Note: Descriptions are shown in the official language in which they were submitted.
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APPARATUS FOR THE SELF-CLEANING OF PROCESS TUBES
FIELD OF THE INVENTION
This invention relates to the mech~ni~l cleaning of process tubes, such
as tubular reactors and heat exchangers, by clP~nin~ members introduced into the tube
and propelled thereLhlough by fluid.
BACKGROUND OF THE INVENTION
Tubular equipment, tubes and pipes, which are taken to be synonymous in this
specification, are used in indl~stri~l, commercial, re~i(lenh~l, and municipal applications
for many different purposes ranging from transport of ~lrinking water to processing
ures of toxic chemicals.
One such use of tubular equipment is for the transport of fluids, such as
gases, liquids, Illi~lures of gases and liquids, and slurries comprising mixtures of
liquids and solids. In many cases, deposits of solid m~tPri~l accumulate on the walls
of the tube and restrict fluid flow th~lclhlough. This increases the power required to
transport the fluid, see for example, Kipin, Peter, "Cleaning Pipelines: a Pigging
Primer", Chem. Eng., Feb. 4, 1985, pp 53-58 . Examples of this type of behavior are
the build-up of paraffin waxes on the inside of pipes used to transport petroleum
products described in Pipeline Pigging Technology, Tiratsoo, J.N.H., editor, Gulf,
Houston, 1988 and the build-up of iron oxide corrosion products on the inside of steel
water pipes described in aforesaid Kipin, Peter, "Cleaning Pipelines: a Pigging
Primer".
Another common use for tubes is as heat exchange equipment in the
indirect heating or cooling of fluids and fluid-solid mixtures through the wall of the
tube. It is common during these processes for an insoluble scale to form on the inside
of the tube due to a change in solubility of solute in the fluid due to a change in
temperature by heating or cooling, as described in Someah, Kaveh, "On-Line Tube
Cleaning: the Basics", Chem. Eng. Prog. July 1992, pp 39-45. A common example
of this is the heating of water in water-cooled steam-condensers in power plants. As
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the cooling water in the tube is heated by con-lPnsing steam the solubility of certain
inorganic salts such as c~lcil1m carbonate and c~lcium sulphate is decreased and these
salts precipitate out of the water and accumulate on the tube wall. Heat sensitive
m~teri~l.e when heated through the tube wall sometimp~s will foul the inside of tubes
when the material is chemically altered by overhP~tin~. The caramelization of sugar
solutions during heating is an example of this common problem.
In addition to causing an increase in flow resistance and, thus, power
required to m~int~in the flow, the build-up of scale and other forms of fouling greatly
impairs the transfer of heat to the fluid through the fluid wall. Said i.llpaillllent of heat
transfer nece~it~tPs that larger and more expensive equipment be employed, colllpared
to operation without scale or fouling.
Tubes are also used to provide residence time for reacting flows of fluids
and fluid-solid ~ lures. In such reacting systems it is often the case that solids will
build-up on the wall of the pipe due to settling of solids from the s~-spen~i-)n,
precipitation of a reaction product, or a reduction in solubility of a non-reacting
component in the stream due to a change in fluid telll~l~lur~ in the reactor. Anexample of a reacting system which exhibits the latter phenomena is su~erclilical water
oxidation of organic wastes co~ g inorganic m~tPri~l as described in U.S. Patent5,252,224 - Modell et al, issued October 12, 1993. In the process described in
USP5252224, the reaction is carried out under adiabatic conditions. As the reaction
progresses, the heat of reaction raises the fluid l~lllp~l~lur~ and inorganic salts tend to
precipitate out of the fluid phase and have been known to cause build-up of solids in
tubular reactors. Such build-up of solids leads to an increase in flow resistance and,
thus, an increase in the consumption of energy for the transport of fluid through the
reactor. If these solids are allowed to continue to accumulate, complete plugging often
occurs and results in the costly event of lost production from the facility.
The use of cleaning members or pigs for the purpose of clP~ning tubular
equipment, such as pipelines and municipal and industrial process piping and equipment
is well known. Cleaning members are used to remove both liquid and solid m~tPri~l
from the lines and are usually propelled by a fluid through the hydraulic forces exerted
on the cle~ning member by the flowing fluid.
In the cle~nin~ of petroleum pipelines a cle~ning member known as a pig
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is introduced in the pipeline at a pig launching station and moved through the pipeline
by the hydraulic force exerted by a motive fluid, usually the petroleum product
transported through the line. Some distance downstream, the cl~nin~ member is
received into a pig receiving or c~tching station. A pig can be loaded into a pig
S launcher, manually or autom~ti~ily and ~imil~rly ~mlo~led from the pig receiver
manually or autom~tic~lly. However, the pig must be transported back upstream to the
launching station by independent means, usually by surface transport.
In the chemical, food, and related process industries pigs are known to
be used to clean process tubes and to act as a barrier between fluids so that a single
tube can be used to transport several different fluids or fluid-solid mixtures without
inlPi"~i~ing of the fluids. In such systems pigs are often introduced and withdrawn
from the tubes using pig launchers and catchers in the same manner as described above
for petroleum pipelines. In ~ltern~tive systems, pigs are launched and received by the
same device by reversal of the direction of flow of the motive fluid in the tube as
described in U.S. Patent Nos. 3,883,431 - Ishii et at, issued May 13, 1975, 4,198,293
-Ogawa _ al, issued April 15, 1980, 4,607,410 - Bersch, and 5,072,476 - Bersch,
issued December 17, 1991. It is known that such systems can be automated to
periodiçally reverse the flow of the fluid through the tube, and by using a launching
and receiving device at each end of the tube the çle~ning member can periodically be
pushed through the tube by the fluid in ~lle~"~l;ng directions. Unfortunately, for many
of the flow systems which use tubes and require periodic cleaning, the periodic reversal
of flow through the tube is not tolerable and thus this method cannot be used.
