Coiled Steam Generator with Critical Constriction for Dry Superheated Output
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Solution Overview
Problem
Existing superheated steam generators face challenges such as pressure safety risks, liquid droplet entrainment leading to wet steam, difficulty in controlling vapor flow at higher pressures, and inefficient heating designs, particularly in small-scale applications like air conditioning and ironing technology.
Innovation Solution
A superheated steam generator design featuring a coiled heating coil with a closed flow channel and critical cross-sectional constriction, cast into a high thermal conductivity material, using electrical heating cartridges and temperature sensors for precise heating, and a pump-controlled system to produce dry superheated steam efficiently across a wide pressure range.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large water space boiler is used, then steam generation capacity is improved, but pressure safety risks increase
Solution Approach 1:
The boiler is divided into multiple independent heating zones with separate heating elements (first heating element in vapor space, second heating element at water level), allowing independent control of each zone to prevent uncontrolled pressure build-up while maintaining overall steam generation capacity
Solution Approach 2:
The system uses dynamic control of heating elements based on steam demand, with the ability to rapidly adjust or shut down heating in response to pressure fluctuations, enabling safe operation at higher pressures without requiring large water spaces
2Productivity
If a high-speed steam generator is used, then steam generation speed is improved, but liquid droplet entrainment increases
Solution Approach 1:
Different regions of the heating system have specialized functions: the first heating element in the vapor space creates gentle vaporization, while the second heating element at water level provides controlled flash evaporation, and the lowest heating element prevents liquid accumulation, collectively eliminating droplet entrainment while maintaining high steam generation speed
Solution Approach 2:
The vapor space acts as an intermediary zone between the water level and steam outlet, allowing vapor to form and separate from liquid droplets before discharge, while the heating elements positioned at different levels control the phase separation process
3Ease of manufacture
If electrically heated steam generators with cast-in pipe coils are used, then manufacturing simplicity is improved, but control precision at higher pressures deteriorates
Solution Approach 1:
The heating system is segmented into multiple independently controllable heating elements positioned at different locations (vapor space, water level, lowest point), allowing precise local control of heat input to match steam demand at higher pressures while maintaining the manufacturing simplicity of cast-in construction
4Ease of operation
If liquid is sprayed onto a heated surface, then vapor generation control is improved, but operation at higher pressures deteriorates
Solution Approach 1:
Instead of spraying liquid onto a heated surface from above, the system heats liquid from below and within the water level, using buoyancy and pressure-driven flow to achieve controlled vaporization at higher pressures, inverting the conventional spray approach to enable high-pressure operation
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 design achieves efficient generation of superheated steam with minimal liquid content, rapid start-up and shut-down, and enhanced safety by ensuring no environmental hazard at high pressures, with symmetrical heating and controlled temperature regulation.
Implementation Method 1
liquid is vaporized in a pressure vessel on electrically heated rods
Implementation Method 2
liquid is vaporized in a pressure vessel on electrically heated rods
Implementation Method 3
the heating coil is cast into a body made of a material or an alloy with a high thermal conductivity, preferably aluminum
Implementation Method 4
entrained liquid droplets in the narrower helices of the inner tube sections are better pressed against the wall by the higher centrifugal forces there and are thus evaporated
Implementation Method 5
Heating elements are provided in the body to heat the heating coil. These heating elements consist of electrical heating cartridges
Data Source
Figure 1~2
AI summary
The invention relates to a hot steam generator, particularly for a thermal spraying machine, for generating hot steam from a fluid, comprising a wound pipe coil (1), on the end of which or in the further course of the steam delivery at least one cross-sectional reduction is located, through which the flow is critical, which is to say with sound velocity.