Integral Exchanger Element for Cryogenic Heat Exchangers
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Solution Overview
Problem
Existing heat exchangers in cryogenic gas separation units face manufacturing defects due to challenging brazing processes, leading to risks of failure under high pressures, and the risk of direct ignition from high-pressure oxygen flow in aluminum alloy exchangers.
Innovation Solution
The exchanger element features a solid, one-piece design with integral plates, ribs, and closure bars, eliminating the need for extensive brazing and enhancing mechanical strength to operate under high pressures, while reducing the risk of ignition through a staggered rib arrangement and specific material selection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If brazing is used to join plates, ribs and closure bars, then assembly is facilitated, but manufacturing defects occur and reliability decreases under high pressure
Solution Approach 1:
The patent merges the plates, ribs and closure bars into a single integral component manufactured from a single piece of material. This eliminates the brazing joints that cause manufacturing defects and reliability issues, while maintaining the assembly functionality through the integrated design. The single-piece construction ensures uniform material properties and eliminates weak points at joints.
2Weight of moving object
If aluminum alloy is used for the heat exchanger, then weight is reduced, but direct ignition risk increases under high-pressure oxygen flow
Solution Approach 1:
The patent changes the material parameter from aluminum alloy to steel, which has higher ignition resistance properties. This parameter change eliminates the direct ignition risk under high-pressure oxygen flow while maintaining the lightweight design through optimized steel alloy selection and the efficient heat exchange geometry of the integral structure.
3Strength
If integral design is used for plate, ribs and closure bars, then mechanical strength increases for high pressure operation, but manufacturing complexity increases
Solution Approach 1:
The patent replaces the mechanical assembly system (brazing multiple separate components) with a single-form manufacturing process. The integral design is achieved through advanced manufacturing techniques that form the complex geometry of plates, ribs and closure bars as one piece, eliminating the need for post-manufacturing assembly operations and reducing overall manufacturing complexity despite the sophisticated geometry.
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 provides a heat exchanger with high mechanical strength to withstand pressures up to 100 bar and reduces the risk of direct ignition, ensuring reliable operation and safety in cryogenic air separation units.
Implementation Method 1
heat exchanger intended to transfer heat from at least one primary fluid, called circulating fluid, to at least one secondary fluid, called refrigerant
Data Source
AI summary
The invention relates to an exchanger element (1) comprising a solid plate (2) and ribs (4) on the plate (2) in order to form exchange channels (6) for the heating or cooling fluid and distribution channels (107) that extend transversely to the exchange channels.