CA2759154A1 - Hybrid materials with enhanced thermal transfer capability - Google Patents
Hybrid materials with enhanced thermal transfer capability Download PDFInfo
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- CA2759154A1 CA2759154A1 CA 2759154 CA2759154A CA2759154A1 CA 2759154 A1 CA2759154 A1 CA 2759154A1 CA 2759154 CA2759154 CA 2759154 CA 2759154 A CA2759154 A CA 2759154A CA 2759154 A1 CA2759154 A1 CA 2759154A1
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D10/00—Modifying the physical properties by methods other than heat treatment or deformation
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F3/00—Changing the physical structure of non-ferrous metals or alloys by special physical methods, e.g. treatment with neutrons
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Abstract
This invention provides a method of preparation of a hybrid material with enhanced thermal transfer properties. The hybrid material comprises a protective oxide layer on a metallic substrate base. The oxide layer has a high thermal conductivity and dimple surface morphology. The metallic substrate material is any of aluminum, magnesium, zirconium, titanium, nickel and their alloys as well as stainless steel, carbon steel, and tool steel. The oxide is synthesized using a plasma oxidation process and metallurgically bonded to the substrate; no interfacial thermal resistance between the layer and substrate exists. The hybrid material can have, for instance, a thermal conductivity 3 to 5 times higher than a typical stainless steel. The hybrid material can be used to manufacture thermal exchanging components with enhanced thermal transfer capability for heat exchangers and heat recovery systems.
Description
Hybrid materials with enhanced thermal transfer capability FIELD OF THE INVENTION
The field of the invention is the preparation of hybrid materials with improved thermal transfer properties for heat exchange and energy recovery applications.
BACKGROUND OF THE INVENTION
With the increasing concern in energy consumption and environmental pollution, improvement in energy efficiency to save fuels and reduce emission is a great deal. There is a need in development of new materials with enhanced thermal transfer capability for heat exchange and energy recovery applications.
For example, a typical natural gas steam generator contains three heat exchange coils, namely an economizer for preheating boiler feed water, an evaporator for generating high pressure steam and a super heater for heating the high pressure steam into superheated steam.
After removing fines, the cooled flue gas may then be discharged into the stack. The boiler-generated steam remains an effective method of heat transfer for most process and manufacturing applications; however, a tremendous amount of energy and water can be lost.
In natural gas combustion products, approximately 18 percent is water vapor.
If the water vapor is left to escape with exhaust, it carries about 10 percent of the input energy with it. So a system can never exceed 90% efficiency if this moisture escapes.
Fuel cost and environmental regulation have created a strong demand for cost-effective solutions to enhance boiler performance to reduce use of natural gas, fuel and other energy forms, decrease water consumption, and lower greenhouse emissions. One of methods to increase performance of the boiler is heat recovery. Heat recovery systems are to recover both sensible and latent heat, as well as water from the exhaust stream. The recovery heat can be used to preheat boiler feed water and thus improve boiler efficiency.
The boiler heat recovery is depending on the condensing economizer. Water passes through a condensing economizer on its way to the boiler. Sensible heat is recovered from the maximum boiler exhaust temperature, staring in the range of 250 degrees Celsius C, down to the condensing point of the flue gas, approximately 55 degrees Celsius C. At the condensing point, or called dew point, water droplets form in the condensing economizer and are recovered. The latent heat is recovered in the phase change of the water when the vapor changes back into liquid. By preheating the boiler feed water with energy harvested from the exhaust stack gases, economizer can potentially recover a large amount of energy and as a result, reduce the otherwise large emission footprint.
Lower flue gas discharge temperatures indicate greater heat recovery from the flue gas, meaning that more thermal energy has been transferred from flue gas back to the boiler feed water. To increase the recovery efficiency of the economizer itself, higher thermal conductive components are needed. Currently, most economizers are made of stainless steels and nickel alloys since they have the required mechanical and anti-corrosion properties.
However, both stainless steels and nickel alloys have a low thermal conductivity which is 3 to 5 times lower than that of aluminum, magnesium and zirconium alloys. From the thermal transferring capability point of view, those non-ferrous alloys should be used to make the heat exchanging components of, for instance, economizers. Unfortunately, the non-ferrous alloys can not withstand high temperatures and they are suspicious to corrosion problems.
