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 thermal efficiency and compactness while maintaining cost-effectiveness, as they are limited by low pressure drops and small heat transfer surface areas, leading to suboptimal heat transfer rates.
Innovation Solution
The system employs a high-pressure heat transfer assembly with a blower to increase the heat transfer fluid velocity across the heat exchanger surfaces, reducing the turbulent boundary layer and enhancing turbulence, thereby increasing the heat transfer coefficient and achieving a Bulk Heat Flux between 45 kW/m2 and 300 kW/m2 with a Pressure Drop between 3 kPa and 30 kPa.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional low pressure drop heat exchangers are used, then device complexity is reduced, but Bulk Heat Flux is limited to below 45 kW/m2
Solution Approach 1:
The patent applies parameter changes by increasing the pressure drop across the heat exchanger from conventional low values to 3-30 kPa, which directly increases the Bulk Heat Flux to 45-300 kW/m2. This parameter change resolves the contradiction by transforming the operating conditions to achieve higher productivity despite increased device complexity
Solution Approach 2:
The patent employs a variable speed blower that can adjust airflow dynamics to maintain optimal pressure drop conditions. This dynamic control allows the system to adapt to varying load conditions while maintaining high Bulk Heat Flux, resolving the contradiction between productivity and device complexity through flexible operational control
2Productivity
If heat transfer surface area is increased to improve heat transfer rate, then Bulk Heat Flux increases, but system volume and manufacturing cost increase
Solution Approach 1:
The patent changes the pressure drop parameter to 3-30 kPa, which dramatically increases the heat transfer coefficient. This allows achieving high heat transfer rates (45-300 kW/m2 Bulk Heat Flux) with significantly reduced heat transfer surface area, thereby reducing system volume while maintaining or improving heat transfer rate
Solution Approach 2:
The patent uses extended surface heat exchanger geometries (fins, corrugations) that effectively increase the heat transfer surface area within a compact volume. These geometric copies of surface structures provide high heat transfer area without proportionally increasing system volume, resolving the contradiction between heat transfer rate and system size
3Productivity
If thermal transfer fluid velocity is increased to enhance heat transfer coefficient, then Bulk Heat Flux increases, but pressure drop increases beyond conventional limits
Solution Approach 1:
The patent explicitly changes the pressure drop parameter to the range of 3-30 kPa, which is higher than conventional heat exchangers but optimized to achieve the desired heat transfer coefficient and Bulk Heat Flux. This parameter change resolves the contradiction by establishing a new operating point where both high productivity and acceptable pressure stress are achieved
Solution Approach 2:
The patent incorporates pressure sensors and control systems that provide feedback on the actual pressure drop across the heat exchanger. This feedback allows the variable speed blower to adjust airflow velocity to maintain optimal conditions, ensuring high heat transfer coefficient while keeping pressure drop within the 3-30 kPa target 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 results in improved thermal transfer efficiency, reduced material and manufacturing costs, and a more compact fluid heating system design, while maintaining reliability and energy efficiency.
Implementation Method 1
increasing the heat transfer coefficient by raising the airspeed through the heat exchanger and decreases the width of the turbulent boundary layer
Implementation Method 2
Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 3 kiloPascals and 30 kiloPascals
Implementation Method 3
a heat exchanger core including a second inlet and a second outlet, and an inner surface and an outer surface
Implementation Method 4
heat transfer from the thermal transfer fluid to the production fluid
Implementation Method 5
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
Implementation Method 6
a blower configured for forcing a gas under pressure through the assembly
Data Source
AI summary
A fluid heating system including: a pressure vessel; an assembly comprising: a heat exchanger core including a second inlet and a second outlet; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; and a blower in fluid connection with the first end of the first conduit, wherein the fluid heating system satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 45 kW/m2 and 300 kW/m2, and wherein the Pressure Drop between the first conduit and the second conduit is between 3 kiloPascals and 30 kiloPascals.