Steam Generator Evaporation Surface Self-Cleaning via Thermal Shock
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Solution Overview
Problem
Steam generating devices face performance and reliability issues due to scale accumulation on evaporation surfaces, which insulates heating elements, blocks passageways, and contaminates steam, requiring effort and expense for partial solutions like cleaning agents or physical removal.
Innovation Solution
An apparatus with a water inlet and evaporation surface where water is fed at a temperature lower than the heated surface, inducing thermal shock to dislodge scale before it reaches a maximum thickness, using a controller to manage water flow and a scale collection region to separate dislodged scale from the evaporation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If water is evaporated on the evaporation surface to produce steam, then steam generation function is achieved, but scale accumulates on the evaporation surface causing performance degradation
Solution Approach 1:
The system performs preliminary action by detecting scale thickness continuously and initiating water feeding at the optimal moment when scale reaches a predetermined thickness threshold. This prevents scale from accumulating to harmful levels while minimizing disruption to steam generation. The controller monitors scale thickness and triggers water feeding proactively before scale becomes problematic.
Solution Approach 2:
The invention converts the harmful effect of scale accumulation into a beneficial self-cleaning mechanism. By feeding water onto the evaporation surface, the system utilizes the thermal contrast between cool water and hot surface to generate thermal shock that dislodges scale. The water serves dual purposes: it cools the surface to remove scale through thermal expansion/contraction, and subsequently evaporates to replenish water levels for steam generation.
2Object-generated harmful factors
If cleaning agents or physical scraping is used to remove scale, then scale removal is achieved, but device complexity and maintenance effort increase
Solution Approach 1:
The system performs self-service by automatically detecting scale accumulation and initiating its own cleaning process. The controller monitors scale thickness and automatically feeds water onto the evaporation surface when needed, eliminating the need for external cleaning agents or manual intervention. The evaporation surface essentially cleans itself through controlled water feeding that creates thermal shock to dislodge scale.
Solution Approach 2:
The invention replaces mechanical cleaning methods (scraping, brushing) with a thermal-based cleaning mechanism. Instead of using mechanical force to remove scale, the system uses thermal shock from feeding cool water onto the hot evaporation surface. This substitutes mechanical cleaning action with thermal expansion and contraction that naturally dislodges scale without requiring mechanical cleaning components.
3Productivity
If water temperature is increased to improve evaporation efficiency, then steam generation speed increases, but scale formation accelerates
Solution Approach 1:
The system implements periodic action by alternating between normal evaporation operation and water feeding cycles. During most of the time, the evaporation surface operates at high temperature for efficient steam generation. Periodically, when scale reaches the predetermined thickness, water is fed onto the surface to cool it and remove scale. This periodic intervention maintains high productivity while preventing excessive scale accumulation.
Solution Approach 2:
The invention utilizes parameter changes by dynamically adjusting the temperature of the evaporation surface. During normal operation, the surface maintains high temperature for efficient evaporation. When water is fed for cleaning, the surface temperature temporarily decreases due to the cooling effect of the water, which also causes thermal shock to dislodge scale. The controller manages these temperature parameter changes to balance steam generation efficiency with scale prevention.
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
Effectively prevents scale accumulation, maintains heating performance, reduces contamination of steam, and extends the lifespan of steam generating devices by continuously removing scale through thermal shock and separate collection.
Implementation Method 1
a heater disposed adjacent to the evaporation surface to heat said evaporation surface to a predetermined temperature such that water fed onto the evaporation surface via the water inlet forms a film on the evaporation surface and is evaporated
Implementation Method 2
the temperature of the water fed onto the evaporation surface is lower than the predetermined temperature, so that scale on the or each region of said evaporation surface to which water is fed cools at a different rate at which water on a remainder of the evaporation surface cools, thereby causing scale on said evaporation surface to break apart and be dislodged
Data Source
AI summary
The present application relates to apparatus for generating steam. It comprises a water inlet, a evaporation surface, and a heater disposed adjacent to the evaporation surface to heat the evaporation surface to a predetermined temperature such that water fed onto the evaporation surface via the water inlet forms a film on the evaporation surface and is evaporated. The apparatus is configured so that water is fed to one or more regions of the evaporation surface, and the temperature of the water fed onto the evaporation surface is lower than the predetermined temperature, so that scale on the or each region of the evaporation surface to which water is fed cools at a different rate at which water on a remainder of the evaporation surface cools. This causes scale on the evaporation surface to break apart and be dislodged from the evaporation surface.