Tube-side Pulsable Flow Shell-and-Tube Heat Exchanger
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Solution Overview
Problem
Conventional shell-and-tube heat exchangers suffer from fouling and reduced heat exchange efficiency due to the inability to maintain consistent flow rates and prevent agglomeration of solids in fouling-prone process fluids, leading to decreased performance and increased maintenance costs.
Innovation Solution
A tube-side sequentially pulsable-flow shell-and-tube heat exchanger apparatus that uses a pulsing mechanism to vary flow rates within the tubes while maintaining an average overall flow rate, inhibiting agglomeration and fouling by ensuring consistent fluid dynamics and turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional shell-and-tube heat exchangers operate with continuous flow, then the overall flow rate is maintained, but fouling occurs due to agglomeration of solids and contaminants in the process fluid
Solution Approach 1:
The patent applies periodic pulsing action to the process fluid flow through the tubes. A pulsing device creates periodic variations in flow rate, causing the fluid to alternate between high-velocity pulsing phases and lower-velocity phases. This periodic action prevents solids and contaminants from settling and agglomerating on tube surfaces, thereby reducing fouling while maintaining overall heat exchange efficiency.
Solution Approach 2:
The pulsing device generates mechanical vibrations in the process fluid by creating periodic pressure fluctuations and flow variations. These vibrations disrupt the formation of fouling layers on tube surfaces and prevent agglomeration of solids, similar to how mechanical vibration is used to prevent deposition in other industrial applications.
2Object-generated harmful factors
If the process fluid flow is stopped and restarted to prevent fouling, then agglomeration is reduced, but the overall flow rate decreases and heterogeneous material settles in hold-up voids
Solution Approach 1:
Instead of stopping and restarting flow, the patent implements continuous periodic pulsing that maintains flow throughout operation. The pulsing creates periodic high-velocity phases that prevent agglomeration without allowing the flow to stop completely, thus avoiding settlement in hold-up voids while maintaining overall productivity.
Solution Approach 2:
The system dynamically varies the instantaneous flow rate through periodic pulsing while maintaining the average flow rate at the desired level. This dynamic adjustment allows the fluid to experience high-velocity cleaning phases without reducing the overall throughput, resolving the contradiction between preventing agglomeration and maintaining productivity.
3Reliability
If pulsed flow is applied to prevent fouling, then heat transfer efficiency improves, but the flow rate varies and may decrease overall throughput
Solution Approach 1:
The pulsing device creates periodic flow variations that enhance heat transfer during high-velocity phases through increased turbulence, while the system is designed to maintain the average flow rate at the required throughput level. The periodic action provides cleaning benefits without sacrificing overall productivity.
Solution Approach 2:
The system changes the flow rate parameter periodically rather than maintaining a constant value. By varying the instantaneous flow rate while controlling the average flow rate, the system achieves enhanced heat transfer during pulsing phases while maintaining the required overall throughput for 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 solution enhances heat exchange rates and reduces fouling by maintaining consistent flow rates and preventing agglomeration, thereby improving operational efficiency and extending the lifespan of heat exchanger components.
Implementation Method 1
inhibiting agglomeration and fouling by ensuring consistent fluid dynamics and turbulence
Implementation Method 2
tube-side sequentially pulsable-flow shell-and-tube heat exchanger apparatus
Data Source
AI summary
The present invention relates to a tube-side sequentially pulsable-flow, shell-and-tube heat exchanger apparatus and a chemical processing system comprising and methods of heat exchange employing the same.