U.S. patent application number 10/686191 was filed with the patent office on 2005-03-17 for method and apparatus for mixing fluids.
Invention is credited to Ginter, Gary, Goheen, Bill, Hagen, David L., McGuire, Allan, Rankin, Janet.
Application Number | 20050056313 10/686191 |
Document ID | / |
Family ID | 34274841 |
Filed Date | 2005-03-17 |
United States Patent
Application |
20050056313 |
Kind Code |
A1 |
Hagen, David L. ; et
al. |
March 17, 2005 |
Method and apparatus for mixing fluids
Abstract
The invention relates in general to methods of controlled mixing
one fluid with another. In particular it relates to a distributed
direct fluid contactor including arrays of streamlined perforated
tubes distributed across a flow to efficiently contact and mix one
or more fluids flowing through one or more tubes with a second
fluid flowing across those tubes. These distributed contactors
thereby mix the fluids in a fairly uniform fashion causing a
prescribed uniformity or variation in the ratio of the first to
second fluid across the space. This thereby to generally creates
and controls the physical and/or chemical changes in those fluids,
including evaporation, condensation, forming powders and conducting
chemical reactions including combustion.
Inventors: |
Hagen, David L.; (Goshen,
IN) ; Ginter, Gary; (Chicago, IL) ; Goheen,
Bill; (Goshen, IN) ; McGuire, Allan; (Elkhart,
IN) ; Rankin, Janet; (Shawano, WI) |
Correspondence
Address: |
KNOBBE MARTENS OLSON & BEAR LLP
2040 MAIN STREET
FOURTEENTH FLOOR
IRVINE
CA
92614
US
|
Family ID: |
34274841 |
Appl. No.: |
10/686191 |
Filed: |
October 15, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10686191 |
Oct 15, 2003 |
|
|
|
10713899 |
Sep 12, 2003 |
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Current U.S.
Class: |
137/3 |
Current CPC
Class: |
B01F 2005/0025 20130101;
B01F 2005/0034 20130101; Y10T 137/0329 20150401; F24F 2013/0608
20130101; B01F 5/0453 20130101; F24F 13/04 20130101 |
Class at
Publication: |
137/003 |
International
Class: |
E03B 001/00 |
Claims
What is claimed is:
1. An apparatus for mixing a first fluid with a second fluid, the
apparatus comprising: a fluid distribution portion comprising at
least one tubular portion having an outer surface and an inner
surface, the inner surface defining a first flow path for the first
fluid, a duct that defines a second flow path for the second fluid,
the duct having an axial direction and a first and second
transverse directions mutually distinct from the axial direction,
the first and second transverse directions defining a plane through
an axial location and containing a cross-sectional area of the
duct, a first fluid delivery system for supplying the first fluid
to the fluid distribution portion a second fluid delivery system
for supplying the second fluid to the duct; the tubular portion
comprising a plurality of orifices each forming a third flow path
along which the first fluid can be injected into the second fluid
within the duct; and wherein the outer surface of the tubular
portion comprising the orifices is positioned within the duct in
the second flow path and the orifices when projected onto a plane
containing the first and second transverse directions have an
average spatial density of at least about 10,000 orifices per
square meter of duct cross sectional area.
2. The apparatus of claim 1, wherein the orifices have an average
lineal density of at least 1000 orifices per meter length of the
tubular portion.
3. The apparatus of claim 1, wherein the orifices when projected
onto a plane containing the first and second transverse directions
have an average spatial density of at least about 100,000 orifices
per square meter of duct transverse cross sectional area.
4. The apparatus of claim 1, wherein the orifices have an average
diameter less than about 80 micrometers.
5. The apparatus of claim 1, wherein the orifices have an average
diameter less than about 20 micrometers.
6. The apparatus of claim 1 wherein the orifices have an average
diameter less than about 5 micrometers.
7. The apparatus of claim 1, wherein the at least one tubular
portion comprises a tube spiraled about an imaginary outwardly
convex shape.
8. The apparatus of claim 1, further comprising a flexible manifold
for connecting the first fluid supply system to each tubular
portion.
9. The apparatus of claim 1, further comprising a support that is
coupled to the distribution portion to support the distribution
portion in the duct.
10. The apparatus of claim 1, wherein the tubular portion comprises
a plurality of tubular curvilinear sections extending in at least
one of the transverse directions, whose flow paths are connected to
at least one manifold that is connected to the first fluid supply
system.
11. The apparatus of claim 10, wherein the curvilinear sections are
positioned sequentially downstream within the second flow path from
each other.
12. The apparatus of claim 1, wherein the tubular portion comprises
at least one tubular member that extends in the axial direction and
at least one manifold which connects the tubular member to the
first fluid supply system.
13. The apparatus of claim 1, wherein the tubular portion comprises
at least one tubular member that extends in the first or second
transverse direction, and are connected to at least one pair of
manifolds at angles between 5 degrees and 175 degrees.
14. The apparatus of claim 13, wherein the manifolds are angled
with respect to each other.
15. The apparatus of claim 13, wherein a differential pressure is
applied to the first fluid between the two manifolds.
16. The apparatus of claim 1, wherein the tubular portion includes
a first portion that extends in the first transverse direction and
at least the size of the orifices or the distribution of the
orifices in the first transverse direction are configured so as to
deliver a non-uniform amount of the first fluid with respect to the
first transverse direction to the second fluid to achieve a desired
transverse distribution of the first fluid in the second fluid.
17. The apparatus of claim 16, wherein the tubular portion includes
a second portion that extends in the second transverse direction
and at least the size of the orifices or the distribution of the
orifices in the second transverse direction are configured so as to
deliver a non-uniform amount of the first fluid with respect to the
second transverse direction to the second fluid to achieve a
desired transverse distribution of the first fluid in the second
fluid in the second transverse direction.
18. The apparatus of claim 16, wherein the first and second
transverse directions are perpendicular to each other.
19. The apparatus of claim 16, wherein the first transverse
direction is radial to the axial direction.
20. The apparatus of claim 16, axial direction wherein the
transverse ratio profile of second to first fluid flows is
non-uniform in at least one of the first or second transverse
directions.
21. The apparatus of claim 16, wherein the desired transverse
distribution of the first fluid in the second fluid is a
substantially uniform distribution of the first fluid in the second
fluid.
22. The apparatus of claim 1, wherein the tubular portion has a
streamlined cross-sectional shape relative to the flow path of the
second fluid.
23. The apparatus of claim 1, wherein the tubular portion has an
anti-streamlined cross-sectional shape.
24. The apparatus of claim 1, wherein the tubular portion is formed
from at least one thin walled sheet attached to a structural member
and wherein the orifices are formed on the thin walled sheet.
25. The apparatus of claim 1, further comprising a vibration
generator that is configured to vibrate the tubular portion.
26. The apparatus of claim 25, wherein the vibration generator
vibrates the tubular portion in a direction that is generally
perpendicular the axes of most of the orifices.
27. The apparatus of claim 1, further comprising a high voltage
power supply which is connected to a plurality of members selected
from the group of the duct, one or more tubular portions, an axial
electrode, a distributed electrode, and a peripheral electrode
displaced from the outer surface of the tubular portion such that
the high voltage delivered creates an electric field about the
outer surface of the tubular portion that modifies jets of the
first fluid exiting the orifices.
28. The apparatus of claim 27, wherein the mean magnitude of the
applied high voltage is within a desired range sufficient to
achieve a desired reduction in the cross sectional area of the jets
and less than the voltage that would cause an arc.
29. The apparatus of claim 27, wherein the fluctuating magnitude of
the applied high voltage is within a desired range sufficient to
achieve a desired oscillation in the jets and less than the voltage
that would cause an arc.
30. The apparatus of claim 1, wherein the tubular portion includes
a wall having a plurality of thinner portions and wherein the
orifices are configured through the thinner portions.
31. The apparatus of claim 1, wherein at least some of the orifices
have a longitudinal axis that is oblique to the longitudinal axis
of the tubular portion.
32. The apparatus of claim 1, wherein the first fluid comprises a
liquid and the second fluid comprises a gas and at least a portion
of the first fluid evaporates when it is injected into the duct so
as to cool the second fluid.
33. A method of mixing a first fluid with a second fluid
comprising: providing a fluid distribution portion comprising at
least one tubular portion having an outer surface and an inner
surface, the inner surface defining a first flow path for the first
fluid, providing a duct that defines a second flow path for the
second fluid, the duct having an axial direction and a first
transverse direction and a second transverse directions
perpendicular to the axial direction, the first and second
transverse directions at an axial location defining a plane
comprising a cross-sectional area of the duct, positioning the at
least one tubular portion in the duct such that it extends in a
direction having a component in the first transverse direction;
providing a plurality of orifices on the at least one tubular
portion, each orifice forming a third flow path along which the
first fluid can be delivered into the second fluid within the duct;
providing a first fluid delivery system for providing the first
fluid to the first flow path; controlling a delivery pressure of
the first fluid; configuring at least one of the (i) the size of
the plurality of orifices in the transverse direction, (ii) the
linear density of the plurality of orifices in the transverse
direction or (iii) the delivery pressure of the first fluid to
deliver a non-uniform amount, with respect to the first transverse
direction, of the first fluid into the second fluid to achieve a
desired distribution of the first fluid in the second fluid in the
first transverse direction downstream of the fluid distribution
portion.
34. The method of claim 33, further comprising providing a second
tubular portion having an outer surface and an inner surface, the
inner surface defining a first flow path for the first fluid and
including a plurality of orifices for delivering the first fluid
from the first flow path to the second flow path; and positioning
the at least one tubular portion in the duct such that it extends
in a direction having a component in the second transverse
direction.
35. The method of claim 34, further comprising configuring on the
second tubular portion configuring at least one of (i) the size of
the plurality of orifices in the transverse direction, (ii) the
linear density of the plurality of orifices in the transverse
direction, or (iii) the delivery pressure of the first fluid to
deliver a non-uniform amount, with respect to the second transverse
direction, of the first fluid into the second fluid to achieve a
desired distribution of the first fluid in the second fluid in the
second transverse direction downstream of the fluid distribution
portion.
36. The method of claim 33, wherein the first transverse direction
is a radial direction with respect to the axial direction.
37. The method of claim 25, wherein the first and second directions
are orthogonal to each other.
38. The method of claim 33, further comprising providing a second
tubular portion having an outer surface and an inner surface, the
inner surface defining a first flow path for the first fluid and
including a plurality of orifices for delivering the first fluid
from the first flow path to the second flow path; and positioning
the at least one tubular portion in the duct such that it extends
in a direction having a component in the second transverse
direction.
39. The method of claim 34, further comprising configuring on the
second tubular portion configuring at least one of (i) the size of
the plurality of orifices in the transverse direction, (ii) the
linear density of the plurality of orifices in the transverse
direction, or (iii) the delivery pressure of the first fluid to
deliver a non-uniform amount, with respect to the second transverse
direction, of the first fluid into the second fluid to achieve a
desired distribution of the first fluid in the second fluid in the
second transverse direction downstream of the fluid distribution
portion.
40. The method of claim 33, wherein the desired distribution of the
first fluid in the second fluid is uniform in the first transverse
direction.
41. The method of claim 33, further comprising adjusting a
circumferetial orientation of the orifices on the first tubular
portion in the first transverse direction to achieve a desired
distribution of the first fluid in the second fluid in the first
transverse direction downstream of the fluid distribution
portion.
42. The method of claim 33, further comprising: providing a second
tubular portion having an outer surface and an inner surface, the
inner surface defining a first flow path for the first fluid and
including a plurality of orifices for delivering the first fluid
from the first flow path to the second flow path; and positioning
the second tubular portion in the duct such that it extends in a
direction having a component in the first transverse direction and
is adjacent the first tubular portion.
43. The method of claim 42, further including controlling a jet
penetration distance in the transverse direction between 10% and
200% of the spacing of the first and second tubular portions.
44. The method of claim 42, further comprising controlling a jet
penetration distance to be about proportional to the spacing of
between the first and second tubular portions.
45. A method of mixing and exchanging heat between a first fluid
and a second fluid, the method comprising: providing a delivery
member for a first fluid, the delivery member comprising tubular
portions with a plurality of orifices; providing a duct for a
second fluid through, the duct having a duct axis and encompassing
the orifices; configuring a non-uniform transverse distribution of
orifice sizes along at least one of a first direction transverse to
the duct axis, and controlling the differential ejection pressure
between the first fluid within the orifices and the second fluid
outside the orifices along at least a first direction transverse to
the duct axis; providing a non-uniform density in the transverse
direction of the orifices on the delivery member, delivering the
second fluid through the duct; and and delivering the first fluid
through the delivery member to control the temperature of the
second fluid exiting the duct.
46. The method of claim 45 further comprising: controlling the
delivery temperature of the first fluid; controlling the
temperature of the duct to a desired level below the freezing
temperature of the first fluid such that a desired portion of the
first fluid solidifies within a desired portion of the duct
length.
47. The method of claim 45 further comprising: controlling the
first fluid temperature so as to evaporate a desired portion of the
first fluid in the second fluid.
48. The method of claim 47 further comprising: controlling the mean
distribution of a measure of first fluid drop size in the first
transverse direction.
49. A method of radiatively exchanging heat with a first fluid
comprising: providing tubular portions comprising numerous orifices
within a duct; configuring the orifices to have a non-uniform
spatial distribution with respect to a transverse axis of the duct;
configuring the orifices to have a non-uniform size distribution
with respect to the transverse axis of the duct; delivering a first
fluid to the tubular portions with a non-uniform differential
ejection pressure with respect to the transverse axis; controlling
the temperature of the first fluid delivered to the tubular
portions, controlling the temperature of a wall of the duct, and
controlling the radiation flux from the duct wall to the first
fluid being delivered from the tubular portions to the duct.
50. The method of claim 49 further including configuring a section
of the duct wall to be desirably transparent to electromagnetic
radiation, transmitting electromagnetic radiation through the
transparent wall section configuring the tubular portions and
orifices to deliver the first fluid across the transmitted
electromagnetic radiation with a desired spatial distribution and
drop size distribution such that a desired portion of the
transmitted electromagnetic radiation is absorbed.
51. The method of claim 49, further comprising utilizing one or
more of gallium, an alkali salt, or mixtures of alkali salts as the
first fluid.
52. The method of claim 49, further comprising: positioning
portions of the tubular portions in a plurality of sub-ducts and
configuring the orifices such that the radiative view factor of the
first fluid drops within the sub-ducts is within a range of 5% and
98% of that within a black body.
53. A method of mixing a first fluid with a second fluid
comprising: providing a fluid distribution portion comprising at
least one tubular portion having an outer surface and an inner
surface, the inner surface defining a first flow path for the first
fluid, providing a duct that defines a second flow path for the
second fluid, the duct having an axial direction and a first
transverse direction and a second transverse directions
perpendicular to the axial direction, the first and second
transverse directions at an axial location defining a plane
comprising a cross-sectional area of the duct, positioning the at
least one tubular portion in the duct such that it extends in a
direction having a component in the first transverse direction; and
dynamically controlling the distribution of the first fluid into
the second fluid with respect to the first transverse direction
downstream of the fluid distribution portion by controlling the
pressures at both ends of the fluid distribution portion.
54. The method of claim 53, further comprising delivering a
non-uniform amount of the first fluid into the second fluid with
respect to the first transverse direction to achieve a
substantially uniform distribution of the first fluid into the
second fluid downstream of the fluid distribution portion.
55. The method of claim 53, further comprising dynamically
controlling the pressures at both ends of the fluid distribution
portion in response to fluctuations in the flow of the second fluid
in the duct.
Description
PRIORITY STATEMENT
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. ______, filed Sep. 12, 2003, which is a
conversion of U.S. Provisional Application No. 60/418,989, filed
Oct. 15, 2002, this application claims the benefit of the earlier
filed applications under 35 U.S.C. .sctn. 119(e) and 35 U.S.C.
.sctn.120 which are also incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates in general to apparatus and methods
for controlling the delivery of a fluid, and to mixing of two or
more fluids, and in particular, to methods and apparatus wherein
the mixing of two or more fluids create and/or control physical
and/or chemical changes in those fluids.
[0004] 2. Description of the Related Art
[0005] Many physical and chemical processes require the delivery of
a first fluid, and of mixing of two or more fluids together. The
effectiveness of the mixing in such processes is dependent upon
many physical phenomena. Mixing may depend upon the surface area of
a liquid or the interfacial area between the fluids (e.g., a
liquid, a vapor, and/or a gas) that are to be mixed. For heat
exchange between two fluids in direct contact, the process depends
in part on the interfacial area between the two fluids and thus on
the specific interfacial area (surface area per mass). In another
example, chemical reactions between a liquid and a gaseous fluid
typically occur between the vapor evaporated from the liquid, and
the surrounding gaseous fluid.
[0006] Traditional methods for mixing two fluids together rely on
relatively few injection nozzles, which are arranged to inject a
first fluid into a second fluid. Such methods produce areas where
local concentrations may be higher or lower than the desired
average concentration. Such discontinuities may adversely effect
the desired physical or chemical processes. There is a general need
for an apparatus and method for improving the mixing of two or more
fluids together.
SUMMARY OF THE INVENTION
[0007] Accordingly, one exemplary embodiment of the invention
involves an apparatus for mixing a first fluid with a second fluid.
The apparatus comprises a fluid distribution portion comprising at
least one tubular portion having an outer surface and an inner
surface, the inner surface defining a first flow path for the first
fluid, a duct that defines a second flow path for the second fluid,
the duct having an axial direction and a first and second
transverse directions mutually distinct from the axial direction,
the first and second transverse directions defining a plane through
an axial location and containing a cross-sectional area of the
duct, a first fluid delivery system for supplying the first fluid
to the fluid distribution portion a second fluid delivery system
for supplying the second fluid to the duct; the tubular portion
comprising a plurality of orifices each forming a third flow path
along which the first fluid can be injected into the second fluid
within the duct; and wherein the outer surface of the tubular
portion comprising the orifices is positioned within the duct in
the second flow path and the orifices when projected onto a plane
containing the first and second transverse directions have an
average spatial density of at least about 10,000 orifices per
square meter of duct cross sectional area.
[0008] Another exemplary embodiment of the invention involves a
method of mixing a first fluid with a second fluid. The method
comprises providing a fluid distribution portion comprising at
least one tubular portion having an outer surface and an inner
surface, the inner surface defining a first flow path for the first
fluid, providing a duct that defines a second flow path for the
second fluid, the duct having an axial direction and a first
transverse direction and a second transverse directions
perpendicular to the axial direction, the first and second
transverse directions at an axial location defining a plane
comprising a cross-sectional area of the duct, positioning the at
least one tubular portion in the duct such that it extends in a
direction having a component in the first transverse direction;
providing a plurality of orifices on the at least one tubular
portion, each orifice forming a third flow path along which the
first fluid can be delivered into the second fluid within the duct;
providing a first fluid delivery system for providing the first
fluid to the first flow path; controlling a delivery pressure of
the first fluid; configuring at least one of the (i) the size of
the plurality of orifices in the transverse direction, (ii) the
linear density of the plurality of orifices in the transverse
direction or (iii) the delivery pressure of the first fluid to
deliver a non-uniform amount, with respect to the first transverse
direction, of the first fluid into the second fluid to achieve a
desired distribution of the first fluid in the second fluid in the
first transverse direction downstream of the fluid distribution
portion.
[0009] Another exemplary embodiment of the invention relates to
method of mixing and exchanging heat between a first fluid and a
second fluid. The method comprises providing a delivery member for
a first fluid, the delivery member comprising tubular portions with
a plurality of orifices; providing a duct for a second fluid
through, the duct having a duct axis and encompassing the orifices;
configuring a non-uniform transverse distribution of orifice sizes
along at least one of a first direction transverse to the duct
axis, and controlling the differential ejection pressure between
the first fluid within the orifices and the second fluid outside
the orifices along at least a first direction transverse to the
duct axis; providing a non-uniform density in the transverse
direction of the orifices on the delivery member, delivering the
second fluid through the duct; and and delivering the first fluid
through the delivery member to control the temperature of the
second fluid exiting the duct.
[0010] Another exemplary embodiment relates to a method of
radiatively exchanging heat with a first fluid. The method
comprising providing tubular portions comprising numerous orifices
within a duct; configuring the orifices to have a non-uniform
spatial distribution with respect to a transverse axis of the duct;
configuring the orifices to have a non-uniform size distribution
with respect to the transverse axis of the duct; delivering a first
fluid to the tubular portions with a non-uniform differential
ejection pressure with respect to the transverse axis; controlling
the temperature of the first fluid delivered to the tubular
portions, controlling the temperature of a wall of the duct, and
controlling the radiation flux from the duct wall to the first
fluid being delivered from the tubular portions to the duct.
[0011] Another exemplary embodiment relates to a method of mixing a
first fluid with a second fluid. The method comprises providing a
fluid distribution portion comprising at least one tubular portion
having an outer surface and an inner surface, the inner surface
defining a first flow path for the first fluid, providing a duct
that defines a second flow path for the second fluid, the duct
having an axial direction and a first transverse direction and a
second transverse directions perpendicular to the axial direction,
the first and second transverse directions at an axial location
defining a plane comprising a cross-sectional area of the duct,
positioning the at least one tubular portion in the duct such that
it extends in a direction having a component in the first
transverse direction; and dynamically controlling the distribution
of the first fluid into the second fluid with respect to the first
transverse direction downstream of the fluid distribution portion
by controlling the pressures at both ends of the fluid distribution
portion.
[0012] For purposes of summarizing the invention, certain aspects,
advantages and novel features of the invention have been described
herein above. Of course, it is to be understood that not
necessarily all such advantages may be achieved in accordance with
any particular embodiment of the invention. Thus, the invention may
be embodied or carried out in a manner that achieves or increases
one advantage or group of advantages as taught or suggested herein
without necessarily achieving other advantages as may be taught or
suggested herein.
[0013] All of these embodiments are intended to be within the scope
of the invention herein disclosed. These and other embodiments of
the invention will become readily apparent to those skilled in the
art from the following detailed description of the preferred
embodiments having reference to the attached figures, the invention
not being limited to any particular preferred embodiment(s)
disclosed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Having thus summarized the general nature of the invention
and some of its features and advantages, certain preferred
embodiments and modifications thereof will become apparent to those
skilled in the art from the detailed description herein having
reference to the figures that follow, of which:
[0015] FIG. 1 is a schematic-perspective view of an exemplary
embodiment of a general distributed direct contact array system
comprising a distribution member with a plurality of orifices and a
controller;
[0016] FIG. 2 is a cross-sectional section view of another
embodiment of a distribution member comprising multiple
orifices;
[0017] FIG. 3 is a cross-sectional view of another embodiment of a
thinned distribution member;
[0018] FIG. 4 is a cross-sectional view of another embodiment of a
curvaciously thinned distribution member;
[0019] FIG. 5 is a cross-sectional view of another embodiment of a
thinned distribution member comprising inward;
[0020] FIG. 6 is a cross-sectional view of another embodiment of a
curvaciously thinned distribution member comprising outward
orifices;
[0021] FIG. 7 is a perspective view of two linear offset arrays of
uniform orifices on a distribution member;
[0022] FIG. 8 is a perspective view of columnar arcs of uniform
orifices on both sides of a distribution tube;
[0023] FIG. 9 is a perspective view two offset lines of orifices
increasing and then decreasing in orifice size along and on both
sides of a distribution member;
[0024] FIG. 10 is a perspective view of a distribution member
containing orifices positioned and sized in a pseudo-random fashion
with varying net orifice area spatial density;
[0025] FIG. 11 is a perspective view of a distribution member
containing orifices with spacing decreasing and then increasing
thus transversely varying the net orifice area spatial density;
[0026] FIG. 12 is a perspective view of a hemispherical end to a
distribution member with orifices;
[0027] FIG. 13 is a schematic cross-sectional view of the wall of
the elongated distribution member of the distributed fluid
contactor of FIG. 101A;
[0028] FIG. 14 is a elevation view of an embodiment for hexagonally
arranging the orifices on the distribution member of FIG. 101A;
[0029] FIG. 15 is an elevation view of another embodiment for
rectangularly arranging the orifices on the distribution
member;
[0030] FIG. 16 is a perspective of a radial variation in orifice
spatial density in a circular array of distribution members;
[0031] FIG. 17 is a perspective view of a transverse variation in
orifice spatial density in a rectangular array of perforated tube
connected to manifolds, having features and advantages in
accordance with one embodiment of the invention;
[0032] FIG. 18 is a conceptual diagramatic view of radial orifice
spacing as a function of fluid flows, tube gap and jet penetration
in an exemplary embodiment;
[0033] FIG. 19 is a conceptual diagramatic view of maximum radial
orifice size configuration designed to achieve a desired
evaporation distance as a function of fluid velocity and
evaporation time in an exemplary embodiment;
[0034] FIG. 20 is a schematic view of the transverse orifice
diameter and spacing, first fluid pressure and resultant first
fluid flow per orifice, across an annulus;
[0035] FIG. 21 is a conceptual view of varying orifice size to
provide different jet penetrations in an exemplary embodiment;
[0036] FIG. 22 is a schematic perspective of tube connection to a
manifold.
[0037] FIG. 23 is an conceptual view of varying orifice
circumferential orientation to provide different micro-jet gap
penetrations in an exemplary embodiment;
[0038] FIG. 24 is an conceptual view of varying orifice
circumferential orientation to provide concentrated asymmetric
micro-jet gap penetrations in an exemplary embodiment;
[0039] FIG. 25 is an conceptual view of varying orifice
circumferential orientation to provide distributed asymmetric
micro-jet gap penetrations in an exemplary embodiment;
[0040] FIG. 26 is a schematic view looking downstream of an
exemplary embodiment of alternating micro-jets penetrating the gap
between two distribution members;
[0041] FIG. 27 is a schematic view, transverse to the flow, of an
exemplary embodiment of alternating micro-jets penetrating the gap
between two distribution members;
[0042] FIG. 28 is a schematic view looking downstream of an
exemplary embodiment of opposed micro-jets penetrating the gap
between two distribution members;
[0043] FIG. 29 is a schematic view, transverse to the flow, of an
exemplary embodiment of opposed micro-jets penetrating the gap
between two distribution members;
[0044] FIG. 30 is a schematic view of aligned distribution members
with diagonally opposed offset orifices;
[0045] FIG. 31 is a schematic view of alternating parallel
distribution members with diagonally opposed orifices;
[0046] FIG. 32 is a schematic view of aligned distribution members
with chevron orifices;
[0047] FIG. 33 is a schematic view of alternating distribution
members with chevron orifices;
[0048] FIG. 34 is a cross-sectional view of a circular distribution
member;
[0049] FIG. 35 is a cross-sectional view of an oval distribution
member;
[0050] FIG. 36 is a cross-sectional view of a streamlined
distribution member;
[0051] FIG. 37 is a cross-sectional view of a flattened
distribution member;
[0052] FIG. 38 is a cross-sectional view of a flattened dual
chamber distribution member;
[0053] FIG. 39 is a cross-sectional view of a flattened single
chamber distribution member;
[0054] FIG. 40 is a cross-sectional view of an asymmetric
streamlined distribution member;
[0055] FIG. 41 is a cross-sectional view of a "bluff" or triangular
distribution member;
[0056] FIG. 42 is a schematic cross section view of a downstream
cusped bluff distribution member in an exemplary embodiment;
[0057] FIG. 43 is a perspective view of an exemplary embodiment of
a compound distribution member;
[0058] FIG. 44 is a perspective view of another embodiment of a
compound distribution member, which has an aerodynamic shape;
[0059] FIG. 45 is a perspective view of another embodiment of a
compound distribution member, which has a ribbed tubular structure
to support perforated foils;
[0060] FIG. 46 is a schematic cross-sectional view of an exemplary
embodiment of a streamlined distribution member formed by bonding
two strips along two dissimilar wires;
[0061] FIG. 47 is a schematic cross-sectional view of an exemplary
embodiment of a streamlined distribution member formed by wrapping
a thin strip about tube stiffeners;
[0062] FIG. 48 is a schematic cross-sectional view of an exemplary
embodiment of a streamlined distribution member formed by wrapping
a thin strip about two similar wires;
[0063] FIG. 49 is a schematic cross-sectional view of an exemplary
embodiment of a streamlined distribution member formed by abutting
and bonding two thinned strips on either side of two dissimilar
wires;
[0064] FIG. 50 is a perspective view of an exemplary embodiment of
a distributed contactor having an elliptical circular array of
distribution members positioned across the flow within a
substantially circular duct;
[0065] FIG. 51 is an expanded view of a portion of the distributed
contactor of FIG. 50;
[0066] FIG. 52 is a schematic perspective view of an exemplary
embodiment of a distributed contactor having an array of
distribution members oriented axially substantially parallel to the
flow within an annular duct;
[0067] FIG. 53 is a schematic perspective view of a tent shaped
array of distribution members orientated at an angle to the flow
within a rectangular duct;
[0068] FIG. 54 is a front view of a circular array of distribution
members;
[0069] FIG. 55 is a front view of a rectangular array of
distribution members;
[0070] FIG. 56 is a front view of an annular array of distribution
members;
[0071] FIG. 57 is a perspective view of a three dimensional
downstream concave array of distribution members;
[0072] FIG. 58 is a perspective view of a three dimensional
rectangular tent array of distribution members;
[0073] FIG. 59 is a perspective view of a three dimensional annular
tent array of distribution members;
[0074] FIG. 60 is a schematic view of an exemplary embodiment of an
annular array of radial distribution members connected to multiple
sub-manifolds formed in arcs, forming a spoke type annular
array;
[0075] FIG. 61 a schematic view of a fluid mixing control
system.
[0076] FIG. 62 is a schematic view of an exemplary embodiment of an
annular axially multi-array configuration of circumferential
distribution members connected to multiple sub-manifolds formed in
radial spokes;
[0077] FIG. 63 is an enlarged upstream cross sectional view of
overlapping inter tube sprays;
[0078] FIG. 64 enlarged view of three axially spaced tubes with
differing orifice specific number spatial density;
[0079] FIG. 65 is a perspective view of a three dimensional
cylindrical array of distribution members;
[0080] FIG. 66 is a perspective view of a three dimensional "top
hat" array of distribution members;
[0081] FIG. 67 is a perspective view of a bulbuous array of
distribution members;
[0082] FIG. 68 is a perspective view of an exemplary embodiment of
streamlined stiffeners supporting an exemplary embodiment of
"funnel" conical array of distribution members;
[0083] FIG. 69 is a perspective view of an exemplary embodiment of
downstream increasing helical "horn array";
[0084] FIG. 70 is a schematic view of distribution members
configured in a "tent" or "conical" arrangement oriented in a
"funnel" shape within a duct;
[0085] FIG. 71 is a schematic view of distribution members oriented
about "pleated" array, within a duct;
[0086] FIG. 72 is a schematic view of distribution members arranged
in a "compound" array;
[0087] FIG. 73 is a schematic illustration of an exemplary
embodiment for controlling fluid flow by minimum largest) orifice
differential fluid pressure switch;
[0088] FIG. 74 is a schematic illustration of an exemplary
embodiment of flow control relative to all orifice differential
fluid pressure;
[0089] FIG. 75 is a schematic illustration of an exemplary
embodiment of flow control by graded differential fluid
pressure;
[0090] FIG. 76 is a schematic illustration of an exemplary
embodiment of flow control by digital pulsation of fluid
pressure;
[0091] FIG. 77 is a schematic illustration of an exemplary
embodiment of flow control by frequency modulation of fluid
pressure;
[0092] FIG. 78 is a schematic illustration of an exemplary
embodiment of flow control by amplitude modulation of fluid
pressure;
[0093] FIG. 79 is a schematic view of an upstream distribution
member in a grounded "horn" conical array with a downstream grid
connected to a high voltage power supply;
[0094] FIG. 80 is a schematic view of an exemplary embodiment of
two sets of distribution members alternatingly connected to
negative high voltage electrode or to ground, within a duct;
[0095] FIG. 81 is a schematic view of an exemplary embodiment of
distribution members connected to a negative high voltage, within a
grounded duct;
[0096] FIG. 82 is a schematic illustration of an exemplary
embodiment of a multiple duct horizontal distributed contactor FIG.
83 is a schematic view of a direct contact heat exchanger;
[0097] FIG. 84 is a schematic view of a power conversion system
comprising an exemplary embodiment of a direct fluid contactor
configured to deliver a vaporizable first fluid into a second
fluid;
[0098] FIG. 85 is a schematic cross section of a peripheral
distribution member in a duct with multiple orifice sizes and jet
penetrations in an exemplary embodiment;
[0099] FIG. 86 is a schematic cross section of an axial
distribution member in a duct with multiple orifice sizes and jet
penetrations in an exemplary embodiment;
[0100] FIG. 87 is a schematic section of a particle separator
utilizing a direct contact heat exchanger.
[0101] FIG. 88 is a perspective view of distribution members
encircling a cylindrical duct and connected to manifolds;
[0102] FIG. 89 is a perspective view of distribution members
oriented about a cylindrical duct and parallel to its axis;
[0103] FIG. 90 is a perspective view of distribution members
encircling a cylindrical port with a valve;
[0104] FIG. 91 is a schematic perspective of a radiative heat
transfer system to cool distributed drops;
[0105] FIG. 92 enlarged perspective view of a contactor tube;
[0106] FIG. 93 is a schematic perspective of a radiative heat
transfer system to heat distributed drops; and
[0107] FIG. 94 Distributed Contactor Modeling Method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0108] A list of some components and certain nomenclature utilized
in describing and explaining the preferred embodiments of the
invention follow:
[0109] 2 Distributed Contactor System
[0110] 3 First Flow Path
[0111] 4 Second Flow Path
[0112] 5 Third Flow Path
[0113] 6 Tube Inner Surface
[0114] 7 Tube Outer Surface
[0115] 8 Tube
[0116] 9 Tube axis
[0117] 10 Distributed Contactor Perforated Tube or Distribution
Member
[0118] 11 First Fluid Distributed Contactor Perforated Tube or Fuel
Contactor
[0119] 12 Liquid Fuel Distributed Contactor Perforated Tube or
Diesel Contactor
[0120] 13 Gaseous Fuel Distributed Contactor Perforated Tube
[0121] 14 Thermal Diluent Fluid Distributed Contactor Perforated
Tube
[0122] 15 Fuel fluid Passage
[0123] 16 Dual Passage Contactor Perforated Tube
[0124] 17 Thermal Diluent Passage
[0125] 18 Compound Dual Passage Contactor Perforated Tube
[0126] 19 Bridging Fuel fluid Contactor Perforated Tube
[0127] 20 Concentric Passage Contactor Perforated Tube
[0128] 21 Curvilinear Perforated Tube Section or Arc
[0129] 22 Insulated Diluent Contactor Perforated Tube
[0130] 24 Insulated Diluent Spray Contactor Perforated Tube
[0131] 26 Streamlined Triple Passage Contactor Perforated Tube
[0132] 28 Cusped Triple Passage Contactor Perforated Tube
[0133] 30 Tube Wall
[0134] 31 Intra-tube wall
[0135] 32 Thin Tube Wall Section
[0136] 33 Tube Side Wall
[0137] 34 Thermal Barrier Coating
[0138] 35 Mechanically Protective Coating, Abrasion or Erosion
Barrier Coating
[0139] 36 Internal Tube Stiffener or Tube Structural Section
[0140] 37 External Tube Support
[0141] 38 Tube Structural Rib
[0142] 39 Bond
[0143] 40 Fin-stiffener, or Thermal Fin
[0144] 42 Web-stiffener
[0145] 44 Perforated Web
[0146] 46 Fin-stiffener Tube
[0147] 48 Dual Fin-stiffener Tube
[0148] 50 Tube Vibrator
[0149] 54 Curvilinear flexible supply tube
[0150] 56 Combustor
[0151] 57 Inner combustor mount
[0152] 58 Outer combustor mount
[0153] 59 Combustor wall
[0154] 60 Combustor liner
[0155] 61 Tube-fin liner
[0156] 62 Tube-fin coolant passage
[0157] 64 Plane fin
[0158] 66 Fluted fin
[0159] 67 Fin expansion Gap
[0160] 68 Thermal Barrier Coating
[0161] 69 Compound wrapped liner
[0162] 70 Tube-fin Stiffening Rib
[0163] 72 Flexible array structural support
[0164] 74 Tube connecting hole
[0165] 80 Orifice (may comprise non-circular openings)
[0166] 82 Fuel Fluid Orifice or Fuel Orifice
[0167] 83 Thermal Diluent Orifice or Diluent Orifice
[0168] 84 Axial Orifice Orifice with predominantly axial
component
[0169] 85 Radial Orifice Orifice with predominantly radial
component
[0170] 86 Angled Orifice Orifice with angle significantly off
perpendicular to flow
[0171] 87 Larger Orifice Opening
[0172] 88 Orifice Entrance
[0173] 89 Smaller Orifice Opening
[0174] 90 Orifice Exit
[0175] 91 Hexagonal Orifice Array
[0176] 92 Cartesian or Rectangular Orifice Array
[0177] 93 Columnar Array
[0178] 94 Fluid Sampler Tube
[0179] 96 Sampler-Diluent Contactor Tube
[0180] 100 Flame Holder, Ignition Authority, Pilot Light, or Pilot
Flame
[0181] 102 Modified Toroidal Chamber
[0182] 103 Internally Concave Redirector
[0183] 104 Fuel fluid Tube/Passage
[0184] 106 Thermal Diluent Tube/Passage, Diluent Tube Passage, Duct
or Member
[0185] 107 Oxidant Intake Port
[0186] 108 Main Oxidant Tube/Passage
[0187] 110 Pilot Oxidant Tube/Passage
[0188] 111 Circumferential Passage
[0189] 112 Mixture Delivery Port
[0190] 114 Hot Gas Intake Port
[0191] 116 Hot Gas Delivery Flame Tube
[0192] 118 Flame Holder Structural Support
[0193] 120 Insulation/Thermal Barrier Coating
[0194] 122 Streamlined Shroud
[0195] 124 Igniter
[0196] 126 Igniter Excitation Source
[0197] 130 Fluid Duct
[0198] 131 Fluid Sub-Duct, Smaller Fluid Duct
[0199] 132 Fluid Duct Wall
[0200] 133 Fluid Duct Axis
[0201] 134 Fluid Duct Entrance Combustor Inlet, Evaporator Inlet,
Saturator Inlet
[0202] 136 Fluid Duct/Combustor Exit Combustor Outlet, Evaporator
Outlet, Saturator Outlet
[0203] 137 Fluid Duct Hub
[0204] 138 Duct Wall Cooling Channel
[0205] 139 Fluid duct "window", electromagnetically transparent
wall.
