Mixer Heat Exchanger Flow Channel Web Plate Geometry
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Solution Overview
Problem
Existing flow channels for mixer heat exchangers face challenges in achieving efficient heat exchange, particularly with high-viscosity fluids, leading to high pressure loss and a suboptimal surface-to-volume ratio, which limits heat transfer efficiency.
Innovation Solution
The flow channel design incorporates at least 28 crossed web plates with specific geometric ratios and angles, additional tubes, and a preferred 45° angle between web plates and the longitudinal axis, along with optimized spacing between web plates and tubes, to enhance heat transfer by improving the surface-to-volume ratio and heat conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If additional tubes are added to improve surface-to-volume ratio, then heat transfer area increases, but Nusselt number decreases and additional heat transfer is minimal
Solution Approach 1:
The patent changes the geometric parameters of the web plates (number, spacing, angle) to optimize heat transfer. Specifically, using at least 28 web plates with optimized spacing ratios (spacing/tube diameter < 6, preferably < 4) and angles (30°-60°, preferably 45°) creates effective turbulence and heat conduction paths without simply adding more tubes.
2Reliability
If web plates are arranged with smaller spacing to improve heat transmission, then heat transfer efficiency increases by up to 60%, but device complexity increases
Solution Approach 1:
The patent segments the heat exchanger into multiple mixing inserts with web plates arranged in specific patterns. Each insert contains at least 28 web plates organized in three plane groups with defined spacing ratios, creating a modular structure that achieves high heat transfer efficiency while maintaining manufacturability through standardized segmentation.
3Reliability
If double-casing design is used to mix substance streams, then heat transfer at tube wall improves, but pressure loss increases and device becomes very long
Solution Approach 1:
The patent introduces web plates arranged in three-dimensional space with specific geometric relationships. The web plates form three plane groups with defined angles and spacing, creating turbulence and heat transfer pathways in multiple dimensions simultaneously, thereby improving heat transfer without requiring excessive length.
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 achieves up to 60% improvement in heat transfer efficiency by optimizing the web plate geometry and tube placement, as evidenced by the Nusselt number measurements, and allows for a more compact heat exchanger construction.
Implementation Method 1
The deflection of the substance streams brings about an improvement in heat transfer at the tube wall
Implementation Method 2
The deflection of the substance streams brings about an improvement in heat transfer at the tube wall
Implementation Method 3
improvement in heat transfer at the tube wall
Data Source
AI summary
The invention relates to a flow channel having a mixing insert and a plurality of tubes guided parallel to the longitudinal axis of the flow channel over the length of the mixing insert, each mixing insert including at least twenty-eight pairwise crossed multi-wall sheets, the ratio of the width of the multi-wall sheets to the inside diameter of the flow channel being no more than 0.25, the ratio of the length of the mixing insert to the inside diameter of the flow channel being no less than 0.4, and the angle of the multi-wall sheets to the longitudinal axis of the flow channel being 30° to 60° and the ratio of the intermediate spacing of neighboring planes to the inside diameter of the flow channel being no more than 0.3, and to the inside diameter of the tubes being less than 6.