A whole-body waste heat exchanger

Abstract

This utility model discloses a whole-body waste heat exchanger, relating to the field of industrial waste heat recovery and utilization technology. It includes an integrally formed whole shell, a waste heat inlet and outlet, multiple heat medium sleeves arranged inside the shell, flow guide baffles, spiral flow guide fins, and an external insulation layer. The waste heat inlet and outlet are located at opposite ends along the shell axis, forming a counter-flow channel. The flow guide baffles divide the waste heat channel into sequentially connected S-shaped flow channels. The spiral flow guide fins generate rotational disturbances in the waste heat fluid while it flows axially, enhancing turbulence intensity and extending the heat transfer path. The heat medium sleeves are U-shaped heat exchange tubes with annular microfins, staggered within the waste heat channel, and sealed to the inlet and outlet water mains via a tube sheet, achieving efficient counter-flow heat exchange with the waste heat fluid. The external insulation layer consists of a ceramic fiber cotton insulation layer, a high-temperature resistant adhesive layer, and a stainless steel cladding layer, providing excellent thermal insulation and protection performance. It is suitable for high-temperature waste heat recovery and utilization.

Description

Technical Field

[0001] This utility model relates to the field of industrial waste heat recovery and utilization technology, specifically a whole-body waste heat exchanger. Background Technology

[0002] In industrial production processes, waste heat recovery and utilization are crucial for improving energy efficiency, reducing operating costs, and minimizing environmental pollution. Existing waste heat exchangers come in various types, including shell-and-tube, plate, and finned-tube heat exchangers. These devices generally rely on heat exchange between the waste heat fluid and the heat transfer medium to convert and utilize waste heat for process heating or domestic hot water systems. In existing technologies, traditional shell-and-tube waste heat exchangers have a relatively simple structure, typically employing a straight-through flow channel design. The waste heat fluid flows unidirectionally along the axial direction, exchanging heat with the heat transfer medium within a limited contact area. This structure suffers from a short heat exchange path and low fluid turbulence, resulting in low heat transfer efficiency. Furthermore, the flow state of the waste heat fluid within the shell is restricted, leading to insufficient fluid disturbance and inadequate utilization of the heat exchange surface. In addition, most heat exchangers lack efficient external insulation, resulting in significant heat loss during operation, which is detrimental to improving overall thermal efficiency.

[0003] For high-temperature waste heat scenarios, some heat exchangers add baffles or fins inside the shell to extend the flow path and increase the heat exchange area, but structural shortcomings still exist. For example, improper baffle arrangement can easily create flow dead zones; finned structures are prone to scaling or wear under high-temperature and dusty exhaust gas conditions, affecting long-term operational stability. Regarding the design of the external insulation layer, traditional methods often use a single layer of insulation material, which has limited high-temperature resistance, waterproofing, and dustproofing capabilities, leading to rapid degradation of insulation performance and frequent maintenance. In summary, existing waste heat exchangers still have room for improvement in heat transfer efficiency, fluid turbulence effect, and insulation performance, especially under high-temperature, dusty, and long-term stable operation conditions. There is an urgent need for a full-body waste heat exchanger with optimized structure, high heat exchange efficiency, low heat loss, and convenient maintenance. Utility Model Content

[0004] The purpose of this invention is to provide a whole-body waste heat exchanger to solve the problems mentioned in the background art.

[0005] To solve the above-mentioned technical problems, this utility model provides a whole-body waste heat exchanger, including: an integrally formed whole shell, multiple heat medium sleeves disposed inside the whole shell, a waste heat inlet and a waste heat outlet, a flow guide baffle and an external insulation layer; the waste heat inlet and waste heat outlet are respectively disposed at both ends along the axial direction of the whole shell and form a counterflow channel, the heat medium sleeves penetrate the whole shell and are connected to the water inlet and water outlet main pipes outside the shell, the flow guide baffle divides the waste heat channel into S-shaped flow channels connected sequentially along the waste heat flow direction, and the external insulation layer covers the outer surface of the whole shell.

[0006] In one possible implementation, the inner wall of the shell body is provided with spiral guide ribs along the axial direction. The spiral guide ribs are continuous strip-shaped metal plates, with one side edge welded and fixed to the inner wall of the shell body along its entire length, and the other side edge extending into the shell body and contacting the waste heat flow channel. The spiral guide ribs are continuously arranged along the axial direction of the shell body at a spiral angle of 15° to 45° relative to the axis of the shell body, and adjacent spiral rings are kept at equal intervals, so that the waste heat fluid generates tangential rotational motion while flowing axially, which is used to extend the heat transfer path and enhance the turbulence intensity.