[0206] 140 Focusing Resonant Duct
[0207] 142 Spring-Fin Coolant Duct
[0208] 144 Circular Duct Elliptical Duct, Cylindrical Duct
[0209] 145 Rectangular Duct
[0210] 146 Annular Duct
[0211] 148 Diluent Fluid Duct
[0212] 150 Insulation
[0213] 152 Insulation Wedge
[0214] 154 Insulation Ring
[0215] 156 Insulation Tile
[0216] 158 Radial Insulation Spring
[0217] 160 Axial Insulation Spring
[0218] 168 Combustor External Enclosure
[0219] 170 Pressure vessel
[0220] 172 Pressure Vessel Wall
[0221] 174 Pressure Vessel End Cap/Port
[0222] 176 Pressure Vessel Feed-Through
[0223] 178 Pressure Vessel Cooling System
[0224] 180 Progressive Thermal Shield
[0225] 182 Progressive Perforated Thermal Shield
[0226] 184 Progressive Insulation Thermal Shield
[0227] 186 Progressive Radiation Shields
[0228] 190 Engine Cylinder
[0229] 192 Combustion Cylinder
[0230] 194 Duct Slide Port, Cylinder Slot Port
[0231] 196 Duct Side Port, Cylinder Side Port
[0232] 197 Reciprocating Piston
[0233] 198 Cylinder Wear Bar
[0234] 200 Compound Perforated Tube, Compound Distribution Tube
[0235] 202 Structural Tube Support
[0236] 220 Multi-passage compound contactor tube
[0237] 222 Tube Passage or Tube Duct
[0238] 224 First Fluid Tube Duct e.g. Fuel Fluid Tube Passage
[0239] 226 Inter-passage Tube Wall
[0240] 228 Third Fluid Tube Duct e.g. Thermal Diluent Tube Passage,
Diluent Tube Passage
[0241] 230 Flow control valve
[0242] 231 Sub-duct Valve
[0243] 232 Purge Valve
[0244] 233 Sub-manifold Valve
[0245] 240 Manifold
[0246] 242 Fuel fluid Manifold
[0247] 244 Thermal Diluent Manifold Diluent Manifold
[0248] 246 Multi-passage Manifold
[0249] 247 Central Manifold Header
[0250] 248 Hydraulic Feed-through
[0251] 249 Manifold Wall
[0252] 250 Manifold Connecting Hole
[0253] 252 Manifold End Opening
[0254] 254 Secondary Manifold or Sub-Manifold
[0255] 255 Tube-Duct Junction
[0256] 256 Mounting Indent/Ridge
[0257] 257 Inter-tube duct
[0258] 258 Bond layer
[0259] 259 Compound Secondary Manifold
[0260] 260 Direct Contactor Perforated Tube Array
[0261] 261 Downstream Increasing Concave Tube Array
[0262] 262 "Horn" Conical Tube Array
[0263] 263 Downstream Decreasing Convex Tube Array
[0264] 264 "Funnel" Conical Tube Array
[0265] 265 Elliptical Planar Tube Array, or Pseudo-Elliptical
Array, e.g. Circular Planar Tube Array
[0266] 266 Rectangular Planar Tube Array or Trapezoidal Planar
Array
[0267] 267 Annular Planar Tube Array or Annular Planar Tube
Section
[0268] 268 Rectangular Tent Tube Array or Pyramidal Tube Array
[0269] 269 Annular Tent Tube Array Annular Tent Tube Section
[0270] 270 Elliptical Tube Array e.g. Cylindrical Tube Array
[0271] 271 Can Tube Array or "Top Hat" Tube Array
[0272] 272 Cusped Tube Array
[0273] 273 Bulbuous Tube Array or "Dandelion" Tube Array
[0274] 274 Perforated Contactor Tube Array Module Contactor Tube
Array Section
[0275] 275 Modular Combustor or Can Combustor
[0276] 276 Heater Tube
[0277] 277 Interior Heater Tube Wall
[0278] 278 Exterior Heater Tube Wall
[0279] 279 Wall of Heater Tubes or Heater Tube Bank
[0280] 280 Structural support
[0281] 282 Array Mount
[0282] 284 Pleated Array
[0283] 290 Micro-swirler
[0284] 291 Over tube "Striding" "saddle" airfoil micro-swirler
[0285] 292 "Sitting" saddle airfoil micro-swirler
[0286] 293 Between Tube "Striding" "T-shirt" vane micro-swirler
[0287] 294 "Sitting" T-shirt micro-swirler
[0288] 295 Helical micro-swirler vane
[0289] 296 Micro-swirler rib
[0290] 297 Micro-swirler airfoil
[0291] 298 Micro-swirler vane
[0292] 299 Mini-swirler
[0293] 300 High Voltage Power Supply
[0294] 301 Power Supply
[0295] 302 Ground electrode
[0296] 304 Positive Electrode
[0297] 306 Negative Electrode
[0298] 308 First voltage electrode
[0299] 310 Second voltage electrode
[0300] 312 Third voltage electrode
[0301] 314 Support Insulator
[0302] 316 High Voltage Feed-through
[0303] 320 Combustor Electrode, distributor electrode
[0304] 322 Fuel fluid Array Electrode
[0305] 324 Diluent Array Electrode
[0306] 326 Grid Electrode
[0307] 328 Cooled Tubular Electrode
[0308] 330 Axial Electrode
[0309] 332 Peripheral Electrode
[0310] 334 Mid-duct Electrode
[0311] 340 Conductive-Liquid Isolator
[0312] 342 Grounded supply pump
[0313] 343 Perforated liquid distributor
[0314] 344 Isolated liquid drop tower
[0315] 346 Droplet collector
[0316] 348 Insulating supports
[0317] 350 Elevated voltage supply pump
[0318] 356 First Fluid Supply
[0319] 358 Third Fluid Supply
[0320] 360 First Fluid Delivery System or Fuel Delivery System
[0321] 361 Third Fluid Delivery System or Diluent Delivery
System
[0322] 362 Storage Tank
[0323] 364 Supply Pump, Fluid Pump
[0324] 366 Delivery Pump
[0325] 367 Differential Manifold Pump
[0326] 368 Recirculating Pump
[0327] 369 Fluid Fluctuation Damper
[0328] 370 Pressure/Flow Modulator
[0329] 372 Pilot Flame/Flame Holder Fuel Delivery System
[0330] 373 Pilot Flame/Flame Holder Thermal Diluent Delivery
System
[0331] 374 Rotary Actuator
[0332] 376 Rotary Pump Head
[0333] 378 Linear Actuator
[0334] 379 Solenoid
[0335] 380 Filter
[0336] 382 Coarse Fluid Filter, Coarse Liquid Filter, or Coarse
Fuel Filter
[0337] 384 Fine Fluid Filter, Fine Liquid Filter, or Fine Fuel
Filter
[0338] 386 Uniform Orifice Filter or Maximum Size Filter
[0339] 388 Recirculating Bypass Filter
[0340] 390 Fluid Filter, Gas Filter or Air Filter
[0341] 392 Spray Direct Contact Filter
[0342] 394 Flow homogenizer/straightener
[0343] 398 Second Fluid Supply
[0344] 400 Second Fluid Delivery System also termed Oxidant
Delivery System
[0345] 402 Distributed Contactor Fogger
[0346] 404 Distributed Contactor Precooler
[0347] 406 Blower
[0348] 407 Compressor
[0349] 408 First/Low Pressure Compressor
[0350] 409 Blower/Compressor intake/entrance
[0351] 410 First Intercooler
[0352] 412 Second/Intermediate Pressure Compressor
[0353] 414 Second Intercooler
[0354] 416 Third/High Pressure Compressor
[0355] 417 After cooler
[0356] 418 Pilot/Flame Holder Oxidant Delivery System
[0357] 420 Diffuser
[0358] 421 Diffuser Vanes or Splitter Vanes
[0359] 422 Connecting Duct
[0360] 424 Combustor
[0361] 426 Transition Zone/Piece
[0362] 440 Expander (Turbine or engine)
[0363] 442 High Pressure Turbine
[0364] 444 Low Pressure Turbine
[0365] 446 Turbine Stage
[0366] 448 Turbine Vane ("Nozzle")
[0367] 450 Turbine Blade ("Bucket")
[0368] 460 Drive System
[0369] 462 First Drive Shaft
[0370] 464 Second Drive Shaft
[0371] 466 Gear Train
[0372] 468 Variable speed drive
[0373] 470 Heat Exchanger or Heat Recovery System
[0374] 472 Superheater
[0375] 474 Evaporator ("Boiler")
[0376] 476 Economizer
[0377] 478 Preheater
[0378] 480 Condensor
[0379] 481 Collector Duct
[0380] 482 Surface (Flue Gas) Condensor
[0381] 483 Direct Contact Heat Exchanger or Direct Fluid
Contactor
[0382] 484 Direct Contact Condensor
[0383] 496 Cooling System
[0384] 488 Liquid--Liquid Heat Exchanger
[0385] 490 Air-Liquid Heat Exchanger
[0386] 492 Recirculation Pump
[0387] 494 Supply Water Tank
[0388] 496 Deionized Water Tank
[0389] 498 Spray Cleaning System
[0390] 500 Generator
[0391] 502 Recompressor
[0392] 510 Stack, chimney, natural draft device or flare
[0393] 512 Dry cooling tower
[0394] 514 Wet cooling tower
[0395] 516 Hybrid cooling tower
[0396] 518 Exhaust Diffuser
[0397] 520 Particulate separator or droplet separator
[0398] 522 Gravity Separator
[0399] 524 Multi-duct Gravity Separator
[0400] 526 Cyclone separator
[0401] 528 Electrostatic Precipitator
[0402] 530 Impingement Separator
[0403] 540 Liquid Conditioner
[0404] 542 Particulate Filter
[0405] 544 pH Conditioner
[0406] 546 CO.sub.2 Stripper
[0407] 548 Deionizer
[0408] 550 Physical Parameter Sensors or Transducers
[0409] 552 Pressure Sensor or Transducer
[0410] 554 Differential Pressure Sensor or Transducer
[0411] 558 Temperature Sensor or Transducer
[0412] 560 First Fluid Flow Sensor or Transducer e.g., Fuel Fluid
Flow Sensor
[0413] 562 Second Fluid Flow Sensor or Transducer e.g., Oxidant
Fluid Flow Sensor
[0414] 564 Third Fluid Flow Sensor or Transducer e.g., Thermal
Diluent Fluid Flow Sensor
[0415] 570 Composition Sensor or Transducer
[0416] 572 Oxygen Sensor or Transducer
[0417] 574 NOx Sensor or Transducer
[0418] 576 Carbon Monoxide Sensor or Transducer (CO)
[0419] 578 Unburned Hydrocarbon Sensor or Transducer (UHC)
[0420] 580 Motion Sensor/Speed Meter
[0421] 582 Pump Position Sensor or Transducer or Speed Meter, or
Rotary Encoder
[0422] 584 Compressor/Blower Position or Speed Meter or
Transducer
[0423] 586 Flow Modulator Control Sensor or Transducer (e.g.,
position/motion sensor)
[0424] 588 Control System
[0425] 590 Controller
[0426] 592 First Fluid Controller e.g. Fuel Fluid Controller
[0427] 594 Second Fluid Controller e.g. Oxidant Fluid
Controller
[0428] 596 Third Fluid Controller e.g. Thermal Diluent Fluid
Controller
[0429] 598 Heating Fluid Controller
[0430] 900 Fluids
[0431] 901 First Fluid, First Reactant Fluid, Fluid Fuel, or
Thermal Diluent.
[0432] 902 Drop or bubble of first fluid.
[0433] 903 Jet or micro-jet of first fluid.
[0434] 904 Second Fluid, Second Reactant, or Oxidant Fluid.
[0435] 920 Energetic Fluid
[0436] 924 Expanded Fluid
[0437] 926 Flue Gas928 Cooled Fluid
[0438] 930 Ambient Cooling Fluid
[0439] 932 Ambient Cooling Water
[0440] 934 Ambient Cooling Air
[0441] 940 Condensate
[0442] 942 Filtered Condensate
[0443] 944 Deionized Condensate
[0444] 950 Evaporated Diluent Fluid
[0445] 952 Superheated Diluent Fluid
[0446] Tube Smallest Inner Diameter D.sub.i
[0447] Tube Smallest Outer Diameter D.sub.o
[0448] Tube Inner Area A.sub.o
[0449] Tube Wall Thickness T=(D.sub.o-D.sub.i)/2
[0450] Thin Tube Wall Thickness t
[0451] Tube Center to Center Spacing H
[0452] Tube to Tube gap G
[0453] Orifice Inner Diameter d.sub.i
[0454] Orifice Outer Diameter d.sub.o
[0455] Orifice Area a.sub.o
[0456] Orifice Inner Pressure at Inner Opening p.sub.i
[0457] Orifice Outer Pressure at Outer Opening p.sub.o
[0458] Orifice Center to Center Spacing h
[0459] Orifice to Orifice gap g
[0460] Orifice axial angle alpha (.alpha.)
[0461] Orifice transverse orientation angle theta (.theta.)
[0462] Orifice Array Width W
[0463] Profiles in the First Transverse Direction
[0464] Radial Pressure Distribution Ppr
[0465] Radial Velocity Distribution Vpr
[0466] Radial Temperature Distribution Tpr
[0467] Radial Density Distribution Rhopr
[0468] Radial Mass Flow Distribution Mdpr
[0469] Profiles in the Second or Circumferential Transverse
Direction
[0470] Circumferential Pressure Distribution Ppc
[0471] Circumferential Velocity Distribution Vpc
[0472] Circumferential Temperature Distribution Tpc
[0473] Circumferential Density Distribution Rhopc
[0474] Circumferential Mass Flow Distribution Mdpc
[0475] The following detailed description of the preferred
embodiments uses many technical terms. In an effort to improve
clarity, several of these terms will be first described in this
section. It should be appreciated that these technical terms are
broad terms and are also used in their ordinary sense in addition
to the definitions provided below.
[0476] First Fluid, commonly comprising one or more of a First
Reactant Fluid, a Fluid Fuel, and a Thermal Diluent, herein also
generically called a "Fuel Fluid". (e.g. a gaseous, liquid or
fluidized powdered fuel or a mixture comprising fuel and thermal
diluent typically passing through a Fuel Perforated Tube or Duct
and moving out Orifices)
[0477] Second Fluid, commonly a Fluid comprising a second Reactant
or an Oxidant, optionally comprising a thermal diluent fluid,
herein also generically called an "Oxidant Fluid". (e.g. humid air
or oxygen enriched air optionally mixed with steam, typically
passing through a Fluid Duct across one or more perforated tubes,
or else passing through an Oxidant Perforated Tube)
[0478] Third Fluid, commonly a "Thermal Diluent" or "Diluent Fluid"
comprising an inert fluid or fluid with low reactivity such as a
mild oxidant, capable of absorbing or giving off heat and changing
enthalpy and temperature, herein also generically called a "Thermal
Diluent" "Diluent Fluid" or "Cooling Diluent", sometimes
distinguished as "Vapor Diluent" and "Liquid Diluent" when the
diluent fluid is vaporizable. (e.g. water, steam, excess air,
carbon dioxide, or recirculated products of combustion, typically
passing through a Thermal Diluent Perforated Tube and out
Orifices)
[0479] Energetic Fluid, a fluid capable of delivering energy,
commonly a hot pressurized fluid comprising products of reaction
and residual portions of the First Fluid and Second Fluid, and
commonly comprising Thermal Diluent (e.g. a hot pressurized fluid
formed by combusting a fuel fluid with oxidant fluid such as
compressed air and diluted with steam and excess air)
[0480] Expanded Fluid, fluid downstream of an expander or work
engine such as a turbine or reciprocating engine, may also be
termed Exhaust Fluid or Spent Fluid
[0481] Flue Gas, expanded energetic fluid exhausting through a
flue
[0482] Cooled Fluid, a fluid with heat withdrawn such as downstream
of a cooling heat exchanger or condensor
[0483] Distribution member, a member having a fluid passage through
which fluid is delivered to orifices through which the fluid is
distributed, such as a tube comprising orifices in a wall.
[0484] Orifice--a mouth or aperture of a tube, cavity etc.;
opening
[0485] Opening--open place or part; hole; gap; aperture
[0486] Aperture--(1) an opening; hole; gap (2) the opening, or the
diameter of the opening, in a camera, telescope, etc. through which
light passes into the lens
[0487] Hole--an opening in or through a solid body, a fabric, etc.;
a perforation; a rent; a fissure; a hollow place or cavity; an
excavation; a pit; Webster 1913 rearranged
[0488] Duct--(1) a tube, channel, or canal through which a gas or
liquid moves; . . . (4) a pipe or conduit through which wires or
cables are run, air is circulated or exhausted etc.
[0489] Tube--a distributed member having an inner surface forming a
passage defining a first flow path to deliver a first fluid, often
having an elongated walled member.
[0490] Prescribed--herein generally refers to a parameter that is
desired or needed, prescribed, predetermined, pre-selected or
otherwise selected.
[0491] Curvilinear--the shape of a generic line comprising one or
more linear and/or curvaceous sections as desired. E.g. comprising
linear, polynomial and/or transcendent functions comprising conic
sections, parabolic, elliptical, hyperbolic, sinusoidal,
logarithmetic, exponential curves.
[0492] Coordinate system--system used to configure planar or
spatial ducts or other fluid delivery system, comprising Cartesian,
cylindrical, spherical, annular, or other suitable curvilinear
co-ordinate systems or combinations thereof.
[0493] Differential Ejection Pressure--differential pressure across
the orifice in the tube wall that ejects the first fluid as a
jet.
[0494] All Orifice Differential Fluid Pressure Poda--the
differential pressure across an array of orifices sufficient to
eject fluid from all the orifices, including the smallest orifices
80.
[0495] Equivalence Ratio or Phi--the ratio of first reactant flow
to second reactant flow or fuel fluid flow to oxidant fluid flow
relative to the stoichiometric ratio of first reactant to second
reactant or fuel fluid to oxidant fluid. I.e. the inverse of Lambda
(E.g. diesel fuel to air ratio relative to stoichiometric diesel
fuel to air ratio.)
[0496] Excess Oxidant Ratio, Lambda, or excess air ratio--the ratio
of the second reactant or oxidant fluid flow to first reactant or
fuel fluid flow relative to the stoichiometric ratio of second
reactant to first reactant or stoichiometric oxidant fluid to fuel
fluid. I.e. the inverse of Phi.
[0497] Lambda Distribution--the distribution of Lambda or relative
stoichiometric ratio of oxidant fluid to fuel fluid (e.g. oxygen to
fuel ratio relative to the stoichiometric ratio of oxygen to
fuel.)
[0498] Rich mixture or composition--a fluid comprising more fuel
(or less oxidant) than the stoichiometric ratio i.e. Lambda less
than one or Phi greater than one.
[0499] Lean mixture or composition--a fluid comprising less fuel
(or more oxidant) then the stoichiometric ratio. I.e. Lambda
greater than one or Phi less than one.
[0500] Diluent enthalpy change--the change in enthalpy of a diluent
between two states, including one or more of change due to heat
capacity, latent heat of vaporization, and chemical
dissociation.
[0501] Specific diluent enthalpy change--the change in enthalpy per
unit mass between two states.
[0502] Total diluent enthalpy change--the diluent enthalpy change
of all fluid components including excess oxidant fluid (in lean
mixtures), excess fuel fluid (in rich mixtures), thermal diluent
vapor, thermal diluent liquid and any other non constituents.
[0503] Excess heat generation--heat of combustion in excess of the
heat required to increase combustion products to the desired
energetic gas exit temperature.
[0504] Combustion cooling--the reduction in enthalpy of hot
combustion gases equal to the excess heat generation and equal to
the total increase in enthalpy of the total thermal diluent
components.
[0505] Distribution--a function describing the variation of a
parameter. Herein frequently used to describe the variation of the
parameter along one or both transverse directions (e.g., radial and
circumferential) or an axial direction. Also used for number
distributions.
[0506] Profile--a function or distribution describing the variation
of a parameter along a direction, such as in a radial direction in
a cylindrical or annular duct. Herein may also be used for a ratio
of two distributions, or to describe a "pattern" along a direction
such as a circumferential direction. Sometimes used to emphasize
spatial rather than number distributions.
[0507] Jet Discharge Cross Area--net cross-sectional area of the
fluid jet as it exits the orifice.
[0508] Orifice Flow Factor--ratio of jet discharge cross-sectional
area to total orifice discharge cross-sectional area
[0509] Fluid flow--the rate of flow of fluid on a mass basis, or
the mol or volumetric rate if so stated.
[0510] Fluid flow distribution--the variation of the fluid flow
along a direction, or along a curvilinear line as specified.
[0511] Fluid flow ratio--the variation in the ratio of two fluid
flows, sometimes the distribution of this ratio.
[0512] Fluid flow ratio profile--the distribution of the ratio of
two fluids along a transverse direction or along an axial direction
or curvilinear line if so specified.
[0513] Fluid Flow Ratio Profile Range--the distribution of the
range of upper and lower fluid flow ratios along a transverse
direction or along an axial direction or curvilinear line if so
specified.
[0514] Minimum Orifice Differential Pressure Podm--the differential
ejection pressure across an array of orifices sufficient to eject
fluid from the largest orifices 80.
[0515] Partial Orifice Differential Fluid Pressure Podp--the
differential ejection pressure across an array of orifices
sufficient to eject fluid from some of the larger orifices 80 but
not from the smallest orifices.
[0516] Temperature--the thermodynamic temperature of a fluid at a
point or the mean temperature of the fluid,
[0517] Temperature distribution--the variation of temperature in a
fluid along a transverse direction or along an axial direction or
curvilinear line as specified.
[0518] Temperature distribution range--the variation in upper and
lower temperatures along a transverse direction or an axial
direction or curvilinear line as specified.
[0519] Uncertainty--the uncertainty evaluated according to
international definitions. Eg See NIST TN 1287.
[0520] Temperature uncertainty--the uncertainty in the temperature
of the fluid or component.
[0521] Flow uncertainty--the uncertainty in fluid flow rate.
[0522] Ratio uncertainty--the uncertainty in ratio of fluid flow
rates.
[0523] Turn Down--the ratio of minimum to maximum fluid flow rates,
or described as reduction in flow divided by the maximum to minimum
flow rates. E.g., 10% minimum to maximum flow ratio; 90% turn down;
or a turn down of 10:1.
[0524] 8.2 Direct Contactor Perforated Tubes with Numerous
Orifices
[0525] Some preferred embodiments of the present invention relate
to apparatus and methods for delivering a first fluid and for
mixing two or more fluids and together. As will be described below,
one embodiment utilizes a distribution member comprising a tube
that is positioned within a duct forming a flow path. The tube
comprises a large number of small orifices. The first fluid is
injected through the orifices into the second flow path of a second
fluid. By positioning the numerous small orifices across the flow
path, very efficient mixing between the first and second fluids can
be achieved.
[0526] FIG. 1 illustrates one embodiment of a distributed contactor
system 2, which can be used to mix a first fluid 901 with a second
fluid 904. The first fluid is delivered to the intake of a manifold
240 by a first fluid delivery system 360. The second fluid is
delivered to the inlet 134 of a fluid duct 130 by a second fluid
delivery system 400. The fluid delivery is controlled by a control
system 580 which may include monitoring the pressure at the inlet
and outlet of the duct 130. The distributed contactor system 2
includes a distributed perforated contactor 10 which is positioned
within a fluid duct 130. External tube supports 37 are used to
support the individual tubes 10. Flexible array supports 72 are
used to support a distributed contactor array 260.
[0527] As shown in the cross section view FIG. 2, the distributed
fluid delivery member or contactor 10 that delivers the first fluid
is formed in part from a fluid delivery duct such as from a tube,
by forming numerous orifices 80 through a tube wall 30 of the tube.
The tube wall 30 has an inner surface 6 that defines a first flow
path 3 for a first fluid 901, and an outer surface 7 which is
encompassed by the duct. The first fluid path 3 is shown
perpendicular to the cross section of the tube wall 30.
[0528] With reference to FIG. 1 and 2, the tube wall 30 is provided
with a large number of small orifices 80 (i.e., holes or openings)
distributed along and about a thin walled contactor tube 10. As
will be explained in more detail below, the first fluid 901 is
directed to flow along the first flow path 3 through the tube 10
and then through a third flow path 5 formed by the orifices 80, out
into the second flow path 4, which is defined by the fluid duct
130. A second fluid 904 is directed through the duct 130 along the
second flow path 4 such that the first fluid 901 and second fluid
904 are mixed together within the duct 130. The second fluid path 4
is shown parallel to the cross section of the tube wall 30, though
it may be at any angle to that tube wall.
[0529] As will be explained in more detail, below, in some
embodiments, users create a differential ejection pressure across
the perforated tube 10 sufficient to force the first fluid 901
through orifices 80 and form drops (or bubbles) 902 or micro-jets
903 of the first fluid 901 in the second fluid 904. In modified
embodiments, the second fluid flows across the orifices 80 to
entrain the micro-flows, micro-jets, drops or bubbles of the first
fluid 901 delivered with a desired differential ejection pressure
into that second fluid 904.
[0530] It should be appreciated that although dictionary
definitions of "tube" refer to a "cylindrically walled member".
Applicants do not intend for tube to have such a limited
definition. Instead, Applicant has used "tube" to refer to a
distributed member which has an inner surface forming a passage
that defines a first flow path to deliver a first fluid. The
distributed member is often an elongated walled member. It may have
a variety of cross-sectional shapes as will be apparent from the
description below. The distributed member comprises orifices which
are often round but which may be elongated or form slots etc.
[0531] 8.2.1 Number of Orifices or Jets
[0532] Conventional systems typically only use a few orifices in a
plate or at the end of an injector. In contrast, users provided one
or more contactor tubes with a lineal orifice density of at least
hundreds of orifices per meter of tube length, more preferably with
thousands of orifices per meter of tube length, and still more
preferably optionally tens to hundreds of thousands of orifices per
meter of tube length depending on the application. In other words,
with respect to FIG. 1 and FIG. 2 the lineal density of the
orifices 80 on the tubes 10 may range from about a few orifices per
centimeter to hundreds or thousands of orifices per centimeter of
tube length.
[0533] The orifices 80 are distributed across the second flow path
4 to achieve a desired transverse flow distribution of the first
fluid 901, or flow ratio profile of the first fluid flow divided by
the mean first fluid flow, preferably on a mass basis, or
alternatively on mol or a volume basis. The flow distribution and
orifice distribution provide a desired mixing distribution of the
two fluids. For example, to produce a uniform ratio of second fluid
to first fluid flow, the orifices 80 are distributed with a
substantially non-uniform distribution across the second flow path
4 within the duct 130 to accommodate the non-uniform flow of the
second fluid. In such configurations, the orifices are configured
in arrays of perforated tubes 10 across the flow path 4 thereby
distributing hundreds and preferably thousands to hundreds of
thousands of orifices or more across the second flow path 4.
[0534] Typical ranges of orifice specific number density (number of
orifices per duct cross sectional area) are shown in Table 1
Orifice Specific Number Density for typical ranges of orifice
lineal density along contactor tubes and for typical ranges of tube
to tube spacing.
1TABLE 1 Orifice Areal Density (Number of Orifices/m.sup.2) Lineal
Density Tube Spacing Gap (mm) (Orifices/meter) 100 30 10 3.0 1.0
0.10 30 300 1,000 3,000 10,000 30,000 300,000 100 1,000 3,333
10,000 33,333 100,000 1,000,000 300 3,000 10,000 30,000 100,000
300,000 3,000,000 1,000 10,000 33,333 100,000 333,333 1,000,000
10,000,000 3,000 30,000 100,000 300,000 1,000,000 3,000,000
30,000,000 10,000 100,000 333,333 1,000,000 3,333,333 10,000,000
100,000,000
[0535] Ranges of Duct to Orifice Area ratios are shown in Table 2
for a range of orifice specific number density, the orifice sizes.
This demonstrates the very wide range of duct to orifice areas that
can be configured with various embodiments of the direct contactor
arrays.
2TABLE 2 Mean Duct to Orifice Area (m.sup.2/m.sup.2) Orifice Areal
Density (No. of Area of each Orifice (mm.sup.2) Orifices/m.sup.2)
7.85E-07 7.85E-05 7.85E-03 7.85E-01 10,000 7.9E-09 7.9E-07 7.9E-05
7.9E-03 30,000 2.4E-08 2.4E-06 2.4E-04 0.024 100,000 7.9E-08
7.9E-06 7.9E-04 0.079 300,000 2.4E-07 2.4E-05 2.4E-03 0.236
1,000,000 7.9E-07 7.9E-05 7.9E-03 0.785 3,000,000 2.4E-06 2.4E-04
2.4E-02 2.4 10,000,000 7.9E-06 7.9E-04 7.9E-02 7.9 30,000,000
2.4E-05 2.4E-03 2.4E-01 23.6 100,000,000 7.9E-05 7.9E-03 0.785 78.5
0.001 0.01 0.10 1.0 Orifice Diameter (mm)
[0536] 8.2.2 Tube Supports
[0537] As shown in FIG. 1, the distributed contactor array 260 may
include one or more structural supports 37 to support the
distributed tubes 10 against the bending forces created by the
cross-flow of the second fluid 904 along the second flow path 4
through the duct 130. In some embodiments, as shown in FIG. 68,
users preferably make these external stiffeners or tube supports 37
from thin streamlined shapes aligned with the flow. This reduces
the pressure drop and pumping power attributed to these
stiffeners.
[0538] The supports 37 are preferably configured to provide
sufficient flexure to accommodate any differential thermal
expansion during operation and are designed to accommodate
vibration, pressure oscillation, gravity, acceleration and other
forces using techniques well known in the art. In some embodiments,
the distributed tubes 10 may form in part the structural supports
37.
[0539] 8.2.3 Differential Ejection Pressure with Numerous
Orifices
[0540] With a large number of orifices, a large cumulative
cross-sectional area of orifices 80 is provided for the first fluid
to flow through. An advantage of this arrangement is that in some
embodiments a large differential ejection pressure is not required
to deliver the first fluid 901 through the orifices 80 into the
second fluid 901. e.g., compare the relevant art which often uses
pressures of about 750 bar to 3000 bar (about 10,000 psi to 40,000
psi).
[0541] In contrast, in one embodiment, a relatively low positive
differential (e.g, about 0.001 bar to 750 bar or about 0.01 psi to
10,000 psi) pressure may be used to force the first fluid 901
within the tube 10 out through the orifices 80 to form drops 902
(See, e.g., FIG. 3). An advantage of this embodiment, is that the
low pressure distribution method reduces the pumping costs
typically required in conventional systems which use conventional
very high positive differential ejection pressures with a few
orifices.
[0542] In various embodiments, (referring to FIG. 2) the
differential ejection pressure is increased to expel the first
fluid through an inner orifice opening 88 at the inner surface 6 of
the tube wall 30, through the orifice 80 along the third fluid path
5 through the outer orifice 90 at the outer surface of the tube
wall 30 and into the second flow path 4. This forms a large number
of short jets or micro-jets 903 through numerous orifices 80 into
the second flow path 4. The orifices may be further designated as
axial orifices 84 along the duct axis, radial orifices 85
perpendicular to the duct axis, or angled orifices 86 at other
angles to the duct axis.
[0543] Alternatively, the full range of differential ejection
pressure is sometimes used to increase fluid delivery turn-down
ratio (such as in FIG. 2). That is, increase the effective
operating range of fluid delivery by the distributed contactor
system by providing a wide range of pressures.
[0544] 8.2.4 Uniform or Prescribed Distribution through Many
Orifices
[0545] As mentioned above, the distributed contactor system 2
preferably includes perforated tubes 10 with a large number of
small, orifices. It is also advantageous to distribute these
orifices 80 across the second flow path 4 to efficiently mix the
first fluid 901 flowing through orifices 80 with the second fluid
904 flowing across those orifices 80. This arrangement causes more
efficient distribution and mixing of the fluids 901, 904. This
results in more locally homogeneous compositions which may vary in
composition as desired transversely across the duct.
[0546] In various embodiments, the distributed fluid contactor 2
may be used distribute drops of a first liquid into a second gas,
distribute a first gas into a second gas, distribute a first liquid
into a second liquid, or distribute a first gas (e.g., bubbles)
into a second liquid. That is, the first fluid 901 may be a liquid,
gas or a combination of liquid and gas (e.g., water droplets, mist,
solution, suspension, fluidized powder, nucleated bubbles of vapor
in a liquid, etc.). Similarly the second fluid 904 may also be a
liquid, gas or combination of liquid and gas (e.g., water droplets,
mist, nucleated bubbles of vapor in a liquid, etc.) In some
configurations, the second fluid 904 may comprise a fluidized
powder.
[0547] 8.3 Numerous Orifice Array Configuration Linear Array
[0548] As mentioned above, rather then a high pressure spray from
one or a few nozzles, in some embodiments the distributed contactor
system 2 utilizes large number of orifices 80 in an array along the
tube wall 30 to provide a more effective, uniform or desired mixing
of the first fluid 901 emitted from the perforated tube 10 with the
second fluid 904. With reference to FIG. 13, the orifices 80 have a
diameter d at the outer tube wall 7, and are formed in the tube
wall 30 having a wall thickness "t". The orifices 80 are spaced at
intervals "h" along the tube wall 30, and have a gap "g" between
orifices. (Note, h=d+g.) The tube 10 has an inner radius Ri and
outer radius Ro (as shown in FIG. 34) and a outer diameter D (as
shown in FIG. 27.)
[0549] When forming drops by gravity or fluid pressure extrusion,
pendant drops are formed with a nominal diameter "d" which are
typically of the order of twice the diameter "d" of the orifice or
hole 80. Thus, holes of about 2 micrometer (.mu.m) diameter
nominally create droplets of about 4 micrcometer (.mu.m) in
diameter at low pressures or velocities.
[0550] As will be explained below, the arrangement of the orifices
80 on the tube 10 may be varied in a variety of ways to achieve
different results. For example with reference to FIG. 7, in some
embodiments, the first fluid 901 flows along fluid path 3 and then
through substantially uniform orifices 80 which are arranged in one
or more lines on the tube wall 30 out to the fluid path 4. They may
be configured as "radial orifices" 85 perpendicular to the second
flow path 4, or as angled orifices 86 at some oblique angle to the
flow path 4.
[0551] 8.3.2 Column or Arc
[0552] In other embodiments, the orifices 80 are distributed in a
columns or arcs 93 about the tube wall 30 as shown in the exemplary
embodiment of FIG. 8. In such an embodiment, the first fluid
flowing from the first fluid path 3 through a column 93 of orifices
80 in line with the second fluid flow 904 will create a number of
in-line parallel sprays traversing the second fluid path 4 of the
second fluid flow. The cooperative in-line spray effect will
desirably reduce the rate the downstream sprays are diverted by the
flow. This advantageously enables sprays of fine drops to penetrate
further across the transverse flow. Preferably many orifices are
arranged in a column or arc about the tube wall 30 to create many
smaller more uniform drops while projecting them further across a
flow than is possible with individual sprays with similar
differential ejection pressures.
[0553] 8.3.3 Curvilinear Spatial Orifice Array
[0554] In other embodiments, users preferably form a spatial array
of orifices by creating an curvilinear array comprising lines,
columns, arcs, or other curvilinear orientations of orifices.
[0555] Hexagonal orifice array: For example, as show in FIG. 14, to
provide a maximum orifice spatial concentration, in some
embodiments, the orifices 80 are arranged in a hexagonal array 91
with orifice spacing h from each neighboring orifice 80. The
orifice array may further be oriented at some angle alpha to the
second fluid flow path 4 between zero and 60 degrees. Alpha is
preferably about 30 degrees as shown in FIG. 14. At low pressures
and flow velocities, pendant drops typically form with diameters d'
about double the diameter d of the orifices 80 from which they are
formed. The orifices 80 are preferably spaced at intervals h such
that the drops have sufficient gaps g' between them to prevent
coalescence. In some embodiments, the orifices are preferably
spaced at a distance h apart that is preferably at least about
three times the orifice diameter d to provide a gap g' of at least
about half the drop diameter d' between drops.
[0556] Cartesian orifice array: In some embodiments, as shown in
FIG. 15, the orifices 80 are arranged in one or more Cartesian or
rectilinear orifice arrays 92 with an angle alpha from the flow
path 4 of the second fluid 904. In Cartesian arrays, alpha is
between zero and 90 degrees, and is preferably about 45 degrees as
shown in FIG. 15. The orifices 80 of diameter d with orifice
spacing h in orthogonal lines, giving gaps g between orifices. As
before, the orifice spacing h is preferably of the order of at
least three times the orifice diameter d to give a gap g between
holes of twice the orifice diameter to reduce probability of drop
coalescence.
[0557] Areal Orifice Density: As mentioned above with reference to
FIGS. 14 and 15, in some embodiments, users preferably configure
the orifices 80 or holes in an hexagonal array for greatest areal
hole density and in other embodiments, these orifice or hole arrays
are formed into a Cartesian pattern. For a hole spacing of h, a
hexagonal array will give 2/(h.sup.23.sup.0.5)=1.1547/h.sup.2 holes
per unit area or 15.5% greater areal density (holes/area) compared
to a Cartesian array with areal density of 1/h.sup.2.
[0558] 8.3.4 Orifice Spacing
[0559] To prevent drop coalescence during formation, the hole
interval h is preferably significantly greater than the drop size
formed. It is preferable to provide significant gaps "g'" between
drops, to prevent droplet coalescence.
[0560] With reference back to FIG. 14, in some embodiments, the
holes are arranged in a hexagonal array with hole spaced at
intervals "h" preferably at least about 300% to 400% of the hole
diameter d. For example, with about 2 .mu.m diameter holes forming
about 4 .mu.m diameter drops, the holes are spaced at intervals of
at least about 6 .mu.m (i.e. drops of 3.times.2 .mu.m in size
preferably spaced at least about 3.times.3 .mu.m apart). Similarly
with reference back to FIG. 15, some embodiments involve holes
arranged in a Cartesian or rectangular array with similar ratios of
hole spacing to hole diameter.
[0561] 8.3.5 Columnar or Rectangular Arrays
[0562] In some embodiments, as shown in FIG. 8, the orifices 80 may
be arranged orifices as multiple discrete arrays 93. The orifices
80 may be arranged in columnar arrays 93, wrapped about the tube
10. In other embodiments as shown in FIG. 45, the orifices may be
arranged 80 in rectangular arrays of orifices, with the arrays
spaced along the tube 10.
[0563] 8.4 Spatial Orifice Density
[0564] In various embodiments, users of the fluid contactor 10 (see
FIG. 1) need or desire to configure and control the spatial
composition distribution or ratio of the flow of the second fluid
904 flowing across the perforated tubes 10 to the flow of a first
fluid 901 flowing through the tubes 10. To do so, users preferably
adjust the orifice specific density (local average of the total
orifice area over a local tube section in the perforated tube 10
relative to the corresponding cross-sectional area of the second
fluid duct 130 at that location. This measure can be refined by
accounting for the reduction in actual jet cross sectional area as
it leaves the orifice. E.g. in the range of about 80% to 99% of the
orifice exit area depending on the geometry and fluid parameters.)
They preferably evaluate or model and account for the velocity and
mass spatial distributions of the second fluid flow such as
radially to the duct to quantify the non-linearity in the flow.
These factors permit much lower differential ejection pressures and
results in more uniform mixing than conventional methods. This
method is contrasts with using a few orifices with high pressure
differences as is typical in the prior art.
[0565] This design parameter is approximately equal to the
effective orifice area per length of contactor tube divided by the
tube to tube spacing h. (Note that this may count multiple rows of
orifices along the tube and orifices of differing size.) The
effective orifice area is obtained by the gross cross-sectional
area of the orifices adjusted for net fluid flow area exiting the
orifice due to the necking down of fluid flow within the orifice
variously caused by roughness, geometry, turbulence, cavitation
and/or entrained bubbles.
[0566] Detailed designs will involve other parameters as desired or
needed such as orifice size, orientation and configuration, the
pressure difference across the tube wall, the pressure drop of the
second fluid flowing across the tubes, the relative fluid
densities, viscosities, surface energies, pressures, temperatures,
tube configurations and relative positions etc. These may further
use full CFD modeling to best position and orient the orifices.
[0567] 8.4.1 Axi-symmetric Flow Distribution for Uniform Ratio of
Fluid Flows
[0568] As is well known in the art, the fluid flow in ducts
commonly displays a substantial velocity distribution being faster
near the duct axis 133 or center and slower near the duct wall 132
(see FIG. 1) relative to the mean flow. These range from highly
parabolic flow profiles for laminar type flows to more truncated
flow profiles for turbulent flows. See for example, FIG. 18, FIG.
19 and FIG. 20 which illustrate examples of skewed parabolic flow
profiles such as found within or after compressors.
[0569] In one embodiment, the contactor is configured to achieve a
uniform or prescribed ratio of the second fluid to first fluid
across a duct with such a non-uniform velocity profile. Referring
to FIG. 18 and FIG. 20, to achieve a uniform ration, the first
fluid 901 is preferably delivered with a transverse spatial
distribution proportional to the mass flow transverse spatial
distribution of the second fluid 904 across the duct. In such an
embodiment, the tubes 10 and the orifices 80 may be distributed
across the duct 130 to provide the desired axi-symmetric flow
distributions.
[0570] For example, FIG. 16 illustrates an embodiment of a fluid
contactor 2 comprising a circular contactor array 265 within a
circular duct 144. In this embodiment, the fluid contactor 2
includes contactor tubes 10A-C that are formed into circular arrays
265, which may have axi-symmetric orifice configurations where the
orifice lineal density along each contactor tube 10A-C, and
specific orifice spatial density across the duct (locally averaged
net orifice area per duct cross-sectional area) (not shown) varies
radially across the circular contactor array 265. External tube
supports 37 are added to stiffen the circular array 265 against the
drag of the axially flowing second fluid 904 entering the duct
entrance 134.
[0571] In a similar manner, the embodiment illustrated in FIG. 1,
the director contactor 2 includes contactor tubes 10 formed into
the contactor array 260 shown as a downstream increasing concave
tube array (similar to a conical array in the "horn" configuration)
with an axi-symmetric orifice configuration. FIG. 68 depicts fluid
contactor 2 with contactor tubes 10 arranged in a "funnel" conical
array 264 that comprises perforate tube arcs (or curvilinear
sections) 21. Each tube arc 21 may be provided with a prescribed
orifice spatial density for each of the perforated tubes 10. E.g.,
the spatial orifice density is uniform at a given radius, or
distance from the cone apex to achieve the desired ratio orifice
spatial density to transverse area that varies in proportion to the
second fluid flow distribution as desired.
[0572] 8.4.2 Radial Variation in Ratio of Fluid Flows
[0573] With continued reference to FIG. 16, in some embodiments, to
obtain a prescribed radial variation or profile in the ratio of
fluid flows, users preferably vary the net orifice specific spatial
density radially from the axis to the circumferential wall of the
fluid duct 130. For example, the tubular array 265 comprises a
first inner ring contactor 10A, an outer ring contactor 10C and
preferably at least one intermediate ring contactor 10B. A manifold
240 delivers the first fluid 901 to at least one spoke like
sub-manifold 254 extending from the outer ring 10C, to the
intermediate ring 10B, and to the inner ring 10A, so as to provide
a fluid path between the rings 10C, 10B and 10A.
[0574] Each contactor ring or perforated tube 10A-C comprising
orifices 80 having an net specific orifice spatial density of the
net area of orifices divided by the relevant cross-sectional duct
area. i.e. the relevant area is the mean tube to tube spacing
multiplied by the mean incremental orifice spacing distance along
the tube 10 at that location. Furthermore, in some configurations
the lineal orifice density varies from one side of each tubular
ring 10A-C to the other side to adjust the net orifice density in
the radial direction transverse to the duct axis or perpendicular
to the tube arcs. In such cases, the area is the half the tube to
tube spacing on that side of the arc multiplied by the orifice
spacing along that side of the tube. Users preferably adjust the
net spatial orifice density along each contactor ring 10A-C to
achieve a radial distribution of spatial orifice density that
varies radially as desired in a circular fluid duct 144, an
elliptical fluid duct (not shown) or annular fluid duct 146 (such
as shown in FIG. 52).
[0575] 8.4.3 Circumferential Variation in Ratio of Fluid Flows
[0576] In some embodiments, to obtain a desired circumferential
profile (or "pattern") in the ratio of fluid flows such as around
an annular duct, users preferably adjust the orifice spatial
density in the circumferential direction around the fluid duct 130.
E.g., in the embodiment of FIG. 16, the contactor 2 has a desirably
uniform circumferential spacing of orifices 80 along circular
contactor arcs 10A-C around the circular array 265 in the circular
fluid duct 144. Similar configurations can be arranged around an
cylindrical tube array 270 or an annular tube array in annular
fluid duct 146 (See. FIG. 52.)
[0577] 8.4.4 Transverse Variation in Ratio of Fluid Flows
[0578] FIG. 17 illustrates a contactor system with a rectangular
array 266 of linear contactor tubes 10, users can vary the spatial
density of orifices from one tube to the next tube to obtain
variations in at least one transverse direction across the duct
130. Such an embodiment is particularly useful in rectangular ducts
(such as in FIG. 53). In FIG. 17, the direct contactor system
includes orifices 80 that are spaced along the contactor tubes 10
to increase and then decrease the net orifice spatial density as
the rectangular fluid duct is traversed along one transverse
direction.
[0579] 8.4.5 Spatial Variation in Ratio of Fluid Flows
[0580] To achieve a multidimensional spatial variation in fluid
ratio, users preferably vary both the spatial density of orifices
along each tube in one dimension (or parameter) as well as the
spatial density or variation in a second direction (or parameter)
such as from tube to tube across the array in some configurations.
E.g., along the major transverse coordinates in cylindrical or
Cartesian coordinates.
[0581] For example, in rectangular arrays 266 as shown in FIG. 17,
the net orifice spatial density may be varied in both directions
transverse to the duct axis in some configurations. In this manner,
both the horizontal and the vertical transverse spatial density of
orifice 80 are configured to accommodate the horizontal and
vertical transverse velocity distributions of the second fluid 904
flowing through the rectangular duct 145 to account for the
variations in transverse profiles due to the effect of boundary
layers and/or turbulence within the duct.
