Finned Heat Exchanger Layout for Condensate-Safe Boiler Efficiency
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat exchanger units in condensing boilers face challenges such as high manufacturing costs and thermal efficiency issues, particularly with plate type heat exchangers, and corrosion risks due to condensate accumulation.
Innovation Solution
A fin-tube type heat exchanger unit is designed with separate sensible and latent heat exchanging parts, featuring pipes and fins that facilitate efficient heat transfer while preventing condensate from reaching sensitive components, thereby maintaining thermal efficiency and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a plate type heat exchanger unit is used, then thermal efficiency is improved, but manufacturing cost increases and manufacturing difficulty arises
Solution Approach 1:
The heat exchanger is divided into multiple heat exchange units, each comprising a tube sheet, tubes, and fins. This modular segmentation allows for standardized mass production of individual units, reducing overall manufacturing cost while maintaining the high thermal efficiency of plate-type heat exchange through the finned tube structure.
Solution Approach 2:
The invention uses finned tube structures that replicate the effective heat transfer characteristics of plate heat exchangers. The fins act as copies of the plate heat transfer surfaces, providing similar thermal performance through a different geometric configuration that is easier and less costly to manufacture.
2Ease of manufacture
If a fin-tube type heat exchange device is used, then manufacturing cost is reduced, but thermal efficiency deteriorates
Solution Approach 1:
The invention adds the dimensional aspect of fins extending from the tubes, transforming a simple tube heat exchanger into a finned tube heat exchanger. This dimensional addition dramatically increases the heat transfer surface area without complicating the basic tube structure, thereby maintaining ease of manufacture while significantly improving thermal efficiency.
Solution Approach 2:
The heat exchange units employ composite construction combining tubes and fins made of different materials optimized for their specific functions. The tubes may be made of corrosion-resistant materials while fins use materials with high thermal conductivity, creating a composite structure that achieves superior thermal efficiency at lower manufacturing cost compared to solid plate constructions.
3Reliability
If condensate accumulates in the heat exchanger, then corrosion risk increases, but operational reliability decreases
Solution Approach 1:
The heat exchanger is segmented into multiple independent heat exchange units that can be individually inspected and maintained. This segmentation allows for easier detection and removal of condensate accumulation in specific units, preventing widespread corrosion and maintaining operational reliability through localized maintenance.
Solution Approach 2:
The tube sheet acts as an intermediary structure between the tubes and the heat exchanger housing, providing a designated collection point for condensate. This intermediary element channels condensate away from critical components, reducing corrosion risk while maintaining the structural integrity and reliability of the overall heat exchanger system.
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 solution effectively maintains thermal efficiency while reducing manufacturing costs and preventing corrosion, ensuring reliable operation of the condensing boiler by isolating sensitive components from condensate.
Implementation Method 1
a sensible heat exchange pipe that is disposed in a sensible heat exchange area for receiving sensible heat generated by a combustion reaction and heating heating-water
Implementation Method 2
a latent heat exchange pipe that is disposed in a latent heat exchange area for receiving latent heat generated during a phase change of combustion gas and heating the heating-water
Implementation Method 3
a sensible heat fin disposed in the sensible heat exchange area and formed in a plate shape across the sensible heat exchange pipe
Implementation Method 4
a latent heat fin disposed in the latent heat exchange area and formed in a plate shape across the latent heat exchange pipe
Data Source
AI summary
A heat exchanger unit according to the present invention comprises: a sensible heat exchanger including a sensible heat exchange pipe disposed in a sensible heat exchange area for heating water used for heating by receiving sensible heat generated by a combustion reaction, wherein the sensible heat exchange pipe receives the water used for heating and flows same through the interior, and a sensible heat fin disposed in the sensible heat exchange area, wherein the sensible heat fin is formed in a plate shape across the sensible heat exchange pipe and penetrated by the sensible heat exchange pipe; and a latent heat exchanger positioned downstream from the sensible heat exchange area on the basis of a reference direction, which is a flow direction of combustion gas generated during the combustion reaction, the latent heat exchanger including a latent heat exchange pipe disposed in a latent heat exchange area.