[0007] In one possible implementation, the heat medium jacket is a U-shaped heat exchange tube, and annular microfins are welded to its outer surface.

[0008] In one possible implementation, the two ends of the U-shaped heat exchange tube are fixedly connected to the inlet main pipe and the outlet main pipe, respectively, and are sealed to the shell body through the tube sheet.

[0009] In one possible implementation, the flow guide baffles are arc-shaped steel plate structures and are arranged at equal intervals along the direction of waste heat flow, with both ends of each flow guide baffle fixedly connected to the inner wall of the shell.

[0010] In one possible implementation, the waste heat inlet is located at one end of the shell and the waste heat outlet is located at the other end, so as to achieve the upward flow direction of the waste heat fluid.

[0011] In one possible implementation, the external insulation layer comprises, from the inside out, a ceramic fiber cotton insulation layer, a stainless steel cladding layer, and a high-temperature resistant adhesive layer between the two. The ceramic fiber cotton insulation layer is laid on the outer wall of the entire shell in a segmented, wrapping manner, with the joints between adjacent wrapping segments arranged in a staggered pattern. The high-temperature resistant adhesive layer is an inorganic silicate-based adhesive material, applied and cured between the outer wall of the shell and the ceramic fiber cotton insulation layer. The stainless steel cladding layer is fixed to the outside of the insulation layer by a combination of overlapping seam riveting and spot welding. The overlapping seam has an outwardly folded rainproof edge to prevent external moisture or dust from penetrating the interior of the insulation layer.

[0012] In one possible implementation, the bottom of the casing has a drain port and the top has an inspection port.

[0013] In one possible implementation, the waste heat channel and the heat medium jacket are arranged in an alternating manner, so that the waste heat fluid and the heat medium fluid exchange heat at multiple intersection points.

[0014] In one possible implementation, a high-temperature dust filter is provided at the waste heat inlet to prevent large particulate impurities from entering the interior of the shell.

[0015] Compared with the prior art, the beneficial effects of this utility model are: This utility model discloses a whole-body waste heat exchanger. Through the combination design of an integrally formed whole shell, a waste heat channel with spiral guide fins, a U-shaped heat exchange tube and annular microfins, combined with an S-shaped flow channel and a high-efficiency external insulation structure, it achieves efficient heat exchange between waste heat fluid and heat medium fluid at multiple intersections, and solves the problems of low heat exchange efficiency, large heat loss and inconvenient operation and maintenance of existing waste heat utilization devices. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the warning component in this utility model; Figure 3 This is a schematic diagram of the structure of the bracket in this utility model. In the diagram: 1. Full shell; 2. Waste heat inlet; 3. Waste heat outlet; 4. Heat medium jacket; 5. Main water inlet pipe; 6. Main water outlet pipe; 8. Annular microfins; 10. Spiral guide fins; 11. External insulation layer; 12. Ceramic fiber cotton insulation layer; 13. Stainless steel cladding layer; 14. High-temperature resistant adhesive layer; 15. Overlap joint; 16. Rainproof edge; 17. Drain outlet; 18. Inspection port; 19. High-temperature dustproof filter. Detailed Implementation

[0017] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0018] Please see Figures 1-3This utility model provides a technical solution: a whole-body waste heat exchanger, comprising an integrally formed whole shell 1, multiple heat medium sleeves 4 arranged inside the whole shell 1, a waste heat inlet 2 and a waste heat outlet 3, a flow guide baffle, and an external insulation layer 11. The waste heat inlet 2 and waste heat outlet 3 are respectively located at both ends along the axial direction of the whole shell 1, forming a counter-current channel; the heat medium sleeves 4 penetrate the whole shell 1 and are connected to the inlet main pipe 5 and outlet main pipe 6 outside the shell; the flow guide baffle divides the waste heat channel into S-shaped flow channels connected sequentially along the waste heat flow direction; the external insulation layer 11 covers the outer surface of the whole shell 1. After the waste heat fluid enters the shell 1 through the waste heat inlet 2, it flows along the counter-current channel and, under the action of the flow guide baffle, passes through multiple S-shaped flow channels in sequence, achieving multiple changes in flow direction, thereby significantly extending the residence time of the fluid in the heat exchange zone. The heat medium flowing inside the heat medium sleeves 4 and the external waste heat fluid undergo sufficient counter-current heat exchange, maintaining a high average temperature difference and improving heat transfer efficiency. The external insulation layer 11 effectively suppresses heat loss and ensures the system's thermal utilization rate. The one-piece molded shell 1 has high structural strength and low leakage risk; the combination of counterflow and S-shaped flow channel increases the heat exchange path length and turbulence, significantly enhancing the heat transfer effect; multiple heat medium sleeves 4 increase the heat exchange area; the external insulation layer 11 reduces heat loss and improves the overall energy efficiency of the system.

