Helical Flow Modifier for Cyclonic Pipeline Transport
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Solution Overview
Problem
Conventional flow of abrasive and particulate-filled materials through pipelines leads to surface erosion, head losses, fluid cavitation, heating, particulates dropping out of suspension, and material composition changes due to laminar flow profiles, resulting in increased energy consumption and costly maintenance.
Innovation Solution
A material flow modifier that transforms laminar flow to a rotational or cyclonic flow profile by using an interior tubular body with expanding cross-sectional area and surrounding helical passage bodies, maintaining particles in suspension and reducing wear on pipeline surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If laminar flow profile is used in pipeline, then flow stability is maintained, but head loss increases and energy consumption increases
Solution Approach 1:
The patent changes the flow profile parameter from conventional laminar flow to rotational flow by introducing a rotational flow generator. This parameter change reduces the velocity gradient at the pipe wall, thereby reducing head loss and energy consumption while maintaining productivity.
Solution Approach 2:
The patent introduces a dynamic rotational flow component to the conventional static laminar flow. The rotational flow generator creates a rotating velocity field that dynamically interacts with the flow, reducing frictional losses at the pipe wall while maintaining overall flow rate.
2Object-affected harmful factors
If conventional flow through elbow fitting is used, then simplicity of piping is maintained, but erosion of pipe wall occurs
Solution Approach 1:
The patent introduces a rotational flow generator as an intermediary device that modifies the flow characteristics before the fluid enters the elbow fitting. This intermediary component creates a rotational flow pattern that protects the pipe wall from direct impingement of abrasive particles, reducing erosion without requiring changes to the piping structure itself.
Solution Approach 2:
The rotational flow generator applies preliminary anti-action by creating a protective rotational flow field that counteracts the erosive effect of abrasive particles before they can impact the pipe wall. This preliminary protective action prevents erosion rather than addressing it after occurrence.
3Loss of energy
If higher pumping pressure is used, then head loss is mitigated, but energy consumption increases and vibration problems occur
Solution Approach 1:
The patent changes the flow profile parameter from conventional laminar flow to rotational flow by introducing a rotational flow generator. This parameter change reduces the velocity gradient at the pipe wall, thereby reducing head loss and energy consumption while maintaining productivity.
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 rotational flow profile increases flow rate, reduces energy consumption, maintains particulates in suspension, and minimizes pipeline wear, while reducing backflow and material deposition, thus enhancing the efficiency and longevity of piping systems.
Implementation Method 1
A material flow modifier transforms laminar flow to a rotational or cyclonic flow profile by using an interior tubular body with expanding cross-sectional area and surrounding helical passage bodies
Implementation Method 2
The plurality of helical passage bodies each surround and extend along a length of the interior tubular body. Each of the helical passage bodies defines a helical passage therein
Implementation Method 3
maintaining particles in suspension and reducing wear on pipeline surfaces
Implementation Method 4
due to centrifugal force, heavier solids and particulates are generally thrown to the outside wall as the flowable material changes direction
Implementation Method 5
conventional flow of flowable material within a flow passage of a material flow conduit has a flow profile characterized by laminar flow effect
Implementation Method 6
Flowable material at the surface of the flow passage exhibits considerable friction and zero flow velocity, thereby reducing velocity of the flowable material
Implementation Method 7
due to centrifugal force, heavier solids and particulates are generally thrown to the outside wall as the flowable material changes direction and tend to continually scour the outer wall
Data Source
AI summary
Material flow modifiers as disclosed herein overcome drawbacks associated with known adverse flow conditions (e.g., surface erosion, head losses, particulate drop-out, and the like) that arise from flow of certain types of materials (e.g., fluids, slurries, particulates, flowable aggregate, and the like) through a material flow conduit. Such material flow modifiers provide for flow of flowable material within a flow passage of a material flow conduit (e.g., a portion of a pipeline, tubing or the like) to have a rotational flow profile. Advantageously, the rotational flow profile centralizes flow toward the central portion of the flow passage, thereby reducing magnitude of laminar flow to overcome the aforementioned adverse flow conditions.