High-efficiency flow guide structure of intelligent heat exchange unit
By introducing spiral guide vanes and adjustment mechanisms into the heat exchange equipment, a forced spiral flow is formed, which solves the problem of efficiency decline of traditional heat exchange equipment when operating conditions change, and achieves efficient and intelligent heat exchange effect.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- QINGDAO YUANSHENG HEAT EXCHANGE EQUIP
- Filing Date
- 2025-08-27
- Publication Date
- 2026-07-14
AI Technical Summary
Traditional heat exchange equipment cannot adjust when operating conditions change, resulting in decreased heat exchange efficiency and even heat transfer dead zones.
The system adopts a high-efficiency flow guiding structure for intelligent heat exchange units, including spiral guide vanes, a central rotating shaft, a support frame, a sealed end cap, and an adjustment mechanism. The spiral flow guide vanes and the central rotating shaft work together to form a spiral flow channel. Combined with longitudinal heat dissipation fins and radial through-hole design, the system achieves forced spiral motion and mixing of the fluid. The adjustment mechanism adjusts the flow rate according to the operating conditions.
It significantly improves heat exchange efficiency, avoids the formation of heat transfer dead zones, realizes intelligent control, improves the adaptability and operating efficiency of the equipment, and has better energy-saving effect and longer service life.
Smart Images
Figure CN224499246U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the technical field of heat exchanger units, and more specifically, it relates to a high-efficiency flow guiding structure for an intelligent heat exchanger unit. Background Technology
[0002] In modern industrial production, heat exchange equipment, as a key process device, is widely used in various fields such as petrochemicals, power, metallurgy, pharmaceuticals, and food processing. Its performance directly affects the efficiency and economic benefits of the entire production process. Traditional heat exchange equipment mainly includes shell-and-tube heat exchangers, plate heat exchangers, and spiral plate heat exchangers. These devices generally suffer from low heat exchange efficiency in practical applications. Although shell-and-tube heat exchangers have a simple structure and low manufacturing cost, the relatively stable flow state of the fluid inside the tubes or on the shell side easily leads to the formation of a laminar boundary layer near the tube wall, resulting in increased heat transfer resistance and decreased heat exchange efficiency. Plate heat exchangers, although having a high heat transfer coefficient, are prone to clogging when handling fluids containing particulate matter, and require high sealing performance, resulting in high maintenance costs. Spiral plate heat exchangers can generate a certain spiral flow, but their structure is relatively fixed and cannot be adjusted according to different operating conditions. In recent years, researchers have proposed various heat transfer enhancement technologies to improve heat exchange efficiency, including setting fins, threads, and corrugations on the heat exchange surface, adding nanoparticles to the fluid, and employing pulsating flow. However, most of these methods only work under specific conditions and lack universality and flexibility. Especially in practical industrial applications, operating conditions often change, and traditional heat exchange equipment cannot adjust to these changes, leading to a significant decrease in heat exchange efficiency under certain conditions, or even the emergence of heat transfer dead zones. Utility Model Content
[0003] In view of this, the present invention provides a high-efficiency flow guiding structure for intelligent heat exchange units, which can solve the problem that the fluid in heat exchange equipment is prone to forming heat transfer dead zones during the heat exchange process and cannot be adjusted according to changes in operating conditions.
[0004] This utility model is implemented as follows:
[0005] This utility model provides a high-efficiency flow guiding structure for an intelligent heat exchanger unit, comprising a heat exchange shell, spiral guide vanes, a central rotating shaft, a support frame, a sealing end cap, and an adjustment mechanism. The heat exchange shell has a cylindrical structure, with an annular groove on its inner wall. An inlet and an outlet are respectively located at both ends of the heat exchange shell. The central rotating shaft is positioned along the axial direction of the heat exchange shell, and its two ends are rotatably connected to the inner walls of both ends of the heat exchange shell via bearings. The spiral guide vanes have a propeller-like structure and are fixedly mounted on the outer side of the central rotating shaft. On the surface, the outer edge of the spiral guide vane forms a clearance fit with the inner wall of the heat exchange shell; the support frame includes a base and a column, the base is a rectangular plate structure, the column is vertically fixed on the base, and the heat exchange shell is fixedly installed on the column by clamps; sealing end caps are respectively installed at both ends of the heat exchange shell, and the sealing end caps are connected to the heat exchange shell by flange bolts; the adjustment mechanism includes a transmission gear and a drive motor, the drive motor is fixedly installed on the base of the support frame, the output shaft of the drive motor is connected to the transmission gear through a coupling, and the transmission gear is meshed with one end of the central rotating shaft.