There is a great need in development of materials which have the improved thermal, mechanical and anti-corrosion properties at high temperatures in dry and wet environments. This invention puts forward hybrid materials with improved thermal properties for enhancing performance of the heat exchange and energy recovery systems.
SUMMARY OF THE INVENTION
In this invention, the hybrid materials are synthesized based on two groups of metallic materials: (1) aluminium, magnesium and zirconium alloys, and (2) stainless steel, carbon steel, tool steel, nickel and titanium alloys. The base materials in Group (1) have a much higher thermal conductivity than the base materials of Group (2). The hybrid materials comprise oxide layers on those metallic bases. The oxide layers have a dimple surface morphology and have high thermal conductivity and thermal emission properties.
The oxides are synthesized using a plasma oxidation process as described in a previous patent CA
2556869. The oxide layers are metallurgically growth from and bonded to the metallic substrate bases. Because there is no interfacial thermal resistance between the layers and substrates, the hybrid materials posses a thermal conductivity as high as 90 percent - 99 percent of thermal conductivity of the base materials of Group (1) have. The thermal transfer capability of the hybrid materials based on Group (1) is 3 to 5 times higher than that of ferrous materials including stainless steels, carbon steels and tool steels in Group (2). The thermal transfer performance of the hybrid materials based on Group (2) is increased by 10 percent -50 percent compared to their base materials of Group (2). The dimple surfaces provide capillary phenomena which are beneficial for condensation of water from vapor when the hybrid materials are used, for instance, in economizers or dehumidifiers.
The hybrid materials intend to be used to manufacture components for thermal exchange and heat recovery applications.
BRIEF DESCRIPTION OF THE DRAWING
FIGURE 1 is a schematic drawing of a cross section of a hybrid material, where the oxide layer is grown with a metallurgical bonding toward the substrate, and the oxide surface has dimples.
FIGURE 2 is a chart showing the thermal conductivity of a typical hybrid material compared with other reference materials.
DETAILED DESCRIPTION
The present invention can be applied to any metallic material including aluminum, magnesium, zirconium, titanium, nickel, stainless steel, tool steel and carbon steel. For ease of description, the process in the present invention will be described with reference to an aluminum alloy-based hybrid material. The same process can also be used to produce hybrid materials based on, for instance, magnesium, zirconium, titanium and nickel alloys as well as stainless steels, tool steels and carbon steels.
Taking an aluminum alloy for the base material, as an example in this invention, the alloy is treated using an electrolytic plasma oxidation process. The process has been described in a patent CA 2556869 where an alkaline electrolyte is applied to internal and external surfaces of a component made of the alloy. The component is biased with a voltage higher than 150 volts, and then plasma discharges are generated on the surface of the component. As a result, an oxide layer forms on the component. The oxide layer is metallurgically bonded to the substrate material without an interfacial separation. The oxide layer also has a large number of dimples on its surface, as shown in schematic drawing in FIGURE 1.
Therefore, the hybrid material comprises an oxide layer on aluminum substrate. Because of the oxide protective layer, the hybrid material has excellent corrosion and wear resistance properties.
The thermal conductivity of the hybrid material has been measured to be 140 W/m=K
when the base material used is a cast aluminum alloy, a material in Group (1).
The thermal conductivity is 2 to 5 times higher than that of stainless steel, P 20 steel and 1113 steel (materials in Group (2)), as shown in FIGURE 2. The hybrid material has a thermal conductivity 90 times higher than a typical oxide ceramic material.
The hybrid materials can also have a high thermal emission property through the integration of the oxide surfaces, which is critical for heat exchangers when the base materials are low thermal conductive stainless steels, carbon steels, titanium alloys and nickel alloys of Group (2).
The hybrid materials intend to be used to manufacture components for thermal exchangers and heat recovery systems.
For example, the shell and tube (u-tube) is the most common type of heat exchanger used in the process, petroleum, chemical and HVAC (heating, ventilation, and air conditioning) industries. It contains a number of parallel u-tubes (called tube bundle) inside a shell. Shell tube heat exchangers are used when a process requires large amounts of fluid to be heated or cooled. Due to their design, shell tube heat exchangers offer a large heat transfer area and provide high heat transfer efficiency. The tube bundle is usually made of stainless steel tubes which allow for strong, durable performance over a wide range of applications.
However, as shown in FIGURE 2, stainless steels have a relatively low thermal conductivity.
If the tube material is replaced with the hybrid materials described in this invention, the heat transfer efficiency can increase by 2-8 times.
