Panel-Plate Fired Heat Exchanger With Two-Stage Cooling Flow
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Solution Overview
Problem
Current fired heat exchangers have complex structures due to multiple elements, leading to a lower heat exchange surface to weight ratio and larger dimensions, requiring welding and additional casing for integration and sealing, which complicates construction and installation.
Innovation Solution
A modular block of panel plates with a combustion chamber integrated with a working heat exchange surface, featuring creased bands that expand the heat exchange surface and allow for two-stage medium circulation, enabling effective cooling and turbulence, thus simplifying integration and production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple elements are used for combustion chambers and heat exchange surfaces, then the heat exchange rate is maintained, but the structure becomes more complicated and dimensions increase
Solution Approach 1:
The patent combines the combustion chamber and heat exchange surface into a single integrated plate structure. The plate contains both the combustion chamber cavity and the heat exchange surface as inherent features, eliminating the need for separate components. This merging reduces structural complexity while maintaining the heat exchange rate, as the integrated design allows combustion gases to directly interact with the heat exchange surface within the same plate element.
Solution Approach 2:
The plate structure serves multiple functions simultaneously: it forms the combustion chamber, provides the heat exchange surface, and acts as a structural support element. This multi-functionality reduces the number of components needed while maintaining effective heat exchange performance, thereby simplifying the overall structure without compromising productivity.
2Productivity
If multiple elements are used for combustion chambers and heat exchange surfaces, then the heat exchange rate is maintained, but the overall dimensions become larger
Solution Approach 1:
By integrating the combustion chamber and heat exchange surface into a single plate, the patent reduces the overall volume required. The combined structure eliminates the space that would be needed for separate components and their interconnections, resulting in a more compact heat exchanger that maintains the same heat exchange rate with smaller dimensions.
Solution Approach 2:
The heat exchange surface is effectively nested within the plate structure that also contains the combustion chamber. This nested arrangement allows the heat exchange functionality to be incorporated within the existing structural volume, maximizing space utilization and reducing overall dimensions while maintaining heat exchange effectiveness.
3Reliability
If plates are welded to the combustion chamber, then full integration is ensured, but construction and installation become difficult
Solution Approach 1:
The combustion chamber and heat exchange surface are merged into a single monolithic plate structure, eliminating the need for welding or other joining operations. This integration is achieved through the plate's inherent design rather than through assembly processes, significantly simplifying construction and installation while ensuring full integration integrity.
Solution Approach 2:
The plate is designed as a modular unit that can be manufactured separately and then installed as a complete assembly. This segmentation allows for simplified manufacturing of individual plates while maintaining full integration of the combustion chamber and heat exchange surface within each plate, making construction and installation easier without compromising reliability.
4Reliability
If a specially designed casing is used, then sealing and proper flow direction are ensured, but the structure becomes more complicated
Solution Approach 1:
The sealing and flow direction functions are merged into the plate structure itself. The plate's design inherently provides the necessary sealing features and flow path configuration, eliminating the need for a separate specially designed casing. This reduces structural complexity while maintaining sealing effectiveness and proper flow direction.
Solution Approach 2:
The plate structure is self-sufficient in providing sealing and flow direction control. The combustion chamber and heat exchange surface are configured within the plate to automatically ensure proper sealing and flow paths without requiring additional external casing elements, thereby simplifying the overall structure while maintaining reliability.
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 solution achieves a high heat exchange surface to weight ratio, simplifies production, and enhances thermal efficiency, allowing for power scaling, reduced fuel usage, and lower emissions, while eliminating the need for additional closing elements.
Implementation Method 1
the combustion chamber is in the upper part of the plate members and is surrounded in its upper side with a water jacket
Implementation Method 2
During the second stage, the combustion chamber is cooled by the water jacket
Implementation Method 3
the working heat exchange surface is created by the lower lateral sides of the panel plates and the creased bands mounted on them
Implementation Method 4
the main process of heat exchange on the working surface takes place
Implementation Method 5
The circulation of the liquid heated medium in the unit of interconnected panel plates has a flow velocity with a medium within the range 0.5 - 2 m/s. It is two-stage type
Data Source
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AI summary
The fired heat exchanger is characterised by the fact that it contains a modular block constituting a set of inseparably interconnected panel plates (1) with a combustion chamber located in its upper internal part (2) ensuring full integration of the combustion chamber (2) with the working heat exchange surface located in the lower part of the panel plates (1). This surface is created by the lower lateral surfaces of the panel plates (1) together with chattered lamella bands mounted on them (3). They expand the working heat exchange surface and the gasses created in the combustion chamber (2) flow around this surface. The circulation of the liquid heated medium in the unit of interconnected panel plates (1) has a medium flow velocity within the range 0.5 - 2 m/s and is of a two-stage type. During the first stage, the main process of heat exchange on the working surface takes place. During the second stage, the combustion chamber (2) is cooled by the water jacket constituting the upper part of the panel plates (1).