[0582] 8.4.6 Varying Spatial Fluid Delivery Profiles
[0583] To dynamically vary spatial fluid delivery distributions and
profiles, users adjust the differential ejection pressure
distribution along the longitudinal axis of the contactor tubes by
adjusting the pressure in one or both sub-manifolds 254 or
manifolds 240 to which the contactor tubes 10 are connected. The
pressure is preferably adjusted using one or more pressure flow
modulator 370 or sub-manifold valve 233.
[0584] 8.5 Orifice Size
[0585] 8.5.1 Magnitude of Orifice Size
[0586] In various embodiments, users preferably form the orifices
80 on the fluid contactor (See FIGS. 1 and 2) may be formed with a
diameter that is about 1% to about 30% of the thickness of the tube
wall according to the hole size required or desired and the hole
forming technology used and the desired jet penetration and
consequent differential ejection pressure required.
[0587] As examples, in other embodiments, the contactor 10 may have
2 micrometer diameter holes to about 60 .mu.m holes in 200 .mu.m
thick walls of the thin-walled tube 10. In other embodiments, the
contactor 10 may have about 0.3 to 10 micrometer diameter holes in
an ultra-thin walled sheet or foil etc. of about 30 micrometer
thick. For applications involving direct contactors with physical
changes such as condensing, the contactor may have orifices ranging
from 50 micrometers to 5 mm, and preferably from 200 .mu.m to 2
mm.
[0588] 8.5.2 Orifice Size Uniformity
[0589] Orifices 80 of differing size typically create drops (or
bubbles) of differing size, given sufficient pressure to emit such
drops. To form drops of uniform size and at a uniform rate, the
orifices 80 are preferably provided with uniform dimensions within
a prescribed statistical distribution parameter. For example, with
a relative standard deviation (RSD)<0.1, preferably<0.01 and
more preferably with the RSD<0.001. Of course, other suitable
RSDs may be efficaciously utilized, as needed or desired. FIG. 7
illustrates one such embodiment, which utilizes radial orifices 85
and angled orifices 86 of uniform orifice size.
[0590] 8.5.3 Pressure Drop Adjusted Orifice Size
[0591] Liquid flow within small diameter tubes 10 may cause a
significant pressure drop along the tube. Conversely, any heating
(or cooling) of the fluid along the tube will reduce (or increase)
the surface tension. To compensate for such effects, as shown
schematically in FIG. 20, where needed, the orifice size 80 can be
increased or decreased along the contactor tube 10 according to the
distance away from the manifold 240 or sub-manifold 254 and the
change in temperature, to compensate for this increasing pressure
drop or heating change in surface energy.
[0592] 8.5.4 Stepped Orifice Sizes
[0593] In other embodiments users make the orifice gradations in
substantially discrete sizes. The orifices may be arranged arranged
in discrete sizes such that the drop size formed or micro-jet
diameter and drop size distribution are significantly varied as
desired. FIG. 9 illustrates one embodiment which utilizes orifices
of three sizes. The orifices are further configured to increase in
size and then decrease in size progressively along the longitudinal
axis of the tube 10. I.e. orifices with smaller openings 89 are
shown followed by medium sized orifices 80 and orifices with larger
openings 87, which are followed by medium orifices 80 and then
small orifices 89.
[0594] With such configurations in low flow with short penetration
distances, users may control which orifices through which drops are
expelled by controlling the positive differential ejection pressure
applied. Accordingly, users can cause drops to be formed from
larger sized orifices and not from smaller orifices by controlling
the differential ejection pressure of the first fluid relative to
the second in relation to differential ejection pressure required
to overcome the interfacial surface energy relative to the given
orifice size.
[0595] 8.5.5 Graded Orifices
[0596] In some embodiments where users need or desire to control
drop size and location of drops, the direct contactor 2 includes
graded orifice arrays. The orifices 80 may have diameters changing
in curvilinear fashion with a prescribed systematic method. In one
embodiment, the orifice area may be systematically varied e.g., the
diameter of the orifices 80 is varied as the square root of the
desired orifice area. The orifices may be formed using lasers or
other suitable orifice forming methods. The desired orifice area in
turn is preferably configured as a function of spatial location. In
this manner, users can control the positive differential ejection
pressure across the tube to control the portion of the orifices
through which fluids or liquids flow.
[0597] They similarly configure gradation in orifice areas and
diameters for arithmetic, geometric, polynomial or other desired
spatial functions E.g., by varying the orifice diameter as the half
power of a transverse dimension, user obtain a generally linear
variation in drop size along that dimension. Similarly, varying the
orifice diameter according to the first power of a transverse
direction gives a generally parabolic variation in drop size along
that direction etc.
[0598] 8.5.6 Tailored Orifice Distribution
[0599] Flow through an orifice is generally proportional to the
square root of the differential ejection pressure across the
orifice. A 100:1 turn down ratio of flow rate would conventionally
or typically require a pressure difference of 10,000:1. To
compensate for this phenomena, in some embodiments, the direct
contactor may be configured to utilize the effect that at low
differential ejection pressures, orifices of different sizes will
selectively pass fluid through some passages and not thru others.
Accordingly, the contactor may be configured such that the orifices
are varied with respect to both their size distribution or profile,
number distribution, lineal net jet area distribution, and/or
spatial net jet area distribution to obtain a desired flow rate
versus differential ejection pressure distribution while achieving
a prescribed micro-jet or drop size distribution. For instance
users can obtain a linear, quadratic or other variation of flow vs
differential ejection pressure instead of (or in combination with)
the default square root relationship. This can expand the relative
control at low differential ejection pressure. This can be used to
expand the overall turndown ratio.
[0600] 8.5.7 Configuring Orifice Size Distribution
[0601] In other embodiments, users form orifices with various
prescribed sizes to correspondingly form drops or micro-jets of
various sizes or with more desired transverse distribution of a
measure of drop size such as the Sauter Mean Diameter (SMD), along
one or more of the axial, first or second transverse
directions.
[0602] 8.5.8 Non-curvilinear, Random & Pseudo-random Arrays
[0603] Random or non-curvilinear arrays: In some embodiments, the
orifices may be formed in a random spatial array in a tube wall as
needed or desired. (Not shown.) E.g., In some configurations, users
randomize the location of orifices. The size of orifices is
randomized in some configurations. In other variations, both the
location and size of the orifices is randomized. In situations
where regular orifice arrays and periodic pulsing cause pressure
oscillations, these oscillations might advantageously be reduced by
shifting to or providing such randomized arrays of orifices.
[0604] Pseudo-random arrays: In another embodiment, the orifices
form pseudo-random or non-curvilinear arrays by combining "random"
placement and/or size of orifices with net variations in the net
orifice spatial density. I.e. the net area of orifices per unit
cross-sectional area of fluid duct. These methods include varying
the net orifice spatial density as desired or needed. E.g.,
increasing and then decreasing the spatial density transversely
across the fluid duct 130. An example of such an embodiment is
illustrated in FIG. 10.
[0605] Non-Curvilinear arrays: Of course, in other embodiments, the
orifices may be oriented other non-curvilinear arrays other than
those explicitly described, as desired or needed.
[0606] 8.5.9 Orifice Cone Angle
[0607] In some embodiments, users adjust one or both of the
thickness of the tube wall and the orifice diameter to adjust the
thickness to diameter ratio (t/d). This in turn is adjusted to
achieve desired micro-jet spray angle which varies by this
ratio.
[0608] 8.5.10 Generalized Orifice Configuration
[0609] Of course, in other embodiments, the orifices may be
located, spaced and/or sized in other suitable manners with
efficacy, to achieve net spatial densities or other parameters or
to avoid certain configurations as desired or needed.
[0610] 8.6 Location of Orifices
[0611] With reference to FIGS. 1, 13 and 23, in some embodiments,
users wish to eject drops or jets (or bubbles) of a first fluid 901
through the orifices in the tube and distribute them into a second
fluid 904 (gas or liquid) flowing across the tube in one or more
desired transverse distributions of first fluid flow, or transverse
profiles of flow ratio of the second fluid to first fluid across
the tube to tube gap G. In some configurations, users inject drops
of the first fluid into a static fluid or into a vacuum. For
example, the orifices are configured uniformly in some
configurations to provide a uniform first fluid transverse
distribution. In still other embodiments, users inject drops (or
bubbles) of the first fluid against the second fluid flow. This is
preferably where gravity, centrifugal acceleration or an
electrostatic field exists or dominates to urge or propel the drops
(or bubbles) against the flow.
[0612] 8.6.1 Circumferential Angle of Orifices
[0613] As shown schematically in FIG. 23, users configure angled
orifices 86 at varying angles to the duct axis giving differing
exit angles for the micro-jets 903 as the exit. The micro-jets 903
follow nominally parabolic trajectories starting at the initial
ejection direction, and turning towards asymptotic to the
transverse second fluid flow direction or second fluid path 4.
(This flow may be perturbed by turbulence downstream of the tubes
which forms alternating vortices parallel to the tube that spin off
with the second fluid flow, depending on velocity.) The penetration
distance with time depends on the relative momentum of the first
fluid jet relative to the second fluid jet. Consequently, by
varying the circumferential angle of the longitudinal axis of the
angled orifice 86, users achieve varying jet penetration distances
of the micro-jets 903 across the gap. Similarly laminar jets will
form fairly uniform drops and position those at differing distances
across the tube to tube gap. By varying the transverse distribution
along the longitudinal axis of the tubes of this circumferential
orifice angle, users achieve varying transverse distributions of
the jet penetration distance across the tube to tube gap.
[0614] As shown in FIG. 23 and FIG. 27, in some embodiments, users
preferably locate radial orifices 85 substantially perpendicular to
(normal to or at 90 deg to) the direction of the second fluid flow
path 4 across the tube 10 (similar to the duct axis with planar
arrays). Such transverse orientations achieve a higher transverse
jet penetration than jets 903 oriented radially more downstream or
upstream, as conceptually shown in FIG. 23. In other
configurations, users preferably configure angled orifices 86 about
135 degrees from the downstream looking duct axis. I.e. 45 degrees
from the upstream looking axis. This orientation gives about the
highest degree of mixing of the two jets.
[0615] 8.6.2 Orifice Circumferential Location
[0616] Again with reference to FIG. 23, in some embodiments, users
position orifices 80 (also shown as angled orifices 86) at
different circumferential locations around the tube 10 resulting in
different locations relative to the duct and the second fluid flow.
This positions orifices 80 at different transverse distances
relative to the tube to tube gap and axial second fluid flow. It
also positions orifices with differing axial locations relative to
the duct or the tube axis.
[0617] 8.6.3 Combined Orifice Angle, Radial Location and Size
[0618] With reference to FIG. 23, in some configurations, users
individually configure the position of the orifice 86
circumferentially around the tube 10, the angle of attack of the
orifice longitudinal axis to the duct axis and the diameter or size
of the orifice. These measures provide four degrees of freedom in
configuring the degree of penetration of the micro-jets.
[0619] In some configurations, users set the circumferential angle
of the longitudinal axis of the orifice to one angle, while
separately varying the orifice circumferential location around the
tube. This adjusts the transverse location of the jet relative to
the tube to tube gap while keeping the same angle of attack between
the jet 903 and the duct axis. Conversely, users may orient the
orifices with differing circumferential angles while maintaining
the same circumferential location around the tube.
[0620] Orifice positions and orientations are preferably adjusted
according to the relative speed of the transverse flows and tube
dimensions. These parameters will vary according to how laminar or
turbulent the flow becomes and affect the flow velocity
profiles.
[0621] In accordance with some embodiments, by forming uniform
orifices and forming laminar jets, users form fairly uniform drops
(or bubbles) of the first fluid that will penetrate a fairly
uniform distance into the second fluid.
[0622] 8.6.4 Orifices at Tube Corners
[0623] For very low flow rates of the first fluid, drops may not be
ejected as the fluid flows out from the tube, but might "dribble"
or "weep" across the tube surface, wetting the tube. Certain flows
of the second fluid flowing transversely across the contactor tube
10 could also influence such wetting. Drops could then aggregate
resulting in larger drops breaking off the tube.
[0624] To reduce the tendency for drops to "dribble" or "weep"
across the outer tube surface at low pressures and with turbulence,
in some embodiments as shown in FIG. 41 users preferably form the
tube wall 30 into a generally hemispherical to triangular
cross-sectional shape comprising a more "bluff" downstream section
and then place orifices 80 near the downstream comers. This may
increase the ability of the drops to break away at low flows,
compared to orifices located normal to the fluid flow in an oval
tube. In modified embodiments (not shown), users form the tube into
a diamond or rotated square shape or similar polygonal shape and
locate orifices at the comers.
[0625] 8.6.5 Orifice Axial Location
[0626] With reference to FIG. 8 and FIG. 11, by configuring
orifices 80 in a line (column) or arc around the tube in some
configurations, users form a columnar multi-orifice spray where
drops collectively travel farther than they would in a jet from an
isolated orifice. This changes the distance the drops or micro-jets
travel into the transverse flow. To utilize or compensate for this
effect, in some embodiments, users systematically align orifices or
displace orifices in incremental locations axially along a tube as
well as around the tube. Thus, in some embodiments, users
preferably position the orifices in arcs that curve both around and
along a tube to distribute drops across the flow. (See e.g., FIG.
23 described above)
[0627] 8.6.6 Orifices in Tube Ends
[0628] As shown in FIG. 12, in other embodiments, users form
orifices 80 in the end of a tube 10, whether closed off by
hemispherical (illustrated), flat (not shown) or other surfaces.
The orifices may be configured as radial orifices 85 pointing
transverse to the flow, axial orifices 84 pointing along the duct
axis, or angled orifices 86 pointing to an intermediate angle.
[0629] 8.7 Orifice Configuration, Spacing and Orientation
[0630] In various embodiments, users preferably adjust the orifice
spacing, circumferential and longitudinal orientation,
circumferential and longitudinal position, and array configuration
to position and mix drops and/or micro-jets of the first fluid into
a second fluid with desired transverse distributions along one or
more of the axial, first and second transverse directions. These
are detailed as follows.
[0631] 8.7.1 Conical Orifice Orientation
[0632] Laser drilling typically forms truncated conical holes
through a tube wall, forming a larger orifice opening nearest the
laser and a smaller orifice opening farthest away from the laser.
With reference to FIG. 5, to reduce hole blockage and facilitate
cleaning, the smaller diameter orifice openings 89 are preferably
oriented as the inward orifice 88 at the tube inner surface 6 so
that the hole size increases outwardly to the outward orifice 90 at
the tube outer surface 7. Holes 80 with this outwardly opening
configuration can be laser drilled directly into tubes 10 from the
outside.
[0633] Where fluid differential ejection pressure is sufficient to
cause the fluid 901 to cavitate as it flows through the orifice 80,
the fluid jet forms an outwardly reducing flow cross section
resulting in a jet exiting the outer orifice 90 that is
significantly smaller than the smaller orifice 89 even though it
forms the inner orifice 88 at the tube inner surface 6.
[0634] With reference to FIG. 6, if the smallest possible holes or
orifices areas 89 are needed on the outer tube surface 7, users
preferably form orifices through strips which become the thin wall
sections 32. E.g., using lasers, etching or mechanical drilling
etc. They then form the perforated strips into tubes 10, aligning
the smaller diameter orifices 89 as the orifice outer openings or
exits 90 at the tube outer surface 7 of the strip or tube wall 32
and the larger orifice diameter 87 with the inward surface 6.
[0635] 8.7.2 Orifice Array Width
[0636] With reference now to FIG. 43, in some embodiments, users
preferably form the orifices or holes into arrays of width W. With
two arrays, the collective width 2W is about equal to about 50% to
about 100% of the diameter D of the contactor tube 10. In the
illustrated embodiment, these orifices 80 are positioned into two
arrays preferably positioned on either side of the tube 10 with a
central blank section near the downstream side of the contactor
tube 10. The central blank section is preferably about 20% to about
140% the diameter of the contactor tube.
[0637] With continued reference to FIG. 43, the exemplary
embodiment, two arrays of about 626 holes 80 across are made, each
forming perforated strips about 3.75 mm wide on either side of a
central solid strip about 1.5 mm wide. This creates a perforated
strip circumference of about 7.5 mm with about 1252 holes. In this
embodiment, the array width of about 7.5 mm is about equal to the
lateral tube spacing of about 7 mm.
[0638] In embodiments having compound tubes which will be described
below this gives a total downstream tube section circumference of
about 9 mm. In such compound tubes, users preferably allow at least
another 0.5 mm to 1.0 mm on each edge to attach to the stiffening
tube. This results in a total strip width of at least about 10 mm
to about 11 mm to form these downstream tube sections.
Alternatively, as shown in FIG. 46 the downstream section can be
configured wider to also wrap around the upstream structural tube
section.
[0639] Note that these dimensions are illustrative taking a
convenient thin walled tube. Similar effects are obtained in
selecting larger or smaller dimensions. Users may select the tube
size, shape and spacing according to the orifice diameter and
maximum micro-jet distance desired or needed relative to the tube
spacing.
[0640] 8.8 Orifice Angular Orientation to 2.sup.nd Fluid Flow
[0641] In some embodiments, in addition to, or instead of,
positioning orifices transversely around the tube, users preferably
orient the orifices at various predetermined or pre-selected angles
relative to the second fluid flow path to adjust the terminal
position of the fine drops injected into the transverse flow. By
such measures, users form drops of substantially uniform size and
position them fairly close to some desired distribution across the
transverse fluid flow in configurations using low differential
ejection pressures to create fairly laminar jets. E.g., uniform, or
proportional to the gas velocity. Similarly with higher pressures,
users form turbulent micro-jets oriented at different angles to
deliver the jet into desired locations across the tube gap.
[0642] This technique or methodology is preferably further refined
to compensate for the variation in velocity of the transverse flow
across the gap between the tubes and for the changes in
differential ejection pressure across tube wall due to the
Bernoulli effect. Accordingly, in some embodiments, users
preferably position drops between and along tubes to achieve fairly
uniform number of drops of the first fluid per unit mass of the
second fluid in the transverse flow.
[0643] 8.9 Orifice Angular Orientation to Tube Axis
[0644] With reference to FIG. 30 through FIG. 33, a jet of the
first fluid 903 exiting the contactor tube 10 imparts momentum and
turbulence to the second fluid 904 it penetrates. To increase the
micro-turbulence in a desired fashion throughout the flow, in some
embodiments users preferably orient the orifices at an angle to the
tube axis other than 90 degrees to the tube axis (off of normal)
i.e., off of a radius to the duct. This adds a momentum component
transversely to the second flow's primary velocity vector.
[0645] For example, as shown in FIG. 30, in some embodiments, users
orient the orifices 80 in the same direction diagonally across the
contactor tube 10. In some configurations, these contactor tubes 10
are aligned in parallel and offset resulting in orifices and
micro-jets alternately opposed parallel to each other across the
tube to tube gap. The alternating jets create numerous
micro-vortices between their opposed jet edges with vortex axes
parallel to the duct axis. This creates efficient thorough
mixing.
[0646] As shown in FIG. 31, in other embodiments, these tubes may
be laid up in alternatingly in opposite directions, resulting in
the orifices and micro-jets pointing the same direction in the
tube-tube gap. This creates more macro swirl first in one
transverse direction in one gap, and in the opposite direction in
the next gap. This results in vortices parallel to the duct axis
being formed beneath each tube.
[0647] As shown in FIG. 32, in other embodiments users form
orifices in a chevron pattern on either side of the distribution
tube. This results in the orifices and micro-jets pointing in the
same direction at a given angle to the tube axis on either side of
the tube 10. This can be visualized as the tube being the
"backbone" of herringbone with the orifices pointing in the
direction of the angled bones of the herringbone. With some
configurations, these chevron or "herringbone" perforated tubes 10
are laid up parallel to each other. I.e. with the chevron orifices
pointing in the same direction as shown for example in FIG. 32.
This results in the micro-jets on either side of a gap pointing in
the same direction into the gap. This results in a general swirling
flow to the entire flow about the duct axis.
[0648] In other configurations, as shown in FIG. 33, the chevron
perforated tubes are laid up alternatingly in opposite directions.
This results in orifices and micro-jets opposing each other across
a gap G. The orifices can be aligned so the micro-jets oppose each
other by the spray width so that they alternate. These sprays will
give some local mixing. They will also result in larger scale
vortices parallel to and downstream of the contactor tubes.
[0649] 8.9.1 Fluid-Droplet Vortex Mixing
[0650] In most embodiments, by providing a distributed tubular
array of tubes, users generate vortices in the second fluid flow
downstream of each of the tubes and manifolds. This distributed
turbulence creates fairly uniform mixing of the first fluid flowing
through the tube orifices with the second fluid flowing over the
contactor tubes 10. The first fluid droplets and second fluid are
mixed in the stream of vortices created immediately downstream of
each tube.
[0651] 8.10 Micro-Jet Penetration & Mixing
[0652] As mentioned above, in various embodiments, users preferably
design, configure and/or control the system so that the micro-jets
and droplets of the first fluid exit orifices 80 on perforated
tubes 10 and penetrate a desired distance into the adjoining tube
to tube gap G.
[0653] 8.10.1 Micro-Jet Penetration Distance
[0654] Users preferably use jet penetration correlations
appropriate to the pressure of the second fluid, and the respective
fluid velocities. As shown in FIG. 21, users adjust the size of
orifices 80 and the differential ejection pressure across the
orifices to adjust the micro-jet penetration distances.
[0655] To calculate these penetration distances, users use the most
effective appropriate correlations of jet penetration distances,
such as summarized by Heywood, Internal Combustion Engines. For
example, Holdeman (ASME, NASA 1997) has published jet penetration
correlations. In integrated design calculations, the desired
correlation of spray distance to orifice diameter is preferably
normalized by the other side of the equation to obtain ratios near
unity.
[0656] 8.10.2 Turn-down Ratio, Mixing & Pumping Work
[0657] Referring to FIG. 26 and FIG. 27, for maximum turn down
ratio, the maximum jet penetration is preferably configured about
equal to or longer than the tube to tube spacing. Accordingly, as
shown in FIG. 26, the tip of one jet 903 penetrates across the gap
G to near the adjacent contactor tube 10. This arrangement is also
advantageous where users desire to increase mixing in which case
they preferably configure the micro-jet penetration at peak design
conditions to about equal to or greater than the tube to tube gap
G.
[0658] It could also be designed to penetrate to about the far side
of contactor tube 10, where the jet will extend downstream of the
adjacent tube at peak flow conditions. The jet may be configured to
spray across the tube into the next gap such as such as to 200% of
the tube to tube spacing H. Opposing orifices are preferably
displaced by about half the orifice spacing h. Consequently
opposing micro-jets nominally fill the gap between the tubes when
viewed from a plan view when the orifices are configured at the jet
width of the sprays axially in line with that opposing jet
wall.
[0659] The contactor tubes 10 may further be angled giving a
varying tube to tube spacing H or tube gap G. As shown in FIG. 26,
the jet penetration may be adjusted to be some portion of the tube
to tube gap G as this varies, by adjusting the orifice size,
orientation and location.
[0660] As shown in FIG. 28, in other configurations, where users
desire reduced pumping work with relatively little change in flow,
they preferably configure the micro-jets 903 to penetrate about
half way across the tube to tube gap G from both adjacent
perforated tubes 10 in the maximum flow design conditions.
[0661] To further improve mixing in either of the arrangements of
FIGS. 26 or 28, users preferably reduce the tube to tube gap G and
increase the number of orifices and micro-jets. As shown in FIGS.
27 and 29, in some configurations, users angle some of the orifices
86 upstream, preferably at about 135 degrees upstream from the
second fluid flow path to obtain about the highest degree of
mixing.
[0662] To achieve these features, the orifice size, location and
orientation, array configuration, gap between tubes, fluid
differential ejection pressure, temperature, and external
electrical field (as discussed further below) are designed or
controlled relative to the flow, density and viscosity of the
second fluid. The droplets will generally follow an approximately
parabolic arc compounded by oscillating vortices formed by
tubes.
[0663] For example, in the embodiments of FIGS. 26 through 29,
tubes of about 4 mm diameter are positioned about every 7 mm giving
about a 3 mm tube to tube gap. In this case, users preferably
inject the droplets about 1.5 mm to 7 mm into the transverse
diverging flow of the second fluid depending on the desired design
operating parameters. Users may inject liquid or gas jets through
orifices 80 of about 1 .mu.m to about 200 .mu.m in diameter in
common applications depending on the dimensions and fluid
properties etc. To achieve fairly small drops with fairly uniform
mixing, users preferably configure orifices for about 5 .mu.m to 40
.mu.m. In cooling applications, these may increase to about 100
.mu.m to about 2 mm or larger.
[0664] 8.10.3 Tube to Tube Transverse Fluid Delivery Distributions
& Ratios
[0665] With continued reference to FIGS. 26-29, to adjust the
delivery distribution of the first fluid 901 delivered across the
gap G between adjacent contactor tubes 10, users model the
transverse fluid distribution for each micro-jet. They then
evaluate the combined transverse fluid distributions or profiles by
summing the distributions of the respective jets.
[0666] To achieve a desired degree composition of the second fluid
904 relative to the first fluid 901, users preferably evaluate the
axial velocity of the second fluid 904 transversely across the tube
to tube gap G. They then configure the orifice area, orifice
orientation and differential ejection pressure across the tube wall
to configure the micro-jets across the tube to achieve the desired
first fluid flows distribution relative to the second fluid flow
distribution in the tube to tube or second transverse direction
across the duct. These are configured such that the mean composite
second transverse delivery distribution of the first fluid 901 is
desirably proportional to the second fluid flow delivery
distribution to achieve a desired ratio profile of the second to
first fluid flows in this second transverse direction.
[0667] 8.10.4 Uniform Tube to Tube Fluid Profiles
[0668] For the most uniform fluid distribution across the gap,
users expect to configure the jets to penetrate about 35% to 45% of
the tube gap G from either side. Similarly the jets penetrate about
60% to 90% of the tube gap G from each side of the gap providing
overlapping jets and overlapping transverse fluid delivery
distributions. In modified embodiments, users preferably provide a
combination of penetrations using radial and upstream orifices to
provide desired combinations of mixing and tube to tube flow
profile of the first fluid relative to the second fluid.
[0669] To configure the delivered fluid 901 to more closely match a
peaked velocity profile and fluid delivery profile of the second
fluid 904 flowing between the tubes, users preferably configure the
jets to penetrate about 40% to 50% of the tube to tube gap G from
either side. Similar results are obtained by configuring jets to
penetrate about 55% to 65% of the tube to tube gap G. Such
configurations provide transverse fluid flow distributions and
profiles between the tubes that are greatest about mid gap, and
fall off towards the tubes.
[0670] 8.10.5 Assymetric Tube-Tube Fluid Profiles
[0671] Users configure the circumferential orientation of the
orifices about the tube to selectively direct the micro-jet spray
to a desired portion of the tube to tube gap G. To achieve an
asymmetric distribution, for example, they orient the orifices on
opposite of the Gap and adjust the orifice areas and differential
ejection pressure to deliver the micro-jet upstream (or
down-stream) so that they are delivered asymetrically across the
gap G.
[0672] With reference to FIG. 24, users position two contactors 10
of diameter D to deliver a first fluid 901 through angled orifices
86 into the gap G between the contactors with a spacing H. The
second fluid flows from the upstream inlet 134 to the downstream
exit 136. For example, users configure the orifice on the first or
"upper" tube to deliver fluid about 25% to 50% across the gap from
the lower tube to the upper tube as before. Then the orifice in the
other tube is adjusted to about 160 degrees * * * to deliver the
micro-jet between 25% and 50% of the Gap distance from the lower to
upper tube. This configuration positions both micro-jets from 25%
to 50% of the distance across the Gap between the lower and upper
tubes giving a highly asymmetric peaked fluid distribution.
[0673] With reference to FIG. 25, in a similar fashion, users form
an orifice on the "upper" side to deliver a micro-jet between 25%
to 50% of the gap G from the "lower" tube to this "upper" tube.
Similarly, they orient the orifices in the opposing tube (e.g., the
"lower" tube) further upstream near 170 degrees to deliver the
micro-jet between 0% and 25% of the gap from this "lower" tube to
the "upper tube". Such a configuration provides fluid on one half
of the tube to tube gap G but not on the other side.
[0674] These methods of asymmetrically orienting tubes on adjacent
tubes about a Gap can be used together with methods of adjusting
the orifice area and jet penetration distance to taylor the mean
intra-gap fluid distribution to a desired asymmetric fluid delivery
distribution. The angle of the orifice longitudinal axis to the
tube longitudinal axis can similarly be varied to adjust the fluid
distribution distance across the gap G.
[0675] 8.10.6 Part Load Operations
[0676] With continued reference to FIG. 26 through FIG. 29, fluid
flow generally varies as the square root of the differential
ejection pressure across the contactor tube wall 30. However,
varying the differential ejection pressure across the tube wall 30
also varies the jet penetration. When the jets penetrate the full
gap under peak design conditions, they penetrate part way under
part load conditions. (See, e.g., FIG. 26 and FIG. 27.) Similarly,
when jets are designed for partial penetration at design
conditions, the penetration is further reduced at off design
conditions. (See, e.g., FIG. 28-FIG. 29.) In some configurations,
users preferably evaluate the relative degree of mixing and the
achieved ratios of second to first fluid as a function of the
degree of gap penetration over the desired operating cycle to
arrive at a desired design penetration for the jets.
[0677] 8.11 Modifying Tube Shape
[0678] In some embodiments, users preferably adjust tube shape to
affect the pressure drop and flow across a contactor tube or
contactor tube array or bank. They change tube shape to affect the
vortex intensity and turbulence downstream of the tubes. Tube shape
is also be used to influence the direction of flow and momentum of
fluid flowing across tubes in some configurations. Flow induced
differential ejection pressure across a contactor tube also causes
bending forces and moments on the tubes.
[0679] In some embodiments, users selectively adjust the cross
section shape of the contactor tubes to streamline a cylindrical
tube 10 and orient perforated tube arrays to adjust these
parameters, as needed or desired. (See e.g., compare FIG. 35, FIG.
36 and FIG. 37 with FIG. 34.) By streamlining tube cross section,
users preferably increase the tube's moment of inertia about the
bending axis and increase its ability to resist the bending
moments. Conversely, users sometimes adjust the cross section of
the contactor 10 to form a more bluff or anti-streamlined
configuration. (Compare e.g., the triangular contactor FIG. 41 and
streamlined cusped contactor FIG. 42 with FIG. 34.)
[0680] By forming a more bluff body shape on the downstream side of
the tube, users increase the turbulence downstream of the tube,
eventually forming two vortices downstream of the two outer edges.
By such methods, users change parameters to improve present value
of total system costs including capital, assembly and operating
costs.
[0681] 8.11.1 Circular Tubes
[0682] In some common configurations, users use generally circular
tubes to form distribution tubes to deliver first fluid, such as,
fuel or thermal diluent. A circular tube shape provides more
turbulent vortex mixing than tube streamlined shapes. (See, e.g.,
FIG. 34.)
[0683] 8.11.2 Streamlined Non-circular Tubes
[0684] In some embodiments, users reduce the pressure drop across
the contactor tube array while increasing the surface heat transfer
coefficient by configuring the contactor fluid tubes and manifolds
to a non-circular shape with the narrower cross section facing into
the fluid flow. This reduces the parasitic pressure drop, reducing
the pumping work to move the second fluid across the distributed
contactor, but it reduces vortex mixing.
[0685] Elliptical or Oval Tubes: As shown in FIG. 35, in some
embodiments, a generally elliptical or oval tube 10 is used.
Utilizing a generally simple process, a generally circular tube is
pressed to flatten it from side to side to easily form the tube 10
into a generally elliptical or oval shape.
[0686] Symmetric Streamlined Aerodynamic Shape: As shown in FIG.
36, in further embodiments, users further form the tube 10 into a
more streamlined cross section using multiple forming rollers where
the downstream tube portion is pressed narrower than the upstream
portion. Such streamlined shapes generate some of the least vortex
mixing.
[0687] Flattened Tubes: Gases have substantially higher volume than
liquids for the same mass. The necessary liquid flow
cross-sectional area through the distribution tube 10 is often much
smaller than that of the gas flowing across the tube. Consequently,
in still further embodiments as shown in FIG. 37, users further
flatten the tubes 10 to reduce the drag from the second fluid 904
flowing across the tube while retaining the stiffness to bending
due to the cross-flow drag.
[0688] Dual Channel Internally Bonded Flattened Tubes: A flattened
tube 10 will expand given sufficient internal pressure. In some
embodiments, as shown in FIG. 38, users internally bond the
flattened tube walls near their middle to form a multi-passage
compound contactor tube 220 while leaving room for liquid flow.
Pressing an elliptical tube in the middle will form a dumbbell or
figure "8" shape. Forming and bonding a flattened tube into this
shape now generates two internal fluid ducts 222. In some
embodiments, users continually bond a dumbbell shaped tube to form
two fluid channels. In modified embodiments, users further flatten
the ducts.
[0689] Single Channel Flattened Tube: In some embodiments as shown
in FIG. 39, by flattening one portion of the tube 10, users obtain
a straightened figure "9" or "6" shaped tube. Users may internally
bond the tube walls 30 by this forming pressure. In other
embodiments users electro-weld the walls, or users internally coat
the tube with a solder or braze and then heat bond the tube
walls.
[0690] Asymmetric Aerodynamic Shape: In some embodiments as shown
in FIG. 40, users use aerodynamic wing shaped tubes 10 to
preferentially redirect the fluid flow across the tube in an
efficient manner. By adjusting the degree of transverse "lift",
users increase or decrease the degree of redirection.
[0691] 8.11.3 Anti-streamlined Bluff Tubes
[0692] In some embodiments, users form the tubes into less
streamlined shapes to increase the inherent turbulent mixing
downstream of the tubes as needed or desired.
[0693] Transverse Elliptical Tubes: In some embodiments (compare,
FIG. 35), by orienting the long axis of an elliptical tube 10
normal (at 90.degree.) to the flow axis of the second fluid, users
increase the flow turbulence as well as the pressure drop across
the perforated tubes. (i.e., by aligning the short axis of the
ellipse with the second flow direction or the axis of the fluid
duct 130.) By using tube shapes that are sufficiently bluff in the
downstream direction, users form two vortex streams from either
side of the anti-streamlined tube, thereby increasing mixing. E.g.,
as in a paddle or oar being pushed through a fluid with the bluff
face in the direction of movement.
[0694] Hemispherical or Triangular Shapes: Users may use shapes
that are somewhat streamlined upstream but bluff downstream in some
embodiments to reduce pressure drop while creating flow separation
with multiple vortices to improve mixing. E.g., as shown in FIG.
41, a tube formed towards a semicircular or triangular
cross-section. To increase drop shedding as the first fluid exits
the distribution tube, users preferably position orifices near the
widest transverse axis to provide about the greatest differential
ejection pressure boost by the Bernoulli effect. For example, as
shown in FIG. 41, users position orifices near the downstream
outside edge of triangular contractor tubes.
[0695] Cusped Bluff Tube: In some configurations, as shown in FIG.
42 users preferably configure the downstream portion of the
contactor tube 10 into one or more downstream facing cusps to form
a cusped contactor tube 28. Using two cusps provides the advantage
of assisting the downstream double vortex formed by the second
fluid flowing past the tube that causes a lower pressure region
which in turn results in a recirculating flow in the upstream
direction towards the axis of the contactor tube 10.
[0696] 8.12 Design Configuration
[0697] As users narrow and streamline the distributed tubes, users
reduce the drag of the second fluid flowing across the tube arrays.
Conversely this increases the capital cost of the tube arrays.
Similarly as users increasing the tube-tube spacing H, users reduce
the drag across the tube arrays. At the same time, users increase
the length of the fluid duct and pressure vessel, as well as the
pumping work to deliver the first fluid through micro-jets. These
parameters will vary with the viscosity and thus the orifice size
and temperature of both the injected first fluid and the transverse
second fluid.
[0698] In some embodiments, users adjust the diameter, shape,
spacing of tubes, the delivery velocity of fluids size of orifices,
and differential delivery pressures to improve drop formation
and/or micro-jet penetration and mixing of fluids while reducing
the parasitic fluid pressure drop and fluid pumping losses, fluid
filtration and associated costs.
[0699] 8.13 Fluid Pressure Drop Ratios
[0700] With reference back to FIG. 1, in many embodiments, users
desire or need to control the ratio of the flow of the second fluid
904 that mixes with the flow of the first fluid 901 delivered
through the contactor tubes 10. This generally relates to the
velocity ratio times the density ratio times the net
cross-sectional flow area of the respective fluids 901, 904 normal
to the fluid flow axis (or specific orifice areal density of
orifice area to duct cross sectional area.) In many embodiments,
the velocities in turn relate to the cumulative acceleration each
fluid experiences from the pressure drop along the duct 130, for
given fluids, pressures and temperatures etc.
[0701] For many embodiments, the corresponding primary control
parameters are the pressure drop across the tube array relative to
the differential ejection pressure drop across the contactor tube
wall. The second fluid flow rate and pressure drop across the tube
array is often held constant or varies relatively slowly in
proportion to the pressure drop across the fluid duct 130 between
the inlet 134 and outlet 136. Users generally primarily control the
differential ejection pressure drop across the orifices of the
respective distribution tubes to rapidly control the delivery of
first fluid 901.
9 Forming Arrays of Perforated Tubes
[0702] In some embodiments, users preferably form the perforated
distribution tubes described above into various two or three
dimensional arrays ranging from a circular (or elliptical) planar
tube array 265 in a circular duct 144 as shown in FIG. 50, to a
cylindrical tube array 270 oriented axially in an annular duct 146
as shown in FIG. 52, and to a rectangular tent tube array 268 in a
rectangular duct 145 as shown in FIG. 53. Such two or three
dimensional arrays provide the benefit of more uniformly
distributing and mixing the first fluid 901 flowing thru the tubes
10 and orifices 80 with the second fluid flow 904 within the fluid
ducts. The second fluid flow 904 commonly flows across those tube
arrays. E.g., users may spray water or fuel into air to uniformly
mix them together within a duct. In some configurations, the second
fluid flow 904 is delivered through such contactor arrays.
[0703] 9.2 Tube Orientation to Duct Flow Tubes Perpendicular to the
Duct or Flow Axis
[0704] With particular reference to FIG. 50, in some embodiments,
users preferably orient the perforated tubes 10 across and
substantially perpendicular to (i.e., normal or at 90.degree.) the
fluid duct 144 and common flow axis of the second fluid 904. FIG.
51 shows an expanded view of a section of the contactor 10 having
orifices 80 from which are ejected micro-jets 903. In such an
embodiment, the tubes 10 may be configured into a circular planar
array 265 comprising a plurality of concentric circular tubes 10.
E.g., Such a transverse circular planar array 265 generally
provides a preferably or an improved distribution of droplets and
greatest and most uniform mixing downstream of the contactor tubes
10 for a given tube length compared to tubes at other angles to the
fluid duct 130. It provides fairly uniform distribution of vortices
downstream of the contactors 10, and thus fairly uniform vortex
mixing within the fluid 904 and transversely across the circular
fluid duct 144 shown.
[0705] 9.2.2 Tubes Parallel to the Duct or Flow Axis
[0706] As shown in FIG. 52, in some embodiments, users provide an
alternative tube orientation is where the perforated tubes 10 are
oriented substantially parallel to or at a small angle to the axis
of the second fluid 904 or the axis of the fluid duct 130. In this
embodiment, users provide axially oriented contactor tubes 10
connected to one or more manifolds 240 or sub-manifolds 254, formed
in an arc or desired curvilinear configuration, and positioned
within an annular fluid duct 146 or duct section. This axial array
orientation desirably provides greater capability and flexibility
in controlling the axial fluid distribution distribution of the
first fluid 901 etc. delivered through the contactor tubes 10.
[0707] 9.2.3 Tubes at an Angle to the Duct or Flow Axis
[0708] In some embodiments, users efficaciously orient the
contactor tubes at some angle to the fluid duct and flow axis as
needed or desired. This typically varies according to the two or
three dimensional array configuration desired. For example, as
shown in FIG. 53, in one embodiment, the contactor tubes 10 are
preferably configured at an longitudinal angle to the second flow
path 4 of the second fluid 904 within a rectangular fluid duct 145.
The contactors 10 are preferably connected to manifolds 240
oriented transversely to the duct 145.
[0709] Users preferably adjust the angle of the contactor tube 10
relative to the axis of the fluid duct 145 according to the
relative degree of control over the axial fluid delivery
distributions and profiles and the transverse fluid delivery
distributions and profiles. These in turn affect the relative
control over the transverse distributions and profiles compared to
axial distributions and profiles of the respective fluid
ratios.
[0710] 9.3 Axial Profile Control
[0711] With continued reference to FIG. 52, in such an embodiments,
users may preferably also control the axial as well as transverse
distributions and profiles of fluid delivery in the distributed
contactor system 2 along the fluid duct 130 such as a rectangular
duct 145.This is variously accomplished by distributing orifices 80
axially along the fluid duct 130 as well as transversely across the
duct. This may include combinations of orienting orifices along the
contactor tubes 10 and configuring tubes 10 across the duct 130.
With reference to FIG. 53, it may also comprise axially orienting
the orifices 84, or radially orienting orifices 86 aligned with or
with a component directed along the axis of the fluid duct 130 or
second flow path in some configurations, such as the axial
orientation of orifices 80 and contactor tubes 10.
[0712] 9.4 Two Dimensional Tube Array Configurations
[0713] 9.4.1 Elliptical/Circular/Spiral Arc Contactor Arrays
[0714] For elliptical or circular ducts, in some embodiments, users
preferably form curvilinear sections 21 of perforated tubes into
elliptical or circular arcs. For example, as shown FIG. 54, users
then form an array of such circular arcs 21 connected to at least
one manifold, preferably connected between two or more radial
manifolds 240 (or secondary manifolds) to create an elliptical or
circular planar array 265 with arc shaped flow passages. They
similarly form the perforated curvilinear sections into one or more
spiral shaped arcs. They then connect these spiral arcs to one or
more manifolds or sub-manifolds to form a spiral contactor array
(not shown.)
[0715] In other embodiments, users connect the contactor tubes to
one radial manifold or sub-manifold. In modified embodiments, users
further form a perforated tube into a single spiral and form a
helical or pseudo circular contactor array. A spiral perforated
tube is typically simple to form. As mentioned above, users
preferably adjust the orifice diameter to compensate for the
progressive pressure drop along the contactor tube from the
manifold to the end of the contactor tube or to the center (e.g.,
outside to inside) resulting in more non-uniform micro-jet
penetration or drop formation along the contactor tube.