The plate and shell heat exchanger offers increased flexibility of use by allowing the fully welded plate pack to be completely withdrawn from the shell for inspection or cleaning.
This is achieved by the use of a flanged and bolted shell construction. The cassette type plate pack allows quick and easy removal and refitting thus ensuring that process downtime is kept to a minimum. The welded plate pack is inserted and either welded or bolted within a steel frame. All liquid contact surfaces are manufactured in stainless steel or nickel that eliminates corrosion due to aggressive media. Again, the low conductive plate materials can be replaced with the hybrid material described in this invention, the heat transfer efficiency will increase by 2-8 times.
A plate and frame heat exchanger is another very efficient heat transfer device.
Specially formed individual thin plates are assembled to form the plate and frame heat exchangers "plate pack." A gasket between the plates seals the fluid and directs the flow. The end frames and heavy threaded rods compress the plate pack to create a highly efficient heat transfer device. The fluid flows through ports located on the frame(s). The plates are usually made of stainless steels. The low conductive stainless steel plates can be replaced with the invented hybrid material, the heat transfer efficiency will increase by 2-8 times.
Flue gas heat recovery systems are a simple and cost-effective way to capture the energy that is lost in flue gas exhaust and to use that energy elsewhere.
Installed in exhaust stacks for steam boilers, hot water boilers, or high temperature ovens for process work, waste heat can be recovered to heat air, water, or water glycol solutions. The boiler heat recovery is depending on the condensing economizer as previously mentioned. Water passes through a condensing economizer on its way to the boiler. Sensible heat is recovered from the maximum boiler exhaust temperature, staring in the range of 200-250 degrees Celsius C, down to the condensing point of the flue gas, approximately 55 degrees Celsius C. At the condensing point, water droplets form in the condensing economizer and are recovered. The latent heat is recovered in the phase change of the water when the vapor changes back into liquid. By preheating the boiler feed water with energy harvested from the exhaust stack gases, economizer can potentially recover a large amount of energy. The heat exchanging components in economizers are usually made of stainless steels. If the stainless steels are replaced by the hybrid materials which have a higher thermal conductivity and enhanced capillary condensation capability, the thermal transfer performance of the economizers will be further improved.
The heat recovery applications include gas turbines, commercial laundry services, hospital / hotel / institutional laundry wash water, textile manufacturers, vegetable wash water, glass manufacturing, industrial ovens, powder coating lines, paint lines, printing processes, food and pharmaceuticals, combustion air preheat.
Besides the above applications, the hybrid materials can also be used in heating and air conditioning systems for environmental controls of buildings and vehicles.
For instance, the hybrid materials can be used to manufacture evaporators in air conditioning systems of hotels, passenger cars and trucks. The dimple surface morphology on the hybrid material provides dehumidifying functions due to its capillary force effect which makes water condensations more readily than with normal finned tube economizers. The condensed water can be drained out or collected for other uses. The collected water can also be blown or sprayed back to the original climates for maintaining the relative humidity.
Thus, it can be used either ways for humidity climate control.
The last but not least example for applications of hybrid materials is mould industry.
A large number of plastic items are made by injection mould processes. Moulds are also needed to produce parts made by fibre-reinforced polymer composites. Those moulds are mostly made of low thermal conductive P20 or H13 steels. If the mould materials are replaced by the hybrid materials, the parts can be produced faster because the hybrid materials conduct heat better than steel and thus make the production cycle shorter. .
Example 1. Heat Exchanger A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall, so that they never mix, or they may be in direct contact. They are widely used in space heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment.
Currently, the solid wall, that is a heat exchanging tube or plate, is mostly made of stainless steel or nickel alloy since they have the required mechanical and anti-corrosion properties. However, both stainless steels and nickel alloys have a low thermal conductivity which is 3 to 5 times lower than that of hybrid materials developed in this invention. The hybrid materials have the improved thermal, mechanical and anti-corrosion properties at high temperatures in dry and wet environments. The hybrid materials can be used to produce tubes, plates and other shaped parts as heat exchanging components. Because of the high thermal conductivity of the hybrid materials, the heat transfer efficiency of the components can be increased by approximately 5-8 times.
