A IMPROVEMENT M THE N02ZLES SCREENS USED IN THE FLUID PROCESSI G UNITS

jJ) OF THE INVE T10JN

Present invention relates to improvement in the Waren! designs of nozzfes/screens used in fluid processing units for fluid distribution/collection, or particularly, present invention relates to Improvement of current wedge wire soreens ^developing Its equivalent In plastics, for flow distribution & collection systems In different process applications, such as: Ion-exchange units, adsorption columns, media f!iters& candle filters to improve Its overall working efficiency & minimizing manufacturing cost,

BACKGROU D OF THE INVENTION IPR1QR ART*

There are variety of the nozzles developed, depending upon the applications, but we will consider the various nozzles / strainers used for fluid processing units only. In the processing units such as media filters, adsorption columns & ion exchange units, various types of nozzles had been developed (as referred in the citations) for the internals. The general construction details are that these nozzles are having cylindrical semi-circular, eonleakapered closed shapes & using their first, outermost body as a boundary having apertures for fluid transport. These apertures are either vertical slots, cross-mesh or horizontal slots. The second boundary inside using apertures of circular shape or sbts or mesh. The fluid transport fakes place through single or multiple boundaries through a conduit or pipe in which area sf cross sections are successively reduced to Increase velocity of the fluid.

The prior art nozzles using mesh type aperture openings, as their first boundary are the worst type of nozzles due to clogging problems^ had been already addressed by number of developers. The rior art nozzles using horizontal slots formed by wedge-wires d een proved the most effective, as t ey ave highest fluid transport area & nosv dogging properties. These wedge-wire-screen noble are made of metals only; such as 88304, 8S318 _S SS316L & Nskel alloys (Such as Hasieiloy). The prices of such nozzles screens are very high compared to many neszies made from thermoplastics, while considering corrosion resistance properties. Due to high fluid transport ability, these nozzle screens deliver/collect different quantities of fluid In a unit time due to variable fluid transporting distances from the central distribution/collection point. This drawback remains in almost all other types of screen nobles also.

Almost all circular/cylindrical wedge-wlre-sereens are using closely pitched wedge wires as their primary filtering surface Sseeondary fluid transporting & controlling apertures on Inside conduit or conical shaped, closed capsu!ated metallic container. The container with apertures is connacfed to inlet/out!et nozzle pipe. The ratio of net aperture area of primary wedge-wire screen & area of the apertures on secondary container Inside decides the fluid transport parameters. In this case, the aparture changes, dua to waar, results uneven fluid transpor

Fluid collection/ distribution through wider angle (nearly 360 ^s ) is the classic feature of this cylindrical profile arrangement of the wedge wire screen ozzles, but fluid oollectien/distrlbution through multiple apertures Inside induces uneven fluid profile outside.

The prior art wedge wire screens are required to be replaced completely when the aperture sizes changes beyond permissible limits due to wear.

The individual nozzle position w.ri, delivery/collection point is not considered In the 'Variable flow screen nobles ^* presented in the citation (USS668459 &US 20120037730), When using such nozzles o the header-lateral type of bottom collector, they bound to deliver different quantities of fluid sn the eounter-flow& co-flow. Similarly, when using such nozzles on the collection plate at the bottom of the processing vessel, tor example, an ion-exchange unit, the counter-current regeneration chemical Injection has dilution effect doe to dead volume of water present in the bottom of the vessel, below collection plate. In case of the ion-exchangers using higher diameter of pressure vessels, the bottom dead volume of water has significant dilution effect on the injection chemical intended for counter-current flow& therefore certain higher amount of chemical dosing is inevitable even after having excellent "distribution screen ozzle .

OBJECTIVES OF THE INVENTION

The primary objective of the invention Is to develop substitute nozzles system for wedge-wire semens MOC ~ Metals) having high flow rate per unit surface a a & non-cogging features, using suitable thermoplastics having very high corrosion resistant properties & minimum wear rate against fluid flows for higher working life span.

