Heat Exchanger Header Ejector Circulation
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Solution Overview
Problem
Existing steam systems require either a circulation pump or a long down comer to maintain circulation, which can be inefficient and limit the positioning of the steam drum relative to the heat exchanger.
Innovation Solution
A header device with an ejector action, utilizing an injector pipe with holes to force the first fluid into a tube arrangement, eliminating the need for a circulation pump and down comer, allowing the steam drum to be positioned closer to the tube arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a circulation pump is used to maintain fluid circulation, then the circulation efficiency is improved, but the device complexity and energy consumption increase
Solution Approach 1:
The patent removes the circulation pump from the system entirely, extracting the active circulation mechanism and replacing it with a passive ejector-based flow generation system. The injector pipe creates suction that naturally draws fluid through the tubes without requiring a separate pump device.
Solution Approach 2:
The system uses the high-temperature fluid flowing through the channel to automatically generate the circulation flow. The injector pipe utilizes the kinetic energy and pressure differential of the existing high-temperature fluid to create suction, making the system self-circulating without external power input for circulation.
2Productivity
If a down comer is used to maintain natural circulation, then the circulation is maintained without a pump, but the system length and complexity increase
Solution Approach 1:
The patent eliminates the down comer structure entirely, removing the need for long vertical conduits required for natural circulation. Instead, the ejector mechanism creates horizontal or near-horizontal flow paths that achieve circulation without the gravitational dependency of down comers.
Solution Approach 2:
The system uses hydraulic principles through the injector pipe, where the high-velocity fluid stream creates a low-pressure region that sucks in and moves the circulation fluid. This pneumatic-hydraulic approach replaces the gravitational-driven down comer system with a pressure-differential-driven flow system.
3Productivity
If a circulation pump is used, then fluid flow to tubes is ensured, but the positioning flexibility of the steam drum is limited
Solution Approach 1:
The ejector system automatically adapts to different steam drum positions because it relies on the natural flow characteristics of the high-temperature fluid and the pressure differential created by the injector pipe. The system self-regulates the circulation flow based on the actual system conditions rather than requiring fixed positioning.
Solution Approach 2:
The system allows for changes in operational parameters such as fluid flow rate, pressure, and temperature without requiring fixed component positions. The injector pipe design enables the system to adapt to varying operational conditions and component arrangements, providing flexibility in steam drum positioning.
4Productivity
If a down comer is used for natural circulation, then circulation is maintained, but the steam drum must be positioned at a high level above the heat exchanger
Solution Approach 1:
The patent removes the vertical down comer structure that imposes the high-level positioning requirement. By eliminating this gravitational-dependent component, the system can be arranged in more compact, flexible layouts without requiring the steam drum to be positioned significantly above the heat exchanger.
Solution Approach 2:
The ejector-based system transitions from the vertical dimensionality requirement of down comers to a more horizontal or flexible three-dimensional arrangement. The circulation flow is generated through pressure differentials rather than gravitational head, allowing components to be positioned in various spatial configurations.
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 solution enables efficient fluid circulation without the need for a circulation pump or down comer, allowing for a more compact system design and improved flow distribution to the tubes.
Implementation Method 1
the second fluid will operate to force the first fluid into the tube arrangement by means of an ejector action
Data Source
Figure 1
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AI summary
A header device (4), a heat exchanger system comprising a tube arrangement for a fluid to be heated, and a method of heating a fluid are disclosed. The header device comprises a header (30) comprising an inlet portion (31) with an header inlet (33) for a first fluid, and an outlet portion (32) with a header outlet (16), which extends through a wall (34) of the outlet portion and is connected to the tube arrangement. The header permits the first fluid to enter an inner space (35) of the outlet portion and to flow from the inner space to the tube arrangement. The header device comprises an injector pipe (40) connected to the header and arranged to inject a second fluid into the header to force the first fluid through the header outlet and into the tube arrangement together with the second fluid, the fluid to be heated comprising the first and second fluids.