Sample Probe Condenser with Helical Fins for Gas Analysis
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Solution Overview
Problem
Existing gas analyzers face challenges with liquid condensation issues due to high sample gas temperatures or low pressures, leading to inaccuracies and reliability problems, as current solutions are often large, slow, expensive, and not compatible with a wide range of sample compositions, temperatures, and pressures.
Innovation Solution
An apparatus featuring an elongated insert member with angled helical fins for cooling and condensing, combined with a reflux section and passive or active shell configurations for efficient heat transfer and condensate drainage, allowing for compact, cost-effective operation across various conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing cooling and condensing devices are used, then liquid condensation is prevented or minimized, but the devices are large, slow in response time, expensive, and require significant utilities
Solution Approach 1:
The condensing device is nested within the sample probe structure, with the insert member fitting inside the probe body. This integration allows the condensing function to be incorporated into the existing probe architecture, reducing overall system size and eliminating the need for separate external cooling devices.
Solution Approach 2:
The device uses the thermal energy from the sample gas itself to drive the condensation process. The cooling medium absorbs heat from the sample gas as it flows through the heat exchange surfaces, requiring no external power source or active cooling utility, thus making the system self-sufficient.
2Reliability
If existing reflux or distillation probes are used, then liquid carryover is reduced, but the devices are very large and prohibitively expensive
Solution Approach 1:
The insert member is divided into distinct functional sections: a condensing section with helical fins for heat exchange, and a reflux section with saddle-shaped fins for liquid redistribution. This segmentation allows each section to perform its specific function efficiently within a compact overall structure.
Solution Approach 2:
Different sections of the insert member have different fin geometries optimized for their specific functions. The condensing section uses helical fins for maximum heat transfer surface area, while the reflux section uses saddle fins designed for liquid drainage and redistribution, creating local optimizations throughout the device.
3Reliability
If sample coolers or chillers are used, then dew point is reduced, but additional high-maintenance devices such as thermoelectric or compressor coolers are required
Solution Approach 1:
The system utilizes the natural thermal gradient between the warm sample gas and the cooling medium to drive condensation. The cooling medium flows through passages in the insert member, absorbing heat passively without requiring thermoelectric coolers or compressor-based refrigeration systems, thereby eliminating high-maintenance components.
Solution Approach 2:
The patent replaces mechanical cooling systems (compressors, thermoelectric coolers) with a passive heat exchange system. The condensation is achieved through thermal conduction and convection between the sample gas and cooling medium, substituting complex mechanical refrigeration with simpler thermal physics-based heat transfer.
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 apparatus effectively cools and condenses fluid samples, ensuring accurate gas analysis by minimizing liquid carryover and being compatible with diverse sample streams, temperatures, and pressures, while being more compact and economical than existing solutions.
Implementation Method 1
The condensing section includes a plurality of angled helical fins defining a plurality of angled helical channels. The insert member is installed within the inside bore of the first shell so that the plurality of angled helical fins and the plurality of saddle fins make thermal contact with the inside bore to allow a heat transfer from the sample to the first shell.
Implementation Method 2
The plurality of multi-start helical fins define a plurality of multi-start helical passages for a cooling media to enter and flow in between the multi-start helical passages
Implementation Method 3
A space between the second shell and the first shell allows a cooling medium to enter and flow in a counter flow manner between the multi-start helical passages.
Implementation Method 4
The reflux section includes a plurality of saddle fins where each of the saddle fins has an upper surface configured for self-draining of the fluid and a bottom surface.
Data Source
AI summary
An apparatus for cooling and condensing a fluid sample that includes an elongated insert member having a condensing section in an upper portion and a reflux section in a lower portion. The condensing section includes angled helical fins defining angled helical channels and the reflux section including saddle fins. Each of the saddle fins having an upper surface configured for self-draining of the fluid and a bottom surface. The insert member may be installed within an elongated first shell having an inside bore and a plurality of multi-start helical fins formed on an exterior surface of the first shell. The plurality of multi-start helical fins define a plurality of multi-start helical passages for a cooling medium to enter and flow in between the multi-start helical passages. The first shell may be installed within a second shell that provides active, liquid cooling. The insert member may alternatively be installed within a passive shell.