conditions that achieve temperature uniformity regardless of alignment between the flue-gases source and boiler inlet
3Ease of manufacture
If the flue gas flow is non-homogeneous, then the installation simplicity is maintained, but the risk of boiler crackage increases
Solution Approach 1:
The inlet diffuser is designed with segmented passage sections that create controlled flow patterns, promoting homogeneous temperature distribution and reducing thermal stresses that could cause cracking, while maintaining simple installation
Solution Approach 2:
The passage section is varied locally to create optimal flow conditions that uniformize temperature distribution, reducing thermal gradients and the risk of crackage without complicating the installation process
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 bulged inlet diffuser ensures uniform flue gas flow, enhancing boiler efficiency and reliability, reducing the risk of damage, and stabilizing flame and emissions, while eliminating the need for complex homogenization systems.
Implementation Method 1
The presence of the bulge in the inlet diffuser allows the creation therein of at least one mixing zone capable of making the flow of flue gases flowing in the inlet diffuser uniform, in terms of speed and temperature
Implementation Method 2
a steam circuit fed with water and extending at least in part inside the flue-gases flowing chamber so as to exploit the heat of the flue-gases to generate steam
Data Source
Figure 1
Figure 2~3
AI summary
A heat recovery boiler is provided with: a flue-gases flowing chamber (11) extending along a longitudinal axis (A) and provided with an inlet (16) and an outlet (17); a steam circuit (14) fed with water and extending at least in part inside the flue-gases flowing chamber (11) so as to exploit the heat of the flue-gases to generate steam; an inlet diffuser (12) connected to the inlet (16) of the flue-gases flowing chamber (11) wherein flue-gases from a flue-gases source (9) flow in one advancing direction (D); at least one first wall (22; 19; 20) of the inlet diffuser (12) being provided with at least one first bulge (30).