U.S. patent application number 09/768099 was filed with the patent office on 2001-09-06 for heat exchanger for preheating an oxidizing gas.
This patent application is currently assigned to American Air Liquide Inc.. Invention is credited to Borders, Harley A., Charon, Olivier, Fossen, Arnaud, Joshi, Mahendra L., Tsiava, Remi Pierre.
Application Number | 20010018962 09/768099 |
Document ID | / |
Family ID | 22824022 |
Filed Date | 2001-09-06 |
United States Patent
Application |
20010018962 |
Kind Code |
A1 |
Joshi, Mahendra L. ; et
al. |
September 6, 2001 |
Heat exchanger for preheating an oxidizing gas
Abstract
A heat exchanger useful for preheating oxidizing gases in a
combustion process includes a shell having an inlet and an outlet
for the ingress and egress of a first heat exchange fluid, such as
a flue gas or preheated air. A first tube manifold couples an inlet
end-cap to the first end of the shell. The inlet end-cap has an
inlet for receiving a second heat exchange fluid, such as an
oxidizing gas. In one embodiment, a second manifold couples an
outlet end-cap to the second end of the shell. The second manifold
includes an outlet tube therein extending from the second manifold
through an outlet opening in the outlet end-cap. A tube bundle is
disposed within the shell for transporting the oxidizing gas
through the heat exchanger and is coupled to the first and second
tube manifolds. The outlet tube collects oxidizing gas flowing
through the tube bundle for discharge to a combustion system. The
outlet end-cap is pressurized with an inert atmosphere and houses a
chemical detector to detect the presence of oxidizing gas within
the outlet end-cap.
Inventors: |
Joshi, Mahendra L.; (Darien,
IL) ; Fossen, Arnaud; (Justice, IL) ; Borders,
Harley A.; (Lombard, IL) ; Tsiava, Remi Pierre;
(Grigny, FR) ; Charon, Olivier; (Chicago,
IL) |
Correspondence
Address: |
Jasper W. Dockrey
BRINKS HOFER GILSON & LIONE
P.O. BOX 10395
CHICAGO
IL
60610
US
|
Assignee: |
American Air Liquide Inc.
|
Family ID: |
22824022 |
Appl. No.: |
09/768099 |
Filed: |
January 23, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09768099 |
Jan 23, 2001 |
|
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|
09220559 |
Dec 23, 1998 |
|
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Current U.S.
Class: |
165/11.1 ;
165/158; 165/163; 165/70 |
Current CPC
Class: |
F28F 13/08 20130101;
F28F 2265/16 20130101; F28D 7/1607 20130101; F28F 9/0219 20130101;
F28F 9/0236 20130101; F28F 2275/20 20130101; F28F 9/26 20130101;
F28F 9/0229 20130101; F28D 7/06 20130101; F28F 27/00 20130101 |
Class at
Publication: |
165/11.1 ;
165/70; 165/163; 165/158 |
International
Class: |
F28F 001/00; F28F
011/00; F28F 009/02; F28D 001/00 |
Claims
1. A heat exchanger for preheating an oxidizing gas comprising: a
shell having an inlet and an outlet for respectively permitting the
ingress and the egress of a first heat exchange fluid comprising a
gas selected from the group consisting of flue gas and preheated
air; a first chamber having an inlet for receiving a second heat
exchange fluid, the second heat exchange fluid comprising an
oxidizing gas; an inner tube; a first manifold configured to
transfer the second heat exchange fluid from the first chamber to
the inner tube; a second chamber having an outlet tube extending
through an opening therein; a second manifold configured to
transfer the second heat exchange fluid from the inner tube to the
outlet tube, wherein the second chamber contains a gas different
from the second heat exchange fluid; and a chemical detector
configured to detect the presence of the oxidizing gas.
2. The heat exchanger of claim 1, wherein the inner tube comprises
a multi-pass tube bundle disposed about a longitudinal axis within
the shell, wherein the tube bundle includes a plurality of tubes
arranged about the longitudinal axis, each tube characterized by a
tube diameter, and wherein tubes positioned proximal to the
longitudinal axis have a larger tube diameter than tubes positioned
distal to the longitudinal axis.
3. The heat exchanger of claim 2, wherein the tube bundle includes
first, second, and third pass tubes and, wherein first and second
pass tubes are positioned distal to the longitudinal axis, and
wherein third pass tubes are positioned proximal to the
longitudinal axis.
4. The heat exchanger of claim 3, wherein the first manifold
comprises: a first transverse segment adjacent to a second
transverse segment, the first transverse segment having a plurality
of holes therethrough proximal to the longitudinal axis, and a
plurality of passageway therein distal to the longitudinal axis,
wherein the second transverse segment includes a first plurality of
holes therethrough for receiving the first pass tubes, a second
plurality of holes for receiving the second pass tubes, and a third
plurality of holes for receiving the third pass tubes, and wherein
the first transverse segment is aligned with the second transverse
segment so as to form a fluid pathway from the first end-cap to the
first pass tubes, and to form a reversing fluid pathway from the
second pass tubes through the plurality of passageways and into the
third pass tubes.
5. The heat exchanger of claim 3, wherein the second manifold
comprises: a first transverse segment adjacent to a second
transverse segment, the first transverse segment having a first
plurality of holes therethrough for receiving the first pass tubes,
a second plurality of holes therethrough for receiving the second
pass tubes, and a third plurality of holes therethrough for
receiving the third pass tubes; and the second transverse segment
having a plurality of passageways distal to the longitudinal axis
and a hole therethrough proximal to the longitudinal axis for
receiving the outlet tube, wherein the first transverse segment is
aligned with the second transverse segment so as to form a
reversing fluid pathway from the first pass tubes to the second
pass tubes and to form a fluid pathway from the third pass tubes to
the outlet tube.
6. The heat exchanger of claim 1 further comprising: a first flange
at an inlet end of the inner tube; first and second gaskets
adjacent to either side of the flange; and a coupling portion of
the first manifold having a bore therein for receiving the first
flange and the first and second gaskets.
7. The heat exchanger of claim 6, wherein the first gasket resides
at a location distal to the first chamber and the second gasket
resides at a location proximal to the first chamber, and wherein
the first gasket is comprised of alumina-silica ceramic fiber, and
the second gasket is comprised of a material selected from the
group consisting of a metal fiber and copper.
8. The heat exchanger of claim 6 further comprising: a second
flange at an outlet end of the inner tube; first and second gaskets
adjacent to either side of the second flange; and a coupling
portion of the second manifold having a bore therein for receiving
the second flange and the first and second gaskets.
9. The heat exchanger of claim 6, wherein the first gasket resides
at a location distal to the second chamber and the second gasket
resides at a location proximal to the second chamber, and wherein
the first gasket is comprised of alumina-silica ceramic fiber, and
the second gasket is comprised of a material selected from the
group consisting of a metal fiber and copper.
10. A heat exchanger for preheating an oxidizing gas comprising: a
shell having a first manifold at a first end and a second manifold
at a second end, and having an inlet and an outlet for respectively
permitting the ingress and egress of a first heat exchange fluid;
at least one tube disposed within the shell for transporting the
second heat exchange fluid therethrough and engaging the first
manifold and the second manifold at a first side of the first
manifold and at a first side of the second manifold; an inlet
chamber adjacent to a second side of the first manifold, the inlet
chamber having an opening for receiving a second heat exchange
fluid, the second heat exchange fluid comprising an oxidizing gas;
an outlet chamber adjacent to a second side of the second manifold,
the outlet chamber having an outlet opening therein; an outlet tube
coupled to the second side of the second manifold passing through
the outlet opening in the outlet chamber and configured to receive
the second heat exchange fluid, wherein the outlet chamber contains
an inert atmosphere; and a gas analyzer in communication with the
inert atmosphere and configured to detect the oxidizing gas.
11. The heat exchanger of claim 10, wherein the at least one tube
comprises a multi-pass tube bundle disposed about a longitudinal
axis within the shell, wherein the tube bundle includes a plurality
of tubes arranged about the longitudinal axis, each tube
characterized by a tube diameter, and wherein tubes positioned
proximal to the longitudinal axis have a larger tube diameter than
tubes positioned distal to the longitudinal axis.
