Helical Cooling Rod for Precise Reactor Temperature Control
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Solution Overview
Problem
Current methods for regulating temperature in chemical and biological processes, such as placing reactors in ice baths, lack precision and consistency in cooling or heating, which can be detrimental to fragile biological cells and require more efficient heat exchange solutions.
Innovation Solution
A process cooling element in the form of a rod with a manifold and an inner flow diverter having helical flutes, made from high heat transfer coefficient materials like polymers or metals, is inserted into bioreactors or reactors to efficiently regulate temperature by flowing cooling or heating fluid through helical passages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a reactor is placed in an ice bath for cooling, then the temperature of the process medium can be reduced, but the cooling amount cannot be accurately and consistently regulated
Solution Approach 1:
The cooling system is segmented into multiple independent cooling rods that can be individually positioned and controlled within the reactor. Each rod contains internal flow passages that allow precise control of cooling fluid distribution, enabling accurate and consistent temperature regulation across different zones of the process medium.
Solution Approach 2:
A cooling fluid acts as an intermediary between the external cooling source and the process medium. The cooling fluid flows through helical passages in the cooling rods, efficiently transferring thermal energy from the process medium to the cooling fluid, thereby achieving accurate and consistent temperature control.
2Power
If cooling fluid flows through straight passages in the cooling rod, then the structure is simple, but the heat exchange efficiency is insufficient
Solution Approach 1:
The cooling rod employs helical (curved) flow passages instead of straight passages. This curvature increases the surface area contact between the cooling fluid and the rod wall, enhances turbulent mixing, and improves heat transfer efficiency while maintaining a relatively simple cylindrical rod structure.
Solution Approach 2:
The flow passages transition from a one-dimensional straight path to a three-dimensional helical path within the rod. This dimensional change increases the effective heat exchange surface area and improves fluid mixing without significantly increasing the external dimensions of the cooling rod.
3Power
If the cooling rod does not extend close to the floor of the vessel, then the installation is easier, but the heat transfer with small amounts of liquid is insufficient
Solution Approach 1:
The cooling rod is designed with enhanced heat transfer features (helical passages, specific surface area distribution) concentrated in the lower section that contacts the process medium. This local optimization ensures efficient heat transfer with small liquid volumes while maintaining standard installation procedures at the upper section.
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 solution allows for rapid and precise temperature regulation within process vessels, effectively cooling or heating the medium, even in small volumes, and is adaptable for various process conditions, including ultra-filtration and drug filling processes, significantly improving temperature control compared to traditional methods.
Implementation Method 1
The outer jacket and flow diverter are desirably formed of a polymer, sometimes transparent, with a high coefficient of heat transfer; which may be greater than 0.50 W/mK @23 C or even greater than 0.90 W/mK @23 C
Implementation Method 2
flowing cooling fluid into the inlet connector which travels down through the central bore and then up through the helical flow passage(s) to the outlet connector
Data Source
AI summary
A process heat exchange rod for cooling or heating liquids in a process vessel. The rod may have a linear form and extend downward through an upper wall of the process vessel into proximity with the lower floor. The rod internally defines a circulatory flow path for the heat exchange medium, including an outer jacket and a flow diverter having a central through bore and external helical flutes. Heat exchange medium travels down through the central through bore and then back up through helical grooves formed between the flow diverter and the outer jacket, or vice versa. Accurate heating or cooling of the process fluid is attained by modification of the configuration of the heat exchange rod as well as the flow rate and temperature of the heat exchange medium. The components may be injection molded of a polymer, often transparent, having a high heat transfer coefficient.