Compact fluid heating system with high bulk heat flux using elevated heat exchanger pressure drop
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Solution Overview
Problem
Current fluid heating systems face challenges in achieving high energy efficiency, compactness, and cost-effectiveness due to limitations in heat transfer rates and pressure drop capabilities, leading to larger heat exchanger sizes and increased material costs.
Innovation Solution
The implementation of a high-pressure fluid heating system with a heat exchanger core inside a pressure vessel, utilizing a blower to force a gas under pressure through the system, which increases the heat transfer fluid velocity and reduces the turbulent boundary layer, thereby enhancing heat transfer efficiency and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional heat exchangers are used with low pressure drop, then the system is easier to operate, but the heat transfer area must be larger to achieve the same heating output
Solution Approach 1:
The patent changes the pressure drop parameter from conventional low values to elevated values (3-30 kPa), which fundamentally alters the heat transfer characteristics. This parameter change enables much higher bulk heat flux (45-300 kW/m2) that compensates for the reduced heat transfer area, resolving the contradiction between compactness and operational ease
Solution Approach 2:
The system uses a variable speed blower to dynamically control the gas flow rate and pressure drop across the heat exchanger. By adjusting the blower speed, the system can optimize the balance between pressure drop and heat transfer efficiency, maintaining ease of operation while achieving high heat flux in a compact design
2Volume of stationary object
If heat exchanger size is reduced to improve compactness, then the system becomes more compact, but the heat transfer area is reduced requiring higher heat flux density
Solution Approach 1:
The patent implements elevated pressure drop (3-30 kPa) which enables bulk heat flux densities of 45-300 kW/m2, approximately 10 times higher than conventional systems. This allows the same heating output to be achieved with much smaller heat transfer area, directly resolving the contradiction between volume reduction and area maintenance
Solution Approach 2:
The invention transitions from conventional low heat flux density operation to high heat flux density operation, effectively adding a dimensional change in heat transfer intensity. This enables compact heat exchanger designs that maintain adequate heat transfer area through intensified heat transfer processes rather than increased physical area
3Productivity
If high pressure drop is used to increase heat transfer coefficient, then heat transfer efficiency improves, but the system complexity increases
Solution Approach 1:
The system uses the process gas itself as the heating medium, eliminating the need for separate heating systems or complex heat transfer fluid loops. The blower-driven gas flow serves dual purposes: providing combustion air and serving as the heat transfer medium, thereby simplifying the overall system while achieving high heat transfer efficiency through elevated pressure drop
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 results in a compact, efficient fluid heating system with improved thermal transfer efficiency, reduced material usage, and lower manufacturing complexity, achieving a Bulk Heat Flux between 45 kW/m2 and 300 kW/m2 and a Pressure Drop between 3 kPa and 30 kPa, while maintaining energy efficiency.
Implementation Method 1
a blower in fluid connection with the first conduit, the blower configured for forcing a gas under pressure through the assembly
Implementation Method 2
increases the heat transfer fluid velocity and reduces the turbulent boundary layer, thereby enhancing heat transfer efficiency
Implementation Method 3
transfer heat from the thermal transfer fluid to the production fluid
Implementation Method 4
disposing a thermal transfer fluid in the heat exchanger core and a production fluid between the inside of the pressure vessel and the heat exchanger core to transfer heat
Data Source
AI summary
A fluid heating system for heating a production fluid using a thermal transfer fluid, the production fluid being contained in a vessel includes an electric blower configured to receive ambient air and electrical input power and to provide output source air, a combustion system configured to receive the source air from the electric blower and to receive fuel and to provide the thermal transfer fluid, a heat exchanger configured to receive the thermal transfer fluid from the combustion system and configured to be in thermal communication with the production fluid to provide convective heat exchange from the thermal transfer fluid to the production fluid, and to provide output exhaust gas, and wherein the electric fan provides a predetermined volume flow rate of the output source air at a predetermined blower efficiency such that the fluid heating system has a Bulk Heat Flux of at least about 14.7 kBTU/Hr/ft2 and a Pressure Drop of at least about 0.7 psi.