Helical Flow Modifier for Pipeline Erosion and Head Loss
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Solution Overview
Problem
Conventional flow of abrasive and particulate-filled materials through pipelines leads to surface erosion, head losses, fluid cavitation, heating, particulate deposition, and composition changes due to laminar flow profiles, which result in increased energy consumption and costly maintenance.
Innovation Solution
A material flow modifier that transforms laminar flow to a rotational or cyclonic flow profile by using an interior tubular body with expanding cross-sectional area and surrounding helical passages, centralizing flow and reducing friction, thereby maintaining particulates in suspension and enhancing flow efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If laminar flow profile is used in conventional pipelines, then flow stability is maintained, but surface erosion and head losses increase due to friction at the pipe wall
Solution Approach 1:
The patent changes the flow profile parameter from laminar to rotational/cyclonic by introducing a flow modifier device with helical vanes. This transforms the velocity distribution and flow characteristics, reducing wall friction and head losses while maintaining flow stability through controlled rotational motion
Solution Approach 2:
The patent replaces the conventional laminar flow mechanical system with a rotational flow system induced by helical vanes. This substitution changes the flow mechanism from boundary-layer-dominated laminar flow to vortex-driven rotational flow, reducing energy losses
2Stability of the object's composition
If laminar flow profile is used, then flow uniformity is maintained, but particulate deposition and aggregation occur due to reduced velocity near the pipe bottom
Solution Approach 1:
The patent changes the velocity distribution parameter by introducing rotational flow. The helical vanes create a velocity profile that prevents stagnant zones near the pipe bottom, maintaining particulate suspension through continuous rotational motion and preventing deposition
Solution Approach 2:
The rotational flow induced by helical vanes creates dynamic motion similar to vibration effects, continuously disturbing the flow near the pipe bottom and preventing particulate settling and aggregation, thereby maintaining flow uniformity
3Ease of operation
If conventional flow through elbow fittings is used, then direction change is achieved, but uneven erosion occurs on the outside wall due to centrifugal force and flow separation
Solution Approach 1:
The patent changes the flow parameter distribution in elbow fittings by introducing rotational flow before the bend. This pre-induced rotation balances the centrifugal forces during direction change, distributing wear more uniformly across the elbow fitting surface
Solution Approach 2:
The flow modifier device performs preliminary action by inducing rotational flow upstream of the elbow fitting. This pre-conditioning of the flow reduces the adverse effects of sudden direction change, minimizing flow separation and uneven erosion on the outside wall
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 rotational flow profile increases flow rate, reduces wear and energy consumption, maintains particulates in suspension, and minimizes deposition, leading to more uniform pipe wear and reduced operational costs.
Implementation Method 1
The plurality of helical passage bodies each surround and extend along a length of the interior tubular body. Each of the helical passage bodies defines a helical passage therein extending along a length thereof.
Implementation Method 2
The central passage of the interior tubular body expands along a length thereof from a smallest cross-sectional area at or near (i.e., adjacent) an inlet of the interior tubular body to a largest cross-sectional area at or near an outlet of the interior tubular body.
Data Source
AI summary
Material flow modifiers as disclosed herein overcome drawbacks associated with known adverse flow conditions (e.g., surface erosion, head losses, particulate drop-out, and the like) that arise from flow of certain types of materials (e.g., fluids, slurries, particulates, flowable aggregate, and the like) through a material flow conduit. Such material flow modifiers provide for flow of flowable material within a flow passage of a material flow conduit (e.g., a portion of a pipeline, tubing or the like) to have a rotational flow profile. Advantageously, the rotational flow profile centralizes flow toward the central portion of the flow passage, thereby reducing magnitude of laminar flow to overcome the aforementioned adverse flow conditions.