Flow Distribution System for Normalizing Multi-Planar Electrochemical Flow

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Solution Overview

Problem

Electrochemical separation systems face challenges in achieving uniform fluid flow distribution across all planes of the cell stack, leading to inefficient treatment processes and potential scaling issues due to turbulent flow entering the system at high velocity, favoring the bottom plane over the center and top planes.

Innovation Solution

A flow distribution system comprising radially spaced baffles and ramps with grooves is integrated into the inlet and outlet manifolds to redirect and normalize fluid flow, ensuring uniform distribution across all planes by converting turbulent flow into transition or laminar flow, with the ramps on the bottom face redirecting fluid to the top and center planes and grooves allowing fluid to flow to the bottom plane.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If turbulent flow enters the electrochemical separation system at high velocity, then the fluid flow rate is high, but the flow distribution becomes non-uniform with the bottom plane receiving more flow than the center and top planes

Engineering Contradiction:

Improvefluid flow rateVSAvoidflow distribution uniformity

Core Design Contradiction:

SpeedVSManufacturing precision

Solution Approach 1:

The flow distribution system is positioned at the inlet of the cell stack to pre-condition the fluid flow before it enters the electrochemical separation channels. The system includes flow distribution members with varying heights that redirect the high-velocity turbulent flow into more uniform flow patterns across all planes (bottom, center, top) of the cell stack, ensuring even distribution from the outset

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flow distribution members have non-uniform heights specifically designed to address local flow distribution needs. The varying heights create different flow resistance and redirection effects at different locations, with taller members directing flow to planes that need more distribution, thereby achieving uniform flow across all planes despite the incoming turbulent flow

Inventive Principle:

Principle #3Local quality

2Device complexity

If the cell stack operates with non-uniform flow distribution, then the system structure is simple, but scaling occurs due to stagnant zones

Engineering Contradiction:

Improvesystem structureVSAvoidscaling

Core Design Contradiction:

Device complexityVSObject-affected harmful factors

Solution Approach 1:

The flow distribution system is installed at the inlet manifold to pre-condition the flow before it enters the cell stack channels. By redistributing the flow uniformly across all planes at the inlet, the system prevents stagnant zones from forming in the first place, thereby eliminating the condition that leads to scaling without requiring complex modifications to the cell stack structure

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system converts the potentially harmful effect of high-velocity turbulent flow into a beneficial uniform flow distribution. The flow distribution members utilize the incoming flow's energy and direction to redirect and spread the fluid evenly across all planes, transforming what would be a source of uneven distribution into a mechanism that promotes uniform flow and prevents scaling

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 less than 20% deviation in fluid velocity across various fluid passageways, minimizing stagnant zones and reducing the likelihood of scaling, thereby enhancing the efficiency and effectiveness of the electrochemical separation process.

Implementation Method 1

the ramps on the bottom face redirecting fluid to the top and center planes

Methodology Applied

Scientific EffectFluid flow redirection:

Implementation Method 2

grooves allowing fluid to flow to the bottom plane

Methodology Applied

Scientific EffectFluid flow through grooves:

Implementation Method 3

converting turbulent flow into transition or laminar flow

Methodology Applied

Scientific EffectTurbulent to laminar flow transition:

Data Source

PatentUS12138591B2Structures for normalizing multi-planar flow distribution within an electrochemical separation system

Publication Date: 2024.11.12 EVOQUA WATER TECHNOLOGIES LLC

AI summary

A module comprises a cell stack having a plurality of alternating ion depleting compartments and ion concentrating compartments, an inlet manifold configured to facilitate a flow of fluid into the cell stack, and a first flow distribution system, associated with the inlet manifold, including a first ramp to promote the circulation of the flow of fluid into the cell stack.