Integrated Modular Four-in-One High-Efficiency Heat Exchanger

Abstract

The present invention provides an integrated modular four-in-one high-efficiency heat exchanger, which relates to the technical field of heat exchange equipment and includes a first tube sheet, a first shell, a second tube sheet, and a second shell that are connected in sequence into an integral body. The first shell is located above, and the second shell is located below. The length extension directions of the first shell and the second shell are the same and their central axes coincide. The beneficial effect of the present invention is that it can realize four functions: precooling, condensation, centrifugal dehydration, and filtration dehydration, and has the effects of small volume and high separation efficiency. Here, the precooling zone and the heating-up zone are integrated in the first shell. Therefore, the high-temperature gas entering the first heat transfer tube will be cooled due to heat exchange with the low-temperature gas in the heating-up zone, and the gas about to be discharged will be heated due to heat exchange with the high-temperature gas in the first heat transfer tube, so that the energy is fully utilized, the energy loss is reduced, and the cost is saved.

Description

Technical Field

[0001] The present invention relates to the technical field of heat exchange equipment, in particular to an integrated modular four-in-one high-efficiency heat exchanger. Background Art

[0002] A gas heat exchanger is a device used to transfer heat between gases at different temperatures. It is often applied in a refrigerated dryer to reduce the temperature of compressed air and remove the water vapor contained in the air. It is of great significance in high-precision industrial manufacturing, medical and health, food processing and other fields, and can provide clean air sources for pneumatic equipment in all walks of life, protect production equipment, extend the service life of pneumatic equipment, and improve production efficiency. This gas heat exchanger is an indispensable and important component in the post-treatment equipment of an air compressor.

[0003] There have been quite a few patents on gas heat exchangers. For example, the Chinese patent authorization announcement number CN217585382U discloses a gas cooling heat exchanger, which has a housing and further includes: an air inlet; an air outlet; a tube bundle assembly connected to the housing and located in the housing, including: finned heat exchange tubes connected to an external cooling water source; a baffle plate including: a connecting edge connected to the inner wall of the housing; an air flow edge; an air flow channel opening existing between the air flow edge and the inner wall of the housing; wherein, there are multiple baffle plates; there is a spacing distance between adjacent baffle plates, and the positions of multiple air flow channel openings are staggered; its working mode is that gas is introduced into the housing through the air inlet, and at the same time, cooling water is introduced into the water inlet cavity through the water inlet and flows in the finned heat exchange tubes. During the gas flow process, heat exchange occurs with the cooling water in the finned heat exchange tubes, so that the water vapor in the gas condenses into condensed water and condenses in the housing; the processed gas is discharged outwards through the air outlet, realizing the drying and dehydration of the gas.

[0004] However, in actual application, it is very difficult for the above heat exchanger to achieve sufficient drying of compressed gas. The cooling and dehydration efficiency of the above disclosed gas cooling heat exchanger is extremely low, and the dehydration rate is usually not higher than 30%, which obviously cannot meet the production requirements of most cases. In addition, the structure of the traditional mainstream products currently on the market is a separated structure of a precooler, a condenser, and a steam-water separator, which has the disadvantages of large volume, many consumables, low drying efficiency, and high cost; there are also a few manufacturers that use an integrated heat exchanger made of aluminum. Although it has the advantage of small volume, it has the defects of poor corrosion resistance of aluminum, short service life, easy leakage, complex product, and long production cycle. That is to say, there is still room for improvement in the prior art, and there is an urgent need to disclose a high-efficiency heat exchanger that can overcome the above defects to meet the current needs. Summary of the Invention

[0005] The present invention overcomes the drawbacks in the prior art and provides an integrated modular four-in-one high-efficiency heat exchanger, which simultaneously realizes four functions of precooling, condensation, centrifugal dehydration, and filtration dehydration. It has the effects of small volume and high separation efficiency, and reduces energy loss.

[0006] To solve the above technical problems, the present invention is realized through the following technical solutions:

[0007] The integrated modular four-in-one high-efficiency heat exchanger includes a first tube sheet, a first shell, a second tube sheet, and a second shell that are connected in sequence into one body. The first shell is located above, and the second shell is located below. The length extension directions of the first shell and the second shell are the same and their central axes coincide. An end cover is connected to the first tube sheet, and an air inlet pipe is provided on the end cover. An air outlet pipe is provided on the first shell. Between the first tube sheet and the second tube sheet, a number of first heat transfer tubes for inputting high-temperature gas are arranged around the central axis of the first shell. One end of the first heat transfer tube is in gas communication with the end cover, and the other end of the first heat transfer tube is in gas communication with the inside of the second shell. The area surrounded by the inner wall of the first heat transfer tube forms a precooling zone, and the area between the outer wall of the first heat transfer tube and the inner wall of the first shell forms a heating-up zone.

