Salt-Bath Steam Generator for Stable High-Pressure Output
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Solution Overview
Problem
Existing steam generators face inefficiencies due to wall losses and inability to compensate for thermal expansion and fluctuating steam parameters, particularly when using biomass as fuel, leading to potential turbine damage and high-pressure risks.
Innovation Solution
A steam generator design utilizing a salt bath as a heat transfer medium between a first heat exchanger element for waste heat from biomass and a second heat exchanger element for water, allowing for flexible steam pressure generation from 50 to 800 bar without additional storage tanks, using a crystalline salt that liquefies to absorb energy and regulate pressure through water flow rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a shell-and-tube heat exchanger is used with high pressure and temperature for efficient steam generation, then steam generation efficiency is improved, but thermal expansion stresses in the heat exchanger material increase
Solution Approach 1:
The patent introduces a compensation mechanism that allows the heat exchanger to adapt to parameter changes (thermal expansion) by providing movable support structures that accommodate dimensional changes in the tube bundles while maintaining sealing and heat transfer efficiency
Solution Approach 2:
The patent implements dynamic compensation for thermal expansion by allowing the tube bundles to move relative to the shell through compensation joints or movable supports, enabling the system to handle thermal stresses without compromising structural integrity or requiring excessive material strength
2Productivity
If the heat exchanger is placed close to the casing to reduce wall losses, then heat exchange efficiency is improved, but wall losses cannot be prevented when fluid flows past the heat exchanger
Solution Approach 1:
The patent introduces an intermediary fluid path or heat transfer medium that captures the thermal energy from fluid flowing past the heat exchanger, converting what would be wasted energy into useful heat for steam generation, thereby reducing wall losses while maintaining efficient heat exchange
3Stability of the object's composition
If an additional steam storage boiler is used to compensate for fluctuating steam parameters, then steam parameter stability is improved, but the risk of destruction increases at high pressures above 250 bar
Solution Approach 1:
The patent implements a self-regulating mechanism where the heat exchanger system automatically compensates for fluctuations in fuel energy content and steam parameters through inherent thermal inertia and controlled heat transfer rates, eliminating the need for additional storage boilers and their associated safety risks at high pressures
4Stability of the object's composition
If a steam storage boiler is added to counteract fluctuation in steam parameters, then steam temperature stability is improved, but device complexity increases
Solution Approach 1:
The patent employs self-regulating heat transfer mechanisms and thermal inertia of the heat exchanger system to automatically stabilize steam parameters in response to fuel energy content fluctuations, providing temperature stability without requiring additional active control systems or complex multi-component configurations
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
Enables efficient, flexible, and reliable steam generation across varying pressures, preventing damage and optimizing heat transfer with rapid pressure adjustments, independent of fuel energy content, and reducing the risk of explosions.
Implementation Method 1
A heat transfer medium is arranged within the housing to transfer heat from the heat exchange fluid flowing through the first heat exchange element to the water flowing through the second heat exchange element
Implementation Method 2
the heat transfer medium is a salt bath that covers both the first heat exchange element and the second heat exchange element
Implementation Method 3
using a crystalline salt that liquefies to absorb energy and regulate pressure through water flow rate
Data Source
Figure 1
Figure 2
AI summary
The present invention relates to a steam generator comprising a housing, a first heat exchanger element arranged in the housing through which a heat exchange fluid flows, and at least one second heat exchanger element arranged in the housing through which water flows for the purpose of generating steam. Furthermore, the steam generator comprises a heat transfer medium arranged in the housing to transfer heat from the heat exchange fluid flowing through the first heat exchanger element to the water flowing through the second heat exchanger element for the purpose of generating steam, wherein the heat transfer medium is a salt bath.