Segmented Heat Exchanger Layout for Thermal Stress Control
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Solution Overview
Problem
Existing heat exchangers face limitations in maximizing heat transfer while maintaining structural integrity due to thermal stress constraints, particularly at corners where temperature differences are highest, leading to reduced efficiency and potential material fatigue.
Innovation Solution
A modular heat exchanger design with variable heat-transfer augmenters in each module, optimized for stress and heat-transfer coefficients, allowing independent configuration of each section to manage thermal gradients and enhance overall performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the temperature difference is increased to maximize heat transfer, then heat transfer capacity is improved, but thermal stress and material fatigue increase
Solution Approach 1:
The heat exchanger is divided into multiple segments along the flow path, with each segment having independently optimized heat-transfer augmenters. This segmentation allows different regions to operate at different temperature differences, maximizing overall heat transfer while preventing excessive thermal stress in any single location.
Solution Approach 2:
Heat-transfer augmenters are configured with locally varying properties - the type, size, and distribution of augmenters change along the flow path based on local thermal conditions. This ensures that each region operates at optimal temperature difference without exceeding material stress limits.
2Ease of manufacture
If uniform heat-transfer augmenters are used throughout the heat exchanger, then manufacturing is simplified, but heat transfer efficiency is reduced due to non-uniform thermal gradients
Solution Approach 1:
The heat exchanger is divided into multiple segments along the flow path, with each segment having independently optimized heat-transfer augmenters. This segmentation allows different regions to operate at different temperature differences, maximizing overall heat transfer while preventing excessive thermal stress in any single location.
Solution Approach 2:
Heat-transfer augmenters are configured with locally varying properties - the type, size, and distribution of augmenters change along the flow path based on local thermal conditions. This ensures that each region operates at optimal temperature difference without exceeding material stress limits.
3Productivity
If heat-transfer augmenters are added to increase heat transfer capacity, then heat transfer efficiency is improved, but thermal stress and material fatigue increase
Solution Approach 1:
Heat-transfer augmenters are configured with locally varying properties - the type, size, and distribution of augmenters change along the flow path based on local thermal conditions. This ensures that each region operates at optimal temperature difference without exceeding material stress limits.
Solution Approach 2:
The configuration of heat-transfer augmenters is dynamically optimized along the flow path, with the density and type of augmenters varying to match local thermal gradients. This dynamic configuration maximizes heat transfer while maintaining stress within acceptable limits.
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 optimizes heat transfer capacity while reducing thermal stress, thereby extending the life and efficiency of the heat exchanger by tailoring each module's internal geometry to meet deterministic stress criteria.
Implementation Method 1
As heat is transferred through a heat exchanger, material of the heat exchanger experiences thermal structural fatigue due to the temperature difference between a hot side and a cold side
Implementation Method 2
Each heat-transfer augmenter in the plurality of heat-transfer augmenters has a different configuration to optimize a heat transfer coefficient for the first fluid in the first plurality of fluid conduits
Data Source
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AI summary
A method can comprise dividing a heat exchanger design into a plurality of modules (10), the plurality of modules (10) arranged in a grid, each module in the plurality of modules (10) including: a first fluid conduit (161) defining an inlet (1611), an outlet (1612), and a heat-transfer surface (602), and a first flow direction, and a second fluid conduit (162) defining a second inlet, a second outlet, a second heat-transfer surface, and a second flow direction, the second flow direction different from the first flow direction; and determining a heat-transfer augmenter arrangement (1161) for the first fluid conduit (161) and the second fluid conduit (162) of each module in the plurality of modules (10) based on a stress threshold of the module (16) in the plurality of modules (10).