[0008] A second heat transfer tube for the flow of refrigerant is arranged in the second shell. The second heat transfer tube is integrally wound around the central axis of the second shell. A hollow tube is coaxially arranged in the second shell, and the hollow tube is connected to the second tube sheet. The area surrounded by the inner wall of the hollow tube forms a reflux zone, and the reflux zone is in gas communication with the heating-up zone. The area between the outer wall of the hollow tube and the inner wall of the second shell forms a condensation zone. A spiral guide plate is also provided in the condensation zone, and the second heat transfer tube is connected and fixed to the spiral guide plate. A spiral channel is formed by the hollow tube, the spiral guide plate, and the inner wall of the second shell. The gas transported from the first heat transfer tube to the second shell enters the spiral channel and is transported to the inlet of the hollow tube. When the gas is transported in the spiral channel, it comes into contact with the second heat transfer tube and condenses to cool down and dehydrate, and at the same time, it undergoes centrifugal movement dehydration as it flows along the spiral channel.

[0009] The high-temperature gas enters from the air inlet pipe, is precooled by heat exchange with the cooled gas in the heating-up zone when flowing through the precooling zone, then continues to flow to the condensation zone, where it exchanges heat with the second heat transfer tube through which the refrigerant flows to cool down and dehydrate, and at the same time undergoes centrifugal movement dehydration. Finally, it flows back along the hollow tube to the heating-up zone, exchanges heat with the high-temperature gas flowing in from the first heat transfer tube, warms up, and is discharged from the air outlet pipe.

[0010] Furthermore, a gas-liquid separation component is arranged at the bottom of the second shell below the hollow tube. The gas flowing out of the spiral channel passes through the gas-liquid separation component from top to bottom, is reflected by the inner wall of the bottom of the second shell, and then passes through the gas-liquid separation component from bottom to top and enters the hollow tube.

[0011] Furthermore, the inner wall of the first heat transfer tube is provided with petal-shaped fins to increase the heat transfer area of the gas inside the first heat transfer tube; the calculation formula of the heat transfer coefficient of the fluid inside the first heat transfer tube conforms to the following: , where is the heat transfer coefficient of the fluid inside the tube, and its unit is w / (㎡×℃); is the inner diameter of the first heat transfer tube, and its unit is m; is the flow velocity of the fluid inside the tube, and its unit is m / s; is the viscosity of the fluid inside the tube, and its unit is Pa×s; is the density of the fluid in the tube pass, and its unit is Kg / m 3 ; is the thermal conductivity of the fluid inside the tube, and its unit is w / (m×℃); is the specific heat at constant pressure of the fluid inside the tube, and its unit is KJ / (kg×℃); n is a constant.

[0012] Furthermore, a number of parallel fins are longitudinally and equidistantly arranged inside the first shell body. A first gas flow hole is opened in the middle of the fins. An advection channel is formed between adjacent fins. The first heat transfer tube is vertically expanded and connected to the fins; the fins are used to increase the heat transfer area of the gas; a number of concave and convex points are arranged on the fins to cause the gas to generate disturbance and turbulence, break the boundary layer, and be more conducive to heat transfer;

[0013] A first baffle plate and a second baffle plate are arranged between the fins. The first baffle plate and the second baffle plate are arranged at intervals. The first baffle plate is arranged in a circular ring shape. A second gas flow hole is opened in the middle of the first baffle plate. The second baffle plate is arranged in a circular shape. The diameter of the first baffle plate is larger than the diameter of the second baffle plate. The edge of the first baffle plate is hermetically connected to the inner wall of the first shell body. A gas flow gap is reserved between the edge of the second baffle plate and the inner wall of the first shell body, so that the gas in the heating area (B) flows in an arc shape along the advection channel, the first gas flow hole, the second gas flow hole, and the gas flow gap under the obstruction of the first baffle plate and the second baffle plate; through holes for installing the first heat transfer tube are opened on both the first baffle plate and the second baffle plate; by increasing the heat transfer area both inside and outside the tube of the first heat transfer tube, breaking the heat transfer boundary layer, and at the same time increasing the Reynolds number, the total heat transfer coefficient of the system is greatly improved. The total heat transfer coefficient K 0 and the heat exchange power Q conform to the following formula:

[0014] where S is the total heat transfer area, and the unit is ㎡; Q is the heat exchange power, and the unit is kcal / h; K 0 is the total heat transfer coefficient, and the unit is w / (㎡×℃); is the logarithmic mean temperature difference, and its unit is ℃; for the heat exchange power Q and the logarithmic mean temperature difference On the premise of remaining unchanged, the larger the overall heat transfer coefficient, the smaller the required heat exchange area; that is, the larger the overall heat transfer coefficient K 0 the more compact the product is, which is beneficial to saving space and cost.

[0015] Furthermore, the second housing is cylindrical. One side edge of the spiral guide plate is connected to the hollow tube, and the other side edge of the spiral guide plate is connected to the inner wall of the second housing to make the gas flow smoothly, eliminate the heat exchange dead angle, and reduce the air flow resistance; an inlet refrigerant pipe and an outlet refrigerant pipe are arranged on the second housing. One end of the inlet refrigerant pipe is connected to the second heat transfer pipe, and the other end of the second heat transfer pipe is connected to the outlet refrigerant pipe; thread fins are rolled on the outer wall of the second heat transfer pipe to increase the heat transfer area with the gas.