[0716] 9.4.2 Rectangular/Trapezoidal Contactor Arrays
[0717] With reference to FIG. 55, in some embodiments, users form
generally parallel arrays of perforated tubes 10 into rectangular
planar arrays 266 for rectangular fluid ducts. To reduce pressure
drops, users preferably run the perforated tubes 10 across the
shorter dimension of the rectangular duct and preferably join the
direct contactor perforated tubes 10 to manifolds 240 or
sub-manifolds oriented about parallel to and generally along the
long sides of the rectangular duct. Where sub-manifolds are used,
they are in turn connected to manifolds 240. In other embodiments,
users run the perforated tubes 10 across the longer dimension of
the rectangle and connect them to one or more manifolds 240 running
across the shorter dimension of the rectangular fluid duct 130. In
other embodiments, users prepare four triangular arrays of direct
contactor perforated tubes 10 preferably extending out from the
center of the rectangle between radial manifolds 240 to form a four
sided rectangular planar array (similar to a flattened
quadrilateral pyramid).
[0718] 9.4.3 Annular Contactor Arrays
[0719] As shown in FIG. 56, for annular fluid ducts or sections of
annular ducts, in some embodiments, users form perforated tubes 10
into an array of arcs running about parallel to the circumference
of the annular duct. Users connect these perforated tubular arcs 10
to one or more radial manifolds 240 or sub-manifolds to form an arc
type annular planar array 267. In a modified embodiment shown in
FIG. 60, users may form the perforated tubes 10 into an annular
array 267 of radial tubes. They connect them to one or more
manifolds 240 or sub-manifolds 254 formed in arcs, to form a spoke
type annular array (See, e.g., FIG. 60).
[0720] 9.5 Three Dimensional Spatial Arrays of Perforated Tubes
With reference to FIG. 54, FIG. 55, and FIG. 56, in some
embodiments, users preferably take the two dimensional contactor
arrays such as described herein, and extend them into three
dimensional contactor arrays such as downstream opening concave
arrays, downstream decreasing convex arrays or similar tent shaped
forms as further described as follows.
[0721] 9.5.1 Conical Array of Helical Wound Tubes
[0722] With reference to FIG. 1, in some embodiments, users
preferably wind the perforated tubes 10 into desired circular arcs
(or forming a helix with a desired helical angle) about a conical
or similar elliptical form. Using a fairly uniform tube to tube gap
or spacing, this configuration efficiently fills the
cross-sectional space of a elliptical or circular duct 130. At the
same time, such configurations provide more room between adjacent
tubes for axial flow of the second fluid and reduce the pressure
drop across this tube array.
[0723] In a modified embodiment, shown in FIG. 57, users may
preferably provide at least one and more preferably two or more
manifolds 240 or sub-manifolds 254 oriented about axially tangent
to the conical surface, and are connected to tubes 10. Using
multiple such manifold tubes 240 improves rigidity while reducing
pressure drops along the perforated tubes 10.
[0724] 9.5.2 Tent Shaped Tube Array
[0725] As shown in FIG. 58 relative to FIG. 55, for rectangular
ducts, in some embodiments, users preferably take a rectangular
array 266 of perforated tubes 10 and extend it to a three
dimensional rectangular tent shaped array 268 of perforated tubes
10. Users preferably bond the perforated tubes 10 transverse to the
flow between V shaped manifolds 240. In modified embodiments, users
orient the perforated tubes 10 and manifolds 240 in the
complementary directions. Here manifolds 240 are oriented about
along one or more of the tent ridge and parallel base edges. Users
then bond the perforated tubes 10 between the base and ridge
manifolds 240. This provides shorter tube lengths with greater
control over axial fluid distributions and profiles.
[0726] 9.5.3 Polygonal Pyramid:
[0727] In some embodiments users form a pyramid array of contactor
tubes for rectangular ducts. Conceptually, users take the
rectangular array formed from four triangular arrays of perforated
tubes as described above and extend that array to three dimensional
pyramid such as a trilateral pyramid or quadrilateral pyramid.
[0728] As with FIG. 58, the perforated tubes are preferably bonded
between radial manifolds oriented down the four extended edges of
the pyramid. In a similar fashion users can form triangular
pyramids from triangular arrays of perforated tubes connected to
manifolds along the array edges. Similarly, users sometimes form
hexagonal pyramids from triangular arrays of perforated tubes
connected to manifolds along the array edges.
[0729] 9.5.4 Annular Tent Tube Array
[0730] Annular ducts are often encountered in industry. E.g.,
between a compressor and a gas turbine. These annular ducts are
often divided into multiple annular duct sections. Accordingly, as
shown in FIG. 59, in some embodiments, users preferably combine and
adapt the annular perforated tube array concept (e.g., FIG. 56)
with the tent shaped perforated tube array e.g., FIG. 58) to form
annular arrays of contactor tubes. As shown in FIG. 59, users may
form a curvilinear tent shaped annular tent array 269 of perforated
tubes 10 that generally conforms to a section of an annulus. Such
an array 269 generally comprises a pair of annular arrays 267 as
shown in FIG. 59 oriented at an angle with respect to each
other.
[0731] As shown in FIG. 60, for gas turbine combustors, users
preferably use a radial spoke configuration of direct contactors 10
connected to one or more arc manifolds 240 around the periphery of
the annulus. Such a "3-D" annular tent array 269 provides the
greatest control over the first fluid flow delivery distribution in
the radial transverse direction. It also reduces the pressure drop
across the annular array. This configuration further simplifies and
shortens the transition pieces commonly used to transition from
circular ducts to annular section ducts. This further reduces the
flow redirection and inefficiencies typically encountered for such
transitions. In other configurations, users configure the direct
contactors 10 into arcs and connect them to radial manifolds 240 or
sub-manifolds 254.
[0732] 9.5.5 Cylindrical Tube Array or "Can" array
[0733] In yet other embodiments, as shown in FIG. 65, users form a
cylindrical tube array 270, using perforated tubes 80 formed into
circular arcs 21 connected to one or more axial manifolds 240 or
sub-manifolds 254. Similarly they form axial direct contactors 80
to generally circular manifolds 240 or sub-manifolds 254. Such
configurations provide a convenient means of mixing a first fluid
uniformly with a second fluid flowing radially into or out of a
circular duct.
[0734] 9.5.6 "Top Hat" Tube Array
[0735] In modified embodiments, as shown in FIG. 66, users adapt a
cylindrical tube array 270, to form "top hat" or "can" shaped tube
arrays 271 by adding a circular array 265 to the end of a
cylindrical array. Users wrap perforated tubes 10 into a
cylindrical or helical shape to form the sides and/or the top.
These can be connected to manifolds 240 or sub-manifolds 254 as
described herein in connection with one or more of the conical
arrays 262, 264.
[0736] 9.5.7 Bulbuous or "Dandelion" Tube Array
[0737] In some embodiments, as shown in FIG. 67, users form
contactor tubes 10 into a bulbuous shaped tube array 273 (or
"Dandelion" or "tulip" shaped.) In some configurations, they
connect the contactor tubes 10 to manifolds 240 or sub-manifolds
preferably oriented generally along a great circle of the bulbuous
array 273. The bulbuous array 273 is preferably oriented about the
end of a fluid duct 130 generally configured as the "stem" of the
array. This configuration preferably provides fluid mixing about a
spherical or similarly bulbuous surface. The second fluid is
delivered through the fluid duct 130 or "stem" into the inside of
bulbuous array. The bulbuous array 273 is elongated in some
modified configurations. Such configurations are useful for radiant
exposed burners.
[0738] 9.5.8 Extended Arrays Tube Arrays
[0739] For large fluid flows, in some embodiments, users preferably
form larger extended arrays of perforated tubes by taking two or
more of the two or three dimensional ("3-D") contactor array
structures described herein and arranging them into extended arrays
of such array structures as desired or needed. Accordingly, users
take tubular arrays with circular, hexagonal, Cartesian or similar
footprints and replicate them in linear, circular, spatial arrays
as desired or needed to fit into the corresponding fluid ducts or
similar regions.
[0740] Similarly in various embodiments, users replicate sections
of annular tube array to form part or all of an annular array. For
circular or polygonal tube arrays are used that do not fill the
desired fluid duct or spatial surface, users preferably provide
blocking structures to fill the inter-array gaps and prevent fluid
from flowing between the tube arrays without being desirably
contacted by contactor tubes.
[0741] 9.5.9 Array Opening Orientation
[0742] "Horn" Orientation: In some embodiments, as shown in FIG.
69, users orient a downstream opening concave tube array such as a
helically wound tube array 262 in the "horn" orientation with the
apex or point upstream and "mouth" downstream relative to the fluid
duct 130 or second fluid flow 904, when users need or desire the
second fluid to flow across the tubes from outside/upstream of the
tube array to the inside downstream of the array.
[0743] With Reference to FIG. 1, such an embodiment may also
comprise a series of circular curvilinear sections 21 connected by
a pair of manifolds 240. With this orientation, the second fluid
flow 904 entrains droplets or micro-jets of a first fluid 901 from
the tube orifices 80 into the inside of the concave tube array 260
(or a similar tubular conical array) on its "downstream" or
"interior" side.
[0744] "Funnel" Array Orientation: In other embodiments, as shown
in FIG. 68 users orient the conical array in a downstream
decreasing convex array or "funnel" tube array configuration 264
with the apex or point downstream and the "mouth" upstream relative
to the fluid duct 130 or second fluid flow 904. Similarly, as shown
in FIG. 70, the funnel tube array configuration may be formed by
providing a plurality of transverse extending tubes 10 that are
connected by a V-shaped manifold 240. This arrangement commonly
causes the second fluid 904 to flow from 4upstream inside the
downstream decreasing convex tubular array or "funnel" conical
array 264 to the outside downstream of the convex array or "funnel"
conical array 264 when users need or desire the droplets or
micro-jets of the first fluid 901 to be entrained by the second
fluid 904 to outside the downstream side of the convex array or
"funnel" conical array 264 as they exit the tube orifices 80.
[0745] 9.6 Flow Direction Tube Offset
[0746] A planar tube array, such as the circular array 265 shown in
FIG. 54, blocks part of the flow cross section, restricting the
flow to the space between the tubes. This can cause a significant
pressure drop in the fluid flow across it. e.g., of the 2.sup.nd
fluid. To reduce this problem, in some embodiments, users
preferably offset tubes along the flow velocity axis to increase
the gap between tubes. This typically reduces the flow constriction
and the pressure drop across the tubes. This generally generates
substantial savings in parasitic pumping energy, resulting in
savings of both capital and operating costs.
[0747] 9.6.1 Offsetting Adjacent Tubes
[0748] For instance, in some configurations users offset adjacent
contactor tubes 10 (See e.g., FIG. 54) by about 122% of the tube
spacing H to increase the gap G between the tubes 10 to about equal
to the tube spacing W. E.g., using tubes of about 4 mm diameter on
about 7 mm intervals, offsetting the tubes by about 8.5 mm will
increase the gap G between tubes from about 3 mm to about 7 mm or
about equal to the tube spacing. In this example, this offset
increases the area between the tubes 10 to about equal to the
unobstructed cross section of the flow.
[0749] In other embodiments, users similarly offset tubes 10 to
increase the gaps between the tubes. While there is still
significant drag across the tubes, offsetting adjacent tubes
significantly reduces the flow constriction and consequent pressure
drop. (See, e.g., FIG. 57.)
[0750] 9.6.2 Conical Arrays
[0751] As shown in FIG. 57 and described above, for circular flow
ducts, some embodiments preferably use a conical or helical tube
array rather than a planar circular array. With such an conical or
helical array, the flow area between tubes can be increased to
greater than the cross-sectional area of the total flow by
sufficiently reducing the cone angle in the "horn"
configuration.
[0752] Similarly, the flow area can be increased by increasing the
cone angle to much greater than 180 degrees in the "funnel"
configuration as shown in FIG. 72. Here the upstream area of the
array is larger than the downstream area.
[0753] 9.6.3 Pleated Array
[0754] At the other extreme, in some embodiments, users may
increase gap area between tubes by offsetting alternating tubes
upstream and downstream in a zig zag pattern to form a pleated
array. For example, FIG. 71 illustrates such a pleated array 284.
In this embodiment, the inter-tube gap by forming tubes 10 into
intermediate pleated arrays 284 with larger zigzags. Here they
offset several tubes 10 in one axial direction along the fluid duct
130, then offset the next several tubes 10 in the other axial
direction. The pleated array 284 comprises a pair of rectangular
arrays 266 axially displaced and offset in the transverse direction
by half the tube to tube spacing.
[0755] Similarly FIG. 72 shows a larger pleated array composed of
two tent shaped arrays 268. Each tent array 268 comprises a series
of transverse extending tubes 10 that are connected by a V-shaped
manifold 240. In this embodiment, the open end of the V-shaped
manifold 240 is positioned upstream of the "ridge" or closed end of
the tent array 268. In this manner, the tubes 10 form a pair of
adjacent V-shaped tube banks. This arrangement significantly
reduces the axial dimension of the fluid duct 130 and associated
costs of the pressure vessel 170 while increasing the inter-tube
gaps and reducing flow constrictions.
[0756] 9.6.4 Compound Arrays
[0757] In further embodiments, users combine and adapt these
contactor array formations. For example, users use a conical tube
array (See e.g., 68) in the center portion of the flow. They then
take the pleated contactor array and form it into a circular
pleated array to surround the conical tube array. (Compare FIG.
71.) These examples of offsetting tubes generally apply fairly
equally to forming circular arrays, rectangular arrays, annular
arrays, or otherwise ordered arrays in respectively circular,
rectangular and annular shaped ducts.
[0758] 9.6.5 Tube Spacing
[0759] In various embodiments, users space the tubes across the
flow at intervals as needed or desired. With reference to FIG. 27
and FIG. 29, users preferably form an array of tubes 10 of diameter
D, spaced at intervals H. This results in a gap G between the
orifices where G=H-D. The tube spacing H and tube diameter D, and
orifice area and differential ejection pressure are preferably
adjusted so that the penetration distance of the micro-jets exiting
the orifices 80 extend between about 1% and 200% of the tube to
tube gap spacing G.
[0760] Where users perforate the tube 10 about a portion of the
circumference of the tube, the tube spacing H is preferably equal
to about the total width of the perforated area about the
circumference. For example, the tube spacing may be nominally
configured about 175% of the tube diameter D, preferably in the
range of about 101% to 500% of the tube diameter D. Similarly,
users may set the gap G between the tubes at about 1% to 400% of
the tube diameter D. E.g., users may configure the tube spacing H
to about 7 mm. This in a gap between tubes G of about 3 mm in the
above example for tubes with diameter D of about 4 mm.
[0761] 9.7 Drilling Orifices
[0762] In some embodiments, users preferably use laser drilling
technology with a high Thickness to Diameter (T/D) drilling ratio
to create numerous small orifices in tube walls 30. E.g., using
technology with about 100:1 thickness/diameter drilling capability
with 200 .mu.m thick walls nominally enables formation of about 2
.mu.m diameter orifices using suitable wavelength lasers. Such
orifice drilling desirably combines a structural tube wall 30 with
numerous fine orifices 80. With reference to FIG. 2, FIG. 3, FIG.
4, FIG. 5, and FIG. 6, users further preferably form thin tube wall
sections 32 through which they drill the orifices 80. This enables
smaller holes for a given Thickness to Diameter drilling ratio, or
conversely, using a less expansive technology with lower
thickness/diameter ratio while achieving similarly sized orifices
80. E.g., using a carbon dioxide laser with T/D of about 10 to
achieve 20 .mu.m diameter orifices in a 200 .mu.m thick wall.
[0763] With reference to FIG. 43, FIG. 44 and FIG. 45, in other
embodiments users use one or more of the compound perforated tube
configurations 200 (which will be described in more detail below)
with thicknesses of thin wall sections 32 of about 1% to 75% of the
structural tube section 36, and preferably about 5% to 50% of the
thickness of the structural wall 36. Using such measures, users
readily form an array of fluid orifices 80 with orifice diameter
from about 10% to 0.1% of the structural tube wall thickness (e.g.,
about 0.5% to 0.05% of the tube diameter). E.g., they may use more
common laser drilling technologies with typically 10:1
Thickness/Diameter capability. Such combinations enable users to
drill orifices ten times smaller with more conventional drilling
equipment than with conventional relevant art. Preferably using
drilling technologies with higher drilling Thickness/diameter laser
drilling capabilities of about 100:1 to 200:1 nominally increase
this range of orifice sizes by an order of magnitude or more.
[0764] 9.8 Drop Array Formation
[0765] Using such measures, users typically configure orifices to
form micro-jets in a suitable array to desirably distribute
droplets across the transverse flow. They similarly configure
orifices along and/or about the tubes. In some embodiments, users
direct orifices longitudinally relative to the cross flow. For
example, configuring 10 .mu.m orifices would nominally form
droplets about 20 .mu.m in diameter giving a specific surface area
(surface area/volume) of about 2,500.sup.-1. Similarly a finer
array of about 2 .mu.m orifices, nominally forms about 4 .mu.m
droplets. Ignoring droplet coalescence, this would nominally create
a specific surface area of about 125,000.sup.-1.
[0766] 9.9 Manifolds
[0767] In various embodiments described above, users preferably
connect multiple distribution tubes to one or more manifolds. For
example, as shown in FIG. 50, FIG. 52 and FIG. 53 a manifold 240
connects a plurality of distribution tubes to each other.
Relatively large manifolds 240 reduce the internal pressure drop
and pumping losses of the first fluid flowing within the
distribution tubes 10. They also provide some structural support
for the distribution tubes 10 against the bending forces of the
second fluid 904 flowing across the tubes 10 and manifolds 240 and
for the pressure oscillations caused by vortices downstream of the
tubes 10 and from resonant pressure oscillations. Various manifold
configurations may be used such as shown in FIG. 54 to FIG. 60.
E.g., aligning the manifolds along an edge of the duct or along a
diagonal or radius of the array or other intersecting plane.
[0768] 9.9.1 Streamlined or "Thin" Manifolds
[0769] By flattening the manifold(s) transverse to the fluid duct
130, in some embodiments, users form a "thin" or streamlined
manifold. This reduces the drag or pressure drop for second fluid
904 flowing across the manifold, similarly to flattening the
distribution tubes 10. Users also desirably increase the bending
strength of the manifold 240 crosswise to the flow 904.
[0770] 9.9.2 Sub-Manifold
[0771] In some configurations, as shown in FIG. 60, users provide
secondary manifolds or sub-manifolds 254 to further distribute the
fluid from manifolds 240. The direct contactor tubes 10 are then
preferably connected to the sub-manifolds 254.
[0772] 9.9.3 Sub-Manifold Valves or Flow Modulators
[0773] With continued reference to FIG. 60, to desirably control
the flow of the first flow 901 through the contactor tubes 10, in
some configurations users provide sub-manifold valves 233 and/or
pressure flow modulators 370 to control the flow of fluid through
manifolds 270 or sub-manifolds 254. They accordingly control the
flow through the arrays of orifices 80 associated with those
manifolds or sub-manifolds 254 such as those configured on the
contactor tubes 10 connected to those manifolds or sub-manifolds
254.
[0774] By these measures, users preferably control the first fluid
flow 901 relative to the second fluid flow 904 over one or more
flow sub-regions as selected by the configuration of sub-manifold
valves 233 allowing fluid to flow through select combinations of
sub-manifolds. They similarly preferably control the flow through
those selected sub-manifolds by controlling the pressure flow
modulators 370.
[0775] 9.9.4 Sub-manifold Arrays
[0776] As will be apparent to one of skill in the art, in various
configurations, users preferably connect contactor tubes to
sub-manifolds and/or manifolds to achieve desired or needed
groupings of orifices in a contactor array section relative to the
flow of the second fluid through the contactor array section. They
similarly configure the contactor array sections together with
corresponding combinations of sub-manifold valves and/or pressure
flow modulators. These arrays are variously configured in
arithmetic, geometric arrays as desired to give the flexibility and
turn-down ratio desired in the controls. Redundancy and/or
degeneracy in these configurations is also provided in some
configurations.
[0777] Arithmetic ratios: For example, users configure areas of
contactor array sections in an arithmetic ratio of second fluid
flow 904 through those sections. E.g., 1:1, 1:2, 1:3, 1:4, 1:5 etc.
according to the respective turn-down ratios needed or desired.
[0778] Geometric ratios: Similarly, they configure contactor arrays
in geometric ratios such as binary, 1:2:4, ternary 1:3:9,
quaternary 1:4:16 etc.
[0779] Hybrid ratios: In other configurations, they configure
arrays in combinations of such arrays or with degenerate
combinations. E.g., such as 1:1:1, 1:1:2, 1:1:1:1, or 1:1:2:4.
[0780] 9.9.5 Sub-manifold Tube Configurations
[0781] In configuring such contactor array sections, users
preferably configure contactor tubes 10 in proportion to the
desired contactor array sections areas. For example, preferably
configure contactor tubes 10 in a radial or spoked configuration
connected to sub-manifolds 254 configured along the inner and outer
circumferences of the annular duct 146. They similarly configure
tubes to sub-manifolds S1, S2 and S3 respectively in a repeated
pattern: #1, #2, #1, #3, #1, #2, #1. (See, e.g., FIG. 60.)
[0782] This configuration provides four tubes #1 to sub-manifold
S1, interspersed with two tubes #2 connected to sub-manifold S2,
interspersed with one tube#3 connected to sub-manifold S3. Where
each of these radial contactor tubes 10 are of similar size and
length, with about an equal number of orifices, users obtain
orifices in the proportion of about 4:2:1. These deliver flows of
first fluid 901 in proportion to flows of second fluid 904 by array
sections.
[0783] 9.9.6 Varying Internal Manifold Cross-sectional Area
[0784] In some embodiments, manifolds 240 are varied in
cross-sectional area with distance to compensate for the fluid
delivered to the perforated tubes 10. The manifold's internal
cross-sectional area preferably varies proportional to the
remaining first fluid flow rate as the distance along the manifold.
E.g., as distance along a radius, an edge, or similar
parameter.
[0785] 9.10 Contactor Tube and Fluid Delivery Profiles
[0786] To provide desired flexibility on fluid delivery, users
preferably control transverse or axial distributions and profiles
of one or more parameters along the tube contactors or contactor
arrays in some embodiments.
[0787] 9.10.1 Orifice Size & Jet Penetration Distance
[0788] In some configurations, users adjust the orifice size and
differential ejection pressure across the tube wall to achieve
desired micro-jet penetration distances. For example, as shown in
FIG. 60, where radial contactor tubes 10 are configured across an
annular duct 146, users increase the orifice size with increasing
radial position to accommodate the increasing tube to tube gap.
[0789] 9.10.2 Orifice Spacing Profile
[0790] In some configurations users preferably configure the
transverse distribution of the spacing of the orifices 80 along one
or both transverse directions and/or axial directions, to provide a
spatial orifice density to achieve a desired orifice area
distribution and profile along that transverse or axial
direction.
[0791] 9.10.3 Spatial Area Density Profile
[0792] In some embodiments, users combine one or more features of
changing orifice size, orifice spacing, and tube spacing to achieve
a desired spatial area density of orifices 80 delivering the first
fluid 901 along one or more directions transverse to the fluid duct
130 and the second fluid flow direction 904.
[0793] 9.10.4 Spatial Fluid Delivery Profiles
[0794] Users combine the prescribed spatial area density
distributions and profiles with controlling the differential fluid
pressure distribution across the tube walls to provide a desired
first fluid delivery distribution in some configurations. For
example, to accommodate varying transverse profiles of axial
velocity in the second fluid 904, users combine the profiles of
orifice size, orifice spacing, tube gap and differential ejection
pressure to achieve a desired first fluid delivery distribution
relative to the transverse flow distributions of the second fluid
904 and one or more of the first and second transverse directions
and the axial direction.
[0795] 9.11 Tube Ribs or Stiffening Supports
[0796] Flow of the second fluid 904 over the perforated
distribution tubes 10 causes turbulence, pressure drops and a flow
drag force in the direction of the second flow or fluid duct 130.
Contactor tubes 10 oriented transverse to the flow of the second
fluid 904 are also subject to bending forces by the flow drag.
Accordingly, as shown in FIG. 1, in some embodiments, users
preferably support these distribution tubes 10 by attaching one or
more supporting stiffeners or external tube supports 37 to the
contactor tubes 10.
[0797] 9.11.1 Structural Supports
[0798] In some embodiments, as shown in FIG. 68, users attach the
tube support or external stiffeners 37 to at least one upstream
structural support 72 attached to the fluid duct so as to support
the drag forces on the tube array which are transferred to the tube
supports 37. In some configurations, these tube supports 37 are
connected to a manifold 240, central manifold header or other
structural support that can sustain the cumulative drag. Users
preferably use a multiplicity of tube supports 37 to provide
transverse supports and counter the turbulence induced force
moments and array vibration or oscillation.
[0799] 9.12 Tube Surface
[0800] 9.12.2 Tube Surface Energy
[0801] With reference back to FIG. 13, the difference in surface
energy between the first fluid 901 being expelled from the
contactor tube 10 and the outer surface of the tube 80 affects
whether the fluid will "wet" the surface of the tube 80 or be
repelled from it. When a second fluid 904 is present flowing across
that surface, this difference in surface energy should also be
compared with the difference in surface energy between that fluid
and the tube surface. To assist droplet formation and to prevent
the first fluid from wetting the exterior of the tube, in some
embodiments, users preferably treat the tube surface to change its
surface energy to repel the first fluid at least about and
downstream of the orifices. E.g., providing a "hydrophobic" surface
when delivering water through the orifices, or correspondingly
"oleophobic" surface (commonly also "hydrophilic" surface) when
distributing diesel fuel or similar "oleophilic" hydrocarbon
fuel.
[0802] 9.12.3 Tube Surface Roughness
[0803] In some embodiments, users preferably create very small
scale roughness or texture on the exterior of the tube 10 about and
downstream of the orifices 80. This helps repel drops and prevent a
liquid 901 from wetting the tube outer surface and so assist in
drop formation and avoid "wetting" or dribbling" down the outer
surface of the contactor tube 10.
10 Forming Smaller Orifices
[0804] 10.3 Smaller Orifices
[0805] As shown in FIG. 2 to FIG. 6, in some configurations, users
preferably form thin sections 32 in tube walls 30 to assist in
making smaller orifices than are readily formed in thicker
walls.
[0806] 10.3.1 Laser Drilling for Smaller Orifices
[0807] Various techniques may be used to create the small orifices
describe above. For example, users may use several different
technologies to create orifices, such as laser drilling,
photo-lithographic etching, x-ray lithographic etching, among
others. Users preferably select the laser power, frequency and
optics according to the orifice diameter and uniformity required.
Common CO.sub.2 lasers can achieve about 20 .mu.m diameter
orifices. To achieve smaller diameters, users sometimes utilize
lasers with smaller wavelengths (higher frequencies.) Eximer lasers
can drill orifices of about 1 .mu.m to about 2 .mu.m in diameter
with Thickness to Diameter ratios (t/d) of up to 100 or even 200.
E.g., in ink jet orifice arrays. Ultraviolet lasers can achieve sub
micrometer orifice sizes.
[0808] Users may also utilize other drilling methods. For example,
friction drilling, mechanical punching, electro drilling. Users
typically use these for larger orifices such as forming orifices in
manifold ducts where tubes are connected.
[0809] 10.3.2 Tube Wall Thickness vs Tube Diameter
[0810] Table 3 shows an exemplary embodiment of the variation in
the thickness of the tube wall 30 as a function of tube wall
thickness to diameter ratios for a range of tube diameters from 1
mm to 16 mm.
3TABLE 3 Tube Wall Thickness .mu.m versus Tube Diameter for various
Tube Wall Thickness/Tube Diameters Tube Wall Thickness/ Tube Outer
Diameter mm Diameter 16 12 10 8 6 5 4 3 2 1 4 4000 3000 2500 2000
1500 1250 1000 750 500 250 6 2667 2000 1667 1333 1000 833 667 500
333 167 8 2000 1500 1250 1000 750 625 500 375 250 125 10 1600 1200
1000 800 600 500 400 300 200 100 12 1667 1000 933 750 500 418 333
250 166 83
[0811] 10.3.3 Wall Thickness to Orifice Diameter Ratio
[0812] Laser drilling can typically achieve a given Wall Thickness
("depth" or orifice "length") to Orifice Diameter ratios (t/d).
E.g., Common laser drilling technology can achieve Wall
Thickness/Orifice Diameter ratios of 10:1. Some technologies can
achieve Wall Thickness/Orifice Diameter ratios of 100:1 to 200:1
with Eximer lasers, depending on wavelength. With laser drilling,
the orifice size is thus limited to the thickness of the sheet
drilled, divided by the Wall Thickness/Orifice Diameter (t/d) ratio
for a given wavelength. e.g., about 20 .mu.m to 1 .mu.m diameter
holes in a 200 .mu.m wall for Wall Thickness/Orifice Diameter
ratios of 0:1 to 200:1.
[0813] Table 4 shows embodiments of the consequent orifice
diameters for various thicknesses of the tube wall 30 as a function
of wall thickness to orifice diameter ratio of the drilling
technology used.
4TABLE 4 Orifice Diameter .mu.m versus Wall Thickness .mu.m for
various Wall Thickness/Orifice Diameter Limits Thickness/ Wall or
Sheet Thickness micrometers (.mu.m) Diameter 1000 500 200 100 50 20
10 5 2 1 2 500 250 100 50 25 10 5 2.5 1 0.5 5 200 100 40 20 10 4 2
1 0.4 0.2 10 100 50 20 10 5 2 1 0.5 0.2 0.1 20 50 25 10 5 2.5 1 0.5
0.25 0.1 0.1 50 20 10 4 2 1 0.4 0.2 0.1 0.04 0 100 10 5 2 1 0.5 0.2
0.1 0.1 0 0
[0814] 10.3.4 Many Orifices
[0815] As mentioned above, some embodiments of the invention form
direct contactors 10 using a few to tens to hundreds of orifices 80
per mm of tube length. E.g., selecting about 80 orifices per mm
typically of 50 .mu.m in diameter, with 3 meters of thin walled
tube would provide about 3,000 orifices. Similarly, by making about
20 .mu.m orifices 80 every 60 .mu.m along a thin walled tube, users
create about 17 orifices/mm tube length. By wrapping about 3 meters
(m) of such thin walled perforated tubing into a direct contactor
perforated tube array 260, users provide up to about 50,000
orifices distributed across the flow. E.g as shown in FIG. 1, in a
downstream opening conical or "horn" distributed fluid contactor
260. Similarly, by reducing orifice size to about 2 .mu.m spaced
about every 6 .mu.m axially along a perforated tube in about 200
axial rows circumferentially about that tube, users nominally
achieve about 33,000 orifices/mm tube length. Using about 3 m of
such conical distributed fluid contactor, users would
advantageously provide about 100 million orifices distributed
across the flow.
[0816] These methods provide far greater number of nozzles than
conventional systems which provide just a few nozzles with one or a
few orifices per nozzle. E.g., a large bore Diesel engine may use
three nozzles each with six orifices, forming a total of 18
orifices.
[0817] 10.4 Thin Wall Perforated Tubes
[0818] Conventional Diesel injectors may use 10 micrometer (.mu.m)
to 60 micrometer (.mu.m) diameter orifices with high pressure heavy
walled tubing. By preferably using many smaller orifices users
significantly reduce the injection pressure and pumping work to
create numerous small drops or droplets while significantly
improving the spatial control over transverse distribution of flows
and flow rate profiles in the first and second transverse and axial
directions. Modified configurations could also use many
conventional nozzles or injectors distributed across the flow,
though at higher expense and without as precise control over
spacing.
[0819] 10.4.1 Thin Walled Tubes
[0820] Thin-walled tubes with diameter to wall thickness ratios
(D/t) of 8 to 10 are available (e.g., with 760 .mu.m or 0.030" OD,
and 500 .mu.m or 0.020" ID). Users nominally consider "thin wall
tubes" as having wall thicknesses of 1,000 micrometer (.mu.m) to
200 .mu.m.
[0821] Users preferably use such thin wall tubing to make 100
micrometer (.mu.m(to 20 .mu.m diameter orifices (0.004" to 0.000,8"
diameter orifices) directly in the thin tube wall 30 using an
orifice forming technology such as laser drilling. Users preferably
use technologies which can form orifices with a 10:1 Wall
Thickness/Orifice Diameter (t/d) ratio and more preferably with a
thickness/diameter ratio (t/d) of 100:1 to 200:1. With such
orifices 80, users advantageously form simple drops with diameters
in the range from about 200 (.mu.m) to 40 .mu.m with low
differential positive pressures and flows. With such thin walls,
users can further reduce the orifice sizes down to a range of about
10 micrometer (.mu.m) to 2 .mu.m by using laser drilling technology
capable of Wall Thickness to Orifice Diameter (t/d) ratios of 100:1
etc.
[0822] Of course, as the skilled artisan will appreciate, other
suitable nominal thicknesses for the thin wall tubes may be
efficaciously utilized, as needed or desired, giving due
consideration to the goals of achieving one or more of the benefits
and advantages as taught or suggested herein.
[0823] 10.4.2 Ultra-Thin Wall Perforated Tubes
[0824] For still smaller orifices, in some embodiments such as with
low differential ejection pressures, users select thinner walled
tubing or use orifice forming technologies capable of higher
Thickness/Diameter (t/d) ratios. Ultra-thin walled tubes are
commonly available with wall thicknesses from about 200 micrometer
(.mu.m) down to about 125 .mu.m (about 0.008" to 0.005") or even to
about 75 .mu.m (about 0.003"). With such ultra-thin walled tubing,
users readily form orifices with diameters down to about 20
micrometer (.mu.m) to 8 .mu.m using laser hole drilling technology
capable of Thickness/Diameter ratios of 10:1. With 100:1 laser
drilling technology using short wavelength (high frequency) lasers,
users could potentially form orifices of 2 micrometer (.mu.m) to
0.8 .mu.m in diameter with such ultra-thin wall tubing.
[0825] 10.5 Thinning Walls for Smaller Orifices in Thin Walled
Tubes
[0826] The size of holes formed in tubing is nominally limited by
the thickness of the tubing and the Length/Diameter capabilities of
the hole forming method. As shown in FIG. 3 and mentioned above, in
modified embodiments, users thin the tube wall 30 to form a thin
tube wall section 32 to assist in forming smaller diameter holes.
E.g., Tube walls 30 are machined, or ground thinner, or thinned by
electrochemical machining to form thin tube wall sections 32. In
other embodiments, as shown in FIG. 3, a portion from about 5% to
about 95% of the tube wall 30 is removed to form a thin tube wall
section 32 using suitable thinning methods. (E.g., See FIG. 3.) The
final thickness is preferably refined by precision surface grinding
as desired or needed. For example, with precision grinding to a
tolerance of about 2.5 .mu.m (0.0001"), users nominally machine a
tube of about 4 mm diameter with about 200 .mu.m thick walls and
then surface grind the tube wall 30 to form a thin tube wall 32
with a thickness of about 20 .mu.m to about 30 .mu.m.
[0827] 10.5.1 Grind Arcs on Tubing
[0828] To form thinner walls, in some embodiments as shown in FIG.
4, users grind a curved surface or arc onto the tube wall 30 to
create a thin wall section 32 aligned axially along the outer
surface of the tubing. The wall thickness at the thinnest sections
could be coarsely machined and then ground down to a wall thickness
of a given a multiple of the grinding precision tolerance. E.g.,
grinding the wall thickness to about a 10 fold multiple of a
grinding precision of about 2.5 .mu.m would nominally permit
grinding down to nominally 25 .mu.m thick walls.
[0829] CNC Industries of Fort Wayne ind. USA, and Alpha Technologie
company of Thyez France, are two companies for example specializing
in precision surface grinding. They claim to nominally hold the
surface tolerance to 2.5 micrometers (0.0001") with precision
grinding. This is about 10% of the desired final wall
thickness.
[0830] 10.5.2 Forming Thin Sheet into Thin Walled Tubing
[0831] To further improve on the uniformity of forming thin walled
tubing, in another embodiment as shown in FIG. 34, users preferably
take thin sheet with substantially uniform thickness, bend and form
it into a thin wall tube 10. The sheet edges are then bonded
together to complete the tube. This method creates the tube wall 30
with much greater wall uniformity than conventional drawing or
grinding etc. Consequently, the orifices created will have much
more uniform diameters for drilling technologies using a similar
thickness to diameter ratio (t/d).
[0832] 10.5.3 Drilling Holes in Thin Walls
[0833] In configurations using an ultra thin wall thickness of
about 25 micrometers, users can drill holes of about 2.5 .mu.m to
0.25 .mu.m, using a drilling technology with a thickness/diameter
ratios of about 10:1 to 100:1. Thus, the hole diameter achievable
is of the order of the precision of the thickness of the thin wall
32. e.g., forming foils or surface grinding tolerance. Users may
drill multiple holes 80 transversely around the perimeter of the
tube 10 in this thin wall section 32. Users may then replicate such
linear arrays along the length of the tube, or vice versa.
[0834] 10.5.4 Multiple Arcs or Flats Around Tubing
[0835] As shown in FIG. 3 and FIG. 4, this methodology may then be
extended to form thin wall sections 32 (multiple arcs or flats) in
the tube wall 30 around the contactor tube 10. E.g., two thin wall
sections 32 on either side of the tube 10. The number of arcs or
flats can be extended to three, four, five or more sections around
the tube. e.g., in hexagonal arcs or flats.
[0836] 10.6 Micro-Orifices in Compound Thin Walled Perforated
Tubes
[0837] With reference now to FIG. 43, to distribute smaller
orifice, in some embodiments, users form compound perforated tubes
200 with thinner walls 33 by bonding perforated thin tube side
walls 32 (e.g., formed strips or foils) to heavier formed tube
stiffeners 36 (e.g., structural supports.) In some embodiments
users form smaller orifices 80 using technologies (such as Laser
drilling) with higher Thickness/Diameter ratios and/or smaller
radiation wavelengths (higher frequency).
[0838] Practical ultra-thin wall tube systems may require
structural support to withstand the bending forces of the external
second fluid flow across the tube as well as to handle forces due
to gravity and vibration. To support these bending forces, in some
embodiments users take a thicker upstream tube stiffener portion 36
formed from strips thick enough to provide structural support.
Users make the small orifices through one or more thin perforated
strips and form them into the downstream portion of the tube
36.
[0839] Users preferably form an ultra-thin walled compound
perforated tube by bonding the downstream thin tube wall 33 to the
upstream structural tube portion 36. E.g users bond thin strips 32,
of about 500 micrometer (.mu.m) to 50 .mu.m thick, onto thicker
tube structural support wall sections 36, either within or without
the upstream support. With this construction method, users
advantageously create compound contactor tubes 10 with effectively
larger tube diameter/wall thickness ratio.
[0840] 10.6.1 Forming Small Orifices in Thin Sheets or Foils
[0841] With a range of Thickness/Diameter orifice forming
technologies and thin sheet or foil thicknesses available, users
variously achieve orifice diameters of about 25 micrometer (.mu.m)
down to sub-micron sizes for a range of sheet thickness from about
1000 micrometer (.mu.m) to 1 .mu.m. (Smaller orifices can be formed
with deep ultra-violet, electron or x-ray forming technologies as
these technologies progress.) Assuming pendant drops are formed
with sizes twice the orifice diameter, users nominally form uniform
drops from about 50 micrometer (.mu.m) to 0.5 .mu.m in diameter
from an array of orifices of substantially uniform size.
[0842] 10.6.2 Compound Foil-Walled Perforated Tubes
[0843] In further embodiments, users form ultra-thin walled
compound tubes using even thinner sheets or "foil" to create thin
walls 32 with still smaller orifices. e.g., walls less than about
50 m thick. Stainless steel structural foils are available at least
in about 30 micrometer (.mu.m), 25 .mu.m, and 20 .mu.m thin sheets.
E.g., Metal Foils, LLC provides stainless steel foils from 250
micrometer (.mu.m) down to 25 .mu.m (0.010" down to 0.001"). Emitec
Inc. of Auburn Hills, Mich., and Lohmar in Germany, manufacturer
heat exchangers using foils of such thicknesses which they purchase
from at least three reliable manufacturers.
[0844] Given the thinnest acceptable thin wall (e.g., metal foil
thickness), users preferably divide by the Wall Thickness/Orifice
Diameter ratio of the drilling technology used to arrive at the
orifice diameter. (e.g., divide wall thickness by 10 for common
laser drilling technologies.) To achieve smaller orifices, users
can select shorter wavelength (higher frequency) lasers and/or use
lasers capable of higher Wall Thickness/Orifice Diameter ratios as
needed or desired. (Some companies claim Wall Thickness/Orifice
Diameter ratios of 100 or higher for eximer laser drilling etc.)
Thus, users can laser drill about 2 m to 0.2 .mu.m diameter
orifices through 20 .mu.m thick stainless steel foil. (Conversely,
given a desired orifice diameter and the Wall Thickness/Orifice
Diameter limit of a drilling technique, users can calculate the
desired thickness of the thin tube wall 32 e.g., sheet or
foil.)
[0845] In modified configurations users utilize even thinner foils.
E.g., ACF Metals of Tucson Ariz. makes ultra-thin metal foils with
thicknesses of about 5 micrometers (.mu.m) down to about 1
nanometer (nm).
[0846] 10.7 Two Section Compound Perforated Tube Cut Structural
Strip
[0847] With reference back to FIG. 43, a modified embodiment, users
form a thin wall 32 by cutting a thin stainless steel sheet and cut
a structural strip to a width about equal to the circumference of
the upstream portion of an elliptical support tube section. I.e.
the sheet is cut to a width of about .pi.D/2. As an example, to
create a half tube about 4 mm in outer diameter, a stainless steel
sheet of about 0.2 to 1.0 mm thick is selected depending on the
bending strength or stiffness required. This is then cut to a width
of about 6.3 mm. This strip is then formed into the desired
upstream streamlined shape.
[0848] 10.7.2 Thin Wall Strip
[0849] In other embodiments, the downstream thin wall portion 32 is
formed by cutting a thin strip 32 from thin sheet material or foil.
For example, users select the stainless steel foil with thin
commercially available thickness, preferably about the desired
diameter of the orifices times the length/diameter ratio of the
hole forming method. E.g., about 20 to 30 .mu.m (about 0.02 mm to
about 0.03 mm) thick to prepare small holes about 2 .mu.m to 3
.mu.m in diameter, using a laser capable of drilling holes with a
10:1 length/diameter ratio.
