High temperature fluid generator
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Solution Overview
Problem
Existing high temperature fluid generators face difficulties in maintenance due to fixed convection tubes, requiring labor-intensive repair and replacement, and are cumbersome due to refractory insulation, which limits their adaptability and efficiency.
Innovation Solution
The design features movably mounted convection tubes for easier access and maintenance, and a furnace module with heating tubes covering all walls to reduce the need for refractory insulation, making the generator lighter and more efficient.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If convection tubes are fixed in the convection module, then structural stability is improved, but maintenance difficulty increases and repair time increases
Solution Approach 1:
The convection module is divided into separate sections with convection tubes that can be independently removed. The tubes are arranged in bundles that can be extracted as units, allowing maintenance personnel to access and service individual tubes without dismantling the entire module, thus maintaining structural stability while enabling easy maintenance.
Solution Approach 2:
The convection tubes are designed with movable mounting mechanisms that allow them to be dynamically repositioned or removed from the convection module. This dynamic design enables the tubes to transition from a fixed state during operation to a removable state during maintenance, resolving the contradiction between structural stability and ease of repair.
2Loss of energy
If refractory material is used to isolate furnace walls, then heat insulation is improved, but device weight increases and adaptability decreases
Solution Approach 1:
The patent changes the thermal insulation parameters by using alternative materials or structures with different thermal properties. Instead of traditional heavy refractory materials, the design employs lighter insulation materials or radiant barrier techniques that provide adequate heat insulation while significantly reducing the overall weight of the furnace module.
Solution Approach 2:
The furnace wall structure uses composite material construction combining multiple layers with different functions - thermal insulation layers, structural support layers, and protective outer layers. This composite approach achieves effective heat insulation without relying solely on heavy refractory materials, thereby reducing weight while maintaining thermal performance.
3Loss of energy
If refractory material is used to isolate furnace walls, then heat insulation is improved, but device complexity and cumbersome design increase
Solution Approach 1:
The patent extracts the heavy refractory insulation layer from the furnace wall design and replaces it with alternative insulation systems that are simpler in structure. This extraction eliminates the complexity associated with installing and maintaining traditional refractory linings while preserving the essential heat insulation function through more modern, streamlined approaches.
4Strength
If convection tubes are fixed in place, then structural integrity is improved, but downtime for maintenance increases
Solution Approach 1:
The convection tubes are pre-assembled in bundles or sections that maintain structural integrity during normal operation. These pre-assembled units are designed to be quickly disconnected and replaced as complete units, allowing maintenance personnel to perform repairs or replacements rapidly without compromising the structural integrity of the remaining system during the maintenance window.
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 simplifies maintenance, reduces downtime, and enhances efficiency by allowing easier access to convection tubes and eliminating the need for heavy refractory materials, resulting in a lighter and more adaptable high temperature fluid generator.
Implementation Method 1
a plurality of cooling tubes covering at least partially the combustion chamber for cooling the combustion chamber
Implementation Method 2
the fluid circulating in the convection tubes where the fluid is heated before circulating into the cooling tubes where the fluid is further heated by the combustion chamber
Implementation Method 3
As the combustion gases flow in the convection module, they contact the convection tubes and transfer at least part of their heat to the tubes and thus to the fluid circulating in them
Implementation Method 4
the furnace module comprises a network of heating tubes fluidly connected to the headers and extending in the floor, ceiling, rear wall, side walls and front wall of the furnace module... the fluid circulating between the headers also circulates in the heating tubes such as to be heated by the combustion chamber
Data Source
AI summary
A high temperature fluid generator is configured to heat a fluid (e.g. water; thermal oil or the like) to a high temperature (e.g. greater than 250 degrees Fahrenheit or 120 degrees Celsius) using a fuel-burning furnace. The generator generally comprises a furnace module, wherein fuel is burned, and a convection module where the combustion gases are put in contact with a series of fluid-bearing convection tubes. The furnace module comprises a series of fluidly interconnected headers, some of which are also fluidly connected to the convection tubes in the convection modules. The various headers contribute to the overall structure of the generator. The convection tubes are arranged into at least two bundles which are movably mounted in the convection module of the generator such to be movable in and out of the convection module for inspection, cleaning, maintenance and/or repair.