[0016] Furthermore, the gas-liquid separation component is composed of five or more layers of stainless steel filter screens stacked, and the stainless steel filter screen is more than 50 meshes to capture and separate tiny water droplets, so that the gas-liquid separation is more sufficient.

[0017] Furthermore, a drain port is arranged at the bottom of the second housing, a flow guide plate is arranged at the inner bottom end of the second housing, the flow guide plate is located below the condensation area, a hydrophobic gap is maintained between the edge of the flow guide plate and the inner wall of the second housing, and the upper surface of the flow guide plate forms an arched shape with a high middle and a low periphery.

[0018] Furthermore, the cross-sectional diameters of the first housing and the second housing are the same, the first tube sheet and the second tube sheet are of the same size and longitudinally coincide, and the horizontal projection areas of the first housing and the second housing are within the second tube sheet.

[0019] Furthermore, tube holes are arranged on both the first tube sheet and the second tube sheet, and the two ends of the first heat transfer pipe are correspondingly connected to the tube holes of the first tube sheet and the second tube sheet; the end cover is arranged in a horn expansion shape from the inlet air pipe towards the first tube sheet.

[0020] Compared with the prior art, the beneficial effects of the present invention are:

[0021] This high-efficiency heat exchanger can achieve four functions: precooling, condensation, centrifugal dehydration, and filtration dehydration. It has a combined structure, which can reduce the volume and cost, and has high separation efficiency. This modular design has fewer specifications and a universal design for large and small machines, making it easy to mass-produce. Here, the precooling area and the heating-up area are integrated in the first housing. Therefore, the high-temperature gas entering the first heat transfer tube will be cooled due to heat exchange with the low-temperature gas in the heating-up area, and the gas about to be discharged will be heated due to heat exchange with the high-temperature gas in the first heat transfer tube to meet the usage requirements, thus making full use of the energy, reducing energy loss, and saving costs. Each component of this high-efficiency heat exchanger has good corrosion resistance and sealing performance, and the product has a long service life. In addition, by using various means such as condensation, centrifugal dehydration, and filtration dehydration, the gas condensation and drying effect is good, and the water removal rate of the gas is very high. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The drawings are used to provide a further understanding of the present invention, and together with the embodiments of the present invention, they are used to explain the present invention, and do not constitute a limitation to the present invention. In the drawings:

[0023] Figure 1 is the three-dimensional view of the high-efficiency heat exchanger described in the present invention Figure 1 ;

[0024] Figure 2 is the three-dimensional view of the high-efficiency heat exchanger described in the present invention Figure 2 , with the end cover removed;

[0025] Figure 3 is the cross-sectional view of the high-efficiency heat exchanger described in the present invention;

[0026] Figure 4 is the schematic diagram of the internal structure of the high-efficiency heat exchanger described in the present invention;

[0027] Figure 5 is the enlarged view of the lower part of the internal structure of the high-efficiency heat exchanger;

[0028] Figure 6 is the schematic diagram of the upper part of the cross-sectional state of the high-efficiency heat exchanger described in the present invention;

[0029] Figure 7 is the schematic diagram of the lower part of the cross-sectional state of the high-efficiency heat exchanger described in the present invention;

[0030] Figure 8 is the schematic diagram of the first baffle and the second baffle of the high-efficiency heat exchanger described in the present invention;

[0031] Figure 9 is the schematic diagram of the structure of the fin of the high-efficiency heat exchanger described in the present invention, and the fin is provided with concave and convex points.

[0032] Figure 10 It is a schematic structural diagram of the hollow tube and the spiral guide plate of the high-efficiency heat exchanger described in the present invention;

[0033] Figure 11 It is a schematic diagram of the petal-shaped fins inside the first heat transfer tube of the high-efficiency heat exchanger described in the present invention.

[0034] In the figure: 1. First tube sheet; 101. Tube hole; 2. First shell; 3. Second tube sheet; 4. Second shell; 5. End cover; 6. Inlet gas pipe; 7. Outlet gas pipe; 8. First heat transfer tube; 9. Second heat transfer tube; 10. Hollow tube; 11. Spiral guide plate; 12. Gas-liquid separation component; 13. Fin; 1301. First gas flow hole; 14. First baffle plate; 1401. Second gas flow hole; 15. Second baffle plate; 16. Through hole; 17. Inlet refrigerant pipe; 18. Outlet refrigerant pipe; 19. Drainage port; 20. Deflector plate;

[0035] A. Pre-cooling area; B. Heating-up area; C. Return area; D. Condensation area. Specific embodiments

[0036] The following is a description of the preferred embodiments of the present invention with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention and are not used to limit the present invention.

[0037] As Figures 1 to 9 shown, the present invention claims protection for an integrated modular four-in-one high-efficiency heat exchanger. Since most of the currently available devices for gas heat exchange, such as refrigerant dryers, on the market adopt a split type to achieve air drying, which has the defects of large volume, many consumables, and high cost. Therefore, this application discloses a heat exchange device that integrates multiple functions such as pre-cooling, condensation, and gas-liquid separation, and has the advantages of small volume, high separation efficiency, reduced energy loss, and cost savings.

