Angled-Baffle Heat Exchanger Unit for Low-Noise Cooling
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Solution Overview
Problem
Conventional heat exchangers used in the oil and gas industry, particularly in fracturing operations, face issues with weight, noise pollution, ineffective cooling due to temperature gradients, structural integrity, and thermal expansion, leading to increased maintenance and operational challenges.
Innovation Solution
A heat exchanger unit with a cube-shaped frame, baffles oriented at specific angles to reduce noise and enhance airflow, and a flexible mount assembly to accommodate thermal expansion, along with sound-absorbing materials to minimize noise emissions and improve cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional heat exchangers are used in fracturing operations, then cooling function is provided, but noise pollution and ineffective cooling due to temperature gradients occur
Solution Approach 1:
The heat exchanger is divided into multiple cooling circuits with separate inlet and outlet manifolds, allowing parallel airflow paths that reduce temperature gradients and improve cooling effectiveness while reducing noise through distributed airflow
Solution Approach 2:
The patent transitions from conventional horizontal airflow to vertical airflow through the cooling circuits, with air entering at the bottom and exiting at the top, improving cooling effectiveness by eliminating temperature stratification and reducing noise through optimized airflow patterns
2Reliability
If conventional heat exchangers are used, then cooling is provided, but structural integrity issues arise due to thermal expansion
Solution Approach 1:
The patent uses flexible bellows between the inlet and outlet manifolds to accommodate thermal expansion and contraction of the heat exchanger core, maintaining structural integrity by allowing controlled movement without causing stress or damage to rigid connections
Solution Approach 2:
The design explicitly accounts for thermal expansion by incorporating flexible bellows and allowing for expansion gaps in the structural design, enabling the heat exchanger to expand and contract with temperature changes while maintaining structural integrity
3Ease of repair
If conventional heat exchangers are used, then cooling function is provided, but maintenance challenges increase due to leakage issues
Solution Approach 1:
The heat exchanger is segmented into modular cooling circuits with separate manifolds, allowing individual circuits to be isolated and maintained without shutting down the entire system, reducing maintenance difficulty while improving reliability through continued operation of functional circuits
Solution Approach 2:
The patent incorporates flexible bellows that can dynamically accommodate thermal movement and pressure changes, preventing stress-induced leakage and reducing maintenance needs while improving overall system reliability
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution reduces noise emissions by at least 10 dB, increases airflow efficiency, and enhances structural integrity by managing thermal expansion, resulting in a more effective and reliable cooling system for heat-generating devices.
Implementation Method 1
The heat exchanger unit may include one or more baffles, any of which may include a sound absorbing material
Implementation Method 2
The heat exchanger unit may include one or more coolers... airflow through the at least one cooler, into the airflow region, and out of the exhaust
Implementation Method 3
Heat exchanger unit... cooling efficiency... for cooling various utility fluids used with a heat generating device
Implementation Method 4
a flexible mount assembly to accommodate thermal expansion
Data Source
AI summary
A heat exchanger unit that includes a frame and an at least one cooler coupled therewith. The heat exchanger unit has a reference axis. The heat exchanger unit includes an airflow region therein. The heat exchanger unit includes an at least one baffle coupled to the frame within the airflow region. The at least one baffle is configured at an angle to the axis.