12. The heat exchanger of claim 11, wherein first and second pass
tubes are positioned distal to the longitudinal axis, and wherein
third pass tubes are positioned proximal to the longitudinal
axis.
13. The heat exchanger of claim 11, wherein the gas analyzer
comprises an oxygen detector.
14. The heat exchanger of claim 10 further comprising a
thermocouple mounted to an instrument port on the outlet chamber
and configured to measure the temperature of the outlet tube.
15. The heat exchanger of claim 10, wherein the inert gas is
selected from the group consisting of nitrogen, argon, and mixtures
thereof.
16. A heat exchanger for preheating an oxidizing gas comprising: a
shell having an inlet and an outlet for permitting the ingress and
egress of a gas selected from the group consisting of flue gas and
preheated air; at least one tube longitudinally disposed within the
shell and configured to receive an oxidizing gas, an inlet manifold
transversely positioned at an inlet end of the shell and configured
to receive a first end portion of the at least one tube; an outlet
manifold transversely positioned at an outlet end of the shell and
configured to receive a second end portion of the at least one
tube; an inlet end-cap positioned around the segmented inlet
manifold and coupled to the inlet end of the shell; and an outlet
end-cap having an axial opening therein, the end-cap positioned
around the segmented outlet manifold and sealed to the outlet end
of the shell; an outlet tube partially inserted into an opening in
the segmented outlet manifold and passing through the axial opening
of the outlet end-cap, wherein the outlet tube is in communication
with the at least one tube; an inert atmosphere within the outlet
end-cap; means in communication with the inert atmosphere for
detecting the presence of the oxidizing gas within the inert
atmosphere; and means mounted to the outlet end-cap for measuring
the temperature of the outlet tube.
17. The heat exchanger of claim 16 further comprising an expansion
bellows integral with the shell.
18. The heat exchanger of claim 16, wherein a tube bundle is
longitudinally disposed within the shell, and wherein the tube
bundle includes a plurality of parallel spaced tubes.
19. The heat exchanger of claim 18, wherein the plurality of
parallel-spaced tubes have inner tube walls of iron nickel chromium
alloy lined with a ceramic material, and wherein the oxidizing gas
comprises oxygen.
20. The heat exchanger of claim 18, wherein the plurality of
parallel-spaced tubes comprise first pass tubes, second pass tubes,
and third pass tubes, and wherein the first and second pass tubes
are alternatingly arranged about a longitudinal axis at a first
radial distance, and wherein the third pass tubes are arranged
about the longitudinal axis at a second radial distance, and
wherein the first radial distance is greater than the second radial
distance.
21. The heat exchanger of claim 20, wherein each of the first,
second, and third pass tubes are characterized by a diameter, and
wherein the diameter of the first pass tubes is less than the
diameter of the second pass tubes, and wherein the diameter of the
second pass tubes is less than the diameter of the third pass
tubes.
22. The heat exchanger of claim 16, wherein the means for measuring
the temperature comprises a thermocouple.
23. A heat exchanger for preheating an oxidizing gas comprising: a
shell having an inlet and an outlet for permitting the ingress and
egress of a heating gas selected from the group consisting flue gas
and preheated air; a tubular oxidizing gas pathway disposed within
the shell, the pathway configured to receive an oxidizer gas at an
inlet and to discharge the oxidizer gas at an outlet, wherein the
tube diameter increases along the direction of oxidizing gas flow,
such that the tube diameter at the inlet is smaller than the tube
diameter at the outlet, and wherein the oxidizing gas pathway is of
metallic weld-free construction, such that only weld-free metallic
surfaces are exposed to the oxidizing gas.
24. The heat exchanger of claim 23, wherein the oxidizing gas
pathway comprises: a plurality of parallel-spaced tubes
longitudinally disposed within the metallic shell between a first
manifold and a second manifold, each tube having an inner tube wall
of a high-temperature metallic alloy lined with ceramic material,
wherein the plurality of parallel-spaced tubes include first pass
tubes and third pass tubes configured to receive an oxidizing gas
at the first manifold and to discharge the oxidizing fluid at a
second manifold, and second pass tubes configured to receive the
oxidizing gas at the second manifold and to discharge the oxidizing
gas at the first manifold.
25. The heat exchanger of claim 24, wherein the ceramic material is
selected from the group consisting of aluminum oxide, zirconium
oxide, chromium oxide, silica, and rare earth oxides.
26. The heat exchanger of claim 25, wherein the first and second
manifolds comprise iron, nickel chromium alloy coated with a
metallic oxide ceramic material.
27. The heat exchanger of claim 24, wherein the first pass tubes
are arranged in a first square pattern, the second pass tubes are
arranged in a second square pattern, and the third pass tubes are
arranged in a third square pattern, and wherein the centers of the
first pass tubes are located at the corners of the first square
pattern, the centers of the second pass tubes are located at the
corners of the second square pattern, and intersect the first
square pattern at the midpoint of each side of the first square
pattern, and the centers of the third pass tubes are located at the
corners of the third square pattern and intersect the midpoints of
each side of the second square pattern.
28. The heat exchanger of claim 24, wherein the first pass tubes
are arranged in a first square pattern, the second pass tubes are
arranged in a second square pattern, and the third pass tubes are
arranged in a third square pattern, and wherein the first pass
tubes, the second pass tubes and the third pass tubes are
positioned at the corners of the first, second, and third square
pattern, respectively, and the tube walls of each first pass tube
are tangent to two sides of the first square pattern, the tube
walls of the second pass tubes are tangent to two sides of the
second square pattern, and the third pass tubes are tangent to two
sides of the third square pattern.
29. A heat exchanger for preheating an oxidizing gas comprising: a
shell having an inlet and an outlet for respectively permitting the
ingress and the egress of a first heat exchange fluid; a chamber
having an inlet for receiving a second heat exchange fluid, the
second heat exchange fluid comprising an oxidizer; a U-shaped inner
tube having a first end and a second end; a manifold configured to
transfer the second heat exchange fluid from the chamber to the
first end of the U-shaped inner tube and to receive the second heat
exchange fluid from the second end of the U-shaped tube, wherein
the end-cap contains a gas atmosphere different from the second
heat exchange fluid; and a chemical detector in communication with
the gas atmosphere and configured to detect the presence of the
oxidizing gas.
30. The heat exchanger of claim 29, wherein the U-shaped tube
comprises a tube bundle disposed about a longitudinal axis within
the shell, wherein the tube bundle includes a plurality of tubes
arranged about the longitudinal axis, each tube characterized by a
tube diameter, and wherein tubes positioned proximal to the
longitudinal axis have a larger tube diameter than tubes positioned
distal to the longitudinal axis.
31. The heat exchanger of claim 30, wherein the tube bundle
includes first, second, and third pass tubes and, wherein first and
second pass tubes are positioned distal to the longitudinal axis,
and wherein third pass tubes are positioned proximal to the
longitudinal axis.
32. The heat exchanger of claim 31, where each of the first,
second, and third pass tubes include a first segment, a second
segment and a third segment, a first union coupling the first
segment to the second segment, and a second union coupling the
second segment to the third segment.
33. The heat exchanger of claim 31, wherein an inner surface of
each of the first, second , and third segments includes a lining
comprising a ceramic material.
34. The heat exchanger of claim 30, wherein the first pass tubes
are arranged in a first square pattern, the second pass tubes are
arranged in a second square pattern, and the third pass tubes are
arranged in a third square pattern, and wherein the centers of the
first pass tubes are located at the corners of the first square
pattern, the centers of the second pass tubes are located at the
corners of the second square pattern, and intersect the first
square pattern at the midpoint of each side of the first square
pattern, and the centers of the third pass tubes are located at the
corners of the third square pattern and intersect the midpoints of
each side of the second square pattern.
35. The heat exchanger of claim 31, wherein the first and second
ends of the first pass tubes are arranged in a first rectangular
pattern, wherein the first and second ends of the second pass tubes
are arranged in a second rectangular pattern, wherein the first and
second ends of the third pass tubes are arranged in a third
rectangular pattern, wherein each of the first, second and third
rectangular pattern is characterized by a height and wherein the
height of the third rectangular pattern is less than the height of
the second rectangular pattern, and the height of the second
rectangular pattern is less than the height of the first
rectangular pattern.
