Flow Element for Non-Newtonian Fluids in Heat Exchangers
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Solution Overview
Problem
Existing flow elements for non-Newtonian fluids, particularly those with inhomogeneous solids content, fail to adequately harmonize viscosity, temperature, and velocity gradients in heat exchangers, leading to inefficient heat transfer and potential clogging due to solid content buildup.
Innovation Solution
A flow element designed as a pipe section with molded flow guide surfaces that separate and merge flow layers, creating a 'flow folding' effect to homogenize temperature and velocity gradients, minimizing pressure loss and preventing solid content buildup by connecting seamlessly to the flow pipe without creating obstacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If baffles or static mixers with complex structures are used to harmonize temperature and velocity gradients in non-Newtonian fluids, then heat transfer efficiency is improved, but the solids content becomes trapped, accumulates, and clogs the flow pipe
Solution Approach 1:
The flow tube is divided into multiple sections with different functions: a first section with a flow element that creates flow folding to harmonize gradients, and a second section with a larger cross-section that receives the fluid after flow folding. This segmentation allows the complex flow management function to be separated from the heat exchange function, preventing clogging while maintaining heat transfer efficiency.
Solution Approach 2:
The flow element is extracted as a separate component from the heat exchanger tubes, allowing it to be positioned in a dedicated first section. This extraction enables the flow management function to be isolated from the heat exchange function, preventing solids from clogging the heat exchange surfaces while still achieving the desired flow harmonization.
2Stability of the object's composition
If known deflection elements or static mixers are used to impart swirl and change flow direction, then velocity gradients are reduced, but pressure losses increase
Solution Approach 1:
The flow element employs curved surfaces and smooth transitions to guide flow folding. The first shaped section has a curved outer surface that smoothly transitions to the second shaped section, minimizing flow separation and pressure losses while effectively creating the flow folding needed to harmonize velocity gradients.
Solution Approach 2:
The flow element creates flow folding by moving flow from the periphery toward the center in a three-dimensional path. The first shaped section extends in the flow direction with an outer surface that guides flow in a curved trajectory, adding a radial component to the flow movement and achieving harmonization without excessive pressure losses.
3Loss of energy
If a flow element is designed to create flow folding and harmonize gradients, then heat transfer rate is improved, but device complexity increases
Solution Approach 1:
The flow element serves multiple functions simultaneously: it creates flow folding to harmonize velocity gradients, guides flow from periphery to center, and integrates with the heat exchanger structure. The first shaped section with its outer surface and the second shaped section work together to achieve both flow management and heat transfer enhancement without requiring separate components.
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 flow element enhances heat transfer rates by up to 30-80% in heat exchangers, maintaining fluid flow integrity and preventing clogging, even with high solid content fluids, while minimizing pressure loss and maintaining a streamlined design.
Implementation Method 1
The flow element is designed to create a flow folding, whereby the degree of gradients in the flowing fluid, be it in terms of viscosity, temperature, and/or flow velocity, is specifically reduced. This is achieved by separating flow layers or merging a boundary layer or edge zone flow and mixing them with other flow layers.
Implementation Method 2
The flow element can be used in a heat exchanger to homogenize the viscosity, flow velocity, and/or temperature distribution. The flow element enhances heat transfer rates by up to 30-80% in heat exchangers
Implementation Method 3
The flow element is designed to prevent the solids content from accumulating and clogging the flow tube. The flow element maintains fluid flow integrity and preventing clogging, even with high solid content fluids
Data Source
Figure 1a~1c
Figure 1d
Figure 2a~2b
AI summary
A flow element (1) for a non-Newtonian fluid, in particular for a shear-thinning fluid with a solids content, comprising a pipe section (10) with an inner wall (13) which can be connected to a flow tube and through which the fluid can flow along a flow direction, and a shaped body (20) arranged on the inner wall (13), comprising a first shaped section (22) extending in the flow direction (3), along which a boundary zone flow can be separated from and/or merged with adjacent flow layers, and at least a second shaped section (24) along which the separated and/or merged boundary zone flow can be guided in the direction of a core flow. The flow element is located in a flow tube for defined fluids and in a heat exchanger tube. A heat exchanger module is also described.