Desuperheater Spray Head Non-Linear Flow Passages
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Solution Overview
Problem
Conventional desuperheaters face challenges in efficiently reducing the temperature of superheated steam to prevent damage to downstream equipment, as they often require complex and costly manufacturing processes and may experience leakage and pressure loss due to uniform flow passages.
Innovation Solution
The development of a spray head for desuperheaters using additive manufacturing techniques, which allows for the creation of nozzles with non-linear, variable cross-section flow passages and independently controllable inlets, reducing pressure loss and improving the distribution and controllability of the discharged fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing techniques are used to produce spray heads, then assembly is simplified, but manufacturing precision and flow passage uniformity are reduced
Solution Approach 1:
The spray head is designed as a single monolithic structure where the body and nozzle are integrated into one component. This merging of parts eliminates assembly complexity while enabling precise, non-linear flow passages to be formed as integral features of the unified structure through additive manufacturing.
Solution Approach 2:
The invention utilizes additive manufacturing technology to fundamentally change the manufacturing parameters and capabilities. This enables the creation of complex non-linear flow passages with varying cross-sections that cannot be achieved through conventional manufacturing, while maintaining the benefit of simplified assembly as a single printed component.
2Ease of manufacture
If uniform cross-section flow passages are used, then manufacturing is simpler, but pressure loss increases
Solution Approach 1:
The flow passage cross-section is designed to vary locally along its length rather than remaining uniform. The cross-sectional area changes progressively to optimize fluid velocity and pressure distribution, reducing turbulence and pressure loss while maintaining manufacturability through additive manufacturing.
Solution Approach 2:
The flow passage employs non-linear, curved paths instead of straight uniform channels. The curved geometry smoothly redirects fluid flow, reducing sharp transitions and turbulence that cause pressure loss, while the varying cross-section optimizes flow velocity throughout the passage.
3Loss of energy
If complex non-linear flow passages are implemented, then pressure loss is reduced, but manufacturing complexity increases
Solution Approach 1:
The invention replaces traditional mechanical manufacturing methods with additive manufacturing technology. This substitution enables the direct creation of complex non-linear flow passages with varying cross-sections as integral features of the monolithic spray head, eliminating the need for complex assembly of multiple precision-machined parts.
4Ease of manufacture
If spray heads are assembled from separate parts, then manufacturing flexibility is improved, but leakage risk increases
Solution Approach 1:
The spray head body and nozzle are merged into a single monolithic component manufactured through additive manufacturing. This eliminates all joints, interfaces, and seals between parts, completely preventing leakage paths while maintaining manufacturing flexibility through the adaptability of additive manufacturing processes.
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 solution enables the production of custom-designed spray heads with reduced leakage and pressure loss, enhancing the quality and distribution of the atomized fluid, while also reducing manufacturing costs and complexity.
Implementation Method 1
the spray nozzle having at least one exit opening and a plurality of flow passages... emits spray water into the flow line
Implementation Method 2
spray water into the steam flow to reduce the temperature of the steam
Implementation Method 3
a first one of the plurality of flow passages follows a first non-linear path and has a first distance, and wherein a second one of the plurality of flow passages follows a second non-linear path and has a second distance different from the first distance
Data Source
AI summary
Spray heads for use with desuperheaters and desuperheaters including such spray heads. One example of a spray head includes a main body having an exterior surface and defining a central passage, the main body adapted for connection to a source of fluid, at least one entrance port formed in the main body along the central passage, and at least one spray nozzle arranged adjacent the exterior surface of the main body. The spray head also includes a plurality of flow passages, each of the plurality of flow passages providing fluid communication between the entrance port and an exit opening of the spray nozzle. A first one of the plurality of flow passages follows a first non-linear path and has a first distance, and a second one of the plurality of flow passages follows a second non-linear path and has a second distance different from the first distance.