High-efficiency condenser pipe with micro-embossed surface

Abstract

The invention discloses a micro-embossed surface efficient condenser pipe which comprises a base pipe and a micro-embossed surface layer arranged on the outer surface of the base pipe, the micro-embossed surface layer is composed of aluminum, nickel and chromium ternary alloy, coating thermal resistance is reduced through attachment of a special sintering process, the heat exchange pipe is suitable for the working condition of condensation outside the pipe, a vapor state medium outside the pipe makes contact with the micro-embossed surface to form a liquid film, and the condensation effect is good. Due to surface tension difference, the liquid film gathers towards the relief root to form condensate and drops, the liquid film at the relief upheaval part is thin, the thermal resistance is small, and the steam is also concentrated towards the root after being quickly cooled into condensate. The specific surface area of the micro-embossed surface layer is large, the heat exchange area of unit volume is increased, and the condensation strengthening effect is 1-2 times that of a common light pipe. The heat exchange tube can be used for various base tubes, can adapt to the low-temperature working condition, is excellent in heat conduction and corrosion resistance, and can optimize the performance by adjusting the alloy particle size and proportion.

Description

Technical Field

[0001] This invention relates to the field of condenser tube technology, and in particular to a high-efficiency condenser tube with a micro-convex surface. Background Technology

[0002] Currently, the heat exchange tubes in condensers widely used in chemical process technology are either smooth tubes or three-dimensional finned surface tubes obtained through machining. Smooth tubes have low heat exchange efficiency and high system energy consumption; while three-dimensional finned surface high-efficiency condenser tubes obtained through machining suffer mechanical damage to the surface, making them difficult to use in low-temperature conditions. Therefore, we have developed a micro-protruding surface high-efficiency condenser tube. Summary of the Invention

[0003] The purpose of this application is to provide a high-efficiency condenser tube with a micro-convex surface to solve the problems mentioned in the background art.

[0004] To achieve the above objectives, this application provides the following technical solution: a high-efficiency condenser tube with a micro-protruding surface, comprising a base tube and a micro-protruding surface layer disposed on the outer surface of the base tube; The base tube is a tubular structure used for transporting cryogenic media; The micro-protrusion surface layer is composed of a ternary alloy of aluminum, nickel, and chromium, and is attached to the outer surface of the base tube through a fusion bonding process; the fusion bonding process enables the fusion metallographic phase in the micro-protrusion surface layer to effectively connect the aluminum-based particles together. The high-efficiency condenser tube with a micro-floating convex surface is suitable for external condensation conditions. The high-temperature gaseous medium outside the tube comes into contact with the micro-floating convex surface layer to form a condensate film. The tension distribution of the condensate film on the micro-floating convex surface layer is uneven. The surface tension at the root of the micro-floating convex surface is greater than that at the top, which causes the liquid film to be pulled towards the root of the micro-floating convex surface to accumulate and form condensate. The condensate is collected through the channels in the concave part of the micro-floating convex surface layer to the lower part of the tube and drips down.

[0005] Preferably, the micro-protrusion surface layer is prepared using thermal spraying technology.

[0006] Preferably, the micro-protruding surface layer and the base tube surface are bonded by a combination of micro-metallurgy and mechanical bonding. During the micro-metallurgical bonding process, high temperature causes the atoms of the micro-protruding surface layer and the base tube surface to diffuse into each other to form a metallurgical bonding layer. At the same time, the mechanical bonding is achieved through the micro-mechanical interlocking of the micro-protruding surface layer and the base tube surface.

[0007] Preferably, the base tube is made of materials including but not limited to carbon steel, stainless steel, and copper alloy.

[0008] Preferably, by adjusting the particle size of each phase in the aluminum-nickel-chromium ternary alloy, the shape, height, and distribution density of the micro-protrusions are changed to obtain the optimal surface protrusion structure and achieve the maximum condensation strengthening effect.

[0009] Preferably, by adjusting the proportions of each phase in the ternary alloy of aluminum, nickel, and chromium, the physical and chemical properties of the micro-protrusion surface layer are optimized to obtain the best surface layer adhesion.

[0010] Preferably, the average geometric dimension of the micro-protrusion surface is 100 micrometers.

[0011] Preferably, the micro-protruding surface high-efficiency condenser tube is manufactured using additive manufacturing technology, forming the micro-protruding surface layer by depositing materials layer by layer.