36. The heat exchanger of claim 31, wherein the manifold and the
first, second, and third pass tubes comprise an alloy of iron,
chromium, and nickel lined with a ceramic material.
37. The heat exchanger of claim 29, wherein the manifold comprises
a first transverse segment adjacent to a second transverse segment,
the first transverse segment having a plurality of holes
therethrough proximal to the longitudinal axis, and a plurality of
passageway therein distal to the longitudinal axis, wherein the
second transverse segment includes a first plurality of holes
therethrough for receiving the first pass tubes, a second plurality
of holes for receiving the second pass tubes, and a third plurality
of holes for receiving the third pass tubes, and wherein the first
transverse segment is aligned with the second transverse segment so
as to form a fluid pathway from the end-cap to the first pass
tubes, and to form a reversing fluid pathway from the second pass
tubes through the plurality of passageways and into the third pass
tubes.
Description
FIELD OF THE INVENTION
[0001] This invention relates, generally, to a heat exchange system
for transferring heat from one heat transfer fluid to another, and
more particularly, to a shell and tube heat exchange system that is
capable of transferring heat to an oxidizer for subsequent use in a
combustion process.
BACKGROUND OF THE INVENTION
[0002] Combustion systems are widely used by industry to provide
heat to different substrates, such as steel, aluminum, cement, and
the like. These load materials require considerable energy to
undergo chemical and physical changes that are required to
transform the load materials into more useful forms. Combustion
systems typically require an oxidant in combination with a fuel to
generate the large amount of energy needed to carry out chemical
and physical transformation of the load materials. Typically, a
hydrocarbon fuel is mixed with air or oxygen to release the
combustion energy. During operation, the combustion systems
generate fumes that take away some of the energy introduced by the
combustion fuel. The fumes represent an energy loss mechanism that
removes energy that otherwise should have been transferred into
heating the load material. In this manner, substantial losses of
energy can occur that impairs the efficiency of the combustion
system and leads to energy waste. To reduce the energy loss, heat
recovery systems are used that capture the heat of the flue gases
and transfer it to another medium to perform useful work, as
mechanical energy, electrical energy, chemical energy, and the
like.
[0003] To improve the efficiency of the combustion system, the
waste heat can be transferred back into the combustion fuel. Heat
recovery systems are known that combine several solutions to
enhance the efficiency of a combustion system. See for example,
U.S. Pat. No. 4,492,568 to Palz and U.S. Pat. No. 4,475,340 to
Tseng. In addition to heating the combustion fuel, systems are
known in which the efficiency is improved by preheating the load
material. For example, in the glass industry, a cullet preheating
system on an oxygen-fuel combustion furnace transfers flue gases
through a raining bed of cullet or batch pellets that are heated
before entering the combustion furnace. See for example, U.S. Pat.
No. 5,578,102 to Alexander and U.S. Pat. No. 5,526,580 to Zippe.
Although the technique of preheating raw materials increases the
combustion efficiency, such techniques are difficult to implement
because of the extensive apparatus needed for handling large, bulky
raw materials. The handling problems make such systems difficult to
retrofit into existing combustion systems. Further, the engineering
modifications necessary for installation of the heat recovery
equipment can make the systems very expensive to build.
[0004] The preheating of natural gas is known technology for most
combustion applications using heat recovery. It can be achieved
through heat exchangers that recover the heat from the flue gases.
Systems described in the U.S. Pat. Nos. 4,492,568 and 4,475,340 are
applied in both combustion engines and industrial furnaces. These
systems involve metallic parts that conduct the heat between the
natural gas and the flue gases, and usually preheat the natural gas
to temperatures below about 400.degree. C. In heat recovery systems
used to preheat natural gas, it is very important that structurally
defective metallic components of the heat exchangers not be exposed
to highly reducing conditions at elevated temperatures. The
disassociated carbon from the natural gas can easily diffuse into
structural defects, such as weld joints. The diffusion of the
disassociated carbon can cause carburizing effects in the metal,
and lead to case hardening and micro-crack formation in the welded
joints.
[0005] To avoid potentially dangerous conditions arising from the
formation of cracks in heat exchanger materials, heat exchangers
can be built using non-metallic components. For example, a ceramic
heat exchanger is described in U.S. Pat. No. 5,630,470 to Lockwood.
Although avoiding the use of welded metals, materials such as
ceramics are often fragile both mechanically and thermally, and
they can fail in an unpredictable manner. In an environment where
the heat transfer fluids may undergo abrupt temperature variations
due to process settings, any failure of the ceramic material can
trigger massive combustion in the heat recovery system. The
potential danger associated with ceramic heat exchangers is shared
by heat exchangers employing other materials, such as plastics and
reinforced plastics, and the like. For example, U.S. Pat. No.
5,323,849 to Korezynski describes a corrosion resistant heat
exchanger in which materials are selected for their corrosion and
erosion resistance. However, it is highly unlikely that heat
exchangers employing ceramic and plastic materials can be safely
operated for preheating an oxidizer in a fuel combustion
system.
[0006] The direct exchange of heat between waste flue gases and
oxidizers used in a combustion system presents engineering
challenges in the design of a safe and efficient heat exchange
system. The breakdown or down time of such a heat exchange system
can cause serious process interruption and increase production
costs. Accordingly, a need exists for a heat exchanger that can
preheat highly combustible fuels, such as hydrocarbon fuels, and
oxidizers, such as oxygen, and the like, and that can be operated
safely and efficiently.
SUMMARY OF THE INVENTION
[0007] In accordance with the invention, there is provided in one
form a heat exchanger for preheating an oxidizing gas. The heat
exchanger includes a shell having an inlet and an outlet for
permitting the ingress and the egress of a first heat exchanger
fluid. A tubular oxidizing gas pathway is disposed within the shell
and it is configured to receive the oxidizing gas at an inlet and
to discharge the oxidizing gas at an outlet. The diameter of the
pathway increases along the direction of flow of the oxidizing gas,
such that the tube diameter at the inlet is smaller than the table
diameter at the outlet. The oxidizing gas pathway is constructed of
metal that does not have any welded metallic surfaces exposed to
the oxidizing gas.
BRIEF DESCRIPTION OF THE DRAWING
[0008] FIG. 1 is a side elevation view, partially broken away, of a
heat exchanger in accordance with the invention;
[0009] FIG. 2 is a cross-sectional view of the inlet portion of a
heat exchanger in accordance with the invention;
[0010] FIG. 3 is cross-sectional view of a segmented tube manifold
arranged in accordance with the invention;
[0011] FIG. 4 is an elevational view of a first segment of the
segmented tube manifold illustrated in FIG. 3;
[0012] FIG. 5 is an elevation view of a second segment of the
segmented manifold illustrated in FIG. 3.
[0013] FIG. 6 is an enlarged cross-sectional view of a tube
coupling arrangement in accordance with the invention;
[0014] FIG. 7 is a cross-sectional view of an outlet end of a heat
exchanger in accordance with the invention;
[0015] FIG. 8 is a cross-sectional view of a segmented tube
manifold arranged in accordance with the invention;
[0016] FIG. 9 is an elevation view of one segment of the segmented
tube manifold shown in FIG. 8;
[0017] FIG. 10 is an elevation view of another segment of the
segmented manifold shown in FIG. 8;
[0018] FIG. 11 is an elevational view of a baffle used in a heat
exchanger in accordance with the invention;
[0019] FIGS. 12-14 are schematic diagrams of tube arrangements in
accordance with the invention.
