Exhaust Gas Recirculation Cooler With Flow Blocking Plate
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Solution Overview
Problem
Heat exchangers used to cool exhaust gases face performance degradation due to fouling, which is exacerbated by increased surface area density and reduced Reynolds number, leading to reduced heat transfer efficiency and increased pressure drop.
Innovation Solution
The design incorporates an exhaust gas flow conduit with arcuately shaped narrow sides and a convoluted fin structure, featuring a flow blocking plate that inhibits exhaust gas from flowing through larger channels, directing it through smaller channels with a reduced hydraulic diameter, thereby reducing fouling susceptibility and maintaining thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface area density is increased to improve heat exchanger performance, then heat transfer capability is improved, but Reynolds number decreases which increases fouling factor
Solution Approach 1:
The patent applies different channel geometries in different locations within the heat exchanger. Specifically, it uses channels with varying hydraulic diameters and cross-sectional areas at different positions to optimize both heat transfer and fouling resistance locally, rather than using a uniform design throughout.
Solution Approach 2:
The patent changes the hydraulic diameter parameter along the flow path by incorporating channels with different cross-sectional areas. This parameter variation allows the system to maintain higher Reynolds numbers in certain sections to reduce fouling while still achieving high overall surface area density for heat transfer.
2Ease of manufacture
If conventional heat exchanger design is used, then manufacturing is straightforward, but performance degrades significantly under fouled conditions
Solution Approach 1:
The heat exchanger is segmented into multiple channels with different geometric characteristics rather than using a single uniform channel design. This segmentation allows different portions of the system to handle different aspects of the flow, with some channels optimized for heat transfer and others for maintaining flow velocity to prevent fouling.
Solution Approach 2:
Instead of trying to prevent fouling by maintaining uniformly small channels throughout, the patent inverts the approach by intentionally including larger channels that can maintain higher flow velocities and Reynolds numbers, thereby reducing fouling deposition through enhanced turbulent flow characteristics.
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 improves thermal performance and reduces pressure drop in fouled conditions, maintaining efficiency and preventing performance degradation, with potential performance improvements of up to 10%.
Implementation Method 1
The convoluted fin structure and flow blocking plate direct exhaust gas flow through smaller channels
Implementation Method 2
directing it through smaller channels with a reduced hydraulic diameter
Implementation Method 3
heat transfer calculation
Implementation Method 4
heat exchanger performance
Data Source
AI summary
An exhaust gas recirculation cooler that includes an inlet tank, an outlet tank, and an exhaust gas flow conduit in fluid communication with the inlet tank and the outlet tank. The exhaust gas flow conduit includes a first end, a second end, a first narrow side, a second narrow side, a first channel adjacent the first narrow side and extending between the first end and the second end, a second channel adjacent the second narrow side and extending between the first end and the second end, and a plurality of third channels located between the first channel and the second channel and extending between the first end and the second end. At least one of the inlet tank and the outlet tank includes a wall that inhibits exhaust gas from flowing through the first channel while allowing exhaust gas flow through the plurality of third channels.