[0006] The technical effects of the high-efficiency flow guiding structure of the intelligent heat exchanger provided by this utility model are as follows: Through the cooperation of the spiral guide vanes and the central rotating shaft, a spiral flow channel is formed in the heat exchange shell, which makes the fluid generate strong spiral motion during the heat exchange process, greatly increasing the contact area and contact time between the fluid and the inner wall of the heat exchange shell. At the same time, the rotational motion of the spiral guide vanes destroys the boundary layer of the fluid, effectively preventing the formation of heat transfer dead zones and significantly improving the overall heat exchange efficiency. The setting of the adjustment mechanism allows the rotation speed of the spiral guide vanes to be adjusted according to the actual working conditions, realizing intelligent control of the heat exchange process. The support frame provides a stable installation foundation for the entire heat exchanger unit.
[0007] Based on the above technical solution, the high-efficiency flow guiding structure of the intelligent heat exchanger unit of this utility model can be further improved as follows:
[0008] The spiral guide vanes are distributed in an equidistant spiral along the axial direction of the central rotation axis. The axial distance between two adjacent spiral guide vanes is 2 to 5 times the diameter of the central rotation axis. The spiral angle of the spiral guide vanes is 30 to 60 degrees. The material of the spiral guide vanes is stainless steel.
[0009] The beneficial effects of adopting the above-mentioned improved scheme are as follows: the structural design of the spiral guide vanes being distributed equidistantly along the central rotation axis ensures that the fluid maintains a uniform spiral flow state throughout the entire heat exchange process, avoiding the phenomenon of excessively high or low local flow velocities; the optimized design of the axial spacing between adjacent spiral guide vanes ensures that the fluid has sufficient spiral development space; the spiral angle range of 30 degrees to 60 degrees ensures both good guiding effect and avoids excessive flow resistance; and the selection of stainless steel material ensures the corrosion resistance and mechanical strength of the spiral guide vanes under various working conditions.
[0010] Furthermore, the inner wall of the heat exchange shell is provided with multiple longitudinal heat dissipation fins. The longitudinal heat dissipation fins are evenly distributed along the circumference of the inner wall of the heat exchange shell. The number of longitudinal heat dissipation fins is 8 to 16. The height of the longitudinal heat dissipation fins is 5% to 15% of the inner diameter of the heat exchange shell. The longitudinal heat dissipation fins and the outer edge of the spiral guide vanes form a labyrinth-like flow channel.
[0011] The beneficial effects of adopting the above-mentioned improvement scheme are as follows: the labyrinthine flow channel structure formed by the longitudinal heat dissipation fins and spiral guide vanes on the inner wall of the heat exchange shell causes the fluid to undergo multiple changes in direction and velocity during the heat exchange process, which greatly enhances the convective heat transfer coefficient during the heat transfer process. The setting of longitudinal heat dissipation fins also increases the heat exchange area. The design of 8 to 16 longitudinal heat dissipation fins ensures sufficient heat exchange area while avoiding excessive flow resistance. The design of the fin height accounting for 5% to 15% of the inner diameter of the heat exchange shell achieves the best balance between heat exchange effect and flow resistance.
[0012] Furthermore, the surface of the central rotating shaft is provided with multiple radial through holes, which are evenly distributed along the axial direction of the central rotating shaft. The diameter of the radial through holes is 10% to 20% of the diameter of the central rotating shaft, and the axial distance between two adjacent radial through holes is 1 to 3 times the diameter of the central rotating shaft. The radial through holes are staggered from the installation positions of the spiral guide vanes.
