Abstract:
A nozzle for controlling the spray pattern and the distribution of particles into a combustion chamber. The nozzle comprises a receiver in communication with a vortex chamber, which in turn is in communication with a discharge hood. The vortex chamber and the discharge hood are designed to reduce the air pressure within the nozzle, and to thereby decrease the velocity at which particles move through the nozzle. The nozzle further comprises a plurality of blades disposed on the vortex chamber which serve to control the spray pattern of the particles. The nozzle further optionally comprises a plurality of deflectors located on the discharge hood which further controls the spray pattern of the particles.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application No. 60/595,794 filed on Aug. 5, 2005. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     This invention relates to a nozzle configured to control the flow of particles. More particularly this invention relates to a nozzle capable of regulating the velocity of particulate matter through the nozzle and the spray pattern of the particulate matter from the nozzle.  
         [0004]     2. Background of the Invention  
         [0005]     Many types of nozzles exist for conveying blown particulate matter from one medium into another. An exemplary application of a nozzle is in the combustion industry where it is desired to transfer combustible particles from a processing site to a combustion site. However, oftentimes the nozzle blows the combustible particles towards the walls of the combustion site, upon which the particles combust on or in close proximity to the walls, and thereby cause heat damage to the walls. Accordingly, what is needed is a nozzle designed to control the flow and/or spray of combustible particles such that the particles combust before they come in proximity to the walls of the combustion site.  
       SUMMARY OF THE INVENTION  
       [0006]     The above-discussed and other drawbacks and deficiencies of the prior art are overcome or alleviated by a nozzle which controls the spray pattern and the distribution of particles as they enter into and are dispersed in a combustion chamber, wherein a combustion chamber is defined as any material burning site, such as a boiler, burner, furnace, and the like. The nozzle comprises a receiver in communication with a vortex chamber, which in turn is in communication with a discharge hood. The vortex chamber and the discharge hood are designed to reduce the air pressure within the nozzle, and to thereby decrease the velocity at which particles move through the nozzle. The nozzle further comprises a plurality of blades disposed on the vortex chamber which serve to control the spray pattern of the particles. The nozzle further optionally comprises a plurality of deflectors located on the discharge hood which further controls the spray pattern of the particles. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]      FIG. 1  is a schematic depicting a side view of the outer surface of an exemplary nozzle;  
         [0008]      FIG. 2  is a schematic depicting a bottom view of a portion of the nozzle depicted in  FIG. 1 ;  
         [0009]      FIG. 3  is a schematic depicting a longitudinal view of an interior of the nozzle depicted in  FIG. 1 ;  
         [0010]      FIG. 4  is a schematic depicting a bottom view of the nozzle of  FIG. 1  showing the discharge hood and plurality of deflectors;  
         [0011]      FIG. 5  is a schematic depicting an exemplary starting material used to form an exemplary deflector; and  
         [0012]      FIG. 6  is a schematic depicting a transparent side view of the nozzle depicted in  FIG. 1  attached to an exemplary piping. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0013]     Disclosed herein is a nozzle which directs the speed and flow of particles. The nozzle is more particularly described with reference to the figures, however, the disclosure is not to be limited to the embodiments shown in the figures, but is intended to include all obvious and natural variations and modifications thereof as would occur to one of ordinary skill in the art.  
         [0014]     Referring to the figures, an exemplary nozzle  10  comprises a receiver  11  connected to a truncated conical vortex chamber  12 , and a truncated conical discharge hood  14  integrally connected to vortex chamber  12 . Both of vortex chamber  12  and discharge hood  14  are tapered such that the widest end of vortex chamber  12  connects to the narrowest end of discharge hood  14 . The narrowest end of discharge hood  14  is located at inner edge  24  and the widest end of discharge hood  14  is located at outer edge  26 , wherein inner edge  24  and outer edge  26  define the outer limits of discharge hood  14 . Discharge hood  14  of nozzle  10  is designed to further reduce the air pressure initially introduced into nozzle  10  and also to assist in determining the diameter of the combustion flame and spray pattern of the particles being combusted.  
         [0015]     Nozzle  10  further comprises a plurality of blades  16  located on an interior side of vortex chamber  12 . In an exemplary embodiment, blades  16  extend along all or a substantial portion of the length of the interior side of vortex chamber  12 , wherein “substantial portion” comprises over about 80 percent of the length of the interior side of vortex chamber  12 . In an exemplary embodiment, the terminal ends of the blades  16  are welded onto the interior side of vortex chamber  12 . Each of blades  16  comprises a helical configuration so as to produce a centrifugal force inside nozzle  10  when in operation. As such, when in position, each of the blades overlaps and/or under laps at least one of the other blades. Although  FIG. 1  depicts a plurality consisting of three blades, 2 or more blades may be used.  
         [0016]     An optional feature of the nozzle of the present invention is the integration of a plurality of deflectors  18  onto an interior surface of discharge hood  14 . When used, plurality of deflectors  18  assists in fine tuning the particle mixture and spray pattern of the particles emitted through nozzle  10 . Each of deflectors  18  may vary in size and shape depending on the application and on the design of the combustion chamber.  