Example 2. Climate Control A wide use of heat exchangers is for air conditioning of buildings and vehicles. Fins or plates in the heat exchangers are improvably made by the hybrid materials with the dimple morphology on their surfaces. Since the dimple morphology increase surface areas and has capillary phenomena, the moisture in the air is condensed, collected, and retained on the fin and plate surfaces in the form of a thin layer of water spreading on the entire surfaces of the fins and plates, which increases the area of evaporation of the condensed water. The evaporated water is then blown back to the climates, and as a result, the relative degree of humidity can be maintained at the different temperatures of the air.
This method can be used for preservation of food products and other instances when it is desirable to maintain a given degree of humidity in the air.
This method can also be used for climate controls of building and vehicles in dry regions such as deserts.
Example 3. Dehumidifying Another use of heat exchangers is for dehumidifying of buildings and vehicles.
Fins or plates in the heat exchangers are improvably made by the hybrid materials with the dimple morphology on their surfaces. Since the dimple morphology increase surface areas and has capillary phenomena, the moisture in the air is readily condensed, collected, and drained away if there is no reservoir underneath of the fins and plates. The moisture is then taken away from the climates, and as a result, the relative degree of humidity can be reduced to a comfortable level.
Example 4. Moulds The hybrid materials can be used to make injection moulds for plastics and composite manufacturing industry. By using the hybrid materials to replace the traditional steel materials, plastic and composite parts can be produced faster because the hybrid materials conduct heat better and thus make the production cycle shorter.
The field of the invention is the preparation of hybrid materials with improved thermal transfer properties for heat exchange and energy recovery applications.
BACKGROUND OF THE INVENTION
With the increasing concern in energy consumption and environmental pollution, improvement in energy efficiency to save fuels and reduce emission is a great deal. There is a need in development of new materials with enhanced thermal transfer capability for heat exchange and energy recovery applications.
For example, a typical natural gas steam generator contains three heat exchange coils, namely an economizer for preheating boiler feed water, an evaporator for generating high pressure steam and a super heater for heating the high pressure steam into superheated steam.
After removing fines, the cooled flue gas may then be discharged into the stack. The boiler-generated steam remains an effective method of heat transfer for most process and manufacturing applications; however, a tremendous amount of energy and water can be lost.
In natural gas combustion products, approximately 18 percent is water vapor.
If the water vapor is left to escape with exhaust, it carries about 10 percent of the input energy with it. So a system can never exceed 90% efficiency if this moisture escapes.
Fuel cost and environmental regulation have created a strong demand for cost-effective solutions to enhance boiler performance to reduce use of natural gas, fuel and other energy forms, decrease water consumption, and lower greenhouse emissions. One of methods to increase performance of the boiler is heat recovery. Heat recovery systems are to recover both sensible and latent heat, as well as water from the exhaust stream. The recovery heat can be used to preheat boiler feed water and thus improve boiler efficiency.
The boiler heat recovery is depending on the condensing economizer. Water passes through a condensing economizer on its way to the boiler. Sensible heat is recovered from the maximum boiler exhaust temperature, staring in the range of 250 degrees Celsius C, down to the condensing point of the flue gas, approximately 55 degrees Celsius C. At the condensing point, or called dew point, water droplets form in the condensing economizer and are recovered. The latent heat is recovered in the phase change of the water when the vapor changes back into liquid. By preheating the boiler feed water with energy harvested from the exhaust stack gases, economizer can potentially recover a large amount of energy and as a result, reduce the otherwise large emission footprint.
Lower flue gas discharge temperatures indicate greater heat recovery from the flue gas, meaning that more thermal energy has been transferred from flue gas back to the boiler feed water. To increase the recovery efficiency of the economizer itself, higher thermal conductive components are needed. Currently, most economizers are made of stainless steels and nickel alloys since they have the required mechanical and anti-corrosion properties.
However, both stainless steels and nickel alloys have a low thermal conductivity which is 3 to 5 times lower than that of aluminum, magnesium and zirconium alloys. From the thermal transferring capability point of view, those non-ferrous alloys should be used to make the heat exchanging components of, for instance, economizers. Unfortunately, the non-ferrous alloys can not withstand high temperatures and they are suspicious to corrosion problems.
There is a great need in development of materials which have the improved thermal, mechanical and anti-corrosion properties at high temperatures in dry and wet environments. This invention puts forward hybrid materials with improved thermal properties for enhancing performance of the heat exchange and energy recovery systems.
