Abstract:
An apparatus and method are disclosed for controlling the thickness of a flowing, laminar fluid film. The film flow may be gravity-induced or the result of an alternative force. The fluid is deposited on an upper end of a flow surface where a relatively thick layer of the film forms. The film flows over a fluid dispersal region where the surface area is rapidly expanding, which results in rapid thinning of the film thickness. The fluid then flows over an active region where the surface area is designed to control the fluid film thickness. For example, in some applications, it may be desirable to maintain an approximately constant film thickness as the fluid flows over the active region of the surface. The geometry of the flow surface is used to obtain the desired control over the fluid film thickness. The flow surface is the outer surface of a solid with a closed upper end and a lower end that may be open or closed. An open lower end allows for injection of a heated material, which may be used to heat the solid surface. This process may be used to heat the fluid flow surface so that evaporation of the flowing fluid results. A falling film evaporator is one application of the disclosed invention. A carbon capture system using a thin, flowing algae film is another application. Other potential uses of the invention are disclosed as well.

Description:
FIELD OF THE INVENTION 
     The present invention relates to a falling film evaporation, and more generally to a solid, flowing fluid film surface configured to manipulate and control the thickness of the fluid film flowing over the surface. The invention further relates to a method of controlling the thickness of a fluid film flowing over a solid surface. 
     BACKGROUND OF THE INVENTION 
     A variety of devices has been constructed to create a thin flowing laminar fluid film. Falling film evaporators are a common example. An evaporator is a device designed to convert a liquid into a gas. Evaporation may be desired for various reasons, including for the distillation or purification of a liquid such as water. Seawater may be converted into potable water using evaporative technology, and this application is particularly important given the growing demand for potable water. 
     In a falling film evaporator, contaminated liquid is supplied to generally vertical heat exchange tubes. For example, in a seawater purification evaporator of this type, the seawater is the input. Seawater flows down vertical tubes while heat—typically in the form of steam—is supplied to the area outside the tubes. By allowing only a thin film of seawater to flow down the tubes, the heat transferred to the water is sufficient to evaporate some of the water. This water vapor, which is now pure water, rises up the center part of the tube. The vapor is then collected in some fashion and condensed to produce pure water. 
     Falling film evaporators work best when the flowing film thickness is maintained at a desired thickness. Returning to the seawater evaporator example, a relatively thin film is desired so that maximum evaporation will occur. If the film is too thick, evaporation will be inhibited. If the film is too thin, all the water will evaporate, leaving the tube surface dry. The latter situation can be damaging because of the combination of the high temperature tube surface with the various salts and other contaminants left behind by the evaporation. Hard scale deposits can result, and such scale can be effectively baked onto the tubes. This scale can be hard to remove, can reduce the heat transfer capability of the tubes, and can cause localized tube corrosion, particularly where the deposited materials are corrosive. For this reason, it is important to prevent drying of the tube surfaces in a falling film seawater evaporator. 
     One means used to avoid drying of the tube surface is to increase the flow rate of the fluid. By flowing more seawater down the tubes, there is less risk of the tubes drying. However, this also means the film layer will be thicker, which tends to reduce the evaporation rate. To offset this reduced thermal efficiency, a seawater falling film evaporator may employ a higher temperature. That is, rather than heating the tubes to 140° F., which is considered an optimal temperature for evaporation without significant scale adhesion to the heat transfer surface, an evaporator using higher seawater flow rates may need to raise the temperature substantially above this point. That increased heating will produce more evaporation, but it also will result in more baked on scale on the tubes. These trade offs render the falling film evaporator much less desirable as a means for purifying seawater. 
     In some applications, it may be desirable to evaporate the flowing fluid quickly within a particular region of the apparatus. For example, some liquids may contain certain entrained or dissolved gasses with relatively low flash points. It may be desired to selectively evaporate off these materials so that each can be separately handled. This operation is difficult to achieve in a conventional falling film evaporator. To achieve this result, long tubes may be needed and separate heating regions used along the tubes. 
     A somewhat new use of flowing film technology involves use of thin films of algae to capture carbon dioxide from the atmosphere. Algae use light and carbon dioxide to create energy, oxygen, and other products. Algae have been identified as a potentially important means of capturing carbon, that is, by removing carbon dioxide from the air. 