[0013] The beneficial effects of adopting the above-mentioned improved scheme are as follows: the radial through-hole design on the surface of the central rotating shaft creates a communication channel between the internal and external fluids, enabling the fluids to mix and exchange radially while flowing in a spiral, further enhancing the heat transfer effect. The radial through-hole diameter accounts for 10% to 20% of the central rotating shaft diameter, which ensures sufficient fluid exchange and maintains the structural strength of the central rotating shaft. The staggered arrangement of the radial through-holes and the spiral guide vanes avoids structural conflicts and forms a more complex flow pattern, effectively improving the heat transfer coefficient and mixing effect.
[0014] Furthermore, the sealing end cap has a disc-shaped structure, and a shaft hole is opened at the center of the sealing end cap. The inner diameter of the shaft hole forms a clearance fit with the outer diameter of the central rotating shaft. A sealing ring is installed in the shaft hole, and the sealing ring is made of nitrile rubber material.
[0015] The beneficial effects of adopting the above-mentioned improved scheme are as follows: the disc-shaped structure of the sealing end cover and the heat exchange shell form a complete sealing cavity, which prevents the leakage of heat exchange medium. The clearance fit design between the shaft hole and the central rotating shaft ensures the free rotation of the central rotating shaft and achieves a good sealing effect. The nitrile rubber sealing ring has excellent oil resistance, heat resistance and elasticity, and can maintain stable sealing performance under various working conditions. The design of the sealing end cover also facilitates the disassembly and maintenance of the equipment, and improves the reliability and service life of the entire heat exchange unit.
[0016] Furthermore, the columns of the support frame are connected by horizontal connecting rods. The horizontal connecting rods are square tubular structures. The two ends of the horizontal connecting rods are welded and fixed to the adjacent columns respectively. Fixing holes are provided in the middle of the horizontal connecting rods. The fixing holes are used to install temperature sensors and pressure sensors. The diameter of the fixing holes is 20 mm to 40 mm.
[0017] The beneficial effects of adopting the above-mentioned improvement scheme are as follows: the transverse connecting rods between the support frame columns form a stable frame structure, which greatly improves the rigidity and stability of the entire support system. The transverse connecting rods with square tubular structure have good bending and torsional resistance and can withstand various loads generated during the operation of the heat exchange unit. The fixing holes in the middle of the transverse connecting rods provide ideal installation positions for temperature and pressure sensors, enabling the sensors to accurately monitor key parameters in the heat exchange process. The fixing hole diameter of 20 mm to 40 mm is compatible with commonly used industrial sensor specifications.
[0018] Furthermore, the surface of the spiral guide vane is provided with corrugated protrusions, which are distributed in a sinusoidal waveform along the length of the spiral guide vane.
[0019] The beneficial effects of the above-mentioned improvement scheme are as follows: the corrugated protrusions on the surface of the spiral guide vane further enhance the turbulence effect of the fluid. The sinusoidal corrugated structure makes the fluid generate a more complex flow pattern when flowing over the surface of the vane, effectively destroying the formation of the fluid boundary layer and significantly improving the convective heat transfer coefficient. The corrugated protrusions also increase the surface area of the spiral guide vane, providing more contact area for heat transfer. This surface structure design greatly improves the heat transfer effect without significantly increasing the flow resistance.
[0020] Furthermore, the outer surface of the heat exchange shell is provided with annular heat dissipation fins, which are evenly distributed along the axial direction of the heat exchange shell.
[0021] The beneficial effects of adopting the above-mentioned improvement scheme are as follows: the annular heat dissipation fins on the outer surface of the heat exchange shell greatly increase the heat exchange area with the external environment, improve the heat exchange unit's ability to dissipate heat to the outside, and the annular structure of the heat dissipation fins is evenly distributed along the axial direction to ensure uniform heat dissipation on the entire surface of the heat exchange shell, effectively avoiding the occurrence of local overheating. The improved external heat dissipation capacity enables the heat exchange unit to operate stably under higher heat loads, while reducing the operating temperature of the heat exchange shell and extending the service life of the equipment.