Methods are known using the continuous circulation of rubber cleaning
balls through process tubes, for example, U.S. Patents 4,620,589 - Koller, issued
November 4, 1986, 4,566,533 - Bochinski et al, issued January 28, 1986, 5,086,833 -
Ben-Dosa, issued February 11, 1992. In these methods, such balls are loaded into the
entrance of the process tube by an automatic loading device and pushed through the
tube by the hydraulic force of the process fluid on the balls out through an exit. After
the exit of the tube the balls are separated out of the process fluid by a screening device
and automatically removed from the process to a recirculation system which returns the
balls to the automatic loading device. Unrollul~alely, the use of such cle~ning systems
is limited to proçess conditions which are col,lpalible with the m~t~ri~l of construction,
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such as rubber, of the balls, and as such cannot be used to clean systems operating at
high tempeldlule or under other conditions which are detrimental to the rubber. In
addition, the methods and appal~tus used for loading, removing, and recirculating the
cle~nin~ members are only useful when the cle~ning member is ec~enti~lly spherical.
U.S. Patent 3,425,083 - Wennerberg et at, issued February 4, 1969
describes a device for cle~nin~ an endless tube. The operation of this device requires
that the flow of fluid through the tube is greater than the flow ent~ring and exiting the
system, such that a portion of the fluid that has passed through the tube is recirculated
from the "end" of the loop to the "beginnin~" of the loop allowing recirculation of the
cle~ning member. Eduction of this recirculating fluid is effected with a second large
flow recirculation loop and pump. In addition to requiring substantial energy to effect
the eduction of the recirculating liquid, this device is deficient in that a large portion
of the fluid exiting the tube must be mixed with the feed to the system.
In addition to the pigging methods described above, which can be
employed in some circumstances to effect tube cle~ning without the intellupLion of fluid
flow, methods exist to clean tubes which require the tubes to be taken out of useful
service. These methods include mechanical means such as bristle brushes, rubber
plugs, scrapers, cutters, vibrators, and water lances. These methods have the
undesirable feature that they require the process tube and attached equipment to be
taken out of service during the cle~ning operation, and in addition often require that the
equipment be partially disassembled prior to çle~ning. An additional method which
also requires the tube to be taken out of service is cle~ning by chemic~l means. For
example, many types of scale which form on heat ~Ych~nger tubes can be removed by
washing the tube with nitric acid. Chemical cleaning methods have the further
disadvantage of requiring disposal, or clean-up and recycle, of the cle~nin~ chemicals.
It is therefore clear that there exists a need for a system which will allow
the cleaning of a process tube by tube cle~ning members on a periodic basis, without
disrupting the continuous unidirectional flow of the process fluid through the tube,
without being limited to the use of spherical rubber cle~ning members, without
requiring mixing of the inlet and outlet streams, and without requiring an additional
pump to provide the means of recirculating the cle~ning members.
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SUMMARY OF THE INVENIION
The present invention is for use with process tubes, such as tubular
reactors and heat exchangers, in which it is beneficial or essenti~l to m~int~inunidirectional continuous flow of the process fluid through the process tube during a
cleaning operation and wherein the çle~ninP member is recycled from the exit of the
process tube back to the entrance of the process tube so that the cle~ning member may
again be launched into the process.
It is, thus, an object of the present invention to provide a self-contained
appa alus of use in combination with a process tube for the self-cl~ning thereof.
It is a further object of the present invention to provide a looped system
comprising a process tube having novel means for launching, receiving and holding a
recycling tube cle~ning member for the process tube without disrupting the continuous
unidirectional flow of fluid through the process tube. The cle~ning member is
propelled through the tube by a motive fluid, and is not restricted to the use of
spherical cle~ning members as are many of the previously known methods for recycling
clP~ning members.
It is a yet further object of this invention to provide novel arrangements
of valves, conduit and lines to allow, optionally, fluid exiting the process tube, the fluid
enterin~ the process or a separate motive fluid to be used to recycle the cleaning
member from the cle~ning member receiving chamber to the cle~nin~ member
nching chamber, thus Plimin~ting the need for an additional pumping device for this
purpose.
Accordingly, in its broadest aspect the invention provides a~al~tus of
use in combination with a process tube for the periodic cle~ninv of said process tube,
said process tube having feed process fluid supply means for receiving a feed process
fluid and discharge process fluid discharge means for discharging process fluid; said
appa~lus comprising
a cle~ning member;
a çle~nin, member recycling conduit in communication with said process tube
to form a recycle loop therewith, said conduit and said process tube being adapted to
receive said cleaning member to allow said member to operably circulate therethrough
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under process fluid flow to effect ç1e~ning of said process tube; wherein said recycling
conduit has a first valve means and a second valve means defining therebetween with
a portion of said conduit a c1e~ning member receiving, holding and launching chamber.
Preferably, the appa,~lus comprises appal~tus as hereinabove defined
S further comprising second feed process fluid supply means in co"~,llul~ication with said
chamber and second discharge process fluid discharge means in communication withsaid chamber.
The novel arrangements of lines and valves allows the chamber to be
used for both cle~nin, member launching and for receiving, whereby the cleaning
member travels unidirectionally through this launching and receiving chamber.
