Multi-Port Heat Exchanger Plate Layout for Overheating Prevention
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Solution Overview
Problem
Existing heat exchangers for recovering thermal energy from combustion gases are inefficient, space-consuming, heavy, and expensive due to limitations in design caused by flame combustion techniques, leading to high emissions and material damage.
Innovation Solution
A heat exchanger plate design with multiple ports and sealing arrangements that facilitate efficient counter-current radial and sequential heat transfer, preventing overheating and material damage, and allowing for compact and cost-effective heat exchange between combustion gases and water.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If flame combustion is used to recover thermal energy from combustion gases, then heat recovery is achieved, but the flame may come into direct contact with heat transfer surfaces causing material destruction and high carbon monoxide emissions
Solution Approach 1:
The patent introduces a catalytic converter as an intermediary device between the flame combustion zone and the heat transfer surfaces. The catalyst promotes complete combustion of combustion gases without requiring direct flame contact with heat exchanger plates, thereby eliminating material destruction risks and reducing carbon monoxide emissions while maintaining effective heat recovery
2Reliability
If material thicknesses are increased to prevent flame contact damage, then durability is improved, but the heat exchanger becomes heavier, more expensive, and less efficient
Solution Approach 1:
By introducing the catalytic converter as an intermediary, the patent eliminates the need for oversized material thicknesses. The catalyst enables complete combustion at lower temperatures that do not require excessive material protection, allowing the use of thinner, lighter materials while maintaining durability and heat exchange efficiency
3Reliability
If material thicknesses are increased to compensate for flame contact risks, then reliability is improved, but the heat exchanger becomes more expensive and space-consuming
Solution Approach 1:
The catalytic converter acts as an intermediary that enables reliable operation with thinner heat transfer surfaces. This eliminates the need for oversized material thicknesses, resulting in a more compact heat exchanger volume while maintaining durability and reliability
4Ease of manufacture
If conventional heat exchanger design is used, then construction is simplified, but heat transfer efficiency is reduced due to overheating at ports and rim areas
Solution Approach 1:
The patent applies local quality by positioning heat transfer plates at specific locations within the combustion chamber - particularly at the periphery and near ports where temperature gradients are most severe. This localized placement optimizes heat transfer efficiency in critical areas without requiring complex overall design changes
Solution Approach 2:
The patent transitions from conventional single-direction heat transfer to multi-dimensional heat exchange by arranging heat transfer plates in three-dimensional spaces within the combustion chamber, including peripheral and port-area positioning. This spatial arrangement enhances overall heat transfer efficiency while maintaining construction simplicity
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
The design enhances heat recovery efficiency, prevents material degradation, and extends the lifespan of heat exchangers while reducing emissions and production costs.
Implementation Method 1
efficient heat transfer from the first medium to the second medium is made possible
Implementation Method 2
counter current radial and the second medium can flow both in parallel and sequentially through a plate package
Data Source
AI summary
A heat exchanger plate for a plate heat exchanger (12) includes a first side, a second side and a center point (P) through which an imaginary center axis (A) extends in a direction perpendicular to a plane of the plate. The plate comprises a first port for a first medium, and at least a second port and a third port for a second medium. The plate further comprises a first sealing arranged on the second side around the first port, a second sealing arranged on the second side at a circumference of the plate, and a closed third sealing arranged between the first and second sealings to form a first heat transfer area and a second heat transfer area separated from the first heat transfer area. The second port is arranged in the first heat transfer area and the third port is arranged in the second heat transfer area.