     In a falling film algae carbon capture apparatus, a thin film of algae may flow through an area exposed to light. Carbon dioxide rich air may be fed into the apparatus in the lighted region. The carbon dioxide is consumed by the algae which then flows past the lighted region and is further processed to remove any desired by products of the operation. For this process to work well, it is important to have the algae at a warm temperature, and that means some evaporation will occur. It is also desirable to maintain the algae at a constant film thickness to better facilitate the carbon capture. 
     These potential uses of falling film technology and the inherent trade offs presented by the use of a falling film evaporator to purify seawater or other contaminated liquids identify an important need. There is a need for an improved falling film apparatus and method that will obtain the potential benefits without the undesirable consequences. The present invention provides just such an apparatus and method. 
     SUMMARY OF THE INVENTION 
     The present invention provides a geometric solution to the problems noted above. A member is disclosed the serves the function of the falling film evaporator tube briefly described above. This member, however, is not an open-ended tube. It is closed on one end, that is, on the upper end in a vertical application. The liquid is deposited on the closed end and then flows down the outside surface of the member. The second end of this member, which is the lower end in a vertical application, may be open or closed. If open, the second end may allow the injection of a heated fluid into an inner chamber, thus heating the surface of the member. This operation is different from the typical falling film evaporator, which supplies heat to the area outside the tubes. In the present invention, if heat is supplied, it is supplied to the inside of the fluid flow member. The fluid to be processed flows down the outside of the member, not down the inside of a tube. 
     The present invention employs at least two distinct fluid flow regions: a fluid dispersal region and an active region. The fluid dispersal region has a rapidly expanding surface area. This geometric configuration results in rapid thinning of the fluid layer deposited on the top of the member. Once the fluid film thickness has reached the desired thickness, the fluid dispersal region ends. 
     The active region begins after the fluid dispersal region, though a transition or other region could be positioned between the fluid dispersal region and active region. Once in the active region, the fluid film thickness is controlled to achieve the desired result. In a seawater purification use, the fluid film would be maintained approximately constant. To achieve this result without altering the overall flow rate, the surface area of the active region may be decreased. That is, with some of the water evaporating off the surface in the active region, the film layer will get thinner unless the surface area is decreasing. By matching the rate of decrease in the surface area to the rate of evaporation, a generally constant fluid film thickness may be maintained. This allows for efficient heat transfer at optimum temperatures (e.g., about 140° F.). It prevents drying of the heat transfer surface, too. 
     If, on the other hand, it is desired to evaporate off certain components separately, then multiple dispersal and active regions could be used. Different heating levels also could be employed toward this end. The present invention provides sufficient flexibility to allow for these types of variations. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a cross-sectional view of a preferred embodiment of the present invention. 
         FIG. 2  is a cross-sectional view of an alternative preferred embodiment of the present invention. 
         FIG. 3  is a cross-sectional view of an alternative preferred embodiment of the present invention. 
         FIG. 4  is a cross-sectional view of an alternative preferred embodiment of the present invention. 
         FIG. 5  is a perspective view of the embodiment of  FIG. 4 . 
         FIG. 6  is an illustration of the fluid film thickness profiles of various embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     One expected use of the present invention is as a falling film evaporator. Such an evaporator is shown in cross-sectional view in  FIG. 1 . This embodiment of the invention may not be the most desired configuration for the purification of contaminated water, such as seawater. The embodiment shown in  FIG. 1  is, however, an accurate representation of certain general characteristics of the present invention.  FIG. 1 , therefore, will be used to explain the basic structure and operation of the present invention. 
     A falling film evaporator  10  is shown in  FIG. 1 . Contaminated input liquid  12  is shown in an upper feed trough  14 . A feed inlet  13  is shown, too, though the supply liquid can be provided in various ways. For example, rather than the dripping trough structure shown in  FIG. 1 , and inlet feed pipe or tube could be used, with its outlet positioned near the point where the liquid is shown dripping out of the trough  14 . The structure and method used to supply the liquid to the apparatus is not central to the present invention. 
     A fluid flow member  16  is shown in the central area of  FIG. 1 . This member, and in particular, the variably curved surface of this member, represent key aspects of the invention. The fluid flow member  16  is separated into two important regions, a fluid dispersal region  18  and an active region  20 . The liquid is quickly dispersed in the fluid dispersal region  18 . That is, the fluid film thickness is quickly reduced in this region. The active region, on the other hand, is the region where maximum evaporation occurs, or where other activity occurs if the invention is not employed in an evaporator. 