In a p~re~d embo~1im~nt the invention provides a novel means of
recycling a c1e~ning member such that the fluid discharged from the the system is not
mixed with the inlet feed process fluid.
In an ~1tern~tive embodiment the invention provides a novel means of
recycling a c1e~ninP member by which there is neither mixing of the discharge fluid
into the inlet feed fluid nor mixing of the inlet feed fluid into the discharge exit fluid.
The valves can be ~ct 1~ted aulolllalically.
The process tube to be cleaned must itself be configured such that a
cl~nin~ member can pass freely from the start of the tube to the end thereof with the
process fluid providing the motive force. Thus, the dirre~ ce in pressure between the
supply of process fluid to the system and the discharge of process fluid from the system
must be sufficient to effect flow of the process fluid through the tube as well as to
effect flow of the fluid through the system and propulsion of the c1e~ning member
through the process tube, simultaneously. Further, when the selected valves of the
apparatus are open, the fluid flow provides the motive forçe to move the c1e~ning
member through the process tube and the recycling conduit. The appalalus of the
present invention, thus, has or is ~soci~ted with fluid pump means for providing feed
process fluid under ples~ule to force the fluid through the process tube and, optionally,
through the recycling conduit.
By the term "pump means" in this specification is meant means for
effecting fluid flow through the process tube and recycling conduit either directly by
a pump associated with the appal~lus of the invention, or, indirectly, for example by
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the creation of a head of fluid p~s~u~ as in an elevated tank. Since operation of the
pig will, typically, only add a very small increm~nt~l pumping energy requirement, no
additional pig cycling pump means is neçes~ry. Cle~ning/flll~hing fluid, typically
water, will generally be provided under pressure from its source, external of the
appa~alus.
The ends of the cleaning member recycling conduit are, thus, connected
to the end of the process tube and the start of the proçess tube such that when all the
valves in the conduit are open, the process tube and conduit form a continuous self-
contained loop. This loop provides the path by which the çl~ning member travels
through the process tube and is recycled unidireçtionally. The start and end of the
process tube will, preferably, be such that the majority of the length of the loop is
occupied by the process tube with only a relatively short length of tube occupied by the
recycling section. The fluid supply means and discharge means are so formed and
arranged as to prevent the cle~ning member from passing therethrough out of the
appal~lus.
A minimum of two valves, forming a minimum of one chamber, or a
plurality of discrete chambers in series as hereinafter described, between the valves,
with each chamber formed being at least as long as the cle~ning member to be used,
are provided in the recycling section to f~ilit~te redirection of the flow of the process
fluid and launching and receiving of a cleaning member.
The supply of the proçess fluid is connected, by separate lines, to both
the start of the process tube and to the u~ a~ end of that chamber in the recycling
seçtion which is used as the cle~ning member launching chamber. Conneçtions are
made in such a manner as to not obstruct or divert the path of a cleaning member from
moving through the aforementioned loop. Each line is provided with a valve to
f~`ilit~tP redirection of the fluid flow during the cl~ning member launching cycle.
The process discharge point is çonneçted, using sepal~te lines, to both
the end of the process tube and the downstream end of the chamber in the recycling
seçtion which forms the seleçted cle~ning member l~l1nchin~ chamber. Connections are
also made in such a manner as to not obstruct the path of a cleaning member moving
through the aforementioned loop. Similarly, the lines are equipped with a valve to
f~-.ilit~te redirection of the fluid flow during the receiving of the cleaning member.
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In the case that a single chamber is used to both launch and receive the cleaning
member, means may be provided to flush the process supply fluid from the chamberafter cleaning member launching and prior to clP~ning member receiving, such that the
process discharge fluid is not con~ ted with the process inlet fluid. In one
embodiment, the fll1~hin~ is effected by connecting a cle~ning or flll~hing fluid supply
line and associated valve to the upstream end of the launching and receiving chamber
and a flu~hing discharge tube and valve to the downstream end of the launching and
receiving chamber. The flll~hing fluid can be a sep~,~te fluid or it can be the process
disaharge fluid itself. The fluid flushed from the process may be collected and
disposed or returned to the start of the process for reuse.
Accordingly, in a pler~d aspect the invention provides appal~lus as
defined hereinabove further comprising cl~ning fluid supply means in co~ unication
with said chamber and comprising a cl~ning fluid supply line, cle~ning fluid supply
chamber inlet means and cl~ning fluid supply valve means, cl~ning fluid discharge
chamber outlet means, cle~ning fluid discharge line and cl~ning fluid discharge valve
means.
The cleaning fluid supply line may be in collllllunication with the
recycling conduit, optionally, either upstream or downstream of the chamber.
Operation of the embodiment in which a single chamber is used to both
launch and receive the cle~ning member proceeds as follows. With a cl~nin~ member
in the launching and receiving chamber and the process fluid flowing from the supply
point to the discharge point directly through the process tube, the flow valves are
operated such as to launch the member into the process tube. After the member has
been launched and is traversing the process tube, and in the case that the chamber is
to be flushed prior to receiving the cle~ning member, the flow valves are now operated
to flush the chamber. While the cl~ning member continues to travel through the
process tube, the flow valves are again operated to receive the cle~ning member in the
chamber. The cl~ning member is then received in the chamber and the flow valves
are operated to effect normal flow of the process fluid from the supply through the
process tube to the discharge point, without flowing through the recycling section. In
the case that it is not acceptable to mix the process discharge fluid with the process
supply fluid, the flow valves are again operated to flush the launching and receiving
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chamber, this time with either a sepal~te flushing fluid or with process supply fluid.