[0038] This integrated modular four-in-one high-efficiency heat exchanger includes a first tube sheet 1, a first shell 2, a second tube sheet 3, and a second shell 4 that are sequentially connected into one body. The first shell 2 is located above, and the second shell 4 is located below. When in use, it is placed vertically, that is, the second shell 4 is located physically below, and the first shell 2 is located physically above; the length extension directions of the first shell 2 and the second shell 4 are the same and the central axes coincide, making the structure compact and regular.

[0039] A first tube sheet 1 is connected with an end cover 5, and an air inlet pipe 6 is arranged on the end cover 5; an air outlet pipe 7 is arranged on a first housing 2; a plurality of first heat transfer tubes 8 for inputting high-temperature gas are arranged between the first tube sheet 1 and a second tube sheet 3 and are distributed around the central axis of the first housing 2. One end of each first heat transfer tube 8 is in gas communication with the end cover 5, and the other end of each first heat transfer tube 8 is in gas communication with the inside of a second housing 4; specifically, tube holes 101 are arranged on both the first tube sheet 1 and the second tube sheet 3, and two ends of each first heat transfer tube 8 are correspondingly connected to the tube holes 101 on the first tube sheet 1 and the second tube sheet 3. The first heat transfer tubes 8 can be fixedly connected to the tube holes 101 through an expanding tube process; the high-temperature compressed gas enters the end cover 5 through the air inlet pipe 6 and flows into the first heat transfer tubes 8.

[0040] Combined Figure 1 with Figure 6 it can be seen that the end cover 5 is arranged in a horn-expanded shape from the air inlet pipe 6 towards the first tube sheet 1, and the inner wall of the end cover 5 is also in a horn-expanded shape. This design not only helps the gas entering from the air inlet pipe 6 to diverge and flow into each first heat transfer tube 8, but also helps to strengthen the smooth flow of the gas, avoid the existence of heat exchange dead corners, and reduce the air flow resistance.

[0041] A second heat transfer tube 9 for allowing a refrigerant to flow is arranged in the second housing 4. The second heat transfer tube 9 is integrally wound around the central axis of the second housing 4. The integral winding shape helps to lengthen the length of the second heat transfer tube 9 in the second housing 4, that is, increases the heat exchange area between the second heat transfer tube 9 and the gas, and improves the heat exchange effect; an inlet refrigerant pipe 17 and an outlet refrigerant pipe 18 are arranged on the second housing 4. One end of the inlet refrigerant pipe 17 is connected to the second heat transfer tube 9, and the other end of the second heat transfer tube 9 is connected to the outlet refrigerant pipe 18; in this embodiment, the refrigerant mainly uses Freon, and the second heat transfer tube 9 allows Freon to flow. The gas enters the second housing 4 from the first heat transfer tube 8 and condenses when coming into contact with the second heat transfer tube 9, so that the gas is cooled and dehydrated. Threaded fins are rolled on the outer wall of the second heat transfer tube 9 to increase the heat transfer area with the gas and improve the heat exchange effect; in this condensation, the gas is cooled below the dew point, so as to release the moisture in the gas.

[0042] Through actual verification, rolling threaded fins on the outer wall of the second heat transfer tube 9 can make the heat transfer area reach more than 2.6 times that of a smooth tube, and also increase the heat transfer area by more than 18% compared with a traditional copper threaded fin tube under the same conditions.

[0043] A hollow tube 10 is coaxially arranged inside the second housing 4, and the hollow tube 10 is connected to the second tube sheet 3; it is set that the region surrounded by the inner wall of the first heat transfer tube 8 forms a pre-cooling zone A, and the region between the outer wall of the first heat transfer tube 8 and the inner wall of the first housing 2 forms a temperature-rising zone B; the region surrounded by the inner wall of the hollow tube 10 forms a reflux zone C, and the region between the outer wall of the hollow tube 10 and the inner wall of the second housing 4 forms a condensation zone D. The reflux zone C is in gas communication with the temperature-rising zone B. In this heat exchanger, the gas flow path is the pre-cooling zone A, the temperature-rising zone B, the condensation zone D, and the reflux zone C; a spiral guide plate 11 is also arranged in the condensation zone D, and the second heat transfer tube 9 is fixedly connected to the spiral guide plate 11.

[0044] The functions of the spiral guide plate 11 are at least in the following two aspects: First, the spiral guide plate 11 and the inner walls of the hollow tube 10 and the second housing 4 surround and form a spiral channel, so that the gas transported from the first heat transfer tube 8 to the second housing 4 enters the spiral channel and is transported to the entrance of the hollow tube 10. On the one hand, when the gas is transported in the spiral channel, it comes into contact with the second heat transfer tube 9 and condenses to cool down and dehydrate, and at the same time, it undergoes centrifugal motion dehydration while flowing along the spiral channel, that is, it already has two dehydration functions during the flow through the spiral channel. Second, through holes are provided on the spiral guide plate 11 for the installation of the second heat transfer tube 9, that is, the spiral guide plate 11 has a certain fixing effect on the second heat transfer tube 9, enhancing the structural stability.