     As the contaminated liquid  12  drips onto the upper area  21  of the fluid dispersal region  18 , a relatively thick film layer is formed. The upper area  21  shown in  FIG. 1  comes to a somewhat sharp point. In most actual embodiments of the present invention, it is expected that the upper area  21  would be less sharp or pointed than is shown in  FIG. 1 . Indeed, a relatively flat upper area  21  may be desirable in some applications. The slope of the curve of the outer member surface within the fluid dispersal region is dependent upon the nature of the fluid. 
     When water or other relatively thin liquids are used, a curvature such as that shown in  FIG. 1  may be desirable. The desired outcome is a fluid film thickness that works best within the active region. With a water purification evaporator, for example, the fluid film with thin quickly. But if a thicker fluid is used, a much different curvature may be needed in the fluid dispersal region. An outer surface curve that is relatively flat at the top  21  will provide and highest rate of increase in surface area with decrease in elevation. In other words, a flatter upper area  21  will allow the fluid film to thin more with a given decrease in elevation. This may be needed for thicker fluids. 
     A parabolic curve is one preferred curvature for the outer surface of the fluid dispersal region  18 . To generate the shape, a parabola is rotated around the vertical central axis  23 . The central longitudinal axis  23  extends from the center of the upper end  21  to a point at the center of the generally cylindrical lower end  55 . The shape of the fluid dispersal region  18  can be varied depending upon the specific parabola, or other type of curve, used. For thick fluids, a parabola with a flatter upper region would be desired, but for thinner fluids like water, a curve similar to that shown in  FIG. 1  may be desirable. The present invention allows the designer to vary this aspect of the invention to best suit the particular needs of the application. 
     One possible application where a flatter upper end  21  may be desired would be the concentration of syrup, molasses, liquid malt extract, or other thick, sticky liquids. Such liquids flow slowly unless heated. By flowing such a liquid down the member  16  of the present invention, and allowing evaporation within the active region  20 , the product may be substantially concentrated. This process may reduce the volume of weight of the material, thus allowing for easier storage or shipping. These applications of the invention are provided to show a specific situation in which a different curvature for the outer surface of the fluid dispersal region  18  might be desired. 
     A relatively thick layer of fluid  22  is shown near the upper end  21 . As the fluid flows through the fluid dispersal region  18  it thins. A thinner film layer  24  is shown near the lower end of the fluid dispersal region  18 . This is the film thickness as the fluid enters the active region  20 . An active film thickness  26  is shown within the active region  20 . In  FIG. 1 , this film thickness  26  is shown as approximately constant within the active region  20 . That result is shown for illustration purposes only, because a different geometry is needed in the active region  20  to achieve that result in an evaporator. Fluid that did not evaporate  34 , is collected at the lower end of the structure and exhausted from the apparatus by outlet  46 . 
     Evaporated vapor  40  leaves the outer surface of the member  16 , with most evaporation occurring within the active region  20 . The vapor  40  rises and is removed from the apparatus through outlet  44 . The outer housing  42  shown in  FIG. 1  is illustrative only, as any suitable housing may be used. In fact, in a practical embodiment of the present invention, there may be multiple members  16  constructed as a group. In this variation, the contaminated or concentrated liquid outlet  46  and the water vapor outlet  44  may be common to multiple members  16 . 
     Within the member  16 , there may be heated fluid inlet tube  32  with an inlet  30  and an outlet  36 . Steam  28  is shown flowing up the tube  32  and then down to the outlet  36 . As the steam flows back down, it is exposed to the inner surface  50  of the member  16 . The surface of the member  16  is heated in this manner, and may thus evaporate some of the fluid flowing down the surface. 
     The member  16  is closed at the top (i.e., the area in which the liquid is initially deposited), and the lower end  55  is shown open in  FIG. 1 . An open lower end  55  allows heat to be supplied to the member  16 . The lower end  55 , however, may be closed if there is not need for external heat. Whether the lower end  55  is open or closed, an inner chamber  25  is formed. The inner chamber  25 , of course, is only accessible if the lower end  55  is open. 
     The active region  20  is generally cylindrical, and is shown in  FIG. 1  with a generally constant radius. This geometry is represented by the same diameters A shown at the upper and lower ends of the active region  20  in  FIG. 1 . As will be explained below, the invention uses different geometries for the active region  20  to achieve different results for the fluid film. 
