Dual-Fluid Heat Exchanger With Recirculation for Stable Output Temperature
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Solution Overview
Problem
Conventional heat exchange systems face challenges in maintaining a consistent output temperature of the warmed fluid, leading to inefficiencies and regulatory issues due to varying flow rates and high steam temperatures, while also occupying excessive space and requiring additional components like condensate pumps and pressure regulating valves.
Innovation Solution
A dual fluid heat exchange system with a re-circulation loop that stabilizes the output temperature by recirculating fluid directly into a mid-section of the tank, allowing for controlled condensation of steam to enhance heat transfer and reduce the temperature of the cooled fluid, eliminating the need for certain valves and pumps, and optimizing the tank structure for minimal footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flow rate of steam is increased to meet higher heating demand, then the heating capacity is improved, but the output temperature of warmed water becomes unstable and exceeds desired temperature
Solution Approach 1:
The heat exchanger is divided into multiple independently controllable heating zones (first, second, and third heat exchange sections) along the steam flow path. Each zone can be selectively activated or deactivated based on heating demand, allowing precise control of total heat input to maintain stable output temperature while meeting varying productivity requirements.
Solution Approach 2:
The system dynamically adjusts the number of active heating zones based on real-time heating demand. Control valves regulate steam flow to each section, enabling the system to transition between different operational configurations (e.g., using only the first section for low demand, or all sections for high demand) to maintain optimal temperature stability across varying productivity levels.
2Temperature
If conventional temperature stabilization methods are used by adjusting cooled fluid flow rate, then the warmed fluid output temperature is stabilized, but the cooled fluid temperature varies drastically reducing energy efficiency
Solution Approach 1:
The heat exchanger is divided into multiple independently controllable heating zones (first, second, and third heat exchange sections) along the steam flow path. Each zone can be selectively activated or deactivated based on heating demand, allowing precise control of total heat input to maintain stable output temperature while meeting varying productivity requirements.
Solution Approach 2:
The system dynamically adjusts the number of active heating zones based on real-time heating demand. Control valves regulate steam flow to each section, enabling the system to transition between different operational configurations (e.g., using only the first section for low demand, or all sections for high demand) to maintain optimal temperature stability across varying productivity levels.
3Use of energy by moving object
If high temperature steam is used for heating, then the heating efficiency is improved, but the temperature of cooled fluid leaving the system is too high causing thermal pollution and regulatory issues
Solution Approach 1:
The heat exchanger is divided into multiple independently controllable heating zones (first, second, and third heat exchange sections) along the steam flow path. Each zone can be selectively activated or deactivated based on heating demand, allowing precise control of total heat input to maintain stable output temperature while meeting varying productivity requirements.
Solution Approach 2:
The system changes the operational parameters of the steam heating process by selectively activating different heat exchange sections. This allows the steam temperature and heat transfer intensity to be adjusted according to demand, ensuring that the cooled fluid exits at an environmentally acceptable temperature while maintaining high heating efficiency when full capacity is needed.
4Area of stationary object
If a vertically oriented heat exchanger is used to reduce footprint, then the space requirement is minimized, but the system complexity increases requiring careful fluid distribution management
Solution Approach 1:
The heat exchanger is divided into multiple independently controllable heating zones (first, second, and third heat exchange sections) along the steam flow path. Each zone can be selectively activated or deactivated based on heating demand, allowing precise control of total heat input to maintain stable output temperature while meeting varying productivity requirements.
Solution Approach 2:
The patent transitions from conventional horizontal heat exchanger layout to a vertical configuration, utilizing the vertical dimension to reduce the horizontal footprint. The heat exchanger is arranged with steam flowing vertically through multiple sections, allowing compact installation in mechanical rooms while maintaining effective heat transfer surface area.
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 system achieves stable output temperatures within ±3° F, increases energy efficiency by extracting heat from the cooled fluid, and reduces the temperature of the steam condensate, minimizing waste and space requirements while eliminating unnecessary components.
Implementation Method 1
steam circulates in the second fluid circuit at temperatures that are often above the boiling point of water. Both circuits meet at a heat exchanger unit where the cool water is warmed by flowing over thermally conductive conduits containing the high temperature steam
Implementation Method 2
the cool water is warmed by flowing over thermally conductive conduits containing the high temperature steam
Implementation Method 3
A dual fluid heat exchange system with a re-circulation loop that stabilizes the output temperature by recirculating fluid directly into a mid-section of the tank
Data Source
AI summary
A dual fluid heat exchange system is presented that provides a stable output temperature for a heated fluid while minimizing the output temperature of a cooled fluid. The heated and cooled fluids are brought into thermal contact with each other within a tank. The output temperature of the warmed fluid is maintained at a stable temperature by a re-circulation loop that connects directly to the mid portion of the tank such that the re-circulated fluid flow primarily warms only a re-circulation section of the tank. The other, lower flow rate, section of the tank may be positioned so that it has a cooler temperature and thus serves to increase the efficiency of the heat exchange by extracting extra heat energy out of the cooled fluid before it leaves the tank. Alternatively, the low flow rate section of the tank may be warmer than the re-circulated section, and thus allow the re-circulated section to be cooler than the output temperature of the warmed fluid.