[0022] Compared with existing technologies, the beneficial effects of the high-efficiency flow guiding structure of the intelligent heat exchanger unit provided by this utility model are as follows: Through the spiral guide vanes, a forced spiral flow mode is established within the heat exchange shell, completely changing the flow state of the fluid in traditional heat exchange equipment. This ensures that the fluid maintains a highly turbulent state throughout the heat exchange process, effectively eliminating the heat transfer boundary layer and avoiding the formation of heat transfer dead zones. The rotational motion of the spiral guide vanes further enhances the mixing and heat transfer effects of the fluid. Combined with the labyrinthine flow channels formed by the longitudinal heat dissipation fins on the inner wall of the heat exchange shell, the heat exchange area and heat transfer coefficient are significantly improved. The radial through-hole design of the central rotating shaft achieves thorough mixing of the internal and external fluids, further strengthening the heat transfer process. The adjustment mechanism allows for intelligent adjustment of the entire heat exchange process according to actual operating conditions, greatly improving the adaptability and operating efficiency of the equipment. Compared with traditional heat exchange equipment, this utility model achieves higher heat exchange efficiency under the same operating conditions, while also exhibiting better energy-saving effects and a longer service life, providing an efficient, intelligent, and reliable technical solution for the industrial heat exchange field. Attached Figure Description
[0023] To more clearly illustrate the technical solutions of the embodiments of this utility model, the drawings used in the description of the embodiments of this utility model will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0024] Figure 1 A schematic diagram of a high-efficiency flow guiding structure for an intelligent heat exchanger unit;
[0025] Figure 2 A schematic cross-sectional view of a high-efficiency flow guiding structure for an intelligent heat exchanger unit;
[0026] The attached diagram lists the components represented by each number as follows:
[0027] 10. Heat exchange shell; 101. Liquid inlet; 102. Liquid outlet; 103. Annular groove; 11. Spiral guide vane; 12. Central rotating shaft; 13. Support frame; 131. Base; 132. Column; 133. Horizontal connecting rod; 14. Sealing end cap; 15. Adjustment mechanism; 151. Transmission gear; 152. Drive motor; 16. Clamp; 17. Longitudinal heat dissipation fins; 18. Radial through hole; 19. Annular heat dissipation fins. Detailed Implementation
[0028] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings.
[0029] Example 1:
[0030] like Figure 1 Figure 2 shows a first embodiment of the high-efficiency flow guiding structure of an intelligent heat exchanger unit provided by this utility model. In this embodiment, it includes a heat exchange shell 10, spiral guide vanes 11, a central rotating shaft 12, a support frame 13, a sealing end cap 14, and an adjusting mechanism 15. The heat exchange shell has a cylindrical structure, and an annular groove 103 is provided on the inner wall surface of the heat exchange shell. An inlet 101 and an outlet 102 are respectively provided at both ends of the heat exchange shell. The central rotating shaft is arranged along the axial direction of the heat exchange shell, and the two ends of the central rotating shaft are rotatably connected to the inner walls of the two ends of the heat exchange shell through bearings. The spiral guide vanes have a propeller-shaped structure. The spiral guide vanes are fixedly installed on the outer surface of the central rotating shaft, and a clearance fit is formed between the outer edge of the spiral guide vanes and the inner wall of the heat exchange shell. The support frame includes a base 131 and a column 132. The base is a rectangular plate structure, and the column is vertically fixed on the base. The heat exchange shell is fixedly installed on the column by a clamp 16. Sealing end caps are installed at both ends of the heat exchange shell and are connected to the heat exchange shell by flange bolts. The adjustment mechanism includes a transmission gear 151 and a drive motor 152. The drive motor is fixedly installed on the base of the support frame, and the output shaft of the drive motor is connected to the transmission gear through a coupling. The transmission gear is meshed with one end of the central rotating shaft.
[0031] In the above technical solution, the spiral guide vanes are distributed in an equidistant spiral along the axial direction of the central rotation axis. The axial distance between two adjacent spiral guide vanes is 2 to 5 times the diameter of the central rotation axis. The spiral angle of the spiral guide vanes is 30 to 60 degrees. The material of the spiral guide vanes is stainless steel.
[0032] Furthermore, in the above technical solution, the inner wall surface of the heat exchange shell is provided with multiple longitudinal heat dissipation fins 17. The longitudinal heat dissipation fins are evenly distributed along the circumference of the inner wall of the heat exchange shell. The number of longitudinal heat dissipation fins is 8 to 16. The height of the longitudinal heat dissipation fins is 5% to 15% of the inner diameter of the heat exchange shell. The longitudinal heat dissipation fins and the outer edge of the spiral guide vanes form a labyrinth-like flow channel.
[0033] Furthermore, in the above technical solution, the surface of the central rotating shaft is provided with a plurality of radial through holes 18. The radial through holes are evenly distributed along the axial direction of the central rotating shaft. The diameter of the radial through holes is 10% to 20% of the diameter of the central rotating shaft. The axial distance between two adjacent radial through holes is 1 to 3 times the diameter of the central rotating shaft. The radial through holes are staggered from the installation positions of the spiral guide vanes.
[0034] Furthermore, in the above technical solution, the sealing end cap has a disc-shaped structure, and a shaft hole is opened at the center of the sealing end cap. The inner diameter of the shaft hole and the outer diameter of the central rotating shaft form a clearance fit. A sealing ring is provided in the shaft hole, and the sealing ring is made of nitrile rubber material.
[0035] Furthermore, in the above technical solution, the columns of the support frame are connected by a transverse connecting rod 133. The transverse connecting rod has a square tubular structure. Both ends of the transverse connecting rod are welded and fixed to the adjacent columns respectively. A fixing hole is provided in the middle of the transverse connecting rod. The fixing hole is used to install temperature sensors and pressure sensors. The diameter of the fixing hole is 20 mm to 40 mm.
[0036] Furthermore, in the above technical solution, the surface of the spiral guide vane is provided with corrugated protrusions, which are distributed in a sinusoidal waveform along the length direction of the spiral guide vane.
[0037] Furthermore, in the above technical solution, the outer surface of the heat exchange shell is provided with annular heat dissipation fins 19, which are evenly distributed along the axial direction of the heat exchange shell.
[0038] Furthermore, in the above technical solution, the transmission gear adopts a helical gear structure with 20 to 40 teeth and a helix angle of 8 to 25 degrees. The helical gear structure offers advantages such as smooth transmission, low noise, and high load-bearing capacity. The 20 to 40 teeth design ensures an appropriate transmission ratio and accuracy. The helix angle range of 8 to 25 degrees ensures the transmission advantages of helical gears while avoiding excessive axial force. The operational stability of the helical gear transmission system directly affects the rotational accuracy of the helical guide vanes, thus influencing the overall heat exchange process. Optimized gear parameter design ensures the long-term reliable operation of the transmission system.
[0039] The specific method of using this utility model is as follows: First, prepare for the installation of the equipment by placing the support frame on a flat foundation, ensuring the base is level. Then, fix the heat exchange shell to the column of the support frame using clamps, ensuring the axis of the heat exchange shell remains horizontal. When installing the central rotating shaft, first remove the sealing end cap at one end, insert the central rotating shaft into the heat exchange shell from one end, ensuring the central rotating shaft can rotate freely in the bearing. Then, reinstall the sealing end cap and tighten the flange bolts. When connecting the adjustment mechanism, fix the drive motor to the base of the support frame, connect the output shaft of the drive motor to the transmission gear through a coupling, and then mesh the transmission gear with the central rotating shaft. Before starting the equipment, a system check is required, including checking whether all connections are tight, whether the seals are good, and whether the transmission system is normal. During startup, first start the drive motor, adjust the speed to an appropriate value, then open the fluid inlet valve and slowly increase the fluid flow rate to the design value. During operation, it is necessary to continuously monitor the system's temperature, pressure, flow rate, and other parameters, and adjust the speed of the spiral guide vanes according to the heat exchange effect requirements. When handling fluids of different properties or changing heat exchange conditions, the rotational speed of the spiral guide vanes should be adjusted accordingly to achieve the best heat exchange effect. When shutting down the equipment, the fluid inlet valve should be closed first, and the drive motor should be stopped only after the fluid in the system has been drained. During regular maintenance, the wear condition of the spiral guide vanes, the lubrication condition of the bearings, and the sealing performance of the seals should be checked. Worn parts should be replaced promptly to ensure the normal operation of the equipment.
[0040] The following is a specific embodiment of this utility model: The intelligent heat exchanger unit's high-efficiency flow guiding structure in this embodiment is applied to the crude oil preheating system of a petrochemical plant. The heat exchange shell is made of 316L stainless steel, with an inner diameter of 800 mm, a length of 2000 mm, and a wall thickness of 12 mm. It can withstand a working pressure of 1.6 MPa and a working temperature of 350 degrees Celsius. Twelve longitudinal heat dissipation fins are arranged on the inner wall of the heat exchange shell, with a fin height of 60 mm and a thickness of 8 mm, evenly distributed circumferentially. The fin surface is precision machined to reduce flow resistance. The central rotating shaft is made of 40Cr alloy steel, with a diameter of 120 mm and a length of 2100 mm. The surface is heat-treated to improve strength and wear resistance. Twenty-four radial through holes, each with a diameter of 15 mm, are evenly distributed along the axial direction at 80 mm intervals. The spiral guide vanes are made of 304 stainless steel plate, 6 mm thick, with a helix angle of 45 degrees and a blade width of 80 mm. They are spirally distributed along the central rotation axis, with an axial spacing of 300 mm between adjacent blades and a 5 mm gap between the outer edge of the blade and the inner wall of the heat exchange shell. The surface of the spiral guide vanes features sinusoidal corrugations with an amplitude of 3 mm and a wavelength of 50 mm, effectively increasing the heat transfer area. The support frame is welded from Q235 carbon steel, with a base size of 1500 mm × 1000 mm × 20 mm, four columns with a diameter of 100 mm and a height of 1200 mm, and lateral connecting rods made of 80 mm × 80 mm square tubing. The sealing end caps are machined from 316L stainless steel forgings, 25 mm thick, with a central shaft hole diameter of 125 mm, and are fitted with high-temperature resistant nitrile rubber sealing rings. The regulating mechanism uses a variable frequency speed-regulating three-phase asynchronous motor with a power of 7.5 kW. It drives the central rotating shaft through a reducer and gear transmission system, allowing for continuous speed adjustment from 10 to 100 rpm. The transmission gears are made of 20CrMnTi carburized steel with 32 teeth, a module of 8, a helix angle of 15 degrees, and a surface hardness of HRC58-62. The entire system is equipped with monitoring devices such as temperature sensors, pressure sensors, and flow meters to achieve real-time monitoring of the heat exchange process. In actual operation, crude oil enters from one end of the heat exchange shell, forming a strong spiral flow under the action of the spiral guide vanes, efficiently exchanging heat with the steam system. The heated crude oil is then output from the other end. The system operates stably, with significantly improved heat exchange efficiency. The crude oil outlet temperature can be precisely controlled near the set value, meeting the requirements of subsequent processes. The equipment has a compact structure, small footprint, and is easy to maintain, offering good economic and social benefits.
[0041] Example 2:
[0042] This embodiment 2 is an improved scheme for heat exchange of high-viscosity fluids based on embodiment 1. Building upon embodiment 1, the structure of the spiral guide vanes is optimized. The corrugated protrusions on the vane surface are replaced with a trapezoidal tooth structure with a tooth height of 5 mm, a tooth pitch of 30 mm, and a tooth angle of 60 degrees. This structure provides stronger shearing action for high-viscosity fluids, effectively reducing the adverse effects of fluid viscosity on heat transfer. The number of radial through-holes on the central rotating shaft is increased to 36, and the hole diameter is enlarged to 20 mm. Micro-spiral grooves are set inside the through-holes to further enhance the fluid mixing effect. The longitudinal heat dissipation fins on the inner wall of the heat exchange shell adopt a variable cross-section design, with a root thickness of 10 mm and a top thickness of 6 mm. This design ensures sufficient heat conduction while reducing flow resistance. The adjustment mechanism adds a temperature feedback control function, automatically adjusting the rotation speed of the spiral guide vanes according to the outlet temperature. When the outlet temperature deviates from the set value, the system automatically adjusts the rotation speed to maintain a stable heat exchange effect. A double-layer sealing structure is added to the shaft hole of the sealing end cap: the inner layer uses a mechanical seal, and the outer layer uses a packing seal, effectively preventing leakage of high-viscosity fluids. Heating pipes are installed inside the transverse connecting rods of the support frame, which can preheat the equipment when handling easily solidifying high-viscosity fluids, preventing fluid solidification and blockage. The entire system is also equipped with a cleaning system that regularly cleans the spiral guide vanes and heat exchange surfaces online to maintain good heat transfer performance.
[0043] Example 3:
[0044] This embodiment 3 is a special structure specifically designed for heat exchange with corrosive media, based on embodiment 1. The heat exchange shell and spiral guide vanes are all made of Hastelloy C-276 material, which has excellent corrosion resistance and can operate stably for a long time in harsh environments such as strong acids and alkalis. The surface of the spiral guide vanes undergoes a special electrochemical polishing treatment, with a surface roughness Ra value of less than 0.4 micrometers, effectively reducing the adhesion and accumulation of corrosive media. The central rotating shaft is made of nickel-based alloy material with a ceramic coating of 0.2 mm thickness, further improving corrosion resistance and wear resistance. The inner surface of the radial through holes is passivated to form a dense oxide film, preventing erosion by corrosive media. The longitudinal heat dissipation fins on the inner wall of the heat exchange shell are manufactured using an integrated casting process, avoiding potential corrosion risks from welded joints. The sealing system adopts a fully enclosed design, and the sealing rings are made of fluororubber material, which has excellent chemical corrosion resistance. The surface of the support frame undergoes double anti-corrosion treatment with hot-dip galvanizing and epoxy resin coating, maintaining structural integrity in harsh environments. The motor and reducer of the regulating mechanism are designed for corrosion resistance. The motor housing is made of stainless steel, and the internal components undergo special anti-corrosion treatment. The entire system is equipped with a corrosion monitoring device to monitor the corrosion status of the equipment in real time, providing a scientific basis for equipment maintenance. The transmission gears are made of ceramic material, which has advantages such as high hardness, corrosion resistance, and wear resistance, significantly extending their service life.
[0045] Specifically, the principle of this invention is as follows: By incorporating rotatable helical guide vanes within the heat exchange shell, this invention fundamentally alters the flow pattern of the fluid during the heat exchange process. Upon entering the heat exchange shell, the fluid is forced to flow along a helical path under the action of the helical guide vanes. Due to the multiple heat transfer enhancement mechanisms inherent in helical flow, firstly, the helical flow significantly increases the contact time and area between the fluid and the heat exchange wall, allowing for greater heat exchange with the surface. Secondly, the centrifugal force generated by the helical flow induces a radial velocity component in the fluid, enhancing radial mixing and effectively eliminating temperature stratification, a common phenomenon in traditional heat exchange equipment. Thirdly, the rotational motion of the helical guide vanes continuously disrupts the formation of the fluid boundary layer, maintaining the fluid in a highly turbulent state and significantly improving the convective heat transfer coefficient. The radial through-holes on the surface of the central rotating shaft further enhance the fluid mixing effect, enabling thorough exchange between the inner and outer fluid layers and eliminating heat transfer dead zones. The labyrinthine flow channel formed by the longitudinal heat dissipation fins and helical guide vanes on the inner wall of the heat exchange shell causes the fluid to undergo multiple directional changes during flow. Each directional change causes variations in flow velocity and pressure, generating additional turbulence effects. The regulating mechanism, by controlling the rotational speed of the helical guide vanes, can adjust the fluid flow intensity according to different operating conditions, thereby controlling and regulating the heat exchange process. The synergistic effect of this multi-faceted enhanced heat transfer mechanism enables this invention to maintain high heat exchange efficiency under various operating conditions.
