Steam Reformer Manifold Saddle Support for Thermal Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing support systems for outlet manifolds in steam reformer furnaces are inadequate in managing thermal expansion, leading to twisting, rupture, or breakage of components due to excessive stress from thermal growth, which results in failures at multiple locations.
Innovation Solution
An independent support system for the outlet manifold is introduced, where the manifold is supported by a separate saddle support allowing it to move independently within the header box, decoupling its thermal expansion from the header box, and enabling vertical, lateral, and longitudinal movement to reduce stress on the manifold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the manifold is rigidly supported within the header box, then structural stability is improved, but thermal expansion stress causes twisting, rupture, or breakage of components
Solution Approach 1:
The patent applies the dynamics principle by making the manifold support system movable rather than fixed. The manifold is supported on movable supports that allow it to move independently within the header box, enabling the system to adapt to thermal expansion dynamically. This resolves the contradiction by allowing structural stability through support while accommodating thermal movement to prevent component failure.
Solution Approach 2:
The patent applies segmentation by separating the manifold support function from the header box structure. The manifold is supported on independent movable supports rather than being rigidly attached to the header box, creating distinct functional segments. This allows the manifold to move independently to accommodate thermal expansion while the header box maintains its structural integrity.
2Manufacturing precision
If the manifold is fixed in position, then manufacturing and installation precision is improved, but thermal growth forces cause excessive stress and component failure
Solution Approach 1:
The support system transitions from a static fixed position to a dynamic movable position. The manifold is initially positioned with precision during installation, but the movable supports allow it to shift position in response to thermal expansion, preventing excessive stress buildup while maintaining initial installation precision.
Solution Approach 2:
The patent applies parameter changes by allowing the manifold's positional parameters to change in response to thermal conditions. The movable supports enable the manifold to adjust its position (change in spatial parameters) to accommodate thermal growth, preventing stress-related failures while maintaining proper initial positioning.
3Reliability
If the header box is allowed to expand thermally, then thermal stress on the manifold is reduced, but the manifold configuration may change substantially
Solution Approach 1:
The patent applies dynamics by enabling controlled movement of the manifold on movable supports. This allows the manifold to adjust its position dynamically in response to header box thermal expansion, accommodating shape changes while preventing excessive stress. The movable supports provide the necessary degrees of freedom to maintain proper configuration during thermal cycles.
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 solution allows for the thermal expansion of the header box and transfer lines without overstressing the manifold, preventing failures and ensuring safe and reliable operation by accommodating thermal growth without forcing substantial changes in the manifold's configuration.
Implementation Method 1
The thermal expansion of the firebox and/or header box that occurs during operation of a reformer is decoupled from the manifold. The manifold is supported independently on a separate saddle support that supports and allows the manifold to move, while the manifold is still substantially enclosed in the header box.
Data Source
AI summary
The disclosure provides an independent support of outlet system in a steam reformer furnace. The thermal expansion of the firebox and/or header box that occurs during operation of a reformer is decoupled from the manifold. The manifold is supported independently on a separate saddle support that supports and allows the manifold to move, while the manifold is still substantially enclosed in the header box. The header box is allowed to expand thermally into different configurations without forcing a substantial change in the manifold configuration. Further, the present invention allows the transfer lines coupled to the manifold through connection tees to laterally move the manifold and reduce lateral stress on the manifold. Thus, the invention provides for independent support of the manifold that allows vertical, lateral, and longitudinal thermal expansion of associated components without overstressing the manifold and causing failures.