Gas Scrubber Thermal Sheets for Uniform Cooling
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Solution Overview
Problem
Existing gas scrubbers face challenges in achieving uniform cooling and maintenance due to clogged tubes and uneven heat exchanger surface distribution, as well as difficulties in cleaning and accessing heat exchangers, especially in applications where high temperatures and chemical decomposition are concerns.
Innovation Solution
The integration of vertically arranged thermal sheets forming a heat exchanger within the gas scrubber, where the gas-liquid mixture flows through the gaps between the sheets and the coolant flows within, providing an evenly distributed heat exchanger surface and allowing for self-cleaning, with optional flow guide plates to enhance heat exchange and turbulence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If tube bundle heat exchangers are used with vertical pipes, then heat exchange surface area is increased, but the heat exchanger becomes difficult to access for cleaning and repair work
Solution Approach 1:
The heat exchanger is divided into multiple modular sections that can be independently accessed and maintained. The thermal sheets are arranged in a segmented pattern within the scrubber, allowing specific sections to be accessed for cleaning without requiring disassembly of the entire heat exchanger assembly.
Solution Approach 2:
The heat exchanger design transitions from traditional horizontal tube bundles to vertically arranged thermal sheets that extend along the vertical axis of the scrubber. This dimensional change allows the heat exchange surface to be distributed throughout the vertical space, improving accessibility for maintenance while maintaining adequate heat exchange area.
2Ease of repair
If U-tube bundle heat exchangers are inserted vertically through the column wall, then ease of maintenance is improved, but the heat exchanger surface is only unevenly distributed over the scrubber cross section
Solution Approach 1:
The thermal sheets are strategically positioned at different vertical locations within the scrubber to create multiple localized heat exchange zones. This local quality approach ensures even distribution of heat exchange surface area across the scrubber cross-section while maintaining the vertical insertion configuration for ease of maintenance.
Solution Approach 2:
The heat exchanger surface is distributed along the vertical dimension rather than concentrated in a single plane. Multiple thermal sheets are arranged at different vertical positions, creating a three-dimensional heat exchange network that provides uniform cooling across the entire scrubber cross-section while maintaining accessibility for maintenance.
3Power
If gas-liquid mixture is passed through heat exchanger tubes, then heat exchange efficiency is improved, but the pipes tend to become clogged and require a lot of cleaning
Solution Approach 1:
The heat exchanger uses flexible thermal sheets instead of rigid tubes. These thin film structures allow the gas-liquid mixture to flow around them rather than through confined tube interiors, reducing the likelihood of clogging while maintaining efficient heat exchange. The flexible nature of the thermal sheets also facilitates easier cleaning and maintenance.
Solution Approach 2:
The thermal sheets are designed to be permeable to the gas-liquid mixture, allowing fluid dynamics to play a role in preventing clogging. The flow patterns created by the sheet configuration promote continuous movement of the mixture through the heat exchange zones, reducing deposition and clogging while maintaining high heat exchange efficiency.
4Stability of the object's composition
If thermal sheets are arranged vertically to fill the entire cross section, then uniform cooling is achieved, but the structure becomes more complex
Solution Approach 1:
The heat exchanger is composed of multiple discrete thermal sheet sections that can be independently manufactured and assembled. This segmentation simplifies the overall structure by allowing modular construction while achieving uniform cooling through the systematic arrangement of the segments throughout the scrubber cross-section.
Solution Approach 2:
The thermal sheets serve multiple functions simultaneously: they provide heat exchange surface area, create flow distribution patterns, and act as structural support elements within the scrubber. This multi-functionality reduces the need for additional components, simplifying the overall structure while achieving uniform cooling.
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 ensures uniform cooling, reduces maintenance effort, and prevents clogging, as the gas-liquid mixture can flow around any deposits, while the thermal sheets provide efficient heat transfer with minimal pressure loss, making it suitable for high-temperature applications like melamine synthesis.
Implementation Method 1
the thermal sheets being arranged vertically and the gas/liquid mixture flowing through the gaps between the thermal sheets and the coolant flowing within the thermal sheets
Implementation Method 2
the cooling medium located within the thermal sheets is evaporated by absorbing the heat from the gas-liquid mixture
Data Source
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AI summary
The invention relates to a gas scrubber, equipped with heat exchanger surfaces constructed from thermal sheets, suitable for cooling and purifying a hot gas, while avoiding excessive thermal loading of the scrubbing liquid.