Heat Exchanger Header Distributor with Vapor-Assisted Flow Mixing
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Solution Overview
Problem
Existing heat exchangers face challenges in uniformly distributing two-phase fluid into microchannel tubes, leading to liquid pool formation and high pressure drops, which affect performance and efficiency.
Innovation Solution
A fluid distributor with a distributor tube having a first segment outside the header and a second segment inside, featuring a hole for vapor phase flow to stir liquid and a nozzle for uniform distribution, along with baffles and porous media to manage flow and prevent pool formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a conventional inlet header is used without internal distributors, then the structure is simple, but liquid pool formation occurs and fluid distribution is non-uniform
Solution Approach 1:
The inlet header is segmented into multiple zones using baffles that divide the internal space. This segmentation creates separate flow paths and prevents liquid pooling by directing fluid toward multiple outlet ports uniformly. The distributor tube is also segmented with multiple holes at different positions to distribute vapor phase fluid to different regions.
Solution Approach 2:
A distributor tube is introduced as an intermediary component between the inlet and outlet ports. This tube extends into the header and provides a controlled path for vapor phase fluid to reach the liquid pool region, facilitating uniform distribution without requiring complex external distribution systems.
2Manufacturing precision
If the header volume is increased to accommodate two-phase flow, then fluid distribution improves, but liquid pool formation increases and pressure drop increases
Solution Approach 1:
The liquid pool is effectively 'taken out' or prevented from forming by introducing vapor phase fluid through the distributor tube. The vapor acts as a stirring medium that continuously mixes with and prevents liquid accumulation, thereby eliminating the need for large header volumes to accommodate liquid pools while maintaining uniform distribution.
Solution Approach 2:
The system utilizes phase transition by introducing vapor phase fluid into the header where it mixes with liquid phase. This phase interaction creates a two-phase flow regime that prevents liquid pooling and maintains uniform distribution. The vapor phase can condense or mix with liquid, continuously refreshing the fluid distribution without requiring increased header volume.
3Manufacturing precision
If vapor phase flow velocity is increased to stir liquid pool, then fluid distribution improves, but pressure drop increases
Solution Approach 1:
The distributor tube introduces vapor phase fluid from a different spatial dimension (through the tube wall holes) directly into the liquid pool region. This dimensional approach allows vapor injection perpendicular to the main flow direction, creating effective stirring without requiring high axial velocity and thus avoiding excessive pressure drop.
Solution Approach 2:
The distributor tube acts as an intermediary that introduces vapor phase fluid at controlled locations and velocities. By positioning holes at specific locations on the tube and controlling vapor injection, effective liquid stirring is achieved without the need for high-velocity main flow, thereby reducing pressure drop while maintaining distribution uniformity.
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 uniform fluid distribution with reduced pressure drop, preventing liquid pools and enhancing heat exchanger performance and efficiency.
Implementation Method 1
the vapor phase flowing out of the hole into the header facilitates stirring of any pool of the liquid phase formed within the header
Implementation Method 2
causing the two-phase fluid and/or a liquid phase associated with the two-phase fluid to flow out of the distributor into the header via the second open end and a vapor phase associated with the two-phase fluid to flow into the header via the hole
Implementation Method 3
the liquid phase flowing out of the second open end flows into one or more ports associated with a plurality of heat exchange tubes
Data Source
AI summary
Described herein is a fluid distributor for a header associated with a heat exchanger. The distributor comprises a distributor tube comprising a first tube segment, and a second tube segment extending at a predefined angle from an end of the first tube segment, wherein the distributor tube comprises a hole at a predefined position on a predefined side, facing towards the first tube segment on an inner side of a bend, of the second tube segment, wherein the distributor tube is configured with the header such that the first tube segment remains outside of the header and the second tube segment extends longitudinally within the header via a first end of the header, with the hole located at the first end of the header.