[0019] Specifically, the shell 1 can be made of carbon steel, stainless steel or alloy steel, and an anti-corrosion or high-temperature resistant coating can be used depending on the working conditions; the heat medium jacket 4 can be a straight pipe, U-shaped pipe or spiral pipe, and the pipe diameter and wall thickness can be adjusted according to the requirements; the number and arrangement angle of the flow guide baffles can be adjusted, and the flow channel shape can also be changed to a multi-fold or curved type; the insulation layer 11 can be made of rock wool, aerogel felt, etc., and a protective shell can be added to adapt to harsh environments.

[0020] As a preferred embodiment, the inner wall of the shell 1 is provided with spiral guide ribs 10 along the axial direction. The ribs 10 are continuous strip-shaped metal plates, with one side welded to the inner wall of the shell 1 along its entire length, and the other side extending into the shell 1 and contacting the waste heat flow channel. The spiral guide ribs 10 are continuously arranged axially at a spiral angle of 15° to 45° relative to the axis of the shell 1, with adjacent spiral coils maintaining an equidistant interval. This causes the waste heat fluid to generate tangential rotational motion while flowing axially, thereby extending the heat transfer path and enhancing turbulence intensity. The spiral guide ribs 10 force the waste heat fluid to generate rotational disturbances as it moves forward, breaking the boundary layer, promoting mixing, and improving the heat transfer coefficient of the outer wall of the sleeve 4. The control of the spiral angle range achieves an optimal balance between pressure drop and enhanced heat transfer. This significantly improves fluid turbulence, ensures uniform heat transfer, and avoids local dead zones. The metal ribs 10 have good thermal conductivity, which helps to achieve uniform heat diffusion.

[0021] Alternative implementation methods: The rib 10 can be made of stainless steel, copper alloy or high temperature wear-resistant steel, or can be made of perforated plate, corrugated plate or other structures; the helix angle can be adjusted to 10°~60°, and the pitch can be optimized according to the fluid viscosity and flow rate.

[0022] As a preferred example, the heat medium jacket 4 adopts the form of a U-shaped heat exchange tube, and its outer surface is uniformly welded with annular microfins 8.

[0023] The U-shaped tube enables two-way flow within the limited length of the shell 1, extending the path and residence time of the heat medium in the heat exchange zone; the annular microfins 8 expand the heat exchange area and generate local disturbances when the waste heat fluid flows through, further enhancing heat transfer. This reduces the number of pipe end interfaces, lowers the risk of leakage, and alleviates thermal stress; the microfins 8 also improve the heat exchange efficiency per unit volume, making the equipment more compact and efficient.

[0024] Alternative implementation methods: The heat exchange tube can be replaced with a straight tube, a coil, or a multi-fold tube; the microfins 8 can be rectangular, corrugated, or needle-shaped, and fixed by welding, mechanical expansion, or fitting.

[0025] As a preferred embodiment, the two ends of the U-shaped heat exchange tube are fixedly connected to the inlet main pipe 5 and the outlet main pipe 6, respectively, and are sealed and isolated from the shell 1 by a tube sheet. The tube sheet strictly seals the heat exchange tube assembly to the shell 1, preventing the mixing of the heat medium and waste heat fluid, while ensuring pressure resistance. The sealing is reliable, facilitating maintenance and replacement of individual tubes, and ensuring long-term stable operation.

[0026] The tube sheet can be a floating head structure, the U-tube can be designed to be detachable, and the sealing material can be metal gaskets, graphite gaskets or high-temperature rubber rings.

[0027] Specifically, the flow guide baffles are arc-shaped steel plate structures, evenly spaced along the waste heat flow direction, and fixed at both ends to the inner wall of shell 1. The arc-shaped baffles guide the fluid to change direction multiple times, forming segmented S-shaped flow channels, uniformly distributing the fluid flow rate and increasing the local flow velocity. This results in low flow resistance, uniform flow field distribution, and more stable heat exchange.

