Heat Exchanger Segmentation for High-Temperature Gas Heating

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Solution Overview

Problem

Regenerators are not suitable for heating gases that must not come into contact with exhaust gases or contaminants, limiting the temperature at which gases can be heated in industrial processes.

Innovation Solution

A heat exchanger with physically separated flow paths, using a gas-impermeable heat-conducting barrier to prevent gas penetration while allowing heat transfer between a heat-regenerative packing and a heat-conductive packing, allowing for high-temperature heating without direct contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a regenerator is used to heat gases to very high temperatures, then the temperature of the heated gas is significantly improved, but the gas to be heated cannot enter into contact with exhaust gases or contaminants present in the exhaust gases

Engineering Contradiction:

Improvetemperature of heated gasVSAvoidcontact with exhaust gases and contaminants

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The heat exchanger is divided into two separate flow paths: a first flow path for exhaust gases containing heat-regenerative packing, and a second flow path for the gas to be heated containing heat-conductive packing. This segmentation allows each path to perform its specific function while preventing harmful contact between the two gases.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A heat-conducting barrier is introduced as an intermediary element between the two flow paths. This barrier is impermeable to gases but conductive to heat, allowing thermal energy transfer from the exhaust gases to the heated gas without permitting direct contact between the two gas streams, thus eliminating contaminant transfer.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If a recuperator is used to prevent contact between exhaust gases and the gas to be heated, then the gas purity is improved, but the temperature to which the gas can be heated is significantly lower than in regenerative heat exchange

Engineering Contradiction:

Improvecontact with exhaust gasesVSAvoidtemperature of heated gas

Core Design Contradiction:

Object-affected harmful factorsVSTemperature

Solution Approach 1:

The heat-regenerative packing in the first flow path is pre-heated by exhaust gases during a first phase of operation. Then, in a second phase, the heat-conductive packing in the second flow path transfers this stored heat to the gas to be heated. This preliminary heating action allows the system to achieve high temperatures while maintaining gas separation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The heat exchanger operates in two alternating phases: a first phase where exhaust gases heat the heat-regenerative packing, and a second phase where the heat-conductive packing transfers stored heat to the gas to be heated. This periodic phase transition enables the system to combine the benefits of both regenerative and recuperative heat exchange.

Inventive Principle:

Principle #36Phase transitions

3Object-affected harmful factors

If a gas-impermeable heat-conducting barrier is introduced to separate flow paths, then gas separation is improved, but the device complexity increases

Engineering Contradiction:

Improvegas penetration between flow pathsVSAvoidstructure of heat exchanger

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The heat-conducting barrier is designed with porous structure that allows heat conduction while maintaining gas impermeability. This porous design enables thermal energy transfer through the barrier while preventing gas penetration, achieving effective separation without requiring complex multi-layer constructions.

Inventive Principle:

Principle #31Porous materials

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

Enables efficient heat recovery from hot exhaust gases to heat combustion gases to higher temperatures than previously possible, combining the advantages of regenerative and recuperative heat recovery.

Implementation Method 1

The first flow path contains a first packing in physical contact with the barrier, said first packing being a heat-regenerative packing

Methodology Applied

Scientific EffectHeat regeneration: Thermal Energy Storage

Implementation Method 2

The second flow path contains a second packing in physical contact with the barrier, said second packing being a heat-conductive packing

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

a gas-impermeable heat-conducting barrier... enabling heat to be transferred from the first flow path to the second flow path

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentEP3559582B1Heat exchanger and heat exchange method using same

Publication Date: 2023.08.23 LAIR LIQUIDE SA POUR LETUDE & LEXPLOITATION DES PROCEDES GEORGES CLAUDE

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AI summary

Heat exchanger (100, 200) presenting a first gas flow path (110, 210) containing a heat-regenerative packing (115, 215) and a separate second gas flow path (120, 220) containing a heat-conductive packing (125, 225) and use of same for heating a gas to be heated(31) by means of heat recovered from a hot gas (11) in a two-phase alternating heat-recovery process.