     The arrows used in  FIGS. 1-4  show the flow paths of the different fluids. Using  FIG. 1  for illustrative purposes, the single-line arrows represent liquids, while the double-line arrows represent gases. The liquid feed enters through inlet  13 , as shown by the arrow. A similar, single-line arrow shows the flow of the liquid down the outside surface of member  16  and then out the outlet  46 . Evaporation of some of the liquid produces water vapor  40 , which rises and then exits the device through vapor outlet  44 , as shown by the double-line arrows. Steam used to supply heat to the device is shown with double-line arrows within the inner chamber  25 . Steam  28  is shown flowing up the tube  32  (by double-line arrows) and then down to the outlet  36  (again represented by the double-line arrows). The same arrow arrangement is used in other figures to represent the flow of fluids within the device. 
       FIGS. 2 and 3  show important variations on the embodiment shown in  FIG. 1 . Each of these figures shows a different curvature in both the fluid dispersal region  18  and the active region  20 .  FIG. 2 , for example, shows a flatter upper end  21  in the fluid dispersal region  18 . This curvature will give fluids more time to thin as the fluids flow down the member  16 . 
     The active region  20  in  FIG. 2  is significantly different from the active region  20  of  FIG. 1 . In  FIG. 1 , the active region  20  has a relatively constant cross sectional area. That is, in  FIG. 1 , the active region  20  is generally cylindrical, with the diameters represented by A and B being approximately equal. Diameter A represents the diameter of the lower end of the active region  20 . Diameter B, on the other hand, shows the diameter of the upper end of the active region  20 , that is, of the point where the fluid dispersal region  18  ends and the active region  20  begins. In  FIG. 1 , diameters A and B are roughly equal, and the outer surface area within the active region  20  is not increasing or decreased as one moves along the longitudinal axis  23 . 
     In  FIG. 2 , however, the active region  20  is quite different. Diameter A is now larger than diameter B. In other words, the upper part of the active region  20  in  FIG. 2  has less surface area than the lower part. The surface area is increasing in the active region  20  in the direction of flow (i.e., downward). The rate of increase of the surface area within the active region  20 , however, is less than the rate of increase in surface area within the fluid dispersal region  18 . 
     This different configuration produces markedly different results. The same inner chamber  25  is shown in  FIG. 2  and steam is supplied to that chamber  25  to heat the member  16 , just as in  FIG. 1 . The heated surface results in evaporation, thus removing some of the liquid from the surface. Because the surface area is increasing and the amount of fluid remaining on the surface is decreasing, the fluid film thickness will continue to decrease in the active region  20  of  FIG. 2 . This result is illustrated by the vapor  40  ending some distance above the lower end of the member  16 , and by the complete elimination of the film layer at a point above the lower end of the member  16 . 
     The flow path arrows helps show this dynamic. Liquid is fed into the trough  14  through the inlet  13 , as shown by the single-line arrow. Double-line arrows show the gaseous form of the material evaporating from the outer surface of the member  16 . Note that no liquid lines are shown leaving the lower end of the device in  FIG. 2 , because all the liquid is evaporated in this embodiment. 
     The complete evaporation of the feed liquid may be undesirable in some applications, such as seawater purification systems. Nevertheless, it may be desirable in other contexts. If for example, it were desired to completely evaporate the entire liquid being supplied to the apparatus, using the configuration shown in  FIG. 2  would greatly enhance the chances of achieving this outcome.  FIG. 2  shows how the curvature of the surface of the active region  20  can be used to substantially vary the performance of the apparatus. 
       FIG. 3  shows another variation, and this one may be more suitable for a seawater purification system. In this embodiment, the upper end  21  of the fluid dispersal region  18  is relatively flat. This allows for rapid thinning of the fluid film thickness. It also allows for more of the length of the element  16  to be used for evaporation, which may be desirable. 
     The active region  20  shown in  FIG. 3  has a decreasing surface area in the downward direction along the longitudinal axis  23 . This can be seen by the difference in the diameters A and C. Diameter A is at the lower end of the active region  20 , and it is shown to be approximately the same diameter as that shown in  FIGS. 1 and 2 . Diameter C, on the other hand, is at the upper end of the active region  20 , near the point where the active region  20  meets the fluid dispersal region  18 . Diameter C is larger than diameter A, meaning that the outer surface area of the active region  20  is decreasing as the fluid flows downward. 
     The embodiment shown in  FIG. 3  may be suitable for a seawater purification system. By decreasing the surface area with decreasing elevation within the active region  20 , an approximately constant fluid film thickness may be achieved. As in  FIGS. 1 and 2 , vapor  40  is shown evaporating from the fluid as is flows through the active region  20 . If the surface area decreases at the same rate as fluid evaporates from the fluid film, a constant film thickness may be achieved. This is a highly desirable result because it prevents drying of the surface (i.e., and thus reduces scale build-up) and allows for maximum thermal efficiency. 