[0028] Specifically, the waste heat inlet 2 is located at one end of the shell 1, and the waste heat outlet 3 is located above the other end, enabling the waste heat fluid to flow from bottom to top. Utilizing the thermal buoyancy effect, the high-temperature fluid rises naturally, reducing power consumption and facilitating the settling of solid particles. This design features a stable flow field, uniform heat exchange, and reduced risk of ash accumulation and blockage.

[0029] The flow direction can be changed to top inlet and bottom outlet or side inlet and side outlet to match different installation and process conditions.

[0030] Specifically, the external insulation layer 11 comprises, from the inside out, a ceramic fiber insulation layer 12, a high-temperature resistant adhesive layer 14, and a stainless steel cladding layer 13. The ceramic fiber insulation layer 12 is laid in a segmented, wrapped, and staggered manner, fully covering the outer wall of the shell 1. The high-temperature resistant adhesive layer 14 is an inorganic silicate-based adhesive material, cured between the outer wall of the shell 1 and the insulation layer 12. The stainless steel cladding layer 13 is fixed by riveting and spot welding through overlapping seams 15, which have outwardly folded rainproof edges 16. The ceramic fiber insulation layer 12 provides effective insulation due to its low thermal conductivity, the adhesive layer 14 eliminates thermal bridging, and the stainless steel cladding layer 13 provides waterproofing, dustproofing, and mechanical protection.

[0031] Specifically, the shell 1 has a drain port 17 at the bottom and an inspection port 18 at the top. The drain port 17 is used to regularly remove deposited impurities, and the inspection port 18 facilitates internal maintenance and parts replacement. This improves maintainability and extends the stable period of heat exchange performance.

[0032] Specifically, the waste heat channel and the heat medium jacket 4 are arranged in an alternating pattern, allowing the two fluids to exchange heat fully at multiple junctions. The alternating arrangement increases the contact area, prevents fluid short-circuiting, and improves the utilization rate of temperature difference.

[0033] Specifically, a high-temperature dust filter 19 is installed at the waste heat inlet 2 to prevent large particles from entering the interior of the shell 1. This mechanical blocking of large particles prevents erosion and clogging of the heat exchange tube surface. It extends component life, reduces maintenance frequency, and ensures long-term heat exchange performance.

[0034] The filter screen 19 can be made of high-temperature resistant stainless steel wire mesh, ceramic honeycomb or multi-layer mesh structure, and can be designed to be detachable for easy cleaning.

[0035] Working Principle: During operation, high-temperature waste heat fluid enters the heat exchanger through the waste heat inlet 2 located at one end of the shell 1. It first passes through a high-temperature dust filter 19, preventing large particles from entering and causing wear or blockage to the heat exchange elements. The filtered waste heat fluid then flows axially along the shell 1 towards the other end, forming multiple interconnected S-shaped flow channels under the guidance of the flow guide baffles 9. These baffles 9 divide the channels into multiple turning sections, causing the waste heat fluid to change direction multiple times during its journey, effectively extending the residence time of the fluid in the heat exchange zone.

[0036] Meanwhile, the spiral guide ribs 10 arranged axially on the inner wall of the shell 1 apply tangential guidance to the waste heat fluid, causing it to rotate while flowing axially. This rotational disturbance breaks the thermal boundary layer, enhances fluid mixing, and further improves the heat transfer coefficient between the waste heat fluid and the outer wall of the heat medium jacket 4.

[0037] The heat transfer medium enters multiple U-shaped heat exchange tubes arranged inside the shell 1 through the main inlet pipe 5 outside the shell 1, and is sealed and isolated from the shell 1 by the tube sheet. The U-shaped structure enables the heat transfer medium to flow in two passes within the limited length of the shell 1, extending its heat transfer path in the high-temperature region. Each U-shaped heat exchange tube has annular microfins 8 welded to its outer surface to increase the effective heat transfer area and generate local turbulence when the waste heat fluid flows through, thereby enhancing the heat transfer effect.

[0038] The waste heat channels and the heat medium jacket 4 are arranged in an alternating pattern, allowing the two fluids to form heat exchange contact zones in multiple spatial locations, avoiding fluid short-circuiting and improving heat exchange uniformity. Since the waste heat inlet 2 and waste heat outlet 3 are arranged in a bottom-in, top-out flow direction, the system utilizes the thermal buoyancy effect, allowing the high-temperature waste heat fluid to rise naturally, reducing external power consumption, and helping solid particles to settle at the bottom of the shell 1 and be periodically discharged through the drain outlet 17.