SUMMARY OF THE INVENTION
In this invention, the hybrid materials are synthesized based on two groups of metallic materials: (1) aluminium, magnesium and zirconium alloys, and (2) stainless steel, carbon steel, tool steel, nickel and titanium alloys. The base materials in Group (1) have a much higher thermal conductivity than the base materials of Group (2). The hybrid materials comprise oxide layers on those metallic bases. The oxide layers have a dimple surface morphology and have high thermal conductivity and thermal emission properties.
The oxides are synthesized using a plasma oxidation process as described in a previous patent CA
2556869. The oxide layers are metallurgically growth from and bonded to the metallic substrate bases. Because there is no interfacial thermal resistance between the layers and substrates, the hybrid materials posses a thermal conductivity as high as 90 percent - 99 percent of thermal conductivity of the base materials of Group (1) have. The thermal transfer capability of the hybrid materials based on Group (1) is 3 to 5 times higher than that of ferrous materials including stainless steels, carbon steels and tool steels in Group (2). The thermal transfer performance of the hybrid materials based on Group (2) is increased by 10 percent -50 percent compared to their base materials of Group (2). The dimple surfaces provide capillary phenomena which are beneficial for condensation of water from vapor when the hybrid materials are used, for instance, in economizers or dehumidifiers.
The hybrid materials intend to be used to manufacture components for thermal exchange and heat recovery applications.
BRIEF DESCRIPTION OF THE DRAWING
FIGURE 1 is a schematic drawing of a cross section of a hybrid material, where the oxide layer is grown with a metallurgical bonding toward the substrate, and the oxide surface has dimples.
FIGURE 2 is a chart showing the thermal conductivity of a typical hybrid material compared with other reference materials.
DETAILED DESCRIPTION
The present invention can be applied to any metallic material including aluminum, magnesium, zirconium, titanium, nickel, stainless steel, tool steel and carbon steel. For ease of description, the process in the present invention will be described with reference to an aluminum alloy-based hybrid material. The same process can also be used to produce hybrid materials based on, for instance, magnesium, zirconium, titanium and nickel alloys as well as stainless steels, tool steels and carbon steels.
Taking an aluminum alloy for the base material, as an example in this invention, the alloy is treated using an electrolytic plasma oxidation process. The process has been described in a patent CA 2556869 where an alkaline electrolyte is applied to internal and external surfaces of a component made of the alloy. The component is biased with a voltage higher than 150 volts, and then plasma discharges are generated on the surface of the component. As a result, an oxide layer forms on the component. The oxide layer is metallurgically bonded to the substrate material without an interfacial separation. The oxide layer also has a large number of dimples on its surface, as shown in schematic drawing in FIGURE 1.
Therefore, the hybrid material comprises an oxide layer on aluminum substrate. Because of the oxide protective layer, the hybrid material has excellent corrosion and wear resistance properties.
The thermal conductivity of the hybrid material has been measured to be 140 W/m=K
when the base material used is a cast aluminum alloy, a material in Group (1).
The thermal conductivity is 2 to 5 times higher than that of stainless steel, P 20 steel and 1113 steel (materials in Group (2)), as shown in FIGURE 2. The hybrid material has a thermal conductivity 90 times higher than a typical oxide ceramic material.
The hybrid materials can also have a high thermal emission property through the integration of the oxide surfaces, which is critical for heat exchangers when the base materials are low thermal conductive stainless steels, carbon steels, titanium alloys and nickel alloys of Group (2).
The hybrid materials intend to be used to manufacture components for thermal exchangers and heat recovery systems.
For example, the shell and tube (u-tube) is the most common type of heat exchanger used in the process, petroleum, chemical and HVAC (heating, ventilation, and air conditioning) industries. It contains a number of parallel u-tubes (called tube bundle) inside a shell. Shell tube heat exchangers are used when a process requires large amounts of fluid to be heated or cooled. Due to their design, shell tube heat exchangers offer a large heat transfer area and provide high heat transfer efficiency. The tube bundle is usually made of stainless steel tubes which allow for strong, durable performance over a wide range of applications.
However, as shown in FIGURE 2, stainless steels have a relatively low thermal conductivity.
If the tube material is replaced with the hybrid materials described in this invention, the heat transfer efficiency can increase by 2-8 times.
The plate and shell heat exchanger offers increased flexibility of use by allowing the fully welded plate pack to be completely withdrawn from the shell for inspection or cleaning.
