Helical Steam Generator Bypass Duct Heat Recovery
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Solution Overview
Problem
Existing waste heat utilization devices in internal combustion engines face challenges in achieving high energy efficiency and cost-effective manufacturing, particularly in the design of steam generators, where heat transfer efficiency and compactness are crucial.
Innovation Solution
A steam generator design featuring a heat exchanger duct with a bypass duct, where the heat exchanger is arranged helically around the bypass duct, allowing for efficient heat transfer with low flow resistance and reduced risk of overheating, and incorporating a control element like a rotatable bypass flap for adjusting heat flow, along with a thermal insulation layer and coiled tubing for ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the heat exchanger is arranged in a conventional configuration, then heat transfer efficiency can be achieved, but the device complexity and manufacturing costs increase
Solution Approach 1:
The heat exchanger duct is arranged concentrically around the bypass duct, with the heat exchanger coils wrapped around the bypass duct. This nested configuration allows the heat exchanger to utilize the space around the bypass duct effectively, improving heat transfer efficiency while maintaining a compact and simple overall structure that reduces device complexity and manufacturing costs.
2Volume of moving object
If the heat exchanger is designed for compactness, then space utilization improves, but heat transfer efficiency may deteriorate
Solution Approach 1:
The heat exchanger transitions from a planar arrangement to a three-dimensional helical configuration wrapped around the bypass duct. This dimensional change allows the heat exchanger to maximize surface area contact with the exhaust gas flow within a compact volume, achieving both compactness and high heat transfer efficiency simultaneously.
3Stability of the object's composition
If the bypass duct is positioned off-center, then structural stability improves, but flow resistance increases
Solution Approach 1:
The design accepts the asymmetric positioning of the bypass duct within the housing as a compromise, where the asymmetric layout provides structural stability and ease of installation, while the concentric arrangement of the heat exchanger around the bypass duct compensates for any flow resistance issues by ensuring uniform heat distribution.
4Loss of energy
If the heat exchanger is tightly coupled to the bypass duct, then heat transfer efficiency improves, but risk of overheating increases
Solution Approach 1:
The bypass duct serves as an intermediary element between the exhaust gas flow and the heat exchanger. By positioning the heat exchanger around the bypass duct rather than directly in contact with the exhaust stream, the bypass duct mediates the heat transfer process, allowing efficient heat extraction while preventing direct exposure to excessive temperatures that could cause overheating.
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 energy efficiency, reduces production costs, and allows for a compact, maintenance-friendly steam generator system that effectively utilizes waste heat, improving the integration of waste heat recovery in internal combustion engines.
Implementation Method 1
a heat exchanger for transferring heat from the heating fluid to the working medium
Implementation Method 2
a thermal insulation layer for thermally insulating the heat exchanger channel relative to the bypass channel
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a steam generator (1) for a Rankine process, in particular for a waste-heat utilization device (37) of an internal combustion engine (36), preferably in a motor vehicle, comprising: a heat exchanger duct (2) in which a heat exchanger (3) is arranged, and a bypass duct (4) for bypassing the heat exchanger duct (2), wherein the heat exchanger duct (2) and the bypass duct (4) can, during operation of the steam generator (1), be traversed by a flow of a heating fluid, and wherein the heat exchanger (3) can, during operation of the steam generator (1), be traversed by a flow of a medium (47) to be evaporated. A compact design with high energy efficiency can be attained if the heat exchanger duct (2) encases the bypass duct (4).