Patent Publication Number: US-2021164578-A1

Title: Gravity Actuated Flow Control Apparatus and Method

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation application of co-pending U.S. patent application Ser. No. 16/984,538, filed on Aug. 4, 2020, which application claims the benefit of U.S. Provisional Patent Application No. 62/882,741, filed on Aug. 5, 2019, all of which applications are incorporated herein by reference as if reproduced in full below. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not Applicable. 
     FIELD OF THE INVENTION 
     The present invention generally relates to sulfur processing. More particularly, embodiments of the present invention are directed to an apparatus and method for controlling the flow of molten sulfur in an industrial application. 
     BACKGROUND OF THE INVENTION 
     In many applications, controlled flow of a liquid, such as molten sulfur, is accomplished by utilizing a device, whereby liquid is introduced to an apparatus such that the liquid contacts a moveable boundary component that is directionally biased (e.g., downward) such that the boundary component prevents flow of the liquid until the liquid pressure exceeds the biasing force, whereupon the boundary component is displaced (e.g., upward) and the liquid is allowed to flow through a fluid outlet. In such a system, once the liquid pressure diminishes to a level less than the biasing force, the boundary component is replaced in its original position (i.e., “reseals”), and liquid flow through the fluid outlet is prevented. Historically, the biasing force was provided by a spring or the like, which is prone to wear and degradation over time. Some recent apparatuses utilize a pressurized fluid to provide the biasing force. Examples of such technology are disclosed in U.S. Pat. No. 9,752,696, issued Sep. 5, 2017, and U.S. Pat. No. 10,054,236, issued Aug. 21, 2018, both to the present inventor, which are both incorporated herein by reference in their entirety. While such technology is useful, in certain systems it would be useful to provide the required biasing force without the necessity of providing and maintaining a pressurized fluid. 
     BRIEF SUMMARY OF THE INVENTION 
     Embodiments of an apparatus of the present invention generally include a vessel equipped with a substantially vertical, bottom-feeding liquid inlet line, a vapor space pressure equalization line, and a liquid outlet, wherein the vessel contains a pair of connected, horizontally oriented, O-ring equipped sealing plates that are designed to rise and fall as a pair in response to gravity provided liquid pressure in the sump of the vessel, whereby an elevation of the sealing plates provides the liquid in fluid communication with the liquid outlet. Embodiments of a method of using embodiments of an apparatus of the present invention are also provided. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a more complete understanding of the present invention, reference is now made to the accompanying drawings, in which: 
         FIG. 1  is cross-sectional side view of an embodiment of a flow controlling apparatus of the present invention in a sealed configuration. 
         FIG. 1A  is a cross-sectional side view of an embodiment of a flow controlling apparatus of the present invention in a sealed configuration. 
         FIG. 2  is a cross-sectional side view of the embodiment of a flow controlling apparatus of the present invention depicted in  FIG. 1  in an open configuration. 
     
    
    
     DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS OF THE INVENTION 
     The exemplary embodiments are best understood by referring to the drawings, like numerals being used for like and corresponding parts of the various drawings. In the following description of embodiments, orientation indicators such as “top,” “bottom,” “up,’ “down,” “upper,” “lower,” “front,” “back,” etc. are used for illustration purposes only; the invention, however, is not so limited, and other possible orientations are contemplated. 
     Referring first to  FIG. 1 , in one embodiment a flow control apparatus  100  comprises a vessel  2 . In one embodiment, vessel  2  is a sealable container adapted and configured to accommodate the liquid whose flow there through is to be controlled. In one embodiment, vessel  2  comprises 316L stainless steel, although the invention is not so limited and vessel  2  may comprise any useful material(s), such as, but not limited to, other metals or metal alloys, plastic, polycarbonate, or graphite. In one embodiment (not shown), vessel  2  may be insulated, as would be understood by one skilled in the art. In one embodiment (not shown), vessel  2  may be equipped with a temperature control mechanism, such as, but not limited to, a steam jacket. In one aspect, such a temperature control mechanism may be positioned proximate at least a portion of the exterior of vessel and/or integral therewith. In one embodiment, at least a portion of vessel  2  may be substantially tubular in shape. 
