Condenser with Tapered Tubes to Reduce Pressure Drop and Weight
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Solution Overview
Problem
Conventional condenser designs with constant cross-sectional areas lead to inadequate heat transfer surface areas near the entrance of hot vapor or vapor/liquid mixtures and excessive surface areas in sections with higher liquid content, resulting in oversized and heavy heat exchangers with imbalanced heat transfer capabilities on the hot and cold sides.
Innovation Solution
The condenser apparatus features a plurality of substantially parallel tubes with varying hydraulic diameters, tapering from a larger diameter at the inlet to a smaller diameter at the outlet, and a method of condensing hot vapor or vapor/liquid mixtures by flowing them through these tubes, optimizing heat transfer by varying the cross-sectional areas based on liquid content, and using fins to enhance surface area for improved heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If constant cross-sectional areas are used for both hot and cold flows, then the heat exchanger design is simplified, but the surface areas become inadequate near the entrance and excessive in mid and lower sections, resulting in oversized and heavy design
Solution Approach 1:
The patent applies local quality by varying the cross-sectional area of tubes along their length, with larger areas near the entrance where heat transfer demand is highest and smaller areas in mid and lower sections where liquid content increases. This non-uniform geometry optimizes heat transfer surface area distribution to match the local heat transfer requirements, eliminating both inadequate and excessive surface areas while reducing overall heat exchanger size and weight.
Solution Approach 2:
The patent implements dynamics by transitioning from static constant cross-sectional areas to dynamic varying cross-sectional areas that adapt to changing flow conditions along the tube length. The cross-sectional area varies continuously or in steps to match the changing heat transfer coefficients and liquid content, allowing the heat exchanger to maintain optimal performance throughout its length rather than being designed for a single average condition.
2Ease of manufacture
If constant cross-sectional areas are used for both hot and cold flows, then manufacturing is easier, but heat transfer surface areas are imbalanced between hot and cold sides
Solution Approach 1:
The patent applies local quality by varying the cross-sectional area of tubes along their length, with larger areas near the entrance where heat transfer demand is highest and smaller areas in mid and lower sections where liquid content increases. This non-uniform geometry optimizes heat transfer surface area distribution to match the local heat transfer requirements, eliminating both inadequate and excessive surface areas while reducing overall heat exchanger size and weight.
3Productivity
If larger cross-sectional areas are used to ensure adequate heat transfer surface area, then heat transfer capability is improved, but pressure drops increase and pump cavitation may occur
Solution Approach 1:
The patent applies local quality by varying the cross-sectional area of tubes along their length, with larger areas near the entrance where heat transfer demand is highest and smaller areas in mid and lower sections where liquid content increases. This non-uniform geometry optimizes heat transfer surface area distribution to match the local heat transfer requirements, eliminating both inadequate and excessive surface areas while reducing overall heat exchanger size and weight.
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 design enhances heat transfer rates, reduces pressure drops, and prevents pump cavitation by optimizing the pressure gradient and mass flow, resulting in a more efficient, smaller, and lighter condenser with balanced heat transfer capabilities on both sides.
Implementation Method 1
Condensers are heat exchangers that convert hot vapor, or high quality vapor/liquid mixtures, to liquids, by transferring heat from the hot vapor or vapor/liquid mixture to the adjacent cooler fluid flows
Implementation Method 2
As heat is removed from the vapor or high quality vapor/liquid mixture, its liquid content increases
Implementation Method 3
enhances heat transfer rates, reduces pressure drops, and prevents pump cavitation by optimizing the pressure gradient and mass flow
Implementation Method 4
using fins to enhance surface area for improved heat transfer
Data Source
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AI summary
A condenser having passages of varying geometry for cooling of fluid. The condenser apparatus includes substantially parallel tubes each defining a channel and having an inlet at a first end and an outlet at a second end, the first end having a greater hydraulic diameter than the second end. Inlet and outlet manifolds are provided. The tubes may be oriented substantially vertically with the inlets above the respective outlets. A heat exchanger core comprises the tubes and substantially horizontally oriented fin material connecting the tubes. The tubes may receive a relatively higher temperature vapor or vapor and liquid mixture into the inlets of the tubes, around the tubes coolant flows substantially horizontally to remove heat from the tubes, and relatively cooler saturated liquid is discharged from the outlets. In one embodiment, the tube's channel splits into multiple channels to reduce the hydraulic diameter and increase the surface area ratio.