Cooled Flare Tip Barrel With Internal Channels

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Solution Overview

Problem

Conventional flare tips experience metallurgical degradation and reduced lifespan due to high temperatures and thermal gradients, leading to deformation, fatigue cracking, and premature failure from flame impingement and thermal cycling.

Innovation Solution

The implementation of a flare tip assembly with internal channels for cooling, such as double-barreled or single-barreled designs with annular regions or machined channels, where a cooling fluid is directed through these channels to reduce peak temperatures and stress, using forced thermal convection and conduction to dissipate heat uniformly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional flare tips are used without cooling, then the design is simple and easy to manufacture, but the flare tip experiences metallurgical degradation and reduced lifespan due to high temperatures

Engineering Contradiction:

Improveflare tip service lifeVSAvoidflare tip structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flare tip is divided into multiple segments with internal channels created within the barrel wall. The barrel is segmented into regions with different channel configurations, allowing cooling fluid to flow through distinct pathways. This segmentation enables effective heat removal while maintaining structural integrity and extending service life.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cooling fluid is introduced as an intermediary substance that flows through internal channels within the flare tip barrel. This cooling fluid acts as a mediator between the hot flare gases and the barrel material, absorbing heat through convection and conduction, thereby protecting the flare tip from thermal degradation and extending its service life.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Temperature

If internal cooling channels are added to the flare tip, then peak temperatures are reduced and metallurgical degradation is mitigated, but the manufacturing complexity increases

Engineering Contradiction:

Improvepeak temperatureVSAvoidbarrel fabrication

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The internal channels are designed with specific dimensional parameters including diameter, length, and spacing that are optimized to achieve effective cooling while considering manufacturing constraints. The channel dimensions are carefully selected to balance heat transfer efficiency with ease of fabrication, allowing standard manufacturing processes to be used.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The flare tip incorporates a composite structure combining the barrel material with integrated cooling channels. This composite design integrates the cooling function directly into the barrel structure, eliminating the need for separate cooling components and simplifying the overall manufacturing process while maintaining effective temperature control.

Inventive Principle:

Principle #40Composite materials

3Productivity

If cooling fluid is injected through nozzles into internal channels, then forced thermal convection enhances heat dissipation, but the device complexity and fluid supply requirements increase

Engineering Contradiction:

Improveheat dissipation rateVSAvoidcooling system configuration

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The cooling system utilizes periodic injection of cooling fluid through nozzles into the internal channels. This periodic action creates forced thermal convection that enhances heat dissipation efficiency. The timing and duration of fluid injection are optimized to maximize cooling effectiveness while minimizing the complexity of the fluid supply system.

Inventive Principle:

Principle #19Periodic action

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 design extends the flare tip's service life by reducing peak temperatures and ensuring uniform thermal gradients, mitigating metallurgical degradation and fatigue, thereby enhancing the flare tip's integrity and longevity.

Implementation Method 1

using forced thermal convection and conduction to dissipate heat uniformly

Methodology Applied

Scientific EffectForced thermal convection: Forced Convection

Implementation Method 2

using forced thermal convection and conduction to dissipate heat uniformly

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

using heat from a flame from the flare tip to evaporate the cooling fluid as the cooling fluid moves through the internal channel, where evaporation of the cooling fluid cools the flare tip

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS20240044489A1Cooled flare tip barrel

Publication Date: 2024.02.08 SAUDI ARABIAN OIL CO

AI summary

A flare tip assembly includes a barrel having a barrel wall with an inner surface and an outer surface, an interior cavity defined within the inner surface and extending axially through the barrel, and internal channels formed through the barrel wall. The internal channels have a first opening at a lower axial end of the barrel wall and a second opening at an opposite, upper axial end of the barrel wall, and the internal channels are enclosed between the inner surface and the outer surface of the barrel wall. The flare tip assembly further includes a pilot positioned proximate to the upper axial end of the barrel.