Heat Exchanger State Determination via Segmented Simulation
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Solution Overview
Problem
Current methods for simulating the mechanical and thermal stress of heat exchanger devices in industrial plants, such as air separation or gas liquefaction plants, require significant computational effort or do not provide precise data, making it difficult to estimate lifetime, maintenance needs, and stability.
Innovation Solution
A thermohydraulic simulation method is employed to determine temperature and heat transfer coefficient profiles within heat exchanger devices, using one-dimensional Navier-Stokes equations and finite element methods to calculate stress distributions, thereby reducing computational effort while providing accurate state variables for structural-mechanical calculations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional simulation methods are used to determine mechanical and thermal stress of heat exchanger devices, then prediction accuracy of lifetime and stability is improved, but computational effort increases significantly
Solution Approach 1:
The simulation method is segmented into two distinct stages: (1) thermohydraulic simulation to determine temperature and heat transfer coefficient profiles, and (2) structural-mechanical simulation using these profiles as boundary conditions. This segmentation allows each stage to be optimized independently, reducing overall computational effort while maintaining prediction accuracy.
Solution Approach 2:
The thermohydraulic simulation is performed as a preliminary step before the structural-mechanical simulation. By pre-calculating temperature and heat transfer coefficient profiles and using them as boundary conditions for the subsequent structural analysis, the method avoids the need for simultaneous coupled simulation, significantly reducing computational effort.
2Reliability
If detailed thermohydraulic simulation is performed to obtain accurate temperature and heat transfer profiles, then boundary conditions for structural-mechanical calculation are improved, but device complexity increases
Solution Approach 1:
The simulation system is divided into independent thermohydraulic and structural-mechanical modules that communicate through standardized boundary conditions (temperature and heat transfer coefficients). This modular segmentation reduces simulation complexity by allowing each module to be developed and validated independently while maintaining high boundary condition accuracy.
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 approach allows for reliable determination of heat exchanger states with reduced computational effort, enabling improved prediction of lifetime, maintenance intervals, and optimized operation of industrial plants by simulating dynamic temperature and heat transfer profiles as boundary conditions for structural-mechanical analysis.
Implementation Method 1
thermohydraulic simulation of the at least one process stream through at least one passage in the heat exchanger device being performed for determining temperature and/or heat transfer coefficient profiles of the means for transferring heat
Implementation Method 2
thermohydraulic simulation of the at least one process stream through at least one passage in the heat exchanger device
Implementation Method 3
structural-mechanical simulation with the aid of finite element methods for calculating stress distributions in the means for transferring heat as a function of position and time on the basis of the temperature profiles determined
Data Source
AI summary
The invention relates to a method for determining the state of a heat exchanger device (10) that comprises means for transferring heat with the aid of at least one process stream. A thermohydraulic simulation of the at least one process stream through at least one passage (14) in the heat exchanger device (10) is carried out in order to determine temperature and/or heat transfer coefficient profiles of the means for transferring heat.