Modular Plate Heat Exchanger for Faster Cleaning and Maintenance
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Solution Overview
Problem
Existing heat exchangers, particularly plate heat exchangers, are difficult and complex to clean, requiring significant time and resources, which can lead to increased costs and downtime in marine applications.
Innovation Solution
A modular heat exchanger system comprising a plurality of open elements and individual gaskets, allowing for simplified dismantling, cleaning, and assembly, reducing the time and effort required for maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If plate heat exchangers are used to maximize heat transfer surface area, then heat exchange efficiency is improved, but maintenance complexity and cleaning time increase significantly
Solution Approach 1:
The heat exchanger is divided into modular plate elements that can be independently removed and cleaned. Each plate can be separated from the assembly without affecting other plates, transforming the maintenance task from cleaning a complex multi-plate assembly to cleaning individual simple plates.
Solution Approach 2:
The plates are designed to be easily extracted from the heat exchanger assembly during maintenance. The connection system allows plates to be quickly removed and replaced without disassembling the entire heat exchanger, significantly reducing maintenance time and complexity.
2Area of stationary object
If multiple plates and gasket elements are assembled to form plate package, then heat transfer surface area is increased, but dismantling and cleaning time increases to full day's job
Solution Approach 1:
The plate package is segmented into individual plates that can be independently handled. This segmentation allows maintenance personnel to work on one plate at a time rather than disassembling and cleaning an entire complex assembly, reducing cleaning time from a full day's job to a much shorter duration.
Solution Approach 2:
The plates are pre-configured with connection features that enable quick assembly and disassembly. The gasket elements are designed to be pre-positioned or easily replaced, eliminating the need for complex assembly procedures during maintenance and significantly reducing the time required to service the heat exchanger.
3Productivity
If 50-150 plates with small fluid flow passages are used, then heat exchange performance is optimized, but cleaning difficulty and resource requirements increase
Solution Approach 1:
By segmenting the heat exchanger into individual plates, each with standardized passages, the cleaning process becomes simpler and more systematic. Each plate can be cleaned using the same procedure and resources, making the overall cleaning task more manageable despite the large number of plates.
Solution Approach 2:
Individual plates can be extracted from the assembly for cleaning, allowing access to all surfaces including small fluid flow passages. This extraction capability enables thorough cleaning of complex passage geometries without requiring disassembly of the entire heat exchanger or specialized cleaning equipment.
4Reliability
If fouling occurs on heat transfer surface area, then heat exchanger efficiency decreases, but dismantling for cleaning requires substantial time and cost
Solution Approach 1:
The segmented plate design allows quick isolation and removal of fouled plates for cleaning. Instead of dismantling the entire heat exchanger when fouling occurs, only the affected plates need to be removed and cleaned, significantly reducing downtime and maintenance costs while maintaining heat exchanger efficiency.
Solution Approach 2:
Fouled plates can be extracted from the assembly for targeted cleaning. This extraction capability allows maintenance personnel to quickly remove and clean only the plates that have accumulated fouling, rather than performing a complete teardown of the heat exchanger, thereby minimizing time loss and maintaining operational efficiency.
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 modular system significantly reduces the time and cost associated with maintenance, allowing vessels to maintain full control over cooling capacity and propulsive power with minimal specialized competence or time requirements.
Implementation Method 1
Heat exchangers are used for the transfer of heat between two fluid flows of different temperatures
Implementation Method 2
heat exchange between two or more fluids
Implementation Method 3
The heat exchanger's performance may also be affected by the addition of fins and/or corrugations in one or both directions, which will increase the heat transfer surface area and may channel the fluid flow or induce turbulence
Implementation Method 4
Such fouling occurs when impurities from the water or seawater deposit on the heat transfer surface area
Data Source
AI summary
A modular system for heat exchange between fluids includes two end plates. At least one end plate is configured with inlets and outlets for fluids. The modular system includes a number of heat exchanger elements and a number of guiding elements. Each heat exchanger element includes a folded sheet material including a plurality of slits extending in a longitudinal direction of the folded sheet material, which longitudinal extending slits form the fluids flow paths. The folded sheet material is cast in one piece in an outer casing. A central opening of the outer casing covers an outer circumference of the folded sheet material, exposing a front side and a back side of the folded sheet material where two through holes, forming the inlets and outlets for each fluid, are provided on opposite sides of the central opening of the outer casing. Each guiding element includes two inlets and two outlets for fluids, and a bead or edge, provided on one side, forming an enclosure around the inlet and outlet for a first fluid, and a bead or edge on an opposite side, forming an enclosure around the inlet and outlet for a second fluid. Heat exchanger elements and guiding elements are arranged successively following each other. The heat exchanger elements are arranged that two adjacent heat exchanger elements on sides facing each other carry the same fluid.