Countercurrent Heat Exchanger Layout for Lower Pressure Loss
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Solution Overview
Problem
Existing counterflow gas-gas heat exchangers for turbomachines are inefficient, unreliable, and bulky, failing to optimize integration, reduce size, and maintain performance levels.
Innovation Solution
A counter-current heat exchanger design with perpendicular secondary inlet and outlet manifolds on the same face, multiple collectors, and additive manufacturing, optimizing flow homogeneity and reducing pressure losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If traditional heat exchanger design is used, then heat exchange function is provided, but the exchanger is bulky and has large frontal area
Solution Approach 1:
The patent reconfigures the manifold arrangement from traditional orthogonal layout to a design where secondary inlet and outlet manifolds are positioned on the same face of the heat exchanger. This dimensional reorganization allows the exchanger to have equivalent dimensions in all three spatial directions, reducing both volume and frontal area while maintaining heat exchange performance.
2Volume of moving object
If heat exchange length is reduced to decrease size, then compactness is improved, but pressure losses increase
Solution Approach 1:
The patent divides the heat exchanger into multiple stages with intermediate manifolds that segment the flow path. This segmentation allows the gas flows to be redistributed at intermediate points, maintaining flow homogeneity and reducing pressure losses even as the overall heat exchange length is reduced for compactness.
Solution Approach 2:
By positioning inlet and outlet manifolds on the same face and creating equivalent dimensions in all three spatial directions, the patent optimizes the flow path geometry. This dimensional balance reduces circuit lengths and edge effects, minimizing pressure losses while achieving compact size.
3Volume of moving object
If circuit lengths are reduced for compactness, then size is decreased, but flow homogeneity deteriorates
Solution Approach 1:
The patent introduces intermediate manifolds that segment the flow circuit into multiple sections. This segmentation allows for redistribution of gas flows at intermediate points, maintaining flow homogeneity throughout the compact structure by preventing flow maldistribution that would occur in shorter, unsegmented circuits.
Solution Approach 2:
The reconfiguration of manifolds to open onto the same face creates equivalent dimensions in all three spatial directions. This dimensional symmetry ensures balanced flow paths and reduces edge effects, maintaining flow homogeneity while achieving compact overall size.
4Device complexity
If heat exchange stages are reduced to simplify structure, then device complexity is decreased, but gas distribution quality worsens
Solution Approach 1:
The patent uses intermediate manifolds to segment the flow distribution function. Instead of requiring multiple heat exchange stages for proper gas distribution, the segmented manifold system performs flow redistribution at intermediate points, achieving homogeneous gas distribution with fewer heat exchange stages and reduced device complexity.
5Weight of moving object
If exchanger size is reduced for integration, then mass is decreased, but thermomechanical stability worsens
Solution Approach 1:
By creating equivalent dimensions in all three spatial directions through the reconfigured manifold arrangement, the patent achieves a compact exchanger with balanced geometry. This dimensional symmetry improves thermomechanical stability by distributing thermal and mechanical stresses more uniformly throughout the structure, preventing localized stress concentrations that would occur in highly asymmetric compact designs.
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 design results in a more compact, reliable, and efficient heat exchanger with improved thermomechanical stability and reduced pressure losses, enhancing integration and performance.
Implementation Method 1
the heat exchange portions of the first and second circuits being delimited by heat exchange walls configured to direct the first and second gas flows in a first direction
Implementation Method 2
counter-current heat exchanger for a turbomachine... used to heat the primary air exiting the high-pressure compressor by the primary air exiting the low-pressure turbine
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A countercurrent heat exchanger (1) for a turbomachine, comprising a first and a second circuit, the first and the second circuit being respectively configured to receive a first flow of gas (10) and a second flow of gas (20), each circuit having a secondary inlet manifold, an exchange part and a secondary outlet manifold (13); the exchange parts of the first circuit and of the second circuit being delimited by exchange walls configured to direct the first flow of gas (10) and the second flow of gas (20) in a first direction (X); and wherein the secondary inlet manifold and the secondary outlet manifold (13) of the first circuit extend in a second direction (Y) substantially perpendicular to the first direction (X), and open out onto one and the same face of the exchanger (1).