[0020] FIG. 15 is an elevation view, partially broken away, of a
U-tube heat exchanger in accordance with the invention;
[0021] FIG. 16 is a cross-sectional view of an inlet/outlet portion
of a U-tube heat exchanger in accordance with the invention;
[0022] FIG. 17 is a cross-sectional view of a segmented U-tube
manifold in accordance with the invention;
[0023] FIG. 18 is an elevation view of a first segment of the
segmented U-tube manifold illustrated in FIG. 17;
[0024] FIG. 19 is an elevational view of a second segment of the
U-tube manifold illustrated in FIG. 17;
[0025] FIG. 20 is an elevational view, partially broken away, of a
heat exchanger in accordance with another U-tube embodiment of the
invention;
[0026] FIG. 21 is a cross-sectional view of an inlet/outlet portion
of a U-tube heat exchanger in accordance with the invention;
[0027] FIG. 22 is a cross-sectional view of a segmented U-tube
manifold in accordance with the invention;
[0028] FIG. 23 is an elevational view of a first segment of the
segmented U-tube manifold illustrated in FIG. 22;
[0029] FIG. 24 is an elevational view of a second segment of the
segmented U-tube manifold illustrated in FIG. 22;
[0030] FIG. 25 is a schematic diagram of a tube pattern for a
U-tube heat exchanger in accordance with the invention; and
[0031] FIG. 26 is a cross-sectional view of a portion of an inner
tube arranged in accordance with the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Illustrated in FIG. 1 is a side elevation of a heat
exchanger 10 arranged in accordance with a preferred embodiment of
the invention. Heat exchanger 10 includes a shell 12 having an
inlet end-cap 14 attached to a first end 16 of shell 12. An outlet
end-cap 18 is attached to a second end 20 of shell 12. An expansion
bellow 22 is coupled to shell 12 by bolted flanges 24 and 26
extending from shell 12 and expansion bellow 22. A second set of
bolted flanges 28 and 30 couples inlet end-cap 14 to first end 16
of shell 12 and outlet end-cap 18 to second end 20 of shell 12,
respectively. A cutaway portion of shell 12 reveals a tube bundle
36 housed within shell 12. Tube bundle 36 includes a plurality of
parallel-spaced tubes 38 that traverse the interior of shell 12
from first end 16 to second end 20. A plurality of baffles 40 are
arranged within shell 12 and support parallel-spaced tubes 38 of
tube bundle 36.
[0033] In operation, a first heat exchange fluid, such as a flue
gas, or hot medium carrying waste heat, or the like, is introduced
to shell 12 through an inlet 42. The first heat exchange fluid
traverses shell 12 through a pathway created by baffles 40 and
exits shell 12 through an outlet 44. A second heat exchange fluid,
such as an oxidizing gas, to be heated within heat exchanger 10
enters inlet end-cap 14 through an inlet 46. The second heat
exchange fluid enters tube bundle 36 and is passed through
parallel-spaced tubes 38, while being heated by the first heat
exchange fluid passing through the shell side of heat exchanger 10.
The second heat exchange fluid eventually passes from tube bundle
36 to outlet end-cap 18 and exits heat exchanger 10 through an
outlet tube 48.
[0034] The term "oxidant" or "oxidizing gas," according to the
present invention, means a gas with an oxygen molar concentration
of at least 30%. Such oxidants include oxygen-enriched air
containing at least 30% vol., oxygen such as "industrially" pure
oxygen (99.5%) produced by a cryogenic air separation plant or
non-pure oxygen produced by e.g. a vacuum swing adsorption process
(about 88% by vol. O.sub.2 or mole), or "impure" oxygen produced
from air or any other source by filtration, adsorption, absorption,
membrane separation, or the like, at either room temperature (about
25.degree. C.) or in a preheated form.
[0035] As described in more detail below, outlet end-cap 18 is
pressurized with an inert gas, such as argon, nitrogen, or mixtures
thereof, or the like. In accordance with one aspect of the
invention, a chemical detector 50 is positioned in outlet end-cap
18 or in shell 12, or in both, to detect the presence of the second
heat exchange fluid within the interior cavity of outlet end-cap
18, or within shell 12. Chemical detector 50 is capable of
detecting any leakage of the second heat exchange fluid from either
tube bundle 36 or outlet tube 48. By prompt and precise leak
detection of the second heat exchange fluid, the heat exchanger of
the invention provides enhanced safety during heat exchange
operations where dangerous oxidizing gases are being heated by heat
exchanger 10. For example, where oxygen is introduced at inlet 46
at an initial temperature of about 21.degree. C., and flue gas is
introduced through inlet 42 at a temperature of about 1093.degree.
C., oxygen exits outlet tube 48 at a temperature of about
982.degree. C. At this temperature, oxygen must be carefully
handled to avoid contact with any oxidizable material. By
configuring chemical detector 50 to detect the presence of oxygen,
any leakage of oxygen from outlet tube 48 and tube bundle 36 can be
quickly detected and heat exchanger 10 shut down to avoid dangerous
operating conditions.
[0036] A portion of heat exchanger 10 is illustrated in
cross-section in FIG. 2. Inlet end-cap 14 is sealed to first end 16
of shell 12 by bolted flange set 28 and first and second gaskets 32
and 34 to form a first chamber 15. A segmented tube manifold 52 is
positioned within inlet end-cap 14 to transfer the second heat
exchange fluid from inlet end-cap 14 to tube bundle 36. The second
heat exchange fluid enters inlet end-cap 14 through inlet 46. Inlet
end-cap 14 directs the second heat exchange fluid into first pass
tubes 54 of tube bundle 36 through openings 56 and segmented
manifold 52.
[0037] FIG. 3 illustrates an isolated cross-sectional view of
segmented manifold 52. Segmented manifold 52 includes a first
transverse segment 58 adjacent to a second transverse segment 60.
First transverse segment 58 and second transverse segment 60 are
adjacently aligned, such that a continuous fluid path is formed
between openings 56 and first pass tubes 54.
[0038] Segmented tube manifold 52 is sealed to shell 12 by bolted
flange set 28 and first and second gaskets 32 and 34. Fasteners 64
attach first transverse segment 58 to second transverse segment 60
and are sealed by an annular gasket 66. The general geometric
arrangement of individual tubes within tube bundle 36, and their
spatial relationship with respect to one another and with respect
to segmented tube manifold 52 can be defined by a longitudinal axis
68. Accordingly, second heat exchange fluid entering inlet end-cap
14 is directed through openings 56 and into first pass tubes 54
through segmented tube manifold 52.
[0039] An elevation view of first transverse segment 58 is
illustrated in FIG. 4, and an elevational view of second transverse
segment 60 is illustrated in FIG. 5. Openings 70 accommodate
fasteners 64 and are arrayed around the periphery of first and
second transverse segments 58 and 60. Openings 56 are arranged
about a central plurality of passageways 72. Plurality of
passageways 72 provide channels within first transverse segment 58
for receiving the second heat exchange fluid from second pass tubes
74 (shown in FIG. 5). Passageways 72 include a plurality of prongs
76 that extend outward from longitudinal axis 68. The apex of
prongs 76 is located at a radial distance from longitudinal axis 68
that is equal to the radial distance of openings 56.
[0040] Referring to FIG. 5, flange 61 forms the peripheral portion
of second transverse segment 60. Second transverse segment 60 also
includes a plurality of bores 62 for receiving terminal ends of
parallel-spaced tubes 38. Parallel-spaced tubes 38 are coupled to
second transverse segment 60 in a concentric arrangement with
respect to longitudinal axis 68. In the present embodiment, third
pass tubes 78 are arranged about longitudinal axis 78 in close
proximity thereto. First and second pass tubes 54 and 74 are
arranged about third pass tubes 78, but at a greater radial
distance from longitudinal axis 68. The elevational view also
illustrates the alternating relationship between first pass tubes
54 and second pass tubes 74. Both sets of tubes are located
equidistant from longitudinal axis 68 and are engaged with second
transverse segment 60 by bores 62.
[0041] First transverse segment 58 and second transverse segment 60
are aligned so as to create fluid pathways for transferring the
second heat exchange fluid between the first, second, and third
pass tubes. For example, upon traversing second pass tubes 74, the
heat exchange fluid enters passageways 72 and travels through
prongs 76 toward longitudinal axis 68. Passageways 72 then reverse
the direction of flow of the heat exchange fluid and direct the
fluid into third pass tubes 78.
[0042] In the embodiment illustrated in FIG. 5, the radial
relationship among the individual tubes within tube bundle 36
enables efficient heat transfer from the first heat exchange fluid
flowing within shell 12 and the second heat exchange fluid flowing
within tube bundle 36. A particular advantage of the present
invention includes the placement of alternating first and second
pass tubes on the outer periphery of tube bundle 36, and the third
pass tubes near the center of tube bundle 36. This arrangement
enables the introduction of relatively lower temperature heat
exchange fluid into heat exchanger 10 near the outside walls of
shell 12, while relatively hotter heat exchange fluid is contained
within the third pass tubes near the center of shell 12. In
addition to the heat transfer between the flue gases on the
shell-side and the oxidizer within tubes, heat is also transferred
by radiation between third pass tubes and first and second pass
tubes 54 and 74. The preferred tube arrangement enables the hotter
fluid within third pass tubes 78 to preheat the relatively colder
fluid traversing first and second pass tubes 54 and 74.
