Static Auger Pipe Insert for Higher Heat Transfer at Lower Cost
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Solution Overview
Problem
Existing heat management systems in pipes are costly and inefficient, necessitating the development of a cost-effective and efficient method to enhance heat transfer while minimizing capital and operational expenses.
Innovation Solution
The integration of a static auger within a pipe, where the auger's outer diameter is at least 90% of the pipe's inner diameter, with a D/P ratio between 2-10, and flute surfaces having a roughness of 50-1000 microns, enhances fluid turbulence and heat transfer, utilizing materials like stainless steel or ceramics for high temperature and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional heat management systems are used, then heat transfer can be achieved, but capital costs and operational costs are high
Solution Approach 1:
The patent extracts the heat transfer enhancement function from complex integrated heaters and implements it through a simple static auger component. The auger with specific D/P ratio (2-10) and surface roughness (50-1000 microns) creates turbulence that enhances heat transfer without requiring active heating elements, thereby reducing system complexity and cost while maintaining or improving heat transfer efficiency.
Solution Approach 2:
The patent employs inexpensive materials for the auger such as stainless steel, carbon steel, Monel, Inconel, Incoloy, Hastelloy, ceramics, silicon carbide, or alumina. These materials provide adequate performance for heat transfer enhancement without the high costs associated with traditional integrated heater systems, achieving cost-effective heat management.
2Temperature
If integrated heaters are used for heat management, then heating capability is provided, but maintenance becomes more difficult and costs increase
Solution Approach 1:
The patent separates the heat transfer enhancement function from the heating source itself. The static auger serves as a passive turbulence promoter that works with external heating sources, eliminating the need for integrated heaters that require complex maintenance. The auger can be easily removed and replaced without affecting the heating system.
Solution Approach 2:
The static auger is a passive component that requires no power, control systems, or active maintenance. It automatically enhances heat transfer through its geometric design (D/P ratio of 2-10 and surface roughness of 50-1000 microns) as fluid flows through the pipe, eliminating the need for operational intervention or complex repairs.
3Device complexity
If simple pipe design is used, then capital costs are reduced, but heat transfer efficiency is insufficient
Solution Approach 1:
The patent applies local quality enhancement by introducing a static auger with specific geometric properties (D/P ratio of 2-10, surface roughness of 50-1000 microns) into the pipe. This localized modification creates turbulence in specific regions where it is most effective for heat transfer enhancement, while the rest of the pipe system remains simple and cost-effective.
Solution Approach 2:
The patent changes physical parameters of the pipe system by introducing an auger with optimized dimensions (outer diameter D, pitch P where D/P ≥ 1 and D ≥ 90% of pipe inner diameter d). These parameter changes transform the flow regime from laminar to turbulent, significantly enhancing heat transfer efficiency without requiring a complete redesign of the pipe system.
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 approach reduces capital and operational costs by eliminating the need for integrated heaters, enhances heat transfer efficiency, and maintains operational reliability with easier maintenance, while maintaining a balance between heat transfer and pressure drop.
Implementation Method 1
enhances fluid turbulence and heat transfer
Implementation Method 2
enhances heat transfer efficiency
Data Source
AI summary
Herein discussed is a heat management system comprising a pipe and a static auger inside the pipe, wherein the pipe has an inner diameter of d, wherein the auger has an outer diameter D and a pitch P, wherein the ratio of D/P is no less than 1, and wherein the auger outer diameter D is no less than 90% of the pipe inner diameter d. In an embodiment, the ratio of D/P is in the range of 2-10, or 2-5, or 2-4, or 5-10. In an embodiment, the pipe is made from stainless steel, carbon steel, Monel, Inconel, Incoloy, Hastelloy, ceramics, silicon carbide, alumina, and combinations thereof. In an embodiment, the system comprises a fluid passing through the pipe, wherein the pipe heats or cools the fluid.