[0850] 10.7.3 Thin Foil Downstream Perforated Wall Section
[0851] Wrapped downstream portion: In still other embodiments, the
ultra-thin sheet is cut into a strip about equal to the
circumference of the desired tube. This is formed into the desired
shape and wrapped around the upper structural tube portion to form
the thin tube wall.
[0852] Part downstream portion: As shown in FIG. 43, in some
embodiments, users form a thin tube wall 32 from a strip of
stainless steel foil about equal to the circumference of the
portion of the desired tube downstream of an upstream structural
tube support 36, plus an amount to overlap and bond to the upstream
portion. For example, the downstream portion may be about 7.5 mm to
8.5 mm wide, with about 0.5 mm to about 1 mm overlap on each side.
This results in a strip thin tube wall 32 about 8.5 mm to 10.5 mm
wide.
[0853] 10.7.4 Indented Attachment Edges
[0854] In some modified embodiments, as shown in FIG. 43 and FIG.
44, users press or grind a thin indent 256 a little greater than
the thickness of the perforated thin wall 32 (foil) on each outer
edge of the structural tube strip 36. e.g., about 25 to 35
micrometers deep. Users preferably form the width of the indent 256
about equal to or a little greater than the desired attachment
width of the thin wall 32 (foil). E.g., about 0.6 mm to 1.1 mm
inward on both outer edges of the structural strip. This provides
the benefit of reducing turbulence at the joint between lower to
upper tube portions. Various companies claim capability to grind
with a precision of about 2.5 .mu.m (0.000,1"). This is about 10%
of the desired indent depth.
[0855] 10.8 Perforate Thin Strip or Foil
[0856] In various embodiments, the thin wall 32 (strip or foil
strip) is perforated with a pattern of fine holes 80 in one or two
dimensional arrays or patterns as desired.
[0857] Laser drilling: The preferred method of forming orifices 80
is to use lasers to drill fine orifices proportional to the
thickness of the material limited by the length/diameter capability
of the laser. E.g., the Department of Defense sought a Small
Business Innovative Research (SBIR) project #AF02-003 to drill
large numbers of 170 .mu.m holes with very high precision. High
power lasers evaporate material rapidly, leaving clean uniform
holes. Shorter wavelength higher frequency lasers may be used to
drill smaller holes. E.g., Ultra-violet lasers can prepare holes
down to micrometer or sub-micrometer capability.
[0858] Mechanical punch: In other embodiments, users may form
linear or spatial arrays of micro-punches to press holes 80 through
thin foils.
[0859] Electro drill: In further embodiments, users may form holes
80 using an electrode type removal process.
[0860] Resist Etch: In some embodiments, users may form holes 80
using a photo-etch method with a resist, similar to methods of
forming circuit boards.
[0861] Form Longitudinal perforated array: In various embodiments,
users preferably form an array of orifices 80 longitudinally along
the thin wall 32. In other embodiments, users may form two parallel
arrays, leaving a solid section in the middle and on either edge.
The width of the array is preferably about 1.0 to about 1.5 times
the diameter of the tube.
[0862] As an example, in some embodiments, users form two parallel
arrays about 3.5 mm wide on either side of a solid center band
about 1.5 mm wide, leaving a solid strip on either edge of about
0.75 mm wide to which to bond the foil to the tube. This results in
perforating about 7 mm of a foil strip of about 10 mm width.
[0863] 10.8.1 Bond Perforated Downstream Portion to Structural
Portion
[0864] In various embodiments, users preferably wrap the lower
perforated tube portion 32 around the upper structural portion 36
as shown in FIG. 43 and FIG. 44. The upper edges of the downstream
portion are bonded to the upper portion.
[0865] In other embodiments, users form the downstream portion 32
and position it to overlap the upper structural portion 36. Where
indents 256 are formed, the edges of the lower thin side wall
section 32 are preferably positioned into the indents 256 in the
upper portion.
[0866] Both edges of the perforated downstream half tube are bonded
to the supporting half tube support 36. E.g., by induction welding,
friction welding, brazing, soldering or gluing according to the
temperature and strength required.
[0867] 10.9 Supported Compound Foil-Wall Perforated Tubes
[0868] Thin walls 32 limit the differential ejection pressure that
a perforated wall can support. The thinner the tube wall 32 (or
foil), the lower the differential ejection pressure or span that
the tube can typically tolerate.
[0869] As shown in FIG. 44, in some embodiments, to accommodate
thinner walls or foils, users support the thin wall 32 with a
heavier structural support 202 having large openings. (For example,
users form large orifices 80 in a suitable structural strip to form
the tube structural support 202). Users further form smaller
orifices 80 in thin tube wall 32 to form a thin perforated tube
wall. They then line the perforated thin wall 32 about the inside
of the perforated tube support strip 202 (e.g., a perforated tube
10 with large orifices.) The large orifices 80 in the structural
support 202 reduce the span across which the thin wall 32 (or foil)
needs to support the differential pressure. The structural support
202 also supports the foil against the drag from the cross-flow and
against the differential fluid pressure.
[0870] In alternative embodiments, users form thin perforated wall
or foil around the large holed structural support 202. They then
bond the thin wall 32 to the supporting large holed perforated tube
202.
[0871] 10.10 Centrally Stiffened Compound Perforated Tube
[0872] Thin perforated foil (e.g., about 20 micrometer (.mu.m) to
about 30 .mu.m thick) is relatively weak and deformable. As shown
in FIG. 45, in some embodiments, users preferably attach a
perforated thin wall 32 (e.g., foil) to a structural support
section 202 comprising one or two axial structural tube support
sections 36 to support and stiffen it. E.g., bond about 200
micrometer (.mu.m) tube side wall 32 (foil) to about 1 mm (1,000
.mu.m) thicker axial support section 36. In modified embodiments,
users form a stiffening tube strip 36 for the downstream portion of
the compound perforated tube. E.g., cut a strip about 1.5 mm wide
by about 0.2 mm to 1.0 mm thick.
[0873] 10.10.1 Attach Central Stiffening Strip
[0874] With reference to FIG. 48, users may attach or bond one
stiffening strip 36 down the middle of the perforated thin wall 32
(foil) on the solid axial section of the foil between the two
perforated thin wall sections 32. E.g., on about 1.5 mm section.
Users variously bond the components by induction welding,
electrical spot welding, capacitance discharge welding, friction
welding, brazing, soldering or gluing according to the temperature
and strength required.
[0875] 10.10.2 Form Support Tube into Upstream Streamlined
Shape
[0876] As shown in FIG. 43 to FIG. 44, the structural support strip
36 may be formed into an upstream streamlined shape. This shape
approximates a half ellipse with the open side being the shorter
axis. For instance, in some moderate sized embodiments, the outer
dimension may be configured from about 0.5 mm to 50 mm, and more
preferably from 2 mm to 10 mm wide. Of course, in other
embodiments, the structural support strip may have a different
shape.
[0877] 10.10.3 Form Stiffened Perforated Foil into Downstream
Streamlined Shape
[0878] In other embodiments, users form the stiffened perforated
foil wall strip 33 into a desired downstream streamlined shape as
shown in FIG. 43 to FIG. 45. This will approximate a narrowed half
ellipse with the open side being the shorter axis. For example, the
outer dimension may be about 2 mm to 10 mm wide resulting in a
circumference of about 3 mm to 15 mm.
[0879] 10.10.4 Fit Perforated Foil Tube to Structural Support Half
Tube
[0880] To assemble the embodiment illustrated in FIG. 43, users may
spread the stiffened perforated lower half thin tube wall 33 and
fit it over the upper half support tube stiffener 36. In some
embodiments users align the edges of the perforated foil into the
indent 256 along one edge of the formed structural strip 36. In the
embodiment of FIG. 47, users preferably wrap the perforated thin
wall 32 (strip) over and around the upstream structural part tube
36.
[0881] 10.10.5 Bond Foil to Tube
[0882] With continued reference to FIG. 43, users preferably bond
both edges of the stiffened perforated foil half tube 33 to the
supporting half tube 36. E.g., by induction welding, friction
welding, brazing, soldering or gluing according to the temperature
and strength required.
[0883] 10.11 Transversely Stiffened Compound Tube
[0884] In some embodiments, users form a compound perforated tube
200 from a thin wall section 32 over structural support 202 formed
from components. E.g., they form the support 202 using periodic
curvilinear circumferential tube structural supports 38 between the
upstream tube support 36 and the downstream stiffener 36 to which
the thin perforated walls 32 are attached. Large openings in the
structural support 202 may be variously formed as circles, slots,
rectangular holes and other openings.
[0885] 10.11.1 Assemble Skeleton Tube from Components
[0886] As shown in FIG. 45, the compound tube may include periodic
circumferential stiffener sections 38 between the preformed
upstream tube support 36 and the downstream stiffener 36 to form a
structural tube support 202.
[0887] 10.11.2 Attach Perforated Foil(s)
[0888] As shown in FIG. 45, the perforated thin wall section 32
(foil) are preferably attached to the inside of the "skeleton" tube
or formed structural support 202. e.g., comprising axial tube
stiffener(s) 36 and circumferential tube structural sections
38.
[0889] 10.12 Forming Curved Perforated Tubes
[0890] When tubes are bent into a curve, there is a danger of
flattening or crinkling the tube side walls 33. Users may use
relevant art bending methods, such as filling the tube with a
liquid and then cool the liquid to a solid. E.g., with beeswax, a
hydrocarbon with a high melting point, or with a fusible metal
(preferably gallium, historically lead). After the tube is bent
into shape, the tube is heated and evacuated to remove the forming
solid.
[0891] 10.12.1 Forming Curved Compound Tube Sections
[0892] It should be appreciated that the compound tubes described
above may be formed into arcs, helices or other non-linear curves
and formed into the various arrays described above (See e.g., FIG.
54 to FIG. 67.) In such configurations, users form the upstream
tube support section 36 and the downstream tube support section 36
to the desired curvilinear shape.
[0893] 10.12.2 Assembling Curved Tube Sections
[0894] The upstream tube portion 36, and downstream tube portion 36
are then assembled and bonded together into or near the desired
final shape. This method significantly reduces the likelihood that
the thin perforated walls 32 will tear or wrinkle compared to the
damage that could happen if linear compound tubes 200 are assembled
and then formed into an arc, helix or other non-linear curve.
[0895] 10.13 Skeleton Compound Tube Formation
[0896] In some embodiments, as shown in FIG. 45, users provide one
or more circumferential tube structural sections 38
circumferentially from the upstream structural tube portion 36
around (or within) the perforated tube wall section 33 to support
it.
[0897] 10.13.1 Remove Gaps Between Stiffener Arcs
[0898] With continued reference to FIG. 45, in some embodiments
users form the structural tube support 202 by machining and
grinding away tube side sections, leaving circumferential stiffener
sections 38 in place between the upper and lower tubular stiffener
sections 36. Then users assemble the compound tube 200 by attaching
the perforated thin walls 32 (or "foils") to the sides or around
the structural tube sections 36 and 38 as described herein.
[0899] 10.13.2 Herringbone Compound Perforated Tube Assembly
[0900] In modified embodiments users attach circumferential tube
support sections 38 approximately perpendicular to the central tube
stiffener 36 on the perforated thin tube wall 32 (sheet or foil)
like a covered herringbone. The stiffened perforated thin wall 32
is then formed into the desired cross-sectional shape (e.g.,
streamlined or bluff). This downstream stiffened perforated wall
section is then bonded to the upper support tube section 36.
[0901] 10.14 Compound Wire Tubes
[0902] As shown in FIG. 47, in some embodiments, users preferably
form compound perforated tubes 200 by wrapping a thin strip 201
around one or more structural tube support(s) 36 and using a bond
39 to those supports 202. Axial structural components 36 such as
wires are readily used to form such structural supports 36. The
curved shape of the wires preferably provides the streamlining form
upstream and downstream. The wires further provide strength and
rigidity to support the perforated tubes against drag and
turbulence within the second fluid. As shown in FIG. 48, in a
modified embodiment, both wires may be the same to form an oval or
elliptically shaped compound contactor 200.
[0903] 10.14.1 Modified Wire Sizes and Shape
[0904] As shown in FIGS. 47 and 46, in some embodiments, users
preferably select an larger diameter wire for the upstream axial
structural 36 and smaller diameter wire as downstream axial
structural support 36 downstream. Where even more streamlined
versions are desired, the thin strip preferably extends beyond the
downstream wire to a narrower trailing edge.
[0905] Conversely, such configurations may be used to increase
turbulence by orienting the bluff side of the contactor 10 or 200
towards the flow (i.e. the longer axis perpendicular to the flow.)
As shown in FIG. 48 and FIG. 46, users form the support wires 36
into more semicircular shapes in modified embodiments. The curved
portions of the structural supports 36 are preferably configured
outward and the flattened portions inward with respect to the
tube.
[0906] 10.14.2 Thin Strip Assembly
[0907] FIG. 47 illustrates a modified embodiment, in which users
warp a thin strip 32 around one support wire 36 and abutted around
a second support wire 36. The thin strip 32 is preferably bonded to
at least one of the wires 36.
[0908] In another embodiment illustrated in FIG. 49, two thin
strips 32 are laid up on either side of two wires 36 and preferably
bonded to both wires. In a preferred modification as shown in FIG.
47, the thin strips 32 wrap around the larger upstream wire 36 and
preferably butt together. These thin strips 32 extend beyond a
smaller downstream support wire 32 and then join, to desirably
improve streamlining. FIG. 46 illustrates another embodiment in
which the thin strips 32 may abut to or overlap one or both of the
support wires 36. Optionally, the thin strip 32 could be press fit
around at least one of the wires 36.
[0909] In some configurations, the strip(s) 32 are preferably
perforated after assembly of the compound tube 200 to facilitate
assembly. These methods commonly form outwardly increasing
orifices. (See, e.g., FIG. 5.) In other embodiments, the thin
strips 32 are perforated before assembly to facilitate movement of
the strip(s) past a laser and to form orifices with larger openings
within the tubes and smaller opening on the outside of the tube.
I.e. inwardly increasing orifices. (See, e.g., FIG. 6.)
[0910] In some embodiments, the thin wall strip(s) 32 are formed
into a desired curve prior to assembling and bonding them to the
support wires 36. Alternatively, in some assembly methods, the wall
strip(s) 32 are assembled flat and the fluid within the compound
tubes 200 is pressurized to a desired forming or proof pressure to
curve the strips.
[0911] In some embodiments, the stiffening wires 36 are moderately
flattened to improve bending stiffness and provide a greater
surface to bond to the thin strip, though circular wires may be
used. In other embodiments, trapezoidal shaped wires may be used to
improve bonding while still providing some streamlining. In
modified embodiments, the upstream or downstream end of the
supporting wire 36 may similarly be formed to improve streamlining.
Similarly, in some embodiments the edges of the thin strips 32 may
be cut at an angle, thinned, beveled, pressed, ground or otherwise
smoothed to improve aerodynamics.
[0912] 10.14.3 Polygonal Wired Tubes
[0913] In embodiments utilizing triangular or other polygonal
shaped contactor tubes 10, this method may be used to provide a
wire support at each vertex of the polygonal tube.
[0914] 10.15 Alternative Assembly of Compound Perforated Tube
[0915] After forming the structural strip and the stiffened
perforated foil as described above, the following modified or other
techniques or steps are used in some embodiments. (See, for
example, FIG. 43, FIG. 44.)
[0916] 10.15.1 Attach Perforated Foil to Structural Strip
[0917] Overlap and align one edge of the perforated foil over the
indented edge of the structural strip. Users preferably reduce hole
blockage and facilitate cleaning by using the "horn" configuration.
I.e. by orienting the smaller hole diameter inward with the hole
size increasing outward (as discussed above and illustrated in FIG.
5.) If the smallest holes are needed or desired, then users use the
"funnel" configuration. I.e. users configure the smaller diameter
of the holes aligned outward with the outer surface of the strip
and larger diameter inward (as discussed above and illustrated in
FIG. 6.) In this assembly method, the perforated strip or foil is
first bonded to the structural strip along one edge.
[0918] 10.15.2 Form Stiffened Perforated Foil into Downstream
Streamlined Shape
[0919] Both sides of the compound strip are bent up about the
tube-foil joint and formed into the desired streamlined shape. This
will be similar to an elliptical shape but with a wider shorter
upstream width and longer narrower downstream section similar to
aircraft strut faring.
[0920] 10.15.3 Align Perforated Foil to Structural Strip
[0921] The free edge of the formed perforated strip is aligned to
the indent in the formed structural strip.
[0922] 10.15.4 Attach Outer Foil Edge to Strip Edge
[0923] The perforated foil edge is attached or bonded to the
structural strip edge to complete the streamlined compound
perforated tube.
[0924] 10.16 Alternative Elliptical Tube Construction
[0925] With reference to FIGS. 43 and FIG. 44, following is a
modified or other method of forming a compound perforated tube
starting with an approximately elliptical tube.
[0926] 10.16.1 Form Elliptical Tube
[0927] A stainless steel tubing of diameter D is pressed into an
approximately elliptical shape. E.g., a tube with about a 4 mm
outer diameter is selected with wall thickness about in the range
0.20 mm to 1.0 mm. This will have a circumference of .pi.D of about
12.6 mm with a half circumference of about 6.3 mm.
[0928] 10.16.2 Cut into Half Elliptical Tube
[0929] This elliptical tube is then cut in half along the short
axis (normal to and half way along the long axis). E.g., using an
abrasive water jet or a power laser. In other embodiments the tube
is machined about in half to remove one half along this line.
[0930] 10.16.3 Form Elliptical Foil
[0931] The thin perforated stainless steel foil is then formed
approximately into the shape of half an ellipse with the ends
forming the short axis of the ellipse. (In modified embodiments the
tube is formed into a similar parabolic shape). This downstream
tube section is formed slightly wider than the net width of the
supporting upstream half tube.
[0932] 10.16.4 Prepare Attachment Indent
[0933] A thin indent is then ground a little greater than the
thickness of the perforated foil on each outer side of the half
tube e.g., about 25 to 35 micrometers. This is extended a little
greater than the desired attachment width of the foil. E.g., about
0.6 mm to about 1.1 mm up both outer edges of the tube.
[0934] 10.16.5 Fit Foil to Tube
[0935] The perforated foil half ellipse is fitted up over the half
ellipse supporting tube to form an approximate ellipse.
[0936] 10.16.6 Bond Foil to Tube
[0937] The thin foil half tube is then bonded to the supporting
half tube. E.g., by induction welding, friction welding, brazing,
soldering or gluing among other methods, according to the
temperature and strength required.
[0938] 10.17 Hybrid Compound Tubes
[0939] Users may combine the various embodiments and assembly
methods described herein.
[0940] 10.17.1 Compound Tubes from Ground Strips
[0941] In some embodiments, users may take a tube wall strip 30 and
grid a thin wall section 32 along a portion of the strip. The thin
strip section 32 is preferably perforated and then the strip 30 is
assembled to form compound perforated tubes by the methods
described herein. This method provides benefits of achieving more
uniform thinned strip thickness. Correspondingly this results in
more precisely sized orifices or uniform orifices being formed by
the laser drilling or other orifice forming technology.
Alternatively, the thin sheet ground walls 32 may be perforated
after assembling the tube.
[0942] 10.17.2 Wire Tubes from Ground Strips
[0943] With reference to FIG. 49, in modified embodiments, users
form one or more thin wall sections 32 from thinned strips around
wire stiffeners 36 to form a stiffened thin wall tube 200. This
method provides very thin walls and small orifices while giving
substantially greater structural strength, stifffiess and
streamlining or widening.
[0944] 10.18 Combination Thinning & Drilling
[0945] With continued reference to FIG. 49, in some embodiments,
users reduce the thickness of tube walls 30 to form thin walls (not
illustrated) using controlled thinning methods (other than
grinding) such as lasers, electrochemical etching or photochemical
etching as described above. Orifices 80 are then formed through the
thinned sections 32 using technologies such as high resolution
laser drilling (as described above). With such methods, users need
only make moderate diameter pits to form thin walls 32, rather than
thinning continuous or extensive sections of the tube 30. ) This
advantageously removes less material and retains more of the wall
strength than other grinding or thinning methods that thin larger
wall sections. This method can utilize conventional lasers with
moderate thickness/depth ratios to form orifices 80 rather than
very high thickness to diameter (T/D) ratios. E.g., using T/D
ratios typically of about 7 to 50 instead of about 50 to 200.
[0946] 10.19 Other Configurations
[0947] Of course, as the skilled artisan will appreciate, other
suitable nominal thicknesses and shapes may be efficaciously
provided for the upstream and downstream structural components 36,
38 (or "wires") used to form the compound perforated tubes.
Similarly, as the skilled artisan will recognize, a variety of
curved, curvilinear, angular or flat strips 32 may be used to form
the side walls 33 of the compound perforated tubes 200. Various
combinations of the thinning and/or forming holes may similarly be
used, as desired or needed. Furthermore, orifices 80 may be
positioned in a variety of locations and orientations about a
thin-walled tube 8 or compound perforated tube 200 depending on the
pressure drop and degree of mixing desired or needed.
11 Fluid Delivery Systems
[0948] FIG. 1 illustrates an exemplary embodiment of a fluid
delivery system that may be used in combination with the
embodiments described above. In general, the fluid delivery system
comprises a first fluid delivery system 360 for delivery fluid to
the first flow path, a second fluid delivery system 400 for
delivering the second fluid to the second flow path and a control
system 588. mentioned above, the first and second fluids may be any
combination of a gas, fluid, fluid with gas or solid suspension or
any combination thereof. With reference to FIG. 61, the first fluid
delivery system 360 may include a first fluid supply 356, such as a
source of clean water. The second fluid delivery system 400 may
include a second fluid supply 390, commonly the atmosphere, but it
could be oxygen enriched air etc.
[0949] 11.2 Fluid Filters
[0950] Further referring to FIG. 61, to effectively use fine
orifices, in some embodiments, users preferably filter one or more
fluids from coarse and fine particulates sufficient to prevent them
from substantially blocking the fine distributed orifices in the
contactor array 260 through which those fluids are delivered.
[0951] Besides filtration, water treatment such as by mixed-bed
demineralizers may be required. Other types of treatment such as
reverse osmosis and other types of demineralizers can be used where
the chemistry is suitable. These treatment methods can remove any
chemicals that are incompatible with the components into which it
will be injected, e.g., turbine hot path.
[0952] 11.2.1 Coarse Fluid Filter
[0953] For example, in the illustrated embodiment in FIG. 61, users
preferably begin filtration by providing using inexpensive coarse
fluid filters 380 upstream of the first fluid storage tank 362 and
before or after the supply pump to remove the bulk of any
particulate material in the fluid being filtered in the beginning
or initial filtering stages. E.g., coarse filters appropriately
configured to filter the first fluid. Duplex coarse filters are
preferably the duplex type such that filter media can be cleaned or
replaced on-line when other filter in the duplex arrangement is
used. Automatic backwash filters media filters down to 100 microns
are also available. The coarse filter system may include a settling
or break tank upstream of the coarse filters. This can hold the
first fluid such as water for start-up as well as serve to
settle-out large particles, lessening the load on the filters.
[0954] 11.2.2 Fine Fluid Filter
[0955] In the exemplary embodiment, users further preferably follow
the initial filter 380 with finer filter(s) 380 capable of
filtering off smaller particulates, preferably capable of filtering
particulates smaller than the diameter d of orifices 80. This
provides an inexpensive means to protect the orifices and any
subsequent filters. E.g., fine filters appropriately configured to
filter the first fluid. Media filters (e.g., sand, anthracite) may
also be used to filter particulates out down to around 10
microns.
[0956] 11.2.3 Maximum Orifice Fluid Filters
[0957] With continued reference to FIG. 61, users preferably
provide fine maximum size fluid filters 386 (e.g., uniform orifice
fluid filters) to further remove particulates and protect the
orifices in the contactor array 260 from being progressively
blocked by particulates. For example, users form such maximum
orifice filters 386 using numerous fine orifices of uniform size.
The fluid is preferably passed though such maximum orifice filters
386 prior to the fluid entering the perforated tubes. The maximum
particle size passed by the fine filter may be in the range of 10%
to 90% of the orifice size. The maximum particle size is more
preferably 2/3.sup.rds (or about 67%) of the orifice size or
less.
[0958] Users preferably form this maximum orifice fine filter 386
using a filter membrane or sheet with a large number of accurately
controlled uniformly sized orifices. This can be formed by suitable
hole drilling technology, e.g., laser orifice drilling or photo
etching similar to making the tube orifices. Users preferably
configure large numbers of uniform orifices in large thin flat
sheets to achieve a low pressure drop across the filter sheet. The
number of orifices and net orifice area in this filter sheet are
preferably in the range of 1.1 to 200 times that of the orifices in
the direct contactor array 260. More preferably these are in the
range of 5 to 50 times, to reduce the total costs of filtration and
the filtration pumping costs.
[0959] In some embodiments, users then preferably support the sheet
with a porous backing that permits the liquid to flow through while
supporting the filter membrane. These uniform orifice filter sheets
may be variously configured into maximum orifice filters 386. These
may be configured like plate heat exchangers or wrapped into spiral
formats similar to reverse osmosis filters.
[0960] 11.2.4 Recirculating "Bypass" Filter(s)
[0961] With continued reference to FIG. 61, to extend the life of
the main filters (including one or more coarse filters, fine
filters, and maximum orifice fine filters 386, the users preferably
also process storage tanks 362 with bypass recirculation filters
380 to pick up most particulates in secondary inexpensive intake
filters 380 which need not have the absolute maximum orifice size
of the maximum orifice fine fluid filters 386.
[0962] 11.2.5 First Fluid Delivery System: e.g., Liquid Pump
[0963] With further reference to FIG. 61, users preferably provide
first fluid delivery system 360, including equipment to pressurize
and deliver the first fluid through orifices in the contactor array
260. Users preferably select equipment sufficient to at least
overcome the pressure drop of the fluid through the contactor
tubes, the pressure drop of delivering the first fluid through the
orifices, the pressure drop needed to exceed the pressure of the
second fluid at the first fluid orifices, the differential surface
energy, and to eject the first fluid into the second fluid to a
desired penetration distance. As the first fluid is more commonly a
liquid (e.g., water or diesel fuel), users preferably configure the
first fluid delivery system to include a pump capable of generating
at least the maximum pressure, flow rate and turndown rate
desired.
[0964] Conventional horizontal centrifugal or vertical turbine type
pumps are readily available in the flow and pressure range required
and can be used as one or more pumps 364 where appropriate. Where
the pressure or flow control or both is needed, flow control valves
on the pump discharge may be used. In some embodiments, users
preferably use a continuous positive displacement pump that creates
very low pressure fluctuations for the pump 364 to improve fluid
delivery performance. (E.g., Krautler GmbH & Co. of Lustenau,
Austria makes precision continuous positive displacement equipment
("KRAL") that can be used as a pump or as a flow meter.)
[0965] Two pumps are preferred. The first is a low developed head
pump. It takes suction from the source of the recycled water (a
tank or other vessel) and pumps the water through the filter(s),
water treatment equipment, and heat recovery equipment etc. to the
suction of the second pump. The piping, pump, and equipment from
the water source through to the second pump, are of low pressure
rating and hence low cost. The second pump preferably has a high
developed head (e.g., 165 bar) to produce the pressure needed at
the first fluid orifices and associated intermediate heat recovery
components as needed. The piping and equipment downstream of the
second pump are of high pressure ratings. Piping is kept as short
as possible to minimize the cost of the heavier piping and to
minimize pressure losses in the pipe.
[0966] 11.2.6 Pump Pressure Fluctuation Dampers
[0967] With reference to FIG. 61, in various embodiments,
oscillations of differential ejection pressure across the
distribution tube orifices 80 between the first fluid 901 and the
second fluid 904 can cause variations in flow of those first fluid
901 through those orifices. E.g., a typical positive displacement
high pressure Diesel pump creates very substantial pressure
pulsations in the diesel fuel. These cause pulsating variations in
the ratio of the flow of first fluid 901 delivered to the flow of
the second fluid 904. As such, as shown in the embodiment of FIG.
61, users preferably provide pressure modulators 370 to reduce
these fluctuations. E.g., pressure or flow fluctuation dampers
between the source of the pulsations (e.g., the pump) within the
fluid delivery system 360 and the fluid distribution orifices.
These dampers 370 are preferably configured to significantly reduce
these fluid oscillations and the corresponding variations in ratio
of the first fluid to the second fluid, and/or the third fluid to
the second fluid.
[0968] 11.2.7 Fluid Flow Transducer
[0969] As shown in FIG. 61, users preferably provide a high
accuracy high resolution fluid flow transducer inline between the
first fluid pump and the manifold to the distribution perforated
tube array 260. In some embodiments, users preferably use a
continuous positive displacement liquid flow transducer with a an
accuracy about 0.1% and a resolution about 0.01%. E.g., the
continuous positive displacement high precision flow meters from
KRAL-USA of Redland Calif. These are used as secondary liquid flow
transfer standards as well as being used with a wide range of
liquids and liquid viscosities in commercial applications. In other
applications, users use lesser flow transducers with resolution
about 0.1% etc. Similarly, a differential pressure monitor may be
used on either side of a venturi or calibrated flow aperture to
monitor flow rates.
[0970] 11.2.8 Further Fluid Treatment
[0971] In some configurations, users provide further fluid
treatment beyond filtration as desired or required by system
components. E.g., water treatment such as by mixed-bed
deimineralizers may be provided. Other types of treatment such as
reverse osmosis and other types of demineralizers can be used to
achieve desirable composition and fluid purity as appropriate. Such
fluid treatment removes chemicals that are incompatible with the
components into which the fluid will be injected, e.g., turbine hot
path.
[0972] 11.3 Second Fluid Delivery System
[0973] In many embodiments, the second fluid 904 delivered is
commonly a gas. (In other embodiments these methods may apply to
delivering a first fluid into a second liquid.) Accordingly, in
such systems as shown in FIG. 61, users preferably provide a second
fluid delivery system 400 to create a pressure difference in the
first fluid 904 between the fluid delivery location at the duct
intake 134 and the fluid exit location at the duct outlet 136.
E.g., providing a suitable pressurizing device, such as a
compressor 407 or blower, to create a pressure difference in the
compressed air between the combustor inlet 134 and the combustor
outlet 136. Users create sufficient pressure difference to move the
gas through at the desired flow rate when constrained by the flow
impedance between the combustor inlet 134 and outlet 136.
[0974] 11.3.1 Blower(s)
[0975] As shown in FIG. 61, users sometimes configure one or more
low pressure compressors 407 or "blowers" within the second fluid
delivery system 400 prior to the fluid contactor tubes 10 to
generate the prescribed pressure differential between the gas
delivery point (e.g., combustor inlet 134) and the combustor exit
136. In other embodiments users place the blower after the fluid
contactors 10 to generate a prescribed draft or negative
differential ejection pressure.
[0976] 11.3.2 Compressor(s)
[0977] In energy conversion systems, with reference to FIG. 84, for
higher pressure applications, in other embodiments, users
preferably configure the second fluid delivery system to include
one or more compressors 407, in series prior to the fluid contactor
to generate the prescribed pressure differential between the gas
delivery point and the contactor exit.
[0978] In some power embodiments, turbomachinery is commonly used
to compress the gaseous fluid 904, e.g., using centrifugal or axial
compressors. These are preferably for applications operating at
high duty levels over relatively narrow speed and flow ranges.
[0979] 11.3.3 Moving Cavity Compressors
[0980] As shown in FIG. 1 and FIG. 61, users may configure the
second fluid delivery system 400 to include precision screw
compressors 407 or other moving cavity compressors to compress
gases with high efficiency and linearity over a wide turndown
ratio. These typically have three lobes, giving three pulses in the
gas pressure per rotor revolution. (E.g., E.g., Kobelco Compressors
(America), Inc. of Elkhart, Ind., provides compressors claiming
about +/-1% linearity over a turn down range from the design flow
of 100% down to about 10% of design flow or less).
[0981] 11.3.4 Natural Draft Device
[0982] In other embodiments users may configure the second delivery
system 400 to provide the motive power to deliver and move this
second fluid 904 through the fluid contactor 10 by use of device or
system that generates a natural draft such as a stack, chimney or
flare.
[0983] 11.4 Fluid Delivery System Control
[0984] With reference to FIG. 1, and FIG. 61, as mentioned above,
the fuel system preferably comprises the first fluid delivery
system 360, the second fluid delivery system 400 and the controller
590. The controller 590 preferably controls and monitors the
overall operation of the system such as pump developed head, pump
speed, speed of the compressor 407 and/or blower, fluid flow rate,
and fluid temperatures. Suitable sensors may be utilized, such as
rotational speeds, pressure, temperature, flow meters and the like,
as needed or desired. The controller may efficaciously incorporate
a feedback system.
[0985] In various embodiments, pumps, blowers and/or compressors
407 are variously driven by work engines, synchronous or
asynchronous motors with fairly constant or varying speed. Where
the pressure or flow control or both is needed, flow control valves
on the pump discharge may be used. Variations in drive speed,
atmospheric pressure and/or humidity cause small but significant
differences in composition and/or the pressure and/or temperature
to which the second fluid is compressed. In various embodiments,
users preferably improve control over the compressor speed to
improve control of the pressure, flow rate and/or temperature of
the second fluid supplied to the fluid contactor.
[0986] 11.4.1 Variable Speed Drive
[0987] In some embodiments, users preferably drive the fluid supply
system by a electrical, mechanical, hydraulic or pneumatic variable
speed drive and/or the pump stroke. Users preferably provide a
synchronous motor and use variable frequency drive and control
system to reduce the variation in drive speed with variations in
pressure differential between atmospheric pressure and the pump
head or pressure supplied. Electronic speed control with induction
motors may similarly be used. In other embodiments users provide an
asynchronous motor or work engine such as a gas turbine or an
internal combustion engine.
[0988] Alternatively, standard pumps with flow control valves may
be used where more economical than variable speed drives. Flow
sensors such as venturies, nozzles, or orifice plates with
differential pressure transducers would be used with single loop or
other types of controllers to vary the flow according to demand,
automatically or manually.
[0989] 11.4.2 Drive Speed Transducer
[0990] Users preferably provide a speed meter 580 as shown in FIG.
61, to monitor the speed of the pump(s) 364 and/or compressor(s)
407 delivering one or more of the first fluid 901 and second fluid
904 (e.g., diesel fuel or water and air). In some embodiments users
preferably control fluid supply drive speed to about an order of
magnitude greater precision. E.g., users preferably control to
about 0.01% to achieve uncertainty of the order of 0.1% in some
configurations. In turn, users preferably provide a speed meter or
rotary transducer 580 with substantially greater resolution than
the desired degree of control. E.g., In some embodiments users
preferably provide a high resolution rotary transducer close
coupled to one or more pump drive shafts of the order of
0.001%.
[0991] High resolution speed meters 580 such as rotary encoders are
available. E.g., optical encoders with 10,000 optical pulses per
revolution are preferably used. Electronic conditioners are
available to multiply that pulse rate 2 times to 20 times. In some
embodiments, users preferably use such rotary encoders 580 to
provide about 200,000 pulses per revolution for design speeds of
about 20 Hz (1200 RPM). They preferably utilize dithering
electronics to reduce errors due to vibration. (e.g., (E.g., such
equipment is provided by BEI Electronics with a 10,000 pulse per
revolution encoder and a 20.times.pulse multiplier). Such pulse
resolution is reduced as needed to accommodate the desired design
rotational speed. E.g., for 4 MHz electronics with 100 Hz pump
speed (6,000 RPM), users preferably keep the electronic frequency
to about 40,000 pulses/revolution such as by using 10,000
pulses/revolution with a four times electronic multiplier.
[0992] Similarly, users preferably provide a high resolution speed
meter 580 for one or more compressors 407 to assist in monitoring
the flow rate of the second fluid 904 (e.g., the oxidant fluid).
They preferably add a differential pressure sensor monitor across
the second fluid compressor(s) and the first fluid pump(s) between
the fluid intake and fluid delivery ports, and an absolute pressure
intake sensor, or equivalently two absolute pressure sensors.
Corresponding temperature sensors are also provided. These assist
in precisely controlling the delivery fluid flow rates.
[0993] 11.4.3 Drive Controller
[0994] As shown in FIG. 61, in the illustrated embodiments, users
preferably control the respective speed of one or more of the fluid
pumps 364 using feedback from speed meters 580 with one or more
controllers 590, to control the first fluid delivery system and the
second fluid delivery system. These controllers preferably can
accommodate the resolution and precision of the speed meters and
other transducers, among other parameters. The controller(s) may be
any type of control system in the art and may include for example
one or more programable computers with associated control routines,
hard wired control circuits, etc. The controllers 590 preferably
incorporate digital control providing the capability of
compensating for system non-linearities and flexible control
algorithms.
[0995] 11.5 Selective Orifice Fluid Control via Intra-Tube Fluid
Pulsation
[0996] In some applications desiring low flows with low
differential ejection pressures, users control the differential
orifice pressure across the tube wall 30 to selectively control
when the first fluid 901 is delivered and through which orifices
80. Such control is selectively combined at the low end of flow
control to improve the turn down ratio and range of flow control in
some embodiments.
[0997] 11.5.1 Minimum Orifice Differential Fluid Pressure to
Overcome Surface Energy
[0998] With small orifices, surface tension becomes a significant
factor in determining drop (or bubble) formation out of orifices
80. A differential ejection pressure (or acceleration) is typically
needed to form liquid drops or micro-jets (in a gas or liquid) or
conversely gas bubbles in a liquid, due to increasing the
interfacial surface energy ("surface tension"). The higher the
interfacial curvature (the smaller the orifice diameter), the
greater the differential ejection pressure needed to form the
interfacial surface energy. When orifices vary in diameter, there
is a Minimum Orifice Differential ejection pressure needed to expel
liquid from the largest holes 80. This will typically be
insufficient to expel fluid from smaller orifices 80.
[0999] Accordingly, as shown in FIG. 73, users apply at least the
Minimum Orifice Differential ejection pressure sufficient to expel
liquid from the smallest orifices 80. Users correspondingly provide
fluid pressure in the manifolds 240 and contactor tubes 10 at least
sufficient to exceed this minimum differential ejection pressure at
the tube orifices 80 when users need or desire to create drops or
micro-jets. This fluid flow continues through orifices 80 as long
as that first fluid 901 is provided with at least a differential
ejection pressure greater than this Minimum Orifice Differential
ejection pressure.
[1000] 11.5.2 Partial Orifice Differential Fluid Pressure
[1001] In other embodiments, as shown in FIG. 73, users apply a
Partial Orifice Differential Fluid Pressure that is generally less
than All Orifice Differential Fluid Pressure but somewhat greater
than the Minimum (Largest) Differential Fluid Pressure, as needed
or desired. By such pressure control, users form drops or
micro-jets from the larger orifices but not from the smaller
ones.
[1002] 11.5.3 All Orifice Differential Fluid Pressure
[1003] When orifices 80 differ in size about the distribution tubes
10, then to create drops or micro-jets (or bubbles) users
preferably control the differential ejection pressures or
accelerations applied across the orifices 80 (or tube wall 30)
between the fluid 901 within the tubes 10 and the surrounding fluid
904 to selectively create drops or micro-jets (or bubbles) from
differing sized orifices 80. As shown in FIG. 74, in some
embodiments, users preferably apply a pressure generally greater
than the All Orifice Differential Fluid Pressure or acceleration
sufficient to form drops or micro-jets through all the
orifices.
[1004] 11.5.4 Control by Graded Differential Ejection Pressure
[1005] In other embodiments, users form orifices 80 with a small
but generally uniform gradient in size e.g., large at the center to
smaller at the periphery. (See, e.g., FIG. 9 and FIG. 10.) As shown
in FIG. 75, users then apply a prescribed differential pressure
sufficient to form drops or micro-jets though a portion of the
orifices but not through all of them, in order of larger orifices
to smaller ones. I.e., they apply a Partial Orifice Differential
Fluid Pressure (Podp) to selectively control the drop and micro-jet
formation through some but not all the graded orifices 80. In some
embodiments, users selectively control the differential ejection
pressure to spatially select where drops or micro-jets are formed.
To do so, they preferably vary the differential ejection pressure
at least above a minimum pressure and generally below the maximum
pressure required to form drops or micro-jets from all the orifices
80.
[1006] 11.5.5 Control by Pressure with Discrete Orifice Sizes
[1007] In some embodiments, users form orifices 80 of varying size
for contactor tubes 10 bent to different radii, arcs or helices. As
shown in FIG. 75, a prescribed differential ejection pressure is
then applied to selectively issue or eject drops or micro-jets (or
bubbles) from orifices 80 in some contactor tubes 80 and not from
others. This provides users with fairly discrete spatial control of
where drops or micro-jets are formed.
[1008] 11.5.6 Control by Digital Fluid Pulsation
[1009] With fairly uniform orifices, in some embodiments, users use
a differential ejection pressure pulse as a pressure "switch" to
form one or more drops or micro-jets of a first fluid 901 out of
each of a prescribed range of orifices 80 as shown in FIG. 76. They
then turn the flow off by reducing the differential ejection
pressure to somewhat below the minimum orifice differential
ejection pressure.
[1010] 11.5.7 Control by Frequency Modulation
[1011] By varying the frequency of fluid pulses of a given
magnitude to the fluid 901 within the contactor tubes 10, in some
embodiments as shown in FIG. 77, users apply a frequency modulation
of drops or micro-jets (or bubbles) injected into the surrounding
fluid flow. The rate at which drops or micro-jets are formed is
generally controlled by the frequency with which a pressure pulse
is given that exceeds the Minimum Orifice Differential ejection
pressure. To refine this control, users preferably provide smaller
changes in the pulse width to compensate for inertia and the
necessary fluid acceleration needed to form a drop or bubble.
[1012] In another variation users provide pulse width modulation
(PWM) control of the differential ejection pressure and thus of the
delivery of the first fluid through the orifices, as shown in FIG.
77 and FIG. 78.
[1013] 11.5.8 Control by Amplitude Modulation
[1014] By varying the amplitude of the differential ejection
pressure across the contactor tubes 10, in some embodiments users
create a form of amplitude modulation. With intermediate
differential fluid pressures, the higher the pressure the more
orifices 80 emit liquid. As shown in FIG. 78, with pressures above
the All Orifice Differential ejection pressure, the higher the
differential ejection pressure, the greater the velocity and rate
of fluid ejected through the orifices 80. Above the All Orifice
Differential ejection pressure, users control the fluid flow about
in proportion to the square root of the applied differential
ejection pressure.
