Heat Exchanger Web Channels for Even Flow and Low Pressure Loss
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Solution Overview
Problem
Existing heat exchangers with web elements or pipes for heat transfer fluids experience uneven flow distribution and high pressure loss, leading to inefficient heat transfer and increased energy costs.
Innovation Solution
A heat exchanger design featuring web elements arranged in alternating rows with different angles to the longitudinal axis, connected via chambers with balanced inlet and outlet openings, allowing for even fluid flow and reduced pressure loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If web elements or pipes are added to improve heat transfer, then heat transfer efficiency is improved, but pressure loss increases and flow distribution becomes uneven
Solution Approach 1:
The heat exchanger is divided into multiple chambers separated by partition walls, with web elements distributed across different chambers. This segmentation allows the heat transfer fluid to flow through multiple pathways simultaneously, improving heat transfer efficiency while distributing flow more evenly to reduce pressure loss.
Solution Approach 2:
Web elements are arranged at different angles in different rows, with adjacent web elements having different orientations. This local variation in web element configuration creates more uniform flow distribution across the heat transfer fluid pathway, reducing dead zones and improving overall heat transfer while maintaining acceptable pressure loss.
2Productivity
If the number of web elements is increased to improve heat transfer, then heat transfer efficiency is improved, but flow distribution becomes more uneven
Solution Approach 1:
By dividing the heat exchanger into multiple chambers with partition walls and distributing web elements across these chambers, the system maintains stable and uniform flow distribution even with an increased total number of web elements. Each chamber acts as an independent flow path, preventing flow maldistribution.
Solution Approach 2:
Adjacent web elements are deliberately arranged at different angles, creating an asymmetric pattern that disrupts flow stagnation and promotes more uniform distribution. This asymmetric arrangement ensures that flow is evenly distributed across all web elements, maintaining flow stability while increasing heat transfer efficiency.
3Productivity
If web elements are arranged to maximize heat transfer surface area, then heat transfer efficiency is improved, but pressure loss increases
Solution Approach 1:
The heat transfer fluid pathway is segmented into multiple chambers with the heat transfer fluid flowing sequentially through each chamber. This segmentation distributes the pressure drop across multiple smaller stages rather than one large continuous path, reducing overall pressure loss while maintaining large total heat transfer surface area through multiple web elements.
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 even flow distribution and low pressure loss, enhancing heat transfer efficiency and reducing energy consumption.
Implementation Method 1
a heat transfer fluid that is supplied to the casing element can flow through the web element channels of the web elements... heated or cooled by heat exchange with the jacket element
Implementation Method 2
the heat transfer fluid flows through the web element channels... flows through the chambers and the web element channels
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
A heat exchanger (100) comprises a shell element (102) and an insert element (103), wherein the shell element (102) forms a fluid channel for a fluid to be heated. The insert element (103) is arranged in the fluid channel. The insert element (103) contains a plurality of web elements (109, 110) which are connected to the shell element (102) at different locations.At least part of the web elements (109, 110) contains web element channels (111, 112) which are in fluid-conducting communication with the shell element (102), so that in the operating state a heat transfer fluid which is supplied to the shell element (102) can flow through the web elements (109, 110), wherein the shell element (102) contains a plurality of chambers for a heat transfer fluid, wherein the chambers contain at least one inlet opening and one outlet opening for the heat transfer fluid, wherein the inlet opening and the outlet opening of the chamber are connected to the web element channels of each pair of web elements belonging to the same web element series.