     In one embodiment, disposed within vessel  2  is a sealing component  4 . In one embodiment, sealing component  4  comprises an upper plate assembly  6 , a lower plate assembly  8 , and a substantially vertically oriented plate connector rod  10 . In one embodiment, plate connector rod  10  is attached at an upper end  12  thereof to a bottom surface  14  of upper plate assembly  6  and/or plate connector rod  10  is attached at a lower end  16  thereof to a top surface  18  of lower plate assembly  8 . In another embodiment, upper end  12  of plate connector rod  10  may be integral to upper plate assembly  6  and/or lower end  16  of plate connector rod  10  may be integral to lower plate assembly  8 . In various embodiments, upper plate assembly  6  and/or lower plate assembly  8  may comprise a single component or a plurality of components, as would be understood by one skilled in the art. In one embodiment, upper plate assembly  6  and/or lower plate assembly  8  may be substantially horizontally circular in shape. In one embodiment, a top surface  32  of upper plate assembly  6  is dome shaped, as depicted in  FIG. 1 . 
     In one embodiment, sealing component  4  is disposed substantially vertically within vessel  2 . In one embodiment, a side surface  20  of upper plate assembly  6  is disposed proximate a portion of the interior wall  22  of vessel  2 . In one embodiment, upper plate assembly  6  is equipped with one or more sealing members  24 A. In one embodiment, at least one of the sealing members  24 A is disposed substantially circumferentially around a portion of upper plate assembly  6 . In one embodiment, side surface  20  of upper plate assembly  6  comprises one or more grooves  26 A into which at least a portion of a sealing member  24 A may be positioned. In one embodiment, sealing component  4  is positioned within vessel  2  such that at least a portion one or more sealing members  24 A abuts interior wall  22  of vessel  2 , whereby upper plate assembly  6  fluidly segregates an upper internal section  28  of vessel  2  from a middle internal section  30  of vessel  2 . 
     In one embodiment, a side surface  34  of lower plate assembly  8  is disposed proximate a portion of the interior wall  22  of vessel  2 . In one embodiment, lower plate assembly  8  is equipped with one or more sealing members  24 B. In one embodiment, at least one of the sealing members  24 B is disposed substantially circumferentially around a portion of lower plate assembly  8 . In one embodiment, side surface  34  of lower plate assembly  8  comprises one or more grooves  26 B into which at least a portion of a sealing member  24 B may be positioned. In one embodiment, sealing component  4  is positioned within vessel  2  such that at least a portion one or more sealing members  24 B abuts interior wall  22  of vessel  2 , whereby lower plate assembly  8  fluidly segregates a lower internal section (sump)  36  of vessel  2  from middle internal section  30  of vessel  2 . 
     In one embodiment, a sealing member  24 A and/or  24 B may be an O-ring. As would be understood by one skilled in the art, an O-ring  24 A,  24 B may comprise any suitable material, such as but not limited to, an elastomer. In one embodiment, an elastomeric O-ring  24 A and/or  24 B may comprise silicone. In other embodiments, an O-ring  24 A,  24 B may comprise a fluoroelastomer comprising tetrafluoroethylene and propylene (TFE/P), available from AGC Chemicals Americas, Inc. under the tradename AFLAS®, or a perfluoro-elastomer (perfluororubber), available from Seals Eastern, Inc. under the tradename PERFLAS®. 
     In other embodiments, a sealing member  24 A and/or  24 B may be a piston ring. A piston ring  24 A,  24 B may comprise any suitable material. In one embodiment, a piston ring  24 A,  24 B comprises metal and/or graphite. In one embodiment, a piston ring  24 A,  24 B comprises cast iron or chromium steel. In one aspect, a piston ring  24 A,  24 B may be (or be similar to) a standard automotive compression piston ring, such as piston rings available from Federal-Mogul Powertrain of Southfield, Mich. In various embodiments, a piston ring  24 A,  24 B may comprise one or more coating materials on at least a portion of the exterior surface thereof, or have at least a portion of its exterior surface hardened, hardfaced, hardbanded, etc., as is known within the art. 
     In one embodiment, vessel  2  comprises one or more fluid conduits  38  disposed at least partially within interior wall  22  thereof. In one embodiment, a conduit  38  may be substantially annular in shape and horizontally oriented. In one embodiment, a conduit  38  may extend circumferentially about vessel  2 . In one embodiment, vessel  2  comprises a plurality of orifices (e.g., holes, slits, etc.)  40  which penetrate interior wall  22  and provide for fluid communication between the interior of vessel  2  and at least one conduit  38 . In one aspect, at least one fluid conduit  38  is in fluid communication with a fluid outlet  42 . 
     In other embodiments (not shown), vessel  2  may be provided wherein fluid outlet  42  is in direct fluid communication with the interior thereof, i.e., wherein no orifices  40  and fluid conduits  38  are employed. In such embodiments, liquid within sump  36  can flow directly into fluid outlet  42  when flow control apparatus  100  is in an “open” configuration as described below. 