[1015] Users further vary the width of pressure pulses to provide
some degree of amplitude modulation because of fluid inertia and
the time it takes to accelerate and expel liquid through the
orifices 80 in some configurations. I.e. using pulse width
modulation (PWM).
[1016] 11.5.9 Higher Pressure Jet Control
[1017] By increasing the differential ejection pressure across the
tube wall 30 above that required to form fluid drops or micro-jets,
in some embodiments as shown in FIG. 78, users increase the flow
rate of the injected first fluid 901 until it forms a jet with a
desired velocity entering the second fluid flow 904. This affects
the drop size, injected fluid flow rate and jet penetration
distance. Users further control the fluid injection rate by
adjusting this high differential ejection pressure within the
working design stress limits of the contactor tube 10 and
construction of orifices 80.
[1018] 11.5.10 Maximum Operating Design Pressure
[1019] The strength of the thin wall strip or foil, orifice
fraction and wall curvature, will have effect on the limit of the
usable differential ejection pressure across the perforated wall.
Accordingly, in some embodiments, users generally limit the upper
differential ejection pressure within suitable safety factors of
the maximum burst pressure, accounting for long term cyclic fatigue
of the contactor tube 10 or compound contactor tube 200. (See, for
example, FIG. 73.)
[1020] 11.5.11 Pressure Difference in Compound Perforated Tubes
[1021] With compound tubes, the thin walls will be the limiting
factor on the pressure difference across the tube walls. However,
much of the bending strength is preferably taken up by the
structural tube portion. For thin perforated walls users preferably
provide reinforcing supports outside of the thin perforated walls.
This transfers much of the internal fluid load to the reinforcing
supports.
[1022] Users preferably conduct a full finite element analysis to
adjust the dimensions for the required flow and pressure
differences. In other embodiments, other suitable modeling and/or
computation techniques empirical or semi-empirical studies and/or
correlations, and the like may be efficaciously utilized to adjust
dimensions, as need or desired.
[1023] 11.6 Control by Spatial Phase Modulation
[1024] In some configurations, users configure orifices 80 with
periodic spacing along a contactor tube 10. Where orifices are
configured circumferentially around the tube, users preferably
configure such orifices in a columnar arc around the contactor tube
10. Users further provide high frequency mechanical excitation to
the first fluid 901 near the juncture of the tube to the manifold
240 or sub-manifold 254. (e.g., ultrasonic or acoustic.) They form
a standing wave in the fluid within the contactor tubes 10. They
preferably control the orifice spacing and the frequency of the
mechanical excitation such that the orifice spacing H is equal to
the wavelength of the fluid within the contactor tube 10, or some
multiple of it.
[1025] Users then preferably control the relative phase of the
excited standing wave in the first fluid 901 within the contactor
tube 10. For maximum ejection, users adjust the phase of the
standing wave is such that the fluid anti-node approximately
matches the orifice locations. This causes the differential
ejection pressure to be at a maximum at the orifice and a minimum
at the node between the orifices. This results in a maximum
differential ejection pressure and fluid ejection rate.
[1026] Similarly by adjusting the phase by about +/-90 degrees,
users adjust the relative phase of the excited standing wave in the
first fluid within the tube 10 is adjusted to position the fluid
pressure nodes at the orifices. This creates a minimum differential
ejection pressure across the orifices. Accordingly this gives the
minimum ejection flow for variations in pressure oscillation
phase.
[1027] These measures provide rapid amplitude control over the
fluid flow by control of fluid excitation wavelength and amplitude
using the mechanical fluid excitation. The control resolution and
speed are adjusted by the excitation frequency and orifice spacing,
and excitation (amplitude or pressure) relative to the total
differential pressure desired. These measures are preferably
combined with one or more other pressure flow control measures to
provide enhanced control flexibility.
[1028] 11.7 Tube Stress and Differential ejection pressure
Control
[1029] In various embodiments, users preferably control the maximum
pressure difference across the tube wall 30 to stay within the
design stress for the perforated tube 10, and prevent the tube 10
from bursting. The hoop stress generated in the tube walls 30 is
preferably kept below the design working stress of the tube
material accounting for the desired the operating temperature, the
operating life and operating pressure oscillations. These are
preferably adjusted for the stress concentrations of the orifices
80, and for tube forming and bonding methods and the drag of
transverse flows across the tube. Users preferably maintain the
fluid pressure to maintain a maximum tolerable design differential
fluid pressure and pressure fluctuation rate within the contactor
tube 10, based on the curvature, stress concentrations, temperature
and operating strength of the tube wall 33.
[1030] 11.7.1 Maximum Differential Ejection Pressure in Perforated
Tubes
[1031] In general users preferably constrain the internal fluid
force within the tube 10 to less than the tensile force in the tube
walls 10 adjusted for operating and safety parameters. Users
preferably use the Lame burst formula incorporating both internal
and external tube radii to account for the influence of relatively
thick walls. Alternatively, they use the Barlow burst formula for
thin wall tubes. E.g., approximating by calculating the tensile
force is about equal to the hoop stress in the tube wall 33
multiplied by the cross-sectional area of both tube wall sections
in that longitudinal plane, where the internal fluid force is about
equal to the fluid pressure times the longitudinal cross-sectional
area of a tube section in a plane through the tube axis.
[1032] In doing so, users preferably account for the stress, creep
and fatigue components. These include stress concentrations due to
orifices, non-circular shapes, bending forces of gases traversing
the flow, vibration due to turbulence and vortex generation,
pressurization to control flow, and cyclic pressurization to vary
flow rates or digitally control the liquid flow.
[1033] Under some circumstances and embodiments, users control
differential ejection pressures to higher than the nominal design
limits, but which remain below the tube burst pressure, when
emergency flow rates higher than nominal design rates are desired
or needed. They then replace the distribution tubes more frequently
to accommodate the greater damage rates.
[1034] 11.7.2 Maximum Thin Wall Tube Diameter for Orifice Size
[1035] A given drilling technology (such as laser drilling)
typically has a design Wall Thickness/Orifice Diameter (T/D) ratio.
E.g., about 10:1. In various embodiments, users preferably select a
desired orifice size. This in turn limits the maximum wall
thickness through which users can create the needed or desired
orifices using that orifice forming technology. E.g., about 100
micrometer (.mu.m) wall thickness to form about 10 .mu.m orifices
with 10:1 T/D, or about 2 mm wall thickness with a 200:1 T/D
etc.
[1036] 11.7.3 Minimum Pressure for Liquid and Orifice
[1037] Conversely, users preferably determine a minimum pressure
needed to force the liquid out through the orifices 80 based on the
orifice size and the fluids 901 used. This is a function of the
differential surface energy between the first liquid being expelled
from the tube 10 and the second fluid 904 flowing across the tube
10.
[1038] In accordance with some preferred embodiments, users
establish a minimum and a Maximum Differential ejection pressure
within which embodiments of the distributed direct contactors 10
can be safely and/or desirably operated. They further preferably
evaluate design minimum and maximum absolute or gauge pressures
based on the operating pressure within of the distributed fluid
contactor system 2. These are configured according to the fluid
dynamics and system geometry including variations in pressure due
to the fluid flows.
[1039] 11.7.4 Maximum Over Pressure
[1040] In some circumstances, the pressure around the perforated
tube 80 may fluctuate. It could be possible for the pressure around
the contactor tube 80 to become greater than the pressure within
the tube. In other embodiments the pressure within the perforated
tube 80 might be decreased below the pressure around the tube 80.
In such circumstances there is potential for a negative
differential ejection pressure on the perforated tube 80.
[1041] Accordingly, in some embodiments, users preferably control
the Maximum Negative Differential ejection pressure to prevent
damage to a perforated tube 10 and/or compound perforated tube 200
from collapse or bending the tube wall 33 inward. This is
particularly applicable for tubes 80 within the pressurized chamber
170 with large oscillating pressures. e.g., such as within an
internal combustion engine.
[1042] 11.7.5 Tube End-end Differential Pressure Profile
Control
[1043] To increase control over the fluid delivery distributions
and profiles along the contactor tubes 10, in some configurations
as shown in FIG. 17, users control the differential pressure
between the adjacent connecting sub-manifolds 254 (or manifolds)
across a section of a tube array 260. For example, users control
the pressure across the shorter or longer sides of rectangular
contactor array 266 or similarly between the inner and outer radii
of an annular contactor array or between radial manifolds at the
two ends of the annular array. For example, users provide
pressure/flow modulators 370 at the entrance to each sub-manifold
254 to control and/or modulate the first fluid flow to the two
sub-manifolds.
[1044] In a similar configuration, users provide a differential
manifold pump to differentially pressurize fluid between the two
sub-manifolds 254 (or manifolds) connected across or to the ends of
contactor tubes 10. The differential manifold pump is preferably
configured as a reversible pump with corresponding bidirectional
controls so as to be able to generate an internal fluid gradient
along the contactor tube 10 in either direction between the two
adjoining sub-manifolds 254. In similar configurations, users
provide controllable valves to control the flow through the two
adjoining sub-manifolds 254.
[1045] Users accordingly configure the controller 590 to suitably
control the Pressure/Flow Modulators 370 (or similarly the
differential manifold pump, controllable valves) or as desired or
needed, such as the control methods shown in FIG. 73 to FIG. 78. In
some configurations they further configure the hydraulic diameter
to length of the contactor tube 10. This varies the relative
internal friction and degree of pressure drop along the tube from
the flow.
[1046] By controlling the differential pressure in the connecting
manifolds 240 or sub-manifolds 254, users control the internal
pressure gradient along a contactor tube 10. They accordingly
control the longitudinal distribution and profile along the tube 10
of the differential ejection pressure across the tube wall and
associated orifices 80. Accordingly, they achieve a dynamic
gradient in fluid delivery distribution and profile along the axis
of the tube section 260 from one end of the tube 10 to another. By
controlling the differential pressure between the two connecting
sub-manifolds 254, users preferably control the gradient of the
first fluid 901 delivery distribution and profile within and along
the direct contactor 10 delivering that fluid. E.g fuel fluid 901,
and/or oxidant fluid 904.
[1047] 11.7.6 Combined Pressure Profile Control
[1048] Preferably, in some embodiments, users combine such methods
and variously control one or more of the mean differential ejection
pressure amplitude across the tube wall 33, the gradient of the
differential ejection pressure along the tube section 260, the
dynamic fluctuating mean differential ejection pressure the fluid
(e.g., the Root Mean Square value) in analog or discrete fashions,
and the dynamic fluctuating gradient of the differential ejection
pressure (RMS value) along the tube section 260.
[1049] Such control enables users to flexibly and precisely control
the static and/or dynamic distribution and profile of the rate of
fluid issuing from the tubes relative to the distribution and
profile of the rate of fluid flow across the tubes 80. These can
cover common turn down ratios or extend to very wide turn down
ranges. For example, users may use pulse width, pulse amplitude,
pulse frequency, analog and/or discrete variations in one or more
of these differential ejection pressures such as depicted in FIG.
73 through FIG. 78.
[1050] With such controls 590, they dynamically adjust the flow
rates to provide a wide range of methods to modulate the fluid flow
and precisely control or meter one or both of the fluid flows,
including digital, frequency, amplitude, pulse width or other
modulation methods. In some embodiments, these are similarly used
to modulate the relative fluid mixing as well as higher pressure
fluid control.
[1051] 11.8 Control of Fluid Ratio Profiles
[1052] With reference to FIG. 18, FIG. 19 and FIG. 20, by
controlling the relative transverse delivery distribution of the
first fluid 901 relative to the transverse flow distribution of the
second fluid 904, users preferably control the profile of the ratio
between those two fluids across the contactors 10 or contactor
arrays 260 over which users control the fluid pressures and
consequent flows. In some configurations users control the profile
of the ratio of the second fluid to the first fluid in the first
transverse direction to the second fluid flow 904 e.g., along the
distributed members, or along a radial or other direction
perpendicular to the duct axis. They similarly control this ratio
profile in the second transverse direction to the second fluid flow
904; e.g., perpendicular to the distributed members, or
circumferentially, or in another direction perpendicular to the
duct.
[1053] In some configurations, users seek to form a fairly uniform
fluid ratio profile along one or both of these transverse
directions. E.g., to form a uniform ratio in the circumferential
direction in an annular array. In other configurations, users will
seek some other desired fluid ratio profile such as along the
second transverse direction.
[1054] 11.8.1 Oxidant to Fuel Ratio Profile
[1055] For example, users preferably control the delivery
distribution and/or profile of the fuel fluid 901 compared to the
delivery distribution and/or profile of the oxidant fluid 904 to
control the distribution and/or profile of the oxidant to fuel
ratio across the contactors 10 or contactor arrays 260 in one or
two transverse directions. Where users provide substantial excess
oxidant containing fluid, controlling the oxidant to fuel ratio
will correspondingly control the temperature of the combustion and
resulting combustion gases or energetic fluid.
[1056] 11.8.2 Water to Air Ratio Profile
[1057] In another example, users preferably control the delivery
distributions and/or profiles of water as a first fluid 901
compared to air flow as the second fluid 904 to control the
distribution and/or profile of the water to air ratio across the
contactors 10 or contactor arrays 260. This beneficially controls
the relative humidity profile in the delivered air.
[1058] 11.9 Vibrate Tubes-Orifices
[1059] With reference to FIG. 50, in some embodiments, users
preferably mechanically and/or electrically excite the perforated
tubes 10 with an array or tube vibrator 50 to excite the perforated
tubes 10 to generate vibrations in those tubes. This causes a
sessile and then pendant drop or liquid jet to oscillate at or near
the excitation frequency. This encourages drops to form with much
greater precision and uniformity than by natural turbulence driven
jet oscillation. Such measure facilitate drop formation and
release, and to improve drop size uniformity or narrow the drop
size distribution.
[1060] The vibrator 50 may be mechanically and/or electrically
excited such as using a pneumatic, hydraulic, or electromagnetic
excitators. Correspondingly, users configure curvilinear flexible
fluid supply tubes 54 that can deliver one or more of the first
fluid 901 while flexibly accommodating the vibrations generated in
the contactor tubes 10. The vibrator 50 may be inertially driven
relative to a suspended mass. Alternatively, it may be supported
between the surrounding structure and the contactor tubes 10 with
tube supports 37 or similar supporting structures. Similarly the
direct contactor array 260 is preferably supported by two or more
flexible array supports 72 to the surrounding fluid duct 130 to
permit the contactor array 260 to vibrate relative to the duct.
[1061] The vibrator 50 is preferably configured to excite
vibrations generally perpendicular to the plane of the outlets of
the orifices 80. E.g., preferably using axial excitation parallel
to the fluid duct 130. This vibration preferably causes a sessile
drop and then a pendant drop or liquid jet to oscillate at or near
the vibrator excitation frequency. This vibration encourages drops
to form with greater precision and uniformity than by natural
turbulence driven oscillation.
[1062] 11.9.1 Orifice Vibration Frequency & Direction
[1063] In some embodiments, users preferably oscillate one or both
of the perforated tubes 10 or tube arrays 260 at or close to the
natural frequency of the liquid micro-jet oscillation. In some
embodiments, users preferably oscillate one or more the contactor
tubes 10 along the axis of the axis of the fluid duct 130 or the
predominant flow direction of the second fluid 904. This vibration
axis is preferably selected when the orifices 80 are oriented
predominantly perpendicular (normal) to that duct axis. In this
mode, preferably all the orifices 80 are vibrated to desirably
obtain more uniform drop size. In some embodiments, orifices
expelling liquid drops or micro-jets are preferably vibrated
transversely to the a vector predominantly parallel to the axis of
the orifices 80 (e.g., the flow axis of the first fluid 901),
especially when the orifice orientation is preferably perpendicular
to the mean flow of the second fluid 904. This maximizes the
formation of the capillary waves in the micro-jets and consequently
encourages formation of drops or micro-jets of uniform size or more
narrow size distribution.
[1064] In various embodiments, users preferably use a frequency
Omega of wavelength lambda with a characteristic capillary speed
V.sub.c where Omega=V.sub.c/lambda=V.sub.c*0.56/(2*Pi*r.sub.o).
[1065] In other embodiments, users preferably oscillate the tubes
10 transversely to the fluid flow direction of the second fluid 904
to create symmetric liquid oscillations. For example, when the
orifices 80 are oriented parallel to the axis of the second fluid
flow 904. In other embodiments, users vibrate the orifice array 260
in the azimuthal direction about the flow axis of the second fluid
904. As the orifice vibration magnitude is proportional to radial
distance from that axis, this azimuthal excitation is most
effective with annular array configurations 267, 269.
[1066] 11.10 Differential Pressure Modulation System
[1067] As shown in FIG. 1, in some embodiments, users provide a
pressure modulation system 370 to vary the pressure of one or more
fluids 901 flowing through the perforated tubes 10 or tube arrays
260. In modified embodiments, they may also or alternatively vary
the pressure of the second fluid 904 flowing across the contactor
tubes 10 or through the tube arrays 260. In some embodiments, users
modulate the fluid pressure by varying the speed of one or more
fluid delivery pumps 366 delivering a first fluid 901 or blowers
406 or compressors 407 to vary one or more of these pressures.
[1068] In other embodiments, users move diaphragms or walls of the
fluid enclosure or duct, or pistons 197 or motion actuation members
such as ultrasonic transducers connected to fluid manifolds and/or
fluid ducts to modulate or fluctuate the pressure. In further
embodiments, users combine such methods of pressure variation in
the pressure modulation system 370.
[1069] By so doing, users preferably provide systems to control the
differential ejection pressures across the perforated tubes and
thus to control the fluid delivery rates through those perforated
tubes.
[1070] 11.11 Electrostatic Jet Reduction
[1071] Some embodiments of a direct fluid contactor incorporate
electrostatic and/or electrodynamic jet reduction. In such
embodiments, users preferably apply an static and/or dynamic
electric field generally in line with the orifice axes. These
arrangements may result in a substantial reduction in the diameter
of liquid jets (such as liquid fuel or liquid diluent jets) exiting
the orifices. Consequently, the surface energy with this
electrostatic deformation or modulation causes the jets breaks up
into substantially smaller and/or more precise droplets than are
typically formed from jets exiting those orifices under similar
differential ejection pressures.
[1072] 11.11.1 Electrical Field Excitation
[1073] For example, as schematically shown in FIG. 79, users
preferably provide a high voltage power supply 300 to deliver one
or more high voltages to one or more distributor or combustor
electrodes 320 or electric grids 326 and corresponding voltages to
one or more tube electrodes comprising perforated tubes 10 or tube
arrays 260 at some suitable distance displaced from the electrodes
320 or grids 326. In general, the tubes are preferably grounded by
connection to a ground electrode 302, with the high voltage applied
to the electric grid 326 by connecting it to a positive electrode
304 of the high voltage power supply 300.
[1074] In this example, users position a conical electric grid 326
positioned downstream of a conical distribution tube array 262
formed into a fuel fluid array electrode 322. By applying a
differential high voltage between the downstream grid electrode 326
and the upstream fluid array electrode 322 will draw micro-jets
from the tube orifices towards the electrode grid 326. The high
voltage causes the jets to neck down and form smaller droplets.
With sufficient voltage and small orifices, the droplets will be
small enough to generally flow around the downstream grid 326
between the inlet 134 and the outlet 136.
[1075] As shown in FIG. 80, in other embodiments, users similarly
position the electrode grid 326 upstream of the grounded tubular
distribution fluid array electrode 322. The electric field draws
the micro-jets outward and generally upstream. Then the jets and
droplets break up and are swept downstream by the transversely
flowing second fluid. Correspondingly, in modified embodiments,
users configure one set of contactor tubes as one electrode and
ground it to a ground electrode 302. e.g., the fluid array
electrode 322 preferably for any explosive fluids. They then
configure a complementary contactor array electrode 322 and connect
it to a high voltage electrode such as the negative electrode 306.
Similarly, one set of contactor tubes may be divided with one set
connected to one electrode (or ground), and the other set to the
other high voltage electrode. In such configurations, the jets
leaving one or more orifices 80 is attracted to the near by
contactor electrode between the inlet 134 and the outlet 136
(similar to the grid electrode 326 described previously.)
[1076] As shown in FIG. 81, in other embodiments, users
electrically excite the tube array 324 and first fluid delivery
systems and connect the duct 130 to ground 302 between an inlet 134
and outlet 136. For instance, users may excite a cylindrical or
conical array positioned within a cylindrical conductive duct. The
duct acts as a grid and is conveniently grounded.
[1077] This high voltage excitation method requires relatively high
voltages, but relatively low power. In some embodiments, the
electric power supplies providing these voltages may be controlled
to vary one or more of the electric voltages and/or currents. Both
the mean and fluctuating amplitude, frequency and/or phase of the
voltage are preferably controlled.
[1078] 11.12 Electric Field Excitation Control
[1079] 11.12.2 Base Electric Field Excitation
[1080] As mentioned above with reference to FIG. 79 to FIG. 81, in
some embodiments, users preferably control the high voltage power
supply 300 to desirably apply one or more suitable electric
voltages to the respective electrodes 302-312 to generate electric
fields generally normal to orifices 80 in perforated tubes 10. In
some embodiments, one or more high differential voltages are
applied between perforated tube arrays 260 and one or more
complementary electrodes 326, 328, 330, 332, or 334 to form these
electric fields. (See, for example, FIG. 79.) In other embodiments,
voltages are applied between two or more sets of distribution tubes
322, 324. (See, for example, FIG. 80.) In another configuration,
the voltages may be applied between contactor tubes 10, 322 or 324
and a portion of one or more ducts, 302, 320, 332. (See, for
example, FIG. 81.)
[1081] Users preferably apply such electric fields to reduce the
size of liquid columns to smaller in diameter than the orifices 80
through which the fluids are delivered. Accordingly, they
preferably break up the liquid column of first fluid 901 into micro
droplets that are smaller than conventional drops, and preferably
smaller than the diameter of the orifice 80. (This contrasts with
sessile or "pendant" drops which form at about twice the size of
the orifice 80. It also differs from high velocity jets which
initially break up into drops of similar size to the orifice. The
differential fluid velocity then variously breaks these drops into
smaller droplets.) In such configurations, users preferably utilize
one or more conductive manifolds 240 to electrically connect
distribution tubes 10 to respective voltage sources at electrodes
302-312.
[1082] In some embodiments, users preferably apply a prescribed,
pre-selected or pre-determined excitation voltage(s) from the high
voltage power supply 300 according to the electric field gradient
desired or required, liquid surface tension and viscosity gas
pressure and flow rates. They further account for the influence of
the tube to tube gaps G, liquid composition and temperature(s). By
using such electric field excitation, users seek to provide the
benefits of using larger orifices 80 that are less susceptible to
clogging while creating smaller drops and micro-jets. They can also
use such methods to create drops or micro-jets from more viscous
fuels such as bunker fuel or crude oil.
[1083] 11.12.3 Control by Oscillating or Pulsing Electric
Fields
[1084] In some embodiments, users pulse or oscillate the applied
high voltage between two or more tubes 10 or tube sets 260, or
between such tubes or arrays and electrodes 302-312, 320, 326-334.
This provides an oscillating excitation to the first liquid 901
being delivered or expelled from the perforated tube orifices 80.
This electric field oscillation in turn generates oscillations in
the liquid column and initiates column breakup and droplet
formation. The liquid excitation will be generally synchronous with
the field excitation and may result in liquid oscillations
synchronous with the electric field. Accordingly, users use the
oscillating electric field excitation to generally create more
uniform droplets according to the precision of pulsing the electric
field in magnitude and frequency. The electric field and the fluid
pressure modulation are preferably controlled together to have the
greatest benefit in controlling the physical pressure oscillations
and the precision of drop formation.
[1085] In some embodiments, users preferably tune the electric
field pulsation or oscillation frequency to the natural liquid jet
oscillation frequency in the presence of the average electrical
field established. This further achieves more uniform drop
formation.
[1086] 11.12.4 Control by Field-Drop Frequency Modulation
[1087] As with pressure modulation, in some embodiments, users
preferably modulate the electrical field to vary drop size and
delivery rate with a prescribed frequency modulation.
[1088] 11.12.5 Control by Field-Drop Amplitude Modulation
[1089] In some embodiments, users preferably modulate the amplitude
of the electric field to expand or reduce the liquid jet as desired
to create drops or micro-jets of differing size, resulting in a
general drop amplitude modulation. Similarly, users can use Pulse
Width Modulation (PWM) to control the time over which the fluid is
ejected. By using such amplitude modulation and pulse width
modulation methods, they provide benefits of varying drop size
and/or micro-jet flow in systems where drop size is generally
controlled by the size of the orifices 80 and the surface energy of
the first fluid 901 relative to the second fluid 904.
[1090] 11.12.6 Control by Combined Frequency and Amplitude Field
Modulation
[1091] In some embodiments, users combine frequency and amplitude
modulation of the applied electric field from the power supply 300.
This enables users to vary both drop size and drop delivery
frequency and thus liquid delivery rate. In some configurations,
users further combine electric field control with differential
fluid pressure to desirably control drop size, drop or micro-jet
delivery rates.
[1092] 11.13 Electrostatic Homogenization
[1093] To more homogeneously distribute drops of a first fluid in a
second fluid, users preferably use high voltage electrostatic
excitation in some configurations. They preferably provide a high
voltage power supply 300 and at least sufficient voltage and
current between the direct contactors 10 or between contactors 10
and electrostatic grids 326, to charge at least 10% of the droplets
formed, preferably more than 50%, and more preferably at least 90%
of the droplets formed downstream of the direct contactors 10
within a prescribed drop formation residence time. By so charging
the droplets and providing a desired residence time, they
preferably cause the droplets to accelerate by mutual electrostatic
repulsion caused by nearby drops having similar electrical charges.
By charging the drops, users further shatter and disperse the drops
of the first fluid 901 within the second fluid 904 when the charged
droplets evaporate and reach a critical charge to mass
condition.
[1094] Users preferably provide a desired drop homogenization
residence time over which the droplets move driven by
self-repulsion towards a smoother mass distribution and profile in
one or both transverse directions, and in the axial direction
relative to the fluid duct 130. By adding electrostatically
charging the drops, users effectively provide a high frequency
filter to at least one of the droplet distributions and/or profiles
about the fluid duct 130. Users preferably select the drop
homogenization residence time to achieve a desired degree of high
frequency filtering or smoothing of at least one of the droplet
distribution profiles along a direction as well as the number
distribution at a point. They preferably provide sufficient
charging and homogenization residence time to effect at least about
10% smoothing preferably about 50% smoothing, and more preferably
more than about 90% smoothing of the droplet spatial distribution
and profile measured across about 20% of the respective duct
dimension, e.g., radius, circumference, transverse width,
transverse height, fluid duct length, bulbuous diameter as
appropriate to the configuration of the contactor array 260.
[1095] By such high frequency electrostatic profile filtration,
users advantageously improve the profile of the desired ratio of
mass flow distributions of a liquid delivered through the contactor
array 260, relative to a second fluid flowing within the fluid
duct. E.g., the ratio of the mass flow distribution of fuel fluid
901 or diluent fluid 907 relative to the mass flow distribution of
oxidant fluid 904. While this method most commonly applies to
charging liquid fuel fluid 901 or liquid diluent fluid 907 through
their respective contactors, it can also be used to charge and
influence gaseous fluids.
[1096] 11.14 Electrically Heating Contactors
[1097] In some embodiments, users electrically heat contactor
tubes. In such embodiments, in reference to FIG. 61, they
preferably provide an electrical power supply 301 with suitable
voltage and current to heat the contactor array 260 in a controlled
manner. In such embodiments, users preferably connect the
distributed fluid contactor array 260 to the power supply 301 using
corrosion and temperature resistant electrical contacts. These
contacts are preferably configured so that there are generally
similar heating rates per surface area along the distribution
tubes. In embodiments using one or more helical distribution tubes,
users preferably connect the power supply 301 to each end of the
distribution tubes.
[1098] The thermal cleaning is preferably performed when the system
off duty with low flow rates of the second fluid to minimize the
heating required. It may also be performed on duty with higher
currents to compensate for higher cooling loads.
[1099] Similarly, in embodiments of contactor arrays 260 comprising
multiple distribution tubes between manifolds, electrical contacts
can be made symmetrically or asymmetrically across the manifolds so
that the current generally flows uniformly from the power supply
301 through the contactor tubes. E.g., connecting voltages to
manifolds on opposite comers of rectangular distribution arrays or
annular arrays. In other embodiments non-uniform heating is also
used. With these various embodiments, the control system 588
preferably utilizes temperature sensors to control the heating to
control the temperatures to which the distribution tubes are heated
and the heating duration.
[1100] 11.14.1 High Temperature Thermal Tube Cleaning
[1101] In some embodiments, users preferably make the perforated
tubes 80 of high temperature materials capable of sustaining
temperatures substantially greater than the pyrolysis temperatures
of for example liquid fuels and blocking biomass materials. E.g.,
substantially higher than about 900 K (about 623.degree. C. or
1153.degree. F.). Correspondingly, users preferably keep the tube
temperature below temperatures at which entrained ash and
particulars melt to form slag that might block the orifices.
[1102] These measures preferably assist in removing fibers and
other materials in the second fluid that come through the
filtration system and build up on the contactor tubes and block the
tube to tube gaps. Similarly unfiltered materials within the first
fluid can block tube orifices.
[1103] In some embodiments with lower stress and temperature
applications, users form the contactor tubes using high temperature
stainless steel. In other embodiments, with higher stress and
temperature applications, users preferably select Incolonel or
Hastalloy or similar high temperature materials to form the
contactor tubes.
[1104] 11.14.2 High Temperature Cleaning Operation
[1105] In some preferred embodiments, further referring to FIG. 1
and FIG. 61, by using high temperature materials to make the
contactor tubes, users preferably apply controlled electric
currents from the power supply 301 to heat the tubes and vaporize
or "gasify" any liquid fuel or biomass materials built up in or on
the tubes 10 or blocking the orifices 80. This operation is
controlled similarly to an electric "oven cleaner." Users
preferably control the temperature carefully and precisely,
sufficient to at least exceed the pyrolysis temperature of liquid
fuels for the necessary duration. Users further preferably maintain
the temperature below prescribed, pre-determined or pre-selected
levels, to stay below creep and deformation design parameters of
the material used, and preferably below salt melting temperatures
or temperatures for slag formation from the deposits. They further
control the duration of heating for sufficient time to sufficiently
gasify the deposits. Such measures preferably remove fibers and
other material in the second fluid that are not filtered out can
build up on the tubes and block tube to tube gaps.
[1106] In some embodiments, users preferably provide a flow of a
reactive cleaning first fluid such as hot water or steam, through
one or more perforated tubes in addition to or instead of
electrically heating the tubes, to assist cleaning the orifices by
the water gas shift reaction.
12 Forming Arrays of Perforated Tubes
[1107] Here are disclosed preferred methods of forming perforated
distribution tubes. In some configurations, users further assemble
these perforated tubes into contactor arrays and connect them to
manifolds to duct the fluid to the tubes as described above.
[1108] 12.2 Materials
[1109] In various configurations described above, the perforated
tubes 10 and manifolds 240 may be formed from a wide variety of
materials according to the applications, temperatures, and desired
or needed design life. Embodiments commonly use corrosion resistant
materials such as stainless steel. High temperature applications
preferably use suitable high temperature materials such as Inconel
or Hastalloy. Other embodiments can use quartz, glass, sapphire or
ceramic. Other embodiments utilize a variety of structural
plastics.
[1110] 12.3 Cutting Tubes and Forming Holes
[1111] Following are preferred ways of forming contactor tubes and
manifolds, which may be used to form the embodiments described
above. Other methods may also used.
[1112] 12.3.1 Cut Tubes
[1113] In one embodiment, users cut long lengths of tube into
suitable shorter lengths. Technology is available to rapidly and
precisely shear or separate tubes into shorter tubular lengths
sections without sawing them and with minimal burr formation. E.g.,
Production Tube Cutting Inc. of Dayton Ohio.
[1114] 12.3.2 Form Manifold Holes & Shape Tube Ends
[1115] Referring to FIG. 22, to attach distribution tubes 10 to
manifolds 240, users form suitably sized manifold connecting holes
250 in the manifold wall 249. In many embodiments, users form
circular holes 250 in manifold walls 249. Accordingly, users
preferably form the ends of distribution tubes 10 into a circular
shape to fit the manifold hole 250. Unperforated tubes are
similarly attached.
[1116] In other embodiments, users may extend the manifold hole 250
to variously form round ended slots, or elliptically shaped holes
etc. as needed or desired. Users correspondingly form the tube ends
into shapes the conveniently fit into such elongated holes.
[1117] 12.3.3 Friction Drilling
[1118] Further referring to FIG. 22, users preferably use friction
drilling to heat and soften or melt manifold walls 249 and press a
hole 250 through it where metal or similar ductile material is
used. Users more preferably create a hole 250 and then pull the
residual material out to form a collar. (For example, by using
equipment from T-Drill company of Norcross, Ga.) This method is
preferably used to provide an outward extension that assists in
welding a connecting tube 10 to the manifold wall 249 and adds
strength to the joint. In other embodiments users may use methods
of hot drilling to create a manifold hole 250, which leaves 80% of
the residual metal pointing inward, 20% outward. (For example by
using equipment from the FlowDrill company of St. Louis Mo.)
[1119] 12.4 Bond Tubes onto Manifolds
[1120] Further referring to FIG. 22, users abut or insert the tubes
10 into the manifold hole 250 in the manifold wall 249. Finally
users join the tubes 10 to the manifold wall 249 at the manifold
hole 250 by welding, brazing, soldering or by a similar suitable
joining method. In some embodiments, tubes 10 are bonded to one or
more manifold walls 250 using one of a variety of methods including
inductive, electric or friction welding. Modem technology is now
available to inductively weld small tubes 10 with thin tube walls
33 to manifold walls 250. (For instance, users may use equipment by
VerMoTec of St. Ingbert, Germany which can inductively weld tubes
with 0.15 mm thick walls.)
[1121] In other embodiments, users braze, solder, glue, thermo-form
or use other suitable techniques to join the tubes 10 to one or
more manifold walls 250.
[1122] 12.5 Structural Supports Manifold Tube Supports
[1123] With reference to FIG. 16 and FIG. 17, attaching the
perforated distribution tubes 10A-C to manifold walls 250 provides
some structural support. Further support is provided by positioning
tube sections between two manifolds 240 or sub-manifolds 254. E.g.,
in planar arrays, or in circular sections.
[1124] 12.5.2 Additional Supports
[1125] As needed or desired, users add further tube supports 37 at
the end of tubes 10, or attach the tube supports 37 in between tube
ends, preferably transversely to the tubes 10. In some embodiments,
these support sections 37 are preferably positioned upstream of the
tubes 10 so that liquid does not impact and build up on downstream
supports. In other embodiments users attach tube supports 37 both
above and below tubes 10 to form a three dimensional structurally
supported array or space frame.
[1126] 12.6 Three Dimensional Structural Supports
[1127] As the tubes 10 are offset along the axis of the fluid duct
130, so the manifolds 240 and structural tube supports 37 are also
generally offset. Axially offsetting the tubes 10 and tube supports
37 advantageously forms a three dimensional structural support or
space frame configuration that is stiffer and generally stronger
than planar arrays.
[1128] 12.6.1 Conical Ray Supports
[1129] As described above with respect to FIG. 57, users form
manifolds 240 and add further tube supports 37 in some embodiments
as conical rays or radial rays about tangential to the surface of a
conical tube array 262 or 264. By these methods, users provide
three dimensional structural strength and stability to the tubular
array 262 or 264. Users use at least two and preferably three or
more radial structural manifolds 240 and tube supports 37 along the
edge of the conical tube array 262 or 264.
[1130] 12.6.2 Space Structure
[1131] In some embodiments, with reference to FIG. 71, users
further provide transverse tube supports 37 between tubes 10, and
manifolds 240. Similarly, they may provide tube supports 37 between
offset arrays 284 or similarly offset arrays 260-273. Such methods
further create space array type structural supports, thus giving
the contactor array 260 or 288 greater strength and rigidity.
[1132] 12.7 Axially Multi-Plane Distribution Array
[1133] With reference to FIG. 62, in some configurations, users
preferably configure two or more sets of multi-tube distributor
arrays each configured with desired transverse distribution(s) of
orifice size, orifice spacing and orifice orientation transverse to
the fluid duct. E.g., as multiple sets of annular arrays 267. As
shown in the enlarged FIG. 63, tubes 10 contain orifices 80
delivering fluid jets 903 across the tube to tube gap. Opposing
orifices are preferably offset to give overlapping sprays.
[1134] These multiple contactor arrays 267 are then spaced axially
along the duct to form an axially multi-plane distribution array.
With further reference to FIG. 62 and the enlarged view FIG. 64,
the contactor tubes 10 in each of these arrays are preferably
oriented axially in-line to reduce drag by the second fluid
904.
[1135] As shown in FIG. 64, users preferably configure differing
mean transverse specific spatial orifice density distributions in
the respective distributor arrays to give the greatest control
flexibility. These spatial orifice specific areal density
distributions are further configured to delivery the desired mass
flow rate distribution of the first fluid, such as needed to
achieve a desired transverse mass flow ratio of second fluid flow
to first fluid flow.
[1136] Contactor tubes in each axially distinct array set 267 are
preferably connected to corresponding sub-manifolds. Each
sub-manifold 254 in turn is connected via pressure-flow modulators
or valves to one or more manifolds 240. This permits at least
on/off control of flow through the differing sets of axial
contactor arrays. More preferably, each axially distinct contactor
array set is preferably individually controlled to provide the
greatest control flexibility and off design performance.
[1137] 12.7.1 Jet Penetration Configurations
[1138] By varying the circumferential orientation of the orifices
80 about the perforated tube 10, users achieve differing jet
penetrations across the tube-tube gap in some configurations. By
starting with jet penetrations of about 10% to 200% of the
tube-tube gap, fairly uniform mixing is achieved in the second
transverse direction perpendicular to the tubes across a wide range
of varying jet penetrations with varying fluid delivery flow
ranges. Similarly, users vary the orifice size and consequently the
relative jet penetrations in configuring the spatial orifice area
density in some configurations.
[1139] 12.7.2 Ranges of Varying Differential Ejection Pressure
[1140] The pressure-flow modulators may be configured to control
the differential ejection pressure for a range of varying
pressures. For example, where a precise narrow range of control is
desired the pressure could be varied over about a 1.04:1 range
giving about a 1.02:1 (i.e. 2%) variation in fluid flow. In another
example, the differential ejection pressure range can be configured
for a range of about 2700 bar to 0.27 bar (40,000 psi to 4 psi) or
10,000 times pressure ratio. This gives an mass flow turndown ratio
of about 100:1. Numerous pressure ranges within this range can be
configured. The variation in mass flow ratio in relation to
pressure flow ratio is shown for example in Table 5.
5TABLE 5 Hybrid Turndown Ratio Orifice Mass Ratio Density Ratio 3.2
5.5 10.0 17.3 31.6 54.8 100.0 1.02 3.2 5.6 10 18 32 56 102 1.04 3.3
5.7 10 18 33 57 104 1.09 3.4 6.0 11 19 34 60 109 1.18 3.7 6.5 12 20
37 65 118 1.41 4.5 7.7 14 24 45 77 141 2 6 11 20 35 63 110 200 4 13
22 40 69 126 219 400 8 25 44 80 139 253 438 800 16 51 88 160 277
506 876 1,600 32 101 175 320 554 1,012 1,753 3,200 64 202 351 640
1,109 2,024 3,505 6,400 128 405 701 1,280 2,217 4,048 7,011 12,800
10 30 100 300 1,000 3,000 10,000 Pressure Ratio
[1141] 12.8 Hybrid Turn-down Ratios
[1142] By such combinations of varying spatial orifice density
distributions, profiles and controls, users configure contactor
arrays 260 which provide very wide turndown ratios of fluid flow
profiles of the first fluid relative to the second fluid. For
example, users may provide a 10:1 ratio in spatial orifice
densities between one array and the next. They may further use a
10:1 flow turn-down ratio in each array by varying the differential
ejection pressure by 100:1. The combination of two such arrays
provides an effective 100:1 turn down ratio. By similarly adding a
third array in like proportions, users achieve a 1000:1 turn down
ratio for the combined array while only requiring a 100:1 pressure
ratio range across each individual array. Similarly controlling the
pressure range to 10,000 for a mass flow turn-down of 100 with
three arrays of 10:1 range each gives a combined turndown ratio of
100.times.10.times.10.times.10 or 100,000. Such very wide turn-down
ratios are achieved while generally preserving the transverse mass
flow profiles of the delivered fluid. Other ratios may be readily
used, as shown in Table 5.
13 Heat Exchangers & Contactors
[1143] In various embodiments, users preferably configure one or
more direct fluid contactor arrays to deliver a first fluid to mix
with a second fluid to accomplish desired heat exchange processes
comprising cooling, condensation, heating, and evaporation. Users
preferably adjust one or more of the transverse distributions of
contactor parameters of orifice size, position, orientation, tube
spacing and fluid delivery pressure, to achieve corresponding
desired transverse distributions of drop size distributions, jet
penetration, and jet orientation. These in turn achieve desired
transverse distributions of heat transfer rates, heat transfer
distances, fluid flow delivery and fluid composition or second to
first fluid ratio profiles. These are variously configured in one
or more of the first and second transverse directions and the axial
direction.
[1144] For example, in various embodiments such as shown in FIG.
82, users preferably configure one or more direct fluid contactors
or direct contact heat exchangers 483 to deliver a first fluid 901
to desirably contact a second fluid 904 with a desired degree of
mixing. E.g., to configure a direct contact condensor 484.
[1145] 13.2 Distributed Contactor Modeling Method
[1146] With reference to FIG. 94, users preferably model and
configure the first and second fluid flows to achieve one or more
constraints and desired spatial distributions of fluid parameters
or profiles or fluid parameter ratios. This method comprises
setting up the appropriate boundary conditions such as one or more
desired, prescribed or evaluated mean or spatial distributions of
fluid mass flows, temperatures, pressures, densities, velocities,
as appropriate to the model. They further provide orifice discharge
coefficients, tube tensile strengths, tube dimensions and other
relevant boundary conditions.
[1147] They further form equations to model the desired
configurations. These include design equations for the tube
parameters of tube length, tube to tube spacing, tube wall
thickness/orifice diameter, orifice cone angle, etc. The spatial
distribution of orifice parameters about the tube and across and
along the duct are similarly modeled.
