Interleaved Manifold Channels for Parallel Flow Heat Exchangers
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Solution Overview
Problem
Conventional heat exchangers face inefficiencies due to fluid stagnation, erosion, and corrosion, particularly in high-temperature applications, and struggle with effective heat transfer and fluid flow management across different temperature fluids.
Innovation Solution
A manifold for a parallel flow heat exchanger designed with interleaved channels and made from Silicon Carbide or its derivatives, allowing fluids from multiple sources to flow in parallel, reducing stagnation and increasing heat transfer efficiency while withstanding high temperatures and corrosive environments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a tube-to-tubesheet construction is employed with orthogonal fluid flow, then heat exchange between fluids can be achieved, but fluid stagnation occurs at contact points leading to increased erosion and fouling
Solution Approach 1:
The patent inverts the conventional orthogonal flow arrangement by implementing parallel flow where both fluids move in the same direction through interleaved channels. This eliminates stagnation zones that occur at tube contact points in orthogonal designs, thereby reducing erosion and fouling while maintaining effective heat exchange.
Solution Approach 2:
The patent transitions from traditional three-dimensional orthogonal flow paths to a two-dimensional parallel flow arrangement with interleaved channels. This dimensional simplification eliminates complex stagnation zones while maintaining adequate heat transfer surface area through the parallel channel configuration.
2Reliability
If conventional metallic heat exchangers are used, then heat transfer efficiency can be achieved, but corrosion and erosion problems increase particularly at elevated temperatures
Solution Approach 1:
The patent employs ceramic materials (such as silicon carbide or alumina) instead of conventional metals, creating a composite structure that combines high-temperature stability with corrosion and erosion resistance. These ceramic channels maintain structural integrity and resistance to aggressive fluids at elevated temperatures where metallic heat exchangers would degrade.
Solution Approach 2:
The patent changes the material parameter from metallic to ceramic composition, fundamentally altering the chemical and physical properties to achieve resistance against corrosion and erosion at high temperatures while maintaining adequate thermal conductivity for effective heat transfer.
3Reliability
If orthogonal fluid flow paths are used, then heat exchange between fluids can occur, but pressure drop increases due to stagnation and turbulence
Solution Approach 1:
The patent inverts the conventional orthogonal flow arrangement by implementing parallel flow where both fluids move in the same direction through interleaved channels. This eliminates stagnation zones that occur at tube contact points in orthogonal designs, thereby reducing erosion and fouling while maintaining effective heat exchange.
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 heat transfer efficiency, reduces fouling, and increases the operating temperature range of heat exchangers, enabling efficient processing of fluids across different temperatures and aggressive environments with minimal maintenance.
Implementation Method 1
heat transfer efficiency
Implementation Method 2
fluids from multiple sources to flow in parallel
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates generally to a manifold for a parallel flow heat exchanger and a heat exchanger incorporating that manifold. The manifold comprising a first plurality of channels each having a first opening facing a first direction and a second opening facing a second direction different from the first direction. The manifold further comprises a second plurality of channels interleaved with the first plurality of channels, the second plurality of channels having a third opening facing a third direction and a fourth opening facing the first direction, wherein the third direction is different from the first direction and the second direction.