Direct Steam Injection Heater Piston Plug Sealing

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Solution Overview

Problem

Existing direct steam injection (DSI) heaters in bitumen froth treatment operations face issues with steam leakage and equipment wear due to dynamic components, leading to inefficient heating and frequent equipment replacement.

Innovation Solution

A DSI heater design featuring a diffuser with outlets arranged in multiple side-by-side rows perpendicular to its longitudinal axis and a piston plug with dual annular seals, allowing for controlled steam injection by axially displacing the piston plug to cover or uncover outlets, thereby preventing steam leakage and cavitation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If dynamic components are used to control steam injection rates, then variable heating requirements can be met, but steam leakage and equipment wear increase

Engineering Contradiction:

Improvevariable heating requirementsVSAvoidsteam leakage

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The piston plug is made movable within the diffuser body, allowing dynamic adjustment of steam injection rates by displacing the piston to expose or block different numbers of outlets. This dynamic mechanism enables adaptation to variable heating requirements while maintaining reliable sealing through properly positioned annular seals that prevent steam leakage despite the moving component.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If dynamic components are used to control steam injection rates, then variable heating requirements can be met, but equipment wear increases

Engineering Contradiction:

Improvevariable heating requirementsVSAvoidequipment lifespan

Core Design Contradiction:

Adaptability or versatilityVSDuration of action of moving object

Solution Approach 1:

The sealing function is extracted from the moving piston surface and placed on stationary annular seals positioned at specific locations within the diffuser. This separation allows the piston to move freely for rate control while the stationary seals maintain reliable sealing, preventing steam leakage and reducing wear on moving components, thereby extending equipment lifespan.

Inventive Principle:

Principle #2Taking out (Extraction)

3Measurement precision

If outlets are arranged in multiple rows, then precise control over steam injection rates is achieved, but device complexity increases

Engineering Contradiction:

Improvesteam injection rates controlVSAvoiddiffuser structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The diffuser outlets are segmented into multiple rows arranged perpendicular to the longitudinal axis, with each row containing a specific number of outlets. This segmentation allows precise control of steam injection rates by selectively blocking entire rows with the piston plug, providing discrete control steps that are easier to implement and control than continuous adjustment mechanisms.

Inventive Principle:

Principle #1Segmentation

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 enhances operational lifespan and efficiency by preventing steam leakage and cavitation, reducing equipment wear, and allowing precise control over steam injection rates to match variable heating requirements, resulting in significant reductions in maintenance and operational costs.

Implementation Method 1

a distal portion comprising a perforated injection section having outlets in fluid communication with the process stream for injecting the steam at sonic flow conditions

Methodology Applied

Scientific EffectSonic flow: Speed of Sound

Implementation Method 2

the proximal annular seal inhibits steam from passing beyond it toward the covered outlets so as to prevent cavitation

Methodology Applied

Scientific EffectCavitation: Cavitation

Implementation Method 3

Direct steam injection (DSI) heaters can be used for this purpose where the DSI heaters include a diffuser that extends into the process stream and has outlets through which the steam is injected directly into the process stream

Methodology Applied

Scientific EffectDirect steam injection heating: Heating

Data Source

PatentUS11525093B2Direct steam injection (DSI) heating and use in bitumen froth treatment operations

Publication Date: 2022.12.13 TRUENORTH ENERGY CORP

AI summary

Direct steam injection (DSI) heating techniques can use a heater to heat a process stream in bitumen froth treatment. The DSI heater can include a diffuser with multiple side-by-side rows of outlets perpendicular to a longitudinal axis of the diffuser, and a piston plug that moves axially within the diffuser to selectively cover rows of outlets to vary steam injection. The piston plug has first and second annular seals and is moved between different axial positions in a stepwise fashion such that when one or more rows of outlets are completely covered, the first annular seal is located in between adjacent rows and the second annular seal abuts against the diffuser to inhibit passage of steam so as to prevent cavitation. The DSI heater can include various other features, such as particular seal unit constructions and diffuser outlet configurations.