This is achieved by the use of a flanged and bolted shell construction. The cassette type plate pack allows quick and easy removal and refitting thus ensuring that process downtime is kept to a minimum. The welded plate pack is inserted and either welded or bolted within a steel frame. All liquid contact surfaces are manufactured in stainless steel or nickel that eliminates corrosion due to aggressive media. Again, the low conductive plate materials can be replaced with the hybrid material described in this invention, the heat transfer efficiency will increase by 2-8 times.
A plate and frame heat exchanger is another very efficient heat transfer device.
Specially formed individual thin plates are assembled to form the plate and frame heat exchangers "plate pack." A gasket between the plates seals the fluid and directs the flow. The end frames and heavy threaded rods compress the plate pack to create a highly efficient heat transfer device. The fluid flows through ports located on the frame(s). The plates are usually made of stainless steels. The low conductive stainless steel plates can be replaced with the invented hybrid material, the heat transfer efficiency will increase by 2-8 times.
Flue gas heat recovery systems are a simple and cost-effective way to capture the energy that is lost in flue gas exhaust and to use that energy elsewhere.
Installed in exhaust stacks for steam boilers, hot water boilers, or high temperature ovens for process work, waste heat can be recovered to heat air, water, or water glycol solutions. The boiler heat recovery is depending on the condensing economizer as previously mentioned. Water passes through a condensing economizer on its way to the boiler. Sensible heat is recovered from the maximum boiler exhaust temperature, staring in the range of 200-250 degrees Celsius C, down to the condensing point of the flue gas, approximately 55 degrees Celsius C. At the condensing point, water droplets form in the condensing economizer and are recovered. The latent heat is recovered in the phase change of the water when the vapor changes back into liquid. By preheating the boiler feed water with energy harvested from the exhaust stack gases, economizer can potentially recover a large amount of energy. The heat exchanging components in economizers are usually made of stainless steels. If the stainless steels are replaced by the hybrid materials which have a higher thermal conductivity and enhanced capillary condensation capability, the thermal transfer performance of the economizers will be further improved.
The heat recovery applications include gas turbines, commercial laundry services, hospital / hotel / institutional laundry wash water, textile manufacturers, vegetable wash water, glass manufacturing, industrial ovens, powder coating lines, paint lines, printing processes, food and pharmaceuticals, combustion air preheat.
Besides the above applications, the hybrid materials can also be used in heating and air conditioning systems for environmental controls of buildings and vehicles.
For instance, the hybrid materials can be used to manufacture evaporators in air conditioning systems of hotels, passenger cars and trucks. The dimple surface morphology on the hybrid material provides dehumidifying functions due to its capillary force effect which makes water condensations more readily than with normal finned tube economizers. The condensed water can be drained out or collected for other uses. The collected water can also be blown or sprayed back to the original climates for maintaining the relative humidity.
Thus, it can be used either ways for humidity climate control.
The last but not least example for applications of hybrid materials is mould industry.
A large number of plastic items are made by injection mould processes. Moulds are also needed to produce parts made by fibre-reinforced polymer composites. Those moulds are mostly made of low thermal conductive P20 or H13 steels. If the mould materials are replaced by the hybrid materials, the parts can be produced faster because the hybrid materials conduct heat better than steel and thus make the production cycle shorter. .
Example 1. Heat Exchanger A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another. The media may be separated by a solid wall, so that they never mix, or they may be in direct contact. They are widely used in space heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment.
Currently, the solid wall, that is a heat exchanging tube or plate, is mostly made of stainless steel or nickel alloy since they have the required mechanical and anti-corrosion properties. However, both stainless steels and nickel alloys have a low thermal conductivity which is 3 to 5 times lower than that of hybrid materials developed in this invention. The hybrid materials have the improved thermal, mechanical and anti-corrosion properties at high temperatures in dry and wet environments. The hybrid materials can be used to produce tubes, plates and other shaped parts as heat exchanging components. Because of the high thermal conductivity of the hybrid materials, the heat transfer efficiency of the components can be increased by approximately 5-8 times.
Example 2. Climate Control A wide use of heat exchangers is for air conditioning of buildings and vehicles. Fins or plates in the heat exchangers are improvably made by the hybrid materials with the dimple morphology on their surfaces. Since the dimple morphology increase surface areas and has capillary phenomena, the moisture in the air is condensed, collected, and retained on the fin and plate surfaces in the form of a thin layer of water spreading on the entire surfaces of the fins and plates, which increases the area of evaporation of the condensed water. The evaporated water is then blown back to the climates, and as a result, the relative degree of humidity can be maintained at the different temperatures of the air.
