Double-flow heat exchanger, method for manufacturing a double-flow heat exchanger, and waste heat recovery system

Abstract

The embodiment of the application provides a kind of double fluid heat exchanger and its manufacturing method, waste heat recovery system, belong to heat exchange equipment technical field.Double fluid heat exchanger includes: shell, first inlet, first outlet, second inlet and second outlet are set on shell;Heat exchange partition, heat exchange partition is set in shell, and the first flow channel and the second flow channel with topology structure are formed by separating in shell, the first flow channel is used to accommodate first fluid, the second flow channel is used to accommodate second fluid, the first flow channel is communicated first inlet and first outlet, and the second flow channel is communicated second inlet and second outlet.The flow channel arrangement of topology structure can extend fluid path in limited installation space, and increase effective heat exchange area, to improve the heat exchange efficiency of heat exchanger.

Description

Technical Field

[0001] This application relates to the field of heat exchange equipment technology, and in particular to a two-fluid heat exchanger and its manufacturing method, and a waste heat recovery system. Background Technology

[0002] In electrode coating ovens or other heating devices and systems, heat is lost to the environment through the equipment casing and exhaust pipes, resulting in energy waste.

[0003] In related technologies, heat exchangers are used to exchange heat with fluids in order to recover and utilize some of the heat lost in electrode coating ovens or other heating devices and systems. Heat exchangers are typically shell-and-tube or plate structures.

[0004] However, existing heat exchangers are suitable for a single fluid and have low heat exchange efficiency. Summary of the Invention

[0005] This application provides a dual-fluid heat exchanger and its manufacturing method, as well as a waste heat recovery system, to solve the problem that existing heat exchangers are suitable for a single fluid and have low heat exchange efficiency.

[0006] In a first aspect, embodiments of this application provide a dual-fluid heat exchanger, comprising:

[0007] The shell has a first inlet, a first outlet, a second inlet, and a second outlet.

[0008] A heat exchange baffle is disposed inside the shell and divides the shell into a first flow channel and a second flow channel with a topological structure. The first flow channel is used to contain a first fluid, and the second flow channel is used to contain a second fluid. The first flow channel connects a first inlet and a first outlet, and the second flow channel connects a second inlet and a second outlet.

[0009] In one possible implementation, the dual-fluid heat exchanger provided in this application embodiment has a first flow channel and a second flow channel that are at least partially interleaved and staggered.

[0010] In one possible implementation, the dual-fluid heat exchanger provided in this application embodiment has a first flow channel and a second flow channel that are centrally symmetrically distributed with respect to the shell.

[0011] In one possible implementation, the dual-fluid heat exchanger provided in this application embodiment has a shell with opposing first and second sides, with both the first inlet and the second outlet located on the first side of the shell, and both the first outlet and the second inlet located on the second side of the shell.

[0012] At any cross section along the first side to the second side, both the first flow channel and the second flow channel have at least two branch flow channels.

[0013] In one possible implementation, the dual-fluid heat exchanger provided in this application embodiment has a portion of the first flow channel surrounding the outside of the second flow channel near the first side between the first side and the second side, and another portion of the first flow channel passing through the inside of the second flow channel.

[0014] In the middle between the first side and the second side, the first flow channel is located on the same side as the first side and the second side, and the second flow channel is located on the other side of the same first side and the second side;

[0015] Between the first and second sides, near the second side, a portion of the second flow channel is arranged around the outside of the first flow channel, and another portion of the second flow channel passes through the inside of the first flow channel.

[0016] In one possible implementation, the dual-fluid heat exchanger provided in this application embodiment has a shell in the shape of a cuboid or cylinder, with the first side and the second side being opposite sides in the length direction of the shell.

[0017] In one possible implementation, the dual-fluid heat exchanger provided in this application embodiment has an insulation layer covering the outer side of the shell.

[0018] Secondly, embodiments of this application provide a method for manufacturing a two-fluid heat exchanger, the method comprising the following steps:

[0019] Determine the optimal topology model for the heat exchange baffle;

[0020] Heat exchange baffles were prepared based on a topological optimization model.

[0021] A heat exchange baffle is installed into the shell so that the first flow channel of the heat exchange baffle connects the first inlet and the first outlet of the shell, and the second flow channel of the heat exchange baffle connects the second inlet and the second outlet of the shell.

[0022] Thirdly, embodiments of this application provide a waste heat recovery system, including a heating element, a heating container, and a two-fluid heat exchanger. The first outlet of the two-fluid heat exchanger is connected to the preheating layer of the heating container. The preheating layer is connected to the inner liner of the heating container through the heating element. The inner liner is connected to the second inlet of the two-fluid heat exchanger. The first inlet and the second outlet are used to communicate with the outside world.

[0023] In one possible implementation, the waste heat recovery system provided in this application embodiment has multiple dual-fluid heat exchangers connected in series or in parallel.

