Conical Diffuser Nozzle Design for Steam Injection Noise Reduction
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Solution Overview
Problem
Existing direct contact steam injection heater diffusers often produce undesirable high-frequency, high-decibel noise due to instability in the steam jet, particularly under certain working conditions.
Innovation Solution
The design incorporates a multiplicity of precisely shaped nozzles with varying diameters and conical transitions, along with angling options, to stabilize the steam jet and reduce noise, and an optional insulating layer on the diffuser tube to prevent scaling and extend service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If steam flows through straight walled cylindrical orifices with sharp edges, then the nozzle structure is simple and easy to manufacture, but instability develops in the steam jet leading to high frequency high decibel noise
Solution Approach 1:
The patent modifies the nozzle geometry parameters by transitioning from straight walled cylindrical orifices to conical diffuser nozzles with specific angle ranges (5-15 degrees). This parameter change stabilizes the steam jet flow and reduces noise generation while maintaining manufacturing feasibility through standard machining processes
Solution Approach 2:
Instead of using sharp-edged orifices that create unstable flow, the patent inverts the approach by using rounded leading edges and conical diffuser geometries. This reversal of the traditional sharp-edge design eliminates flow separation and instability, thereby reducing noise without significantly complicating manufacturing
2Productivity
If steam is expelled at high velocity into process fluid, then heat transfer efficiency is improved, but instability in the jet leads to undesirable high frequency noise
Solution Approach 1:
The patent optimizes the cone angle parameter of the diffuser nozzle within a specific range (5-15 degrees) to balance two competing requirements: maintaining high exit velocity for efficient heat transfer while preventing flow instability that causes noise. This precise parameter control resolves the contradiction between productivity and noise reduction
3Reliability
If the diffuser operates under certain working conditions, then heat transfer function is maintained, but instability develops leading to high decibel noise
Solution Approach 1:
The conical diffuser geometry is designed in advance to pre-condition the steam flow before it exits into the process fluid. The gradual expansion angle prepares the flow for stable discharge across various operating conditions, preventing instability and noise before they can develop, thus maintaining reliable heat transfer function
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 solution effectively decreases noise levels and enhances the stability and efficiency of steam injection into process fluids, while also reducing scaling and extending the service life of the heater.
Implementation Method 1
The first and second cylinders are joined to each other by a conical transition zone. This configuration for the nozzle decreases the noise created by the flow of heated gas through the nozzles
Implementation Method 2
The outer wall of the diffuser tube includes a layer of insulating material. The layer of insulating material applied to the outer surface of the outer wall of the diffuser tube reduces the temperature of the surface over which the fluid being heated passes. The reduced temperature of the outer surface reduces scaling and extends the service life of the injection heater
Data Source
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AI summary
A nozzle design for diffusing high pressure steam into by flowing process fluid of substantially lower pressure while reducing the noise intensity generated. The injection nozzles (3) include an opening having a first diameter (D1) to receive steam and a second diameter (D2) to inject the steam into a flow of liquid. The diameters (D1, D2) of the first and second openings can vary relative to each other to enhance the flow characteristics of the steam or other gas being injected into a flow of liquid. The outer surface (98) of a diffuser tube (2, 6) is coated with an insulating material, such as plastic. In alternate embodiments, the orientation of the injection holes (3, 5) can be angled either upstream or downstream to further enhance mixing characteristics of the steam.