The chamber is then isolated again by operating the flow valves, so that the cleaning
member is ready for another çle~ning cycle.
In the cases that either the cle~ning member transit time through the tube
is so short that there is in~llfficient time to change the flow configuration from a
launching to receiving mode during transit or that it cannot be tolerated that the process
discharge fluid comes into contact with chambers that have been in contact with the
process supply fluid, separate launching and receiving chambers are provided. When
sepalale launching and receiving chambers are provided, the operation of the
embodiment proceeds as follows. With a cle~ning member in the launching and
receiving chamber and the process fluid flowing from the supply point to the discharge
point directly through the process tube, the flow valves are operated such as to route
the process fluid from the end of the process tube through the receiving chamber and
back to the process discharge. Next, the flow valves are operated such as to route the
process fluid from the supply point through the launching chamber and back to the start
of the process tube, such as to effect the l~lmching of the cleaning member. After the
member has been launched, has travelled through the process tube and has been
received in the receiving chamber, the flow valves are operated so as to re-establish
flow directly from the supply through the process tube to the process discharge. In the
case that the process supply fluid cannot be cont~min~ted by the process discharge
fluid, the flow valves are then operated so as to flush the receiving chamber with an
acceptable fluid. Next in the operaling sequence the flow valves are operated to push
the cle~nin~ member from the receiving chamber to the launching chamber, with anacceptable fluid, and then the flow valves are operated so as to again isolate the
cl~ning member in the launching chamber so that it is ready for another cle~ningcycle.
The cle~ning member may be formed of any suitable m~teri~l, including
the same m~t~ri~l as is the process tube as described, for example, in aforesaidUSP5252224 in the oxidation of organic m~t~ori~ls under preS:~Ul~ and ~llpel~lule
values supercritical for water, which description is incol~ol~led herein by reference.
The cl~ning member is periodically replaced with a new or refurbished
cl~ning member by either aulolllalically or manually removing and inserting cle~ning
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members into the l~llnchin~ or receiving chamber.
In more pr~felled embo-1im~nt~ of the invention, the operation of the
flow valves are aulolllated and controlled by an eYtern~l electronic device, preferably
a programmable logic controller.
The appa,~lus of the invention is of particular value when the process
tube is an elongate tubular reactor. One such tubular reactor is of the type described
in aforesaid USP5252224 suitable for the oxidation of organic m~tPri~l with a source
of oxygen in an aqueous reaction Illi~luie at least at the critical l~mpel~lure and critical
pl`~S:~Ul`e for water.
Accordingly, the invention further provides appal~us as hereinabove
defined wherein said process tube is an elongate tubular reactor, and more preferably,
when the elongate tubular reactor a~aralus comprises means for the oxidation of
organic m~teri~l with a source of oxygen in an aqueous reaction mixture at least at the
critical Le~llp~ ure and critical pres~ure of water; and means for feeding said aqueous
reaction mixture and said source of oxygen to said tubular reactor.
BRIEF DESCRIPIION OF THE DRAWINGS
In order that the invention may be better understood, prerell~d
embo(liment~ will now be described, by way of example only, with reference to the
acco,npanying drawings, wherein:
Fig. 1 is a diagr~mm~tic layout of an embodiment of the present invention;
Figs. 2 - 7, inclusive, represent diagr~mm~tic layouts of several ~lt~rn~tive
embo liment~ of the present invention;
Fig. 8 represents, in part, a diaglA~ ic layout of a further embodiment of the
invention wherein the process tube is con~tituted as part of a su~l~liLical water
oxidation tubular reactor;
and wherein in the drawings, the same numerals denote like parts.
DETAILED DESCRIPIION OF THE PREFERRED EMBODIMENTS
With reference to Fig. 1, this shows generally as 10, appal~Lus
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comprising in combination a process tube 12 connected to a recycle conduit 14 toconstitute a continuous, recycle loop L. Tube 12 has a supply process fluid inlet 16
and a discharge process fluid outlet 18. Inlet 16 supplies fluid feed via a feed line 20
controlled by a valve 22 from a main feed line 24. Outlet 18 discharges fluid to an
outlet line 26 controlled by a valve 28 to a main outlet line 30.
Conduit 14 at a portion 32 has a launch valve 34 and receiving valve 36
disposed thererlolll, which valves 34 and 36 with portion 32 define a cleaning member
launching and receiving chamber 38. Tube 12 and conduit 14 are of such size as to be
able to receive and allow a cle~ning member 40 to circulate through loop L under the
influence of the process fluid. Further, member 40 is so shaped as to cause intimate
contact with any m~t~ri~l deposited on the inside of tube 12 to effect removal of such
deposited m~t~ri~l thelerlolll. In the embodiment shown, member 40 is within chamber
38. Member 40 is, in this embodiment shown a sponge rubber ball. ~ltern~tive pigs
may be a cle~ning brush, or any of the other numerous devices known to be effective
for clP~ning tubes, whereby such devices can be pushed through the tube by the normal
flow of process fluid as described in the hereinbefore described prior art.
A second conduit feed line 42, under control of a valve 44, connects
main feed line 24 with chamber 38. A second conduit fluid discharge line 46, under
control of a valve 48, connects chamber 38 with main outlet line 30. The connecting
points between line 42 and chamber 38 and line 46 and chamber 38 are such that
clP~nin~ member 40 cannot pass from chamber 38 to either line 42 or line 46. This
is accomplished, for example, by guide bars over the connecting points, as described
in aforesaid Tiratsoo, J.N.H. reference, such that fluid and debris removed from the
pipe walls can flow bc;lween the rods whereas the cl~ning member is too large to pass
between the rods.
