Solid-State Heat Exchanger Module for Bulk Materials
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional heat exchangers for solid free-flowing bulk materials face issues with blockages, inefficient heat exchange, and maintenance challenges, especially when using unpurified vapors, which can lead to condensation and corrosion.
Innovation Solution
A heat exchanger module comprising bundled heat exchanger tubes with specific rectangular or rhombic cross-sections and staggered arrangements, allowing for efficient heat transfer using unpurified vapors and preventing blockages by promoting turbulent flow and reducing condensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conventional parallel heat exchange plates are used for free-flowing bulk material, then the heating area is broad, but the heat exchange efficiency is poor because the bulk material is not mixed between rows
Solution Approach 1:
The patent introduces movable mixing elements that actively move and mix the bulk material as it flows through the heat exchanger. This dynamic mixing ensures that material from different rows intermixes, dramatically improving heat exchange efficiency while maintaining the broad heating area provided by the parallel plate structure
Solution Approach 2:
The patent employs vibratory mixing elements that create mechanical vibrations to disrupt the bulk material flow and promote mixing between adjacent rows. This vibration-based mixing enhances heat transfer efficiency without compromising the extensive heating surface area of the parallel plate configuration
2Loss of energy
If unpurified vapors are used for heating, then direct heat utilization is achieved, but condensation causes corrosion damage and clogging
Solution Approach 1:
The patent converts the harmful condensation effect into a beneficial cleaning mechanism. The condensing vapors are directed to flush through the heat exchanger tubes, creating a self-cleaning effect that removes deposits and prevents clogging, while the heat from condensation is still utilized for heating the bulk material
Solution Approach 2:
The system uses its own operating medium (unpurified vapor) to perform the dual function of heating and self-cleaning. The condensation process itself generates the flushing action that maintains the heat exchanger, making the system self-maintaining and eliminating the need for separate purification systems
3Stability of the object's composition
If shaft coolers with inclined wings are used to prevent material fall-out, then wall distortion is avoided, but the construction becomes very complicated
Solution Approach 1:
The patent divides the heat exchanger into modular sections with standardized tube bundles and support structures. This segmentation allows for simpler, repeatable construction without requiring complex integrated designs like inclined wings, while still providing adequate structural support and material containment
Solution Approach 2:
The patent employs universal support structures and standardized tube bundle designs that serve multiple functions: structural support, material containment, and heat transfer. This multi-functionality eliminates the need for specialized components like inclined wings, reducing overall construction complexity while maintaining structural integrity
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 solution enhances heat exchange efficiency, reduces maintenance needs, and allows for compact, high-output heat exchangers that can handle a variety of bulk materials with improved flow characteristics and reduced risk of corrosion.
Implementation Method 1
Heat exchanger tubes for the supply with heating or cooling media
Implementation Method 2
The bulk material is subjected to a heat exchange
Implementation Method 3
vapors are usually used for the heating, which must first be condensed and cleaned
Data Source
AI summary
The invention relates to a novel solid heat exchanger module containing a plurality of heat exchanger tubes having a particular shape and being arranged in a special manner.