Another objective is to develop stack ring of the nozzles enclosure with optimum thickness & width with suitable supporting features to retain stability at different pressure conditions.

Yet another objective of the stack ring development Is to achieve highest degree of fluid transporting angle through its peripheral way (nearly 360 deg.}.

Yet another objective of the invention Is to develop variable flow nozzle with easy construction features. For example, eaey assembly & maintenance of the dlfioser/strainer stack of the nozzles.

Another objective of the nozzle development is to achieve equal flow distribution / collection through their connecting laterals & headers also, of the system. Another objective of the innovation is to achieve flow control of the wedge-wire screen as per locations to achieve u iform flow velocities, which is required in number of process column operations.

Yet another objective of the nozzle development Is to achieve better process efficiencies of the working columns, where the said nozzles are components of the distribution & selection network.

STATEMENT OF INVE TION;

Accordingly Invention provides an Improvement in the conventional nozzSes screen for fluid flew distribution/collection used In fluid flow processing units comprises wedge wire screen (0¾of wedge wire profiles (208) wound eyllndheaily, with pitch 206a to form a screen (210a) & welded with vertical rods (207) to form an open cylinder from its either side; characterised In that a pair of threaded couplings {228, 22S) having external diameter nearly equal to the cylinder of the screen 210a is welded from either of its openings; one of the said coupling (229) height Is kept minimum, Just to Intrcduee a flew resthctor 30 and the said other end coupling (228) Is standard to receive piping connection (34); a flow resthctor 30 Is made of plastic (e.g. PP, PVDF, OHMWPE) having basic cylindrical shape, having threaded end (229a) matching with the said short coupling end (429) for introducing inside the screen cylinder (210e);the said fluid restrlctor (30), given taper (231) nearly up to half-way mark of the screen (210a) height, and thereafter turned into cylindrical shape (232) with conical tip (233) such that the said cylindrical shape (232) of the flow restrlctor (30) passing through end coupling (228) makes washer shape orifice (235) with internal face of the pipe connection (34).

According to one embodiment the invention provides an Improved noEzies/screen for fluid flow distribution/collection used In fluid processing units comprises a cylindrical outer casing of screen made of number of stacked rings, having taper towards centreonone side and flat other side or tapered both sides or flat both sides, hav ng defined width and thickness with radially extending number of lugs formed herein with thickness slightly more than that of said ring to give desired gap between the said stacked rings; a centra! conduit with threaded ends located at the centre of said outer casing with the help of the said lugs having equai lengths just touching periphery of the said conduit & at least one of the lug having extended length; the said one of the lug is having extended iength to engage a slot in the said conduit; the said conduit provided with number of holes at distant in line in each of channel formed by said adjacent lugs; the said outer casing held by check nut or threaded ring in the said conduit; the said conduit is provided with a flow restrictor (30CJ, having tapered, conical shape such that the highest cylindrical end can enclose the condu!l from inside from one end; the said flow rest ictor (30C) Inserted from the opposite end to that of field distribution / collodion end so that enclosing if from opposite end & the tapered end pointing towards the fluid distribution /collection end.

According to the second embodiment the invention provides an improved distribution /collection through plurality of Improved nozzles connected to number of latorals(pipas) or the laterals themselves formed of perforated pipes (532); the laterals connected to another header (pipe) Intended for fluid collection /distribution; the header-lateral assembly remain on one single plane; the laterals & the header pipes are applied with flow restricted (30/30A 30B); the said flow restrictor having basic cylindrical (bar) shape closing the respective dead end of the pipes from inside (533) & cantf levered; the said flow restriotors (30 30A 308) of the lateral or header has given taper towards distribution/ collection end; the said taper of the flow restrictor (3GA) may have two sided chamfer (S34) or in another case the flow restrictor (3GB) may have one sided chamfer, depending on sub branching (S37 /S37B) of the header.