Chamber 38 has a drain plug 50 through which chamber 38 may be
drained of fluid. In the embodiment shown, member 40 is inserted into or removedfrom chamber 38 by disassembly of the connections between valve 36 and conduit 14
or valve 34 and conduit 14.
The appal~tus according to the invention shown in Fig. 1 is suitable for
those processes in which it is acceptable to have a portion of the supply process fluid
mix with a portion of the process fluid discharged to outlet line 30, in which it is
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acceptable to mix a portion of the discharge process fluid with a portion of the fluid
supplied to process tube 12, and for which the transit time of cle~ning member 40 in
process tube 12 is substantial such that the required operation of the valves ashereinafter described, can be pelrolllled while member 40 is travelling through process
tube 12.
Thus, the appal~us is suitable for those processes which meet the
following three criteria. First, it is acceptable for process supply fluid which comes
to be in chamber 38 during operation of the appal~lus, as described hereinafter, to exit
the ap~aralus unprocessed from chamber 38 via line 46 and 30. Second, it is
acceptable for process discharge fluid that comes to be in chamber 38 during operation
of the apparatus, as described hereinafter, to flow back to process tube 12 via conduit
14 to mix with process supply fluid. Third, wherein the duration of time required for
cle~nin~ member 40 to traverse the length of process tube 12 is substantial, such that
the required operation of the valves as hereinafter described can be performed while
member 40 is travelling through process tube 12.
An example of an application for use of the embodiment shown in Fig.
1 is the periodic cle~nin~ of a steam condenser having a long tubular cooling coil
con~t~ ting process tube 12, in which hard cooling water flows thel~ ough to cool
the hot surfaces of tube 12. Cold cooling water is supplied through line 24 and heated
cooling water is discharged through line 30. The embodiment shown in Fig. 1 is
beneficial in that cl~nin~ member 40 is used to remove hard water scale formed on the
inside walls of cooling water coil 12, thereby effecting improved heat transfer and
reduced pumping requirements. In this emb~im~nt, it is not dettime-nt~l to discharge
a portion of cooling water from chamber 38 via lines 46 and 30, and neither is it
detriment~l to allow a relatively small volume of warm cooling water contained in
chamber 38 to flow back to the beginning of cooling coil 12 via conduit 14.
Process supply fluid is provided by upstream equipment through feed
lines 24 and 20 under control of valve 22 through inlet 16 to process tube 12. The
pleSSU~ of the fluid in line 24 is s-lfficiently greater at all times than the pressure of
the fluid in line 30 so as to effect flow of fluid through the system in the direction
shown by the arrows and being sufficient during cle~nin~ cycles, as hereinafter
described, to effect the flow of fluid through the system and the propulsion of cleaning
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member 40 through process tube 12 simultaneously.
In operation, wherein the fluid is either gaseous or liquid, cl~nin~
member 40 is inserted into l~llnching and receiving chamber 38. Normal process
operation is carried out by first closing valves 34, 36, 44 and 48 and then opening
valves 22 and 28, such that process fluid enters process tube 12 at 16, via lines 24 and
20, travels through process tube 12 and flows to discharge via lines 26 and 30 after
exiting outlet 18.
Periodically, when desired after sufficient period of processing action in tube 12,
cle~ning of tube 12 is carried out as follows.
To effect launching of cl~ning member 40 from chamber 38, valves 34
and 44 are opened followed by closing of valve 22. This forces fluid through line 42
to chamber 38 and propels member 40 out of chamber 38 and through downstream
portion of conduit 14 into process tube 12. After member 40 has entered tube 12,which event is determined by an appropliate sensing device or viewing window (not
shown), valve 22 is reopened and followed by closing of valves 34 and 44. This
effects re-establi~hmPnt of the process supply fluid flow directly to process tube 12
through line 20 while member 40 is travelling through and cl~ning process tube 12.
In plepal~lion for receiving member 40 in chamber 38, valves 36 and
48 are opened followed by the closing of valve 28. This re-directs process discharge
fluid through chamber 38 through line 46 to line 30. Member 40, after travelling the
length of tube 12, is thus propelled by process fluid into chamber 38 and comes to rest
against the rear of valve 34. Any debris which has been removed from tube 12 andpushed therethrough by member 40 is carried away by process fluid through lines 46
and 30 to a process discharge point out of line 30.
After member 40 has been received in chamber 38, which event is
detected by an approp,iate sensing device or viewing window (not shown), normal
process flow is re-established by opening valve 28 followed by closing valves 36 and
48. Thus, at this point a cle~ning and recycling cycle has been completed and the
system is ready for another cle~ning cycle when required.
Periodically, as wear, corrosion and other detrim~nt~l effects dictate,
member 40 is replaced either manually or through use of an automatic loading andunloading device (not shown) associated with chamber 38.
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The embodiment shown in Fig. 1 can be modified to provide means to
allow flushing of undesirable fluids from chamber 38 either while cle~nin~ member 40
is travelling through process tube 12 or while cl~ning member 40 is in chamber 38.
Flushing is advantageous when it is not desirable to mix a portion of the process feed
fluid with a portion of the process fluid discharged to outlet line 30 or when it is not
desirable to mix a portion of the process discharge fluid with a portion of the process
fluid fed supplied to process tube 12.