[0024] The dual-fluid heat exchanger and its manufacturing method, as well as the waste heat recovery system provided in this application, utilize heat exchange baffles within the shell to divide the interior into a first flow channel and a second flow channel with a topological structure, respectively connected to the corresponding inlet and outlet. This topological flow channel arrangement extends the fluid path and increases the effective heat exchange area within a limited installation space. This allows for the rational organization of the flow paths of the first and second fluids, balancing flow resistance and flow rate matching within a limited space, and promoting heat exchange between the two fluids, thereby improving the heat exchanger's efficiency. Attached Figure Description

[0025] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0026] Figure 1 This is a schematic diagram of the structure of a two-fluid heat exchanger provided in an embodiment of this application;

[0027] Figure 2 for Figure 1 Schematic diagram of the heat exchange baffle in the middle;

[0028] Figure 3 for Figure 2 Sectional view along line AA;

[0029] Figure 4 for Figure 2 Sectional view along the BB direction;

[0030] Figure 5 for Figure 2 C-axis sectional view;

[0031] Figure 6 This is a schematic diagram of the waste heat recovery system provided in the embodiments of this application;

[0032] Figure 7 A schematic diagram of a two-fluid heat exchanger connected in series in a waste heat recovery system provided in this application embodiment;

[0033] Figure 8 A flowchart illustrating a method for manufacturing a two-fluid heat exchanger as provided in an embodiment of this application.

[0034] Explanation of reference numerals in the attached figures:

[0035] 100 - Housing; 110 - First inlet; 120 - First outlet; 130 - Second inlet; 140 - Second outlet;

[0036] 200 - Heat exchange baffle; 210 - First flow channel; 220 - Second flow channel.

[0037] 300 - Heating element;

[0038] 400 - Heating container; 410 - Preheating layer; 420 - Inner liner; 430 - Insulation layer;

[0039] 500 - Blower.

[0040] The accompanying drawings illustrate specific embodiments of this application, which will be described in more detail below. These drawings and descriptions are not intended to limit the scope of the concept in any way, but rather to illustrate the concept of this application to those skilled in the art through reference to particular embodiments. Detailed Implementation

[0041] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, 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, 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. In the absence of conflict, the following embodiments and features can be combined with each other.

[0042] Heat exchanger technology is widely used in the field of industrial heat recovery, especially suitable for the waste heat utilization of continuous heating and drying equipment such as lithium battery electrode coating ovens.

[0043] For example, in the electrode coating process, the oven needs to continuously supply air and exhaust heat-carrying exhaust gas to maintain the thermal conditions required for coating drying and solvent evaporation. The corresponding system typically includes the oven body, air inlet duct, air outlet duct, and heat exchange devices installed in the duct. Cold-side air can be supplied to the oven as fresh air, while hot-side air is the high-temperature gas exhausted from the oven.

[0044] Since such equipment is mostly installed in confined spaces within factory buildings, the heat exchange device not only needs to undertake the function of heat exchange between hot and cold airflows, but also needs to adapt to the layout of the intake and exhaust channels, and take into account pressure drop control and operational stability. Therefore, its structural layout directly affects the waste heat recovery efficiency of the oven and the overall energy consumption level.

[0045] In related technologies, heat exchangers are typically shell-and-tube or plate-type structures suitable for a single fluid. They facilitate heat exchange between the fluid and recover lost heat. However, the flow channels in heat exchangers are often fixed structures, making it difficult to balance flow resistance and flow rate matching, which can easily lead to uneven pressure drop distribution and limited heat exchange efficiency.

[0046] To overcome the shortcomings of existing technologies, the dual-fluid heat exchanger and its manufacturing method, as well as the waste heat recovery system provided in this application, utilize heat exchange baffles within the shell to divide the interior into a first flow channel and a second flow channel with a topological structure, respectively connected to the corresponding inlet and outlet. This topological flow channel arrangement extends the fluid path and increases the effective heat exchange area within a limited installation space. This allows for the rational organization of the flow paths of the first and second fluids, balancing flow resistance and flow rate matching within a limited space, and promoting heat exchange between the two fluids, thereby improving the heat exchanger's efficiency.

[0047] The present invention will now be described in detail with reference to the accompanying drawings, so that those skilled in the art can have a clearer and more detailed understanding of the present invention.

[0048] Reference Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, this application embodiment provides a two-fluid heat exchanger, including:

[0049] The housing 100 has a first inlet 110, a first outlet 120, a second inlet 130, and a second outlet 140.

[0050] A heat exchange baffle 200 is disposed inside the housing 100 and divides the housing 100 into a first flow channel 210 and a second flow channel 220 with a topological structure. The first flow channel 210 is used to contain a first fluid, and the second flow channel 220 is used to contain a second fluid. The first flow channel 210 connects a first inlet 110 and a first outlet 120, and the second flow channel 220 connects a second inlet 130 and a second outlet 140.

[0051] It is understood that the shell 100 forms a pressure-bearing shell 100 that encloses the heat exchange space, providing a common mounting carrier for the first fluid and the second fluid (where the first fluid and the second fluid have different temperatures, and under normal circumstances, the temperature of the first fluid is lower than that of the second fluid), and through the cooperation between the inner wall of the shell 100 and the heat exchange baffle 200, mutually isolated flow paths (first flow channel 210 and second flow channel 220) are formed, thereby ensuring that the first fluid and the second fluid complete heat exchange in the same device without mixing.

[0052] The housing 100 is typically configured as a cavity structure with a certain rigidity and sealing performance. Its spatial position can be arranged between the air inlet and exhaust pipes of the waste heat recovery system according to the equipment installation conditions. The housing 100 is respectively provided with a first inlet 110, a first outlet 120, a second inlet 130, and a second outlet 140 to provide independent inlet and outlet interfaces for the two fluids. The air inlet and exhaust pipes are connected to the housing 100 through flanges, welded nozzles, or quick-connect couplings to form a stable fluid channel.

