Helical Fin Flow Control Device for Foam Reduction
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Solution Overview
Problem
Existing flow control devices and separators fail to effectively manage fluid flow conditions, leading to unwanted foam and emulsion formation, inefficiencies, and reduced performance due to inadequate design based on empirical rules that do not account for changing fluid compositions and upstream conditions.
Innovation Solution
A flow control device with a cylindrical body and internal helical fins that convert linear fluid flow into rotational flow, creating a vortex chamber to separate gas and liquids, featuring a pivotable ball element and a collar with outer and inner helical fins to control fluid communication and promote vorticity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional flow control valves are used to control fluid flow, then flow speed can be controlled, but excessive speed and turbulence cause unwanted foam and emulsion formation
Solution Approach 1:
The patent employs a ball element with a spherical geometry that rotates within the valve body. The curved surface of the ball and the helical flow passages create smooth, curved flow paths that guide the fluid gently through the valve, avoiding sharp edges and abrupt directional changes that would generate turbulence and foam.
Solution Approach 2:
The valve utilizes a dynamic rotating ball element that can pivot between open and closed positions to control flow. The rotation of the ball element creates dynamic flow patterns through the helical passages, allowing the system to adapt to varying flow conditions while maintaining laminar flow characteristics that prevent foam formation.
2Ease of manufacture
If separators are designed based on predefined empirical rules, then initial design can be simplified, but they fail to adapt to changing fluid compositions and inlet conditions over time
Solution Approach 1:
The flow control device allows dynamic adjustment of flow parameters (speed, direction, distribution) by rotating the ball element to different positions. This enables the separator to adapt to changing inlet conditions by modifying the flow characteristics before the fluid enters the separation chamber, maintaining optimal separation performance despite variations in fluid composition.
Solution Approach 2:
The valve design serves multiple functions: it controls overall flow rate, directs flow distribution to different outlets, and conditions the flow to prevent foam formation. This multi-functionality allows a single device to handle various fluid conditions and separation requirements without requiring multiple specialized components.
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 device effectively separates gas and liquids by controlling fluid flow, reducing foam and emulsion formation, enhancing separation efficiency, and adapting to changing fluid conditions.
Implementation Method 1
A flow control device with a cylindrical body and internal helical fins that convert linear fluid flow into rotational flow, using a ball element and vortex chamber to separate fluids, promoting vorticity
Implementation Method 2
using a ball element and vortex chamber to separate fluids, promoting vorticity and reducing shear forces
Data Source
Figure 1
Figure 2
Figure 2A
AI summary
A flow control device includes a cylindrical body disposed about a primary axis. The cylindrical body includes a primary flow passage extending therethrough. A ball element having an inlet flow passage extending therethrough is pivotable relative to the cylindrical body between an open position and a closed position. In the open position, the inlet flow passage is in fluid communication with the primary flow passage, and in the closed position, the inlet flow passage is not in fluid communication with the primary flow passage. The flow control device further comprises an internal flow control body having a collar positioned within the cylindrical body about the primary axis. A plurality of outer helical fins extend outwardly from the collar and define a plurality of outer helical passageways, and a plurality of inner helical fins are positioned inwardly from the collar and define a plurality of inner helical passageways.