Accordingly, the heat transfer from the first heat exchange fluid
to the second heat exchange fluid is carried out at high
efficiency.
[0043] In addition to providing high heat exchange efficiency, tube
bundle 36 also minimizes the pressure drop of the second heat
exchange fluid flowing within tube bundle 36. This is accomplished
by varying the tube diameter of the individual tubes within tube
bundle 36. The overall fluid pressure drop within the tubes is
reduced by using small diameter tubes for first pass tubes 54,
slightly larger diameter tubes for second pass tubes 74, and still
larger diameter tubes for third pass tubes 78. The gradual increase
in tube diameter with the progression of fluid flow and with the
radial distance from longitudinal axis 68 maintains a constant
pressure drop within tube bundle 36 despite the volumetric
expansion of the second heat exchange fluid as its temperature
increases.
[0044] Those skilled in the art will appreciate that, although the
invention is illustrated with an alternating tube arrangement
between first and second pass tubes 54 and 74, the individual tubes
within tube bundle 36 can be arranged in a progressively decreasing
radial distance from longitudinal axis 68. Additionally, tube
bundle 36 can be a single tube generally aligned with longitudinal
axis 68. Accordingly, the present invention contemplates a variety
of tube arrangements and geometries to reduce fluid pressure drop,
and to increase heat transfer efficiency.
[0045] The coupling of the individual tubes of tube bundle 36 to
segmented tube manifold 52 is illustrated in FIG. 6. A flange 80 is
located near a terminal end 82 of tube 54. A first tube gasket 84
and a second tube gasket 86 encircle tube 54 and reside adjacent to
flange 80. Bore 62 and second transverse segment 60 accommodates
flange 80 and first and second tube gaskets 84 and 86, such that
tube 54 can longitudinally expand and contract without inducing
stress within segmented tube manifold 52.
[0046] The floating tube coupling created by bore 62, flange 80,
and first and second tube gaskets 84 and 86 provide enhanced
operational safety of heat exchanger 10. By arranging flexible
gaskets on either side of the tube flanges, the sliding or
longitudinal floating action of the tubes within tube bundle 36 can
occur as the tubes expand and contract with temperature changes.
The double gasketing system insures proper sealing between the
tubes and first and second transverse segments 58 and 60.
Preferably, first tube gasket 84 is constructed of alumina-silica
ceramic fiber to provide high-temperature gasketing near the
interior regions of shell 12. Second tube gasket 86 is preferably
an expansion gasket constructed of a metal, such as copper, or
metal fibers and accommodates stress near the adjoining regions of
first and second transverse segments 58 and 60. To insure safe
operation, the inner surface of tube 54 can be lined with a lining
87. Preferably, lining 87 is a ceramic material, and more
preferable a metallic oxide, such as aluminum oxide, zirconium
oxide, chromium oxide, yitrium oxide, and the like. Within the
scope of the present invention, many different rare earth oxides
will provide protection to tube 54 from attack by oxidants
comprising oxygen. Accordingly, all such rare earth oxides can
provide a suitable material for lining 87.
[0047] A cross-sectional view of the outlet side of heat exchanger
10 is illustrated in FIG. 7. A segmented manifold 88 is positioned
within outlet end-cap 18 and sealed by bolted flange set 30 and
gaskets 34 and 35 to form a second chamber 31. Segmented manifold
88 includes a first transverse segment 90 positioned adjacent to a
second transverse segment 92. An outlet tube 94 is threaded and
welded on exterior surface of first transverse segment 90. Outlet
tube 94 extends through outlet end-cap 18 and exits outlet end-cap
18 through an opening 96. A sliding support flange 98 seals outlet
tube 94 within opening 96. This is accomplished using high
temperature O-rings or seals. The interior end of outlet tube 94 is
engaged with first transverse segment 90 so as to collect the
second heat transfer fluid exiting from third pass tubes 78. An
opening 100 in first transverse segment 90 accommodates an end
portion of outlet tube 94, and provides a collection point for heat
transfer fluid from third pass tubes 78.
[0048] In accordance with the invention, second chamber 31 contains
a gas that is different from the second heat exchanger fluid. In a
preferred embodiment, second chamber 31 is pressurized with an
inert gas, such as argon, nitrogen, and the like. Sliding support
flange 98 and gasket 34 prevent the inert gas from escaping outlet
end-cap 18. In a preferred embodiment, the inert gas is pressurized
to a higher pressure than the second heat exchange fluid flowing
within tube bundle 36 and outlet tube 94. The greater
pressurization of the inert gas makes it more difficult for a leak
to develop from segmented tube manifold 88. Another function of the
inert gas within outlet end-cap 18 is to cool the components of
heat exchanger 10 at the outlet side of the heat exchanger. This
feature is important where the second heat exchange fluid is an
oxidant comprising oxygen that has been heated to a high
temperature by heat exchanger 10. Isolating the heat exchanger
components in close proximity to the exiting high oxidizing fluid
reduces the chances of unwanted spontaneous combustion occurring
near the exit point of the heat exchanger.
[0049] A further safety feature of the invention is the sliding
arrangement of outlet tube 94. The sliding arrangement allows
outlet tube 94 to expand and contract as the temperature of the
second heat exchange fluid changes. By allowing outlet tube 94 to
move longitudinally within end-cap 18, compression stress between
outlet tube 94 and segmented tube manifold 88 is minimized. To
accommodate longitudinal motion, sliding support flange 98 permits
outlet tube 94 to slide back and forth as changing temperature
causes outlet tube 94 to expand and contract.
[0050] In one embodiment, outlet end-cap 18 is further equipped
with an instrument port 102. Instrument port 102 is configured in
such a way as to support a variety of different instruments for
monitoring the performance of heat exchanger 10. For example,
instrument port 102 can accommodate a thermocouple 104 for
monitoring the outlet temperature of the second heat exchange
fluid. Additionally, instrument port 102 can accommodate a chemical
analyzer, such as a residual gas analyzer, and the like. For
analyzing the chemical components of gases within second chamber
31. As previously described, an additional instrument port can also
be positioned in shell 12. Further, an additional instrument port
105 can be mounted to end cap 18.
[0051] The chemical analyzer can be configured to detect the
presence of the second heat exchange fluid within outlet end-cap
18, and/or within shell 12. By continuously monitoring for
particular chemical species within the second heat exchange fluid,
any leakage from within the tubes of tube bundle 36 and outlet tube
94 can be readily detected. By providing for precise leak detection
within heat exchanger 10, the heat exchanger can be employed to
heat oxidizing gases, while maintaining a margin of safety during
heat exchange operations. If an oxidizing species, such as oxygen,
is detected within end-cap 18, heat exchanger 10 can be quickly
shut down to avoid spontaneous combustion.
[0052] To provide increased operating safety, electronic monitoring
and display devices (not shown) can be used to notify an operator
in the event of equipment failure of the chemical analyzer or
temperature monitoring device. In addition to monitoring for
equipment failure, the electronic device can also alert an operator
to perform periodic maintenance on the leak detection and
temperature monitoring devices. For example, the operator can be
alerted to periodically replace the chemical sensor to insure that
the sensor will always be fully operational.
[0053] A cross-sectional view of segmented tube manifold 88 is
illustrated in FIG. 8. Fasteners 106 coupled first transverse
segment 90 to second transverse segment 92 and a seal is provided
by an annular gasket 108. First and second pass tubes 54 and 74 are
engaged by second transverse segment 92 in the same manner as with
segmented tube manifold 58.
[0054] An elevation of first transverse segment 90 is illustrated
in FIG. 9 and second transverse segment 92 is illustrated in FIG.
10. A plurality of openings 110 are arranged at the periphery of
first and second transverse segments 90 and 92 to accommodate
fasteners 106. A plurality of passageways 112 are arranged about
opening 100 and provide for a fluid transfer between first pass
tubes 54 and second pass tubes 74. Passageways 112 are coupled with
the first and second pass tubes, such that the flow of the second
heat exchange fluid from first pass tubes 54 enters a passageway
and flows to a second pass tubes 74, reversing direction in the
process. The opening 100 is aligned with third pass tubes 78, such
that the second heat exchange fluid flowing through third pass tube
78 is collected and transferred to outlet tube 94.