[0053] The first inlet 110 and the first outlet 120 correspond to the first flow channel 210 and the first fluid, respectively. The second inlet 130 and the second outlet 140 correspond to the second flow channel 220 and the second fluid, respectively, forming a fluid interface for the directional introduction and exit of the two fluids. These interfaces, in conjunction with the heat exchange baffle 200 inside the casing 100, form independent fluid boundaries. The aforementioned inlets and outlets define the flow direction and connection interface of the fluids, ensuring that the first fluid enters the first flow channel 210 only through the first inlet 110 and exits through the first outlet 120, and the second fluid enters the second flow channel 220 only through the second inlet 130 and exits through the second outlet 140, thus preventing direct contact between the two fluids and affecting the purity of the heat exchange medium. The aforementioned inlets and outlets are generally arranged on opposite sides of the casing 100, at different heights on the same side, or at the end of the casing 100 to accommodate co-current, counter-current, or cross-flow arrangements.

[0054] The heat exchange baffle 200 is a partition component disposed inside the housing 100, dividing the interior of the housing 100 into a first flow channel 210 and a second flow channel 220 that are isolated from each other but capable of heat transfer. It enhances the heat exchange efficiency between the hot and cold fluids through its thermal conductivity and topological structure. The heat exchange baffle 200 completely occupies the internal space of the housing 100, and its edges are sealed to the inner wall of the housing 100, forming a partition interface that prevents fluid bypass. The heat exchange baffle 200 can be made of metal plate, composite material plate, high thermal conductivity substrate molded part, or graphene-reinforced metal matrix material.

[0055] The first flow channel 210 is a first fluid channel jointly defined by the heat exchange baffle 200 and the shell 100. It is used to contain the first fluid and connect the first inlet 110 and the first outlet 120, guiding the first fluid through the interior of the shell 100 along a predetermined path to exchange heat with the second fluid in the second flow channel 220 during the flow process. The spatial shape of the first flow channel 210 is usually set as a straight-through, baffle, tortuous, or branch-and-converge type according to the internal topology of the heat exchanger, so as to increase the fluid residence time and heat exchange contact opportunity while controlling the pressure drop. The connection between the first flow channel 210 and the first inlet 110 and the first outlet 120 must ensure a smooth transition to reduce local resistance and flow dead zones. The second flow channel 220 can be arranged in parallel, staggered, or stacked with the first flow channel 210 to increase the utilization efficiency of the temperature difference between the fluids on both sides, and to achieve heat transfer across the wall without generating medium mixing through the heat exchange baffle 200.

[0056] Since the first inlet 110, the first outlet 120, the second inlet 130 and the second outlet 140 are respectively connected to the corresponding flow channels, the fluid is constrained in its respective channel by the heat exchange baffle 200 after entering the shell 100. This avoids direct mixing of hot and cold media and allows the two fluids to continuously transfer heat through the baffle wall.

[0057] The dual-fluid heat exchanger provided in this embodiment of the application uses a heat exchange baffle 200 disposed within the shell 100. The heat exchange baffle 200 divides the shell 100 into a first flow channel 210 and a second flow channel 220 with a topological structure, respectively connecting the corresponding inlet and outlet. This topological flow channel arrangement extends the fluid path and increases the effective heat exchange area within a limited installation space. This allows for a rational organization of the flow paths of the first and second fluids, balancing flow resistance and flow rate matching on both sides within a limited space, and promoting heat exchange between the two fluids, thereby improving the heat exchanger's heat exchange efficiency.

[0058] Furthermore, for applications in continuous drying equipment such as lithium battery electrode coating ovens, the dual-fluid heat exchanger facilitates the transfer of heat from the exhaust gas to the incoming fresh air, thereby reducing the external heat source load and improving system energy efficiency. Meanwhile, since the housing 100 and interfaces can adopt different connection methods depending on the site piping, and the heat exchange baffle 200 can also be implemented using various structures and materials, this dual-fluid heat exchanger can adapt well to limited installation space and different operating conditions.

[0059] Therefore, the two-fluid heat exchanger can accommodate both the first and second fluid flows, ensuring high heat exchange efficiency. Compared to other types of heat exchangers (shell-and-tube, plate, etc.), it has a simpler structure, is easier to install, and occupies less space. Furthermore, the two-fluid heat exchanger can be modularly deployed according to actual heat exchange scenarios. For example, it can be installed in the inlet and outlet pipes of an electrode coating oven for waste heat recovery, improving the utilization rate of factory space.

[0060] In some embodiments, refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5 As shown, the first flow channel 210 and the second flow channel 220 are at least partially intersecting and staggered.

[0061] The first flow channel 210 and the second flow channel 220 are at least partially interwoven and staggered, so that the two sets of flow channels within the housing 100 for accommodating the first and second fluids are not completely separated and extend parallel to each other in local areas. Instead, they form a spatially staggered relationship through concave, circling, nesting, alternating distribution, or folding enclosure, allowing the two fluids to flow along their respective independent paths while remaining relatively close within a longer adjacent path, thereby increasing the effective heat exchange contact area and enhancing heat transfer. For example, the first flow channel 210 and the second flow channel 220 are geometrically adjacent through partition boundaries, channel walls, or topological pores, but the fluid paths remain independent and unconnected to avoid medium mixing and ensure heat exchange safety.

