Perforated Plate Flow Equalization for Large Compressor Coolers
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Solution Overview
Problem
Large compressors with coolers of significant dimensions face issues with uneven flow of the gaseous medium, limiting the cooling capacity and operational efficiency, and increasing pressure loss and vibration stress.
Innovation Solution
The implementation of at least two perforated, plate-like flow equalization elements upstream of the heat exchanger, with one extending at an angle, and optionally divided into segments of different porosity, to ensure a uniform flow through the cooler.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cooler is designed with large dimensions to handle high compression volumes, then the cooling capacity increases, but uneven flow of the gaseous medium forms within the cooler
Solution Approach 1:
Flow equalization elements are positioned upstream of the heat exchanger to pre-distribute the gaseous medium before it enters the cooling sections. This preliminary flow distribution prevents uneven flow patterns from developing during the cooling process, allowing the cooler to maintain uniform flow throughout its large dimensions while preserving high cooling capacity.
2Device complexity
If the cooler operates without flow equalization, then the structure is simpler, but the cooler cannot be operated optimally due to uneven flow
Solution Approach 1:
Perforated plate-like flow equalization elements are used to distribute the gaseous medium uniformly. These porous structures are relatively simple in design—essentially plates with holes—but effectively equalize the flow across all cooling sections, enabling optimal operation without requiring complex flow distribution systems.
3Stability of the object's composition
If flow equalization elements are added to the cooler, then flow uniformity and cooling capacity improve, but the device complexity increases
Solution Approach 1:
The flow equalization function is divided into multiple discrete perforated plate elements positioned at different locations within the cooler. Each element handles a specific region's flow distribution, and together they achieve comprehensive flow equalization throughout the entire cooler. This segmented approach maintains flow uniformity while keeping individual components simple and manageable.
4Productivity
If uneven flow occurs through the cooler, then the cooling capacity is limited, but pressure loss increases
Solution Approach 1:
By pre-distributing the flow uniformly through perforated plates before the gas enters the heat exchanger sections, the system avoids the formation of uneven flow patterns that would cause localized high velocities and excessive pressure losses. This preliminary flow equalization maintains optimal cooling capacity while minimizing energy loss through reduced pressure drop across the cooler.
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
This solution achieves optimal operating conditions for the cooler, enhancing cooling capacity, reducing pressure loss, and minimizing vibration stress, while improving condensate separation.
Implementation Method 1
at least two perforated, plate-like flow equalization elements are positioned in the housing upstream of the section of the heat exchanger on the flow inlet side
Implementation Method 2
a heat exchanger for cooling the compressed gaseous medium being arranged in the housing. Such a cooler has several tubes through which coolant flows and around which the gaseous medium to be cooled flows
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The radiator (10) has a heat exchanger (12) which is positioned in housing (11) to supply coolant to a gaseous medium flowed around pipes. An inlet (13) is provided to supply gaseous medium into housing through a flow enter side portion (14) of heat exchanger. An outlet (15) is provided to discharge gaseous medium from housing through a flow withdraw side portion (16) of heat exchanger. Perforated plate-like flow comparison moderation elements (18,19) are positioned in a flow direction of gaseous medium seen from upstream of flow enter side portion.