浅析换热器产品制造技术

本文阐述了换热器产品水室、管系、外壳及总装在制造过程中的关键工序及制造难点,解决了管孔加工、管子-管板胀接、焊接及清洁控制等工艺难题。     

换热器产品制造难点

阐述换热器产品管系、外壳及总装在制造过程中的难点和重点,给出各种换热器产品在封头加工、筒体加工、管板加工、管系组立、穿管等工艺难题的解决方案。     

倒置立式高压加热器研制

通过倒置立式高压加热器研制,阐述了倒置立式高压加热器制造过程中的水室、管系、外壳及总装等关键工序和制造难点控制,解决了管系与外壳套装等工艺难题。     

国内首台倒置立式1060MW核电机组高压加热器制造研究

针对倒置立式核电常规岛高压加热器的研制,阐述了倒置立式高压加热器水室、管系、外壳及总装在制造过程中的关键工序及制造难点,并给出了在高加管孔加工、管端胀接焊接、管系与外壳套装等工艺难题的解决方案。     

超长管束换热器关键制造工艺研究

本文介绍了某项目超长管束换热器的结构特点和制造难点,重点阐述了管板制造、隔板管孔加工、换热管-管板胀接、换热管-管板管端焊、管束组立和套装等制造难点的控制。     

1000MW等级核电机组高压加热器制造技术研究

通过对1000MW等级核电机组高压加热器制造工艺的研发,阐述了核电高压加热器管板制造、隔板管孔加工、换热管-管板胀接、换热管-管板管端焊、内壁防锈等制造难点的控制。     

新技术在600MW高压加热器制造中的应用

600MW高压加热器在制造工艺上采用了先进的管板深孔钻、管子与管板液压胀接等先进技术,保证了产品设计制造质量。     

氨合成塔外壳制造技术

介绍了氨合成塔外壳的主要制造过程,重点阐述了筒体成形、锻件机加等工艺方案。     

FWEC管式空气预热器试制

本文综合论述了FWEC管式空气预热器制造技术,介绍了主要零、部件的制造工艺及技术要求。描述了管板制造、管板孔加工,管子管板焊接及检漏试验,防变形控制措施,整体尺寸及形位偏差控制方法及要点,管箱组装经验,起吊及翻身经验等。并为今后类似产品提出改进措施及建议。     

亚临界锅炉墙式辐射再热器管屏制造技术

本文主要阐述了亚临界锅炉辐射再热器管屏结构特点、制造难点及解决方案。重点对辐射再热器管屏管子弯管、套管装焊、与水冷壁管屏的装配、最终油漆等问题在制造时的难点及解决办法进行了详细的叙述。     

某管壳式换热器制造工艺技术

本文主要阐述了某管壳式换热器的结构特点、制造难点及关键制造技术。重点介绍了内外壳体套装、封头组件、管束等关键部件的制造工艺措施及控制重点。     

基于前馈-自抗扰算法的换热器动态试验温度控制研究

为了使换热器试验测控系统满足动态换热试验中对温度控制的要求,分析了试验系统中被控温度对象动态模型,设计了前馈-自抗扰温度控制算法。动态换热试验对象为管壳式换热器,试验过程管程流体为强迫对流换热,壳程流体自然对流换热,同时管程流体循环利用,要求控制管程入口温度稳定。控制算法全面利用模型信息,将壳程温度作为管程温度控制中的干扰,为其设计前馈补偿,同时设计自抗扰控制算法,处理模型偏差问题。利用AMESim软件搭建系统模型,在Simulink中设计控制算法,进行了AMESim/Simulink联合仿真,通过对比多种控制算法,验证了在壳程温度变化干扰的换热过程中,使用前馈-自抗扰控制算法能够使管程入口温度波动更小,更快达到稳定。     

新型锅壳式水火管燃煤热水锅炉的结构设计述评

通过介绍一台29MW锅壳式水火管燃煤热水锅炉的结构、水系统、烟气流程的技术特点,进一步说明新型锅壳式水火燃煤热水锅炉在大容量热水锅炉的发展及优势。     

The evaluation of a small capacity shell and tube ammonia evaporator

The use of ammonia as refrigerant is widespread in vapour compression and ammonia/water absorption systems. Ammonia is not actually used in low capacity applications mainly because of the lack of economical available equipment. For this reason, the objective of this study is the numerical and experimental evaluation of a small capacity ammonia shell and tube evaporator with enhanced heat transfer surfaces.An experimental system to evaluate small capacity heat exchangers was developed. A shell and tube evaporator with external low fin tubes was successfully tested. The experimental uncertainty for the evaporator capacity has been estimated within ±5.5%. The experimental results were used to validate a heat exchanger numerical tool that predicts reasonably well the cooling capacity and load outlet temperatures. The methodology presented in this work can be applied to evaluate other refrigerants in similar shell and tube evaporators and to optimize the design of an evaporator for a specific application.     

