Helical Baffle Heat Exchanger with Perforated Flow Guide
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Solution Overview
Problem
Traditional heat exchangers face limitations in increasing heat exchange area and heat flux, which can lead to inefficient heating of working fluids due to space constraints and material limitations, resulting in reduced heat transfer efficiency and potential fouling.
Innovation Solution
A heater assembly featuring a continuous series of perforated helical members and heating elements that create a geometric helicoid structure, guiding the working fluid in a helical flow path to enhance heat transfer efficiency and reduce radiative heat loss, while maintaining a consistent linear temperature rise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the total heat exchange area is increased, then heat transfer efficiency is improved, but the space required in the heat exchanger increases
Solution Approach 1:
The patent transforms the traditional linear arrangement of heating elements into a three-dimensional helical configuration. The helical members wrap around the fluid flow path, utilizing the radial and angular dimensions to maximize heat exchange surface area within the same axial length, thereby increasing heat transfer efficiency without proportionally increasing the overall volume.
Solution Approach 2:
The helical heating elements are nested within the tubular vessel, with multiple helical members arranged concentrically. This nesting allows multiple heating surfaces to occupy the same spatial envelope, effectively packing more heat exchange area into the available space without increasing the external dimensions of the heat exchanger.
2Productivity
If the heat flux of heating elements is increased, then heat output is improved, but material limitations and design constraints are exceeded
Solution Approach 1:
The heating system is divided into multiple discrete helical members rather than using a single high-flux element. Each helical member operates at moderate heat flux levels, distributing the total heat output across several segments. This segmentation avoids the material stress and design complexity associated with single high-flux elements while achieving the same overall heat output.
Solution Approach 2:
Different helical members can be positioned to provide localized heating zones along the fluid flow path. Each helical member is optimized for its specific position, with variations in pitch, diameter, or heating element density to match local thermal requirements, thereby achieving high overall heat output without exceeding material constraints at any single location.
3Productivity
If heating elements are added to increase heat exchange area, then heating efficiency is improved, but the structural complexity of the heat exchanger increases
Solution Approach 1:
Multiple heating elements are merged into a unified helical structure where adjacent helical members are connected or positioned to form a continuous thermal field. This merging reduces the number of separate support structures, mounting points, and connections required compared to traditional arrays of discrete heating elements, thereby increasing heating efficiency while minimizing the increase in structural complexity.
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 solution increases heat transfer efficiency by ensuring uniform fluid flow across heating elements, reducing fouling, and minimizing radiative heat loss, thereby improving the heating process without increasing the physical footprint of the heat exchanger.
Implementation Method 1
The heat is transferred from the heating fluid to the working fluid via the walls of the tubes
Implementation Method 2
Working fluid enters the tubular vessel at one longitudinal end and exits at the other longitudinal end. The working fluid is heated by the plurality of heating elements as the working fluid flows inside the tubular vessel
Implementation Method 3
A heater assembly featuring a continuous series of perforated helical members and heating elements that create a geometric helicoid structure, guiding the working fluid in a helical flow path to enhance heat transfer efficiency and reduce radiative heat loss
Data Source
AI summary
A heater includes a flow guide and electrical resistance heating elements. The flow guide defines a continuous geometric helicoid disposed about a longitudinal axis and defines perforations that extend in a longitudinal direction through a first longitudinal length of the geometric helicoid. The first longitudinal length is less than a full longitudinal length of the geometric helicoid. The electrical resistance heating elements extend through the perforations. For each electrical resistance heating element, a length of that electrical resistance heating element and a pitch of the geometric helicoid at a distal end of that electrical resistance heating element are such that the distal end of that electrical resistance heating element is a distance X from the geometric helicoid at the distal end of that electrical resistance heating element. The distance X is less than or equal to 40% of the pitch at the distal end of that electrical resistance heating element.