         [0017]     Nevertheless, in an exemplary embodiment, each of deflectors  18  comprises a cavity  20  surrounded by a shell  22  attached to the interior surface of discharge hood  14 . In an exemplary embodiment, each of shell  22  comprises a truncated conical configuration. Additionally, in an exemplary embodiment, shells  22  are welded onto discharge hood  14 . Additionally, shells  22  taper such that the narrowest ends of shells  22  are directed towards, and preferably meet at, inner edge  24  of discharge hood  14 , and the widest ends of shells  22  are directed towards, and preferably meet, at outer edge  26  of discharge hood  14 . In an exemplary embodiment, each of shells  22  may be formed from about a 13 inch long and about a 2 inch wide solid stainless steel, or other corrosion resistant alloy, pipe  28 . Pipe  28  may be bored through to form the desired truncated conical structure. Although six individual deflectors are depicted, it is contemplated that any number may be used to accomplish the purpose of directing the spray of particles out of the nozzle.  
         [0018]     Nozzle  10  further comprises a mount  30  surrounding the outer periphery of nozzle  10 . Mount  10  is preferably located at the point where vortex chamber  12  and discharge hood  14  meet. Mount  30  comprises a plurality of vias  32 , wherein nails or screws may be inserted through vias  32  to further secure nozzle  10  onto a desired structure. Of course, fastening elements other than vias may be used to attach the nozzle to the desired structure so long as the structure to which the nozzle is mounted comprises complementary fastening elements.  
         [0019]     Exemplary materials for forming the nozzle include stainless steel and other non-corrosive alloys, such as hastelloy®. The Example provided below describes exemplary measurements for forming the nozzle as described herein. However, it is noted that the size and taper of the nozzle may be varied based on the size of, for example, a combustion chamber, boiler, or furnace.  
       EXAMPLE 1  
     Dimensions of an Exemplary Nozzle  
       [0020]     Referring to  FIGS. 4 and 5 , an exemplary nozzle was constructed having the following dimensions. Referring to  FIG. 4 , discharge hood  14  comprises an outer diameter A of 15.75 inches and an inner diameter B of 12 inches. Shell  22  comprises an opening having a maximum length F of 1 inch. Referring to  FIG. 5 , discharge hood  14  comprises a length C of 13 inches. Vortex chamber  12  comprises a length D of 24 inches. Receiver  11  comprises a length E of 6 inches and receives a supply pipe  34  having a 6.5 inch inner diameter. Referring to  FIG. 2 , plurality of blades  16  are arranged to create an inner diameter G of 3 inches.  
         [0021]     An exemplary application of the nozzle described herein is in the transport of particles into a combustion chamber. In this application, it is envisioned that the particles enter the nozzle through the receiver under a pressure of about 1.3 pounds per square inch (“psi”). As the vortex chamber is tapered, the pressure at the widest end of the vortex chamber is less than that at the narrowest end. Accordingly, the velocity of the particles as they move through the length of the vortex chamber and into the discharge hood lessens. This is particularly important in the present application as it is desired to combust or to burn the particles as close as possible in the center of the combustion chamber. Where combustion occurs too close to the walls of the combustion chamber, a high amount of heat energy is more likely to contact the walls of the combustion chamber, thereby increasing the likelihood of damage to the walls. To accomplish burning towards the center of the combustion chamber, the velocity in which the particles are emitted from the nozzle into the combustion chamber is slowed. Such reduction in velocity is accomplished by reducing the amount of pressure within the vortex chamber, which, as previously stated, is accomplished by gradually increasing the internal diameter of the vortex chamber towards the discharge hood.  
         [0022]     In this application, the particles may be blown into the vortex chamber by a pressurized flow of air. For example, the particles may be blown through a supply pipe, which is connected to the receiver. As the particles are blown through the vortex chamber and make contact with the plurality of blades, a centrifugal force is generated which assists in spreading the particles in the combustion chamber as desired.  
         [0023]     The size and pitch of the plurality of blades inside the vortex chamber will vary based on the application. However, the construction and dimension is determined such that the particles emitted from the nozzle are sprayed in a desired pattern to create a desired flame size and length. The design and the arrangement of the plurality of blades preferably cause centrifugal motion to blow the heavier particles to the edges of the combustion chamber so that the particles have a longer burn time. Therefore, the plurality of blades is designed to create centrifugal force inside the nozzle. This process allows the fuel to exit the nozzle in such a manner so as to spread the particles in the combustion chamber as desired. The larger fuel particle sizes are ejected out of the nozzle at the outer perimeter of the nozzle which provides for the longest period of time for combustion available.  
         [0024]     Furthermore, the mount may be secured to the outer side walls of the combustion chamber or boiler such that the outer edge  26  of discharge hood  14  jets into the combustion burner. In this application, it is preferred that fire brick insulation is used to buffer the nozzle and the combustion chamber.  
         [0025]     The nozzle of the present invention is particularly useful when used in cooperation with a dedensification and delivery unit (“DDU”) as described in U.S. application Ser. No. 11/160,061, and which is incorporated herein in its entirety, and which is used to prepare and burn specification raw materials as a fuel source. In this embodiment, the nozzle of the present invention may replace or constitute the low volume blower hose which connects the refining area to the combustion chamber. In this manner, then, the nozzle of the present invention can convey a dedensified alternative fuel source to a combustion chamber in a controlled manner.  
         [0026]     As required, detailed embodiments of the present invention have been disclosed herein. However, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure.