A high viscosity static heat exchanger

Abstract

The utility model discloses a kind of high viscosity static heat exchangers, including hollow shell, first tube plate and second tube plate are respectively fixedly connected with shell two ends, shell side surface one end is equipped with heat exchange medium inlet, shell side surface other end is equipped with heat exchange medium outlet, heat exchange medium inlet and heat exchange medium outlet are all communicated with shell interior;Heat exchange tube is fixedly provided between first tube plate and second tube plate, mixed element is fixedly installed in heat exchange tube interior, mixed element includes multiple first and last connected mixing units, each mixing unit is spiral twist sheet structure, and adjacent two mixing units are crossed and welded fixed with cross shape mode arrangement.

Description

Technical Field

[0001] This utility model relates to the field of heat exchange equipment technology, specifically to a high-viscosity static heat exchanger. Background Technology

[0002] High-viscosity fluids (such as polymer melts, crude oil, heavy oil, syrups, and ointments) are prevalent in the production processes of industries such as petrochemicals, food processing, pharmaceuticals, and polymer synthesis. The heat exchange process of these fluids is a critical link in their technological flow, directly impacting product quality, energy consumption, and production efficiency. However, the inherent physical properties of high-viscosity fluids, such as extremely high viscosity, low Reynolds number (Re), laminar flow dominance, and low thermal diffusivity, pose significant challenges to efficient heat exchange. Currently, the main types of static heat exchangers used for fluid heat exchange in industry include shell-and-tube heat exchangers, plate heat exchangers, and spiral plate heat exchangers, which primarily rely on the fluid's own flow and the structure of the heat exchange elements for heat exchange, with no moving mechanical parts.

[0003] However, traditional static heat exchangers were originally designed for low-viscosity, high-Reynolds-number turbulent fluids, relying on the turbulence effect to disrupt the boundary layer and achieve efficient heat exchange. However, they have many limitations when handling high-viscosity fluids. For example, high-viscosity fluids are typically in a laminar flow state within the tubes, and heat transfer mainly relies on slow thermal conduction, resulting in extremely low heat transfer coefficients and poor heat exchange efficiency. To achieve the required heat exchange capacity, an extremely large heat exchange area is often needed, leading to bulky equipment and high costs. Furthermore, the narrow flow channels of plate heat exchangers are easily clogged by high-viscosity fluids and are difficult to clean. At the same time, their gaskets have limitations regarding material compatibility and operating temperature, making them unsuitable for many high-temperature or corrosive high-viscosity process media. Utility Model Content

[0004] To address the shortcomings of existing technologies, this invention provides a high-viscosity static heat exchanger that overcomes these deficiencies. The design is reasonable; by fixing a mixing element composed of cross-mixing units inside each heat exchange tube of the shell-and-tube heat exchanger, radial mixing is generated through forced separation and rotation of the fluid, disrupting laminar flow and greatly enhancing the heat transfer process.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A high-viscosity static heat exchanger includes a hollow shell, with a first tube sheet and a second tube sheet fixedly connected to both ends of the shell, a heat exchange medium inlet at one end of the side surface of the shell, and a heat exchange medium outlet at the other end of the side surface of the shell, both of which are connected to the interior of the shell.

[0007] A heat exchange tube is fixedly inserted between the first tube sheet and the second tube sheet. A mixing element is fixedly installed inside the heat exchange tube. The mixing element includes multiple mixing units connected end to end. Each mixing unit is a spiral twisted sheet structure, and adjacent mixing units are arranged in a cross shape and welded together.

[0008] Preferably, multiple baffles are fixedly installed inside the housing in a direction perpendicular to the axis. The multiple baffles are arranged at intervals along the axial direction of the housing, and the baffles are staggered among themselves.

[0009] Preferably, the baffle plate has through holes for the heat exchange tubes to pass through.

[0010] Preferably, multiple heat exchange tubes are provided, and the multiple heat exchange tubes are arranged in parallel between the first tube sheet and the second tube sheet.

[0011] Preferably, the heat exchange tube is sealed and fixed to the first tube sheet and the second tube sheet by fusion welding.

[0012] Preferably, a detachable quick-connect structure is formed between the first tube sheet and the second tube sheet and both ends of the housing.

[0013] This invention provides a high-viscosity static heat exchanger with the following advantages: Through the spiral-twisted plate structure of the mixing unit, the originally unified fluid stream is divided into two thin streams, changing their flow direction and inducing initial rotation. Furthermore, because adjacent mixing units are arranged in a cross shape, when the thin stream continues to flow to the next mixing unit that intersects with the previous one, it is again divided, its direction changed, and it collides and mixes with fluids from other channels. This process is repeated in each mixing unit. This causes the material to undergo multiple division, reversal, and mixing processes within the heat exchange tube, resulting in a strong radial secondary flow that completely breaks the inherent, stable laminar flow state of the high-viscosity fluid. This allows the fluid with a uniform temperature at the center of the heat exchange tube to be continuously "sweeped" to the tube wall region for sufficient heat exchange, while simultaneously mixing the fluid near the tube wall that has already undergone heat exchange back into the main fluid. This allows for the continuous thinning or even destruction of the thermal boundary layer with the greatest heat transfer resistance, ensuring that the temperature gradient between the pipe wall and the fluid core remains at an extremely high level, thereby transforming the heat transfer mode from inefficient heat conduction to efficient convection heat transfer. Attached Figure Description

[0014] To more clearly illustrate the technical solutions in this utility model or the prior art, the accompanying drawings used in the description of this utility model or the prior art will be briefly introduced below.

[0015] Figure 1 A schematic diagram of the structure of this utility model;

[0016] Figure 2 A schematic diagram of the cross-sectional structure of this utility model;

[0017] Figure 3 A schematic diagram of the structure of the hybrid element in this utility model;

[0018] Figure 4 A schematic diagram of the structure of the hybrid unit in this utility model;

[0019] Explanation of the labels in the diagram:

[0020] 1. Shell; 2. First tube sheet; 3. Second tube sheet; 4. Heat exchange medium inlet; 5. Heat exchange medium outlet; 6. Heat exchange tube; 7. Mixing element; 8. Baffle; 701. Mixing unit. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of this utility model clearer, the technical solutions of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0022] Example 1, as Figure 1-4 As shown, a high viscosity static heat exchanger includes a hollow shell 1. A first tube sheet 2 and a second tube sheet 3 are fixedly connected to both ends of the shell 1. A heat exchange medium inlet 4 is provided at one end of the side surface of the shell 1, and a heat exchange medium outlet 5 is provided at the other end of the side surface of the shell 1. Both the heat exchange medium inlet 4 and the heat exchange medium outlet 5 are connected to the interior of the shell 1.

[0023] A heat exchange tube 6 is fixedly inserted between the first tube sheet 2 and the second tube sheet 3. A mixing element 7 is fixedly installed inside the heat exchange tube 6. The mixing element 7 includes multiple mixing units 701 connected end to end. Each mixing unit 701 is a spiral twisted sheet structure, and adjacent mixing units 701 are arranged in a cross shape and welded and fixed.

[0024] Working principle:

[0025] In actual operation, the heat exchange medium (steam or cooling water) enters the shell 1 from the heat exchange medium inlet 4, then flows through the space between the outer wall of the heat exchange tube 6 and the shell 1, and exchanges heat with the material in the heat exchange tube 6. After absorbing or releasing heat, the heat exchange medium is finally discharged through the heat exchange medium outlet 5.

[0026] In this process, high-viscosity material enters the heat exchange tube 6 from the end of the shell 1 near the heat exchange medium outlet 5. As the high-viscosity material flows inside the heat exchange tube 6, when it passes through the mixing unit 701, the spiral-twisted sheet-like structure of the mixing unit 701 splits the originally unified fluid stream into two thin streams, changing their flow direction and causing initial rotation. Since adjacent mixing units 701 are arranged in a cross shape, when the thin stream continues to flow to the next mixing unit 701 that intersects with the previous one, it will be split and changed direction again, colliding and mixing with fluids from other channels. This process is repeated in each mixing unit 701. This causes the material to undergo multiple splitting, turning, and mixing processes within the heat exchange tube 6, resulting in a strong radial secondary flow that completely breaks the inherent, stable laminar flow state of the high-viscosity fluid. The fluid, with a uniform temperature at the center of heat exchange tube 6, is continuously "sweeped" to the high-temperature (or low-temperature) tube wall region for sufficient heat exchange. Simultaneously, the fluid near the tube wall that has already undergone heat exchange is "replaced" and mixed back into the main fluid. This mechanism is equivalent to continuously thinning or even destroying the thermal boundary layer with the greatest heat transfer resistance, ensuring that the temperature gradient between the tube wall and the fluid core region remains at an extremely high level. This transforms the heat transfer mode from inefficient heat conduction to efficient convection heat transfer. Subsequently, the high-viscosity material that has completed heat exchange inside heat exchange tube 6 is finally discharged from the end of shell 1 near the heat exchange medium inlet 4, achieving a highly efficient and continuous heat exchange process.

[0027] In addition, during the entire material flow process, the strong shearing and radial movement of the fluid can effectively flush the inner wall of the heat exchange tube, preventing material scaling, coking or deposition, maintaining the long-term cleanliness and efficiency of the heat exchange surface, and reducing the maintenance frequency.

[0028] This invention utilizes a spirally twisted, sheet-like structure and a cross-shaped arrangement of multiple mixing units 701 to form a strip-shaped mixing element 7. This forces the material to undergo a "splitting-rotating-recombining" physical process during flow, completely disrupting the stable laminar flow state of the high-viscosity fluid and inducing strong radial secondary flow, thus significantly thinning the thermal boundary layer. This effectively transforms inefficient heat conduction into highly efficient forced convection. Compared to traditional shell-and-tube heat exchangers, it requires a smaller heat exchange area and is more compact to achieve the same heat exchange load.

[0029] In Example 2, as a further preferred embodiment of Example 1, multiple baffles 8 are fixedly installed inside the shell 1 perpendicular to the axial direction. These baffles 8 are spaced apart along the axial direction of the shell 1 and are staggered. The staggered distribution of the baffles 8 divides the inner cavity of the shell 1 into several interconnected tortuous flow channels, forcing the heat exchange medium to flow in a Z-shape along the channels formed by the baffles 8 within the shell 1. This prolongs the residence time of the heat exchange medium within the shell 1 and enhances the heat exchange effect between the heat exchange medium and the heat exchange tube 6.

[0030] In embodiment three, as a further preferred embodiment two, the baffle plate 8 has a through hole for the heat exchange tube 6 to pass through. By having a through hole in the baffle plate 8, the heat exchange tube 6 can pass through the through hole, thereby fixing and supporting the heat exchange tube 6 through the through hole of the baffle plate 8, effectively improving the stability of the heat exchange tube 6 within the shell 1.

[0031] In Example 4, as a further preferred embodiment of Example 1, multiple heat exchange tubes 6 are provided, arranged in parallel between the first tube sheet 2 and the second tube sheet 3. Therefore, in actual production, heat exchange tubes 6 of different diameters and models can be used to adapt to materials of different viscosities and flow rates, thereby further optimizing the heat exchange effect, according to different material requirements.

[0032] In Example 5, as a further preferred embodiment of Example 2, the heat exchange tube 6 is sealed and fixed to the first tube sheet 2 and the second tube sheet 3 by fusion welding. By adopting the fusion welding sealing method, the sealing performance and strength of the connection between the heat exchange tube 6 and the first tube sheet 2 and the second tube sheet 3 can be ensured, effectively preventing material leakage and improving the stability and reliability of the entire heat exchanger.

[0033] In Example 6, as a further preferred embodiment of Example 2, a detachable quick-connect structure is formed between the first tube sheet 2 and the second tube sheet 3 and both ends of the shell 1. This detachable quick-connect structure allows for convenient and quick assembly and disassembly of the first tube sheet 2 and the second tube sheet 3 with the shell 1, facilitating equipment maintenance, repair, and replacement. Simultaneously, the quick-connect structure design ensures the sealing and strength of the connection, preventing material leakage and ensuring the normal operation of the heat exchanger. Specifically, the detachable quick-connect structure can employ clamp connections, flange connections, or threaded connections, flexibly selected according to actual operating conditions. In this embodiment, a threaded connection is used, meaning that external threads are machined at the shell end, while internal threads are machined on the corresponding connecting end faces of the first tube sheet 2 and the second tube sheet 3. The cooperation of the internal and external threads enables quick installation and disassembly.

[0034] The above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although this utility model 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 of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this utility model.

Claims

1. A high-viscosity static heat exchanger, characterized in that: The shell (1) includes a hollow shell (1), with a first tube sheet (2) and a second tube sheet (3) fixedly connected to both ends of the shell (1). A heat exchange medium inlet (4) is provided at one end of the side surface of the shell (1), and a heat exchange medium outlet (5) is provided at the other end of the side surface of the shell (1). Both the heat exchange medium inlet (4) and the heat exchange medium outlet (5) are connected to the interior of the shell (1). A heat exchange tube (6) is fixedly inserted between the first tube sheet (2) and the second tube sheet (3). A mixing element (7) is fixedly installed inside the heat exchange tube (6). The mixing element (7) includes multiple mixing units (701) connected end to end. Each mixing unit (701) is a spiral twisted sheet structure, and two adjacent mixing units (701) are arranged in a cross shape and welded together.

2. The high-viscosity static heat exchanger according to claim 1, characterized in that: Multiple baffles (8) are fixedly installed inside the housing (1) perpendicular to the axis direction. The multiple baffles (8) are arranged at intervals along the axial direction of the housing (1), and the baffles (8) are staggered.

3. A high-viscosity static heat exchanger according to claim 2, characterized in that: The baffle plate (8) has through holes through which the heat exchange tube (6) passes.

4. A high-viscosity static heat exchanger according to claim 1, characterized in that: Multiple heat exchange tubes (6) are provided, and the multiple heat exchange tubes (6) are arranged in parallel between the first tube sheet (2) and the second tube sheet (3).

5. A high-viscosity static heat exchanger according to claim 1, characterized in that: The heat exchange tube (6) is sealed and fixed to the first tube sheet (2) and the second tube sheet (3) by fusion welding.

6. A high-viscosity static heat exchanger according to claim 1, characterized in that: The first tube sheet (2) and the second tube sheet (3) form a detachable quick-connect structure with both ends of the housing (1).

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