Polyurethane Liquid Distributor for Rotary Atomizer Wear Resistance
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Solution Overview
Problem
Conventional liquid distributors for spray dryers in emission control plants are expensive, heavy, and prone to wear due to their use of Hastelloy®, offering a limited lifespan of 5-7 years, while alternatives like PTFE lack abrasion resistance and sealing properties.
Innovation Solution
A rotary atomizer with a liquid distributor made from polyurethane or elastomer materials, designed with volute parts and a mechanical connection, providing resistance to abrasive and corrosive environments, and ensuring ease of assembly and reduced costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Hastelloy® material is used for liquid distributor, then durability and resistance to corrosive/abrasive environment is improved, but cost and weight increase
Solution Approach 1:
The patent changes the material parameter from traditional Hastelloy® metal to polyurethane elastomer, maintaining the required durability and corrosion resistance while significantly reducing weight and cost. The polyurethane material is specifically selected to withstand the abrasive and corrosive environment of emission control plants.
Solution Approach 2:
The patent uses composite construction with polyurethane volute parts combined with a metal separator disc, creating a hybrid material solution that leverages the advantages of both materials - the corrosion and abrasion resistance of polyurethane combined with the structural integrity of metal where needed.
2Reliability
If Hastelloy® material is used for liquid distributor, then resistance to corrosive and abrasive environment is improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the material parameter from expensive Hastelloy® alloy to cost-effective polyurethane elastomer, achieving comparable or superior resistance to corrosive and abrasive environments while significantly reducing manufacturing cost.
Solution Approach 2:
The patent adopts a more economical material (polyurethane) that, while potentially having a shorter lifespan than Hastelloy®, provides sufficient durability for the application at a fraction of the cost, making it an economically viable solution for emission control plants.
3Ease of manufacture
If PTFE material is used for liquid distributor, then cost is reduced, but abrasion resistance and sealing properties deteriorate
Solution Approach 1:
The patent changes the material parameter from PTFE to polyurethane elastomer, which offers superior abrasion resistance and sealing properties compared to PTFE while maintaining cost-effectiveness. The polyurethane material's elastic properties enable better sealing and wear resistance.
Solution Approach 2:
The patent uses polyurethane elastomer as a composite material solution that combines the benefits of low cost with high abrasion resistance and sealing capability, overcoming the limitations of PTFE in this application.
4Ease of manufacture
If PTFE material is used for liquid distributor, then manufacturing cost is reduced, but sealing properties deteriorate
Solution Approach 1:
The patent changes the material parameter from PTFE to polyurethane elastomer, which possesses superior sealing properties due to its elastic nature. The material can deform to accommodate surface irregularities and maintain effective seals, unlike rigid PTFE.
Data Source
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AI summary
The present invention relates to a liquid distributor of a rotary atomizer used in a spray drying apparatus. The liquid distributor comprises a volute part for fluid communication between an inlet and a rotary atomizer of the spray drying apparatus, wherein the volute part is made from a polyurethane or elastomer. The invention furthermore relates to a spray drying apparatus comprising a rotary atomizer including such a liquid distributor.