Burner Parting Sheet Baffles for Swirl Cooling Without Plugging
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Solution Overview
Problem
Existing burners face issues with local plugging and hot spots due to inadequate gap sizes between the parting sheet and cooling channel enclosure, leading to potential burner failure and increased operational costs, while conventional methods to enhance cooling fluid velocity result in higher capital and operating expenses.
Innovation Solution
A parting sheet with baffle elements manufactured using additive processes, such as 3D printing, is designed with specific angles to create a swirl flow, maintaining a large gap and optimizing fluid velocity, reducing mechanical stresses, and allowing for efficient cooling without increasing fluid flow rates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the gap size between the parting sheet and cooling channel enclosure is reduced to increase cooling fluid velocity, then the heat transfer coefficient improves, but the risk of plugging from particles and geometric deviations increases
Solution Approach 1:
The patent changes the geometric parameters of the parting sheet by adding baffle elements with specific angles (e.g., 45 degrees) to the sheet surface. This modifies the flow characteristics without changing the gap size, allowing maintained cooling performance while avoiding plugging issues associated with narrow gaps.
Solution Approach 2:
The parting sheet is segmented by adding multiple baffle elements at different positions and angles. This segmentation creates multiple flow paths and swirl patterns that enhance cooling while preventing particle accumulation and plugging in any single location.
2Reliability
If the gap size between the parting sheet and cooling channel enclosure is increased to avoid plugging, then the reliability improves, but the cooling fluid velocity decreases
Solution Approach 1:
The baffle elements create a swirl flow that introduces rotational motion and turbulence to the cooling fluid. This mechanical motion enhances heat transfer coefficients and maintains cooling efficiency even with larger gap sizes that prevent plugging.
Solution Approach 2:
By modifying the flow parameters through angled baffle elements, the patent achieves enhanced mixing and heat transfer in the cooling fluid without requiring a narrow gap, thus maintaining cooling efficiency while avoiding plugging.
3Temperature
If the fluid flow rate is increased to maintain cooling performance with larger gap size, then the cooling efficiency is maintained, but the capital expenditure and operating expense increase
Solution Approach 1:
The swirl flow generated by the angled baffle elements creates turbulent mixing and enhanced heat transfer, allowing effective cooling with lower fluid flow rates, thereby reducing both CAPEX and OPEX of the cooling system.
Solution Approach 2:
The baffle elements create rotational and swirling flow patterns (curved flow paths) that enhance heat transfer efficiency. This curved flow mechanism improves cooling performance without requiring increased fluid quantity, reducing operational costs.
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 enhances burner cooling performance, increases lifetime, and reduces operational costs by minimizing mechanical stresses and maintaining optimal fluid flow, while allowing for precise geometric adjustments and cost-effective manufacturing.
Implementation Method 1
Each of these baffle elements is provided at a predetermined position on a surface of the sheet element inclined by a predetermined angle towards the sheet element... configured to influence, affect or adapt a fluid flow of the respective cooling fluid, especially to create a swirl of the fluid flow
Data Source
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Figure 3a
AI summary
The present invention relates to a parting sheet (1200) for a burner (1000), to a burner and to methods of manufacturing the same, wherein the parting sheet (1200) is configured to be arranged in or to be manufactured in a cavity (1120) inside a wall (1110) of the burner (1000) for flowing a cooling fluid through the wall of the burner, the parting sheet (1200) comprising a sheet element (1210) and a number of baffle elements (1220, 1230, 1240), wherein each of these baffle elements (1220, 1230, 1240) is provided at a predetermined position on a surface of the sheet element (1210) inclined by a predetermined angle (1221, 1231) towards the sheet element.