Plate Heat Exchanger Shell Layout With Bent Flanges and Constant Gaps
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Solution Overview
Problem
Plate-type heat exchangers face challenges in maximizing heat transfer area per unit area and reducing thermal resistance due to the presence of numerous flange portions and welded areas that interact with high-temperature exhaust gas.
Innovation Solution
A plate-type heat exchanger design featuring heat transfer shells with bent flange portions and varying heat transfer areas, where the shells are stacked to form passages for fluid flow without physical contact, utilizing spacing bars and bending portions to maintain constant gaps and reduce thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple flange portions are formed at the edges of heat conduction plates to enable stacking and welding, then the structural integrity and sealing of the heat exchanger are improved, but the heat transfer area per unit area is reduced due to the space occupied by flange portions
Solution Approach 1:
The heat conduction plate is segmented into a body portion and a flange portion, where the flange portion is bent at a predetermined angle (e.g., 90 degrees) relative to the body portion. This segmentation allows the flange to serve as a separate functional element for stacking and welding while the body portion maximizes heat transfer area, thereby resolving the contradiction between structural integrity and heat transfer area.
Solution Approach 2:
The flange portion is bent to extend in a direction substantially perpendicular to the plane of the body portion, transitioning from a two-dimensional layout to a three-dimensional configuration. This dimensional change allows the flange to protrude outward for stacking and welding operations without occupying significant area within the heat transfer plane, thus maintaining high heat transfer area while ensuring structural integrity.
2Strength
If heat conduction plates are welded at the edges to form stacked structures, then the mechanical strength and stability are improved, but thermal resistance increases at the welded areas contacting high-temperature exhaust gas
Solution Approach 1:
The welding operation is extracted from the heat transfer path by positioning the flange portions (which are welded to each other) perpendicular to the body portions. This extraction ensures that the welded joints are located outside the region contacting high-temperature exhaust gas, eliminating the thermal resistance issue while maintaining mechanical strength through the welded flange connections.
Solution Approach 2:
The flange portion acts as an intermediary element that connects adjacent heat conduction plates through welding while being positioned away from the heat transfer path. This intermediary structure allows mechanical strength to be provided by the welded flanges without introducing thermal resistance into the high-temperature gas contact area, as the flanges serve as a separate connection medium.
3Productivity
If the number of flange portions is reduced to increase heat transfer area, then the heat transfer efficiency is improved, but the ease of assembly and stacking of heat conduction plates is worsened
Solution Approach 1:
The flange portion is designed to serve multiple functions: (1) providing a connection surface for welding adjacent heat conduction plates, (2) maintaining spacing between plates when bent perpendicular to the body, and (3) enabling modular stacking without requiring additional components. This multi-functionality allows the heat exchanger to achieve high heat transfer efficiency with minimal flange portions while maintaining ease of assembly through the universal applicability of the flange design.
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 design increases the heat transfer area per unit area, reduces thermal resistance, and enhances the efficiency and service life of the heat exchanger by minimizing the number of flange portions and optimizing heat exchange without physical contact between fluids.
Implementation Method 1
heat exchange occurs between the first fluid passing through the first passage and the second fluid passing through the second passage without physical contact
Data Source
AI summary
A plate type heat exchanger wherein the heat transfer assembly includes a plurality of heat transfer shells stacked in multiple layers.