Vortex finder with segmented rings for thermal stress reduction
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Solution Overview
Problem
Current vortex finders in cyclone separators suffer from thermal cycling, ash buildup, and stress-induced deformation due to inadequate expansion and contraction, leading to maintenance challenges and reduced performance in fluidized bed combustion systems.
Innovation Solution
A vortex finder design featuring superposed, circumferentially extending rings composed of non-flat plate segments with offset ends and integral support members, allowing for gravity-assisted assembly and reducing stress, along with ceramic coatings for improved heat resistance and ash shedding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded or segmented plate vortex finder is used, then the structural strength is improved, but thermal cycling and stress induce deformation and warping over time
Solution Approach 1:
The vortex finder is divided into multiple hanging segments that can independently expand and contract with thermal cycling. Each segment is suspended from the one above it, allowing differential movement without inducing stress in welded joints. This segmentation prevents the deformation and warping that occurs in traditional welded plate designs.
Solution Approach 2:
The design changes the physical state and arrangement of the segments by hanging them vertically with offset centerlines. This geometric parameter change allows the segments to accommodate thermal expansion and contraction movements, transforming the rigid welded structure into a flexible assembly that resists thermal deformation.
2Strength
If pockets with solid bottoms are used to support segments, then structural support is provided, but ash accumulates in the pockets
Solution Approach 1:
The pocket bottoms are designed with open bottoms or porous structures instead of solid bottoms. This allows ash particles to pass through the pockets and be removed from the system, preventing accumulation while maintaining structural support for the hanging segments.
3Ease of manufacture
If segmented interlocking pieces are used, then ease of assembly is improved, but complexity of the structure increases
Solution Approach 1:
The vortex finder is segmented into multiple independent hanging segments that can be assembled separately and then suspended from one another. This segmentation simplifies manufacturing and assembly compared to welding large plates, while the hanging connection method keeps the overall structural complexity manageable.
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 design enhances the strength and durability of vortex finder components, reduces stress and heat loss, and facilitates easier maintenance by allowing individual segment replacement, while the ceramic coating improves temperature control and prevents ash accumulation.
Implementation Method 1
The plate segments of one of the rings are suspended under the force of gravity from the plate segments of the adjacent ring positioned above the one of the rings
Data Source
AI summary
A vortex finder for a cyclone separator, comprising a plurality of superposed rings each including a plurality of suspended plate segments. Each of the plate segments includes a main plate having radially offset upper and lower end portions, opposite inner and outer faces, an upper support member integrally formed with the upper end portion to protrude from the outer face, and a lower support member integrally formed with the lower end portion to protrude from the inner face. The upper support member of the plate segments of the one of the rings engages and is supported by the lower support member of the plate segments of another of the rings positioned above the one of the rings. The lower support member defines an open-bottom pocket having at least one pass-through opening for fluidly connecting a space inside the vortex finder with a space outside the vortex finder.