Stacked Perforated Plates for Liquid Distribution in Urea Decomposers
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Solution Overview
Problem
Current urea production processes face challenges in evenly distributing liquid streams to multiple pipes within carbamate decomposers and concentrators, leading to uneven heat transfer and reduced efficiency due to non-homogeneous flow profiles, which affects the decomposition and concentration of urea solutions.
Innovation Solution
A vertical distribution chamber with a series of stacked perforated plates, including a conical, ring-shaped, and disk-like design, ensures even distribution of the liquid stream across the entire cross-section of the chamber, aligning the flow with each pipe opening to achieve symmetrical and homogeneous flow velocities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a simple inlet structure is used to feed liquid stream into the decomposer, then the device complexity is reduced, but the flow distribution uniformity deteriorates leading to uneven heat transfer
Solution Approach 1:
The distribution chamber is segmented into multiple functional zones using stacked perforated plates (first, second, and third plates) with varying hole distributions. This segmentation creates distinct flow control regions that progressively distribute the liquid stream from the central inlet to the peripheral pipe openings, achieving uniform flow distribution without complex mechanical components.
Solution Approach 2:
The invention transitions from a simple single-plate distribution approach to a multi-plate three-dimensional arrangement. The stacked plates create vertical flow layers that transform the liquid stream from a concentrated inlet flow into a distributed radial flow pattern across multiple horizontal planes, improving distribution uniformity while maintaining a relatively simple overall structure.
2Device complexity
If the inlet diameter is much smaller than the decomposer diameter to concentrate the liquid stream, then the piping complexity is reduced, but the flow distribution homogeneity deteriorates
Solution Approach 1:
Each perforated plate is designed with locally optimized hole distributions tailored to specific radial zones. The first plate has holes concentrated near the central inlet, the second plate has holes in an intermediate ring pattern, and the third plate has holes aligned with peripheral pipe openings. This local quality variation ensures that each region receives appropriate flow quantities, achieving homogeneous distribution from the compact central inlet.
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 enhances heat transfer efficiency by ensuring uniform flow distribution, increasing the decomposition of ammonium carbamate and reducing water content in urea solutions, thereby improving the overall efficiency of the urea production process.
Implementation Method 1
A vertical distribution chamber with a series of stacked perforated plates, including a conical, ring-shaped, and disk-like design, ensures even distribution of the liquid stream across the entire cross-section of the chamber, aligning the flow with each pipe opening to achieve symmetrical and homogeneous flow velocities.
Implementation Method 2
Each pipe is heated up with steam (or another heating medium, such as steam condensate or process vapors) so that the ammonium carbamate decomposes back to carbon dioxide and ammonia.
Implementation Method 3
the stream is directed into a decomposer, where the stream is divided into a plurality of streams that each enter a pipe in the main chamber of the decomposer. Each pipe is heated up with steam (or another heating medium, such as steam condensate or process vapors) so that the ammonium carbamate decomposes back to carbon dioxide and ammonia.
Data Source
AI summary
A distribution chamber suitable for distributing a liquid stream to a plurality of pipe openings distributed over a planar surface. The distribution chamber includes three perforated plates. A method to distribute a liquid stream to a plurality of pipe openings, a method to decompose ammonium carbamate from an aqueous solution comprising ammonium carbamate and a method to produce a concentrated aqueous urea solution from a diluted aqueous urea solution.