Compact Shell-and-Tube Heat Exchanger Without Tube Sheets
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Solution Overview
Problem
Existing shell and tube heat exchangers face challenges in maximizing heat transfer efficiency and minimizing pressure drop, particularly in applications with low pressure differentials, due to the need for baffles and tube sheets, which restrict fluid flow and increase complexity.
Innovation Solution
The use of heat exchange tubes arranged to form a hypocycloidal enclosure gap with a pitch of substantially 1, eliminating the need for baffles and tube sheets, and employing tessellating tube ends for self-support and secure connections, allowing for improved fluid flow and reduced pressure drops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional heat exchanger designs are used, then manufacturing simplicity is maintained, but cleaning accessibility and efficiency are insufficient
Solution Approach 1:
The heat exchanger is divided into multiple modules, each comprising a support structure with integrated cleaning feature receptacles. This segmentation allows each module to be independently manufactured and assembled, maintaining manufacturing simplicity while enabling effective cleaning access through the modular design.
Solution Approach 2:
Cleaning feature receptacles are introduced as intermediary structures that facilitate the cleaning process. These receptacles receive cleaning tools and provide structured access points, acting as mediators between the operator and the heat exchanger surfaces that require cleaning.
2Ease of operation
If complex cleaning features are added to improve cleaning accessibility, then cleaning efficiency improves, but device complexity increases
Solution Approach 1:
The cleaning features are merged with the support structures, creating integrated units where the cleaning functionality is built into the existing structural framework. This merging avoids adding separate, complex cleaning systems while still providing effective cleaning access.
Solution Approach 2:
The support structures are designed to serve multiple functions: structural support and cleaning feature integration. The cleaning feature receptacles can accommodate various cleaning tools, providing universal cleaning capability across different heat exchanger configurations without requiring tool-specific structures.
3Ease of operation
If modular design with multiple support structures is implemented, then cleaning accessibility improves, but manufacturing complexity increases
Solution Approach 1:
The heat exchanger is divided into multiple modules, each comprising a support structure with integrated cleaning feature receptacles. This segmentation allows each module to be independently manufactured and assembled, maintaining manufacturing simplicity while enabling effective cleaning access through the modular design.
Solution Approach 2:
The modular design allows for parameter standardization across modules, where key dimensions and interface specifications are maintained consistently. This standardization simplifies manufacturing by enabling repeated production of identical components while still providing cleaning accessibility through the modular configuration.
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 heat transfer area and reduces pressure drops, resulting in a more compact and efficient heat exchanger design with increased performance and reduced volume.
Implementation Method 1
a first heat transfer fluid is transferable across a wall of the housing to a second heat transfer fluid
Data Source
Figure 1a~1b
Figure 2~4a
Figure 4b~5
AI summary
The present invention relates to shell and tube heat exchangers, specifically to compact heat exchangers without the need for a tube sheet. There is provided a shell and tube heat exchanger having an outer shell and a series of heat exchange tubes located therein, said shell comprising a shell side fluid inlet and a shell side fluid outlet for transfer of a first fluid, said tubes, capable in use of permitting flow of a second fluid, said tubes comprising a first end and second end, wherein said tubes are arranged such that they are touching, forming a hypocycloidal enclosure gap, which provides a path for the transfer of said first fluid, wherein said tubes comprise a first region of reduced diameter located proximate to said shell side fluid inlet nozzle and second region of reduced diameter located proximate shell side fluid outlet nozzle, to allow said first fluid to form a flow path through said hypocycloidial enclosure gap.