[0062] This extends the adjacent heat exchange path between hot and cold fluids, improves temperature difference utilization and heat exchange uniformity, and is suitable for the compact arrangement requirements of heat exchangers in waste heat recovery of continuous drying equipment.

[0063] For example, the interlaced first flow channel 210 and second flow channel 220 can be defined as two sets of independent flow channels with a spatially adjacent relationship. The first flow channel 210 is used to guide the lower temperature fresh air or cold side air, and the second flow channel 220 is used to guide the higher temperature exhaust gas or exhaust air. When they flow through the interior of the housing 100, they form a high heat transfer gradient by locally alternating close proximity. The first flow channel 210 and the second flow channel 220 can specifically be represented as a serpentine winding channel, a nested branch channel, a honeycomb alternating channel, a spiral winding channel, a sinusoidal corrugated channel, a zigzag channel, or a multi-channel parallel channel.

[0064] Furthermore, refer to Figure 1 , Figure 2 , Figure 3 , Figure 4 and Figure 5As shown, the first flow channel 210 and the second flow channel 220 are centrally symmetrically distributed with respect to the shell 100.

[0065] This arrangement uses the geometric center or equivalent center plane of the shell 100 as a symmetry reference, and the first flow channel 210 and the second flow channel 220 are arranged in a mirror-image relationship along this reference inside the shell 100. Furthermore, the first flow channel 210 and the second flow channel 220 maintain a correspondence in length, direction, turning points, and relative distance from the boundary of the shell 100, thereby ensuring a high degree of consistency in the flow resistance and heat transfer path experienced by the two fluids after entering the heat exchanger.

[0066] Furthermore, the first flow channel 210 and the second flow channel 220 can respectively undertake the functions of guiding and heat exchange for different fluids, and form a mutually balanced flow environment inside the shell 100, which is conducive to reducing the pressure drop difference on both sides and improving the overall heat exchange stability. This symmetrical relationship can be expressed as the first flow channel 210 and the second flow channel 220 being located on both sides of the central symmetry plane of the shell 100, or symmetrically distributed in a ring, radial or upper and lower layer around the central axis of the shell 100, with their corresponding bending sections, branch sections, contraction sections and expansion sections matching each other to ensure that the fluids on both sides complete the flow under the same or approximately the same structural conditions.

[0067] When the first fluid and the second fluid enter the shell 100 through the corresponding first inlet 110 and second inlet 130, respectively, and enter the first flow channel 210 and the second flow channel 220 under the constraint of the heat exchange baffle 200, since the two flow channels are symmetrically arranged with respect to the center of the shell 100, the flow path length, number of turns, and local resistance conditions of the fluids on both sides are basically the same, and the flow state of the fluids in their respective flow channels can maintain a good matching relationship. As the fluids continue to exchange heat through the heat exchange baffle 200, the centrally symmetrical structure makes the force and flow distribution on both sides of the shell 100 more balanced, reducing local flow deviation, short-circuit flow, and heat exchange fluctuations caused by uneven flow channels, thereby enabling the heat exchanger to maintain relatively stable heat transfer performance and relatively consistent pressure drop characteristics during continuous operation.

[0068] For applications in continuous drying equipment and waste heat recovery systems, this centrally symmetrical arrangement helps to obtain a more uniform temperature response during heat exchange, reduces energy loss caused by flow channel imbalance, and improves the reliability and consistency of long-term equipment operation.

[0069] In specific implementation, refer to Figure 2 , Figure 3 , Figure 4 and Figure 5As shown, the housing 100 has a first side and a second side opposite to each other. The first inlet 110 and the second outlet 140 are both located on the first side of the housing 100, and the first outlet 120 and the second inlet 130 are both located on the second side of the housing 100. At any cross section along the first side to the second side, the first flow channel 210 and the second flow channel 220 each have at least two branch flow channels.

[0070] The first inlet 110 and the second outlet 140 are arranged on the same side, and the first outlet 120 and the second inlet 130 are arranged on the other side, so that the external pipeline can be connected in a relatively simple direction. At the same time, the two fluids form an in-out and out-in-opposite flow relationship in the shell 100, thereby extending the effective heat exchange temperature difference and improving the continuity of heat exchange.

[0071] In this embodiment, the first and second sides of the housing 100 can correspond to opposite end faces along the length of the housing 100. In other embodiments, they can correspond to opposite side faces along the width or height. The first inlet 110 and the second outlet 140 can be respectively opened in different areas of the first side, and the first outlet 120 and the second inlet 130 can be respectively opened in different areas of the second side. Furthermore, each inlet and outlet extends outward to form a pipe structure for connection with other pipelines.

[0072] At least two branch channels are provided, causing the shell 100 to flow upwards along the main flow from the first side to the second side. The first channel 210 and the second channel 220 are not arranged as a single continuous channel in any cross-section, but rather form two or more interconnected or parallel sub-channel structures to split, guide, and re-converge the fluid. This distributes the first or second fluid entering the corresponding channel into multiple branches, increasing the contact area between the fluid and the heat exchange baffle 200 and the walls of adjacent channels, reducing the local velocity peak within a single channel, and making the flow rate more uniformly distributed in the cross-sectional direction, thereby reducing flow deviation, dead zones, and local pressure drop concentration.