BS¾8EF DESCRIPTION QF THE DRAWINGS g. No; 01 (Prior Art) shows the vertical & horizontal (SECTION - I) cross section of ^* wedge wire servers' nozzle s construction details.

Fig, No: Θ2Α shows a vertical cross section of Improved wedge wire screen" & its details.

Fig. No: 02B shows a vertical section of the "flow resirictor" (30) & lis details.

Fig. No: 02G shows a vertical section of the Improved wedge wire screen assembly" NOZZIE-A & Its sectional view (SECTION-li).

Rg, No: 02D shows 3D view of the "flow restricted (30) & Its details.

Fig, No: 02E shows 3D view of the Improved wedge wire screen assembly ^* & its details.

Fig. Ne:Q3A shows TOP & BOTTOM view of the "Stack Ring Type-Γ § Its features.

Fig, No; 03B & 03C shows the SECTION-IN of the stack ring type-! Ms' details after stacking.

Fig. No: 04A shows TOP & BOTTOM view of the "Stack Ring Type-!l" § its features.

Fig. No: 04B & 04C shows the SECTiON-iY of the stack ring type-!! & lis ^* details after stacking.

Fig. No: OSA shows NOZZLE-B assembly details using stack rings of Typs-i or Type~iL

Rg. No: 058 shows vertical eross section of the N02ZLE-B without stack rings & their details.

Fig. No: GSC shows vertical cross section of the NOZZLE-B with ^!i flow restricted loading but without stack rings loading.

Rg. No: 06A shows details of the SECTJON-V, in which stack ring Interlocking with nozzle conduit Is elaborated.

Fig, No: 06B shows 'Blank Ring' used for supporting & partitioning the main stack-rings assembly.

Fig. No: 07A shows cross-section of a pressure vessel having 'Header-Lateral ^* type distribution / collection system with main header applied with "flow restricted ap lic tions! branches with improved nosztes.

Fig. No: 07B shows 'Front View & Top View ¹ of a cylindrical (Bar shaped) shaped How restricted with two-side chamfers. Fig. No: 07C shows horizontal cross section of a header (Top View), having laterals connections on its either sides & containing flow restriotor with either two-sided chamfer (taper) or conical shape.

Fig. No; Q7D shows 'Front View & Top Vi ' of cylindrical (Bar shaped) shaped "flow restricted with one-side chamfer.

Fig. No: 07Eshows horizontal cross section of a header (Front View), having laterals connections on its bottom & containing flow restricted with one-sided chamfer (taper).

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Prior to giving details of the preferred embodiments, we would like to brief out the development for easy understanding for the present disclosure given below.

"Flow distribution nozzle systems ^4* consists ^* of a set of nozzles used for fluid processing units for Hold distribution / collection applications under varied physical parameters. In the present disclosure, an attempt made to explain development work related to:

1} improved wedge wl screens for mcurate flow con ro .

2) lastic nozzies substitute to wedge wire screen nozzles.

3) improved "Header-Lateral" distribution &coi!ectiQn by sppiying flow res rictors.

The following description of the parts & body components, represented by numeral annotations, elaborates prior art & the development work:

Fig, No 01 f Frier Art) represents a typical wedge wire screenOt, for which a plastic nozzle/screen substitute development, is Intended, Wedge wire OS of nearly triangular shape is wound in cylindrical shape by giving pitch (gap) 05a for fluid transport 10. Pitch between two successive wires Is given to separate smallest media particles from the Interior cavity of the screen also defines the single minimum aperture area developed at Its circumference for fluid transport. The total wedge wire screen cylinder Ida defines the total available area of fluid transport at its peripheral surface. From inside of the wedge wires screen cylinder, vertical rods 0?are welded at equidistance for physical stability. The vertical rods 87are also welded to the top circular cap 18a, whioh closes the screen from one end. Tha bottom circular cap 18b having central Inlet /outlet part 11 closes tha bottom of the screen cylinder, A cylindrical cup shaped fluid restnctor 68s, having lesser diameter than screen, having apertures OS uniformly spread over its ⁵ cylindrical surface, is welded Inslda tha bottom closing cap 18b at the centre, at Its' open and. Tha total aperture area of the fluid restrlcior Oia formed by apertures it Is less than the total aperture area of the wedge wire screen at its periphery, An orifice ring Oia having circular opening of diameter e¾. Is fixed at the entry of the nozzle port 11 The area of the orifice ring ClSa(dO) is less than the total area of tha openings 09 on the fluid restrlcior 08a.

