Ceramic Nozzle for Wet Gas Scrubber Erosion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional nozzles in jet ejector venturi wet gas scrubbers, particularly those made of hardened stainless steel, are prone to corrosion and erosion, leading to vane assembly failure due to improper installation and movement issues, which results in costly shutdowns and inefficiencies in contaminant removal from refinery flue gases.
Innovation Solution
A single-piece ceramic nozzle assembly with a ceramic vane assembly, designed to eliminate the joint between the vane and nozzle components, featuring a central vane support and angled vanes with optimized geometry and cross-sectional areas to enhance durability and reduce erosion, manufactured using techniques like 3D printing or co-sintering, such as nitride bonded silicon carbide.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a hardened stainless steel vane assembly is used in a ceramic-lined nozzle assembly, then the vane assembly can be manufactured with reasonable ease, but it is susceptible to corrosion and erosion leading to failure
Solution Approach 1:
The patent applies composite materials by transitioning from hardened stainless steel vanes to ceramic vanes that are integrally formed with the ceramic nozzle assembly. This composite ceramic structure provides superior resistance to corrosion and erosion while maintaining manufacturability through advanced ceramic forming and sintering processes.
2Ease of operation
If the vane assembly is ground-to-fit within the cylindrical portion of the ceramic nozzle assembly, then it can be installed, but over-grinding can permit movement between the vanes and cylindrical portion leading to spinning and catastrophic failure
Solution Approach 1:
The patent merges the vane assembly and nozzle assembly into a single integral ceramic structure. The vanes are formed as one piece with the cylindrical portion, eliminating the need for separate installation and grinding operations. This integration eliminates movement and spinning issues while maintaining ease of operation as a pre-assembled unit.
3Ease of manufacture
If conventional separate-piece nozzle and vane assemblies are used, then manufacturing and installation are feasible, but joints between components can lead to movement and spinning under liquid impact
Solution Approach 1:
The patent combines the previously separate nozzle assembly and vane assembly into a single integral ceramic component. This merging eliminates all joints and interfaces between the vane assembly and cylindrical portion, ensuring complete stability and preventing any movement or spinning under scrubbing liquid impact.
4Reliability
If a single-piece ceramic nozzle assembly with integral vane assembly is manufactured, then durability and stability are increased, but manufacturing complexity increases
Solution Approach 1:
The patent applies segmentation in reverse by creating an integral monolithic structure rather than separate components. The single-piece ceramic nozzle assembly with integral vane assembly eliminates the need for multiple components and joints, reducing operational complexity despite requiring advanced ceramic manufacturing processes.
Data Source
AI summary
A nozzle and methods of gas stripping utilizing the nozzle are provided. A nozzle is provided comprising a ceramic nozzle assembly comprising an inlet at one end of a cylindrical portion, an outlet at one end of a conical portion; the cylindrical portion transitioning to the conical portion at an end of the cylindrical portion distal from the inlet; the conical portion transitioning to the cylindrical portion at an end of the conical portion distal from the outlet; and a ceramic vane assembly within the cylindrical portion; the vane assembly comprising a central vane support located substantially concentrically within the cylindrical portion, and a plurality of angled vanes extending from the central vane support to an inner wall of the cylindrical portion; wherein the ceramic nozzle assembly and the ceramic vane assembly are manufactured such that the two assemblies comprise a single piece of ceramic.