[0073] Branches can be interconnected through branching sections, confluence sections, or transition connecting sections, allowing fluid to propagate simultaneously along multiple paths as it passes through the heat exchanger. The branches of the first flow channel 210 and the second flow channel 220 can be staggered in planar projection or arranged in layers along the thickness direction to adapt to the topology of the heat exchange baffle 200 and maintain structural compactness. The branch channels can take the form of Y-shaped bifurcations, tree-like bifurcations, or grid-like connecting channels.

[0074] Furthermore, refer to Figure 2 , Figure 3 , Figure 4 and Figure 5As shown, near the first side between the first side and the second side, a portion of the first flow channel 210 is arranged around the outside of the second flow channel 220, and another portion of the first flow channel 210 passes through the inside of the second flow channel 220.

[0075] In the middle between the first side and the second side, the first flow channel 210 is located on the same side of the first side and the second side, and the second flow channel 220 is located on the other side of the same first side and the second side.

[0076] Between the first side and the second side, near the second side, a portion of the second flow channel 220 is arranged around the outside of the first flow channel 210, and another portion of the second flow channel 220 passes through the inside of the first flow channel 210.

[0077] Thus, a staggered topological flow channel arrangement structure with segmented changes along the flow direction of the shell 100 is formed. The first flow channel 210 and the second flow channel 220 form a local nested relationship with both external wrapping and internal penetration in the region near the first side. In the middle region, they are placed on opposite sides inside the shell 100 to maintain a stable heat exchange contact relationship. In the region near the second side, the second flow channel 220 forms a staggered relationship with both external wrapping and internal penetration in the opposite direction. This allows the two fluids to achieve segmented and mirrored spatial interchange in the direction from the first side to the second side.

[0078] The heat exchange baffle 200 restructures the flow channels within the shell 100 to form a continuous variable cross-section flow channel system. The first flow channel 210 and the second flow channel 220 respectively guide the flow and exchange heat of the first and second fluids. They have both an encircling relationship and an intersecting relationship in local areas, and form a relatively separated arrangement in the middle to enhance the utilization efficiency of the temperature difference on both sides of the wall while ensuring flow continuity. The outer encircling section is used to extend the residence path of the fluid in the high temperature difference region, the inner intersecting section is used to shorten the local flow resistance and enhance the close heat exchange of the fluid to the wall, and the relatively separated sections in the middle are used to maintain a stable flow direction distribution while ensuring overall connectivity.

[0079] When the first fluid and the second fluid enter the first flow channel 210 and the second flow channel 220 within the casing 100 through their respective inlets, firstly, in the region near the first side, the first flow channel 210 expands around the second flow channel 220 simultaneously through its outer and inner sections, allowing the first fluid to form a longer heat exchange path and maintain a larger wall contact area with the second fluid in this region. As the fluids continue to advance along the length of the casing 100, when they enter the middle region, the first flow channel 210 and the second flow channel 220 are located on opposite sides within the casing 100, allowing the fluids to move smoothly in relatively separated spaces, continuously completing heat exchange while maintaining laminar or controlled turbulent flow. As the fluids further approach the second side, the second flow channel 220 transforms into an alternating state, outerly surrounding the first flow channel 210 and partially penetrating its inner side, causing the second fluid to undergo path extension and local wall adhesion enhancement again before the outlet, thereby improving the utilization efficiency of the terminal temperature difference driving force.

[0080] Furthermore, in some embodiments, reference is made to Figure 1 As shown, the shell 100 is a cuboid or cylinder, with the first side and the second side being opposite sides along the length of the shell 100.

[0081] When the shell 100 is rectangular, it forms a regular box-type load-bearing structure that accommodates a two-fluid heat exchange channel and connects to external pipelines. When the shell 100 is cylindrical, it forms a rotationally symmetrical load-bearing structure with axial or circumferential flow space.

[0082] The housing 100 can be a box-type housing 100 formed by welding steel plates. In another possible embodiment, it can be a cylindrical housing 100 formed by rolling stainless steel plates. In yet another exemplary embodiment, it can be a housing 100 assembled from aluminum alloy profiles or formed from composite plates. If necessary, it can also be a carbon steel housing 100, a galvanized steel housing 100, or a corrosion-resistant composite material housing 100 to adapt to different temperature, humidity, and exhaust gas corrosion environments.

[0083] In addition, the outer side of the shell 100 is covered with an insulation layer 430.

[0084] The insulation layer 430 is a thermal insulation covering structure installed on the outer surface of the shell 100 to suppress heat loss to the environment. It can reduce heat loss from the outer surface of the shell 100, reduce environmental thermal pollution, and improve the utilization efficiency of heat from inside the heat exchanger to the cold-side fluid.

[0085] In specific configuration, the insulation layer 430 is closely attached to the outer wall of the shell 100 and can be fixed to the surface of the shell 100 by means of bonding, binding, clamping, riveting or pressing with the outer protective plate. If necessary, a moisture-proof layer or sealing layer can also be set between the shell 100 and the insulation layer 430 to avoid the thermal conductivity from increasing and reducing the insulation performance after being exposed to moisture.

