Heat exchange cell and method
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Solution Overview
Problem
Existing heat exchange cells face inefficiencies in heat transfer due to preferential bypass pathways of combustion gases, leading to reduced thermal power delivery and increased size, while configurations with partition elements compromise on thermal power for improved condensing capacity but at the cost of larger size and axial extension.
Innovation Solution
A heat exchange cell design featuring a helically-shaped heat exchanger with a separating element mounted externally, allowing parallel fluid flow between collection chambers and optimizing fluid dynamics to minimize axial size while maximizing thermal power and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a helically-shaped heat exchanger is used to achieve high heat exchange efficiency and compactness, then heat transfer performance is improved, but preferential bypass pathways form reducing thermal power delivery
Solution Approach 1:
The heat exchanger is segmented into multiple independent helical coils arranged in parallel, each coil acting as a separate heat transfer channel. This segmentation prevents preferential bypass pathways by distributing the second heat transfer fluid flow across multiple coils, ensuring uniform heat extraction and maintaining both high heat exchange efficiency and thermal power delivery capability
Solution Approach 2:
Different regions of the heat exchanger are optimized with varying coil densities and pitch configurations. The local quality of heat transfer is enhanced by adjusting coil spacing in different zones to match the thermal load distribution, preventing bypass pathways while maximizing thermal power delivery in high-demand areas
2Productivity
If partition elements are added to improve condensing capacity, then condensation efficiency is improved, but device size and axial extension increase
Solution Approach 1:
The partition elements are positioned radially rather than axially, creating separate flow channels in the radial dimension. This allows the second heat transfer fluid to flow through multiple parallel paths between the helical coils without increasing the axial length, thereby improving condensing capacity while maintaining a compact axial footprint
Solution Approach 2:
The partition elements are nested within the containment casing and positioned between the helical coils, utilizing the existing radial space. This nested configuration creates additional heat exchange surfaces and flow channels without extending the axial dimensions, achieving improved condensing capacity within the same axial envelope
3Productivity
If the second heat transfer fluid flows radially through interstices between coils, then heat transfer is improved, but dead zones form reducing flow uniformity
Solution Approach 1:
Distribution elements are introduced as intermediaries between the fluid source and the helical coils. These elements guide and distribute the second heat transfer fluid uniformly across the inlet faces of multiple coils, preventing dead zones and ensuring consistent flow through each heat transfer channel, thereby maintaining both heat transfer efficiency and flow uniformity
Solution Approach 2:
The heat exchanger design incorporates dynamic flow distribution through the radial arrangement of multiple coils and interstices. The fluid naturally distributes itself across multiple parallel paths with varying local resistances, creating a self-balancing flow pattern that maintains uniformity across different operating conditions while preserving high heat transfer efficiency
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 design enhances heat exchange efficiency, flexibility, and condensing capacity by uniformly distributing the second heat transfer fluid, reducing dead zones, and minimizing the axial size of the heat exchange cell.
Implementation Method 1
a fluid path for the flow of the second heat transfer fluid (for example hot combustion gases produced by a burner) along a substantially radial, or an axial-radial direction
Implementation Method 2
transfer thermal energy between two fluids
Implementation Method 3
the latent condensation heat contained in the combustion gases
Data Source
AI summary
A heat exchange cell is described comprising a containment casing comprising a rear wall, a front wall and a peripheral side wall, a helically-shaped heat exchanger comprising at least one tubular duct for the flow of a first heat transfer fluid coiled about a longitudinal axis of the helix according to a plurality of coils and mounted in the containment casing; a feeding zone of a second heat transfer fluid, intended for the heat exchange with the first heat transfer fluid, defined in the casing coaxially and internally with respect to the heat exchanger; a first chamber for collecting the second heat transfer fluid externally defined with respect to the heat exchanger between a radially outer wall thereof and the peripheral side wall of the containment casing; and a second chamber for collecting the second heat transfer fluid at least partially delimited by at least one separating element.