Boiler
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Solution Overview
Problem
Boilers with electrostatic separators face limitations in separation efficiency due to a small separation area of the collector electrode, which restricts compliance with strict fine dust level limits, especially when maintaining a compact design.
Innovation Solution
The movably mounted turbulator is used as the collector electrode, electrically connected to the boiler's mass via a flexible conductor, increasing the separation surface and efficiency through turbulence and reduced electrical resistance, while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the heat exchanger tube inside is used as the collector electrode, then the boiler design remains compact, but the separation surface area is limited and separation efficiency is reduced
Solution Approach 1:
The patent applies the dynamics principle by making the collector electrode movable rather than fixed. The collector electrode is designed to move axially within the heat exchanger tube, transforming from a static structure to a dynamic one. This movement capability allows the electrode to be pulled out for cleaning and maintenance without dismantling the entire boiler, thus increasing the separation surface area while managing design complexity through functional movement.
Solution Approach 2:
The patent implements multi-functionality by integrating the collector electrode with multiple functions: it serves as both the electrostatic separation surface and a mechanically cleanable component. The electrode structure combines electrical collection function with mechanical accessibility for cleaning, allowing one component to fulfill multiple roles that would otherwise require separate systems.
2Productivity
If the collector electrode separation surface is enlarged, then separation efficiency increases, but the boiler size increases and compact design is lost
Solution Approach 1:
The movable collector electrode allows the system to achieve larger separation surface area when needed (during operation) while maintaining a compact form factor during storage or maintenance phases. The electrode can be extended or deployed to maximize separation area, then retracted or removed for cleaning, enabling high productivity without permanently increasing boiler volume.
3Productivity
If the turbulator is movably mounted to increase separation surface, then separation efficiency improves, but electrical connection stability deteriorates
Solution Approach 1:
The patent introduces an intermediary electrical connection system between the movable collector electrode and the fixed boiler structure. This intermediary mechanism (such as sliding contacts or flexible conductors) mediates the electrical connection, allowing the electrode to move axially for cleaning while maintaining continuous electrical contact. The intermediary element decouples the mechanical movement from the electrical connection stability, enabling both mobility and reliable electrical contact.
4Ease of repair
If the collector electrode is made movable for cleaning access, then maintenance ease improves, but electrical resistance increases due to moving contacts
Solution Approach 1:
The intermediary electrical connection system serves as a low-resistance pathway between the movable collector electrode and the fixed electrical circuit. This intermediary mechanism (such as spring-loaded contacts, sliding brushes, or flexible conductors) is specifically designed to maintain low electrical resistance while accommodating the axial movement required for cleaning access, thus resolving the conflict between ease of repair and electrical reliability.
Solution Approach 2:
The movable collector electrode is designed to be self-cleanable through its own movement. By moving axially within the heat exchanger tube, the electrode can be pulled out to access its surface for cleaning without requiring external disassembly or complex maintenance mechanisms. This self-service capability improves ease of repair while the intermediary electrical connection maintains low resistance throughout the movement range.
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
This configuration enhances the separation efficiency of the electrostatic separator, effectively reducing fine dust levels and ensuring stability and robustness over the boiler's lifespan, even under varying operating conditions.
Implementation Method 1
an electrostatic precipitator having at least one collector electrode in the flue gas pass of the heat exchanger and at least one spray electrode
Implementation Method 2
The swirling effect of the separation surfaces in the flue gas stream can further improve the separation efficiency
Data Source
Figure 1
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Figure 3
AI summary
A heating boiler (1) with a flue gas duct (5), which has at least one flue gas flue (10.1), with at least one heat exchanger (8) provided for heating the boiler water (9), which forms at least one flue gas flue of the flue gas duct (5), with at least one movably mounted turbulator (11.1) which is provided in the flue gas flue (10.1) of the heat exchanger (8), and with an electrostatic precipitator (12) which has at least one collector electrode (14) in the flue gas flue (10.1) of the heat exchanger (8) and at least one spray electrode (13), which collector electrode (14) is electrically connected to ground (16) of the boiler as a reference potential for the potential of the spray electrode (13). In order to enable a high degree of separation on the electrostatic precipitator (12), it is proposed that the boiler (1) has a flexible electrical conductor (17) and that at least the movably mounted turbulator (11.1) connects the collector electrode (14) of the electrostatic precipitator (12 ) forms and for this purpose the movably mounted turbulator (11.1) is electrically connected to the ground (16) of the heating boiler (1) via the flexible electrical conductor (17).