     In one embodiment, flow control apparatus  100  comprises a liquid inlet line  44  which is fluidly connected to sump  36 . In one embodiment, liquid inlet line  44  comprises a substantially horizontal segment  54  and a substantially vertical segment  46 . As is described in detail below, the appropriate height and internal diameter of vertical segment  46  is determined by the density of the liquid (not shown) and the weight of sealing component  4 . In one embodiment, flow control apparatus  100  comprises a vapor equalization line  48  which provides for pressure equalization between upper internal section  28  and liquid inlet line  44 . 
     In one embodiment, sealing component  4  is adapted and configured to be vertically displaceable within vessel  2 . In the embodiment shown in  FIG. 1 , the sealing component  4  is in a vertical position wherein any liquid (not shown) in sump  36  is prevented by lower plate assembly  8  from entering any orifices  40 ; i.e., flow control apparatus  100  is in a “closed” configuration with regard to liquid flow there through. 
     Referring now to  FIG. 2 , flow control apparatus  100  is depicted in an “open” configuration with regard to liquid flow there through. In one aspect, when the weight of liquid (not shown) in sump  36  and vertical segment  46  has forced lower plate assembly  8  (and therefore sealing component  4 ) upward such that liquid (not shown) in sump  36  may enter at least some of orifices  40 , the liquid (not shown) flows into one or more fluid conduits  38  and out of flow control apparatus  100  via fluid outlet  42 . 
     In one embodiment, flow control apparatus  100  may be equipped with one or more upper vertical stops  50 , as shown in  FIGS. 1 and 2 . In the embodiment depicted in  FIGS. 1 and 2 , an upper vertical stop  50  may be affixed to or integral with interior wall  22  of vessel  2 , although the invention is not so limited. In one embodiment, an upper vertical stop  50  may extend circumferentially horizontally along interior wall  22 , although other configurations may be employed. In one aspect, upper vertical stop(s)  50  is/are adapted and configured such that when sealing component  4  (and therefore upper plate assembly  8 ) is displaced upward, the upper vertical stop(s)  50  prevent upward movement of sealing component  4  beyond a certain height, as such upward movement is blocked by contact between top surface  32  of upper plate assembly and the upper vertical stop(s)  50 . 
     In one embodiment, flow control apparatus  100  may be equipped with one or more lower vertical stops  52 , as shown in  FIGS. 1 and 2 . In the embodiment depicted in  FIGS. 1 and 2 , a lower vertical stop  52  may be affixed to or integral with interior wall  22  of vessel  2 . In one embodiment, a lower vertical stop  52  may extend circumferentially horizontally along interior wall  22 , although other configurations may be employed. In one aspect, lower vertical stop(s)  52  is/are adapted and configured such that when sealing component  4  (and therefore upper plate assembly  8 ) is displaced downward, the lower vertical stop(s)  52  prevent downward movement of sealing component  4  beyond a certain height, as such downward movement is blocked by contact between bottom surface  14  of upper plate assembly and the lower vertical stop(s)  52 . 
     Operation 
     Generally, a flow control apparatus  100  is provided proximate a liquid source (not shown) whose flow is to be controlled. The liquid (not shown), such as, but not limited to, molten sulfur, is allowed to flow into horizontal segment  54  of liquid inlet line  44 . In one aspect, it may be preferable to maintain a vapor space above the liquid within horizontal segment  54 . The liquid then flows downward through vertical segment  46  of liquid inlet line  44  and into sump  36  of vessel  2 . In one embodiment, the flow control apparatus  100  is actuated when sump  36  is full and a sufficient level (weight) of liquid has collected in vertical segment  46 . The appropriate internal dimensions of vertical segment  46  are determined by taking into account the density of the liquid and the weight of sealing component  4  (along with frictional drag thereof along interior wall  22 ) such that when a desired amount of liquid is present within vertical segment  46 , the weight thereof forces liquid upward against a bottom surface  72  of lower plate assembly  8 , and forces lower plate assembly  8 , and therefore sealing component  4 , upward sufficiently to allow for the liquid to enter one or more of orifices  40 , which is/are no longer blocked by lower plate assembly  8 . Liquid that enters an orifice  40  flows through a conduit  38  and out of flow control apparatus  100  via liquid outlet  42 . Thus, flow control apparatus  100  allows for downstream flow of the liquid only when a desired quantity thereof has accumulated. 
     In one embodiment, as sealing component  4  rises and falls, vapor pressure in upper internal section  28  is equalized by vapor flow (in either direction) through vapor equalization line  48 . In one aspect, a domed configuration of top surface  32  of upper plate assembly  6  serves to minimize collection of any liquid (not shown) present in upper internal section  28  by allowing for gravity drainage thereof back into liquid inlet line via vapor equalization line  48 . In one embodiment, to minimize collection of any liquid (not shown) present in upper internal section  28 , vapor equalization line  48  may be disposed vertically proximate upper vertical stop  50 , as depicted in  FIGS. 1 and 2 . 