[0086] For example, the insulation layer 430 can be a rock wool layer, a ceramic fiber layer, an aerogel felt layer, thermal insulation foam, a vacuum insulation board, or a multi-layer composite thermal insulation felt.

[0087] Reference Figure 8 As shown in the figure, this application embodiment also provides a method for manufacturing a two-fluid heat exchanger, the method comprising the following steps:

[0088] Determine the topology optimization model of heat exchange baffle 200;

[0089] Heat exchange baffle 200 was prepared based on the topology optimization model;

[0090] The heat exchange baffle 200 is installed into the housing 100 such that the first flow channel 210 of the heat exchange baffle 200 connects the first inlet 110 and the first outlet 120 of the housing 100, and the second flow channel 220 of the heat exchange baffle 200 connects the second inlet 130 and the second outlet 140 of the housing 100.

[0091] Specifically, it includes the following steps:

[0092] S101: Determine the physical properties and flow boundary conditions of the first and second fluids, and determine the installation dimensions of the shell 100 of the two-fluid heat exchanger.

[0093] Based on the application scenario of the two-fluid heat exchanger, the physical property parameters of the first fluid and the second fluid are determined, including thermal conductivity k, specific heat capacity at constant pressure Cp and density ρ, as well as the flow boundary conditions at the first inlet 110 and the second inlet 130 of the first fluid and the second fluid, including temperature ℃ and velocity u.

[0094] The dimensions of the shell 100 of the two-fluid heat exchanger are determined. The external dimensional parameters of the shell 100 include length L, width W, and height H. A geometric model of the heat exchanger is established, specifically, L = 2W = 2H. Since the two-fluid heat exchanger is symmetrical in the height direction, only half of the model is solved, and a symmetrical boundary is set at the height H / 2 plane.

[0095] By pre-determining the physical properties, flow boundary conditions, and shell 100 installation dimensions of the two fluids, the heat exchanger design can simultaneously match the exhaust and fresh air conditions of the electrode coating oven and the requirements of confined space.

[0096] S102: Determine the topology optimization design domain of the heat exchange baffle 200 of the two-fluid heat exchanger and discretize the design domain.

[0097] Specifically, the design domain for topology optimization is determined, and the design domain is discretized and modeled. At the same time, the correspondence between the design variable γ and the first fluid, the second fluid, and the solid is established.

[0098] In order to enable topology design for the first and second fluids within the same design domain, the design variable γ is modified as follows: when γ=0, the discrete cell represents the first fluid; when 0<γ<1, the discrete cell represents the solid; and when γ=1, the discrete cell represents the second fluid.

[0099] To save computational costs, only the first fluid is solved. The physical field of the second fluid is obtained through a mapping method, specifically set as u2 = -u1.

[0100] Setting a design domain and discretizing the heat exchange baffle 200 is beneficial for reconstructing the flow channel distribution within a given volume.

[0101] S103: Determine the topology optimization model of the heat exchange baffle 200 and solve the fluid-thermal coupling physical field until convergence.

[0102] Specifically, the objective function is determined based on the design requirements of the two-fluid heat exchanger, thereby establishing a heat exchanger topology optimization model, including topology optimization methods, interpolation functions, and optimization algorithms.

[0103] The design of the heat exchange baffle 200 needs to take into account the flow conditions of the first fluid and the second fluid, as well as the heat exchange efficiency. Therefore, the objective function is to maximize the total heat exchange of the first fluid and the second fluid, the heat dissipation work of the hot fluid, and the heat exchange efficiency, as shown in the following formula:

[0104]

[0105] Where φ is the total convective heat transfer of the first fluid and the second fluid, ϕ is the viscous dissipation work of the first fluid and the second fluid, ψ is the heat transfer efficiency of the first fluid and the second fluid, and λ is the weighting coefficient of the target.

[0106] Therefore, the mathematical model for optimizing the topology of heat exchanger baffle 200 is as follows:

[0107]

[0108] The topology optimization model adopts the density model, the interpolation function is Darcy interpolation, the optimization algorithm is the moving asymptote method, the maximum number of iterations is set to 100, and the convergence tolerance is set to 1E-4.

[0109] Then, the fluid-thermal coupling physical field is solved, and the design variable γ in the design domain space is optimized according to the optimization algorithm. The optimal material distribution is obtained by iteratively step by step.

[0110] Determine if the change in the objective function is less than the set tolerance value. If it is, obtain the initial topological geometry. Otherwise, modify the design variables and repeat step S103 until the requirements are met.

[0111] By establishing a topology optimization model and solving the fluid-thermal coupling physical field, flow resistance, heat transfer efficiency and channel connectivity can be taken into account, thereby obtaining a baffle structure that is more suitable for stable heat transfer in dual airflow.

[0112] S104: Prepare heat exchange baffle 200 according to the topology optimization model, and smooth the heat exchange baffle 200.

[0113] The optimization results were filtered with a criterion of 4.5 ≤ γ ≤ 5.5, and the heat exchange baffle 200 with the initial topology was obtained. Then, the heat exchange baffle 200 was smoothed using methods such as filtration and smoothing.

[0114] Smoothing the topology can reduce sharp corners, dead zones, and local resistance, thereby improving manufacturing feasibility and operational reliability.