       FIGS. 4 and 5  show the invention used in an algae-based carbon capture apparatus. The member  16  is shown with a closed upper and lower end. This may be desired in this embodiment for simplicity of design and because there may not be a need for a means of heating the inner chamber  25 . Algae  52  are shown in the feed trough  14 . The algae are deposited on the upper end  21  of the fluid dispersal region  18 , where the algae  52  thin to a layer thickness appropriate for carbon capture. 
     The active region  20  in  FIG. 4  is that area in proximity to the light source  54 , shown as a light ring in cross section in  FIG. 4 . Some evaporation  40  may occur, but it may be desirable to minimize evaporation in this embodiment. 
     The member  16  shown in  FIG. 4  has three distinct regions. The fluid dispersal region  18  and active region  20  are present, as in prior drawings. In  FIG. 4 , the active region is somewhat similar to that shown in  FIG. 3 . That is, the surface area decreases in the active area in the direction (i.e., downward) of the algae flow. This accounts for some evaporation, while keeping the algae film at a generally constant thickness. If no evaporation is expected, the active region  20  for this embodiment may be shaped like that shown in  FIG. 1 . 
     The third region in  FIG. 4  is a recovery region  56 . In this region, the algae cease functioning because they are too far from the light source. The algae flow though the recovery region  56  and are then collected for further use. A recovery region  56  as shown in  FIG. 4  may be included in any embodiment of the invention, but may be less desirable is space is at a premium. For example, in a water purification system, it may be desirable to use as much of the member  16  as possible for heat transfer and evaporation, thus increasing the productivity of the apparatus. 
       FIG. 5  is a perspective view of the carbon capture apparatus of  FIG. 4 . The fluid dispersal region  18  and active region  20  are shown, with the light ring  54  surrounding the active region  20 . The member  16  is shown in  FIG. 5  without any housing or other structure. This illustration is provided to give a perspective image of the invention. 
       FIG. 6  is a series of curves that illustrate the performance of the invention with different geometries. Curve  1  shows possible performance of an embodiment like that shown in  FIG. 1 . The upper end  21  of the fluid dispersal region  18  of  FIG. 1  has a relatively sharp point. This shape will allow the fluid to flow downward without a great deal of thinning. This result is illustrated in  FIG. 6  by the relatively flat section at the start of Curve  1 . In this part of Curve  1 , the film thickness decreases rather slowly with axial distance (i.e., with decrease in elevation for a vertically oriented member  16 ). The film thickness begins to decrease more rapidly as the distance increases because of evaporation. If there is sufficient evaporation, or insufficient flow rate, the film thickness may decrease to zero, as shown for Curve  1 . 
     There are ways to prevent the film thickness from decreasing to zero in the embodiment represented by Curve  1 . Either the flow rate may be increased, the heat input may be decreased, or a combination of the two. If these changes are made, it is possible to maintain flow along the entire length of member  16 , as is shown in Curve  2 . This curve, however, represents suboptimal evaporation (i.e., because the fluid film is thicker) and, therefore, may not be a desirable result. 
     Curve  3  shows the result of the embodiment shown in  FIG. 3 . The flatter upper end  21  of the fluid dispersal region  18  results in a rapid thinning of the fluid layer thickness, as shown in Curve  3 . The film thickness decreases until it reaches a constant level, denoted by the constant C. This film thickness is maintained by decreasing the surface area of the active region  20  in proportion to the evaporative losses, as explained above in connection with  FIG. 3 . 
     Curve  4  shows the result of using the embodiment of  FIG. 2 . A relatively flat upper end  21  is used, thus producing rapid reduction of the film thickness in the fluid dispersal region. But the film thickness continues to decrease in Curve  4  because the surface area continues to increase in the active region  20  of the embodiment shown in  FIG. 2 . This results in the film thickness being reduced to zero, quite possibly at a point relatively far up the length of the member  16 . This result is illustrated by Curve  4  of  FIG. 6 . 
     While the preceding description is intended to provide an understanding of the present invention, it is to be understood that the present invention is not limited to the disclosed embodiments. To the contrary, the present invention is intended to cover modifications and variations on the structure and methods described above and all other equivalent arrangements that are within the scope and spirit of the following claims.