[1148] They further form the flow equations for the first and
second fluids. These preferably include models of the flow through
the tubes, through the orifices, spray penetration correlations and
spray cone angle correlations. The equations include the desired
composition mass or mol (or volume) flow rate relations either in
the mean flows, or more particularly the spatial distributions of
compositions as desired or prescribed.
[1149] Users further apply desired or required constraints. For
example, the desired transverse distribution(s) of spray
penetration such as the degree of penetration across the tube to
tube gap. Similarly the spatial profiles of the ratio of second to
first fluid flow rates or equivalent spatial composition
distributions. These may also include spatial constraints on the
time to achieve desired fractions of heat transfer and/or on the
corresponding distance distributions needed to achieve those
fractions of heat transfer. For example, these may include the
spatial distributions of evaporation time and/or evaporation
distance. They further apply the constraints of tube strength and
maximum burst pressure, realizable tube diameters, maximum orifice
length/diameter ratios in drilling etc.
[1150] With these models, users then initialize parameters as
needed by the computational methods. They further normalize or
configure the equations into ratios to assist in convergence etc.
In some configurations, the equations are configured into
non-linear search programs as desired or needed to provide
convergence.
[1151] Users then configure the programs to produce the desired
output values and figures. For example, these include the spatial
distribution(s) of fluid pressure, orifice number, orifice spacing,
orifice diameter, orifice orientation, and orifice length/diameter
ratio profiles. Similarly they obtain the spatial distributions of
spray cone angle, spray penetration, injection velocity,
differential ejection pressure and fluid compositions or profiles
of the ratios of second to first fluid flow rates. They similarly
obtain the desired distributions of tube to tube gap, wall
thickness, diameter and length. These methods are further
exemplified in the following discussions of configuring heat
exchangers.
[1152] 13.3 Residence Time
[1153] 13.3.2 Residence Time vs Drop Size Distribution
[1154] The speed of many physical phenomena and chemical reactions
depends on the surface area of a fluid, or the interfacial area
between two fluids. The time for the process to finish in turn
depends on change in a process through the drop and thus on the
drop size. Drop formation in most prior art systems results in a
broad distribution of drop sizes. Disadvantageously, this results
in a broad distribution of corresponding drop reaction residence
times. In the relevant art, systems are commonly sized for the
largest drops or micro-jets and longest acceptable residence times
with large spatial variations resulting from a few jets.
[1155] In some embodiments, users advantageously configure a direct
contact heat exchanger 483 or direct contact condensor 484 to form
drops or micro-jets with prescribed distributions and/or profiles
of orifice sizes in the transverse and/or axial directions relative
to the fluid duct 130. Using the preferred methods described with
respect to FIG. 18, FIG. 19 and FIG. 20 and herein, they configure
achieve desired transverse drop size distribution distribution(s),
profile(s) and/or fluid delivery distribution(s) and/or profile(s)
using distributed perforated tube arrays 260 of embodiments of the
invention. In turn, users achieve a fairly uniform and/or more
narrowly controlled distribution of residence times for most of the
drops or micro-jets. Consequently, users can significantly improve
throughput, improve quality and reduce costs etc. Some applications
of these methods and benefits are detailed as follows.
[1156] In other configurations, users can configure the fluid
delivery and orifice size distribution(s) and/or profile(s) to
achieve substantially non-uniform distribution(s) and profile(s) to
achieve particular transverse or axial distribution(s) and/or
profile(s) of fluid composition and transformation times etc.
[1157] 13.3.3 Evaporation Residence Time
[1158] Users preferably configure the direct fluid contactor 483
with desired or prescribed transverse distribution(s) and/or
profile(s) of orifice size and spatial orifice density. These are
variously configured to provide desired transverse distributions of
orifice size with corresponding transverse distributions of drop
size or micro-jet size 903 of the first fluid. E.g., by configuring
fairly uniform transverse distributions of distributed orifices
these form provide fairly uniform drops or micro-jets 903 with
fairly narrow drop size distribution of a first fluid 901 in
perforated tube arrays 260 in various embodiments of the invention.
With continuing reference to FIG. 18, FIG. 19, and FIG. 20 in other
configurations, users configure desired transverse distribution(s)
of orifice size, transverse distribution(s) of orifice spacing and
transverse distribution(s) of orifice spatial density to achieve
desired transverse evaporation time distributions, evaporation
distance transverse distributions and transverse fluid delivery
distribution(s).
[1159] Users consequently obtain evaporation time transverse
distribution(s) for the fluid drops or micro-jets to evaporate
within desired transverse distribution(s) of evaporation distance
in flows of the second fluid 904 with various transverse
distributions of unsaturated fluids. Similarly, users may form
micro-jets from fairly uniform transverse distributions of orifice
size with fairly uniform transverse distribution(s) of differential
ejection pressure across the orifices 80, resulting in fairly
narrow transverse distribution(s) of a measure of drop size such as
the Sauter Mean Diameter (SMD). Consequently, these form narrower
transverse distribution(s) of evaporation time and more controlled
transverse distribution(s) of evaporation distance.
[1160] Since the time to evaporate drops strongly depends on the
largest drops in a spray, users significantly reduce the portions
of large drops in the spatial and number fluid delivery
distribution(s) and/or profile(s). Accordingly they significantly
reduce the size and cost of the evaporation equipment. William
Sirignano (1999) reviews droplet evaporation rates including
transient effects due to changing temperature in combustion, and
the effects of neighboring drops in sprays or drop arrays. Davis
& Schweiger (2002) further review the evaporation of drops. The
vapor pressure of the first fluid 904 and the diffusion coefficient
in turn depend on the effective temperatures of both the liquid and
gas. The evaporation rate of a drop is generally proportional to
its surface area, the difference between local and remote vapor
pressures and a diffusion coefficient. Users utilize such methods
in evaluating and configuring the parameters described herein.
[1161] To ensure substantially complete evaporation, users control
the drop size or size distribution and residence time sufficient to
generally limit the maximum evaporation time with a suitable
statistical probability.
[1162] Accordingly, users create orifices with about the desired
diameter distribution and/or profile and prescribed uniformity,
adjust tube oscillation frequency, control the pressure pulsation
pattern of the first fluid 901 and/or the external electric field
outside the orifice, and the temperature of the two fluids and
vapor pressure of the first liquid 901 in the second fluid 904 as
appropriate, needed or desired. Then users select the area and
length of the fluid duct 130, and the velocity (or pressure drop)
of the second fluid 904 in a prescribed manner to control the first
fluid residence time for evaporation. This similarly applies to
using direct contactor arrays 260 to evaporate the first fluid
901.
[1163] 13.3.4 Heat Exchanger Residence Time
[1164] Drops (or bubbles) of a first fluid 901 traveling in a
second fluid 904 change in temperature with evaporation,
condensation and/or heat transfer and time. To achieve a given
proportional change in temperature compared to the total
temperature difference, users preferably configure a direct fluid
contactor 483 of FIG. 82 to incorporate numerous orifices with
desired orifice area and spatial distributions and/or profiles to
create and distribute fairly uniform drops or a narrow drop size
distribution of the first fluid 901. By controlling those
distributions and/or profiles together relative to the velocity
distributions and/or profiles of the second fluid 904, users
further provide prescribed spatial and number residence time
distributions for the droplets of the first fluid 901 in the second
fluid 904 in some configurations. By controlling those residence
time distributions, users preferably control the spatial and number
size distributions and fluid fraction distributions of the first
fluid 901 that exits the fluid duct 130.
[1165] 13.3.5 Condensation Residence Time
[1166] Cooler drops of a first fluid 901 contacting a second fluid
904 saturated with some vapor of a fluid will cool the second fluid
904 and condense some of that vapor. In some embodiments, users
preferably configure the direct fluid contactor system 483 as a
direct contact condensor 484. They preferably configure distributed
contactor arrays 260 to distribute a cooler first fluid 901 in a
second fluid 904 with desired transverse delivery distributions
and/or profiles. The temperature of the first fluid 901 is
preferably kept below a generally prescribed temperature. The
contactor array 260 is configured with transverse orifice size
distributions and/or profiles to achieve desired transverse drop
size spatial and number distributions and/or profiles. E.g., in
some configurations, these may be fairly uniform drops of the first
fluid 901 or drops with a narrow size distribution.
[1167] They may further distribute those drops or with one or more
desired transverse delivery distributions and/or profiles to
achieve desired transverse profile ratios of the second fluid 904
to first fluid 901. E.g., These can be configured for fairly
uniform ratios of the second to first fluids where there are
distinctly non-uniform transverse flow distributions and/or
profiles of the second fluid 904 in the fluid duct 130. The
contactor array 260 is commonly positioned across and within the
fluid duct 130. The contactor 260 may also be arrayed near the
upstream end, or across the inlet 134 to the fluid duct 130.
[1168] Users preferably provide a residence time distributions
and/or profiles for the coolant fluid generally sufficient to
achieve a desired or prescribed distributions and/or profiles of
the fraction of the desired total temperature change. This achieves
a certain amount of cooling of the second fluid 904 by the first
fluid 901. This in turn will generally condense a certain fraction
of the vapor in the second fluid 904. By controlling the uniformity
or narrowness of drop size distributions, and the ratio profile of
the distributions of first fluid 901 to the distributions of the
second fluid 904 transversely across the fluid duct 130, (and/or
axially) and the distributions in the difference in temperature
between the first fluid 901 and the second fluid 904, users
generally achieve a given condensation fraction.
[1169] 13.4 Counter-Flow Direct Contact Heat Exchanger
[1170] Exhausting hot products of combustion to the atmosphere
results in significant energy losses. Surface heat exchangers are
typically used to recover such exhausted energy. Using sprays with
a wide distribution of drops results in a portion of the smallest
droplets being entrained in the exhaust plume with consequent loss
of water.
[1171] With reference to FIG. 83, to prevent or mitigate this
droplet entrainment, users preferably configure a direct fluid
contactor 483 as a heat exchanger to counter-flow drops of cold
first fluid 901 against the hot second fluid 904 comprising one or
more of a heated oxidant fluid, energetic fluid, and expanded
fluid. They use distributed fluid contactor embodiments 10 or 260
to distribute fairly uniform drops of fairly uniformly across the
second fluid or with desired transverse size distributions and/or
profiles and transverse orifice spatial density distributions
and/or profile(s). More preferably, they distribute the cooling
first fluid 901 having a narrow drop size distribution with a flow
distribution and/or profile across the duct 130 corresponding to
the relative enthalpy flow transverse distributions of the incoming
hot second fluid 904. I.e. taking the velocity distribution times
the density distribution times the temperature difference above a
reference temperature such as the cooling temperature to arrive at
a relative enthalpy flow distribution.
[1172] Users preferably configure a generally vertical duct 130.
They preferably select a mean drop size or narrow size distribution
and design the transverse inlet fluid velocity distributions so
that the drops of cooling first fluid 901 fall through the counter
flowing fluid. I.e. most coolant fluid drops 901 are formed larger
and heavier than those that are entrained by the cooled fluid flow
928 exiting the duct. The force of gravity on the drops is greater
than the sum of the hot fluid drag on the coolant drops and the
buoyancy of drops in the counter flowing hot fluid. Conventional
sprays generate "drafting" or coordinated drop motion. This
increases drop entrainment. With distributed drop contactors, users
preferably adjust drop velocity to compensate for the small
drafting component.
[1173] As the drops fall through the counter flow of hot flue gas
904, they cool the flue gas. The hot gas in turn heats the drops.
As a result, users recover hot liquid drops at the fluid collector
481 at the bottom of the flue 130, and deliver cold flue gas
exiting the top 136 of the flue duct 130.
[1174] In some embodiments, users provide a particle separator 520
(e.g., gas-liquid separator) to separate the hot water near the
bottom of the flue duct 130 from the hot flue gas 926 (See FIG.
83). The separator 520 may be conveniently formed using a
separator. 520 comprising series of turning vanes that direct the
second fluid flow 904 upwards. At the same time, the separator 520
permits the heated diluent and condensed vapor or condensate to
fall through the separator do the fluid collector 481. The heated
coolant fluid 901 is collected in the collector 481 at the bottom
of the flue 130. It is then preferably cooled, a portion is
preferably recycled and portion of the condensate is recovered. The
cooling fluid is preferably the same fluid as the vapor being
condensed. By this counter-flow direct contact heat exchanger, 483
or 494, users desirably achieve an efficient and inexpensive
recovery of the heat in flue gas exhaust stream. Users configure
similar processes to recover heat in an hot exhaust fluid stream in
some configurations. E.g., in the case of an exothermic reaction or
where the fluids are otherwise heated.
[1175] 13.4.1 Direct Contact Fluid Condensor
[1176] Further referring to FIG. 83, when there is a condensable
vapor in a hot second fluid 904 (e.g., steam or hot water vapor, or
flue gas), the cold drops will condense that vapor and become
hotter. In some embodiments, users preferably configure the direct
contact heat exchanger 483 as a direct contact condensor to use the
same liquid 901 as the vapor being condensed e.g., cold water to
condense steam. Small drops provide a very high surface area giving
rapid heat transfer. This process of using a direct contact
condensor advantageously provides an efficient means of recovering
the first liquid fluid 901 from the second hot fluid stream
904.
[1177] In other embodiments, users use a preferably fairly inert
liquid as the liquid coolant first fluid 904. For example users can
use a low vapor oil such as is used in vacuum pumps, or a synthetic
fluid or refrigerant. In modified embodiments users efficaciously
use a liquid metal such as gallium which has a low vapor pressure
and a very wide liquid range, as needed or desired.
[1178] Further referring to FIG. 82, users preferably provide a
spray cleaning system 498 to delivery a high intensity and volume
spray to flush out accumulated particulates and wash the fluid
contactor system periodically or as needed or desired. They
correspondingly preferably provide a controller 590 to control the
delivery of contacting fluid and contacted gas, and of the spray
cleaning system 498. The cleaning system may move across the front
of the ducts 131, or along them to clean the ducts as needed or
desired.
[1179] 13.5 Cross-Flow Contactor
[1180] In some embodiments, users configure the direct fluid
contactor heat exchanger as a cross-flow contactor.
[1181] 13.5.1 Cross-Flow
[1182] Further referring to FIG. 82, users preferably increase the
effective surface contact area of drops by reducing the size
distribution of orifices 80 and thus the spatial and number size
distributions and/or profiles of drops delivered while increasing
the number of orifices 80 and increasing the mixing and improving
the transverse fluid distributions and/or profiles. However, the
drop terminal velocity decreases with drop size. With counter-flow
configurations, the maximum fluid velocity exiting the fluid duct
130 is preferably configured lower than the coolant liquid drops'
terminal velocity to prevent drops from being entrained by the
fluid exiting the duct at the outlet 134 and lost. Consequently the
cross-sectional area of the duct is preferably increased as the
drop size decreases i.e. so that the fluid velocity decreases.
Conventional systems disadvantageously result in a wide range of
drop size. This undesirably requires the fluid flow and duct area
to be sized for the smallest size for the tolerable droplet loss
rate in the exit fluid stream.
[1183] Users preferably generate fairly uniformly sized drops or
drops with a desired narrow spatial and number size distributions
in transverse or axial directions with embodiments of distributed
contactors 260. Users thus preferably increase the first fluid flow
901 and reduce the duct size while still achieving a very high
droplet recovery. Even when users provide fairly uniform orifices
80 to obtain smaller more uniform droplets, there will typically be
a bimodal distribution of drop size with narrow peaks. The users
preferably size orifices or transverse orifice size distributions
for a prescribed fraction of droplets recovered. Similarly users
use a range of orifices in some configurations to increase turn
down range. This provides narrower range of drop sizes than
conventional spray systems. Again users preferably determine the
desired fluid flow velocity distribution and size the ducts 130
accordingly to achieve the desired droplet recovery.
[1184] 13.5.2 Multiple Horizontal Plates
[1185] With reference to FIG. 82, to overcome various limitations
of residence times and velocity distributions, users preferably
configure the direct fluid heat exchanger/contactor 483 to direct
the inlet flow of the second fluid along the second flow path 4
through multiple thin sub-ducts 131 configured within the larger
fluid duct 130. These can be formed by forming multiple duct walls
132 within the larger fluid duct 130. In some embodiments, users
preferably orient these sub-ducts 131 and intermediate duct walls
132 somewhat horizontally, and more preferably tending downwards
towards the exit, within the larger duct 130. Users then configure
a direct contactor array 260 wherein they direct the fluid orifices
80 generally horizontally and upstream toward the inlet 134 near
the inlet and upper portion of each horizontal thin sub-duct
131.
[1186] Users preferably use fairly uniformly sized orifices or with
a narrow desired size distribution to form fairly uniform drops or
micro-jets to give fairly uniform drop velocities and residence
times. Similarly users form micro-jets forming a fairly narrow drop
size distribution and which are fairly uniformly configured
transversely across the sub-duct 130 to provide fairly narrow
distributions in drop velocities and transverse spatial drop
distributions and/or profiles. The orifice size, spacing and
differential delivery pressure are preferably configured so that
adjacent micro-jets overlap. Users preferably size the duct height
relative to the second fluid flow velocity so that the fluid flow
is generally laminar within the thin sub-ducts 131.
[1187] Fluid Residence Times: With further reference to FIG. 82,
users preferably size the vertical depth of the thin ducts 131
together with their length and width relative to the inlet design
fluid flow velocity and contacting fluid drop size distribution so
that the contacting liquid drops traverse the thin duct 131 and
contact the lower surface of the thin duct 131 in desirably less
time than the residence time of the fluid within the duct. Users
then preferably control the fluid flow rate and the drop delivery
rate relative to the fluid flow distribution so that a desired
fraction of the fluid has a fluid residence time greater than the
time for a desired fraction of the drops to fall from the top to
the bottom of the thin horizontal ducts.
[1188] Spray flushing: Users preferably configure the spray
cleaning system 498 to clean each thin duct and periodically flush
and wash out the accumulated particulates. Users preferably provide
numerous spray orifices along the contactor tube 80 for the first
fluid 901 with a high pressure delivery pump to provide a flushing
spray across the full width of the sub-duct 131. In other
embodiments, users provide a moveable spray cleaning system 498
that periodically moves across the sub-ducts 131 and sprays each
sub-duct in turn. In modified embodiments, users use a narrow high
pressure spray system to sequentially traverse across each sub-duct
to clean it.
[1189] Duct Angle: To reduce the tendency for the contacting fluid
such as water to stand in the sub-duct, with further reference to
FIG. 82, users preferably tilt the cross-flow duct 130 and
sub-ducts 131 to a predetermined or pre-selected angle, preferably
downhill towards the duct exit 136. This enhances the contacting
liquid flow down the duct 130 in the direction of the inlet fluid
flow, preferably carrying recovered particulates with it. When
users spray clean each sub-duct 131, this preferable tilt similarly
assists in flushing the duct 131 and removing the accumulated
particulates. This configuration reduces liquid waves and duct
blockage relative to other configurations.
[1190] To further assist the fluid flow, users preferably tilt the
sub-ducts 131 downwards transverse to the fluid flow 904. This
assists in flowing the fluid 901 to one downstream corner of the
fluid duct 130. Users provide a collector duct 481 to collect the
fluid 901 flowing out the sub-ducts 131.
[1191] In other embodiments, users further tilt the sub-ducts
downwards towards the upstream direction so that the resulting
collected contacting liquid at the bottom of the duct flows counter
flow to the fluid flow towards the duct inlet 134.
[1192] Sizing: Users preferably size and configure the number of
sub-ducts 131 and their width and length to reduce net present
value of the life cycle costs of the fluid contactor system. (See
FIG. 82.) These include pumping power needed to deliver or exhaust
the contacted fluid, pump and recirculate the contacting fluid or
liquid, the cost of spray cleaning the system 498, and of the
cleaning operations.
[1193] 13.5.3 Direct Contact Co-Flow Heat Exchanger
[1194] In some embodiments, with further reference to FIG. 82,
users configure the direct fluid contactor system 483 to distribute
droplets of the first fluid 901 that are entrained into the
co-flowing second fluid 904 or are injected in the direction of
fluid flow. This configuration will form in a direct contact
co-flow heat exchanger 483. It is useful or particularly
significant where the second fluid is saturated with the first
fluid, or where the first fluid has a low volatility.
[1195] In embodiments where users desire or need to recover the
first fluid, various liquid retrieval methods may be used, such as
electrostatic precipitators, cyclones, impingement separators, etc.
The fairly uniform size drops used will result in much greater
recovery of the injected liquid.
[1196] 13.6 Fluid Scrubber
[1197] In other embodiments, users configure the direct fluid
contactor 483 as a fluid scrubber to remove various contaminants,
such as shown in FIG. 82.
[1198] 13.6.1 Intake Water Scrubber
[1199] Intake air or compressed oxidant containing fluid is
commonly filtered through a porous intake filter to remove
particulates. This reduces the compressor 407 and turbine fouling
thus preventing efficiency losses at the expense of a pressure drop
with consequent pumping losses. By using a multi-duct direct
contactor 483, users achieve both wet scrubbing to remove
particulates and fibers from the intake air, as well as cooling the
intake second fluid 904. (See, e.g., FIG. 82.)
[1200] 13.6.2 Exhaust Water Scrubber
[1201] Users similarly configure a direct fluid contactor 483 with
numerous in a desired size distribution to scrub the exhaust fluids
from combustion or power generation system. (See, e.g., FIG. 82).
By controlling the profile of the ratio of the spatial flow
distribution of scrubber contacting first fluid 901 to the flow
distribution of the second fluid 904 being scrubbed, users
desirably achieve a more effective scrubbing action.
[1202] 13.6.3 Solution Scrubber
[1203] With further reference to FIG. 82, users similarly extend
this scrubbing method to using solutions instead of clean water
first fluid 901. Caustic solutions first fluid 901 are commonly
used to scrub flue gases 926 from acidic emissions. By reducing
drop size and increasing the direct contact drop surface, users
significantly improve the scrubbing rate of such acidic and other
emissions from a fluid stream.
[1204] 13.7 Direct Contact Thermal Fluid Control
[1205] With reference to FIG. 82, in other embodiments, users
utilize the perforated tube arrays 260 to heat or cool second
fluids 904 by direct fluid contact with a first fluid 901 by
forming a direct contact fluid heat exchanger 483. Users can use
the sensible heat of changing the temperature of the injected first
fluid 901, and/or the latent heat from evaporation of an injected
first fluid liquid 901. They may similarly use the multi-duct
horizontal configuration of the direct contact heat exchanger as
shown in FIG. 82.
[1206] 13.7.1 Cooling by Cold or Refrigerated Liquid
[1207] With reference to FIG. 82, to cool a fluid, users configure
the direct contact heat exchanger 483 in a vertical configuration
to preferably distribute cool or refrigerated liquid first fluid
901 through the distributed contactor arrays 260 to provide a very
high surface area direct contact heat exchanger 483. This provides
faster and more efficient heat transfer than the relevant art. For
maximum effect, users preferably cool or refrigerate the water in
the range of 0.1.degree. C. to 4.degree. C., and preferably to
about 2.degree. C. Users then take this cold water first fluid 901
and contact the oxidant fluid 904 (e.g., air) with one or more
distributed contactor arrays 260. This enables efficient cooling of
the oxidant fluid 904 (e.g., intake air) without large amounts of
evaporation of the first fluid 901 as in conventional "fogging"
systems.
[1208] With reference to FIG. 82, users further use the direct
fluid contactor system 2 to preferably cool the intake air to a
energy conversion system as needed or desired. E.g., when users
wish to increase the fluid density and the pumping capacity of a
compressor 407. By using a direct fluid contactor system 483, users
preferably achieve more uniform transverse fluid distribution
between the diluent first fluid 901 and the oxidant fluid 904, thus
achieving more desirable or uniform spatial ratio profiles of
diluent to oxidant. Advantageously, this improves the compressor
efficiency, and the temperature uniformity of the downstream
combustor. In turn, this enables users to increase the fuel flow
rate and system power and efficiency.
[1209] 13.8 Distributed Direct Contact Fluid Heater
[1210] With reference to FIG. 82, in situations where users wish to
heat fluids, users preferably dispose a perforated tube array 260
across the duct containing a second cool fluid duct to form a
direct contact heat exchanger 483. Users then deliver a hot first
fluid through the perforated tube array 260. With fairly uniform
orifices, users form fairly uniform fluid jets or drops with
desired spatial flow distributions and/or profile resulting an a
very high direct contact surface area with a desired ratio of
contactor first fluid 901 to contacted second fluid 904.
[1211] 13.8.1 Low Vapor Pressure Liquid
[1212] When users wish to heat a cool fluid without vaporizing a
significant portion of the hot first fluid, users preferably use a
liquid with a very low vapor pressure. High molecular weight
hydrocarbons such as vacuum pump oil may be used for moderate
temperatures up to a few hundred degrees C. For higher
temperatures, users preferably use the liquid metal gallium which
has a very low vapor pressure and a very wide liquid temperature
range.
[1213] 13.8.2 High Vapor Pressure Liquid
[1214] With reference to FIG. 82, in cold climates, it is
preferable to both heat and humidify oxidant second fluid 904 or
air when heating it. In using a diluent liquid first fluid 901 such
as water that has a significant vapor pressure, a substantial
portion will evaporate as it traverses the second fluid 904,
humidifying the air. Users preferably distribute hot water though a
perforated tube array 260 configured across the air duct. By
providing fairly uniform orifice and drop sizes or micro-jet sizes,
users achieve a more compact direct contact heat exchanger 483 with
higher heat transfer rates.
[1215] Where heating is associated with a demand for power, users
preferably use a direct contact heat exchanger 483 as a direct
contact condensor to cool the exhaust fluid 926 and condense the
thermal diluent first fluid vapor 901 (e.g., steam and water vapor)
while recovering high purity hot thermal diluent first fluid 901
(e.g., hot water). Users then pass that high purity hot water
through a liquid-liquid surface heat exchanger 470 to preheat
common water. Users preferably recycle the high purity cooled water
first fluid 901. Users take the heated common water and use it for
district heating applications.
[1216] 13.8.3 Hot Contact Liquid Recovery
[1217] With reference to FIG. 82, when delivering a hot liquid,
users preferably provide a direct contact heat exchanger 483 in a
counter flow configuration such that the fairly uniform hot liquid
drops of the first fluid are delivered through the cool second
fluid. E.g., a thermal diluent first fluid 901 through an oxidant
fluid 904. The hot first fluid drops cool while they heat the
second fluid. As before, users preferably adjust the drop size and
fluid velocity so that the fairly uniform hot liquid drops traverse
the cool second fluid. Alternatively users can utilize the
cross-flow or co-flow contactors described above with reference to
FIG. 82. With high vapor pressure liquids, users preferably account
for the evaporation and change in drop size when sizing the direct
contact heat exchanger 483 and configuring the fluid velocities for
a desired residence time distribution, and selecting the spatial
distribution of orifices and drop formation or micro-jet size and
distribution.
14 Distributed Liquid Evaporator
[1218] In some embodiments, with further reference to FIG. 82,
users configure one or more direct contactors 10 or contactor
arrays 260 to deliver a first liquid within the fluid duct 130 with
one or more desired fluid delivery spatial distributions relative
to the mass flow distribution of a second fluid within that duct to
evaporate the first liquid 901 within the second fluid 904 to a
desired degree.
[1219] For example, the direct contactor 2 may be configured to
preferably form direct contactors to deliver a first fluid 901
through numerous orifices 80 with a desired distribution within a
combustor. In such an embodiment, the first fluid 901 may be
gaseous or liquid fuel, such as natural gas or diesel fuel, or a
thermal diluent fluid such as steam or water. Users preferably
select combinations of one or more orifice diameters, number of
orifices, orifice configurations, orifice distributions,
differential fluid pressure, fluid temperature and electric field
magnitude and gradient to achieve the desired or needed delivery
drop size and distribution as described herein. Users
correspondingly select the thickness and diameter of the tube wall
and/or orifice forming technology with suitable Thickness/Diameter
capabilities to cost effectively form the number of orifices 80
with the desired parameters. In some configurations, they provide
protective coatings to protect against high thermal fluxes,
erosion, oxidation and corrosion.
[1220] 14.2 Narrow Size & Residence Time Distributions
[1221] Fairly large distributions in drop size cause corresponding
differences in evaporation time with the residence time having to
be selected for the longest evaporation times caused by the largest
drops. To improve evaporation times of the first liquid 901 within
the second fluid 904 within prescribed dimensions of a fluid duct
130, users preferably position a distributed contactor array 260
with a desired size distribution of orifices 80, in one or both
directions transverse to the axis of the fluid duct 130 containing
the second fluid 904 with further reference to FIG. 82. They
similarly preferably control the differential fluid pressure across
the orifices 80 and thus control the spatial distribution of drop
formation or micro-jet formation and corresponding fluid flow
distributions. Accordingly, they provide one or more desired
spatial (and number) distributions and/or profiles of drop sizes or
spatial profiles of fairly narrow drop size distribution across
(and along) the duct 130.
[1222] 14.2.1 Static or Uniform Flows & Evaporation Times &
Distances
[1223] For example, referring to FIG. 82, with where the second
fluid 904 is fairly static or has a fairly uniform axial flow
distribution across the fluid duct 130, or in a vacuum, users
preferably form fairly uniform orifices 80 in the contactor array
260 across the duct 130 containing the second fluid 904. They thus
generate fairly uniform drops of the first fluid 901 fairly
uniformly distributed across the fluid flow 904 within the duct
130. Similarly they provide fairly uniform micro-jets with fairly
uniform narrow drop size distributions across the duct 130.
[1224] These drops of the first liquid 901 evaporate within a
fairly narrow range of time. In similar flow velocities, this
narrow spatial distribution of residence times results in fairly
narrow axial distribution of locations where the drops evaporate.
The evaporation residence times and evaporation locations are
broadened somewhat by turbulence within the flow. Users thus obtain
a fairly narrow transverse spatial variation of the cumulative
distribution of evaporation distances. Users preferably adjust the
orifice size 80 and applied differential ejection pressure to
adjust the drop size to obtain the desired cumulative probability
of evaporation and/or cumulative probability of drop size at a
desired distance from the contactor array 260.
[1225] Similarly, with higher differential ejection pressures,
users provide numerous larger micro-jets along the contactor array
260. They achieve a fairly narrow size distribution of drops with a
fairly narrow distribution of evaporation residence times. 14.3
Orifice size profiles, evaporation time & distance
distributions In other configurations, with reference to FIG. 19,
the second fluid 904 exhibits substantial variations in one or more
transverse distributions of axial velocities within the fluid duct
130. For example, with laminar flows, the flow exhibits highly
parabolic profile while with highly developed turbulent flows, the
flow distribution is much flatter in the center with rapid declines
in the boundary layers near the walls. In such configurations,
users preferably adjust the orifice size distribution and
differential ejection pressure to achieve a drop size distribution
where the evaporation time varies approximately inversely with the
fluid velocity distribution such that the transverse distribution
of axial evaporation distances is about the same across the duct in
at least one or preferably both transverse directions. E.g., users
preferably form smaller orifices 80 and drops near the center where
the velocity is the greatest to provide shorter evaporation times
compared with larger orifices near the wall with longer evaporation
times to compensate for the varying transit times to achieve fairly
uniform evaporation distances.
[1226] 14.4 Transverse Flow Distribution Profiles & Ratios
[1227] With further reference to FIG. 18, FIG. 19, and FIG. 20, in
some configurations users seek to control the transverse mass
delivery spatial distributions and/or profiles of the first fluid
901 relative to the transverse mass flow distributions and/or
profiles of the second fluid 904. They preferably adjust the
spatial density of orifices 80 in the contactor array 260 together
with the transverse distribution of orifice sizes and orifice flow
factors (cross-sectional area of the liquid jet as it exits the
orifice to total orifice discharge cross-sectional area) to achieve
a desired transverse spatial net specific discharge area of
orifices 80 per cross-sectional area of the fluid duct 130. They
correspondingly adjust the differential ejection pressure across
the tube wall 30 and account for the longitudinal distribution of
the differential ejection pressure along the tube 10 to achieve a
desired transverse fluid flow distribution through the tube.
[1228] Users similarly adjust the transverse fluid flow
distributions and/or profiles of the first fluid 901 relative to
the fluid flow distributions and/or profile of the second fluid 904
accounting for the tube to tube gap distribution and upstream to
downstream spatial distribution of pressure drop across the
contactor array 260 to achieve the desired ratio of mass flow
distributions (or profiles) of first fluid 901 relative to the mass
flow distributions (or profiles) of the second fluid 904.
Accordingly, users preferably control the spatial transverse and
axial flow distributions and/or profiles of the first fluid 901
relative to the transverse flow profiles of the second fluid 904 to
achieve desired spatial transverse and axial flow profile ratios of
the second fluid to first fluid.
[1229] 14.5 Distributed Evaporator or Cooler
[1230] Users preferably use embodiments of distributed contactor
arrays where users wish to evaporate a first liquid (e.g., water)
to cool and/or increase that vapor concentration in a second fluid.
E.g., evaporate water to cool or humidify air. Water is being
introduced to cool intake air in power generation systems to
increase power and reduce NO.sub.x emissions. Users preferably use
distributed contactor arrays, as described herein, in such
applications to provide substantial benefits over prior art. Some
embodiments are detailed as examples of these applications as
follows.
[1231] 14.6 Quasi-isothermal compression
[1232] As schematically shown in FIG. 84, in some embodiments,
users provide one or more direct contactor arrays to deliver a
thermal diluent first fluid 901 into a power conversion system
utilizing a second fluid 904 (such as an oxidant containing fluid
such as air or oxygen enriched air.) This may be accomplished
through a direct contactor configured as a distributed contactor
precooler 404 that provides an "overspray" of vaporizable thermal
diluent into the intake of a first compressor 407. Similarly, users
may configure an direct contactor as an intercooler 410 between two
compressors 407. A further contactor may be provided as an
aftercooler 417 after the compressor and before the combustor 424.
Contactor tubes may further be configured within the compressor to
progressively distribute thermal diluent within the compressor.
Similarly a distributed contactor may be configured within the
combustor 424.
[1233] This thermal diluent 901 is preferably a vaporizable liquid
(such as water) to provide evaporative cooling of the second fluid
904 when mixing the diluent. The latent heat of vaporization of the
vaporizable first fluid 901 absorbs heat, reducing the temperature
of both the second fluid 904 and the first fluid 901. This in turn
beneficially reduces the net work of compressing that second
fluid.
[1234] As shown in FIG. 35, FIG. 36 and FIG. 37 users preferably
streamline the perforated tubes 10 to reduce the pumping work of
delivering the second fluid through the contactor array 260. In
some configurations, users preferably use heated vaporizable fluid
901 and deliver it under pressure so that vapor bubbles nucleate
within the droplets to rapidly shatter the drop into smaller
droplets ("flashes") on delivery. These droplets evaporate faster
and within shorter distances than conventional methods. They
further provide means to recover heat in the hot fluid exhausted
from the expander 440 and recycle it.
[1235] For example, users preferably spray water as the first fluid
901 into the flow of an oxygen containing second fluid 904 such as
air, after, between, within or before the compressor(s) 407 to
evaporatively cool the gaseous fluid 904 being compressed and
reduce the work of raising the pressure of the second fluid 904.
They preferably configure the spatial orifice spatial density
distributions and profiles and/or spatial orifice area profile to
provide prescribed or desired profile ratios of the transverse
delivery profiles of the second fluid to the first fluid e.g. in
transverse and/or axial directions. By adjusting these ratios users
beneficially achieve more controlled fluid composition and
temperature than in relevant art methods.
[1236] In some configurations users configure the precooler to
deliver non-uniform distributions of the first fluid to accommodate
the centripetal motion of droplets and their evaporation patterns
within the compressor. These may be weighted more towards the
compressor radius than in conventional methods. In other
configurations, users provide more uniform transverse fluid
compositions and temperatures than are obtained in the relevant
art.
[1237] 14.6.1 Inter-Compressor Diluent Drop Delivery
[1238] With continuing reference to FIG. 84, in some configurations
where multiple compressors 407 are used to achieve a desired
pressure, users cool the compressed second fluid 904 between the
compressors 407 by configuring a distributed contactor array as an
inter-cooler 410 to efficiently deliver the vaporizable cooling
first fluid 901 into the compressed second fluid 904, in some
embodiments. Depending on the velocity profiles, temperature
profiles and humidity profiles of the compressed fluid 904 at that
location, users preferably configure one or more of the pressure
and/or temperature of the coolant fluid 901, the spatial (e.g.,
transverse) distribution(s) of orifice sizes, the transverse
distribution(s) of net orifice specific spatial density (net
orifice area per duct cross sectional area) to achieve desired
transverse distribution(s) of first fluid mass delivery rate. These
are configured to achieve the desired spatial (e.g., transverse)
profile(s) of relative fluid flow rates and desired spatial (e.g.,
transverse) profiles of the relative fluid composition or ratio of
the second fluid to the first fluid (or vice versa).
[1239] They preferably configure one (or both) spatial or
transverse spatial distributions of orifice area and the profile
ratio of second to first fluid flows, to desirably provide one or
more spatial or transverse profile(s) of the rate of liquid
evaporation, transverse profile(s) of the droplet evaporation
residence time, and spatial (e.g. transverse) distribution(s)
and/or profile(s) of the evaporation distance. For example, FIG. 18
exhibits a conceptual transverse velocity flow profile of a second
fluid from inner radius to outer radius of an annular duct. This is
shown as a multi-parametric transverse distribution similar to a
skewed inverted parabolic distribution. There are similar
transverse distributions for the temperature and pressure of the
second fluid (not shown). These parameters are used to evaluate the
corresponding transverse distributions of mass flow of the second
fluid (not shown).
[1240] Users preferably desire evaporation distance spatial
distribution(s) or profile(s) for the vaporizable diluent. E.g., to
provide desired composition, or temperature distributions or
profiles, and/or to reduce impact erosion from large drops. A
conceptual evaporation distance transverse distribution is shown in
FIG. 19 as a nonlinear transverse distribution similar to a shallow
parabolic curve.
[1241] From the desired evaporation distance transverse
distribution(s) and the second fluid boundary conditions, users
preferably evaluate the available transverse distribution of the
allowable maximum residence time or maximum evaporation for the
first fluid. This maximum evaporation time transverse distribution
is shown schematically in FIG. 19 as the solid curve with high
evaporation times near the inner and outer radius of the annular
duct and low residence times near the middle of the duct.
[1242] E.g., these calculations incorporate the spatial (e.g.
transverse) velocity distributions or profiles of the two fluids,
their temperature and pressure distributions or profiles, the
relative saturation pressure distributions, diluent vapor pressure
distributions, and drag distributions on the diluent drops. From
the desired evaporation time and the relevant parameters, users
obtain the desired spatial (e.g., transverse) distributions of
measures of the first fluid drop size such as the Sauter Mean
Diameter (SMD) or similar measures of drop size number
distribution.
[1243] Users similarly evaluate the ratio of transverse fluid mass
flow profile(s) desired to obtain desired transverse composition or
ratio profile(s). E.g., they take the second fluid spatial or
transverse flow velocity, pressure and temperature distributions
and/or profiles to evaluate the desired spatial or transverse
density and mass flow distributions. From these, they evaluate the
desired first fluid spatial or transverse mass flow distribution(s)
needed to achieve the desired spatial or transverse composition
ratio profile(s).
[1244] Combining the desired spatial or transverse drop size
profile(s) (as needed to achieve the evaporation distance
distribution), with the desired first fluid spatial flow
distribution(s) (to achieve the composition distribution(s) or flow
ratio profile(s), users preferably solve the relevant simultaneous
equations obtain the desired spatial or transverse orifice spacing
distribution(s) (or the inverse lineal orifice density), and the
spatial or transverse net orifice spatial density distribution(s)
(per duct cross section area).
[1245] From the orifice size and first fluid flow rates, users
obtain the desired jet penetration spatial distributions or
profiles and the spatial differential ejection pressure
distributions required to achieve those flows, and the desired tube
gap distributions. Where there are constraints among these
parameters, users adjust some of the parameters to achieve other
parameters within desired ranges. E.g., by adjusting tradeoffs in
evaporation distance, tube size and tube gaps and their spatial
distributions.
[1246] In a similar embodiment, users select the desired tube to
tube gap size distribution. E.g., as a increasing gap between two
radial direct contactor "spokes", or as a uniform spacing between
two circumferential direct contactor arcs. Users preferably select
a desired spray penetration distance relative to these tube to tube
gaps to provide a more uniform transverse distribution of the
second to first fluids across the tube to tube gap, downstream of
the contactor array. E.g., equal to about 90% of the tube to tube
gap at the design conditions. The transverse distribution of tube
gap and jet penetration are conceptually shown from the inner
radius to the outer radius in FIG. 18.
[1247] From the constraints of the transverse distribution of the
jet penetration distance (eg as a function of the tube to tube gap
distribution), and the transverse distribution of the first fluid
drop size measure (e.g., SMD), they calculate the required fluid
delivery pressure required to achieve the transverse distribution
of differential ejection pressures and the transverse
distribution(s) of orifice size required to achieve those drop
sizes and penetration distances.
[1248] With these parameters, users further constrain the local
desired transverse distribution of composition or second fluid to
first fluid flow ratio profiles. From these constraints and
parameters, they calculate the orifice spacing or lineal density,
and the net orifice spatial density required to achieve the first
fluid flows to give the desired local transverse distribution of
fluid composition or second fluid to first fluid flows.
[1249] In performing these calculations, users preferably account
for the pressure drops along the contactor tubes as well as the
friction losses and pressure drops for the flows through the
orifices. The pressure drops through orifices are particularly
significant for higher orifice thickness to diameter ratios
resulting from small orifices and thick tube walls, and for long
contactor tubes relative to the tube hydraulic diameter. For
example, as shown in FIG. 20, with small tube diameters relative to
the contactor tube length, the pressure of the first fluid along
the first flow path pressure drop inside the contactor tube may
drop very substantially. The pressure drop can be markedly
non-uniform as a result of the longitudinal distributions of
orifice size and spacing along the contactor tube. These variations
in fluid flow and pressure within the tube are preferably accounted
for in configuring the desired transverse parameters.
[1250] FIG. 20 shows schematically the resulting transverse
distribution of orifice diameter from inner to outer radius of an
annular duct to meet the desired constraints for one embodiment.
The transverse distribution of the orifice to orifice spacing from
inner to outer radius is similarly shown. Note that sprays are
specifically allowed to overlap or move apart to achieve this
variation in orifice spacing. FIG. 20 further shows the highly
nonlinear variation in the first fluid pressure transversely along
the contactor tube with small contactor tube hydraulic diameters
relative to the contactor tube length. The consequent highly
non-linear first fluid flow per orifice is further shown in FIG. 20
as an skewed inverted parabolic type transverse distribution.