[0115] S105: The heat exchange baffle 200 is installed into the housing 100 so that the first flow channel 210 of the heat exchange baffle 200 connects the first inlet 110 and the first outlet 120 of the housing 100, and the second flow channel 220 of the heat exchange baffle 200 connects the second inlet 130 and the second outlet 140 of the housing 100.

[0116] The heat exchange baffle 200 is combined with an outer shell and connected to the corresponding inlet and outlet to obtain the final two-fluid heat exchanger topology.

[0117] After being installed in the housing 100, the first flow channel 210 and the second flow channel 220 are formed and connected respectively, thereby realizing independent flow of two fluids and efficient heat exchange within a compact structure.

[0118] In addition, refer to Figure 1 , Figure 6 and Figure 7 As shown in the embodiment of this application, a waste heat recovery system is also provided, including a heating element 300, a heating container 400 and a two-fluid heat exchanger. The first outlet 120 of the two-fluid heat exchanger is connected to the preheating layer 410 of the heating container 400. The preheating layer 410 is connected to the inner liner 420 of the heating container 400 through the heating element 300. The inner liner 420 is connected to the second inlet 130 of the two-fluid heat exchanger. The first inlet 110 and the second outlet 140 are used to communicate with the outside.

[0119] The two-fluid heat exchanger has been described in the above embodiments and will not be repeated here.

[0120] The heating element 300 is thermally coupled to the heating container 400, continuously replenishing heat to the medium fed in through the preheating layer 410, ensuring the medium reaches the temperature required for subsequent processes, and maintaining the stability of the heating process in conjunction with the flow path within the inner liner 420. For example, the heating element 300 can be an electric heating tube, an electric heating wire assembly, or a gas-fired heat exchange heating assembly; it can also be one or more of a resistance heating plate, a thermal oil heat exchange coil, or a hot air circulation heating module to adapt to different energy forms and heating rate requirements.

[0121] The heating container 400 contains the medium to be heated and completes preheating, heating, and processing. It provides a relatively stable fluid and heat exchange space between the preheating layer 410, the heating element 300, and the inner liner 420, and allows the recovered waste heat to be transferred and utilized step by step within the container. The heating container 400 can be a metal cavity, an insulated cavity, or a composite insulated cavity, or it can have a double-layer or multi-layer structure formed by a composite insulation layer 430 and an insulation layer on the outside of the metal shell to reduce heat loss to the environment. For example, the heating container 400 can be a coating container oven.

[0122] The preheating layer 410 is located in the intermediate heat exchange area adjacent to the external heat source passage on the outside or inside of the heating container 400. It receives the preheated medium from the first outlet 120 of the two-fluid heat exchanger and further heats the medium by utilizing the heat exchange relationship between the preheating layer 410 and the wall of the heating container 400 and the heating element 300, thus forming a buffer and transitional heating before entering the inner tank 420. The inner tank 420 carries the final heating medium and completes the process treatment. After the preheating layer 410 and the heating element 300 complete the initial heat input, the medium is further heated, held, or treated, and the treated high-temperature medium is guided back to the second inlet 130 of the two-fluid heat exchanger to continue participating in waste heat exchange.

[0123] A blower 500 can be installed in the connection path between the dual-fluid heat exchanger, the heating element 300, and the heating container 400 to guide the airflow at high speed.

[0124] The two-fluid heat exchanger is arranged with the first and second fluid directions in a counter-current configuration. The incoming cold air and the outgoing hot air in the heating container 400 first exchange heat, utilizing the heat energy in the exhaust air to preheat the incoming air to a certain extent. After preheating in the two-fluid heat exchanger, the incoming air enters the preheating layer 410 of the heating container 400 for further preheating, fully utilizing the heat dissipated from the inner liner 420. Heat exchange fins are provided on the outer surface of the inner liner 420 of the heating container 400 to increase the heat exchange area. Furthermore, an insulation layer 430 can be provided on the outermost layer of the heating container 400 to reduce heat loss.

[0125] Furthermore, refer to Figure 6 and Figure 7 As shown, multiple dual-fluid heat exchangers are connected in series or in parallel.

[0126] By combining and arranging multiple two-fluid heat exchangers, the overall heat exchange area and processing capacity can be expanded, enabling the system to maintain stable waste heat recovery performance under different air volumes, temperature differences, and installation space conditions.

[0127] Multiple dual-fluid heat exchangers can be arranged in the same pipeline area between the heating container 400, the air inlet pipe and the air outlet pipe. When connected in series, the outlet of each heat exchanger is connected to the corresponding inlet of the next heat exchanger in sequence, so that the first fluid and the second fluid exchange heat step by step along the preset flow channel. The temperature state after the previous heat exchanger is reduced is used as the inlet condition of the next heat exchanger, thereby improving the overall temperature difference utilization rate.

[0128] When connected in parallel, multiple heat exchangers are connected to the same inlet manifold and outlet manifold respectively, so that the fluid is split in multiple branches, exchanges heat at the same time, and then merges and outputs, thereby improving the flow capacity and reducing the local pressure drop of a single heat exchanger.

[0129] Therefore, in the waste heat recovery system provided in this application embodiment, the dual-fluid heat exchanger uses a heat exchange baffle 200 within the shell 100 to divide the shell 100 into a first flow channel 210 and a second flow channel 220 with a topological structure, respectively connecting the corresponding inlet and outlet. The topological flow channel arrangement extends the fluid path and increases the effective heat exchange area within a limited installation space. This allows for the rational organization of the flow paths of the first and second fluids, balancing flow resistance and flow rate matching within a limited space, and promoting heat exchange between the two fluids, thereby improving the heat exchanger's efficiency.

