Low-Shear Control Valve With Variable Vortex Chamber
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional flow control devices and separators face inefficiencies due to fixed designs that do not adapt to varying fluid flow speeds and compositions, leading to premature failure, foam, and emulsion formation, which can result in reduced performance and the need for frequent upgrades.
Innovation Solution
A flow control device with a variable vortex chamber, featuring a stack of annular discs and a moveable plug that creates a rotational fluid flow, allowing for adjustable flow control and minimizing shear levels, capable of adapting to different operating conditions by varying the number and configuration of fluid passageways and the size of the vortex chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional flow control valves are used to control flow speed, then flow velocity can be reduced, but high shear levels are generated causing erosion, vibrations, and premature failure
Solution Approach 1:
The patent employs a dynamic vortex chamber whose volume can be adjusted to match varying flow rates. By dynamically adapting the chamber volume to the actual flow conditions, the system maintains optimal vortex formation across different operating ranges, preventing high shear levels and erosion while still controlling flow velocity effectively
Solution Approach 2:
The system changes the physical parameter of vortex chamber volume to adapt to different flow rates. This parameter change allows the vortex chamber to maintain effective vortex formation and low shear conditions across a wide range of operating conditions, resolving the contradiction between flow control and shear generation
2Productivity
If cyclonic inlet is installed to improve separator performance, then separation efficiency increases under high flow rates, but fluid is destroyed by high shear levels at low speeds
Solution Approach 1:
The vortex chamber volume is made dynamically adjustable to match the actual flow rate entering the separator. At low flow rates, the reduced chamber volume prevents excessive vortex intensity and shear levels that would destroy the fluid. At high flow rates, the full chamber volume enables effective vortex formation for improved separation, thus resolving the contradiction between separation efficiency and fluid integrity
Solution Approach 2:
The system adjusts the vortex chamber volume parameter according to flow rate conditions. This parameter adaptation allows the cyclonic inlet to operate effectively across different flow rates without generating destructive shear levels, maintaining both separator efficiency and fluid quality
3Ease of manufacture
If fixed design separators are used, then initial setup is simple, but they cannot adapt to varying fluid compositions and flow regimes over time
Solution Approach 1:
The vortex chamber is designed with adjustable volume capability, transforming the fixed separator into a dynamic system. This allows the separator to adapt to varying fluid compositions and flow regimes over time while maintaining relatively simple construction, resolving the contradiction between manufacturing simplicity and operational adaptability
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 provides low shear control, effectively handling and separating foam and emulsions, maintaining performance across a range of flow conditions, reducing the need for frequent upgrades and improving separator efficiency by adapting to dynamic fluid compositions and flow regimes.
Implementation Method 1
The fluid passageways in the stack of annular discs and the tapered section of the plug collectively impart a rotational fluid flow around the central axis
Implementation Method 2
The inner perimeters of the stack of annular discs and the tapered section of the plug collectively define an annular vortex chamber
Data Source
AI summary
A flow control device includes a stack of annular discs positioned in a flow path. Each disc includes fluid passageways extending between inner and outer perimeters of the disc, with each passageway defining a flow axis extending out of the disc and radially offset from a central axis of the discs. A plug is moveable relative to the discs between closed and open positions. In the closed position, a cylindrical section of the plug is positioned to block fluid flow through the annular discs. In the open position, the annular discs and a tapered section of the plug collectively define an annular vortex chamber. The fluid passageways in the annular discs and the tapered section of the plug collectively impart a rotational flow when the plug is in the open position and as fluid exits the annular discs.