In the case that it is neither acceptable to mix a portion of the process
feed fluid with a portion of the process fluid discharged to line 30 nor to mix a portion
of the process discharge fluid with a portion of the fluid fed to process tube 12,
separate flushing fluid is used to flush chamber 38 which is compatible with both the
process feed and discharge fluids. Fig. 2 shows, by way of example, modifications to
the embodiment of Fig. 1 which provide means to flush chamber 38 with a sepal~leflushing fluid.
An example process for which the embodiment shown in Fig. 2 is
beneficial is the supercritical water oxidation of non-toxic organics with inorganics in
an elongate tubular reactor as described in aforesaid U.S. Patent 5,252,224. In said
process, high lel-lpelatures and reaction conditions dictate that cle~ning member 40 be
preferably metallic, such as a metal wire brush designed to be propelled by the fluid.
The flushing fluid is preferably water and flllshin~ of chamber 38 is performed while
the cleaning member is travelling through the process tube, such that a portion of
untreated feed fluid will not mix with a portion of treated fluid discharged from the
process.
With reference to Fig. 2, the al)palalus shown generally as 200 has
modifications to Fig. 1 shown as the additions of flushing fluid discharge line 52,
controlled by a valve 54, which connects chamber 38 to a fl~l~hing fluid discharge
point; and a flushing fluid conduit feed line 56, under control of a valve 58, which
connects flushing fluid supply to chamber 38.
After launching of member 40 into process tube 12, as described
hereinabove, flushing of chamber 38 is effected, if desired, by the opening of valves
58 and 54 to allow sufficient flll~hing followed by the closing of the same valves, which
is in turn followed by prc;pal~lion for and subsequent receiving of member 40 in
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chamber 38, as described hereinabove. Flushing of chamber 38 and member 40 whilemember 40 is in chamber 38 is also effected, if desired, by the opening of valves 58
and 54 to allow sufficient flushing followed by the closing of same valves.
AltPrn~tive means of fll1~hing are shown by way of example with
reference to Figs. 3, 4 and 5, showing a~al~lus generally as 300, 400 and 500,
respectively.
With reference to Fig. 3, the modifications shown, which differ from
those shown in Fig. 2 in that they allow more complete flu~hing of chamber 38, are the
following additional fealur~s. A portion 62 has a valve 136 ~it~ted upstream thereof.
Conduit 14 has a portion 60 having a valve 134 ~itu~ted downstream thereof, and a
discharge line 46 has a second valve 148 !~it~ tP,d downstream of valve 48. Feed line
42 has a second valve 144 ~itl1~tPd upstream of valve 44.
Flushing fluid conduit feed line 56, under control of valve 58, splits to
form four flushing fluid supply lines 56A, 56B, 56C, and 56D which connect,
respectively, to line 46 between valves 48 and 148, line 42 between valves 144 and 44,
portion 60 of conduit 14 and portion 62 of conduit 14. Flushing fluid discharge lines
52 and 152, controlled, respectively, by valves 54 and 154, connect, respectively, the
downstream and upstream ends of chamber 38 to the fl~1~hing fluid discharge point.
An example process for which the embodiment shown in Fig. 3 is
benefici~l is the ~u~rcfilical water oxidation of toxic organics with inorganics in an
elongate tubular reactor of aforesaid U.S. Patent 5,252,224. As discussed hereinabove,
the prer~ d cle~ning member is a metallic brush. The fl~1~hing fluid is preferably
water and flll~hin~ of chamber 38 is p~lrolmed while the cle~ning member is travelling
through the process tube, such that a portion of unlrealed feed fluid will not mix with
a portion of treated fluid discharged from the process. More complete flllchin~ of the
chamber is required in said example, colllpared to ~u~rclilical water oxidation of non-
toxic organics discussed above, since release of even small qu~ntitiPs of toxic organics
with the discharge fluid is unacceptable.
Normal operation, cleaning member launching, and çle~ning member
clP~ning are effected in the same manner as that described above for the embodiment
of Fig. 1, with the additional requirement that during said operations valves 134, 136,
144 and 148 are synchronized to open and close with valves 34, 36, 44 and 48
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respectively.
Normal process flow having been re-established, flu~hing of chamber 38,
or chamber 38 and clP~ning member 40 together, is effected by first opening valves 34,
36, 44 and 48, while valves 134, 136, 144 and 148 remain closed, followed by theopening of valves 58, 54, and 154. After sufficient flu~hing, valves 58, 54 and 154 are
closed followed by closing of valves 34, 36, 44 and 48. When cleaning member 40 is
in chamber 38 during flushing, it is retained in chamber 38 by, for example, only the
partial opening of valves 34 and 36.
For the case wherein it is unacceptable to mix a portion of the process
feed fluid with a portion of the fluid discharged to line 30, but it is acceptable to mix
a portion of the process discharge fluid with a portion of the fluid fed to process tube
12, the process discharge fluid may be used to flush chamber 38. For example, in the
~u~rclilical water oxidation of pulp and paper mill wastes, overall water usage can be
reduced by employing the treated discharge from the process as the flush fluid.
A modification to the embodiment shown in Fig. 2, which provides
means to flush chamber 38 with the process discharge fluid, is shown by way of
example in Fig. 4. In the embodiment shown in Fig. 4, flushing fluid conduit feed line
56, under control of a valve 58, connects conduit 14 between outlet 18 and valve 36.
Flushing of chamber 38 as cle~ning member 40 travels through process tube 12 is
effected by opening valves 58 and 54, while valves 34, 36, 44 and 48 are closed.Following sufficient flushing, valves 58 and 54 are closed.