Thus, the first boundary of fluid transport Is defined by wedge wire screen peripheral openings, the second by the total openings on fluid restrietor G8a& the third by orifice opening @fa (dO). Tha ratio of tha net areas of tha successive boundaries influences the fluid transport or No zle/Dlffuser action. Therefore, the change of apertures due to wear of lha metals results uneven flow parameters.

Tha improvement In the conventional wedge-wire-screens is achieved by Introducing a flow restnctor (30) In the nozzles, its connecting laterals (S32}& main header (531). The application of flow restnctor (30, 30A, 308} achieves uniform distribution / collection In the processing vessel.

Fig. No: Q2A, Q2 & 02G elaborates tha improvement in tha conventional wedge wire screen nozzle with few alterations (NOZZLE - A}, The same NOZZLE - A Is shown with 3d perspectives in the Fig, No: 92D & 02E.

These alterations create immaculate fluid coilectlon distri ution profile from its peripheral openings, which Is required In accurate collection/distribution of fluids in the processes. Fig. No: 02A & 02E shows modified edge wire screen 2. Wedge wire profiles 206 wound cylindricaliy, with pftch 236a to form screen 21®a & welded with vertical rods 20? lo form an open cylinder from its either side. Threaded couplings 228, 228 having external diameter nearly equal to the cylinder of the screen 218a is welded from either of its openings. At on® end the coupling 220 height is kept minimum, Just to Introduce a flow resi ictor 36. The other end coupling 220 is standard to receive piping connection 34. Row res!ric!or 3d is mad® of plastic (e.g. PP, PVDF, UHMWPE) having basic cylindrical shape, having threaded end 22Sa matching for the short coupling end 229 for Introduc ng Inside the screen cylinder 210a. The fluid restricior 30, has given taper nearly up to half-way mark of trie screen 210a height, then it Is turned Into cylindrical shape 232 & finally conical tip 233. Cylindrical shape 232 of the flow restricts* 3d passing through end coupling 228 makes washer shape orifice 23S with Internal fese of the pipe connection 34. By manipulating the diameter of the cylindrical shape 232 of trie restrlotor 30, at the crossing with pipe connection 34 _s the flow can be controlled.

The development of the equivalent of wedge wire in thermoplastics involves in creating a circular ring which can be stacked en a conduit to receive/deliver fluid &for which the said ring must have following features:

(1) Nearly triangular shape at Its cross section

(2) Thin (minimum thickness)

(3) Optimum width to offer minimum resistance to flow

(4) Supporting features on stacking

(5) Maximum fluid transporting angle (nearly 360°)

Fig. No; 03A _S 03B & 03C shows the features of stack ring c-f Type-1, The stack rings are moulded from thermoplastics such as 'PVDF, HOPE, Polypropylene' etc, depending on the physical properties & chemical resistance required. These stack rings are stack-mounted on a conduit having apertures for fluid transport to form different types of nozzles or long lateral connecting to header pipe directly. Stack ri g of is aving idt V and thickness ⁴ t ^» 0.2Smm' where the aperture opening between two successive rings Is 0.25mm intended. The top side of the ring surface is having taper 13a, while the opposite surface (bottom) Is flat 13b, To create peripheral aperture openings In successive rings, after stacking^ to support them centr lly, the rings are provided with lugs 14 of flat shape having thickness'?. The lugs 14 are the part of the ring (single mould) having tapered shape towards periphery & protruding towards the centre of the stack ring just like spoke of a wheel& touching the central conduit IS assigned for fluid transport.The surface of the lugs 14, just touching the central conduit linearly follows the curvature 19 of the conduit The f at bottom surface of the stack ring aligns with the fiat surface of the lugs 14(SECTION-]ll). The top tapered ring surface creates offset of thin ga (0,25mm) where the lugs intersects the ring. When the rings are stacked centrally on a conduit! S, by keeping lugs aligned, they create uniform aperture 17. between two successive rings as shown in the Fig vertical Isolated port Sfoetweentw© adjacent logs. A thin fluid path 17ais shown In the Fig. 03A.