[1251] These substantially non-linear transverse distributions of
orifice size, orifice spacing, pressure and mass flow per orifice
are required to achieve the uniform transverse ratio profile of
second fluid to first fluid shown in FIG. 20, given the constraints
on the transverse evaporation distance, transverse distribution of
jet gap penetration, and the local average ratio of second to first
fluid mass flow in the first transverse directions as shown in FIG.
18, FIG. 19 and FIG. 20. Correspondingly, these parameters can
similarly be configured to achieve other substantially non-uniform
transverse ratio profiles of second to first fluid flows.
[1252] In a similar fashion, the constraints and parameters can be
evaluated the corresponding transverse distributions of orifice
size, effective net orifice spatial density (including orifice
spacing and tube to tube gap) and fluid delivery pressures. These
can be configured as before to achieve the desired transverse
distributions of evaporation distance, jet penetration, and locally
averaged composition or second to first fluid flow ratio profiles,
whether uniform or non-uniform as desired.
[1253] 14.6.2 Post-cooler Compressor Diluent Drop Delivery
[1254] In some embodiments or power systems, users preferably
provide embodiments of distributed contactors as a post-cooler 417
to introduce the first fluid 901 thermal diluent (e.g., water) into
the compressed second oxidant containing fluid 904 after the
sequence of one or more compressors 407 and before the downstream
utilization device such as a turbine 440. The evaporation after the
compressor cools the compressed second fluid 904, reducing the back
pressure on the compressor 407 (compared to adding a
non-evaporating fluid). Evaporation after the compressors (407)
further reduces the temperature and volume of the second fluid
while increasing the total mass of the fluid flowing through the
utilization device 440. These parameters reduce the work of the
compressor compressing the second fluid 904 compared to systems
without post diluent delivery and evaporative cooling.
[1255] The second fluid 904 exiting the compressor 407 commonly has
spatial or transverse flow velocity distributions or profiles that
vary markedly from the mean flow. The transverse flow distributions
or profiles exiting the high pressure compressor 407 often vary
substantially from the transverse flow distributions or profiles
exiting the low pressure compressor 407. Users preferably apply the
methods described above in reference to FIG. 18, FIG. 19 and FIG.
20 to arrive at one or both desired spatial or transverse
distributions or profiles of the orifice area sizes to form
transverse profiles of drop size distributions to achieve drop
evaporations within desired spatial or transverse distributions of
drop evaporation times. These transverse drop evaporation times are
preferably configured relative to the spatial or transverse flow
velocity distributions to achieve desired distributions of axial
evaporation distances.
[1256] In doing so, they preferably account for the hotter
temperature, higher pressure, increased diluent content and higher
density of the second fluid 904, and more non-uniform transverse
velocity distribution than within the compressor 407, resulting in
faster evaporation and lower evaporation residence time than within
or between compressors.
[1257] Where substantially non-uniform velocity distributions
exist, users preferably adjust the spatial or transverse orifice
size distributions relative to the velocity to achieve fairly
uniform spatial distributions of drop evaporation distances. They
further preferably configure the orifice spacing relative to gap
spacing and velocity to configure one or more spatial or transverse
distributions or profiles of net spatial orifice specific density
and deliver the first fluid with flow distributions to achieve
prescribed spatial or transverse profile ratios of the second fluid
relative the first fluid flows.
[1258] In some embodiments, users preferably deliver the first
fluid 901 through streamlined direct fluid contactor arrays 417 and
mix it with the second fluid 904. For the same amount of
evaporative cooling, water delivered and evaporated after the
compressor 407 and before the turbine appears to give lower fluid
pumping and turbo-machinery parasitic losses from turbulence, wall
friction etc in the second fluid 904 by reducing the compressor
back pressure than the same amount of water evaporated prior to or
within compressors 407.
[1259] With continuing reference to FIG. 19, in some
configurations, these transverse distributions of drop evaporation
distance are preferably configured uniformly across the fluid duct
130, such as were uniform fluid composition distributions and
temperatures are desired entering a downstream combustor. In other
configurations, these axial evaporation distance transverse
distributions are adjusted to conform to other spatial transverse
distributions desired in delivering the oxidant fluid 904 into a
downstream combustor.
[1260] Users preferably deliver the diluent water through
distributed contactor arrays with numerous orifices forming small
drop sizes of less than about 100 .mu.m in diameter, preferably
less than about 30 .mu.m, and more preferably less than about 10
.mu.m. Users preferably use streamlined water distribution
contactors to reduce the pressure drop across the array. By more
uniformly delivering the first fluid 901 (e.g., water) throughout
the second fluid 904 with smaller drop size and greater surface
area than conventionally, users reduce the energy and entropy loss
required for mixing compared to conventional water spray systems.
Such combinations provide significantly faster evaporation, smaller
volume and pressure vessel cost, and lower pressure drop than
relevant art systems. (E.g., compare Humidified Air Turbine
(HAT.RTM.) or the Evaporated Gas Turbine (EvGT) power systems.)
[1261] 14.6.3 Intra-Compressor Drop Delivery
[1262] In some configurations, users similarly preferably apply
this distributed water delivery method to intra-compression to
deliver a diluent liquid first fluid 901 into the second fluid 904
being compressed within a compressor 407. They preferably configure
direct contactor tubes 10 to distribute vaporizable diluent from
near the hub or along compressor vanes as direct contactor tubes 10
to deliver the vaporizable thermal diluent fluid 901 with a desired
flow distribution relative to the flow of second fluid 904 being
compressed, using the methods described herein. In some
configurations, they further provide contactor tubes along the
compressor blades. These may be further combined into the vane and
blade shapes with orifices exiting the vane or blade surfaces.
These measures provide the benefit of more uniformly cooling the
compressed flow and reducing its volume (compared to using excess
air as diluent) and thus reducing the compression work required
compared to the relevant art.
[1263] 14.6.4 Pre-compressor Drop Entrainment
[1264] With continued reference to FIG. 84, users seek to provide
water droplet entrainment (or "overspray") into the air flow 904
into the compressor intake duct, using a precompressor distributed
fluid contactor 404 with numerous orifices distributed across the
fluid duct at or near the entrance of the compressor 407. Users
preferably configure streamlined contactor tubes to reduce the
intake pressure loss at the duct inlet.
[1265] With numerous orifices in the streamlined fluid contactor
260 users provide numerous micro-jets. These achieve narrower
spatial and number drop size distributions across the intake.
Improving the spatial distributions and profiles of drop size
resulting in a smaller fraction of large drops significantly
reduces blade erosion within the compressor 407.
[1266] Users preferably configure the orifice net spatial density
distributions and differential ejection pressure distributions to
achieve one or both desired spatial profiles of the ratio the
second fluid 904 to first fluid 901. These profiles are preferably
configured to provide more uniform profiles of the second to first
fluids (e.g., air to water.) Where users entrain vaporizable
diluent into the compressor, they preferably provide fairly uniform
spatial delivery distributions in proportion to the fairly uniform
velocity distributions for the oxidant fluid entering the
compressor 407. Users preferably utilize the methods of configuring
the contactor array parameters as above, but with reference to the
much more uniform velocity distributions, lower pressures and lower
diluent content at the entrance to the low pressure compressor
407.
[1267] Improving these transverse distributions of fluid ratios
significantly improves the uniformity of fluid cooling, fluid
density and fluid velocity within the compressor 407. This reduces
propensity for compressor surge and improves compressor efficiency
compared to the relevant art, giving significant cost advantages.
The improved evaporation and fluid ratio profile uniformity further
improves downstream combustion temperature uniformity, combustion
stability, and turbine efficiency.
[1268] Evaporation prior to compression results in an additional
volume of water vapor that is compressed with corresponding
parasitic flow losses. Providing distributed contactor arrays 260
to entrain or deliver fairly uniform water drops into the
compressor(s) 407, between compressors 407 or after the
compressor(s) is significantly more efficient than "fogging" before
the compressor 407.
[1269] 14.6.5 Cooling Gas by "Fogging"
[1270] Evaporative air cooling is being added to the air intake
systems for power plants to cool the air, increase air density and
mass flow into the energy conversion system, increasing its power,
and to add thermal diluent to reduce nitrogen oxides formed by
combustion. Conventional systems create wide drop size
distributions. Unevaporated drops impacting on blades can cause
blade erosion. Wide drop size distributions require long residence
times and distances to evaporate the largest drops or to let them
fall out. This requires a large volume duct prior to the compressor
407.
[1271] In some embodiments, users provide distributed contactors
with numerous orifices in the fluid duct upstream of the compressor
407. In some configurations they preferably form fairly uniform
orifices to provide fairly uniform size transverse profiles of drop
sizes or micro-jets with transverse size profiles of narrow drop
size distributions.
[1272] With one or more of these measures, users configure
desirable transverse distributions of drop evaporation residence
times to evaporate the drops and correspondingly narrower spatial
profiles of evaporation distances.
[1273] They further preferably configure a fairly uniform ratio of
second to first fluid flow profiles. Where "fogging" is desired,
users position the distributed contactor upstream of the compressor
407 sufficiently far to evaporate a desired fraction of the water
drops prior to entrainment into the compressor 407.
[1274] Users may also position a multi-duct cooler 483 (as shown in
FIG. 82) before the compressor. This system can be used to spray
cold water into the intake air to cool it without as much
evaporation prior to the compressors. With one or more of these
methods, users can reduce system size and cost compared to the
prior art.
[1275] 14.7 Counter Flow Evaporator
[1276] In some embodiments, users configure a direct fluid
contactor 483 as a highly counter flow evaporator. The fluid duct
130 is preferably configured vertically. Users configure a direct
contactor array 260 across the duct 130 near the top of the fluid
duct 136. They size orifices 80 to form drops of the first fluid
901 generally of sufficient size and velocity so that they will
fall or move against the second fluid flow 904. They typically
provide a means of recovering the drops near the bottom or inlet
134 of the duct 130. Where fluid drops 901 are formed that are
entrained with the second fluid flow 904, users preferably position
the contactor array 260 a suitable distance below the top of the
duct 136 so that the entrained drops 901 are evaporated to a
desired degree before exiting the duct.
[1277] 14.8 Hybrid Counter-Co Flow Evaporator
[1278] To more efficiently evaporate a liquid 901 in a fluid duct
130 with a vertical updraft flow, users preferably provide a direct
contactor 260 across the duct 130 and form numerous drops or
micro-jets with a fairly narrow size distribution to form a hybrid
counter-co flow evaporator. Drops of fluid 901 below a critical
size will be entrained by the vertical counter flow 904, while
larger drops will initially fall as they evaporate. The contactor
array 260 is preferably sized to form fairly uniform drops which
will initially fall against the counter-flowing fluid 904.
[1279] Users preferably size the drops 901, height of the contactor
array 260 above the inlet 134 to the evaporator, and velocity of
the second fluid 904 such that when the drops have partially
evaporated, the drag of the counter-flowing fluid 904 will then
reverse the droplet velocity and entrain the drops 901 vertically
upward along with the flow before the droplets fall to the bottom
inlet 134 to the evaporator. This results in drops evaporating
while they twice traverse the same region within the fluid duct
130. Consequently users have about twice as many drops within the
fluid duct 130 for a given number and size of orifices 80 as
compared with a co-flow configuration. This significantly increases
the evaporation rate within a given duct 130, while permitting
larger orifice sizes 80, thus reducing filtration requirements.
[1280] Users similarly configure the location of the contactor
array 260 below the top (outlet) of the evaporator 136 sufficient
to evaporate most of the droplets entrained vertically upward to a
desired degree before exiting the evaporator. Users preferably size
the size distribution of first fluid drops delivered relative to
the second fluid flow so that a prescribed fraction of the drop
mass will evaporate within the period when they are falling,
entrained upward through the contactor array 260 and before they
leave through the evaporator exit 136. (E.g., 99.97%.)
[1281] More preferably, users adjust the spatial orifice size
distributions to achieve desired spatial distributions of
evaporation residence times, and spatial distributions of
evaporation distances as described herein. They further adjust the
net spatial density distributions to achieve desired spatial
profiles of the ratio of second fluid flow 904 to first fluid flow
901, and associated transverse evaporation time and distance
distributions and spatial saturation distributions.
[1282] 14.9 Co-flow Evaporator
[1283] In other configurations, to evaporate a first liquid 901 in
a second fluid 904, users configure a co-flow evaporator system
with a direct contactor array 260. Users preferably size orifices
80 to generate drops of sufficiently small size that the drops are
entrained in the flow and carried away from the contactor array
260.
[1284] 14.9.1 Upward Co-Flow Evaporator
[1285] When users have a temperature differential, users preferably
orient the evaporator duct 130 in the vertical direction to benefit
from natural updrafts. To achieve a highly co-flow configuration,
users preferably size the orifices to form drops of the first fluid
901 that are sufficiently small to be generally entrained by the
second fluid 904 against gravity. I.e. the drag on those drops is
less than the force of gravity on them. Gravity reduces the
velocity of the entrained drops 901 to less than the velocity of
the second fluid 904. Such a vertical updraft configuration
provides a desirably longer evaporation residence time and shorter
length of the evaporator 130 than a downdraft configuration.
[1286] 14.9.2 Downward Co-Flow Evaporator
[1287] In alternative embodiments, users configure a co-flow
evaporator with a downward flow of the second fluid and
corresponding downward flow of the first liquid drops. Here gravity
accelerates the first liquid 901 as well as the flow of the second
fluid 904 resulting in higher velocity and lower residence time
than the hybrid counter-co flow and the upward co-flow
configurations.
[1288] 14.10 Radial Co-Flow Evaporator
[1289] Where a second fluid 904 flows radially into or out of a
duct, users preferably configure and position a distributed
contactor 260 across the opening of that fluid duct 130. The first
fluid 901 is then desirably mixed with the second fluid 904 as it
flows radially into or out of that duct. Users preferably size the
orifices 80 such that when liquid drops are formed, they are
entrained by the second fluid 904. In other embodiments, where some
of the first liquid drops 901 settle out, users preferably provide
a liquid collector 481 to recover that liquid 901 and recycle
it.
[1290] 14.11 Cross-Flow Evaporator
[1291] In other embodiments users configure a direct fluid
contactor 483 in a cross-flow configuration with horizontal ducts.
This is similar to the configuration shown in FIG. 82. Users
preferably position an array of distributed contactors 260 across
the horizontal duct 130 (instead of parallel to and above as
shown). Users preferably position these contactors vertically
across the entrance 134 to the fluid duct 130. A collection basin
481, pump 364 and return pipe is provided to recover droplets 901
that fall through the duct 130 before fully evaporating.
Alternatively the distributed contactor arrays 260 may be placed
horizontally across the upper portion of the duct 130 near the
inlet 134 (as shown in FIG. 82). In this case, orifices 80 are
preferably sized to form drops that evaporate before reaching the
bottom duct wall 132 to a desired probability by the time they
reach the exit 136.
[1292] 14.11.1 Layered cross-flow saturator
[1293] In other embodiments, users preferably enhance the
evaporation and saturation uniformity by forming a multi-duct
cross-flow evaporator 483. (See, for example, FIG. 82.) They
provide multiple generally horizontal duct walls 132 to divide the
large horizontal duct enclosure 130 into multiple thin sub-ducts
131, thereby providing a more laminar fluid flow. They provide a
distributed contactor array 260 across each thin horizontal duct
131. Users preferably position an array of distributed contactors
260 horizontally across the upper portion of each thin duct 131
near the inlet 134.
[1294] In this case, users size the orifices 80, length and height
and number of thin ducts 130 to form numerous micro-jets and drops
that do not completely evaporate by the time they reaching the
bottom duct wall 132 near the exit 136. Users so size the number
and size of orifices 80 and dimensions of the contactor array 260
and duct 130 to provide at least a prescribed mass flow rate,
surface area formation rate and residence time of the first fluid
901 falling through the fluid duct 130 per mass flow of the second
fluid 904 flowing through the fluid duct 130 for prescribed
temperatures and composition of those fluids. By so doing, users
can achieve a prescribed degree of saturation with a prescribed
probability more efficiently and compactly than with the prior art.
Users can similarly apply this methodology to the simpler cases of
the other evaporator configurations.
[1295] 14.12 Distributed Hydrocarbon Evaporator
[1296] Users preferably configure various evaporator embodiments
483 to evaporate hydrocarbon liquids including various petroleum
distillate fractions, vegetable oils and liquid chemicals. These
configurations are variously used to evaporate fuels 901 in oxygen
containing second fluids 904 such as in combustion systems, to
evaporate chemicals in petroleum refining or chemical processing,
to evaporate potable liquids in food processing, or to concentrate
liquids in biochemical processing systems.
[1297] 14.13 Delivering Fluids into Work Engines
[1298] In some embodiments, users use direct contactor arrays 260
or direct fluid contactors 483 to deliver one or more first fluids
901 into second fluid 904 to be used in work engines. For example,
users preferably deliver one or more fuel fluids as the first fluid
901 into a second fluid 904 containing oxygen to form a mixed fluid
comprising fuel and oxygen. (e.g., delivering fuel fluids such as
natural gas or diesel fuel into oxygen containing fluids ranging
from air to oxygen enriched air to oxygen).
[1299] 14.13.1 Entraining through Cylindrical Wall Opening
[1300] In the relevant art, work engines are shown which draw their
air in through openings, slots or perforations in or around a fluid
duct 130, or in or around a fluid sub-duct 131 connected to such a
fluid duct 130. E.g., a fluid delivery duct 131 connected to a
cylinder, or within the cylinder itself As shown in FIG. 88, in
some embodiments, users preferably place a cylindrical array 268 of
streamlined perforated tubes 10 around the fluid duct wall 130 or
131 covering these openings. Users preferably wind streamlined
perforated tubes around the fluid duct 130 or 131 over these
openings in the direction circumferential to the relevant fluid
wall 132. Users preferably connect both tube ends to a fluid supply
manifold 240.
[1301] As shown in FIG. 89, in other embodiments, users position
the perforated tubes 10 of the cylindrical tube array 268 around
the fluid duct wall 132 (cylinder wall) parallel to the axis of the
fluid duct 130 or 131. Users preferably connect one or both ends of
the perforated tubes 10 to a fluid supply manifold.
[1302] Where a reciprocating compressor or piston moves over such
wall openings 196, users preferably provide cylinder slider wear
bars 198 for the piston to ride on. The perforated tubes 10 are
configured upstream of the slider wear bars 198 and preferably in
line with them.
[1303] 14.13.2 Delivering a Fluid through an Intake Duct or
Port
[1304] As exhibited in FIG. 90, in some embodiments, users position
one or more contactor arrays of perforated distribution tubes 10
across one or more intake ducts 131 to deliver at least one first
fluid into the second fluid flowing through those ducts or ports
into a larger cylindrical fluid duct 130. Such embodiments may use
a planar array, conical array, or other contactor array as
described herein.
[1305] In other configurations using arc or circular contactor
tubes 10 about a cylindrical duct, users configure radial orifices
85 with multiple diameters to provide micro-jets with multiple
penetration distances as desired. These are configured to penetrate
a desired fraction of the radius from the peripheral fluid duct
wall 132 towards the axis of the fluid duct 130.
[1306] They correspondingly configure the frequency and spacing of
the orifices areas and micro-jet penetration distances to desirably
fill the cross-sectional area to be covered at the respective jet
penetration distances. For example, as shown in FIG. 85, these
long, medium and short micro-jets are preferably configured in the
ratio of about 1:2:4 or similar ratios to spread the fluid over the
duct cross section. E.g., user may select penetration distances of
about 95%, 47% and 23% of the radius of the fluid duct 130 or
sub-duct 131.
[1307] Users further configure combinations of contactor tubes 10
across the fluid duct 130, about or along the periphery of the duct
130 or 131, or about or along an axial hub of the fluid duct 130 in
some embodiments.
[1308] As shown in FIG. 86, in some configurations, users position
one or more contactor tubes 10 around and/or along an axial fluid
duct hub 137. They preferably configure the orifice diameters and
spacing to desirably delivery micro-jets with multiple desired
penetrations. The orifice spacing is correspondingly configured
along and about the tubes to achieve the desired spatial delivery
distributions of the first fluid 901 relative the second fluid 904
flow distribution to achieve desired spatial ratio profiles of
those fluid distributions.
[1309] 14.13.3 Delivering a Fluid into a Prechamber
[1310] With further reference to FIG. 90, some work engines use
prechambers 131connected to main cylinder(s) 130. In some
embodiments, users position one or more perforated distribution
tubes 10 around one or more ducts connecting to such prechambers
131 to deliver fluids into those prechambers 131. In another
embodiment, the perforated distribution tubes 10 or contactor
arrays 260 are positioned about or along ports 196 leading to or
from such prechambers 131.
[1311] Where flow of the second fluid 904 through such sub-ducts or
prechambers 131 into main chambers 130 is controlled by sub-duct
valves 231, users preferably configure the contactor arrays 260 to
desirably control the transverse evaporation time distributions and
evaporation distance distributions relative to those sub-duct
valves 231. These are desirably controlled to achieve desired
degrees of fluid evaporation and mixing within the sub-ducts 131
and/or to control the level of splashing on the sub-duct valve 231
controlling that second fluid flow 904.
[1312] 14.13.4 Delivering a Fluid into a Chamber
[1313] In some embodiments, with further reference to FIG. 85,
users preferably use a perforated distribution tube 10 around the
periphery of the chamber or fluid duct 130. They preferably form
numerous orifices 80 to inject numerous fine micro-jets of fuel
into the chamber 130 at low pressure. The perforated tube 10 may be
wound around the cylinder head space above the limit of piston
travel. The orifices 80 preferably point towards the center of the
chamber 130, away from the walls 132. More preferably providing
some tangential orientation of the orifices 80 imparts some swirl
component to the fluids and increases mixing.
[1314] This method permits the first fluid 901 (e.g., fuel) to
penetrate and evaporate to a desired degree by the time the oxygen
containing fluid 904 is compressed within the combustion chamber.
This provides smaller more uniform drops with more uniform
residence time. The results in significantly improved charge
uniformity.
[1315] 14.14 Delivery of Other Liquids
[1316] In some configurations, users use the direct contactor array
deliver a fine spray of drops or "mist" of a lubricant into a
transversely flowing fluid or gas. E.g., to add a suitable
hydrocarbon, or hydro-fluorocarbon, water or other lubricant with
desired transverse distributions of fluid flows to achieve the
desired transverse distributions of composition or ratio of the
first fluid to the second fluid. Some configurations deliver a fine
mist of lubricants into refrigerants.
[1317] In a similar fashion users deliver cleaning fluids,
refrigerants, fertilizers such as ammonia or other fluid with a
desired transverse distribution of drop size and relative mass
flows. In such configurations, achieving the desired transverse
composition distributions are often more important than any heat
transfer involved.
15 Powder Former
[1318] In further embodiments, users preferably form powders using
one or more methods of liquid solidification, evaporation or
chemical reaction.
[1319] 15.2 Forming Uniform Liquid Drops
[1320] The contactor 2 of FIG. 1 and the other embodiments
described herein may be used in some embodiments, to form fairly
uniformly sized powders by delivering liquid drops through these
distributed orifices 80 in the perforated tubes 10. Users utilize
these distributed orifices 10 to form drops from molten liquid,
from a reactive liquid, or from a solution or suspension. In such
applications, users preferably place axial holes 84 at the
downstream side of the perforated tubes 10, generally aligned with
the axis of the fluid duct 130. They preferably control the
differential ejection pressure across the orifices 80 to form
fairly uniform pendant drops of the first fluid 901 to provide the
greatest size uniformity.
[1321] Users preferably control the temperature of the liquid being
delivered within a narrow prescribed range. This helps control the
variation in surface energy, viscosity and density which affect
drop size. Users preferably also control the temperature of the
structure around the distributed orifices which helps control the
solidification rate and solidification time.
[1322] 15.2.1 Uniform Micro-jets
[1323] In a similar fashion, users preferably form uniform
micro-jets of fluid and adjust the differential ejection pressure
to form drops with fairly narrow size distributions. E.g., by
preferably maintaining the liquid jets in the laminar region and
forming single micro-jets rather than sprays whose oscillations
form fairly uniform drops.
[1324] 15.3 Distributed Direct Contact Drier
[1325] Spraying a fluid with slurried or dissolved materials into a
hot gas is a common method of evaporating the carrier liquid,
drying and recovering the solid materials such as milk powder.
Users preferably deliver such compound fluids through embodiments
of distributed perforated tube arrays to create drops with a
desired transverse drop size distribution relative to a flow of
second fluid flowing through the drier such as a heated gas. These
drops are configured to evaporate within desired transverse
distribution of residence times enabling much more controlled
transverse distributions of evaporation distance. These measures of
controlling drop size and evaporation distance further reduce the
frequency of very small drops and particles, thus increasing
product recovery. The narrow drop and particle distribution further
reduces or prevents the formation of large drops. This reduces
residence time and liquid carrier liquid carryover into the
product. Users preferably utilize the methods described with
respect to FIGS. 18, FIG. 19 and FIG. 20 herein with adjustment for
the evaporation rate caused solidification or powder formation
within the drops.
[1326] As before, users preferably filter the compound fluid using
a filter with a fairly uniform orifice size smaller than the
product delivery orifices. With solids that tend to agglomerate,
users preferably provide a wiper to remove solids built up on the
filter. Users further provide a back flushing system to clear the
filter.
[1327] 15.4 Melt Drop Powder Former
[1328] In a similar fashion, users form powders from liquid melts,
giving respectively more attention to radiation heat transfer than
to evaporation. Users preferably hold the first fluid or "melt"
temperature within a narrow prescribed range near the freezing
point. With reference to FIG. 91, they deliver the fluid through
contactor tubes 10 with a large number of orifices 80.
[1329] As shown in the enlarged view FIG. 92, the contactor tubes
preferably have a combination of radial orifices 85, axial orifices
87 and intermediate angled orifices 86 to efficiently spread out
the falling drops. The fluid flow through the orifices is
preferably controlled to be in the laminar range to give more
uniform drops.
[1330] With further reference to FIG. 91, users preferably use a
coolant flow through a coolant manifold 240 to maintain the duct
walls 132 at a temperature lower than the temperature of the molten
drops. Users further control the vertical length L (height) of the
duct 130 (or "drop vessel") as a function of drop size to ensure
sufficient residence time for the drops to cool and solidify. The
thermal response time for drops to reach a prescribed fraction of
temperature difference between the liquid melt and the walls is
proportional to the drop surface area or the square of the drop
diameter.
[1331] As before users preferably control the transverse
distributions of contactor parameters of orifice size, position,
orientation and fluid delivery pressure and temperature to achieve
the desired transverse distributions of drop size and
solidification distance. Users preferably use orifices smaller than
about 50 .mu.m to obtain rapid cooling and small drop size. E.g.,
Reducing drop size from about 500 .mu.m to about 50 .mu.m achieves
about 100 times faster equilibrium for the same mass. This method
provides a significantly shorter drop height, faster production
with associated benefits than the prior art.
[1332] 15.4.1 Extended Cool Walls
[1333] With further reference to FIG. 91, if the falling drops
encompass a large cross section of the cooling vessel 130 as they
fall, the interior portions will be optically hidden by other drops
from the cool exterior walls 132 and not cool as fast as drops
nearer the cool exterior walls. To improve cooling rates, users
preferably provide additional intermediate vertical cooled walls
132 within the duct 130 to form fluid sub-ducts 131 to assist in
radiatively cooling the falling droplets. For example, users
preferably further intersperse perforated distribution tubes 10
with one or more cool duct walls 132 which can be cooled with duct
wall coolant channels 138 carrying a cooled fluid. In other
embodiments, these cooled walls may be formed from radiative
finsfin-tubes 64. Users can use alternating drop passageways and
cooled walls with perforated tubes above the passageways. These
contactors 10 are preferably configured as rectangular arrays.
[1334] In some embodiments, users form the tubes, drop passageways
and cooling walls in spiral or concentric forms. In other
embodiments, users form cooling walls by using cooling vertical
tubes carrying coolant interspersed across the drop space,
preferably in a hexagonal pattern.
[1335] 15.4.2 Drop through a Vacuum
[1336] Molten metals often react with oxygen to form oxides. Many
organic compounds similarly react with oxygen. To prevent or
mitigate such reactions, users preferably evacuate the vessel
through which the drops fall. The vacuum also eliminates convective
cooling. The residence time for drops falling within the vessel is
based on gravity caused acceleration. The dispersed cooling wall
methods described above become even more advantageous with this
configuration.
[1337] Users preferably use pipes for cooling surfaces as they can
easily handle the pressure differences. In other embodiments, users
can use coolant containing cooling walls where the walls are
periodically bonded together to accommodate the pressure
difference.
[1338] 15.4.3 Drop through an Inert Gas
[1339] As a modification to falling liquid drops through a vacuum,
users preferably deliver liquid drops to fall through an inert gas
such as argon or possibly nitrogen. In calculating the drop
velocity falling within the gas users preferably account for
velocity dependent differential drag on the drop and buoyancy from
differential density. In calculating the thermal residence time
users preferably account for the influence of internal drop
circulation on increasing heat transfer to the surface such as
developed by Sirignano (1999) and others.
[1340] 15.5 Uniform Powder Former by Reactive Liquids
[1341] 15.5.2 Ultra Violet Solidification
[1342] Some chemicals are formed by exposing a reactive compound to
Ultra Violet (UV) radiation. Users preferably form fine drops of
the reactive compound with embodiments of direct contactor systems
2. Users then preferably send the drops through or exposed to an
ultra violet radiation field. Users preferably form this UV
radiation field with banks of UV lamps, preferably located at the
foci of parabolic or similar reflectors to direct all the radiation
across the falling drops. Users can also use vertical UV lamps with
drops falling between them.
[1343] Often the UV radiation lamps are more intense and narrow.
Consequently much of the UV radiation is poorly or non-uniformly
intercepted by drops. Users preferably distribute the UV radiation
more uniformly along the drop cavity. Users preferably provide
reflective surfaces, linear Fresnel mirrors, or Fresnel lenses in a
normal V or inverted V configuration in parallel with the UV lamps.
In other embodiments, the UV lamps are interspersed among the
perforated tubes, preferably above the drop space, but may also be
below that drop space.
[1344] 15.5.3 Drop through Reactive Gas
[1345] For liquids that react with a gas to form solids, users
preferably form the drops with distributed perforated tube arrays
2. The reactive gas is flowed across the perforated tubes 10. The
gas flow is preferably vertical to improve product uniformity. The
drop residence time is preferably controlled to ensure a prescribed
portion of the reactive liquid in the drops reacts with the
surrounding gas.
16 Recovering Droplets & Particulates
[1346] Direct contactor arrays may be used to assist in recovering
droplets and particles in some configurations. See, for example,
FIG. 87.
[1347] 16.2 Gravity Settling
[1348] In some embodiments, users configure a gravity separator in
a very similar fashion to the direct contact heat exchanger 483
shown in FIG. 82 to separate non-gaseous components from a fluid
flow using gravity. E.g., to separate liquid drops and solid
components from the flow. The gravity separator commonly comprises
a generally horizontal fluid duct 130 that provides sufficient
residence time for the non-gaseous components to settle to the
lower side of the duct. To recover the first fluid, users provide
suitable channels 481 to collect direct the first fluid flow to
drains where they collect the fluid.
[1349] In some embodiments, users preferably select duct dimensions
to provide a smooth laminar flow. Steps, baffles and other flow
changes that cause eddies are preferably avoided. Users preferably
utilize numerous fairly uniform orifices 80 to form fairly uniform
micro-jets or fairly uniform drops of a first fluid 901 and deliver
them to the fluid duct 130 to effectively contact the second fluid
904.
[1350] Where users form fairly uniform sized drops of the first
fluid 901, this results in a generally uniform settling velocity
across the second fluid flow 904. Fairly uniform drops have a
fairly predictable residence time depending on where they are
released, the relative uniformity of the flow, the difference in
density, the viscosity of the second fluid, and the maximum duct
height through which the drops settle. Users then select a length
of fluid duct 130 long enough and/or the duct area large enough or
reduce the velocity slow enough to provide the desired residence
time so that they recover at least a prescribed portion of the
drops.
[1351] 16.3 Settling Planes
[1352] As in the discussion herein on using multiple planes in
layered cross-flow contactors and heat exchangers, users preferably
provide multiple settling planes or duct walls 132 to form multiple
sub-ducts 131 to recover the fluid 901 in some embodiments. (See,
for example, FIG. 82.) These settling planes 132 significantly
reduce the distance droplets must typically travel before they
contact one of these recovery planes 132. This correspondingly
increases the separator effectiveness, reduces the duct length and
reduces system costs.
[1353] Suitable methods are further described above in the
discussion of the cross-flow contactor, heat exchanger 483 and/or
evaporator. As before, users preferably adjust the transverse
distributions of direct contact parameters to achieve desired
transverse distributions of settling time according to the
respective second fluid parameters and duct parameters.
[1354] 16.4 Cyclones
[1355] Cyclones are commonly used to recover drops and solid
particles. However, conventional drop or particulate formation
results in a wide distribution of drop or particulate sizes. The
efficiency of cyclones drops off dramatically for smaller drop or
particulate sizes. E.g., Kim and Lee (1990) measured the efficiency
of a small cyclone 3.11 cm diameter by 9.5 cm high (barrel and
cone). They found the efficiency drop off from 80% at about 7
microns to less than 10% at about 4.5 microns. Griffiths and Boysan
(1996) obtained very close correlation with those experimental
results by modeling the cyclone with Computational Fluid Dynamics
using a Randomized Normal Grouping (RNG) based k-.epsilon.
turbulence model to account for the swirling flow.
[1356] With a broad distribution, a cyclone will typically only
recover a portion of the drops or powders. Often cyclones are sized
much smaller and more numerous than needed for mean drops to
recover smaller drops or particles. This undesirably requires many
more cyclones. It also requires much higher pressure drops with
higher pumping costs.
[1357] In some embodiments of distributed direct contactor arrays,
users preferably generate fairly uniform sized drops or a narrow
prescribed distribution of drop sizes. By using the analysis
methods of Griffiths and Boysan (1996) users preferably obtain a
cumulative distribution of drops recovered vs size. In modified
embodiments, other suitable analysis methods may be efficaciously
used, as needed or desired.
[1358] As shown schematically in FIG. 87, the direct contactor
array 260 is configured within the duct 130 to form the direct
contact heat exchanger 483 shown here as an evaporative dryer. This
is followed by a particle separator 520 shown here as a cyclonic
separator. The first fluid 901 is delivered through the manifold
240 to the direct contactor array 260 through which it is sprayed
into the duct 130. The second fluid is delivered to the direct
contact heat exchanger 483 to flow through the duct 130 past the
direct contactor array 260. In the evaporative dryer, the second
fluid is preferably heated. The first fluid drops dry to form
particulates. Larger particulates are preferably recovered at the
bottom of the direct contact heat exchanger 483. Smaller
particulates are carried over into the particle separator 520 which
collects a major fraction of the particulate carried out of the
heat exchanger 483.
[1359] Using such methods, users preferably size the cyclone
dimensions and flow parameters to achieve a prescribed cumulative
distribution of drops recovered. By such methods, users preferably
achieve greater than about 99% drop recovery at significantly lower
rates of flow of the fluid per cyclone. This improves recovery and
revenues and lowers pumping costs compared to conventional systems.
In other embodiments, for the same gas flow rate, users can use
larger or fewer cyclones and thus reduce operating and/or capital
costs.
[1360] In modified embodiments, users use the experimental methods
of Kim and Lee (1990) to obtain recovery efficiency versus drop
size. Users then extrapolate the recovery efficiency versus size to
identify the drop size at nominally 100% recovery. Users then
select the drop size to be greater than the size needed to achieve
greater than this nominal 100% recovery with the cyclone under
consideration.
[1361] 16.5 Electrostatic Precipitators
[1362] Electrostatic precipitation technology is used to remove
droplets or particulates from a gas stream. Prior art sprays result
in a wide distribution of droplet or particulate sizes.
Consequently, and disadvantageously, the electrostatic
precipitation equipment are sized to remove the smallest
particulates or droplets tolerable. Particulates smaller than that
are undesirably lost with the exhaust gas flow.
[1363] 16.5.1 Recovering Liquid Drops
[1364] In some embodiments, distributed direct contactors are used
to form drops of the first fluid of fairly uniform size. This
enables users to size the electrostatic precipitators and the
voltages provided by the high voltage power supply used to remove
these generally uniform drops. This provides a substantial
reduction in size of the electrostatic precipitator and/or power
required to recover a prescribed fraction of particles.
[1365] 16.5.2 Recovering Solidified Powders
[1366] Users preferably utilize distributed direct contactors to
form fairly uniform drops. Users solidify these drops to form
fairly uniform powders. To recover these powders, an electrostatic
precipitator is then provided. Users adjust the dimensions gas flow
and power to efficiently recover these fairly uniform particles.
Users obtain greater recovery efficiency with associated benefits
than the prior art.
[1367] 16.5.3 Recovering Evaporated Powders
[1368] Users similarly apply this method with driers to recover the
powders formed by drying fluids containing slurries or dissolved
solids. By creating fairly uniform drops, users form much more
uniformly sized powders. Users then recover these powders with this
electrostatic precipitator method with greater efficiency and
associated benefits than the prior art.
[1369] 16.6 Impingement Separators
[1370] Another common method of separating entrained droplets from
the second fluid is to direct the flow through a tortuous passage
which changes the fluid flow direction. A fluted array is commonly
used to force the gas to change direction by traversing the flutes.
Particles with a drop size and mass to drag ratio greater than
certain values will impinge on the passage wall. Particles with
smaller drop size and smaller mass to drag ratios will be carried
on through by the gas.
[1371] By generating fairly uniform drops, users significantly
improve recovery of impingement separators. Users preferably size
the impingement passages, orifice size drop size and gas velocity
such that most of the particles will impinge on the impingement
separator with very few carried past the separator. Correspondingly
users adjust the gas velocity and passage size to reduce the
pressure drop and pumping cost of forcing the fluid through the
impingement separator.
17 High Flux Solar Receiver
[1372] As with steam generation, heat recovery in concentrated
solar collectors in prior art is typically limited by the material
thermal stress limits. The solar flux is focused on tubes
containing a fluid that is heated such as water or helium, or
liquid sodium. In some embodiments, users preferably use
distributed perforated tube arrays 260 to provide a dense "rain" of
very small drops across the duct 130 receiving the high intensity
concentrated solar flux, as shown in FIG. 93. Users preferably use
a suitable low vapor pressure metal or salt as the first fluid to
form the drop arrays. E.g., gallium. Users preferably form the
drops with a dense distributed array of perforated tubes 260 so
that the drops form an optically thick "fluid" to absorb the solar
flux. The preferred configuration of the contactor tube 10 is shown
in the enlarged view FIG. 92. More broadly, the receiver is
configured to have a view factor between 5% and 98% of that of a
black body. The direct contactor receiver is configured to absorb
90% to at least 98% of the incident flux.
[1373] With reference to FIG. 93, the receiver is preferably formed
as a deep concave array to obtain the near "black body" (i.e.,
"gray body") high absorption benefits of a cavity. Users preferably
focus the solar flux through portion of the duct wall 139
transparent to a desired range of electromagnetic radiation. E.g.,
using a sapphire window to form the transparent duct wall section
139 positioned to receive the solar flux. High purity sapphire
windows can withstand the high solar fluxes and resultant high
temperatures involved. In other configurations users use a clear
quartz window. Users select the window thickness according to the
vapor pressure of the fluid being heated. With a low pressure metal
such as gallium, there is not a substantial pressure difference
across the window so users can use a relatively thin window.
[1374] In other embodiments, users form the wall of the cavity with
an array of sapphire contactor tubes. Users then pass the absorbing
heat transfer fluid through the tubes and numerous surrounding
micro-jets to absorb the heat from the solar flux. This helps cool
the tubes as well as increase the optical absorption density within
the duct 130.
18 Generalization
[1375] From the foregoing description, it will be appreciated that
a novel approach for distributed contacting, mixing and/or reacting
of two or more fluids has been disclosed using one or more methods
described herein. While the components, techniques and aspects of
the invention have been described with a certain degree of
particularity, it is manifest that many changes may be made in the
specific designs, constructions and methodology herein above
described without departing from the spirit and scope of this
disclosure. Where dimensions are given they are generally for
illustrative purpose and are not prescriptive. Of course, as the
skilled artisan will appreciate, other suitable nominal
thicknesses, diameters, spacings and other dimensions and
parameters for perforated tubes, tube arrays, and other components
may be efficaciously utilized, as needed or desired, giving due
consideration to the goals of achieving one or more of the benefits
and advantages as taught or suggested herein.
[1376] Where tube or array configurations are provided, similar two
or three dimensional configurations or combinations of those
configurations may be efficaciously utilized. Where the terms fuel,
diluent, water, air, oxygen, and oxidant have been used, the
methods are generally applicable to other combinations of those
fluids or to other combinations of other fluids. Where assembly
methods are described, various alternative assembly methods may be
efficaciously utilized to achieve configurations to achieve the
benefits and advantages of one or more of the embodiments as taught
or suggested herein.
[1377] Where transverse, axial, radial, circumferential or other
directions are referred to, it will be appreciated that any general
coordinate system using curvilinear coordinates may be utilized
including Cartesian, cylindrical, spherical or other specialized
system such as an annular system. Similarly when one or more
transverse or axial distributions or profiles are referred to, it
will be appreciated that the configurations and methods similarly
apply to spatial control in one or more curvilinear directions as
desired or prescribed. Similarly, the contactor, array, device or
duct orientations may be generally rearranged to achieve other
beneficial combinations of the features and methods described.
[1378] Where fluid delivery controls refer to controlling the size
and flow rate of ejecting drops or micro-jets, it will be
appreciated that the control measures may utilize one or more
measures to control the differential ejection pressure
distributions across the orifices 80, vibrate the orifices, and/or
control the electric field outside the orifices 80 using one or
more measures described herein or using similar means of modulating
the orifices location, the fluid pressure and the surrounding
electric field.
[1379] While the components, techniques and aspects of the
invention have been described with a certain degree of
particularity, it is manifest that many changes may be made in the
specific designs, constructions and methodology herein above
described without departing from the spirit and scope of this
disclosure.
[1380] Various modifications and applications of the invention may
occur to those who are skilled in the art, without departing from
the true spirit or scope of the invention. It should be understood
that the invention is not limited to the embodiments set forth
herein for purposes of exemplification, but includes the full range
of equivalency to which each element is entitled.
* * * * *