Descaling Spray Nozzle With Offset Vane Segmentation
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Solution Overview
Problem
Existing descaling spray nozzle assemblies face issues with turbulence in high-pressure liquid flow, leading to uneven liquid distribution and reduced impact force, which affects the uniformity of scale removal on steel slabs, and are costly to manufacture due to precise assembly requirements.
Innovation Solution
A multi-stage liquid straightening vane section with a greater number of radial vane elements, circumferentially offset to control the liquid flow and reduce turbulence, allowing for improved uniformity and impact without restricting fluid passage or increasing pressure losses, and enabling more economical manufacturing with relaxed assembly tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a limited number of radial vane elements (e.g., five) are provided in the liquid straightening vane, then the device complexity is reduced and manufacturing is easier, but the turbulence in the liquid flow stream is not adequately reduced, resulting in uneven liquid distribution and reduced impact force
Solution Approach 1:
The liquid straightening vane is divided into multiple radial vane elements (e.g., 12 vanes) that segment the liquid flow into multiple smaller flow passages. This segmentation allows each vane element to independently straighten a portion of the turbulent flow, collectively achieving superior turbulence reduction and uniform liquid distribution across the spray pattern without requiring excessive complexity in any single component
Solution Approach 2:
The invention changes the parameter of the number of radial vane elements from a limited small number (e.g., five) to a greater number (e.g., 12), which fundamentally alters the flow characteristics. This parameter change enables adequate turbulence reduction while maintaining acceptable device complexity, as the additional vanes create more numerous but smaller flow passages that collectively better straighten the liquid stream
2Reliability
If a greater number of radial vane elements are provided in the liquid straightening vane, then the turbulence reduction effectiveness is improved, but the laminar flow passageways become smaller, restricting fluid passage and creating undesirable pressure drops
Solution Approach 1:
By segmenting the flow into multiple smaller passages through numerous radial vane elements, the invention achieves effective turbulence reduction without creating excessive pressure drops. The segmentation distributes the flow restriction across many small passages rather than a few large ones, maintaining adequate flow velocity and pressure while still straightening the liquid stream effectively
Solution Approach 2:
The invention uses a greater number of radial vane elements than traditionally employed (excessive action), which provides more than adequate turbulence reduction. However, this is balanced by the fact that each individual vane element creates only partial flow restriction, and the cumulative effect of many small restrictions is less severe than fewer large restrictions, thereby avoiding excessive pressure drops
3Ease of manufacture
If the spray tip and liquid straightening vane section are assembled without special orientation, then the ease of manufacture and assembly is improved, but the uniformity of the discharging spray pattern is adversely affected
Solution Approach 1:
The liquid straightening vane section is designed with radial symmetry and uniform spacing of vane elements, making it functionally equivalent regardless of rotational orientation. This universal design allows the spray tip to be assembled in any angular position relative to the vane section without affecting spray pattern uniformity, as the symmetric configuration ensures consistent flow distribution in all orientations
Solution Approach 2:
The invention employs symmetric (rather than asymmetric) design of the radial vane elements, where all vanes are identical in shape, size, and spacing. This symmetry creates a rotationally invariant configuration that eliminates the need for precise angular orientation during assembly, as any rotational position produces the same flow straightening effect and spray pattern uniformity
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 achieves a more uniform and efficient scale removal with higher pressure impact across the entire width of the steel slab, maintaining a controlled thin-line spray pattern and reducing manufacturing costs by allowing for greater tolerance variations in assembly.
Implementation Method 1
High pressure liquid directed through the strainer can incur considerable turbulence
Implementation Method 2
a vane having a plurality of radial vane elements immediately downstream of the strainer, which effectively defines a plurality of circumferentially-spaced laminar flow passages
Implementation Method 3
a liquid flow passageway that tapers inwardly in a downstream direction for accelerating the liquid flow
Implementation Method 4
a strainer affixed to an upstream end of the tubular body for straining particulate matter and scale from recycled steel mill water
Implementation Method 5
directing a wide thin line high pressure spray onto the surface of steel slabs for penetrating and removing iron oxide scale buildup
Data Source
AI summary
A spray nozzle assembly for directing thin, straight line, high pressure liquid spray onto moving steel slabs for penetrating and removing scale buildup in steel processing operations. The spray nozzle assembly includes a high impact attachment tube for accelerating liquid flow, a tungsten carbide spray tip at a discharge end of the high impact attachment tube for directing a flat spray pattern, an inlet defined by a strainer at an upstream end of the high impact attachment tube, and a staged vane section intermediate the inlet and spray tip for reducing liquid turbulence in the flow passageway. The vane section comprises a pair of axially spaced vanes each having a plurality of radial vane elements that define a plurality of laminar flow passageways, with the laminar flow passageways of one vane being circumferentially offset to the laminar flow passageways of the other vane.