[0055] Referring to FIG. 10, a flange 93 forms a peripheral portion
of second transverse segment 92. The arrangement of bores 62 to
receive the parallel-spaced tubes 38 of tube bundle 38 is similar
to second transverse segment 60. In keeping with the geometric
arrangement of the invention, first and second pass tubes 54 and 74
are received at a location distal from longitudinal axis 68, while
third pass tubes 78 are received at a location proximal to
longitudinal axis 68. The individual tubes of tube bundle 38 are
engaged with second transfer segment 92 in the same manner as
illustrated in FIG. 6. Preferably, both segmented tube manifold 52
and segmented tube manifold 88 are formed of thick alloy steel.
Further, the tube manifolds can be coated with a metallic oxide
ceramic material, such as alumina, zirconia, and the like.
[0056] Those skilled in the art will recognize the many design
characteristics of the present invention provide for expansion and
contraction of the various components in heat exchanger 10. For
example, expansion bellows 22 provides shell 12 with the ability to
longitudinally expand and contract during operation. Expansion
bellow 22 accommodates the longitudinal expansion of
parallel-spaced tubes 38 within shell 12. To select a proper
expansion bellows, the effective longitudinal expansion of shell 12
is calculated and a commercially available bellows is selected to
accommodate the necessary longitudinal expansion. Preferably, shell
12 is manufactured of a high-temperature alloy steel. Further,
shell 12 can be lined with a ceramic coating to include both
temperature and corrosion resistance. Baffles 40 within shell 12
must necessarily also accommodate longitudinal expansion. The
optimal number of such baffles provides higher heat transfer
efficiency and effectively reduces the overall length of heat
exchanger 10.
[0057] An elevation of a baffle 40 is illustrated in FIG. 11.
Baffle 40 includes a flat edge surface 114 to permit the flow of
the first heat exchange fluid from one section of shell 12 to
another. Baffle 40 contains a plurality of holes 116 to accommodate
parallel-spaced tubes 38. Baffle holes 116 are machined to have
slightly larger diameter than the individual tubes of tube bundle
38. The larger size of baffle holes 1 16 allows for longitudinal
movement of shell 12 and tube bundle 36. By sizing baffle holes 116
to be slightly larger than parallel-spaced tubes 38, a
floating-tube arrangement is formed within heat exchanger 10.
Expansion gaskets adjacent to the flanges of parallel-spaced tubes
38 in conjunction with baffles 40 enable the tubes within shell 12
to longitudinally move independent of shell 12 and segmented tube
manifolds 52 and 88.
[0058] The arrangement of the structural components of a heat
exchanger formed in accordance with the invention provide the
transfer of an oxidizing fluid, such as oxygen, air, air/oxygen
mixtures, and the like, through the heat exchanger, while avoiding
exposure of the oxidizing fluid to surfaces having welds or other
structural weaknesses. Additionally, the heat exchanger described
above effectively isolates the first and second heat exchange
fluids, so as to avoid unwanted mixing of the fluids. In the event
such unwanted mixing should occur, the heat exchanger of the
invention provides detection means to quickly alert an operator to
shut the heat exchanger down and avoid unwanted spontaneous
combustion.
[0059] In accordance with the invention, further embodiments of
tube arrangements for tube bundle 36 are illustrated in the
schematic diagrams illustrated in FIGS. 12-14. The schematic
diagrams display different arrangements of tubes by an end view of
tube bundle 36. The geometric relationship of the first pass,
second pass, and third pass tubes in each embodiment are depicted
by the dashed lines provided in each schematic drawing.
[0060] Illustrated in FIG. 12 is a schematic diagram of a tube
arrangement within two bundle 36 in accordance with a preferred
embodiment of the invention. The centers of first pass tubes 54 are
arranged at the corners of a first square pattern 116. The centers
of second pass tubes 74 are arranged at the corners of a second
square pattern 118 and intersect first square pattern 116 at the
midpoint of each side of first square pattern 116. The centers of
third pass tubes 78 are arranged at the corners of a third square
pattern 120 and intersect the midpoints of each side of second
square pattern 118. The geometric relationships among the first,
second and third pass tubes can be characterized by equations (1)
to (3) and inequalities (4) to (7). 1 r 1 = a 2 = 2 r 2 ( 1 ) r 2 =
a 2 = 2 r 3 ( 2 ) r 3 = a 2 2 ( 3 ) r 1 2 d 1 2 + d 3 2 ( 4 ) r 2 d
1 2 + d 2 2 ( 5 ) r 3 d 2 d 2 + d 3 2 ( 6 ) r 2 d 3 ( 7 )
[0061] Equation (1) sets forth a mathematical relationship for the
distance (r.sub.1) between the centers of first pass tubes 54 and
longitudinal axis 68, and the length (a) of a side of first square
pattern 116 and the distance (r.sub.2) between the centers of
second pass tubes 74 and longitudinal axis 68. Equation (2) sets
forth a relationship between (r.sub.2) and (a), and the distance
(r.sub.3) between the centers of third pass tubes 78 and
longitudinal axis 68. Equation (3) sets forth a relationship
between (r.sub.3) and (a). The spacing between the tubes can also
be specified by the inequalities (4) to (7), which relate the
distances (r.sub.1, r.sub.2, r.sub.3) to the diameter (d.sub.1) of
first pass tubes 54, the diameter (d.sub.2) of second pass tubes
74, and the diameter (d.sub.3) of third pass tubes 78.
[0062] The geometric relationships set forth by equations (1) (2)
(3) and inequalities (4) to (7) describe a tube arrangement for
tube bundle 36 that provide high heat transfer efficiency from both
conductive and radiative heat transfer.
[0063] FIG. 13 illustrates a schematic diagram of a tube
arrangement in accordance with another embodiment of the invention.
In the embodiment shown in FIG. 13, first pass tubes 54, second
pass tubes 74, and third pass tubes 78 are positioned tangential to
first, second, and third square patterns 116, 118, and 120,
respectively. The geometric relationship between the tubes in tube
bundle 36 and longitudinal axis 68 can be expressed by equations
(8) to (10) and inequalities (11) to (14). 2 a 2 = d 2 2 + r 1 2 (
8 ) a 2 2 = d 2 2 + r 2 2 ( 9 ) a 4 = d 3 2 + r 3 2 ( 10 ) r 2 - r
3 d 1 2 + d 3 2 ( 11 ) r 1 2 + r 1 2 - 2 r 1 r 2 ( d 1 + d 2 2 ) 2
( 12 ) r 2 2 + r 3 2 - 2 r 2 r 3 ( d 2 + d 3 2 ) 2 ( 13 ) r 3 2 d 3
x 1 2 ( 14 )
[0064] Equation (8) relates the length (a) of a side of first
square pattern 116 to the diameter (d.sub.1) of first pass tubes
54, and to the distance (r.sub.1) between the centers of first pass
tubes 54 and longitudinal axis 68. Equation (9) relates (a) to the
diameter (d.sub.2) of second pass tubes 54 and to the distance
(r.sub.2) between the centers of second pass tubes 74 and
longitudinal axis 68. Equation (10) relates (a) to the diameter
(d.sub.3) of third pass tubes 78 and the distance (r.sub.3) between
the centers of third pass tubes 78 and longitudinal axis 68. The
inequalities (11) to (14) establish the spacing relationships based
on the previously described parameters.
[0065] Yet another embodiment of a tube arrangement of tube bundle
36 appears in the schematic diagram illustrated in FIG. 14. In
similarity with the preferred embodiment of FIG. 12, the centers of
first pass tubes 54 are aligned with the corners of first square
pattern 116. Also, the centers of second pass tubes 74 are aligned
with the corners of second square pattern 118. Further, the centers
of third pass tubes 78 are aligned with the corners of third square
pattern 120. Additionally, the centers of both first pass tubes 54
and second pass tubes 74 lie on a circular pattern 122. A
comparison between the embodiment shown in FIG. 14 and the
embodiment shown in FIG. 5 illustrates the similar relationship of
the radial distance between the centers of first and second pass
tubes 54 and 74, and longitudinal axis 68. The embodiment
illustrated in FIG. 14 differs with that illustrated in FIG. 5 in
that the centers of third pass tube 78 are rotated 45 degrees
relative to their position in the embodiment of FIG. 5.
