Parallel-Channel Waste Heat Recovery Unit With Integrated Bypass

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Solution Overview

Problem

Current waste heat recovery units (WHRUs) face challenges in reducing size and weight, maximizing heat transfer coefficients, and minimizing space requirements, especially in offshore applications, due to inefficiencies in heat transfer and increased weight from separate bypass ducts and large damper systems.

Innovation Solution

A compact WHRU design with a duct divided into three parallel channels, including a central bypass channel and a damper system with rotatable blades, and a baffle system with finned tubing and insulating baffles to enhance heat transfer and reduce leakage, allowing for adjustable heat exchanger operation and reduced space and weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If separate bypass ducts and large damper systems are used, then heat transfer efficiency is improved, but weight increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidweight

Core Design Contradiction:

Loss of energyVSWeight of moving object

Solution Approach 1:

The patent combines the bypass duct and heat exchanger channels into a single integrated duct structure with internal partitions. The damper system is integrated within this unified structure, eliminating the need for separate bypass ducts and reducing overall weight while maintaining heat transfer efficiency through the combined channels.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent nests the bypass channel and heat exchanger channels within a single duct structure, with the bypass channel positioned centrally and heat exchanger channels on either side. This nested arrangement allows multiple functions (bypass flow and heat exchange) to coexist in a compact, weight-efficient configuration.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Loss of energy

If separate bypass ducts and large damper systems are used, then heat transfer efficiency is improved, but size increases

Engineering Contradiction:

Improveheat transfer efficiencyVSAvoidspace requirements

Core Design Contradiction:

Loss of energyVSVolume of moving object

Solution Approach 1:

The patent merges the bypass duct and heat exchanger channels into a single integrated duct structure, significantly reducing the overall space envelope required. The internal partitioning allows both bypass and heat exchange functions to occur simultaneously within the same spatial footprint, eliminating the need for separate large-scale components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent transitions from a multi-duct three-dimensional arrangement to a single duct with internal two-dimensional channel partitioning. This dimensional reorganization maintains all necessary heat transfer pathways while compressing the overall external dimensions and reducing space requirements.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Loss of energy

If complex damper systems are used, then heat transfer control is improved, but device complexity increases

Engineering Contradiction:

Improveheat transfer controlVSAvoiddevice complexity

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent combines multiple damper blades into a single integrated damper system with common actuation. The rotatable blades are mounted on a shared axis and controlled by a single actuator, simplifying the control mechanism while maintaining the ability to regulate heat transfer across different channels through coordinated blade positioning.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The damper system is designed with multi-functional rotatable blades that can simultaneously control flow in multiple channels. A single actuator provides universal control over the entire damper system, enabling one component to perform multiple control functions and reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables a more compact, efficient, and maintainable WHRU with improved heat transfer performance, reduced size and weight, and enhanced sealing to prevent heat leakage, addressing the inefficiencies of existing systems while maintaining heat transfer efficiency.

Implementation Method 1

Exhaust gases from the gas turbine are passed around the exterior of the tubing thereby transferring heat to the fluid stream within the tubing

Methodology Applied

Scientific EffectHeat transfer: Convection

Implementation Method 2

Each blade includes an upstream plate spaced from a downstream plate, and means to supply pressurised gas into the spacing between the upstream and downstream plates

Methodology Applied

Scientific EffectPressurization: Pressurisation

Implementation Method 3

Each baffle may include a rigid plate within an outer insulating blanket

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS11215406B2Waste heat recovery units

Publication Date: 2022.01.04 BOUSTEAD INT HEATERS

AI summary

A waste heat recovery unit includes a duct for hot gas. The duct is divided into first, second and third adjacent and parallel channels each with an inlet and an outlet. A heat exchanger is located in each of the first and third channels. The second channel is located between the first and third channels and provides a bypass channel. A damper system is operable to selectively open and close the inlets of the three channels. This provides a more compact waste heat recovery unit configuration which is more straightforward to manufacture and maintain.