[0012] In summary, the technical effects and advantages of this invention are as follows: High-efficiency heat exchange level Significantly improved condensation efficiency: Through its unique micro-protruding surface structure, when the gaseous medium outside the tube contacts the surface, the uneven distribution of liquid film tension causes the liquid film to accumulate at the root of the protrusion, forming condensate and dripping down. Furthermore, the liquid film is thin and has low thermal resistance at the protrusions, allowing steam to cool rapidly into condensate. Simultaneously, the large specific surface area of ​​the micro-protruding surface increases the heat transfer area per unit volume, enhancing heat exchange between the media inside and outside the tube. These combined factors result in a condensation enhancement effect 1-2 times that of ordinary smooth tubes, effectively improving heat exchange efficiency, meeting the demands for high-efficiency heat exchange in industrial production, and thus effectively reducing system energy consumption and achieving energy-saving goals.

[0013] Scope of application Multiple base tube applicability: Micro-protrusion surface layers can be prepared on the surface of various base tubes, which means that the technology is not limited by the material and type of base tube and can be widely used in different industrial scenarios and equipment, providing more choices and flexibility for industrial production.

[0014] Low-Temperature Availability: Utilizing a special manufacturing process, the base tube surface is not mechanically damaged, and its mechanical properties are not altered, making it suitable for various low-temperature conditions. This overcomes the limitation of traditionally machined three-dimensional ribbed surface tubes being unsuitable for low-temperature applications, expanding the application range of heat exchange tubes and effectively solving the problem of condensation heat exchange in low-temperature environments.

[0015] Superior performance Excellent thermal conductivity: The micro-protrusion layer on the surface is made of an aluminum-based nickel-chromium ternary alloy. This alloy material has significantly better thermal conductivity than the three-dimensional rhomboid fins formed by ordinary machining. This excellent thermal conductivity facilitates rapid heat transfer, further improving the heat exchange efficiency of the heat exchange tube and ensuring effective heat exchange during industrial production.

[0016] Exceptional corrosion resistance: The micro-convex surface layer of the aluminum-based nickel-chromium ternary alloy exhibits significantly superior corrosion resistance compared to ordinary carbon steel three-dimensional diamond-shaped finned condenser tubes. In industrial fields with severe corrosive environments, such as chemical plants, this excellent corrosion resistance effectively extends the service life of heat exchange tubes, reduces equipment replacement frequency and maintenance costs, and improves the stability and economy of industrial production.

[0017] Adjustability level Structural optimization and adjustment: By adjusting the particle size of each phase in the aluminum-based nickel-chromium alloy, the optimal surface convex structure can be obtained. Different particle sizes affect the microstructure and performance of the micro-convex surface, allowing for precise adjustment of the surface structure according to specific industrial needs and operating conditions. This achieves maximum condensation enhancement and enables customized, high-efficiency heat exchange solutions.

[0018] Optimization and adjustment of adhesion: By adjusting the proportions of the aluminum-based nickel-chromium phases, the optimal adhesion of the surface layer can be obtained. Appropriate adhesion ensures the stability of the coating during long-term use, prevents coating peeling or damage, ensures the stable and reliable performance of the heat exchange tube, and provides a guarantee for the continuous operation of industrial production. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a schematic diagram of the structure of the high-efficiency condenser tube with a slightly raised surface in the embodiments of this application; Figure 2 The high-efficiency condenser tube with a micro-protruding surface in the embodiments of this application Figure 1 Enlarged structural diagram at point A.

[0021] In the diagram: 1. Base tube; 2. Micro-protruding surface layer; 3. Basic metal particles; 4. Welded metal particles. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] In the description of this disclosure, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," "outer," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this disclosure and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this disclosure. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0024] It should also be noted that all standard parts used in this application are commercially available, and can be custom-made according to the description and drawings. Unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to fixed connections, detachable connections, or integral connections; they can refer to mechanical connections or electrical connections; they can refer to direct connections or indirect connections through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this disclosure based on the specific circumstances, and unless explicitly limited, machinery, parts, and equipment can all adopt conventional models in the prior art.

