Sintered Tungsten Steam Injector with Rotational Mixing
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Solution Overview
Problem
Existing steam injection systems face issues with wear and tear, particularly in handling effluent streams from mining operations, leading to erosion and high maintenance costs, and require shutdowns for servicing, while also being prone to the 'hammering effect' at high pressures and variable outlet temperatures.
Innovation Solution
A modular steam injection system with a sintered tungsten biscuit element and conically-shaped features within a cylindrically-shaped primary conduit, equipped with removable mixing elements and a secondary conduit for efficient steam introduction and mixing, which induces rotational angular velocity to the fluid stream, enhancing durability and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If static mixing elements are used for steam injection, then installation and servicing cost are reduced, but wear and erosion resistance is insufficient
Solution Approach 1:
The mixing element is constructed from a composite material consisting of a metal matrix (such as stainless steel or Inconel) reinforced with ceramic particles (such as alumina or silica). This composite structure provides both the mechanical strength and erosion resistance needed for high-pressure steam injection, while maintaining the static, easy-to-service design advantage.
Solution Approach 2:
The mixing element design incorporates changes in geometric parameters including angled surfaces, curved flow paths, and optimized opening configurations. These parameter modifications enhance the mixing effectiveness and reduce direct impingement erosion while maintaining the static structure's ease of installation and servicing.
2Device complexity
If static mixing elements are used for steam injection, then moving parts are eliminated, but component accessibility for servicing is difficult
Solution Approach 1:
The steam injection system is segmented into modular components, with the mixing element designed as a separate, removable unit that can be independently accessed and serviced. The mixing element can be removed from the steam injection device through a service port or by disassembling external connections, eliminating the need to shut down entire processing lines or disconnect pipelines for servicing.
3Power
If steam is injected at high pressure, then heating efficiency is improved, but water hammer effect occurs
Solution Approach 1:
The mixing element incorporates features that induce controlled vibration or oscillation of the steam flow as it mixes with the liquid. This vibrational action prevents the formation of large steam bubbles that collapse to cause water hammer, while maintaining the high-pressure steam injection for efficient heating.
Solution Approach 2:
The mixing element acts as an intermediary device between the high-pressure steam source and the liquid stream. It provides a controlled interface where steam is gradually mixed and condensed within the liquid, preventing sudden bubble collapse and water hammer while maintaining the energy transfer efficiency of high-pressure steam injection.
4Loss of energy
If direct steam injection is used, then heat transfer efficiency is improved, but temperature control precision is reduced
Solution Approach 1:
The steam injection system incorporates temperature sensing and feedback control mechanisms that monitor the outlet temperature and adjust the steam flow rate accordingly. This feedback system maintains precise temperature control while preserving the high heat transfer efficiency of direct steam injection by optimizing the steam-to-liquid ratio in real-time.
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 system significantly reduces wear and tear, allows for convenient servicing by removing components for cleaning and replacement, and maintains stable temperature control, addressing the 'hammering effect' and erosion issues, while being more resistant to corrosive effects and operational disruptions.
Implementation Method 1
Each opening is provided with a mixing element that induces a rotational angular velocity to the fluid stream passing therethrough
Implementation Method 2
Each opening is provided with a mixing element that induces a rotational angular velocity to the fluid stream passing therethrough
Implementation Method 3
As steam is injected directly into a liquid, one can realize almost 100 percent of the BTU's in the steam which are absorbed directly into the liquid
Implementation Method 4
one can realize almost 100 percent of the BTU's in the steam which are absorbed directly into the liquid
Implementation Method 5
The biscuit element is provided of sintered tungsten... significantly reduces wear and tear... more resistant to corrosive effects
Data Source
AI summary
A device for the injection and mixing of steam into a fluid stream. The device is intended to be used in a substantially cylindrically-shaped primary conduit having a longitudinal axis and circular cross-section for carrying the fluid stream. The primary conduit is provided with an inlet for accepting the fluid stream and an outlet for discharging the fluid stream along the longitudinal axis. A secondary conduit is joined to the primary conduit for discharging steam within the fluid stream along the longitudinal axis. A biscuit element is provided of sintered tungsten having upstream and downstream circular faces sized to fit within the primary conduit along its interior wall having a geometric center coincident with the longitudinal axis and having a plurality of openings, each having a longitudinal axis parallel to the longitudinal axis of the primary conduit. Each opening is provided with a mixing element that induces a rotational angular velocity to the fluid stream passing therethrough. Conically-shaped features extend from the circular faces and are centered along the longitudinal axis at the geometric centers thereof.