     Referring now to  FIG. 1A , an embodiment of a flow control apparatus  100  comprising an embodiment of another vapor equalization system is depicted. An embodiment of a vapor equalization system  56  is shown in  FIG. 1A . In the embodiment of  FIG. 1A , vapor equalization system  56  comprises a vapor equalization chamber  58  in-line with vapor equalization line  48 , although other configurations may be employed. In one embodiment, vapor equalization system  56  comprises, within vapor equalization chamber  58 , a flotation member  60 , a flotation member seat  62 , and a flotation member stop  64 . 
     In one embodiment, flotation member  60  comprises a substantially spherical component, although the invention is not so limited and other shapes are contemplated. In one embodiment, flotation member seat  62 , which may be attached to or integral with the interior wall  68  of vapor equalization chamber  58 , comprises a substantially annular component that extends horizontally at least partially circumferentially about the interior of vapor equalization chamber  58 . In one embodiment, flotation member seat  62  comprises a single component, although the invention is not so limited and other configurations may be employed. In one embodiment, flotation member seat  62  comprises one or more openings  66  extending vertically there through. In one embodiment, a flotation member stop  64  comprises a substantially annular component that protrudes from interior wall  68  of vapor equalization chamber  58  and extends horizontally circumferentially about the interior of vapor equalization chamber  58 . In one embodiment, a flotation member stop  64  comprises a beveled bottom surface  70 . 
     In one embodiment, when vapor equalization chamber  58  is substantially devoid of liquid, flotation member  60 , which has an external diameter greater than the internal annular diameter of flotation member seat  62 , rests on flotation member seat  62 . In such a situation, vapor pressure equilibrates between upper internal section  28  and liquid inlet line  44  by means of vapor equalization line  48  and vapor flow through vapor equalization chamber  58  via one or more of the openings  66 , as would be understood by one skilled in the art. In one embodiment, when liquid (not shown) is introduced to vapor equalization chamber  58  (due to, e.g., a pressure surge in liquid inlet line  44 ), liquid may force flotation member  60  upward into at least partial abutment with flotation member stop  64 , which has an the internal annular diameter less than the external diameter of flotation member  60 . In such a situation, flotation member  60 , in conjunction with flotation member stop  64 , substantially prevents liquid within vapor equalization chamber  58  from flowing into upper internal section  28 . In one aspect, such sealing of vapor equalization chamber  58  (from flotation member stop  64  downward) further induces the pressurized liquid to flow through vertical segment  46 , where increased pressure triggers actuation of flow control apparatus  100  and the liquid is able to exit the system via fluid outlet  42 , as previously described. 
     In other embodiments (not shown), flow control apparatus  100  may be equipped with other known pressure relief devices and systems, such as, but not limited to, devices and systems fluidly connected to upper internal section  28 . 
     Method 
     An exemplary method of flow control utilizing an embodiment of a flow control apparatus  100  of the present invention comprises: 
     A Flow Control Apparatus Provision Step, comprising providing a flow control apparatus  100  in fluid communication with a liquid source, whereby liquid is able to be introduced to the flow control apparatus via a liquid inlet line, such as liquid inlet line  44 ; 
     A Liquid Introduction Step, comprising flowing liquid through the liquid inlet line and into a sump, such as sump  36 ; and 
     A Flow Control Apparatus Actuation Step, comprising flowing sufficient liquid into the flow control apparatus such that a volume of the liquid accumulates in a vertical segment of the liquid inlet line, such as vertical segment  46 , such that a sealing component, such as sealing component  44 , is vertically displaced, whereby a portion of the liquid is provided to orifices, such as orifices  40 , and liquid flows, via one or more fluid conduits, such as fluid conduits  38 , out of the flow control apparatus via a fluid outlet, such as fluid outlet  42 . 
     The foregoing method is merely exemplary, and additional embodiments of a method of utilizing a flow control apparatus of the present invention consistent with the teachings herein may be employed. In addition, in other embodiments, one or more of these steps may be performed concurrently, combined, repeated, re-ordered, or deleted, and/or additional steps may be added. 
     The foregoing description of the invention illustrates exemplary embodiments thereof. Various changes may be made in the details of the illustrated construction and process within the scope of the appended claims by one skilled in the art without departing from the teachings of the invention. Disclosure of existing patents, publications, and/or known art incorporated herein by reference is to the extent required to provide details and understanding of the disclosure herein set forth. The present invention should only be limited by the claims and their equivalents.