Composite Tube for Explosive Cleaning of Heat Exchangers
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Solution Overview
Problem
Existing methods for cleaning the internals of installations like furnace heat exchangers and flue gas heat exchangers are inefficient in removing production residues and deposits, which affect efficiency, runtime, and output, and often cause damage or leave debris.
Innovation Solution
A device with a tube comprising multiple layers of materials, including synthetic and metal layers, containing a pyrotechnical or explosive charge, which is flexible and can be bent to fit the shape of deposits, allowing for controlled deflagration or explosion to clean surfaces with reduced material use and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a single-material tube is used for cleaning, then the tube can be simple in structure, but it cannot provide both heat shielding and sufficient mechanical strength simultaneously
Solution Approach 1:
The tube is constructed from composite materials consisting of a heat-resistant material layer (such as ceramic coating, refractory concrete, or heat-resistant alloy) and a structurally strong material layer (such as steel or high-strength alloy). The heat-resistant layer shields the cleaned surfaces from thermal damage during explosive cleaning operations, while the structurally strong layer provides the necessary mechanical strength and pressure resistance. This composite structure resolves the contradiction by combining materials with complementary properties that a single material cannot provide alone.
2Productivity
If larger amounts of explosive material are used, then cleaning effectiveness is improved, but costs and risks increase
Solution Approach 1:
The invention optimizes the parameters of the explosive charge, including its composition, density, confinement pressure, and configuration within the tube. By carefully controlling these parameters, the explosive energy is maximized for cleaning effectiveness while minimizing the total quantity of explosive material required. The composite tube structure also helps contain and direct the explosive force more efficiently, reducing energy waste and allowing smaller charges to achieve the same cleaning effect.
3Adaptability or versatility
If the tube structure is simplified, then manufacturing is easier, but the tube cannot be customized for different cleaning requirements
Solution Approach 1:
The tube is designed as a segmented or modular structure with distinct functional layers (heat-resistant layer and structurally strong layer) that can be manufactured separately and then assembled. This segmentation allows each layer to be optimized and manufactured using appropriate processes for that specific function, then combined into the final composite tube. The modular design enables customization for different cleaning requirements by adjusting layer thicknesses, material compositions, or tube dimensions without fundamentally changing the entire manufacturing approach.
Solution Approach 2:
The composite tube structure allows customization through variation of material compositions, layer thicknesses, and material combinations to match specific cleaning requirements (different temperatures, pressures, deposit types). Meanwhile, established composite material manufacturing techniques (such as coating processes, laminating, or metallurgical bonding) provide relatively straightforward production methods, balancing adaptability with ease of manufacture.
4Object-generated harmful factors
If explosive cleaning is performed without proper tube design, then debris is generated and surfaces may be damaged, but using conventional single-material tubes does not sufficiently reduce these harmful effects
Solution Approach 1:
The composite tube structure with heat-resistant and structurally strong layers contains the explosive force more effectively, directing it toward deposit removal while preventing tube fragmentation and reducing debris generation. The heat-resistant layer protects cleaned surfaces from thermal damage, and the strong structural layer prevents tube failure under pressure. This reliable composite construction ensures consistent cleaning performance without the harmful side effects associated with poorly designed single-material tubes.
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 effectively removes residues and deposits with minimal damage and debris, using smaller amounts of explosive material, providing heat shielding and mechanical strength, and reducing the number of explosions required, thus lowering costs and risks.
Implementation Method 1
containing a pyrotechnical or explosive charge, which is flexible and can be bent to fit the shape of deposits, allowing for controlled deflagration or explosion to clean surfaces
Implementation Method 2
allowing for controlled deflagration or explosion to clean surfaces with reduced material use and debris
Implementation Method 3
The metal layer was found to provide a degree of heat shielding and/or contribute considerably to mechanical strength, in particular at temperatures in excess of 75 °C, e.g. in excess of 300 °C
Data Source
Figure 1~3
Figure 4~5
AI summary
The invention relates to a device (1) for on- or offline cleaning the internals of installations, such as a furnace heat exchanger and/or a flue gas heat exchanger in a boiler of an incinerator, the heat exchanger comprising bundles of tubes or a membrane wall formed by or containing tubes, which device (1) comprises a tube (2) containing an explosive (3) and/or pyrotechnical charge, and a detonator (4) to cause explosion and/or deflagration of the charge. The wall of the tube (2) comprises two or more materials (8,9,10), preferably two or more layers (8,9,10) of different materials.