壳管式相变蓄热器传热效率研究

设计了一套定量测试不同工况下壳管式相变蓄热器传热效率装置。采用壳管式相变储热,石蜡填充入壳管间,管内通入冷、热载流体,模拟吸热放热过程。测试发现:相同入口条件下,单位时间传热量随入口水温增加呈线性增加;管内载流体流量加大有助于提高传热水平,15~60 L/h流量内单位时间传热量增速随流量增加放缓;不同材质传热管单位时间传热量变化并不明显,表明管道热阻在相变蓄热器总热阻中所占份额较小;相同工况下的蓄热过程,热载流体由下向上流动传热形式明显优于由上向下管排形式;尝试在封装相变材料中添加金属网状结构,强化相变材料内部热传导速率,对比发现相同工况下相变材料中添加金属网状结构,可提高10%~15%左右传热量。     

摩托车催化器性能考核台架试验中换热器的研究

催化器性能评价试验中，起燃特性和温度特性是两个重要性能，这两个特性的研究都需要对催化器入口温度进行稳定连续的调节。本文设计了冷轧翅片管、整体轧制式、U型管壳式换热器和单程管壳式换热器，通过比较，选定冷轧翅片管换热器进行温度特性和起燃特性试验，试验结果表明该换热器能够达到设计要求，对温度的控制也比较稳定。     

Patterns of Fluid Flow in a Shell-and-Tube Heat Exchanger

The oil-lampblack technique was employed to reveal the patterns of fluid flow in a shell-and-tube heat exchanger. Flow patterns were visualized adjacent to the shell wall, to the baffle plates, and to each tube of the array. From the flow patterns adjacent to the shell, three recirculation zones were identified. The patterns adjacent to the baffles were similar to those for cross flow over a tube bank, with curvature-related deviations near the shell. The flow patterns adjacent to the tubes showed, typically, a stagnation line/circumferential flow system on the upstream face of each tube and a recirculation tone dominating the tee side. Turn-related deviations from these patterns were in evidence at the window region.     

Design and economic optimization of shell and tube heat exchangers using Artificial Bee Colony (ABC) algorithm

In this study, a new shell and tube heat exchanger optimization design approach is developed. Artificial Bee Colony (ABC) has been applied to minimize the total cost of the equipment including capital investment and the sum of discounted annual energy expenditures related to pumping of shell and tube heat exchanger by varying various design variables such as tube length, tube outer diameter, pitch size, baffle spacing, etc. Finally, the results are compared to those obtained by literature approaches. The obtained results indicate that Artificial Bee Colony (ABC) algorithm can be successfully applied for optimal design of shell and tube heat exchangers.     

Optimal geometry and flow arrangement for minimizing the cost of shell‐and‐tube condensers

This paper presents a model for estimating the total cost of shell‐and‐tube heat exchangers (HEs) with condensation in tubes or in the shell, as well as a designing strategy for minimizing this cost. The optimization process is based on a genetic algorithm. The global cost includes the energy cost (i.e. pumping power) and the initial purchase cost of the exchanger. The choice of the best exchanger is based on its annualized total cost. Eleven design variables are optimized. Ten are associated with the HE geometry: tube pitch, tube layout patterns, baffle spacing at the center, baffle spacing at the inlet and outlet, baffle cut, tube‐to‐baffle diametrical clearance, shell‐to‐baffle diametrical clearance, tube bundle outer diameter, shell diameter, and tube outer diameter. The last design variable indicates whether the condensing fluid should flow in the tubes or in the shell. Two case studies are presented and the results obtained show that the procedure can rapidly identify the best design for a given heat transfer process between two fluids, one of which is condensing. Copyright © 2008 John Wiley & Sons, Ltd.