The custom micro channel perforated plate allows contactless heat exchange between the high temperature radiator circuit and the domestic hot water circuit. Moreover, it is one of the most important elements of the boiler.
For this reason, the exchanger must be cleaned frequently, especially to remove the limescale that forms inside it and replace the micro channel plate as soon as there are malfunctions and serious blockages.
Let's see together in this article how and when to replace the micro channel plate.
- How does the micro channel plate work?
- When to replace the micro channel plate, encrusted with limescale
- Who to contact to replace the micro channel plate?
How does custom micro channel perforated plate work?
The micro channel plate allows contactless heat exchange between the two circuits: the high temperature radiator circuit and the domestic hot water circuit. Moreover, these 2 circuits cross in countercurrent to improve heat exchange.
It works by means of a system of plates, generally metallic, although the material can vary depending on the model.
The plates are thin and slightly spaced, this allows for better heat recovery.
When to replace the micro channel, plate encrusted with limescale
Limestone, in fact, leads to various failures and malfunctions: it reduces the flow and pressure of hot water; leads to changes in custom micro channel perforated plate of boiler temperature when it is in operation. However, it can cause water leaks from the boiler or, in the worst case, cause the boiler to block.
Who should I contact to replace the micro channel plate?
Moreover, the micro channel plate has a life of about 3 years, its life span depends in particular on:
- The frequency of use of the boiler,
- The set temperature
- The amount of limescale present in the water.
To preserve the boiler and all parts of the device subject to wear, we recommend setting the water temperature to 45 ° C and equipping the boiler with an anti-limescale filter.
This is not an operation to be taken lightly
It is not easy to access the exchanger and disassemble it. If you are not a professional, you could risk damaging the boiler irreparably. The replacement of the custom micro channel perforated plate therefore requires the presence of an expert technician, who knows the boiler mechanisms and all the individual elements well, even if you are practical with DIY. Moreover, it is not an operation that we recommend you do.
Reliable, safe and easy to maintain, plate heat exchangers replace the outdated shell and tube units. They better cope with the transfer of energy from the primary to the secondary circuit and perfectly withstand pressure fluctuations. However, the devices are much smaller and work faster.
In this article, we will consider in detail the design of a custom micro channel perforated plate heat exchanger. The principle of operation of the equipment, the scope and features of the operation of these high-performance units.
Plate heat exchanger: element Features
The efficiency of the shell-and-tube units is increased by increasing the length of the coil. Moreover, at the same time, even large-sized installations in many cases cannot provide the required level of flow of the heated medium.
With plate heat exchangers, the situation is different. The energy transfer area is adjusted by adding and removing custom micro channel perforated plate of the same size. Devices with smaller dimensions cope much better with their tasks and provide a large flow of heated fluid. However, this, for example, is especially important for the needs of domestic hot water.
Moreover, consider the design features and principle of operation of plate heat exchangers in more detail.
Scheme of a typical plate heat exchanger
The composition of a typical heat exchanger includes the following elements:
- Branch pipes (supply and return) for connecting the primary circuit
- Front (fixed) and rear (movable) plates
- Branch pipes (inlet and outlet) for connecting the secondary circuit
- Holes for the coolant flow
- Working plate
- Small sealing gasket (ring)
- Guides (upper and lower)
- Rear support
- Hairpin
- A large gasket located along the contour of the plate
Relief corrugation is made on each custom micro channel perforated plate. This increases the heat transfer surface. The elements arrange at an angle of 180° to each other.
Branch pipes can be located both on both sides of the apparatus, and on one side. Moreover, the principle of operation of a plate heat exchanger does not change from this.
Features of the manufacture of heat exchange plates
Stainless steel is common for the production of plates for heat exchangers. It perfectly resists the effects of high temperatures and low-quality media. The main elements of heat exchangers obtain by stamping.
Only in this way can a corrugated board be made while maintaining the key characteristics of the metal. Not every stainless steel is suitable for the production of custom micro channel perforated plate. Manufacturers use special brands.
Off-Set technology is common to obtain a relief surface. As a result, grooves appear on the products, which may or may not be symmetrical. Moreover, the relief increases the area of contact of the plates with the coolant and the heated medium and serves to evenly distribute liquids.
Use of corrugation for the production of heat exchange plates
Manufacturers use two types of corrugation for the production of heat exchange plates.
- Thermally hard. The grooves are at an angle of 30°. Plates with rigid corrugation have maximum thermal conductivity, but do not withstand high pressure from the circulating coolant.
- Thermally soft. The grooves are at an angle of 60°. Such custom micro channel perforated plate, on the contrary, withstand high pressure, but characterize by low thermal conductivity.
By combining plates of different types, you can create a heat exchanger with the most optimal efficiency. In this case, one should take into account the fact that for effective operation the apparatus must operate in a turbulent regime. Moreover, it is necessary to ensure that, with high heat transfer, the liquid flows through the channels without difficulty.
Features of the manufacture and fastening of gaskets
To obtain maximum tightness, gaskets for custom micro channel perforated plate are made from various polymeric materials. Materials withstand different loads. The operating temperature range of ethylene propylene is from -30 to + 170 °C. The maximum limit for NBR is +110 °C.
Gaskets attach to the plates with clips and adhesives. The first method is common much more often.
Moreover, the alignment of the gaskets along the guides occurs automatically. In the process of installing the plates, you do not have to support or push anything. The cuff edging creates a reliable barrier that excludes the possibility of coolant leakage.
Working principle of high-speed plate heat exchanger
The principle of operation of a custom micro channel perforated plate heat exchanger is as follows. The space between the plates fill alternately with a heated medium and a coolant. Moreover, the sequence regulates by gaskets. In one section, they open the way to the coolant, and in the other - to the heated medium.
In conclusion, during the operation of a high-speed plate heat exchanger, intensive energy transfer occurs in all sections, except for the first and last. Liquids move towards each other.