[0045] In this embodiment, the second housing 4 is cylindrical. One side edge of the spiral guide plate 11 is connected to the hollow tube 10, and the other side edge of the spiral guide plate 11 is connected to the inner wall of the second housing 4. The structure is compact, that is, the formed spiral channel has a very high sealing performance, so that the gas can only flow along the spiral channel. The second housing 4 is designed to be cylindrical, and its inner wall is also cylindrical and quite smooth, that is, the gas will not encounter the blockage of corners and step positions during the flow, so that the gas can flow smoothly, eliminating heat exchange dead corners and reducing air flow resistance.

[0046] The heat exchange process of the gas is as follows: The high-temperature gas enters from the inlet pipe 6, exchanges heat with the cooled gas in the temperature-rising zone B when flowing through the pre-cooling zone A and is pre-cooled, and then continues to flow to the condensation zone D, exchanges heat with the second heat transfer tube 9 through which the refrigerant passes and cools down and dehydrates, and at the same time undergoes centrifugal motion dehydration. Finally, it flows back along the hollow tube 10 to the temperature-rising zone B, exchanges heat with the high-temperature gas flowing in from the first heat transfer tube 8, is heated up, and is discharged from the outlet pipe 7.

[0047] In this embodiment, in order to enhance the dehydration effect, a gas-liquid separation component 12 is arranged at the bottom inside the second housing 4 below the hollow tube 10. The gas flowing out of the spiral channel passes through the gas-liquid separation component 12 from top to bottom, is reflected by the inner wall of the bottom of the second housing 4, and then passes through the gas-liquid separation component 12 from bottom to top and enters the hollow tube 10.

[0048] The spiral guide plate 11 makes the gas follow a spiral path, achieving preliminary gas-water separation; it can eliminate heat transfer dead zones, making heat transfer more sufficient; and reduce air flow resistance.

[0049] In actual experiments, under the premise of the same heat transfer effect, using a spiral guide baffle can save more than 22% of the heat transfer area compared to a common bow-type baffle. That is to say, the structure of the spiral guide plate 11 is more material-saving.

[0050] By rolling threaded fins on the outer wall of the second heat transfer tube 9 and using the spiral guide plate 11, not only the heat transfer area is increased, but also through structural optimization, the fluid resistance is reduced, gas-water separation is achieved, the total heat transfer coefficient between the refrigerant and the compressed gas is increased, the product volume is reduced, and the product cost is lowered.

[0051] A drain port 19 is provided at the bottom of the second housing 4, and the drain port 19 is connected to a drain valve, which only discharges water and does not release gas. Therefore, the gas flowing out from the spiral channel will only be conveyed along the hollow tube 10 to the heating zone B.

[0052] In practical applications, the temperature of the high-temperature gas entering from the inlet pipe 6 is generally 90 - 100 °C, and the temperature of the dehydrated gas we finally need is 50 - 60 °C. However, the gas after pre-cooling and condensation may be at 10 - 20 °C. Therefore, in this heat exchanger, the condensed and dehydrated gas is refluxed through the hollow tube 10 to the heating zone B, where it exchanges heat with the high-temperature gas flowing in from the first heat transfer tube 8 and then is discharged from the outlet pipe 7 after being heated; while the high-temperature gas in the first heat transfer tube 8 will be preliminarily cooled due to heat exchange with the low-temperature gas in the heating zone B. That is to say, the high-temperature gas and the low-temperature gas each take what they need, enabling the energy to be fully utilized, reducing energy loss, and saving costs.

[0053] In this embodiment, petal-shaped fins are provided on the inner wall of the first heat transfer tube 8 to increase the heat transfer area of the gas inside the first heat transfer tube 8; the calculation formula for the fluid heat transfer coefficient inside the first heat transfer tube 8 is as follows:

[0054] Among them, is the fluid heat transfer coefficient inside the tube, and its unit is w / (㎡×°C); is the inner diameter of the first heat transfer tube, and its unit is m; is the flow velocity of the fluid inside the tube, and its unit is m / s; is the viscosity of the fluid inside the tube, and its unit is Pa×s; is the density of the fluid in the tube pass, and its unit is Kg / m 3 ; is the thermal conductivity of the fluid inside the tube, and its unit is w / (m×°C); is the specific heat at constant pressure of the fluid inside the tube, and its unit is KJ / (kg×°C); n is a constant.

[0055] Through research by the inventor, petal-shaped fins are provided on the inner wall of the first heat transfer tube 8, and the heat transfer area of the gas in the first heat transfer tube 8 is increased by more than 1.5 times compared to that of a smooth tube.

