Transfer Line Exchanger Cross-Section for Lower Pressure Drop
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Solution Overview
Problem
Current transfer lines in olefin crackers suffer from high pressure drop, erosion, fouling, and cost inefficiencies due to their circular cross-section design, which does not effectively minimize these issues.
Innovation Solution
A transfer line with a smoothly varying cross-section and aspect ratio (ARQ) from 1.02 to 1.5, optimized through computational modeling and deformation to reduce pressure drop and erosion rate, featuring a non-circular shape with a radius of curvature between 1 to 5 internal pipe diameters and a composition of 20-50% chromium, 25-50% Ni, and trace metals, to improve operational efficiency and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If circular cross-section transfer lines are used, then manufacturing cost is minimized, but pressure drop and erosion rate increase
Solution Approach 1:
The patent applies asymmetry by transitioning from a circular cross-section to an oval cross-section with an aspect ratio between 1.02 and 1.5. This asymmetric shape optimizes the flow characteristics by reducing turbulence and improving flow distribution, thereby decreasing pressure drop and erosion rate while maintaining manufacturability through controlled deformation of the circular geometry.
Solution Approach 2:
The patent implements parameter changes by modifying the cross-sectional geometry parameters of the transfer line. Specifically, the aspect ratio of the oval cross-section is adjusted to fall within the range of 1.02 to 1.5, and the radius of curvature is optimized to be between 1 to 5 times the internal pipe diameter. These parameter changes achieve optimal balance between pressure drop, erosion rate, and manufacturing cost.
2Ease of manufacture
If circular cross-section transfer lines are used, then manufacturing simplicity is maintained, but erosion rate and operational lifespan deteriorate
Solution Approach 1:
The patent applies asymmetry by transitioning from a circular cross-section to an oval cross-section with an aspect ratio between 1.02 and 1.5. This asymmetric shape optimizes the flow characteristics by reducing turbulence and improving flow distribution, thereby decreasing pressure drop and erosion rate while maintaining manufacturability through controlled deformation of the circular geometry.
Solution Approach 2:
The patent implements parameter changes by modifying the cross-sectional geometry parameters of the transfer line. Specifically, the aspect ratio of the oval cross-section is adjusted to fall within the range of 1.02 to 1.5, and the radius of curvature is optimized to be between 1 to 5 times the internal pipe diameter. These parameter changes achieve optimal balance between pressure drop, erosion rate, and manufacturing cost.
3Ease of manufacture
If standard circular pipe design is used, then cost-effectiveness is maintained, but process efficiency and productivity decrease
Solution Approach 1:
The patent applies asymmetry by transitioning from a circular cross-section to an oval cross-section with an aspect ratio between 1.02 and 1.5. This asymmetric shape optimizes the flow characteristics by reducing turbulence and improving flow distribution, thereby decreasing pressure drop and erosion rate while maintaining manufacturability through controlled deformation of the circular geometry.
Solution Approach 2:
The patent implements parameter changes by modifying the cross-sectional geometry parameters of the transfer line. Specifically, the aspect ratio of the oval cross-section is adjusted to fall within the range of 1.02 to 1.5, and the radius of curvature is optimized to be between 1 to 5 times the internal pipe diameter. These parameter changes achieve optimal balance between pressure drop, erosion rate, and manufacturing cost.
Data Source
AI summary
The present invention provides a transfer line exchanger which is optimized for one or more objective functions of interest such as pressure drop, erosion rate, fouling, coke deposition and operating costs. The transfer line exchanger is designed by computer modeling a transfer line exchanger in which the cross section of flow path is substantially circular and modeling the operation of the transfer line under industrial conditions to validate the model design and its operation. Then iteratively the model design is deformed and the operation of the deformed part is modeled and compared to values obtained with other deformed models until the value of the objective function is optimized (e.g. at an extreme) or the change in the objective function is approaching zero.