Electric heater system
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Solution Overview
Problem
Conventional direct electric heat exchangers struggle to achieve desired vaporization at specific temperature and outlet pressure, and fail to produce the desired velocity and annular flow regime of a two-phase mixture.
Innovation Solution
An electric heater system comprising a series-connected plurality of heat exchanger assemblies with varying fluid guide members and electrical components, designed to generate a predetermined pressure drop and produce a two-phase mixture in an annular flow regime, utilizing resistive heaters and fluid guide members such as helical-shaped baffles and segmented baffles to enhance vaporization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional direct electric heat exchangers are used, then heating function is provided, but desired vaporization at specific temperature and outlet pressure cannot be achieved
Solution Approach 1:
The heat exchanger is divided into multiple heating zones with independent heating elements and fluid guide members. Each zone can be controlled separately to achieve precise temperature and pressure control for vaporization, resolving the contradiction between temperature control and pressure control reliability.
Solution Approach 2:
The system incorporates adjustable fluid guide members and controllable heating elements that can dynamically adapt to maintain desired vaporization conditions. The fluid guide members can be repositioned to control flow patterns, enabling dynamic adjustment of outlet pressure while maintaining target vaporization temperature.
2Speed
If conventional direct electric heat exchangers are used, then heating function is provided, but desired velocity and annular flow regime of two-phase mixture cannot be produced
Solution Approach 1:
Helical-shaped fluid guide members are used to create swirling flow patterns that promote annular flow regime. The curved geometry of the baffles induces rotational motion in the fluid, transforming the flow pattern to achieve the desired annular regime with appropriate velocity distribution.
Solution Approach 2:
Multiple fluid guide members with specific geometries are arranged to replicate optimal flow patterns throughout the heating zones. By copying the effective single-baffle flow guidance to multiple locations, the system achieves consistent annular flow regime and velocity distribution across the entire heat exchanger.
3Ease of manufacture
If uniform heating is applied, then simple design is maintained, but hot spots are generated reducing heat transfer efficiency
Solution Approach 1:
Different heating zones have different heating element configurations and power levels tailored to local thermal requirements. The fluid guide members are strategically positioned in zones where hot spots are likely to form, creating non-uniform but optimized heating distribution that prevents hot spots while maintaining manufacturing simplicity through modular design.
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 effectively achieves the desired vaporization and pressure drop, producing a two-phase mixture in an annular flow regime, thereby improving heat transfer efficiency and reducing hot spots.
Implementation Method 1
heating elements disposed within the vessel
Data Source
AI summary
An electric heater system includes an inlet, an outlet, a plurality of heat exchanger assemblies, and one or more connectors. The plurality of heat exchanger assemblies are connected in series. Each heat exchanger assembly includes a vessel, heating elements disposed within the vessel, and a fluid guide member. The connectors secure the vessels of the plurality of heat exchanger assemblies to each other. The connectors are also in fluid communication with the vessels. Fluid entering the inlet flows through the heat exchanger assemblies and through one or more connectors where it exits the outlet. The fluid guide members of the heat exchanger assemblies are of different or the same combinations to generate a predetermined pressure drop between the inlet and the outlet.