[0066] All of the illustrated embodiments of tube arrangements for
tube bundle 36 provide the beneficial radiative heat transfer
associated with placing the hotter third pass tubes near
longitudinal axis 68, while removing first and second pass tubes to
a greater distance from longitudinal axis 68. Each illustrated
embodiment offers a different arrangement of the tubes within tube
bundle 36, and each embodiment provides an optimum packing density,
while maintaining high efficiency heat transfer. Maintaining a high
tube packing density serves to reduce the overall size of heat
exchanger 10. Additionally, the illustrative embodiments
accommodate the variation in diameter between first pass, second
pass, and third pass tubes 54, 74, and 78. The larger diameter of
third pass tube 78 relative to second pass tube 74 and first pass
tubes 54 requires precise spacing conditions to achieve an optimal
packing density. Those skilled in the art will appreciate that
other alternatives are possible for arranging the tubes of tube
bundle 36, and those arrangements are contemplated by the present
invention.
[0067] Although the multi-pass heat exchanger described above fully
addresses the advantages of the present invention, those skilled in
the art will recognize that other kinds of heat exchangers can be
used to preheat an oxidizer for use in a combustion system. For
example, U-tube heat exchangers can also be used to preheat
oxidizers in a combustion system. Illustrated in FIG. 15 is an
elevational view of a U-tube heat exchanger 124 arranged in
accordance with the invention. U-tube heat exchanger 124 includes a
shell 126 having an inlet/outlet end-cap 128 attached to a first
and 130 of shell 126. A cover 132 is attached to a second end 134
of shell 126. A first bolted flange set 136 attaches inlet/outlet
end-cap 128 to first and 130 of shell 126, and a second bolted
flange set 138 attaches cover 132 to second end 134 of shell 126.
Shell 126 includes an inlet 140 to permit the ingress of a first
heat exchange fluid, such as a flue gas, and the like, and an
outlet 142 to discharge the first heat exchange fluid from U-tube
heat exchanger 124. Inlet 146 permits the ingress of a second heat
exchange fluid, such as an oxidizer comprising oxygen, at
inlet/outlet end-cap 128 and is coupled to a U-tube bundle 150
longitudinally disposed within shell 126. An outlet tube 152
extends from inlet/outlet end-cap 128 and permits the discharge of
the second heat exchange fluid from U-tube heat exchanger 124. A
first instrument port 152 extends through inlet/outlet end-cap 128,
and a second instrument port 154 extends through shell 126. A
plurality of baffles 156 support tube bundle 150 within shell
126.
[0068] A cross-sectional view of inlet/outlet end-cap 128 is
illustrated in FIG. 16. A segmented tube manifold 158 is positioned
within inlet/outlet end-cap 128 to transfer the second heat
exchange fluid from inlet/outlet end-cap 128 to tube bundle 150.
The second heat exchange fluid enters segmented tube manifold 158
through openings 160 and 162. Outlet tube 152 is coupled to an
opening 164 and threaded into segmented tube manifold 158. Opening
164 collects the second heat exchange fluid discharging from tube
bundle 150 and transfers the fluid to outlet tube 152. A flange 165
of segmented tube manifold 158 is secured by bolted flange set 136.
Instruments for monitoring the interior temperature and for
monitoring for the presence of constituents, such as oxygen, are
mounted in first and second instrument ports 152 and 154.
[0069] An isolated view of segmented tube manifold 158 is
illustrated in FIG. 17. In similarity with previously described
embodiments of the invention, segmented tube manifold 158 includes
a first transfer segment 166 and a second transfer segment 168.
First and second transfer segments 166 and 168 are aligned, such
that fluid passageways are created by openings 160 and 162. First
and second transfer segments 166 and 168 are attached by fasteners
170 and sealed by a gasket 172. Flange 164 extends from the
periphery of first transfer segment 166 and cooperates with first
bolted flange set 136 to secure segmented tube manifold 158 within
shell 126. In similarity with the previous embodiment, the general
geometric arrangement of individual tubes within tube bundle 150,
and their spacial relationship with respect to one another and with
respect to segmented tube manifold 158, can be defined by a
longitudinal axis 174. In the U-tube embodiment of the invention,
segmented tube manifold 158 directs the flow of the second heat
exchange fluid both to and from inlet/outlet end-cap 128. To
transfer the heat exchange fluid from the shell to the end-cap and
out of the heat exchanger, opening 164 collects the second heat
exchange fluid that has traversed to bundle 150 and now has an
elevated temperature. The tubes within tube bundle 160 are secured
within segmented tube manifolds 158 by flanges 176 and gaskets 178
encircling the perimeter of each tube and positioned on both sides
of flanges 176.
[0070] An elevational view of first transfer segment 166 is
illustrated in FIG. 18, and an elevational view of second
transverse segment 168 is illustrated in FIG. 19. The elevational
views illustrate the arrangement of the individual tubes of tube
bundle 150 and the manner in which the second heat exchange fluid
is transferred between the individual tubes of bundle 150. Openings
160 and 162 are arranged about longitudinal axis 174. Slots 180 are
machined into first transverse segment 166 and receive the second
heat transfer fluid returning from first pass tubes 182 and
transfer the second heat exchange fluid into second pass tubes 184.
Correspondingly, slots 186 receive the second heat exchange fluid
from second pass tubes 184 and transfer the fluid to third pass
tubes 188. Upon traversing U-tube heat exchanger 124, openings 162
collect the second heat exchange fluid and transfer the fluid to
collector opening 164 for discharge.
[0071] The elevational view illustrated in FIG. 19, displays the
arrangement of first, second, and third pass tubes 182, 184, and
188 about longitudinal axis 174. In similarity with the previous
embodiment the tubes are arranged, such that as the second heat
exchange fluid traverses U-tube heat exchanger 124, the fluid is
progressively transferred to tubes residing in close proximity to
longitudinal axis 174. Also, in similarity with the previous
embodiment, the diameter of the tubes increases with the length of
traverse of the second heat exchange through U-tube heat exchanger
124. As in the previous embodiment, the diameter of third pass
tubes 188 is greater than the diameter of second pass tubes 184,
and the diameter of second pass tubes 184 is greater than the
diameter of first pass tubes 182.
[0072] The tube arrangement illustrated in FIG. 19 is similar to
that illustrated in FIG. 12, and represents a preferred arrangement
of tubes within U-tube heat exchanger 124. However, those skilled
in the art will recognize that the tube arrangement can be similar
to that shown in FIGS. 10, 13, and 14. In the U-tube arrangement,
the length of the individual tubes of first past tubes 182 is
substantially the same. Also, the length of the individual tubes of
second pass tubes 184 are substantially the same, and the length of
the individual tubes of third pass tubes 188 are also substantially
the same. However, to accommodate the U-tube arrangement of tube
bundle 150 within shell 126, the overall length of first pass tubes
182 is greater than the overall length of second pass tubes 184.
Also, the length of second pass tubes 184 is greater than the
length of third pass tubes 188. In this manner, the bending of the
tubes near cover 132 can be accomplished, while maintaining a
relatively compact packing density.
[0073] An elevational view of a U-tube heat exchanger 190 in
accordance with another embodiment of the invention is illustrated
in FIG. 20. U-tube heat exchanger 190 includes a shell 192 having
flat sides. A first heat exchange fluid, such as a flue gas and the
like, enters shell 192 through an inlet 194 and exits from an
outlet 196. A second heat exchange fluid, such as an oxidant,
enters U-tube heat exchanger 190 through an inlet 198 and exits
through an outlet 200. An inlet/outlet end-cap 202 is attached to
shell 192 by a bolted flange set 204, and a cover 206 is attached
to shell 192 by a bolted flange set 208. A plurality of baffles 210
support a tube bundle 212 disposed within shell 192. A first
instrument port 214 connects to inlet/outlet end-cap 202, and a
second instrument port 216 connects to shell 192.