[0056] As Figure 6 shown, a number of parallel fins 13 are longitudinally and equidistantly arranged in the first housing 2. A first gas flow hole 1301 is provided in the middle of the fin 13, and a laminar flow channel is formed between adjacent fins 13. The first heat transfer tube 8 is vertically expanded and connected to the fin 13; that is, the high-temperature gas introduced into the first heat transfer tube 8 will transfer the temperature to the fin 13 and dissipate it, and the fin 13 increases the heat transfer area of the gas; in addition, a number of concave and convex points are provided on the fin 13 to cause the gas to generate disturbance and turbulence, break the boundary layer, and be more conducive to heat transfer; the first heat transfer tube 8 adds concave and convex points to the fin 13, so that the heat transfer area of the fin 13 can reach more than 5 times that of a smooth tube; the heat transfer area of the fin 13 can reach more than 2.5 times that of a traditional threaded tube area.

[0057] In this embodiment, a first baffle 14 and a second baffle 15 are provided between the fins 13. The first baffle 14 and the second baffle 15 are arranged at intervals. The first baffle 14 is arranged in a circular ring shape, and a second gas flow hole 1401 is provided in the middle of the first baffle 14. The second baffle 15 is arranged in a circular shape. The diameter of the first baffle 14 is larger than the diameter of the second baffle 15. The edge of the first baffle 14 is hermetically connected to the inner wall of the first housing 2, and a gas flow gap is reserved between the edge of the second baffle 15 and the inner wall of the first housing 2. That is, during the flow of the gas in the heating zone B, it can only flow through the first gas flow hole 1301, the second gas flow hole 1401, the gas flow gap, and the laminar flow channel between adjacent fins 13, so that the gas in the heating zone B flows in an arc shape along the laminar flow channel, the first gas flow hole 1301, the second gas flow hole 1401, and the gas flow gap under the blockage of the first baffle 14 and the second baffle 15, which helps to extend the flow path and enhance the contact area with the fin 13 during the flow; plus from Figure 6 it can be seen that the fins 13 are arranged in parallel, that is, the gas flows horizontally in the laminar flow channel, so that the gas can flow as long a path as possible in a limited height space, and the heat exchange efficiency is high; in other words, this structure helps to reduce the height of the first housing 2, making the overall structure small and compact, and saving the manufacturing cost.

[0058] Through holes 16 for installing the first heat transfer tube 8 are provided on both the first baffle 14 and the second baffle 15. That is, the setting of the first baffle 14 and the second baffle 15 also helps to enhance the fixing effect on the first heat transfer tube 8.

[0059] By increasing the heat transfer area both inside and outside the first heat transfer tube 8, the heat transfer boundary layer is disrupted, and at the same time, the Reynolds number is increased, thus greatly improving the overall heat transfer coefficient of the system. The overall heat transfer coefficient K 0 and the heat exchange power Q conform to the following formula: where S is the total heat transfer area in ㎡; Q is the heat exchange power in kcal / h; K 0 is the overall heat transfer coefficient in w / (㎡×℃); is the logarithmic mean temperature difference in ℃; on the premise that the heat exchange power Q and the logarithmic mean temperature difference remain unchanged, the larger the overall heat transfer coefficient, the smaller the required heat transfer area; that is, the larger the overall heat transfer coefficient K 0 is, the more compact the product is, which is beneficial to saving space and cost.

[0060] In this embodiment, the gas-liquid separation component 12 is composed of five or more layers of stainless steel filter screens stacked together, and the stainless steel filter screen is above 50 meshes to capture and separate tiny water droplets, so that the gas-liquid separation is more sufficient.

[0061] The gas-liquid separation component 12 is closely attached to the lower end opening of the hollow tube 10, so that the gas flowing out of the spiral channel can pass downward through the gas-liquid separation component 12, be reflected by the bottom of the second housing 4 and then pass upward through the gas-liquid separation component 12 into the hollow tube 10. The gas can be filtered twice, which is more conducive to removing water droplets.

[0062] In this embodiment, in the condensation zone D, through condensation and centrifugal gas-liquid separation, the water is first roughly separated with relatively high efficiency; then, through the gas-liquid separation component 12 which uses multiple layers of filter screens for physical gas-liquid separation, tiny water droplets can be captured and separated, so that the gas-liquid separation is more sufficient.

[0063] The present invention adopts a structure combining centrifugal and filter screen type gas-liquid separation, which helps to improve the water removal rate and can meet the occasions with relatively high requirements for the purity of compressed air.

[0064] A drain port 19 is provided at the bottom of the second housing 4, and a flow guide plate 20 is provided at the inner bottom end of the second housing 4. The flow guide plate 20 is located below the condensation zone D, and there is a hydrophobic gap between the edge of the flow guide plate 20 and the inner wall of the second housing 4. Since water droplets will be generated when the low-temperature second heat transfer tube 9 exchanges heat with the gas in the condensation zone D, when the water droplets drip onto the flow guide plate 20, they will finally flow down along the hydrophobic gap around the flow guide plate 20 into the drain port 19; in this embodiment, the upper surface of the flow guide plate 20 is formed with a raised shape that is high in the middle and low around, which helps the water droplets dripping onto the flow guide plate 20 to slide around and will not form water accumulation.