This method can be used for preservation of food products and other instances when it is desirable to maintain a given degree of humidity in the air.
This method can also be used for climate controls of building and vehicles in dry regions such as deserts.
Example 3. Dehumidifying Another use of heat exchangers is for dehumidifying of buildings and vehicles.
Fins or plates in the heat exchangers are improvably made by the hybrid materials with the dimple morphology on their surfaces. Since the dimple morphology increase surface areas and has capillary phenomena, the moisture in the air is readily condensed, collected, and drained away if there is no reservoir underneath of the fins and plates. The moisture is then taken away from the climates, and as a result, the relative degree of humidity can be reduced to a comfortable level.
Example 4. Moulds The hybrid materials can be used to make injection moulds for plastics and composite manufacturing industry. By using the hybrid materials to replace the traditional steel materials, plastic and composite parts can be produced faster because the hybrid materials conduct heat better and thus make the production cycle shorter.
Claims (22)
1. A process for producing a hybrid material having an enhanced thermal transfer capability.
2. The process according to Claim 1 wherein said hybrid material comprises an oxide layer on a metallic item.
3. The process according to Claim 2 wherein said oxide is metallurgically bonded on the said metallic item.
4. The process according to Claim 1 wherein said oxide has a high thermal conductivity.
5. The process according to Claim 1 wherein said oxide has a high thermal emission property.
6. The process according to Claim 1 wherein said hybrid material has a dimple surface morphology.
7. The process according to Claim 2 wherein said metallic item is an aluminum alloy.
8. The process according to Claim 2 wherein said metallic item is a magnesium alloy.
9. The process according to Claim 2 wherein said metallic item is a zirconium alloy.
10. The process according to Claim 2 wherein said metallic item is a titanium alloy.
11. The process according to Claim 2 wherein said metallic item is a nickel alloy.
12. The process according to Claim 2 wherein said metallic item is a stainless steel.
13. The process according to Claim 2 wherein said metallic item is a tool steel.
14. The process according to Claim 2 wherein said metallic item is a carbon steel.
15. The process according to Claim 3 wherein said oxide is synthesized using a plasma oxidation process.
16. The process according to Claim 6 wherein the dimple surface morphology enhances liquid condensation.
17. The process according to Claims 6 and 16 wherein the dimple surface morphology enhances water condensation.
18. The process according to Claim 1 wherein said hybrid material is used to manufacture components in thermal exchangers.
19. The process according to Claim 1 wherein said hybrid material is used to manufacture components in heat recovery systems.
20. The process according to Claim 1 wherein said hybrid material is used to manufacture components in condensing economizer systems.
21. The process according to Claim 1 wherein said hybrid material is used to manufacture components in evaporators of air conditioning systems.
22. The process according to Claim 1 wherein said hybrid material is used to manufacture components in injection moulds and die casting moulds.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2759154 CA2759154A1 (en) | 2011-11-18 | 2011-11-18 | Hybrid materials with enhanced thermal transfer capability |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA 2759154 CA2759154A1 (en) | 2011-11-18 | 2011-11-18 | Hybrid materials with enhanced thermal transfer capability |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2759154A1 true CA2759154A1 (en) | 2013-05-18 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA 2759154 Abandoned CA2759154A1 (en) | 2011-11-18 | 2011-11-18 | Hybrid materials with enhanced thermal transfer capability |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102015117825A1 (en) | 2014-12-23 | 2016-06-23 | Zapadoceska Univerzita V Plzni | Hot deformation process for hybrid parts |
| US11584115B2 (en) | 2020-01-31 | 2023-02-21 | Zapadoceska Univerzita V Plzni | Method of manufacturing hybrid parts consisting of metallic and non-metallic materials at high temperature |
-
2011
- 2011-11-18 CA CA 2759154 patent/CA2759154A1/en not_active Abandoned
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE102015117825A1 (en) | 2014-12-23 | 2016-06-23 | Zapadoceska Univerzita V Plzni | Hot deformation process for hybrid parts |
| US10060000B2 (en) | 2014-12-23 | 2018-08-28 | Západoceská Univerzita V Plzni | Method of hot forming hybrid parts |
| US11584115B2 (en) | 2020-01-31 | 2023-02-21 | Zapadoceska Univerzita V Plzni | Method of manufacturing hybrid parts consisting of metallic and non-metallic materials at high temperature |
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