Heat Exchanger Plate Layout for Dual Flow Paths and Lower Thermal Stress
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Solution Overview
Problem
Existing heat exchange arrangements in gas-fired hot water heaters and burners face thermal stress, leakage, and scaling issues due to high temperature variations, which compromise efficiency and reliability.
Innovation Solution
A plate design with a first and second heat transferring surface, featuring protrusions that divide the surface into inner and outer regions to create multiple flow paths, allowing the first medium to flow twice through the channel for enhanced cooling of the second medium and heating of the first medium, while maintaining metal surface temperatures within safe limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the heat exchange arrangement uses high temperature metal surfaces to maximize heat transfer efficiency, then heat exchange efficiency is improved, but thermal stress and leakage risk increase
Solution Approach 1:
The plate is divided into multiple flow paths for the first medium (water), with separate inlet and outlet portholes creating distinct flow channels. This segmentation allows different regions of the plate to operate at different temperature zones, with water flowing through cooler regions first and progressively heating up, thereby reducing thermal stress on any single metal surface region while maintaining overall heat exchange efficiency.
2Device complexity
If the heat exchange arrangement uses compact design to reduce size and cost, then device complexity is reduced, but temperature control and thermal stress management become more difficult
Solution Approach 1:
The plate design integrates multiple functions into a single component: it serves as both the heat transfer surface and the flow path divider. The protrusions on the plate simultaneously create separation between hot and cold media channels while defining the flow paths for water heating. This multi-functionality achieves compact design without sacrificing temperature control capability.
3Productivity
If the heat exchange arrangement allows water to flow once through the channel, then flow rate is maximized, but cooling efficiency and energy recovery are insufficient
Solution Approach 1:
The first medium (water) flows continuously through the heat exchange arrangement in a controlled manner, with the plate's protrusions ensuring continuous contact between water and heat transfer surfaces. The design maintains steady flow through defined inlet and outlet portholes, maximizing the continuous heat absorption process while optimizing energy recovery from the hot gas stream.
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 design achieves optimal cooling and heating while reducing thermal fatigue and leakage risks, enabling a compact, cost-effective, and efficient heat exchange arrangement for gas-fired systems with extensive condensation and energy efficiency.
Implementation Method 1
The plate has a first heat transferring surface arranged in use to be in contact with the first medium and a second heat transferring surface arranged in use to be in contact with the second medium
Implementation Method 2
Condensation provides additional thermal energy from the fuel due to the release of latent heat. Water vapour from the combustion gases condenses when in contact with low temperature metal surfaces of the heat exchange arrangement
Data Source
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AI summary
A plate (1) for a heat exchange arrangement has a first heat transferring surface (A) with a protrusion (7) forming a continuous and closed ridge. This ridge divides said surface into a closed inner region (A1) and an outer region (A2). The inner region (A1) encloses a first inlet porthole (2) and a first outlet porthole (5) for a first medium. The outer region (A2) has a second inlet porthole (3) and a second outlet porthole (6) for the first medium. A heat exchange arrangement comprises a stack of first and second plates of the above type. The protrusions (7) on the first heat transferring surfaces (A) of said plates are connected to each other to separate first channels into first and second flow paths for the first medium. Each first flow path is configured to direct the first medium from a first inlet to a first outlet inside the inner region (A1) and each second flow path is configured to direct the first medium from a second inlet to a second outlet in the outer region (A2), said inlets and outlets being defined between said inlet and outlet portholes (2, 3 and 5, 6 respectively).