Helical Flow Guide Insert for Heat Transfer Without Turbulence
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Solution Overview
Problem
Existing heat exchanger tubes face challenges in maximizing thermal efficiency without inducing turbulence, which can lead to increased pressure drop and reduced performance.
Innovation Solution
A heat exchanger tube insert comprising a central rod with a cap and protruding guides positioned helically around its outer surface, extending across the annulus between the rod and the tube's inner surface, which increases the residence time and contact area of the working fluid without inducing turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If baffles or turbulators are added inside the HX tube to enhance turbulence, then thermal efficiency is improved, but pressure drop increases
Solution Approach 1:
The patent introduces a flow guide insert as an intermediary component between the working fluid and the HX tube wall. This insert extends the fluid's travel path and enhances contact with the tube surface without creating turbulence, thereby improving heat transfer efficiency while avoiding the pressure drop penalty associated with traditional turbulators.
Solution Approach 2:
The flow guide insert adds a spatial dimension to the fluid flow path by extending it along the length of the HX tube. The insert comprises a support structure with multiple flow guides that direct the fluid to travel a longer distance and maintain closer contact with the tube wall, effectively utilizing the longitudinal dimension to enhance heat transfer without increasing turbulence.
2Duration of action of moving object
If the HX tube length is increased to extend residence time, then heat transfer efficiency is improved, but device complexity and space requirements increase
Solution Approach 1:
The flow guide insert utilizes the longitudinal dimension within the existing HX tube to extend the fluid's residence time. By guiding the fluid to travel a longer path along the tube length rather than taking a direct route, the insert effectively increases residence time without adding external components or increasing overall device complexity.
Solution Approach 2:
The flow guide insert is nested within the existing HX tube structure. The insert comprises a support structure with multiple flow guides that are contained within the tube's internal volume, utilizing the available space without requiring additional external space or increasing device complexity.
3Temperature
If multiple dimple like deformations are added to the HX tube surface to increase velocity, then turbulence is improved, but manufacturing complexity increases
Solution Approach 1:
Rather than modifying the HX tube surface with complex dimple deformations, the patent introduces a separate flow guide insert as an intermediary component. This insert achieves the desired flow enhancement through its geometric structure with multiple flow guides, simplifying the manufacturing process while maintaining heat exchange efficiency.
Solution Approach 2:
The flow guide insert is divided into multiple segments including a support structure and multiple flow guides. This segmentation allows for simplified manufacturing of individual components that can be assembled together, reducing the manufacturing complexity compared to creating multiple dimple deformations on the tube surface.
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 enhances thermal efficiency by extending the travel length and residence time of the working fluid, improving heat transfer while maintaining acceptable pressure drop and compliance with standards, potentially increasing efficiency by 0.2-2%.
Implementation Method 1
increases the residence time and fluid contact area within a HX tube... enhancing the turbulence of working fluid inside the HX tube... increases the thermal efficiency of the HX tube
Data Source
AI summary
A heat exchanger tube insert for use in a heat exchanger tube located within a fuel fired apparatus or non-fired storage tank heat exchanger. The heat exchanger tube insert includes a central rode, a cap, and at least two protruding helical guides that are configured to direct a flow of heated working fluid around the inner circumference of the heat exchanger tube.