High efficiency fluid heating system exhaust manifold
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Solution Overview
Problem
Fluid heating systems suffer from thermal energy losses due to inefficient heat transfer, particularly in systems with external exhaust manifolds, leading to reduced overall thermal efficiency.
Innovation Solution
The system incorporates an exhaust manifold where the interior surface is exposed to combustion gases and the exterior surface is in contact with the production fluid, promoting thermal energy transfer and enhancing efficiency by utilizing the temperature differential for heat recovery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If an external exhaust manifold is used in a fluid heating system, then the system structure is simpler and easier to manufacture, but thermal energy is lost to ambient air reducing overall thermal efficiency
Solution Approach 1:
The exhaust manifold is merged with the pressure vessel by forming an integral structure where the manifold becomes part of the pressure vessel wall. This integration eliminates the need for separate external manifold components while simultaneously capturing thermal energy that would otherwise be lost to ambient air, resolving both the manufacturing simplicity and thermal efficiency concerns
Solution Approach 2:
The exhaust manifold is nested within the pressure vessel structure, with the manifold interior containing combustion gases and the manifold exterior contacting production fluid. This nested configuration allows the manifold to serve dual purposes: exhaust gas transport and heat transfer surface, eliminating external components while recovering thermal energy
2Temperature
If the exhaust manifold exterior is exposed to ambient air, then heat dissipation occurs, but this represents thermal energy loss rather than useful heating
Solution Approach 1:
The thermal energy that would normally be wasted by dissipating heat from the exhaust manifold exterior to ambient air is converted into a beneficial resource. By contacting the manifold exterior with production fluid instead of ambient air, the previously harmful heat loss becomes useful heat transfer that warms the production fluid, directly improving thermal efficiency
Solution Approach 2:
The production fluid acts as an intermediary medium between the hot combustion gases in the manifold interior and the intended heating application. Instead of allowing direct heat loss to ambient air, the production fluid absorbs thermal energy through the manifold wall, serving as an efficient heat transfer intermediary that captures and transports useful thermal energy
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 configuration results in improved thermal efficiency, with simulated examples showing energy recovery rates that increase system efficiency by 0.37% to 0.5%, achieved through latent and sensible heat transfer, by effectively recovering energy stored in combustion gases along the exhaust path.
Implementation Method 1
the interior wall of the exhaust manifold is exposed to combustion gases exiting the heat exchanger and at least a portion of the exterior surface of the exhaust gas manifold is exposed to the production fluid, the temperature differential promotes the transfer of thermal energy
Implementation Method 2
thermal energy transfer and enhancing efficiency by utilizing the temperature differential for heat recovery
Implementation Method 3
achieved through latent and sensible heat transfer, by effectively recovering energy stored in combustion gases along the exhaust path
Implementation Method 4
achieved through latent and sensible heat transfer, by effectively recovering energy stored in combustion gases along the exhaust path
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A fluid heating system including: a pressure vessel shell com including prising a first inlet; a heat exchanger disposed in the pressure vessel shell, the heat exchanger including a second inlet and a second outlet, wherein the second inlet of the heat exchanger is connected to the first inlet of the pressure vessel shell; and an exhaust manifold disposed in the pressure vessel shell, the exhaust manifold including a third inlet and a third outlet, wherein the third inlet of the exhaust manifold is connected to the second outlet of the heat exchanger, wherein the third outlet of the exhaust manifold is outside of the pressure vessel shell, and wherein the exhaust manifold penetrates the pressure vessel shell.