Shell-and-tube heat exchanger distribution tray for corrosion protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing shell-and-tube heat exchangers face challenges in evenly distributing a passivation agent to protect against corrosion, leading to uneven distribution and potential corrosion on unpassivated surfaces.
Innovation Solution
A vertical top-to-bottom shell-and-tube heat exchanger design with a distribution tray having two sets of through-holes to evenly distribute the passivation agent across the top tubesheet and allow gas flow, while preventing liquid from entering the tubes, ensuring even coverage and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional shell-and-tube heat exchanger is used without a distribution plate, then the structure is simpler, but the liquid distribution across the tubesheet becomes uneven leading to corrosion
Solution Approach 1:
The distribution plate is segmented with multiple through-holes arranged in specific patterns to distribute liquid evenly across different regions of the tubesheet. This segmentation allows controlled liquid flow paths that ensure uniform passivation agent distribution without requiring complex additional components.
Solution Approach 2:
The distribution plate acts as an intermediary component between the liquid inlet and the tubesheet. It mediates the liquid flow by distributing it evenly across the tubesheet surface, preventing direct uneven impingement and ensuring uniform passivation agent coverage for corrosion protection.
2Reliability
If the distribution plate has through-holes for liquid distribution, then liquid distribution improves, but gas stream distribution to tubes may be affected
Solution Approach 1:
The distribution plate features different regions with different through-hole characteristics. Certain areas have through-holes optimized for liquid distribution while other areas maintain open structures for gas flow. This local differentiation ensures that liquid and gas streams are distributed according to their specific requirements without interfering with each other's efficiency.
Solution Approach 2:
The through-holes are strategically positioned asymmetrically relative to the tube locations and liquid inlet position. This asymmetric arrangement creates optimized flow paths where liquid is distributed evenly across the tubesheet while gas streams can access the tubes effectively, resolving the conflict between liquid distribution and gas condensation efficiency.
3Reliability
If liquid is allowed to reach all areas of the tubesheet, then passivation coverage is improved, but liquid may enter the tubes causing operational issues
Solution Approach 1:
The distribution plate is positioned and configured to preemptively distribute liquid across the tubesheet surface before liquid can potentially enter the tubes. The through-holes create a liquid distribution pattern that wets the tubesheet and forms a protective film, preventing harmful liquid intrusion into the tubes while ensuring comprehensive passivation coverage.
Solution Approach 2:
The distribution plate performs preliminary liquid distribution action by creating an even liquid film across the tubesheet surface before the liquid reaches the tube inlets. This preliminary wetting ensures that passivation agents are distributed uniformly and that excess liquid is controlled, preventing intrusion into the tubes while maintaining protective coverage.
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
Ensures even distribution of the passivation agent, reducing corrosion and extending the lifetime of the heat exchanger components by creating a protective layer, thereby improving operational reliability.
Implementation Method 1
the distribution tray (14) is adapted to distribute both the gas stream and the liquid comprising passivation agent, wherein the distribution tray (14) comprises two sets of through-holes perforating the distribution tray, the first set of through-holes being configured to distribute the liquid comprising a passivation agent across the top of the top tubesheet
Implementation Method 2
a heat exchanging section comprising a set of vertical tubes, an inlet for a cooling medium, an outlet for a cooling medium
Implementation Method 3
a vertical top-to-bottom shell-and-tube heat exchanger for condensing a gas stream
Implementation Method 4
a liquid inlet for a liquid comprising a passivation agent... oxygen is always moving downstream and so remains in the liquid solution to be treated. It is important that the liquid solution containing passivation agent is evenly distributed to the vertical tubes of the heat exchanger in order to efficiently protect the device
Data Source
Figure 1~2
Figure 3~5
AI summary
The present disclosure provides a vertical top-to-bottom shell-and-tube heat exchanger and a method for condensing a gas stream comprising water, ammonia, and carbon dioxide.