[0025] In this document, the term "comprising" is intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitation, an element defined by the phrase "comprising..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0026] Example: The high-efficiency condenser heat exchanger tube with a micro-floating convex surface of the present invention consists of the following parts: Base tube 1: As the basic structure of the heat exchange tube, a heat exchange tube with a normal wall thickness can be used, without the need to use a special specification base tube with a thicker wall.

[0027] Micro-protrusion surface layer 2: A micro-protrusion surface layer 2 is formed on the outer surface of the base tube 1 through a special fusion bonding process. The micro-protrusion surface layer 2 consists of basic metal particles 3 and fused metal particles 4 covering the outside of them. This surface layer has the following characteristics: Material composition: The surface raised layer is a ternary alloy of aluminum, nickel and chromium.

[0028] Structural characteristics: The fusion metallographic structure in the coating effectively connects the aluminum-based particles together, while effectively reducing the porosity in the coating and lowering the thermal resistance of the coating.

[0029] Performance advantages: Its thermal conductivity is far superior to that of three-dimensional rhomboid fins formed by ordinary machining; its corrosion resistance is far superior to that of ordinary carbon steel three-dimensional rhomboid fin condenser tubes.

[0030] Working principle This tube type is suitable for external condensation applications, where the high-temperature medium outside the tube transfers heat to the low-temperature medium inside the tube through condensation, or the low-temperature medium inside the tube absorbs heat from the vapor outside the tube, thus condensing the vapor. When the gaseous medium outside the tube comes into contact with the slightly raised surface, a condensate film forms. The surface tension distribution of the liquid film on the raised surface is uneven, with higher surface tension at the root and lower surface tension at the top. This causes the liquid film to be pulled towards the root of the raised surface, where it accumulates and forms condensate. The condensate then collects through the grooves in the surface depressions and drips down the bottom of the tube. Because the liquid film on the raised surface is very thin, the thermal resistance at this location is very low, and the vapor in contact with it is rapidly cooled, forming condensate. This condensate then concentrates towards the root of the raised surface under the action of surface tension, condenses, and collects through the surface grooves, dripping down the bottom of the tube. This process repeats, making the condensation effect of the tube significantly higher than that of a regular smooth tube. In addition, since the specific surface area of ​​the micro-protruding surface is higher than that of ordinary bare tubes, the heat transfer area per unit volume is higher than that of ordinary bare tubes, and the heat transfer between the medium inside and outside the tube is further enhanced, thereby further improving the condensation effect.

[0031] Structural features Unique manufacturing process: The micro-protruding surface is prepared using thermal spraying technology, which is unique and advanced.

[0032] Excellent bonding: The micro-protrusion surface layer and the base tube surface are bonded by micro-metallurgy and mechanical means, which does not have any negative impact on the mechanical properties of the base material.

[0033] High applicability: It can prepare micro-protrusion surface layers on the surface of various base tubes; it does not cause mechanical damage to the base tube surface, does not change the mechanical properties of the base tube, and can be used in various low-temperature working conditions.

[0034] Adjustability: By adjusting the particle size of each phase of the aluminum-based nickel-chromium alloy, the optimal surface texture structure can be obtained, thereby achieving the maximum condensation strengthening effect; by adjusting the proportion of each phase of the aluminum-based nickel-chromium alloy, the optimal surface layer adhesion can be obtained, thereby ensuring the stability of the coating operation.

[0035] Significant enhancement effect: The micro-protrusion structure of the surface results in more condensation units per unit surface, which enhances the condensation effect more significantly; the average geometric size of the micro-protrusion surface is about 100 micrometers; the condensation enhancement effect of the micro-protrusion surface prepared by this process is significant, which is 1 to 2 times that of ordinary optical tubes.

[0036] Advanced manufacturing technology: The micro-convex surface heat exchange tube adopts additive manufacturing technology, and the base tube uses a heat exchange tube with a normal wall thickness, eliminating the need for a special specification base tube with a thicker wall.

[0037] Implementation method: Preparation of micro-protrusion surface layer A micro-protrusion surface layer 2 is prepared on the outer surface of the base tube 1 using thermal spraying technology. The specific steps are as follows: Base tube pretreatment: The surface of the base tube 1 is cleaned and pretreated to remove oil, impurities and other contaminants to ensure good bonding between the micro-protrusion surface layer 2 and the base tube 1.

[0038] Material preparation: Prepare ternary alloy powders of aluminum, nickel, and chromium, and adjust the particle size and proportion of each phase according to the required performance and structural requirements.

