Superheated Steam Boiler Single Unit Design
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Solution Overview
Problem
Existing steam boilers require separate units for producing superheated steam, which increases complexity and costs, whereas a single unit capable of producing superheated steam is needed to provide all the benefits of steam boilers efficiently.
Innovation Solution
A superheated steam boiler design featuring an inner tank system with a first wet tank and a second dry tank separated by an isolation member, an outer sleeve, and a burner system including a combustion/expansion chamber, distribution chamber, heat tubes, and an exhaust tube, allowing for the production of superheated steam within a single unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a separate superheater device is used to produce superheated steam, then the steam can be heated to temperatures above its vaporization point, but the system complexity and costs increase
Solution Approach 1:
The patent combines the boiler and superheater functions into a single integrated unit. The combustion chamber serves dual purposes: generating steam in the wet tank and superheating it in the dry tank. This eliminates the need for separate superheater equipment while achieving the same temperature elevation above the vaporization point.
Solution Approach 2:
The combustion chamber is designed to perform multiple functions simultaneously: it acts as both a steam generator (heating water in the wet tank) and a superheater (heating steam in the dry tank). This multi-functionality reduces overall system complexity while maintaining the capability to produce superheated steam.
2Quantity of substance
If saturated steam is heated at constant pressure to increase vapor quality, then the temperature remains constant until 100% vapor quality is reached, but additional heat input is required to superheat the steam
Solution Approach 1:
The system changes the heating parameters by transitioning from constant pressure heating (in the wet tank) to constant volume/higher temperature heating (in the dry tank). This parameter change allows the steam to be superheated efficiently without requiring excessive additional heat input, as the combustion chamber maintains high temperatures that naturally superheat the steam.
Solution Approach 2:
The combustion chamber provides continuous heating action that first generates steam and then continues to superheat it without interruption. The hot combustion gases continuously transfer heat to both the wet tank and dry tank, ensuring that once steam is generated, it is immediately and continuously superheated, maximizing energy utilization.
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
The solution enables efficient production of superheated steam within a single unit, reducing complexity and costs while maintaining the benefits of steam boilers, as demonstrated by temperature control and efficiency improvements in test data.
Implementation Method 1
combusting a flammable material within the combustion/expansion chamber, the combustion of the flammable material causing hot gas to travel up the plurality of heat tubes
Implementation Method 2
hot gas to travel up the plurality of heat tubes into the distribution chamber
Implementation Method 3
hot gas to travel up the plurality of heat tubes into the distribution chamber and out the exhaust tube
Implementation Method 4
the hot gas causing the fluid within the first wet tank and outer sleeve to reach its boiling point, wherein superheated steam in the first wet tank and outer sleeve is formed
Implementation Method 5
superheated steam in the first wet tank and outer sleeve is formed that travels through the one or more dry tank steam openings into the second dry tank
Data Source
AI summary
A superheated steam boiler includes an inner tank system including a wet tank and a dry tank separated by an isolation member, an outer sleeve surrounding the inner tank system, wherein wet tank fluid openings allow the wet tank to be in communication with the outer sleeve, and dry tank steam openings in the dry tank allow the dry tank to be in communication with the outer sleeve, and a burner system within the inner tank system. The burner system includes a combustion/expansion chamber having spherical surfaces located in and fluidly isolated from the wet tank, a distribution chamber located in and fluidly isolated from the dry tank, heat tubes extending through the isolation member between the combustion/expansion chamber and the distribution chamber; and an exhaust tube extending from the distribution chamber and out of the inner tank system to exit the boiler.