[0065] In this embodiment, the cross-sectional diameters of the first housing 2 and the second housing 4 are the same. The first tube sheet 1 and the second tube sheet 3 are of the same size and longitudinally coincident. Moreover, the horizontal projection areas of the first housing 2 and the second housing 4 are within the second tube sheet 3, that is, the area of the second tube sheet 3 is larger than the cross-sectional areas of the first housing 2 and the second housing 4, which helps the edges of the first housing 2 and the second housing 4 to be hermetically connected to the first tube sheet 1 and the second tube sheet 3 respectively.

[0066] The present invention provides an integrated modular four-in-one high-efficiency heat exchanger that can perform four functions of pre-cooling, condensation, centrifugal dehydration, and filtration dehydration on high-temperature gases, and has the effects of small volume and high separation efficiency. Here, the pre-cooling zone A and the heating-up zone B are integrated in the first housing 2. Therefore, the high-temperature gas entering the first heat transfer tube 8 will be cooled due to heat exchange with the low-temperature gas in the heating-up zone B, and the gas about to be discharged will be heated due to heat exchange with the high-temperature gas in the first heat transfer tube 8 to meet the usage requirements, so that the energy is fully utilized, the energy loss is reduced, and the cost is saved.

[0067] Finally, it should be noted that the above are only the preferred embodiments of the present invention and are not used to limit the present invention. Although the present invention has been described in detail with reference to the embodiments, for those skilled in the art, they can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements on some of the technical features. However, any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. Integrated modular four-in-one high-efficiency heat exchanger, characterized by: The invention comprises a first tube sheet (1), a first shell (2), a second tube sheet (3) and a second shell (4) which are connected in sequence and integrated into one body, the first shell (2) being located at the top and the second shell (4) being located at the bottom, the length extension direction of the first shell (2) and the second shell (4) being the same and the central axis thereof coinciding with each other; an end cover (5) being connected to the first tube sheet (1), an air inlet pipe (6) being arranged on the end cover (5); an air outlet pipe (7) being arranged on the first shell (2); a plurality of first heat transfer tubes (8) for inputting high-temperature gas being arranged and distributed around the central axis of the first shell (2) being arranged between the first tube sheet (1) and the second tube sheet (3), one end of the first heat transfer tube (8) being in gas communication with the end cover (5), and the other end of the first heat transfer tube (8) being in gas communication with the inside of the second shell (4); an area surrounded by the inner wall of the first heat transfer tube (8) forming a pre-cooling area (A), and an area between the outer wall of the first heat transfer tube (8) and the inner wall of the first shell (2) forming a temperature rising area (B); A second heat transfer tube (9) for the flow of refrigerant is arranged in the second shell (4), and the second heat transfer tube (9) is arranged in an integral winding shape around the central axis of the second shell (4); a hollow tube (10) is coaxially arranged in the second shell (4), and the hollow tube (10) is connected to the second tube sheet (3); the area surrounded by the inner wall of the hollow tube (10) forms a reflux zone (C), the reflux zone (C) is gas-connected to the temperature rising zone (B), and the area between the outer wall of the hollow tube (10) and the inner wall of the second shell (4) forms a condensation zone (D). The condensation zone (D) is further provided with a spiral guide plate (11), and the second heat transfer tube (9) is connected and fixed to the spiral guide plate (11); the hollow tube (10), the spiral guide plate (11) and the inner wall of the second shell (4) surround and form a spiral channel, and the gas transported from the first heat transfer tube (8) to the second shell (4) enters the spiral channel and is transported to the entrance of the hollow tube (10). When the gas is transported in the spiral channel, it contacts the second heat transfer tube (9) and condenses to reduce temperature and dehydrate, and at the same time flows along the spiral channel to cause centrifugal movement and dehydration; The high-temperature gas enters from the air inlet pipe (6), and when flowing through the pre-cooling zone (A), it exchanges heat with the gas cooled in the heating zone (B) to be pre-cooled. Then, when continuing to flow to the condensation zone (D), it exchanges heat with the second heat transfer tube (9) through which the refrigerant passes to be cooled and dehydrated. At the same time, centrifugal movement and dehydration occur. Finally, it flows back to the heating zone (B) along the hollow tube (10), exchanges heat with the high-temperature gas flowing in from the first heat transfer tube (8), and is heated before being discharged from the air outlet pipe (7).

2. The integrated modular four-in-one high-efficiency heat exchanger according to claim 1 is characterized in that: A gas-water separation component (12) is provided at the bottom of the second shell (4) below the hollow tube (10); the gas flowing out of the spiral channel passes through the gas-water separation component (12) from top to bottom, is reflected by the inner wall of the bottom of the second shell (4), and then passes through the gas-water separation component (12) from bottom to top into the hollow tube (10).

