Integrated Heat Exchange Pipeline Casing for Flue Gas Recovery
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Solution Overview
Problem
Existing heat recovery systems for high-temperature fluids, such as flue gas from glassmelting furnaces, are inefficient and costly due to the need for additional space and infrastructure, particularly in oxygen-enriched combustion processes where energy recovery is essential for environmental protection and cost reduction.
Innovation Solution
Integration of a heat exchange apparatus within the existing high-temperature fluid pipeline, featuring a heat exchange base plate, thermal isolation layer, and a coil for heat-recovering fluid, which allows for indirect heat transfer and minimizes space and cost requirements by utilizing a refractory layer and sealing materials for efficient heat exchange.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an indirect heat exchanger with separate heat exchange regions is used, then heat recovery efficiency is improved, but space occupation and investment cost increase
Solution Approach 1:
The patent combines the heat exchange apparatus with the existing flue gas pipeline by forming the pipeline casing itself from the heat exchange apparatus. The heat exchange base plate becomes part of the pipeline structure, eliminating the need for separate external heat exchange regions. This merging allows heat recovery functionality to be integrated into the existing pipeline space, thereby improving heat recovery efficiency without increasing overall space occupation.
Solution Approach 2:
The heat-recovering fluid coil is installed inside the heat exchange cavity formed by the pipeline casing. The coil is nested within the existing pipeline structure, utilizing the internal space of the pipeline for heat exchange operations. This nesting approach allows the heat recovery system to function within the existing pipeline footprint, avoiding additional space requirements.
2Loss of energy
If an indirect heat exchanger with separate heat exchange regions is used, then heat recovery efficiency is improved, but investment cost increases
Solution Approach 1:
The heat exchange apparatus is merged with the existing flue gas pipeline, where the pipeline casing is formed by the heat exchange apparatus itself. This integration eliminates the need for separate external heat exchange equipment and reduces material requirements. The weight-bearing plates and thermal isolation layer are incorporated into the pipeline structure, reducing overall material consumption and manufacturing complexity, thereby lowering investment costs while maintaining heat recovery efficiency.
Solution Approach 2:
The pipeline casing serves multiple functions: it contains the flue gas, provides structural support, and acts as the heat exchange apparatus. The heat exchange base plate and thermal isolation layer form a multi-functional structure that simultaneously provides thermal insulation and heat transfer surfaces. This multi-functionality reduces the number of separate components needed, simplifying manufacturing and reducing investment costs.
3Area of stationary object
If the pipeline casing is formed by heat exchange apparatus, then space and cost are reduced, but heat exchange efficiency must be maintained
Solution Approach 1:
The heat exchange base plate is designed with specific local properties to optimize heat transfer. The base plate is positioned in direct contact with the flue gas flow, creating a localized high-efficiency heat transfer zone. The thermal isolation layer is applied selectively to the outer surface, providing insulation where needed while allowing heat transfer at the base plate interface. This local quality approach ensures high heat exchange efficiency within the integrated pipeline structure.
Solution Approach 2:
The heat exchange base plate acts as an intermediary between the flue gas and the heat-recovering fluid coil. It transfers thermal energy from the flue gas through conduction to the coil, enabling efficient heat exchange. The thermal isolation layer serves as another intermediary, directing heat flow toward the heat exchange cavity while insulating the external environment. These intermediary elements ensure high heat exchange efficiency within the compact integrated structure.
4Loss of energy
If thermal isolation layer with heat-reflecting plate is used, then heat recovery efficiency is improved, but device complexity increases
Solution Approach 1:
The thermal isolation layer is constructed as a composite structure combining heat-reflecting plates with thermal isolation materials. The heat-reflecting plates are positioned to reflect radiant heat back into the heat exchange cavity, while the thermal isolation materials (such as insulation wool or perlite) provide conductive and convective insulation. This composite approach enhances heat recovery efficiency by addressing multiple heat transfer mechanisms simultaneously, while the modular nature of the composite structure keeps device complexity manageable through standardized component assembly.
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 enhances heat exchange efficiency, reduces costs, and ensures safety and controllability by allowing multiple heat exchange apparatuses to be installed in parallel, effectively recovering thermal energy from high-temperature fluids while preventing leakage and corrosion.
Implementation Method 1
a heat exchange base plate (1) in contact with the high-temperature fluid... the heat-recovering fluid is heated by the high-temperature fluid through heat conduction by the auxiliary fluid and heat radiation by the heat exchange base plate
Implementation Method 2
a thermal isolation layer (3) in contact with an external environment... A thermal isolation material is packed between the inner and outer walls of the thermal isolation layer
Implementation Method 3
the inner wall of the thermal isolation layer at least partially comprises a heat-reflecting plate
Implementation Method 4
a coil for a heat-recovering fluid being installed in the heat exchange cavity... the heat-recovering fluid is heated by the high-temperature fluid through heat conduction by the auxiliary fluid
Implementation Method 5
the heat-recovering fluid is heated by the high-temperature fluid through heat conduction by the auxiliary fluid and heat radiation by the heat exchange base plate
Data Source
Figure 1~2
Figure 3~4
AI summary
A transporting pipeline for a high-temperature fluid, the transporting pipeline integrating a heat exchange apparatus, wherein heat contained in the high-temperature fluid can be recovered during the transportation thereof. The heat exchange apparatus comprises a hermetic heat exchange cavity 20, and a coil 12 for a heat-recovering fluid installed therein, as well as a method of heat exchange, whereby the high-temperature fluid heats an auxiliary fluid in the cavity 20 via a heat exchange base plate 1 of the heat exchange cavity 20 in contact therewith, and the heated auxiliary fluid then conducts the heat to the heat-recovering fluid in the coil 12, the high-temperature fluid being, for example, flue gas generated by combustion, an upper part of a flue gas transporting pipeline being replaced by the heat exchange apparatus of the present invention, the auxiliary fluid being an inert gas such as air, and the air heated by the high-temperature flue gas conducting heat to fuel and/or oxygen-enriched gas (as an oxidant/combustion aid) flowing in the coil 12.