Cleaning system
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Solution Overview
Problem
Plate heat exchangers in domestic boilers face frequent clogging due to limescale buildup, leading to inefficient operation and costly replacements, as existing solutions like stainless steel plates and water softeners are either ineffective or impractical.
Innovation Solution
A pressurized two-tank cleaning system that uses an acidic solution to chemically remove limescale from both sides of the plate heat exchanger, with a recycling mechanism to re-pressurize the system and ensure thorough cleaning of narrow channels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If stainless steel plates are used to expand and contract with temperature fluctuations, then limescale deposits should break up, but the design does not sufficiently clear limescale deposits to prevent loss of function
Solution Approach 1:
The patent replaces the mechanical thermal expansion/contraction system with a chemical cleaning system. An acidic cleaning solution is circulated through the plate heat exchanger channels to chemically dissolve limescale deposits, providing reliable and sufficient limescale removal that mechanical expansion cannot achieve.
Solution Approach 2:
The patent changes the cleaning approach from mechanical (thermal expansion) to chemical (acidic solution). By changing the parameter of cleaning mechanism from physical force to chemical reaction, the system achieves effective limescale dissolution and prevents channel blockage reliably.
2Reliability
If plate heat exchangers are removed and replaced, then limescale buildup is resolved, but this is costly and causes delays with the boiler being ineffective
Solution Approach 1:
The patent applies preliminary chemical cleaning action to the plate heat exchanger in situ, preventing the need for removal and replacement. The acidic solution is circulated through the channels to dissolve limescale deposits before they cause complete blockage, restoring function and avoiding downtime associated with replacement.
Solution Approach 2:
The cleaning system allows the plate heat exchanger to be cleaned in place without removal from the boiler. The chemical cleaning process serves the system self-contained, eliminating the need for external replacement services and reducing downtime.
3Ease of manufacture
If manual cleaning is attempted, then some limescale may be removed, but this is far from trivial and is typically ineffective
Solution Approach 1:
The patent replaces manual mechanical cleaning with an automated chemical cleaning system. The acidic solution is pumped through the plate heat exchanger channels, chemically dissolving limescale deposits effectively. This eliminates the complexity and ineffectiveness of manual cleaning while providing reliable results.
4Reliability
If water softeners are used, then limescale buildup is prevented, but they are bulky and expensive
Solution Approach 1:
The patent extracts the cleaning function from complex water treatment systems like softeners. Instead of installing bulky water softeners, the system uses a targeted chemical cleaning approach where acidic solution is circulated through the plate heat exchanger channels to remove limescale, providing effective prevention without the bulk and cost of complete water softening systems.
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
Effectively removes limescale from both the Central Heating and Mains Water sides of the plate heat exchanger simultaneously, reducing the need for replacements and minimizing downtime, while being cost-effective and less likely to damage the exchanger.
Implementation Method 1
by contacting and reacting the limescale in the plate heat exchanger (9) with an acidic solution (descaler, 3)
Implementation Method 2
a first pressurisable container (2) having: a descaler portion to accommodate descaler, and a gas portion (35) to accommodate gas
Implementation Method 3
a primer (37) for pre-pressurising said first pressurisable container
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Provided is a cleaning system (1), suitable for chemically removing limescale from a plate heat exchanger(9), having at least one inlet (8a, 8b) and at least one outlet (13a, 13b), by contacting and reacting the limescale in the plate heat exchanger (9) with an acidic solution (descaler, 3). The system comprises a first pressurisable container (2) having a descaler portion to accommodate descaler, and a gas portion (35) to accommodate gas; a primer (37) for pre-pressurising said first pressurisable container; and at least one first conduit (7a, 7b) for establishing a fluid connection between the descaler portion (34) of said first pressurisable container (2) and the inlet(s) (8a, 8b)on a plate heat exchanger (9).The system also comprises a second pressurisable container (11) having;at least one second conduit (12a, 12b) for establishing a fluid connection between the outlet(s) (13a, 13b) on the plate heat exchanger (9) and said second pressurisable container (11); and a reaction product portion (38) to accommodate reaction products, and a gas portion (39) to accommodate reaction product gas. The system also comprises a third conduit(19) comprising a valve: (21). The third conduit (19) is positioned to establish a fluid connection between the gas portion (39) of said second pressurisable container (11) and the gas portion (39) of said first pressurisable container (2) so as to recycle reaction product gas to the gas portion (35) of said first pressurisable container (2), and thereby re-pressurize said first pressurisable container (2). The valve (21) restricting said fluid connection between said first and second pressurisable containers (2, 11). Also provided is a method of cleaning said exchangers using this system.