For the case that it is acceptable to mix a portion of the process feed
fluid with a portion of the fluid discharged to line 30, but it is unacceptable to mix a
portion of the process discharge fluid with a portion of the fluid fed to process tube 12,
the process feed fluid may be used to flush chamber 38.
A mo lifi~tiQn to the embodiment shown in Fig. 2, which provides
means to flush chamber 38 with the process supply fluid, is shown by way of example
in Fig. 5. An example of a process for which the embodiment shown in Fig. 5 is
benefici~l is plug flow ferment~tinn in the process of converting natural sugars to
ethanol by action of yeasts. In this process the plug flow reactor (process tube)
becomes fouled with organic solids over time and requires periodic cle~ning. It is
undesirable to mix the product stream with the feed stream in this process as the
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alcohol in the product stream will inhibit the growth of the yeast, while it is of little
consequence to mix a small portion of the feed with the product stream, as it only
results a small amount of dilution.
- In the embodiment shown in Fig. 5, flll~hing fluid conduit feed line 56E,
under control of a valve 58E, connects with conduit 14 between valve 34 and inlet 16.
Flushing of chamber 38 with c1e~ning member 40 in chamber 38 is effected by opening
valves 58E and 54, valves 34, 36, 44 and 48 being closed. Following sufficient
fll1~hing valves 58 and 54 are closed.
In operations employing short process tubes an ~ltern~tive embodiment
of the present invention as follows is prere~red.
With reference to Fig. 6, this shows generally as 600, a~a,~dtus
comprising in combination a process tube 12 connected to a recycle conduit 14 toconstitute a continuous, recycle loop L. Tube 12 has a supply process fluid inlet 16
and a discharge process fluid outlet 18. Inlet 16 supplies fluid feed via a feed line 20
controlled by a valve 22 from a main feed line 24. Outlet 18 discharges fluid to an
outlet line 26 controlled by a valve 28 to a main outlet line 30.
Conduit 14 at a portion 72 has a receiving valve 74 and a transfer valve
76 disposed thelerlolll, which valves 74 and 76 with portion 72 define a clP~ning
member receiving and holding chamber 78. Conduit 14 at a portion 80 has a secondtransfer valve 82 and a launch valve 84 disposed therefiolll, which valves 82 and 84
with portion 80 form a cl~ning member launching and holding chamber 86. A
portion 88 of conduit 14, between valves 76 and 82, forms a cle~nin~ member transfer
path 90. In the embodiment shown, member 40 is within launching chamber 86.
A second conduit feed line 42, under control of a valve 44, connects
main feed line 24 with launching and holding chamber 86. A second conduit fluid
discharge line 46, under control of a valve 48, connects receiving and holding chamber
78 with main outlet line 30. A third conduit discharge line 92, under control of a valve
94, connects launching and holding chamber 86 main outlet line 30 via outlet line 46.
The connecting points of lines 42 and 92 with launching and holding chamber 86, and
of line 46 with receiving and holding chamber 78, are such that cle~ning member 40
cannot pass from chamber 86 to either line 42 or line 92, or from chamber 78 to line
46. This is accomplished, for example, by a pattern of rods over the connecting points,
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such that fluid and debris removed from the pipe walls can flow between the rodswhereas the cl~ning member is too large to pass between the rods.
Chamber 86 has a drain plug 50 through which chambers 78 and 86
along with transfer path 90 may be drained of fluid. In the embodiment shown,
member 40 is inserted into or removed from receiving chamber 78 or launching
chamber 86 by disassembly of the connections between one of valve 74, 76, 82 or 84
and conduit 14.
The appal~us according to the invention shown in Fig. 6 is suitable for
those systems which use a short process tube 12 such that the transit time of cle~ning
member 40 through tube 12 is brief i.e. wherein there is not sllfflcient time to carry out
the valve operations described above for the embodiment shown in Fig. 1, and forwhich it is acceptable to have a portion of the supply process fluid mix with a portion
of the process fluid discharged to outlet line 30 and in which it is also acceptable to
mix a portion of the discharge process fluid with a portion of the fluid supplied to
process tube 12. Periodic cle~ning of the inner pipe of a double pipe steam condenser,
in which the cooling water flows through the inner pipe, is an example of an
application when the embodiment shown in Fig. 6 would be benefici~l In this example
application, it would be suitable to use a sponge rubber ball or a foam style plug as
cleaning member 40.
In operation, cleaning member 40 is inserted into launching and holding
chamber 86. Normal process operation is carried out by first closing valves 44, 48,
74, 76, 82, 84 and 94 followed by opening valves 22 and 28, such that process fluid
enters process tube 12 at 16, via lines 24, 20, travels through process tube 12 and flows
to discharge via lines 26 and 30 after exiting outlet 18.
Periodically, when desired after sufficient period of proces~ing action in
tube 12, cleaning of tube 12 is carried out as follows.
In prt;pal~lion for receiving member 40 in chamber 78, valves 74 and
48 are opened followed by the closing of valve 28. This re-directs process discharge
fluid through chamber 78 through line 46 to line 30.
To effect launching of cleaning member 40 from chamber 86, valves 84
and 44 are opened followed by closing of valve 22. This forces fluid through line 42
to chamber 86 and propels member 40 out of chamber 86 and the downstream portion
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of conduit 14 into process tube 12.
Member 40, after travelling the length of tube 12, is thus propelled by
process fluid into chamber 78 and comes to rest against the rear of valve 76. Any
debris which has been removed from tube 12 and pushed therelhrough by member 40
is carried away by process fluid through lines 46 and 30 to a process discharge point
out of line 30.
