Heat Exchanger Effluent Collector for Clog Prevention
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Solution Overview
Problem
Conventional gas to gas heat exchangers experience increased pressure drop due to accumulation of substances like fly ash and heavy metals on heat transfer elements, leading to re-entrainment of these substances in the flue gas stream and potential environmental discharge during cleaning.
Innovation Solution
A gas to gas heat exchanger with element supporting baskets and heat transfer elements that define closed passageways, equipped with a cleaning system using high-pressure fluid jets to remove accumulated substances and an effluent collector hopper/tray with a cleaning system to prevent clogging and re-entrainment, maintaining heat transfer efficiency while reducing pressure drop.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high-pressure water wash is used to clean heat transfer elements, then accumulated substances are removed and pressure drop is reduced, but removed substances become re-entrained in the flue gas stream and may be discharged to the environment
Solution Approach 1:
The invention extracts the cleaning function from the heat transfer element itself by using a separate effluent collector hopper positioned downstream. The hopper collects removed substances before they can re-entrain in the flue gas stream, separating the collection function from the heat transfer function.
Solution Approach 2:
The effluent collector hopper acts as an intermediary device between the heat transfer elements and the flue gas stream. It intercepts and collects removed substances, preventing direct re-entrainment while maintaining the cleaning effectiveness of the high-pressure water wash system.
2Productivity
If heat transfer elements are cleaned to remove accumulated substances, then heat transfer efficiency is maintained, but cleaning operations require additional systems and complexity
Solution Approach 1:
The invention merges the effluent collection function with the existing heat exchanger structure by positioning the hopper downstream within the same housing. This integration reduces the need for separate complex collection systems while maintaining heat transfer efficiency through effective substance removal.
Solution Approach 2:
The effluent collector hopper is designed to automatically collect and contain removed substances without requiring additional active control systems. The gravitational flow and structural positioning enable self-service collection, reducing operational complexity while maintaining cleaning effectiveness.
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
Significantly reduces pressure drop and re-entrainment of substances, maintaining heat transfer rates and improving system efficiency and reducing environmental impact and costs.
Implementation Method 1
the untreated hot flue gas FG has a flow 20 through the untreated gas sector 36 of the heat exchanger 10 transferring heat to the heat transfer elements 34 on the continuously rotating rotor 12
Implementation Method 2
In treated flue gas sector 38, treated flue gas TG has a flow 26 between the heat transfer elements 34. Treated flue gas TG is thereby heated by heat transfer elements 34.
Implementation Method 3
a heat transfer element cleaning system 160 equipped with a plurality of nozzles 170 fluidly connected to a fluid supply 168 arranged and operable for fluid F spray cleaning of accumulated substances from the heat transfer elements 134
Data Source
AI summary
A gas to gas heat exchanger 110 is equipped with a heat transfer element cleaning system 160, effluent collector hopper 162 and effluent collector hopper cleaning system 164. The heat transfer element cleaning system 160 is useful to remove accumulated substances from the heat exchanger 110 heat transfer elements 134. The effluent collector hopper 162 is useful to capture a cleaning fluid used to remove accumulated substances from the heat exchanger 110 heat transfer elements 134. The effluent collector hopper cleaning system 164 is useful to remove accumulated substances captured with the cleaning fluid from the effluent collector hopper 162 to prevent clogging thereof.