Heat Exchanger Header Dividers for Uniform Flow Distribution
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Solution Overview
Problem
Existing heat exchanger designs face challenges in transitioning from a piping system to a monolithic structure without incurring unacceptably high pressure losses, while maximizing thermal contact and minimizing flow resistance and material usage.
Innovation Solution
A header is designed with a round configuration at one end for connection to a circular pipe and a plurality of discrete channels at the other end, featuring dividers that extend from the second end to the first end to divide internal channels into discrete channels, allowing for a smooth transition with minimal flow resistance and uniform pressure distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a monolithic structure with many small channels is used to maximize heat exchange surface area, then thermal contact between fluids is improved, but pressure losses increase due to the transition from piping system to monolithic structure
Solution Approach 1:
A header acts as an intermediary component between the circular pipe and the monolithic heat exchanger body. The header contains internal channels that receive fluid from the circular pipe and distribute it to multiple discrete channels in the monolithic structure. This intermediary structure enables smooth fluid transition, minimizing pressure losses while maintaining access to the high surface area of the monolithic channels for effective heat exchange.
2Temperature
If the number of channels in monolithic structure is increased to maximize heat exchange surface area, then thermal contact is improved, but flow resistance increases
Solution Approach 1:
The header is segmented into multiple internal channels, each connected to specific discrete channels in the monolithic heat exchanger body. This segmentation allows the fluid flow to be divided into multiple parallel streams, reducing the velocity and pressure drop in each individual channel while collectively providing access to a large number of heat exchange channels. The dividers within the header further segment the flow paths to ensure uniform distribution across all discrete channels.
3Quantity of substance
If small channel dimensions are used in monolithic structure to allow high pressurized fluids, then material usage is reduced, but transition from piping system becomes more complex
Solution Approach 1:
The header is designed as an integrally formed single piece that combines the functions of both the circular pipe connection and the distribution to multiple discrete channels. This merging of functions into a single component simplifies the overall transition structure, eliminating the need for multiple separate connection pieces while maintaining the ability to handle high pressurized fluids through small channel dimensions.
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 enables efficient transformation of fluid flow into parallel flows with minimal resistance, facilitating uniform pressure and heat exchange, and allows for a compact and efficient configuration of discrete channels in heat exchangers.
Implementation Method 1
The header is provided with a plurality of dividers dividing one or more internal channels of the circular pipe into the plurality of discrete channels at the second end
Implementation Method 2
the surface areas of the walls between the two fluids to be as large as possible in order to maximize the thermal contact between the relatively hot and cold fluids
Data Source
AI summary
The disclosure relates to a header connected to or formed as a part of a heat exchanger. The heat exchanger has a heat exchanger body with a plurality of discrete channels for a first fluid and a plurality of discrete channels for a second fluid. The header has a first end having a round configuration and a second end being provided with a plurality of discrete channels. The header is provided with a plurality of dividers dividing one or more internal channels of the circular pipe into the plurality of discrete channels at the second end. At least some of the dividers extend from the second end to the first end and define a plurality of channel mouths at the first end. The disclosure also relates to a heat exchanger.