[0130] It should be noted that the terms "one embodiment," "embodiment," "exemplary embodiment," "some embodiments," etc., mentioned in the specification indicate that the described embodiment may include a specific feature, structure, or characteristic, but not every embodiment necessarily includes that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Moreover, when a specific feature, structure, or characteristic is described in connection with an embodiment, implementing such a feature, structure, or characteristic in conjunction with other embodiments, whether explicitly described or not, is within the knowledge scope of those skilled in the art.

[0131] Generally speaking, terms should be understood at least in part by their use in context. For example, at least in part by context, the term "one or more" as used in the text can be used to describe any feature, structure, or characteristic of the singular meaning, or a combination of features, structures, or characteristics of the plural meaning. Similarly, at least in part by context, terms such as "a" or "the" can also be understood to convey either singular or plural usage.

[0132] It should be readily understood that the terms “on,” “above,” and “on top of” in this application should be interpreted in the broadest possible sense, such that “on” means not only “directly on something” but also “on something” with an intermediate feature or layer therebetween, and that “above” or “on top of” means not only “on something” but also “on something” without an intermediate feature or layer therebetween (i.e., directly on something).

[0133] Furthermore, for ease of explanation, spatially relative terms such as "below," "below," "under," "above," and "above" may be used to describe the relationship of one element or feature relative to other elements or features as shown in the figures. Spatially relative terms are intended to encompass different orientations of the device in use or operation other than those shown in the figures. The device may have other orientations (rotated 90° or in other orientations), and the spatially relative descriptive terms used herein may be interpreted accordingly.

[0134] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A two-fluid heat exchanger, characterized in that, include: A housing (100) having a first inlet (110), a first outlet (120), a second inlet (130), and a second outlet (140). A heat exchange baffle (200) is disposed inside the housing (100) and divides the housing (100) into a first flow channel (210) and a second flow channel (220) having a topological structure. The first flow channel (210) is used to contain a first fluid, and the second flow channel (220) is used to contain a second fluid. The first flow channel (210) connects the first inlet (110) and the first outlet (120), and the second flow channel (220) connects the second inlet (130) and the second outlet (140).

2. The two-fluid heat exchanger according to claim 1, characterized in that, The first flow channel (210) and the second flow channel (220) are at least partially intersecting and staggered.

3. The two-fluid heat exchanger according to claim 2, characterized in that, The first flow channel (210) and the second flow channel (220) are centrally symmetrically distributed with respect to the housing (100).

4. The two-fluid heat exchanger according to claim 3, characterized in that, The housing (100) has a first side and a second side opposite to each other, the first inlet (110) and the second outlet (140) are both located on the first side of the housing (100), and the first outlet (120) and the second inlet (130) are both located on the second side of the housing (100); At any cross section along the first side toward the second side, both the first flow channel (210) and the second flow channel (220) have at least two branch flow channels.

5. The two-fluid heat exchanger according to claim 4, characterized in that, Between the first side and the second side, near the first side, a portion of the first flow channel (210) is disposed around the outside of the second flow channel (220), and another portion of the first flow channel (210) is disposed inside the second flow channel (220); In the middle between the first side and the second side, the first flow channel (210) is located on the same side of the first side and the second side, and the second flow channel (220) is located on the other side of the same side of the first side and the second side; Between the first side and the second side, near the second side, a portion of the second flow channel (220) is disposed around the outside of the first flow channel (210), and another portion of the second flow channel (220) is disposed inside the first flow channel (210).

6. The two-fluid heat exchanger according to claim 4 or 5, characterized in that, The housing (100) is in the form of a cuboid or cylinder, and the first side and the second side are opposite sides in the length direction of the housing (100).

7. The two-fluid heat exchanger according to any one of claims 1-6, characterized in that, The outer side of the shell (100) is covered with a thermal insulation layer (430).

8. A method for manufacturing a two-fluid heat exchanger, characterized in that, The manufacturing method for the two-fluid heat exchanger according to any one of claims 1-7 comprises the following steps: Determine the topology optimization model for the heat exchange baffle (200); The heat exchange baffle (200) is prepared according to the topology optimization model. The heat exchange baffle (200) is installed into the housing (100) such that the first flow channel (210) of the heat exchange baffle (200) connects the first inlet (110) and the first outlet (120) of the housing (100), and the second flow channel (220) of the heat exchange baffle (200) connects the second inlet (130) and the second outlet (140) of the housing (100).

9. A waste heat recovery system, characterized in that, The device includes a heating element (300), a heating container (400), and a two-fluid heat exchanger as described in any one of claims 1-7. The first outlet (120) of the two-fluid heat exchanger is connected to the preheating layer (410) of the heating container (400). The preheating layer (410) is connected to the inner liner (420) of the heating container (400) through the heating element (300). The inner liner (420) is connected to the second inlet (130) of the two-fluid heat exchanger. The first inlet (110) and the second outlet (140) are used to communicate with the outside.

10. The waste heat recovery system according to claim 9, characterized in that, Multiple dual-fluid heat exchangers are connected in series or in parallel.

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