Modular fired heat exchanger
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing modular heat exchangers for industrial boiler water heating installations face limitations in efficiently exchanging heat and structurally supporting high temperatures and varying loads, with a need for flexible configurations and enhanced thermal efficiency.
Innovation Solution
A modular fired heat exchanger design featuring a cylindrical dome-shaped combustion chamber segment within a water jacket with detachable connections, hollow-like indentations for improved strength and heat exchange, and a modular structure allowing for easy expansion and configuration, including a casing for inserting heat exchange elements and detachable water supply and collection tubes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a modular structure is used to improve flexibility and ease of assembly, then adaptability and ease of operation are improved, but structural strength and reliability under high temperature and varying loads may deteriorate
Solution Approach 1:
The heat exchanger is divided into multiple modular units, each comprising a combustion chamber segment, water jacket segment, and heat exchange elements. These modules can be assembled in series to create heat exchangers of various sizes and capacities, enabling flexible configuration adaptation to different industrial applications while maintaining structural integrity through standardized connection interfaces designed for high temperature and load conditions
2Reliability
If traditional monolithic heat exchanger design is used to ensure structural strength, then reliability is improved, but adaptability and ease of assembly deteriorate
Solution Approach 1:
The monolithic structure is segmented into standardized modular units that can be reliably assembled in series. Each module maintains structural reliability through robust design of combustion chamber segments, water jacket segments, and connection interfaces, while the modular architecture enables flexible configuration by assembling different numbers of modules according to specific application requirements
Solution Approach 2:
The modular design creates universal building blocks that can serve multiple functions and configurations. The standardized modules with universal connection interfaces can be assembled in various arrangements to meet different heating capacities and spatial requirements, providing both structural reliability and configuration flexibility
3Loss of energy
If complex structural design is used to enhance heat exchange efficiency, then thermal efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Heat exchange elements are strategically positioned within the combustion chamber segments to optimize thermal efficiency at critical locations. The design incorporates local quality improvements such as enhanced heat transfer surfaces where thermal exchange is most needed, while maintaining simpler structures in less critical areas, thus improving overall heat exchange efficiency without excessive complexity
Solution Approach 2:
The heat exchanger is segmented into modular units, each with integrated heat exchange elements designed for optimal thermal performance. This segmentation allows for standardized manufacturing of individual modules with optimized heat transfer characteristics, reducing overall manufacturing complexity compared to designing a single complex monolithic structure
4Ease of operation
If modular design with detachable connections is used to simplify assembly, then ease of operation is improved, but manufacturing precision and assembly reliability may deteriorate
Solution Approach 1:
The heat exchanger is divided into modular segments with standardized connection interfaces designed for straightforward assembly. The segmentation enables easy assembly by allowing modules to be connected in series using standardized interfaces, while the design incorporates precision features in the connection elements to ensure reliable and accurate assembly of the modular components
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 design enhances heat exchange efficiency, structural strength, and flexibility, allowing for scalable configurations while reducing material consumption and simplifying assembly, thereby improving the overall performance and adaptability of the heat exchanger.
Implementation Method 1
heat exchange elements are provided and are associated with the supply duct in order to increase the thermal efficiency
Implementation Method 2
heat exchange elements... increase the thermal efficiency
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A fired heat exchanger module having at least one set of heat exchange elements, at least one fluid inlet stub pipe, and at least one fluid outlet stub pipe, characterised in that at its top there is a segment of the combustion chamber (2) encased in a segment of the water jacket (3) fitted with at least one fluid outlet stub pipe (4), wherein, connected to the segment of the combustion chamber (2) is at least one set (5) of the elements for the exchange of heat between the combustion gases and the fluid, at the bottom fitted with at least one fluid inlet stub pipe (6), where the chamber through which the fluid flows in each set (5) of heat exchange elements is connected to a segment of the water jacket (3). The module (1) connected to each other form a heat exchanger with a single combustion chamber, heated with a single burner.