To retain stack hng alignment on mounting centra! conduit, at least one lug la provided with rectangular extension 14a to form a 'male' interlock with the vertical slot of the conduit.

Fig. : Θ4Α, 04B & 04C shows the features of stack ring of Type-2. The stack rings are moulded from thermoplastics such as 'PVDF, HOPE, Polypropylene ⁵ etc. These stack rings have similar features just like stack ring of Type~1 with minor differences.

The top side& the bottom side of the ring syrfaces113aare identical & having tape on both sides as shown in SECTIO -IV. The lugs 114 are the parts of the hng similar to the stack rings of Type-1 , but are having offset of thin elevation on either of its side with respect to the hng (Refer Fig. 848). For example if a 0,25mm aperture size is Intended, then the lugs 114have 0,125mm offset on elevation on either side. Fig. hie: 4C represents the aperture 7 created by to successive rings. Referring to the cross sections (SEGT!QM-M V) of both types of the slack rings, the taper angle given may variable, In our case we have maintained it in e een 6 to 8 degrees with respect to fiat surface of the lugs 14, 114. To Increase the effective life of the stack rings from wear or erosion, the hng taper can be given by leaving a thin surface straight, at the peripheral ¾ntry of the ring fe..g, 0.2§mm). The taper given to these rings Is actually Identical to the wedge wire screen profiles available.

Both the above given stack hng features ar© Intended for nozzle designs for 'outslde-ln-flo ' applications, In which the media remains outside the screens. When the nozzle design Is Intended for ins de~out~flow ^s then the taper given to the stack rings follows exactly reverse direction with respect to the central longitudinal axis of the stacks, while the ring lugs 148.114 remain identical for the respective types of the rings. In another method, the ring faces (13a, 1 13a - top & 13b, 113b - bottom) can be kept f at (no taper) & the lugs having desired elevation to create thin aperture.

Fig. No; ©SAsbo s a sample nozzles (Q4)(HOZ2LE-8)wilh the stack mounting. Fig, N ; SSBsho s vertical sections of the nozzles In which without stack rings, for simplicity. Whereas Fig. No; OSCshows vertical cross section of the NOZZLE-B with flow resirictor (30c) applied. The taper of the flow restrictor (30c) guides the Incoming fluid from the nozzle (or a long lateral) outer stack- rings & apertures (120) en the central conduit of the nozzle.

All these nozzles are either machined from ihe reds of the plastics, such as 'UHlvlWPE, PVDF, Polypropylene, HOPE etc. Ultra-High Molecular Weight Polyethylene (UHyWPE) Is our first choice, as It Is having lowest wear rate & easy machlnabilliy. However, moulding options of other thermoplastics are also satisfactory with respect to costing, easiness & overall results.

Now referring to the Fig, No; ©5A & ©SB, NOZZLE - B, 04a; the nozzle conduit 12¾olds the stack assembly 12S In between two open threaded ends 11 Mil la u ing shack nuts or threaded rings 124, 124af r lacking, respectively. Apertures 1 0 are assigned on the conduit per complied channels for fluid transport. The flow restrictor (3Ge) having conical shape oen be Introduced at the end such that the taper ends at the fluid Inlet outlet end. This flow restrictor achieves unique flow distribution & collection. This type of nozzles can ba connected in series to form a distributor or collector lateral by using pipe connection accessories. In this case, the fluid restrictor (30c) is introduced from the last (end) nozzle-section & its tapered end reaches the inlet nozzle-section. Or the noz le length can be extended to convert It into a long collection/ distribution lateral. Due to the length extension, the fluid restrictor (30c) ca be given support at the end, mechanically, Instead of cantilever.

