High-Pressure Plate Heat Exchangers for Viscous Material Flow
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Solution Overview
Problem
Conventional heat exchangers for viscous materials, such as meat emulsions, face issues with obstructed flow, equipment clogging, and reduced flexibility due to complex designs and pressure limitations, leading to inefficiencies in production.
Innovation Solution
A high-pressure plate heat exchanger with multiple stacked plates and a uniquely designed inlet manifold that allows for uniform material flow and increased throughput, minimizing obstructions and enabling higher pressures without increasing equipment space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional concentric tube heat exchangers are used to cool or heat viscous materials, then heat exchange function is provided, but the design partially obstructs the flow of product through the heat exchanger, causing equipment clogging and reduced output
Solution Approach 1:
The heat exchanger is divided into multiple plates stacked together, creating multiple flow channels. This segmentation eliminates the single obstructed path of conventional tube heat exchangers and distributes flow across multiple parallel channels, preventing clogging while maintaining heat exchange efficiency
Solution Approach 2:
The invention transitions from a conventional tube-based three-dimensional flow path to a plate-based two-dimensional flow path. The plates are stacked to create multiple channels, allowing viscous materials to flow in a more open, less obstructed manner while still providing sufficient heat exchange surface area
2Reliability
If tube length and diameter of concentric tube heat exchanger are increased to ensure cooling/heating on both sides, then heat exchange effectiveness is improved, but the complexity of the design increases while reducing process flexibility
Solution Approach 1:
Instead of using a single long tube with increased diameter, the heat exchanger is segmented into multiple plates of standard dimensions stacked together. Each plate provides heat exchange surface area, and the cumulative effect of multiple plates achieves the required cooling/heating effectiveness without increasing individual component complexity
Solution Approach 2:
The plate heat exchanger design allows for flexible configuration where plates can be added or removed based on process requirements. This dynamic adaptability enables adjustment of heat exchange capacity without redesigning the entire system, unlike fixed complex tube designs
3Reliability
If conventional plate heat exchangers are used, then heat exchange is provided, but the product must flow through a tortuous path causing obstructions in the material product as it moves from plate to plate
Solution Approach 1:
The plate design incorporates specific local features such as optimized flow channels, smooth transitions between plates, and strategically placed openings. These local quality improvements ensure uniform material flow distribution across the plates, preventing obstructions and clogging while maintaining effective heat exchange
4Reliability
If existing heat exchanger designs are used, then heat exchange capability is provided, but limitations exist regarding pressure rating, uniform product flow, expandability and flexibility
Solution Approach 1:
The modular plate structure allows the heat exchanger to be easily expanded by adding or removing plates. Each plate is a standardized component that can be independently configured, enabling flexible adaptation to different pressure ratings, flow rates, and heat exchange requirements without redesigning the entire system
Solution Approach 2:
The plate heat exchanger design serves multiple functions: it provides heat exchange capability, accommodates various pressure ratings through gasket selection, ensures uniform product flow through optimized channel design, and allows easy expansion by adding plates. This multi-functionality replaces the need for multiple specialized heat exchanger designs
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
The solution enhances production rates and reduces clogging while maintaining operational flexibility, allowing for efficient heating or cooling of viscous materials like meat emulsions with improved product quality and increased capacity.
Implementation Method 1
The first plate, the second plate and/or the third plate comprise energy exchanging capabilities. For example, the first plate, the second plate and/or the third plate can be constructed and arranged to heat or cool (e.g., via conduction or convection) the product in the passages.
Implementation Method 2
The first plate, the second plate and/or the third plate can be constructed and arranged to heat or cool (e.g., via conduction or convection) the product in the passages.
Data Source
AI summary
Methods and devices heat or cool viscous materials, such as meat emulsions useful for producing food and other products. The devices have a heat exchanger including a first plate, a second plate attached to the first plate, and a first spacer and a second spacer arranged between the first plate and the second plate. The first plate, the second plate, the first spacer, and the second spacer define at least one temperature controlled passage for a product to pass through the heat exchanger.