Condensate Trap Using Combusted Gas Heat to Prevent Freezing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heating systems face issues with condensate formation and freezing, leading to corrosion and blockages, especially in cold climates, where existing solutions like 80% efficient gas systems waste energy or use electric heat tape, which are not optimal.
Innovation Solution
A condensate trap system that uses combusted gases to heat and thaw frozen condensate, incorporating a trap inlet, condensate chamber, trap outlet, header box inlet, and condensate outlet, with a controller determining temperature and activating the burner to provide heat through combusted gases for condensate drainage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an 80% efficient gas system is used to keep exhaust temperatures above dew point, then condensate formation is prevented, but heating energy is wasted significantly
Solution Approach 1:
The patent converts the harmful cold ambient temperature into a beneficial heating source by using the temperature differential to drive heat transfer from the combusted gases to the condensate trap, eliminating the need for additional heating energy while preventing condensate freezing
Solution Approach 2:
The system uses its own combusted gases to heat the condensate trap, making the heating function self-contained and eliminating dependence on external energy sources like electric heat tape
2Reliability
If electric heat tape is used to wrap around heating system components, then condensate freezing is prevented, but device complexity and energy consumption increase
Solution Approach 1:
The condensate trap uses heat from the combusted gases passing through it to prevent freezing, making the system self-heating and eliminating the need for external electric heat tape components
Solution Approach 2:
The patent removes the electric heat tape component entirely by extracting the heating function into the existing combusted gas flow path, simplifying the overall system design
3Loss of energy
If 90%-plus efficient gas systems are used, then heating energy efficiency is improved, but condensate formation increases leading to freezing risks
Solution Approach 1:
The patent converts the harmful effect of increased condensate formation into a beneficial heat transfer opportunity, using the combusted gases to heat the condensate trap and prevent freezing
Solution Approach 2:
The condensate trap acts as an intermediary heat exchange medium, receiving heat from combusted gases and transferring it to prevent condensate freezing in the drainage system
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 prevents condensate freezing and ensures efficient heating by utilizing the heat from combusted gases to thaw condensate, maintaining system efficiency and preventing blockages without wasting energy.
Implementation Method 1
Combusted gas that passes through the condensate trap provides heat to condensate within the condensate trap to thaw frozen condensate or to prevent condensate from freezing
Data Source
AI summary
A condensate trap for a furnace system includes a trap inlet configured to receive combusted gases, a condensate chamber coupled to the trap inlet and configured to trap condensate, a trap outlet coupled to the condensate chamber and configured to exhaust the combusted gases, a header box inlet configured to receive condensate from a header box, and a condensate outlet configured to drain condensate from the condensate chamber. Combusted gas that passes through the condensate trap provides heat to condensate within the condensate trap to thaw frozen condensate or to prevent condensate from freezing.