3. The integrated modular four-in-one high-efficiency heat exchanger according to claim 1 is characterized in that: The inner wall of the first heat transfer tube (8) is provided with petal-shaped fins to increase the heat transfer area of ​​the gas in the first heat transfer tube (8); the calculation formula of the heat transfer coefficient of the fluid in the first heat transfer tube (8) conforms to the following: in, is the heat transfer coefficient of the fluid in the tube, and its unit is w / (㎡×℃); is the inner diameter of the first heat transfer tube, in m; is the flow rate of the fluid in the pipe, and its unit is m / s; is the viscosity of the fluid in the tube, its unit is Pa×s; is the density of the fluid in the tube, and its unit is Kg / m 3 ; is the thermal conductivity of the fluid in the tube, and its unit is w / (m×℃); It is the constant-pressure specific heat of the fluid in the tube, and its unit is KJ / (kg×℃); n is a constant.

4. The integrated modular four-in-one high-efficiency heat exchanger according to claim 3 is characterized in that: A plurality of fins (13) are longitudinally and equidistantly arranged in parallel in the first shell (2); a first gas flow hole (1301) is provided in the middle of the fin (13); a horizontal flow channel is formed between adjacent fins (13); and the first heat transfer tube (8) is vertically expanded on the fin (13); the fin (13) is used to increase the heat transfer area of ​​the gas; a plurality of concave and convex points are provided on the fin (13) to cause disturbance and turbulence of the gas, destroy the boundary layer, and be more conducive to heat transfer; a first deflection baffle (14) and a second deflection baffle (15) are provided between the fins (13); the first deflection baffle (14) and the second deflection baffle (15) are arranged at intervals; the first deflection baffle (14) is arranged in a circular shape; a second gas flow hole (1401) is provided in the middle of the first deflection baffle (14); the second deflection baffle (15) is arranged in a circular shape; the straightness of the first deflection baffle (14) is 1 / 4 of the length of the first deflection baffle (14); and the second deflection baffle (15) is arranged in a circular shape. The diameter of the first baffle plate (14) is larger than the diameter of the second baffle plate (15); the edge of the first baffle plate (14) is sealedly connected to the inner wall of the first shell (2); a gas flow gap is reserved between the edge of the second baffle plate (15) and the inner wall of the first shell (2), so that the gas in the temperature rise zone (B) flows in an arcuate shape along the horizontal flow channel, the first gas flow hole (1301), the second gas flow hole (1401), and the gas flow gap under the obstruction of the first baffle plate (14) and the second baffle plate (15); the first baffle plate (14) and the second baffle plate (15) are both provided with a through hole (16) for installing the first heat transfer tube (8); by increasing the heat transfer area inside and outside the first heat transfer tube (8), the heat transfer boundary layer is destroyed, and the Reynolds number is increased, thereby improving the total heat transfer coefficient of the system, and the total heat transfer coefficient K0 and the heat exchange power Q meet the following formula: Among them, S is the total heat transfer area, unit is ㎡; Q is the heat transfer power, unit is kcal / h; K0 is the total heat transfer coefficient, unit is w / (㎡×℃); is the logarithmic mean temperature difference, its unit is ℃; in the heat transfer power Q and logarithmic mean temperature difference Under the premise of unchanged, the greater the total heat transfer coefficient, the smaller the required heat exchange area.

5. The integrated modular four-in-one high-efficiency heat exchanger according to claim 2 is characterized in that: The second shell (4) is cylindrical, one side edge of the spiral guide plate (11) is connected to the hollow tube (10), and the other side edge of the spiral guide plate (11) is connected to the inner wall of the second shell (4); the second shell (4) is provided with a refrigerant inlet pipe (17) and a refrigerant outlet pipe (18), one end of the refrigerant inlet pipe (17) is connected to the second heat transfer pipe (9), and the other end of the second heat transfer pipe (9) is connected to the refrigerant outlet pipe (18); the outer wall of the second heat transfer pipe (9) is rolled with threaded fins.

6. The integrated modular four-in-one high-efficiency heat exchanger according to claim 5 is characterized in that: The gas-water separation component (12) comprises more than five layers of stainless steel filter screens stacked together, and the stainless steel filter screens are usually larger than 50 meshes.

7. The integrated modular four-in-one high-efficiency heat exchanger according to claim 1 is characterized in that: The bottom of the second shell (4) is provided with a drainage port (19), and the inner bottom end of the second shell (4) is provided with a guide plate (20), the guide plate (20) being located below the condensation zone (D), a hydrophobic gap being maintained between the edge of the guide plate (20) and the inner wall of the second shell (4), and the upper surface of the guide plate (20) is formed into an arched shape with a high middle portion and low surrounding portions to facilitate drainage.

8. The integrated modular four-in-one high-efficiency heat exchanger according to claim 1 is characterized in that: The cross-sectional diameters of the first shell (2) and the second shell (4) are the same, and the first tube sheet (1) and the second tube sheet (3) are the same in size and overlap in the longitudinal direction.

9. The integrated modular four-in-one high-efficiency heat exchanger according to claim 8, characterized in that: The first tube sheet (1) and the second tube sheet (3) are both provided with tube holes (101), and the two ends of the first heat transfer tube (8) are correspondingly connected to the tube holes (101) of the first tube sheet (1) and the second tube sheet (3); the end cover (5) is arranged in a trumpet expansion shape from the air inlet pipe (6) toward the first tube sheet (1).

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