Crossflow Exchanger With Stacked Distribution Tubes for Lower Pressure Drop
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Solution Overview
Problem
Existing heat exchangers with counterflow configurations face challenges of high pressure drop and thermal stress due to local temperature differences, which can induce stress within the exchanger.
Innovation Solution
A crossflow heat exchanger design with stacked distribution tubes and core channels that are fluidly isolated and connected in a specific pattern, featuring tapered and length-matched inlet and outlet tubes, baffles, and heat fins to enhance heat transfer while reducing pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If counterflow configuration is used to maximize heat transfer, then heat transfer efficiency is improved, but pressure drop increases and thermal stress challenges arise
Solution Approach 1:
The heat exchanger is divided into multiple flow channels separated by partitions, with each channel containing staggered tubes. This segmentation allows the fluid to follow a zigzag path through alternating channels, achieving counterflow heat transfer while distributing pressure drop across multiple smaller channels rather than one large channel, thereby reducing overall pressure loss and thermal stress.
2Stress or pressure
If local temperature difference is reduced to minimize thermal stress, then thermal stress is improved, but heat transfer efficiency may be compromised
Solution Approach 1:
The heat exchanger employs a dynamic flow path where fluid alternates direction through staggered tubes in adjacent channels. This creates multiple temperature gradients along the flow path rather than a single large gradient, reducing peak thermal stress while maintaining overall heat transfer efficiency through the cumulative effect of multiple smaller temperature differences across the zigzag path.
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 achieves efficient heat transfer with reduced pressure drop and thermal stress, making it suitable for high-pressure and temperature applications.
Implementation Method 1
core channels within the core that extend from the first side to the second side of the heat exchanger, wherein the core channels are fluidly isolated from each other within the core and connect the inlet tubes to the outlet tubes
Implementation Method 2
a first set of heat fins that are coupled to the core channels and the first baffle; and a second set of heat finds that are coupled to the core channels and the second baffle
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
A heat exchanger having: an inlet header (140) having inlet tubes (142) stacked against the first side of the heat exchanger; an outlet header (150) having outlet tubes (144) stacked against the second side of the heat exchanger, first inlet and outlet tubes have a same length as each other, second inlet and outlet tubes have the same length as each other and are longer than the first inlet and outlet tubes, and third inlet and outlet tubes have a same length as each other and are longer than the second inlet and outlet tubes; core channels (190) extend from the first side to the second side of the heat exchanger, the core channels (190) connect the inlet tubes (142) to the outlet tubes (144) such that: the first inlet tube and third outlet tube are connected; the second inlet tube and second outlet tube are connected; and the third inlet tube and first outlet tube are connected.