Recuperator With Ribbed Thin Gauge Strips For Thermal Stress Management
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Solution Overview
Problem
Existing recuperators face challenges in achieving high energy efficiency and low pressure drop while minimizing material usage and addressing thermal expansion issues, which affects the durability and cost-effectiveness of gas-to-gas heat exchangers in industries like gas turbines and solid oxide fuel cells.
Innovation Solution
A recuperator design featuring thin gauge strips with a contra-flow configuration, ribbed heat exchange surfaces, and an outer casing that allows for thermal expansion, ensuring high effectiveness (>80%) with low pressure drop (<4% of inlet pressures) and reduced material usage, along with expansion joints to manage thermal stresses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If thin gauge strip less than 0.5mm thickness is used, then weight is reduced and heat transfer is maximized, but structural strength and durability are compromised
Solution Approach 1:
The heat exchange surface is divided into multiple panels joined by ribs, creating a segmented structure that distributes mechanical stresses across multiple components rather than requiring a single thick plate. This segmentation allows thin gauge material to maintain adequate structural strength through the collective reinforcement of the ribbed framework.
Solution Approach 2:
The ribbed profile provides localized structural reinforcement at critical stress points (ridges and valleys) while maintaining thin gauge material in the heat transfer areas. This local quality approach strengthens the structure where needed without adding unnecessary weight or reducing heat transfer efficiency in the panel regions.
2Temperature
If high temperature special alloy material is used, then high temperature resistance is improved, but cost and weight increase
Solution Approach 1:
The segmented panel structure with ribs allows the use of thin gauge high temperature alloy material, reducing the total volume and weight of expensive material required while maintaining adequate high temperature resistance through the distributed structural support across multiple panels and ribs.
3Reliability
If conventional heat exchanger design is used, then structural durability is maintained, but thermal expansion stresses cause failure
Solution Approach 1:
The thin gauge strip material with ribbed profile creates a semi-flexible structure that can accommodate thermal expansion and contraction movements better than rigid thick plates. The ribbed configuration allows controlled deformation during thermal cycling, reducing thermal stress accumulation and improving durability.
4Productivity
If effective heat transfer is achieved, then energy recovery efficiency increases, but pressure drop increases requiring more mechanical energy
Solution Approach 1:
The ribbed profile adds a third dimension to the heat exchange surface, creating channels and increasing surface area without significantly increasing flow path length or resistance. This dimensional enhancement improves heat transfer efficiency while maintaining acceptable pressure drop characteristics.
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 design achieves high energy recovery efficiency, low pressure drop, and durability by maximizing heat transfer and minimizing material usage, while effectively managing thermal expansion, resulting in a lightweight and cost-effective solution for gas-to-gas heat exchangers.
Implementation Method 1
to transfer heat energy from the exhaust gas to the incoming air
Implementation Method 2
each heat exchange surface being formed from a single sheet of material to maximize heat transfer
Implementation Method 3
the thermal expansion must be addressed to ensure durability of the heat exchanger
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A recuperator (100) comprising: a heat exchange assembly comprising a plurality of heat exchange plates (200); an inlet for a first fluid (101), and an outlet for said first fluid (102); an inlet for a second fluid (103) and an outlet for said second fluid (104); a plurality of first fluid channels, extending along a plurality of first paths between the inlet for the first fluid (101) and the outlet for the first fluid (102); a plurality of second fluid channels extending along a plurality of second paths between the inlet for the second fluid (103) and the outlet for the second fluid (104); characterised in that said plurality of first fluid channels are arranged side by side with and to follow closely said plurality of second fluid channels, such that said first fluid flowing in said plurality of first fluid channels flows adjacent and in an opposite direction to said second fluid flowing in said plurality of second fluid channels, said first and second channels separated by at least one said heat exchange plate (200) such that heat transfers through said heat transfer plate between said first and second fluids.