Condensing Boiler Heat Exchanger Layout With Aligned Condensate Flow
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Solution Overview
Problem
Conventional condensing gas boilers face challenges in maximizing heat transfer area and efficiency due to differences in heat exchanger designs for present and latent heat, leading to reduced heat exchanging efficiency and lack of compactness, while also struggling with corrosion resistance.
Innovation Solution
The arrangement structure includes a slantly arranged present heat exchanger and a parallel latent heat exchanger with a double structure of copper and aluminum materials, along with a condensed waterspout and exhaust gas flowing plate to enhance heat transfer and flow direction alignment, and the use of exhaust gas resistant bodies and heat absorbing pins to maximize heat exchange efficiency and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminum or stainless steel is used for the heat exchanger to suppress corrosion, then corrosion resistance is improved, but thermal efficiency decreases and the heat exchanger size must be increased
Solution Approach 1:
The patent applies composite materials by combining copper (for high thermal efficiency) and aluminum (for corrosion resistance) in a single heat exchanger structure. The heat exchanger includes a copper base material that provides excellent thermal conductivity, while an aluminum coating or aluminum alloy layer is applied to the surface to provide corrosion resistance against acidic condensation. This composite structure allows the heat exchanger to maintain high thermal efficiency while resisting corrosion, eliminating the need to choose between the two properties.
2Reliability
If the heat exchanger area is increased to compensate for low thermal efficiency of corrosion-resistant materials, then corrosion resistance is improved, but the boiler cannot be compact
Solution Approach 1:
By using composite materials (copper base with aluminum coating or aluminum alloy), the patent achieves both corrosion resistance and high thermal efficiency in a compact heat exchanger. The high thermal conductivity of copper allows for a smaller heat exchanger surface area to achieve the same heating capacity, while the aluminum coating provides corrosion protection. This eliminates the need to increase the boiler volume to compensate for material limitations.
3Ease of operation
If separate heat exchanger areas are designed for present heat and latent heat portions to identify exhaust gas flow direction, then flow direction is identified, but heat exchanging efficiency is reduced
Solution Approach 1:
The patent merges the heat exchanger structures for present heat and latent heat portions into a single integrated heat exchanger unit. The exhaust gas flows through the heat exchanger in a serpentine or multi-pass pattern, allowing simultaneous heat transfer for both present heat (sensible heat) and latent heat (condensation heat) recovery. The integrated design eliminates dead zones and improves flow distribution, maximizing heat exchanging efficiency while naturally guiding exhaust gas flow through the entire heat exchanger length.
4Use of energy by moving object
If copper material is used to maximize thermal efficiency, then thermal efficiency is improved, but corrosion resistance deteriorates due to acid moisture and exhaust gas components
Solution Approach 1:
The patent uses composite materials where copper serves as the base material providing high thermal conductivity and efficiency, while an aluminum coating or aluminum alloy layer is applied to the surface to provide corrosion resistance. The aluminum layer acts as a protective barrier against acid moisture, sulfuric oxide, and nitric oxide in the exhaust gas, preventing corrosion of the copper base material while maintaining its excellent thermal properties.
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 maximizes heat transfer area, improves heat exchanging efficiency, and achieves compactness and corrosion resistance by aligning exhaust gas flow with condensed water flow, enhancing thermal efficiency and reducing corrosion risks.
Implementation Method 1
a present heat exchanger slantly arranged with a predetermined slope with respect to a horizontal axis on a transverse cross-section in the casing, so that present heat can be absorbed from the combustion heat generated by the gas burner
Implementation Method 2
re-absorbs condensed latent heat in exhaust gas, to thus heighten a thermal efficiency
Implementation Method 3
a latent heat exchanger disposed in parallel with the present heat exchanger, in the same area as that of the present heat exchanger in the upper portion of the present heat exchanger, so that the exhaust gas generated by combustion proceeds toward an exhaust gas exit
Data Source
AI summary
An arrangement structure of heat exchangers in a condensing gas boiler is provided, which includes a casing provided with a combustion chamber therein, and a gas burner provided in the lower portion of the combustion chamber. The arrangement structure of heat exchangers in a condensing gas boiler includes: a present heat exchanger slantly arranged with a predetermined slope with respect to a horizontal axis on a transverse cross-section in the casing; a latent heat exchanger disposed in parallel with the present heat exchanger, in the same area as that of the present heat exchanger in the upper portion of the present heat exchanger; a condensed waterspout provided in parallel with between the present heat exchanger and the latent heat exchanger, whose one end contacts one of the inner wall surfaces of the casing and whose other end is disposed spaced from the other of the inner wall surfaces thereof; and an exhaust gas flowing plate provided in parallel with the outer wall of the latent heat exchanger, whose one end is spaced from one of the inner wall surfaces of the casing and whose other end contacts the other of the inner wall surfaces of the casing in order to induce condensed water and exhaust gas to flow in an identical direction. Thus, the heat transfer area is maximized, and present heat and condensing conditions are made to improve a heat exchanging efficiency, and to accomplish compactness and corrosion resistance of the boiler.