After member 40 has been received in chamber 78, which event is
detected by an al~p~opliate sensing device or viewing window (not shown), valve 22 is
reopened followed by the closing of 84 and 44. This effects re-establishment of the
process supply fluid flow directly to process tube 12 through line 20.
Transfer of cle~ning member 40 from receiving and holding chamber 78
to l~lmchin~ chamber 86 through transfer path 90 is effected by opening valves 76, 82
and 94 followed by closing of valve 48, which allows the process fluid to propelmember 40 through path 90.
After member 40 has been propelled to chamber 86, which event is
detected by an appropliate sensing device or viewing port (not shown), normal process
flow is re-established by opening valve 28 followed by closing valves 74, 76, 82, 84
and 94. Thus, at this point a cle~ning and recycling cycle has been completed and the
system is ready for another cle~ning cycle when required.
Periodically, as wear, corrosion and other detriment~l effects dictate,
member 40 is replaced either manually or through use of an automatic loading andunloading device or devices (not shown) associated with chambers 78 and 86.
In the case that receiving and holding chamber 78 and launching and
holding chamber 86 are closely coupled together, it is obvious that transfer path 90 and
transfer valve 82 are not required.
The basic embodiment shown in Fig. 6 can be modified to provide means
to allow flushing of undesirable fluids from l~llnching chamber 86 and transfer path 90.
An embodiment in which an PYtern~l flushing fluid is used to both flush chamber 86
and transfer path 90 and to propel member 40 from receiving and holding chamber 78
to launching and holding chamber 86 is shown by way of example in Fig. 7.
An example process for which the embodiment shown generally as 700
in Fig. 7 is beneficial is the ~upelcli~ical water oxidation of organics with inorganics
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in an elongate tubular reactor. In said process high temperatures and reactive
conditions dictate that cle~ning member 40 be metallic, such as a metal wire brush
which is designed to be propelled by the fluid. The flushing fluid is preferably water
and flushing of chamber 86 and 90 is pelrolllled simultaneously with the transfer of
cle~ning member 40 from chamber 78 to chamber 86.
The embodiment shown diagr~mm~tic~lly in Fig. 7 differs from that
shown in Fig. 6 as follows. The third conduit discharge line 92 is not employed. A
flushing fluid conduit feed line 56, under control of a valve 58, connects a flushing
fluid supply point to chamber 78. A flushing fluid conduit discharge line 52, under
control of a valve 54, connects chamber 86 to flushing fluid discharge point.
Launching of c1e~ning member 40 from chamber 86 and receiving of said
member into chamber 78 are effected as described hereinabove for the embodiment of
.
Flg. 6.
After member 40 has been received in chamber 38, which event is
detected by an approp-iate sensing device or viewing window (not shown), valves 22
and 28 are reopened followed by the closing of valves 44, 84, 74 and 48, thus effecting
re-establi.~hment of normal process fluid flow directly to and from process tube 12
through lines 20 and 26.
Transfer of cle~ning member 40 from receiving and holding chamber 78
to launching and holding chamber 86 through transfer path 90 and fl~ching of chamber
78 and 90 are effected simultaneously by opening valves 76, 82, 54 and 58.
After member 40 has been transferred to chamber 86, which event is
detected by an appfop-iate sensing device or viewing port (not shown), and sufficient
flll~hing of path 90 and chamber 86 has been effected, valves 54, 82, 76 and 58 are
closed. Thus, at this point a cl~ning and recycling cycle has been completed and the
system is ready for another cleaning cycle when re~uired.
With reference to the basic embodiment shown in Figs. 6 and 7, it has
been demonstrated that çle~ning member 40 can be transferred from chamber 78 to
chamber 86 by either using the process discharge fluid or a s~)al~te flushing fluid. An
obvious extension is to use the process supply fluid to transfer cle~ning member 40
from chamber 78 to chamber 86.
A means of flll~hin~ chamber 86 and path 90 has been plesellled by way
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of eY~mI)le in Fig. 7.
With reference to Fig. 8, process tube 12 at a portion 12A is provided
with a heating jacket 100, and at portion 12C with a cooling jacket 102. Between tube
portions 12A and 12C process tube 12 has an ~ b~tic tubular reactor portion 12B.~e~ting jacket 100, cooling jacket 102 and tube portion 12B are thermally in~ t~d by
insul~t;on 104. A further cooling jacket 106, having cooling fluid supply line 108 and
cooling fluid discharge line 110, is provided ~ cent outlet 18. ~e~ting jacket 100 and
cooling jacket 102 with pump 110 and heat transfer fluid conduits 112, 114 and 116
comprise a heat recovery loop. Line 24 has a pump 118 and an oxygen contail~il1g gas
supply line 120.
In operation, with process tube 12 con~titlting a supercritical water
oxidation tubular reactor of the type referred to in aforesaid U.S. 5252224 for the
oxidation of organic m~tPri~l, a supply of oxygen is fed through lines 120, 24 and 20
and organic m~tPri~l in an aqueous m~ium through lines 24 and 20 to tube 12.
Combined oxygen-organic aqueous ~ ure is heated in tube portion
12A, reacted in tube portion 12B and the reslllt~nt mi~ule cooled by heat exchangers
102 and 106.
Although this disclosure has described and illustrated certain prefelled
embodiments of the invention, it is to be understood that the invention is not restricted
to those particular emboflim~nt~. Rather, the invention includes all embo~lim~nt~ which
are functional or mech~nic~l equivalence of the specific embodiments and reatules that
have been described and illustrated.