[0074] A cross sectional view of inlet/outlet end-cap 202 is
illustrated in FIG. 21. A segmented tube manifold 218 is positioned
within inlet/outlet end-cap 202 and is secured to both the end-cap
and shell 192 by a flange 220 and bolted flange set 204. An opening
222 in segmented tube manifold 218 transfers the second heat
exchange fluid from inlet 198 to tube bundle 212. Also, an opening
224 collects the second heat exchange fluid returning from tube
bundle 212 and transfers it to outlet tube 200.
[0075] An isolated view of segmented tube manifold 218 is
illustrated in FIG. 22. In similarity with the previous embodiments
of the invention, a first transverse segment 226 is attached to a
second transverse segment 228 by fasteners 230 and a gasket 232.
The individual tubes of tube bundle 212 are secured in segmented
tube manifold 218 by flanges 234 and gaskets 236 on either side of
flanges 234. First and second transverse segments 226 and 228 are
aligned so as to create fluid pathways for the entry of the second
heat exchange fluid into two bundle 212 and for the discharge of
the second heat exchange fluid through opening 224.
[0076] An elevational view of first transverse segment 226 is
illustrated in FIG. 23, and an elevational view of second
transverse segment 228 is illustrated in FIG. 24. Segmented tube
manifold 218 generally follows the flat-sided geometry of shell
192. The generally rectangular arrangement of first pass tubes 238,
second pass tubes 240, and third pass tubes 242 corresponds with
the generally flat-sided geometry of segmented tube manifold 218.
Slots 244 and first transverse segment 226 collect the second heat
exchange fluid from the return portion of first pass tubes 38 and
transfer the fluid to the first portion of second pass tubes 240.
Slots 246 collect the heat exchange fluid returning from the second
portion of second pass tubes 240 and transfer the fluid to the
first portion of third pass tubes 242. Opening 224 collect the heat
exchange fluid returning from the second portion of third pass
tubes 242 and transfer the fluid to outlet tube 200.
[0077] The general geometric arrangement of the individual tubes
within tube bundle 212 can be characterized as generally following
rectangular patterns. For example, first pass tubes 238 received
the second heat transfer fluid through opening 222 in first
transfer segment 226, and discharge the second heat transfer fluid
into slots 244. A schematic diagram illustrating the geometric
arrangement of the first, second and third pass tubes of tube
bundle 212 is illustrated in FIG. 25. Generally, the centers of
first pass tubes 238 are arranged along the topside and the bottom
side of a first rectangle pattern 250. Also, the centers of second
pass tubes 240 are arranged at the top side and bottom side of a
second rectangular pattern 252, and the centers of third pass tubes
242 are arranged at the top and bottom sides of a third rectangular
pattern 254. Each rectangular pattern is characterized by a length
(l) and a height (h). In accordance with the generally flat edge
geometry of segmented tube manifold 218, the height (h.sub.1) of
first rectangular pattern 250 is greater than the height (h.sub.2)
of second rectangular pattern 252. Also, the height (h.sub.2) of
second rectangular pattern 252 is greater than the height (h.sub.3)
of third rectangular pattern 254. By arranging the individual tubes
of tube bundle 212 in generally rectangular patterns, a tight
packing density can be maintained, while accommodating the bends of
the tubes within tube bundle 212, and the generally flat-sided
geometry of segmented tube manifold 218.
[0078] Illustrated in FIG. 26 is a cross-sectional view of a
portion of an inner tube arranged in accordance with the invention.
In the embodiment illustrated, short tube segments are employed to
construct a U-bend for a U-tube heat exchanger of the invention. By
employing segments to construct the bend, all inner surfaces of the
inner tube can be coated with a oxidant-resistant material, such as
alumina, and the like. To construct the bend, a first tube segment
256 and a second tube segment 258 are coupled to a third tube
segment 260 by L-shaped unions. A first union 262 couples first
tube segment 256 to third tube segment 260, and a second union 264
couples second tube segment 258 to third tube segment 260. In
accordance with the weld-free construction of the heat exchanger of
the invention, each tube segment is joined to the L-shaped union by
a non-weld coupling. For example, as illustrated in FIG. 26, the
tube segments are threaded into first and second unions 262 and
264.
[0079] An oxidant-resistant lining 266 lines the inner surfaces of
the tube segments and the L-shaped unions. In accordance with the
invention the oxidant-resistant lining can be aluminum oxide,
chromium oxide, a rare earth oxide, and the like. To further insure
resistance to corrosion, the tube segments and unions are
preferably constructed of an iron, chromium, and nickel
(Ni--Fe--Cr) alloy. By employing non-weld couplings,
corrosion-resistant metals, and oxidant resistant lining oxidizer
fluid pathways are created within the heat exchanger of the
invention, such that only weld-free surfaces are exposed to the
oxidizer fluid. Although the foregoing description of tube
construction materials and ceramic lining is illustrated with
respect to the U-tube embodiment, the invention contemplates the
use of such materials in the previously described embodiment and in
all other embodiments of the invention.
[0080] The overall design of the heat exchanger in accordance with
either of the illustrative shell and tube embodiments of the
invention described above is such that the heat exchanger can be
easily adapted and/or retrofitted into existing combustion systems,
and chemical reactors and the like. Within the tube bundle,
relatively cooler tubes are located on the periphery of the bundle,
while relatively hotter tubes are located near the center of the
tube bundle for higher heat exchanger effectiveness. Segmented
baffles are positioned within the shell so as to produce a high
shell-side heat transfer coefficient. The relatively cooler
end-caps enable easy access to the interior of the heat exchanger
for periodic maintenance and lower temperature operation produces
longer useful life. Stress created by temperature induced expansion
and contraction is minimized by the sliding discharge tube
arrangement of the outlet tube within the outlet end-cap.
[0081] In a still further embodiment of the invention, the heat
exchanger described herein can be operated in a reverse flow
arrangement, where the oxidizer fluid is preheated to the shell
side, and flue gas is introduced on the tube side. In this
embodiment, the tubes are coated externally with ceramic coating to
prevent high temperature oxidation, and an inner ceramic lining is
applied to the inner surfaces of the shell.
[0082] In summary, the heat exchanger of the invention offers a
weld-free, metallic, shell-and-tube heat exchanger for preheating
an oxidizer. Non-welded construction is used throughout the heat
exchanger and all materials are corrosion-resistant,
high-temperature, oxygen-compatible materials. The materials
include high-temperature specialty alloys, and commercial alloys
coated with a ceramic layer, preferably containing both silica and
chromia. The ceramic coatings can be applied by various deposition
techniques, such as chemical vapor deposition, physical vapor
deposition, plasma-spraying, diffused packed-cementations, and the
like. The inner tubes and shell are constructed of heavy duty,
thick metal that does not contain any weld surfaces, so that
oxidizers and flue gases are not exposed to weld surfaces. The tube
manifolds are constructed of robust material for effective
multi-pass flow geometry, and provide positive sealing within the
shell. The tube bundle is a floating-tube assembly with special
flange and gasket seals for compensating longitudinal expansion and
contraction within the shell.
[0083] Additionally, the heat exchanger of the invention is
designed so that oxidizer leaking from within the heat exchanger
can be contained first within the shell, then within the outlet
end-cap. Leak detection is carried out through an instrument port
located in the outlet end-cap, or alternatively, in the shell. The
outlet end-cap is sealed, so that it can be pressurized with an
inert gas, such as air or nitrogen, or mixtures thereof.
[0084] Further, a fluid pathway is provided within the shell of the
heat exchanger that gradually increases in diameter along the
direction of oxidizer fluid flow. This design effectively
compensates for the pressure drop of the oxidizer fluid as it
traverses the inner tubes of the heat exchanger.
[0085] Thus, it is apparent that there has been described, in
accordance with the invention, a heat exchanger for preheating an
oxidizer that fully provides the advantages set forth above.
Although the invention has been described and illustrated with
reference to specific embodiments thereof, it is not intended that
the invention be limited to those embodiments. Those skilled in the
art will recognize that variations and modifications can be made
without departing from the spirit of the invention. For example,
several temperature detection and chemical sensing devices can be
placed at various locations in and around the heat exchanger.
Additionally, different overall design shapes can be used, such as
a multi-stage heat exchanger in which two or more shell and tube
units are staged together to further increase the amount of heat
transfer. It is therefore intended to include within the invention
all such variations and modifications as fall within the scope of
the appended claims and equivalents thereof.
* * * * *