[0039] The entire heat exchanger is externally protected by a composite insulation structure consisting of a ceramic fiber insulation layer 12, a high-temperature resistant adhesive layer 14, and a stainless steel cladding layer 13. This structure effectively reduces heat loss and keeps the shell temperature within a safe range. Meanwhile, the stainless steel cladding layer 13 provides rainproof, dustproof, and mechanical protection, making it suitable for outdoor and high-dust environments.

[0040] Under the influence of multiple changes in flow direction and rotational disturbances, the waste heat fluid undergoes efficient countercurrent heat exchange with the heat medium fluid on the outer wall of the staggered heat exchange tubes. Finally, the waste heat fluid is discharged from the waste heat outlet 3 at the other end of the shell 1, while the heat medium fluid is output from the main water outlet 6, which can be used as a heat source for subsequent process heating or heating.

[0041] Through the aforementioned flow and heat exchange processes, the heat exchanger achieves high heat transfer efficiency, low leakage risk, good maintainability, and environmental adaptability within a compact structure.

[0042] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A whole-body waste heat exchanger, characterized in that, include: The integrally formed shell, multiple heat medium sleeves set inside the shell, waste heat inlet and waste heat outlet, flow guide baffle and external insulation layer; The waste heat inlet and the waste heat outlet are located at opposite ends along the axial direction of the shell and form a counter-flow channel. The heat medium sleeve penetrates the shell and is connected to the main water inlet and outlet pipes outside the shell. The flow guide baffle divides the waste heat channel into S-shaped channels connected sequentially along the waste heat flow direction. The external insulation layer covers the outer surface of the shell.

2. The whole-body waste heat exchanger according to claim 1, characterized in that, The inner wall of the shell body is provided with spiral guide ribs along the axial direction. The spiral guide ribs are continuous strip-shaped metal plates, with one side edge welded and fixed to the inner wall of the shell body along its entire length, and the other side edge extending into the shell body and contacting the waste heat flow channel. The spiral guide ribs are arranged continuously along the axial direction of the shell body at a spiral angle of 15° to 45° relative to the axis of the shell body, and adjacent spiral rings are kept at equal intervals. The waste heat fluid generates tangential rotational motion while flowing axially, which is used to extend the heat transfer path and enhance the turbulence intensity.

3. The whole-body waste heat exchanger according to claim 1 or 2, characterized in that, The heat exchanger jacket is a U-shaped heat exchange tube, and annular microfins are welded to its outer surface.

4. The whole-body waste heat exchanger according to claim 3, characterized in that, The two ends of the U-shaped heat exchange tube are fixedly connected to the inlet main pipe and the outlet main pipe, respectively, and are sealed to the shell through the tube sheet.

5. The whole-body waste heat exchanger according to claim 1, characterized in that, The flow guide baffles are arc-shaped steel plate structures, and are arranged at equal intervals along the direction of waste heat flow. The two ends of each flow guide baffle are fixedly connected to the inner wall of the shell.

6. The whole-body waste heat exchanger according to claim 1, characterized in that, The waste heat inlet is located at one end of the shell, and the waste heat outlet is located at the other end, which is used for the flow direction of waste heat fluid from bottom to top.

7. The whole-body waste heat exchanger according to claim 1, characterized in that, The external insulation layer, from the inside out, includes a ceramic fiber cotton insulation layer, a stainless steel covering layer, and a high-temperature resistant adhesive layer located between the two. The ceramic fiber cotton insulation layer is laid on the outer wall of the entire shell in a segmented wrapping manner, and the joints between adjacent wrapping segments are staggered. The high-temperature resistant adhesive layer is an inorganic silicate-based adhesive material, which is applied and cured between the outer wall of the shell and the ceramic fiber cotton insulation layer. The stainless steel cladding layer is fixed to the outside of the insulation layer by a combination of overlapping seam riveting and spot welding. The overlapping seam is provided with an outward folded rainproof edge to prevent external moisture or dust from entering the interior of the insulation layer.

8. The whole-body waste heat exchanger according to claim 1, characterized in that, The bottom of the casing has a drain port, and the top has an inspection port.

9. The whole-body waste heat exchanger according to claim 1, characterized in that, The waste heat channels and heat medium jackets are arranged in an alternating manner, so that the waste heat fluid and the heat medium fluid exchange heat at multiple intersection points.

10. The whole-body waste heat exchanger according to claim 1, characterized in that, A high-temperature dust filter is installed at the waste heat inlet to prevent large particles of impurities from entering the interior of the casing.

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