The sectional view (SECTIGN-V) of the NOZZLE - B _s is shown In the Fig. o; 06A. Stack ring 313, having lugs 314 nearly touching central conduit 322 of the nozzle. The nozzle conduit 322 is having vertical rectangular slot 314c, shown In the enlarged view, which receives extended lugs314a of the stack rings for Interlock. Apertures 320, In between adjacent lugs on the conduit 322, receives fluid In the direction321 from the ring periphery, A thin layer of fluid path is shown, which reflects ability o the stack ring to receive fluid from Its periphery just like wedge wire screens.

Fig. No: 0SB shews the blank stack ring 27, used to partition or to block fluid channels of the stack ring nozzles already elaborated, in the front view, the SECTlOHA l shows the stack thickness, which Is just like any washer.

Fig- No: 07Ά shows horizontal cross section of a cylindrical processing vessel & its 'Header-Lateral" type distribution / collection system. Header (531) connecting transition header (531a). The transition header (331 a) passing through the vessel body & connecting the inlet/outlet (535) piping. Header {531) having branch cutlets for lateral connections (S32) on its either side at equidistance. Flew restrictor (30) is Introduced in the header (531) which closes its dead end & having taper towards the distribution / collection end. The laterals (532) are constructed by connecting Improved nozzles/ strainers {539, S40 _f 641 etc.) with the help of con ecting piece {538}. The connecting piece (538) can also be used for fixing laterals as support. The nozzles (539, 540, 541 etc.) are having successively lower conduit diameter, as starting from branch connection towards vessel wall to achieve equal hydraulics. These modifications applied are in such a way that, the nozzles distribution & collection achieve equalization effect If the main header (531) has square /rectangular shape at Its cross-section, then the flow restrictor will have square /rectangular shape with appropriate taper. In any type of header type distribution / collection system the application of flow restrlotor (30) maintains the applied pressure of distribution evenly & its gives uniform collection via all branching or collection apertures.

Fig. No: 0TB shows a FRONT VIEW, SIDE VIEW& TOP VIEW of flow restrictor (3QA).The round bar having diameter equal to the pipe - Inter al diameter (It may be header o lateral) has given two sided chamfer (534). The flow restrictor (30A) closes the dead-end of the pipe & its taper follows towards the distribution/collection end of the pipe from inside.

Fig. Mo: 07C shows flow restrictor (3GA) applied In the header (531c) having branching on its either sides (337), The taper (634) of the flow restrictor (30A) end or nearly merges before inlet outlet end (635) of the header.

F g. No: 07D shows a FRONT VIEW, SIDE VIEW & TOP VIEW of flow restrlotor (30B). The round bar having diameter equal to the pipe - internal diameter (ft may be header or lateral) has given one sided chamfer (534). The flow restrictor (30B) closes the dead-end of the pipe & its taper follows towards the distribution/collection end of the pipe from inside.

Fig. No: Θ7Ε shows the application of the flow restrictor (3GB) in a pipe, which could be a header or lateral (531 E) having its branching (537B) at the one side

(bottom). The flow restrictor (30B) closes the dead-end of the pipe & Its taper follows towards the inlet / outlet end (535) of the pipe from inside.

The flow restrictor (30) can have simple conical shape taper, regardless of the pipes branching, Instead of the various shapes shown In the fig, no-07B & 07C. The preferred embodiments, in the different types of systems considered here, are subjected to minor changes or additions or st ndardization & the seme shall be covered by the given claims below.