Claims
1. A high-efficiency flow guide structure of an intelligent heat exchange unit, characterized in that, The system includes a heat exchange shell, spiral guide vanes, a central rotating shaft, a support frame, sealing end caps, and an adjusting mechanism. The heat exchange shell has a cylindrical structure with an annular groove on its inner wall. An inlet and an outlet are located at both ends of the heat exchange shell. The central rotating shaft is positioned along the axial direction of the heat exchange shell, and its two ends are rotatably connected to the inner walls of both ends of the heat exchange shell via bearings. The spiral guide vanes have a propeller-like structure and are fixedly mounted on the outer surface of the central rotating shaft, with a clearance fit between the outer edge of the spiral guide vanes and the inner wall of the heat exchange shell. The support frame includes a base and a column. The base has a rectangular plate structure, and the column is vertically fixed to the base. The heat exchange shell is fixedly mounted on the column using clamps. Sealing end caps are installed at both ends of the heat exchange shell and connected to the heat exchange shell via flange bolts. The adjusting mechanism includes a transmission gear and a drive motor. The drive motor is fixedly mounted on the base of the support frame, and its output shaft is connected to the transmission gear via a coupling. The transmission gear meshes with one end of the central rotating shaft.
2. The high-efficiency flow guiding structure of the intelligent heat exchanger unit according to claim 1, characterized in that, The spiral guide vanes are distributed in an equidistant spiral along the axial direction of the central rotation axis. The axial distance between two adjacent spiral guide vanes is 2 to 5 times the diameter of the central rotation axis. The spiral angle of the spiral guide vanes is 30 to 60 degrees. The material of the spiral guide vanes is stainless steel.
3. The high-efficiency flow guiding structure of the intelligent heat exchanger unit according to claim 2, characterized in that, The inner wall of the heat exchange shell is provided with multiple longitudinal heat dissipation fins. The longitudinal heat dissipation fins are evenly distributed along the circumference of the inner wall of the heat exchange shell. The number of longitudinal heat dissipation fins is 8 to 16. The height of the longitudinal heat dissipation fins is 5% to 15% of the inner diameter of the heat exchange shell. The longitudinal heat dissipation fins and the outer edge of the spiral guide vanes form a labyrinth flow channel.
4. The high-efficiency flow guiding structure of the intelligent heat exchanger unit according to claim 3, characterized in that, The surface of the central rotating shaft has multiple radial through holes, which are evenly distributed along the axial direction of the central rotating shaft. The diameter of the radial through holes is 10% to 20% of the diameter of the central rotating shaft, and the axial distance between two adjacent radial through holes is 1 to 3 times the diameter of the central rotating shaft. The radial through holes are staggered from the installation positions of the spiral guide vanes.
5. The high-efficiency flow guiding structure of an intelligent heat exchanger unit according to claim 4, characterized in that, The sealing end cap has a disc-shaped structure, and a shaft hole is opened at the center of the sealing end cap. The inner diameter of the shaft hole and the outer diameter of the central rotating shaft form a clearance fit. A sealing ring is installed in the shaft hole, and the sealing ring is made of nitrile rubber material.
6. The high-efficiency flow guiding structure of the intelligent heat exchanger unit according to claim 5, characterized in that, The columns of the supporting frame are connected by horizontal connecting rods. The horizontal connecting rods are square tubular structures. The two ends of the horizontal connecting rods are welded and fixed to the adjacent columns respectively. A fixing hole is provided in the middle of the horizontal connecting rod. The fixing hole is used to install temperature sensors and pressure sensors. The diameter of the fixing hole is 20 mm to 40 mm.
7. The high-efficiency flow guiding structure of an intelligent heat exchanger unit according to claim 6, characterized in that, The surface of the spiral guide vane is provided with corrugated protrusions, which are distributed in a sinusoidal waveform along the length of the spiral guide vane.
8. The high-efficiency flow guiding structure of an intelligent heat exchanger unit according to claim 7, characterized in that, The outer surface of the heat exchange shell is provided with annular heat dissipation fins, which are evenly distributed along the axial direction of the heat exchange shell.