Modular Heat Exchanger Segmentation for Viscous Fluids
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Solution Overview
Problem
The production of heat exchangers with thick-walled tubes for processing highly viscous fluids is complex, expensive, and prone to quality issues, especially when dealing with high pressures and temperatures, as they require individual manufacturing and have limited heat exchange efficiency due to the arrangement of finned tubes which restricts fluid mixing and heat transfer.
Innovation Solution
A modular heat exchanger design featuring a jacket element and an insert element with web elements that can be easily connected and adapted to different pressure ranges, allowing for a thinner insert element to be housed within a thicker intermediate jacket element, enabling efficient heat transfer and mixing across a larger cross-section while reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stress or pressure
If thick-walled tubes are used to withstand high pressures, then pressure resistance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The heat exchanger is divided into two separate components: a thin-walled insert element with web elements and channels, and a thick-walled jacket element. The insert element handles the heat transfer function with its internal channels, while the jacket element provides the necessary pressure resistance. This segmentation allows each component to be optimized for its specific function, reducing overall manufacturing complexity while maintaining pressure resistance capability.
2Area of stationary object
If finned tubes are used for heat exchange, then heat transfer surface area is improved, but fluid mixing and heat transfer efficiency deteriorate
Solution Approach 1:
The web elements are arranged at non-zero angles to the main flow direction, creating curved flow paths that enhance mixing. This angular arrangement causes the fluid to follow curved trajectories around the web elements, improving heat transfer efficiency through enhanced convection and mixing, while still providing sufficient heat transfer surface area through the web element surfaces.
3Stress or pressure
If thick-walled tubes are used for high pressure applications, then pressure resistance is improved, but production cost increases
Solution Approach 1:
The system separates the pressure-bearing function (jacket element) from the heat transfer function (insert element). The jacket element can be manufactured as a simple thick-walled tube or pressure vessel, which is cost-effective for high pressure applications. The insert element with its complex internal channel structure and web elements can be manufactured separately using more cost-effective methods such as casting or additive manufacturing, avoiding the need to expensive machine complex geometries into thick-walled tubes.
4Stress or pressure
If individual manufacturing is performed for each heat exchanger, then pressure resistance is improved, but productivity decreases
Solution Approach 1:
The jacket element and insert element are designed as separate, modular components that can be manufactured independently using standardized processes. The jacket element can be produced as a standard pressure vessel component, while the insert element can be manufactured using cost-effective methods like casting or additive manufacturing. These pre-manufactured components are then assembled together, eliminating the need for individual custom manufacturing of each complete heat exchanger and significantly improving productivity.
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 design allows for a heat exchanger that can withstand high pressures and efficiently mix and heat/cool viscous fluids, achieving a larger heat exchange area with reduced production costs and improved mixing performance, preventing deposits and decomposition, and maintaining a compact structure.
Implementation Method 1
A heat transfer fluid flows through the web element channels. The flowable medium flows over the web elements and through the insert element, thereby generating a pressure gradient
Implementation Method 2
The flowable medium flows through the insert element and thereby generates a pressure gradient. The pressure gradient can be generated for example by the use of pumps
Data Source
AI summary
The heat exchanger (1) contains a jacket element (2) and an insert element (3), wherein the insert element (3) is arranged in the operating state in the interior of the jacket element (2). The insert element has a longitudinal axis (4). The insert element (3) contains an insert jacket element (31) and a plurality of web elements (9, 10), the web elements (9, 10) having a first end (13) and a second end (14). The first end (13) and the second end (14) of each web element (9, 10) are connected to the insert jacket element (31) at different locations. At least a portion of the web elements (9, 10) includes web element channels (11, 12), the web element channels (11, 12) extending from the first end (13) of the web element (11) to the second end (14) of the web element (11). An intermediate jacket element (5) is arranged between the insert jacket element (31) and the jacket element (2).