Orifice Plate for Uniform Solids Flow Distribution
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Solution Overview
Problem
In moving bed heat exchangers, uneven distribution of hot solids and ashes leads to inefficiencies and potential component failure due to large temperature differences, resulting from poor heat transfer performance and mal-distribution of solids flow.
Innovation Solution
An orifice plate with multiple plates having orifices is introduced downstream of the tube bundle and upstream of the solids flow control system, regulating the flow of solids to ensure uniform distribution and guiding additional solids into orifices or hoppers, thereby controlling the flow and reducing temperature variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional solids flow control systems are used without orifice plates, then the structure is simpler, but solids flow distribution is uneven leading to temperature imbalances and inefficiencies
Solution Approach 1:
The orifice plate divides the solids flow into multiple discrete streams through multiple orifices, distributing solids uniformly across the heat exchanger. This segmentation of flow paths ensures even temperature distribution and prevents localized overheating or inefficiency.
Solution Approach 2:
The orifice plate serves as an intermediary device between the solids source and the heat exchanger, controlling and regulating solids flow before it enters the heat exchanger. This intermediate control mechanism ensures uniform distribution without requiring complex downstream control systems.
2Ease of operation
If multiple ash control valves are used to control solids flow, then flow control capability is improved, but device complexity and number of moving parts increase
Solution Approach 1:
The invention extracts the flow control function from multiple complex ash control valves and concentrates it into a single orifice plate structure. This eliminates the need for multiple moving parts while maintaining effective solids flow control capability.
Solution Approach 2:
The orifice plate provides passive flow control through its geometric structure alone, without requiring active control mechanisms or multiple valves. The solids flow self-regulates through the fixed orifice geometry, reducing operational complexity.
3Productivity
If the moving bed heat exchanger height is increased to improve solids flow distribution, then heat transfer performance improves, but equipment size and investment cost increase
Solution Approach 1:
The orifice plate performs preliminary flow distribution before solids enter the heat exchanger, ensuring uniform distribution from the start. This pre-conditioning of solids flow eliminates the need for excessive heat exchanger height to achieve adequate mixing and distribution.
Solution Approach 2:
Instead of solving flow distribution problems by increasing vertical height, the orifice plate addresses distribution uniformity through horizontal segmentation via multiple orifices arranged in a pattern, achieving good heat transfer performance without excessive height.
Data Source
AI summary
Disclosed herein is an orifice plate comprising one or more plates having orifices disposed therein; the orifices being operative to permit the flow of solids from a moving bed heat exchanger to a solids flow control system; where the orifice plate is downstream of a tube bundle of the moving bed heat exchanger and upstream of the solids flow control system and wherein the orifice plate is operative to evenly distribute the flow of solids in the solids flow control system.