Injection Cooler Rotary Control and Laval Mixing
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Solution Overview
Problem
Existing injection coolers for superheated steam in power plants face issues such as limited service life due to high stress on seals and guide elements, complex maintenance, uneven coolant distribution, and inadequate atomization of cooling water, leading to inefficient cooling and high operating costs.
Innovation Solution
The design features a control element outside the steam line with separate coolant supply lines for each injection nozzle, a Laval nozzle-like mixing section for even distribution and fine atomization, and a rotary control mechanism to reduce stress on moving parts, allowing for efficient and uniform cooling of superheated steam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lifting control system is used to regulate cooling water flow, then the injection nozzles can be controlled, but the seals and guide elements are subjected to very high stress due to high line pressure, limiting service life
Solution Approach 1:
The patent replaces the lifting control system with a rotary control system. Instead of moving parts vertically against high steam pressure, the control spindle rotates to open and close control bores. This substitution reduces the mechanical stress on seals and guide elements from linear pressing to rotational movement, thereby extending service life while maintaining control functionality.
Solution Approach 2:
The control system transitions from static linear positioning to dynamic rotary movement. The control spindle rotates to vary the opening cross-section of control bores, enabling continuous regulation of cooling water flow. This dynamic approach allows precise control while reducing peak stresses compared to fixed lifting mechanisms.
2Reliability
If a lifting control system is used, then the injection nozzles can be controlled, but the nozzles can only be switched on in a fixed order from top to bottom or bottom to top, resulting in unfavorable water distribution
Solution Approach 1:
The patent employs asymmetric control bore arrangements on the control spindle, allowing different nozzles to be activated in optimized sequences. The control bores are positioned and sized asymmetrically to enable simultaneous or staggered activation of multiple nozzles, achieving uniform water distribution throughout the steam stream rather than sequential top-to-bottom or bottom-to-top activation.
Solution Approach 2:
The rotary control system enables dynamic activation of nozzles in optimized sequences. As the control spindle rotates, different control bores are exposed to the cooling water supply at different angles and positions, allowing flexible control of which nozzles receive water and when, thereby achieving uniform distribution across the steam stream.
3Reliability
If all moving parts are located in the injection cylinder within the pipeline, then the cooling function is effective, but the wear on the injection cooler is very high under extreme conditions, requiring complex maintenance
Solution Approach 1:
The patent segments the injection cooler into distinct functional modules: the injection cylinder with nozzles remains within the pipeline for effective cooling, while the control element with moving parts is positioned externally. The control bores and control spindle are accessible from outside the pipeline, allowing maintenance and replacement without disrupting the high-pressure steam environment, thereby reducing maintenance complexity.
Solution Approach 2:
The control element is extracted from the high-stress injection cylinder environment and positioned externally. The control spindle and control bores are located in an accessible external position, separated from the extreme thermal and pressure conditions inside the pipeline. This extraction protects moving parts from extreme wear while maintaining their control function through external actuation.
4Productivity
If standard injection nozzles are used, then the structure is simple, but the coolant is not atomized sufficiently finely, leading to inefficient cooling
Solution Approach 1:
The patent employs specially designed injection nozzles with curved or angled geometries to optimize atomization. The nozzles may feature spiral patterns, angled outlets, or curved flow paths that create rotational motion and finer droplet distribution of cooling water. These curved geometries enhance the atomization effect compared to simple straight nozzles, improving cooling efficiency through better steam-water mixing.
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 design extends the service life of injection coolers, simplifies maintenance, ensures uniform coolant distribution, and achieves efficient cooling by finely atomizing the coolant, reducing operating costs and improving temperature control within the pipeline.
Implementation Method 1
The injection device has a tubular mixing section (25) which can be connected to the pipeline (20), wherein the mixing section (25) has a Laval nozzle-like longitudinal section (251) along a longitudinal axis (L)
Implementation Method 2
The injected water is atomized due to the differential pressure between the water and the steam in the pipeline
Implementation Method 3
The injected water is atomized due to the differential pressure between the water and the steam in the pipeline. It evaporates and superheats while the vapor itself cools.
Implementation Method 4
The injected water is atomized due to the differential pressure between the water and the steam in the pipeline. It evaporates and superheats while the vapor itself cools.
Data Source
AI summary
The invention relates to an injection cooler (10) for cooling hot steam conducted in a pipeline (20), comprising an injecting device (30) which can be connected to the pipeline (20) and which has multiple injection nozzles (32); comprising a regulating body (50), a connection (52) of which can be connected to a coolant supply, said regulating body (50) being equipped with a valve arrangement (60) with which the coolant feed to the injection nozzles (32) of the injecting device (30) can be regulated; and comprising coolant feed lines (70) which are provided between the injecting device (30) and the regulating body (50), a separate coolant feed line (70) being provided for each injection nozzle (32). According to the invention, the ends (71), of the coolant feed lines (70), associated with the injecting device (30) are secured to a common first flange plate (73) which can be secured to a receiving surface (36) on the injecting device (30). The ends (72), of the coolant feed lines (70), associated with the regulating body (50) are secured to a common second flange plate (74) which can be secured to a receiving surface (56) of the regulating body (50). The injecting device (30) has a tubular mixing portion (25) which can be connected to the pipeline (20), said mixing portion (25) having a de Laval nozzle-type longitudinal section along a longitudinal axis (L).