Modular Cold Box Assembly for Simplified Heat Exchanger Installation
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Solution Overview
Problem
The existing methods for connecting heat exchanger cold boxes in cryogenic air separation units are complex and require significant on-site workload, involving numerous conduit connections and the use of cranes, which increases costs and complexity.
Innovation Solution
A method and assembly for connecting heat exchanger cold boxes that reduces the number of pipelines to be connected on-site by using thermally isolating casings and materials, allowing for simpler connections with a forklift truck instead of a crane, and enabling more rational arrangement of cold boxes according to site conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conduit box with multiple fluid pipelines, control lines and air lines is used for heat exchanger connections, then the interconnection of fluid pipelines and control lines is achieved, but the on-site workload and complexity of connecting conduit connection ends is significantly increased
Solution Approach 1:
The patent divides the heat exchanger system into separate cold boxes (first heat exchanger cold box, second heat exchanger cold box, and subcooler cold box) that can be manufactured and transported independently. Each cold box is a self-contained module with its own insulation and connection points, allowing for simplified on-site assembly without requiring complex conduit box interconnections.
Solution Approach 2:
The cold boxes are pre-assembled with their respective heat exchangers, insulation materials, and connection components before transportation to the installation site. This preliminary preparation reduces the on-site workload to simple connection tasks rather than complex assembly operations involving multiple pipelines and control lines.
2Weight of moving object
If a crane is used for on-site hoisting of the conduit box, then the conduit box can be positioned at the installation site, but the on-site workload and cost are increased
Solution Approach 1:
By segmenting the system into separate cold boxes, each unit can be sized and weighted for standard forklift truck handling rather than requiring heavy crane operations. The modular design allows each cold box to be transported and positioned using conventional material handling equipment.
Solution Approach 2:
The patent employs standard, readily available material handling equipment (forklift trucks) instead of expensive, specialized equipment (cranes). This substitution of cheaper, more accessible equipment reduces on-site costs and simplifies the hoisting operation.
3Loss of energy
If thermally isolating material is packed around heat exchangers to prevent heat exchange, then thermal insulation is achieved, but the complexity of on-site assembly and connection is increased
Solution Approach 1:
The thermally isolating material is packed around the heat exchangers during factory assembly before the cold boxes are transported to the installation site. This preliminary insulation operation ensures thermal performance is achieved without requiring complex on-site assembly, as the insulation is already in place when the modular units are connected.
Solution Approach 2:
Each cold box is independently insulated as a separate module during manufacturing. This segmentation allows each unit to be pre-insulated in a controlled factory environment, simplifying on-site assembly to merely connecting the pre-insulated modules without dealing with complex insulation installation.
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 approach simplifies the on-site connection process, reduces costs, and maximizes site utilization by minimizing the complexity of hoisting and workload, while maintaining effective thermal insulation.
Implementation Method 1
a thermally isolating casing comprising a casement and thermally isolating material packed in the casement
Data Source
Figure 1~2
Figure 3
AI summary
Disclosed in the present invention are a heat exchanger assembly and a method for assembling the heat exchanger assembly. The heat exchanger assembly comprises a first heat exchanger and a second heat exchanger, and a subcooler; a first heat exchanger cold box, for accommodating the first heat exchanger and heat exchange fluid pipelines, with a first opening being disposed in a side of the first heat exchanger cold box, and a first group of pipelines extending through the first opening; a second heat exchanger cold box, for accommodating the second heat exchanger and heat exchange fluid pipelines, with a second opening being disposed in a side of the second heat exchanger cold box, and a second group of pipelines extending through the second opening; a subcooler cold box, for accommodating the subcooler and heat exchange fluid pipelines, with a third opening and a fourth opening being disposed in a side of the subcooler cold box, and a third group of pipelines and a fourth group of pipelines extending through the third opening and the fourth opening respectively, wherein the first group of pipelines and the third group of pipelines are connected and encapsulated in a first thermally isolating casing, and the second group of pipelines and the fourth group of pipelines are connected and encapsulated in a second thermally isolating casing.