Helical-Flow Shell Heat Exchanger With Arcuate Tube Layout
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Solution Overview
Problem
Current heat exchangers face challenges in increasing efficiency, reducing size, and lowering costs while maintaining effective heat transfer without fluid mixing, particularly in designs like the 'plate and frame' and 'tube and shell' configurations.
Innovation Solution
A heat exchanger design featuring a shell with inner and outer series of heat exchange tubes, utilizing baffles to direct air flow in a helical configuration, which increases airflow velocity and enhances heat transfer by optimizing the arrangement of tubes and airflow passageways, including rectilinear baffle configurations and counter-flow water and air configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the area of plates and the number of plates are increased to increase total heat transfer surface, then heat transfer efficiency is improved, but device size and complexity increase
Solution Approach 1:
The patent transitions from traditional planar plate arrangements to a three-dimensional tubular configuration where tubes are arranged in multiple layers and orientations within a compact shell. This spatial reconfiguration allows substantial heat transfer surface area to be achieved within a reduced volumetric footprint, effectively resolving the contradiction between heat transfer efficiency and device size.
Solution Approach 2:
The patent employs a nested arrangement where inner series of tubes are positioned concentrically within the outer series of tubes, creating a compact multi-layered structure. This nesting approach maximizes the heat transfer surface area within a confined space, allowing multiple heat exchange surfaces to occupy overlapping spatial regions and thereby reducing overall device volume while maintaining high productivity.
2Productivity
If tube arrangement is optimized to increase heat transfer surface area, then heat transfer efficiency is improved, but manufacturing complexity increases
Solution Approach 1:
The patent divides the heat exchanger into modular sections with standardized tube bundles that can be manufactured independently and assembled systematically. The tubes are arranged in discrete inner and outer series with consistent spacing and orientation, allowing for repetitive manufacturing processes and simplified assembly procedures, thereby reducing overall manufacturing complexity despite the sophisticated three-dimensional arrangement.
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 design enhances heat transfer efficiency, reduces the size of the heat exchanger, and lowers material costs by increasing the surface area for heat exchange, thereby improving overall performance and manufacturability.
Implementation Method 1
the baffle sheet, in cooperation with a neighboring baffle sheet, directs air flow within the heat exchanger in a helical configuration from a center of the shell toward an outer region of the shell
Implementation Method 2
Heat exchangers are devices for transferring heat from one medium to another, typically from one fluid to another or to a surrounding environment, without allowing the fluids to mix
Implementation Method 3
A first tube set is arcuately arranged around a hot gas burner at or near the center of the heat exchanger
Data Source
AI summary
Disclosed is a heat exchanger that has an internal air flow pattern such as a helical pattern. The heat exchanger includes a shell that encompasses an inner series of heat exchange tubes and an outer series of heat exchange tubes. A baffle sheet is juxtaposed next to the outer series of heat exchange tubes. And the baffle sheet is configured to direct air flow within the heat exchanger in a configuration, such as a helical configuration, from a center of the shell toward an outer region of the shell.