[0039] Thermal spraying operation: Ternary alloy powder is uniformly sprayed onto the outer surface of the base tube 1 using thermal spraying equipment, and then fused to the base tube surface at high temperature to form a micro-protrusion surface layer 2. During the spraying process, process parameters such as temperature and spraying speed are carefully controlled to ensure the quality and performance of the micro-protrusion surface layer 2.

[0040] Performance testing and optimization After preparation, the performance of the high-efficiency condenser heat exchanger tube with the micro-protruding surface was tested, including condensation heat transfer efficiency, thermal conductivity, and corrosion resistance. Based on the test results, the particle size and proportion of each phase of the aluminum-based nickel-chromium alloy were further adjusted to obtain the optimal surface protrusion structure and surface layer adhesion, thereby achieving the maximum condensation strengthening effect and coating stability.

[0041] Application Cases The high-efficiency condensing heat exchange tube with a micro-floating convex surface of the present invention can be widely used in condensers in the petroleum, chemical and other fields. For example, in the condensing system of a chemical enterprise, the heat exchange tube of the present invention was used to replace the original ordinary bare tube. After actual operation testing, the condensing efficiency was increased by about 1.5 times, the system energy consumption was significantly reduced, and the corrosion resistance of the heat exchange tube was also significantly improved, extending the service life of the equipment and achieving good economic and social benefits.

[0042] Finally, it should be noted that the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-efficiency condenser tube with a micro-convex surface, characterized in that: Includes a base tube and a micro-protrusion surface layer disposed on the outer surface of the base tube; The base tube is a tubular structure used for transporting cryogenic media; The micro-protrusion surface layer is composed of a ternary alloy of aluminum, nickel, and chromium, and is attached to the outer surface of the base tube through a fusion bonding process; the fusion bonding process enables the fusion metallographic phase in the micro-protrusion surface layer to effectively connect the aluminum-based particles together. The high-efficiency condenser tube with micro-floating convex surface is suitable for external condensation conditions. The high-temperature gaseous medium outside the tube comes into contact with the micro-floating convex surface layer to form a condensate film. The tension distribution of the condensate film on the micro-protrusion surface layer is uneven. The surface tension at the root of the micro-protrusion is greater than that at the top, causing the liquid film to be pulled towards the root of the micro-protrusion to accumulate and form condensate. The condensate is collected through the channels in the concave part of the micro-protrusion surface layer to the lower part of the tube and drips down.

2. The high-efficiency condenser tube with a micro-convex surface according to claim 1, characterized in that, The micro-protrusion surface layer is prepared using thermal spraying technology.

3. The high-efficiency condenser tube with a micro-convex surface according to claim 1, characterized in that, The micro-protruding surface layer and the base tube surface are bonded by a combination of micro-metallurgy and mechanical methods. During the micro-metallurgical bonding process, high temperature causes the atoms of the micro-protruding surface layer and the base tube surface to diffuse into each other to form a metallurgical bonding layer. At the same time, the mechanical bonding is achieved through the micro-mechanical interlocking of the micro-protruding surface layer and the base tube surface.

4. The high-efficiency condenser tube with a micro-convex surface according to claim 1, characterized in that, The base tube is made of materials including but not limited to carbon steel, stainless steel, and copper alloy.

5. The high-efficiency condenser tube with a micro-convex surface according to claim 1, characterized in that, By adjusting the particle size of each phase in the aluminum-nickel-chromium ternary alloy, the shape, height, and distribution density of the micro-protrusions can be changed to obtain the optimal surface protrusion structure and achieve the maximum condensation strengthening effect.

6. The high-efficiency condenser tube with a micro-convex surface according to claim 1, characterized in that, By adjusting the proportions of each phase in the ternary alloy of aluminum, nickel, and chromium, the physical and chemical properties of the micro-protrusion surface layer are optimized, thereby obtaining the best adhesion of the surface layer.

7. The high-efficiency condenser tube with a micro-convex surface according to claim 1, characterized in that, The average geometric dimension of the micro-protrusion surface is 100 micrometers.

8. The high-efficiency condenser tube with a micro-convex surface according to claim 1, characterized in that, The high-efficiency condenser tube with a micro-protruding surface is formed by additive manufacturing technology, which involves depositing materials layer by layer to create the micro-protruding surface layer.

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