EP1888995A1 - Systeme d echange de chaleur a flux thermique variable - Google Patents
Systeme d echange de chaleur a flux thermique variableInfo
- Publication number
- EP1888995A1 EP1888995A1 EP06753618A EP06753618A EP1888995A1 EP 1888995 A1 EP1888995 A1 EP 1888995A1 EP 06753618 A EP06753618 A EP 06753618A EP 06753618 A EP06753618 A EP 06753618A EP 1888995 A1 EP1888995 A1 EP 1888995A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- heat exchanger
- heat
- plate
- heat transfer
- variable
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D9/0093—Multi-circuit heat-exchangers, e.g. integrating different heat exchange sections in the same unit or heat-exchangers for more than two fluids
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/0006—Controlling or regulating processes
- B01J19/0013—Controlling the temperature of the process
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/24—Stationary reactors without moving elements inside
- B01J19/2415—Tubular reactors
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J19/24—Stationary reactors without moving elements inside
- B01J19/248—Reactors comprising multiple separated flow channels
- B01J19/249—Plate-type reactors
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F13/00—Arrangements for modifying heat-transfer, e.g. increasing, decreasing
- F28F13/06—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by affecting the pattern of flow of the heat-exchange media
- F28F13/08—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by affecting the pattern of flow of the heat-exchange media by varying the cross-section of the flow channels
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F27/00—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus
- F28F27/02—Control arrangements or safety devices specially adapted for heat-exchange or heat-transfer apparatus for controlling the distribution of heat-exchange media between different channels
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00002—Chemical plants
- B01J2219/00004—Scale aspects
- B01J2219/00015—Scale-up
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00051—Controlling the temperature
- B01J2219/00054—Controlling or regulating the heat exchange system
- B01J2219/00056—Controlling or regulating the heat exchange system involving measured parameters
- B01J2219/00058—Temperature measurement
- B01J2219/00063—Temperature measurement of the reactants
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00051—Controlling the temperature
- B01J2219/00074—Controlling the temperature by indirect heating or cooling employing heat exchange fluids
- B01J2219/00087—Controlling the temperature by indirect heating or cooling employing heat exchange fluids with heat exchange elements outside the reactor
- B01J2219/00094—Jackets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00051—Controlling the temperature
- B01J2219/00159—Controlling the temperature controlling multiple zones along the direction of flow, e.g. pre-heating and after-cooling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00191—Control algorithm
- B01J2219/00193—Sensing a parameter
- B01J2219/00195—Sensing a parameter of the reaction system
- B01J2219/00202—Sensing a parameter of the reaction system at the reactor outlet
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00191—Control algorithm
- B01J2219/00211—Control algorithm comparing a sensed parameter with a pre-set value
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- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/00049—Controlling or regulating processes
- B01J2219/00191—Control algorithm
- B01J2219/00222—Control algorithm taking actions
- B01J2219/00227—Control algorithm taking actions modifying the operating conditions
- B01J2219/00238—Control algorithm taking actions modifying the operating conditions of the heat exchange system
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2451—Geometry of the reactor
- B01J2219/2453—Plates arranged in parallel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2451—Geometry of the reactor
- B01J2219/2456—Geometry of the plates
- B01J2219/2458—Flat plates, i.e. plates which are not corrugated or otherwise structured, e.g. plates with cylindrical shape
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2461—Heat exchange aspects
- B01J2219/2462—Heat exchange aspects the reactants being in indirect heat exchange with a non reacting heat exchange medium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2461—Heat exchange aspects
- B01J2219/2462—Heat exchange aspects the reactants being in indirect heat exchange with a non reacting heat exchange medium
- B01J2219/2464—Independent temperature control in various sections of the reactor
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2476—Construction materials
- B01J2219/2477—Construction materials of the catalysts
- B01J2219/2479—Catalysts coated on the surface of plates or inserts
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2476—Construction materials
- B01J2219/2477—Construction materials of the catalysts
- B01J2219/2481—Catalysts in granular from between plates
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2476—Construction materials
- B01J2219/2483—Construction materials of the plates
- B01J2219/2485—Metals or alloys
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
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- B01J2219/2476—Construction materials
- B01J2219/2483—Construction materials of the plates
- B01J2219/2485—Metals or alloys
- B01J2219/2486—Steel
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2476—Construction materials
- B01J2219/2483—Construction materials of the plates
- B01J2219/2488—Glass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2219/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
- B01J2219/24—Stationary reactors without moving elements inside
- B01J2219/2401—Reactors comprising multiple separate flow channels
- B01J2219/245—Plate-type reactors
- B01J2219/2491—Other constructional details
- B01J2219/2492—Assembling means
- B01J2219/2493—Means for assembling plates together, e.g. sealing means, screws, bolts
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0022—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for chemical reactors
Definitions
- This present invention relates to heat exchangers where the process material flows over a heat transfer surface
- Typical examples include plate heat exchangers, shell and tube heat exchangers, drilled block heat exchangers, jacketed tanks, jacketed pipes, vessels with internal coils etc
- the invention is particularly concerned with heat exchangers used for heating or cooling (or both) flowing materials where conditions change as the process material progresses through the heat exchanger (such as chemical reactions, polymerisation reactions, crystallisation, condensation, gas cooling etc) For example many chemical reactions are exothermic and have a rate of reaction which decays with time Thus as a reacting fluid progresses through the heat exchanger, the rate of heat liberation also declines and hence requires less cooling (per unit volume of process fluid) if the process fluid is to be held at constant temperature
- the invention also applies to systems where other parameters change such as velocity (e g heating or cooling of gases), mass flow (e g condensing vapours) or physical properties (e g viscosity or phase change) If similar cooling (or heating) conditions are employed throughout the heat exchanger, the heat transfer rate may be ideal in one zone but excessive (or insufficient) in other zones
- the invention is also suitable for applications where the product needs to be heated and cooled at different points within the heat exchanger
- the temperature control strategy in a conventional heat exchanger involves controlling the flow or temperature of a single stream of heat transfer fluid into the heat exchanger
- the disadvantage with this is that the cooling power in one zone cannot be altered without changing the cooling power in all the other zones
- the user might choose to reduce the temperature of the cooling fluid to cope with the high heat load within the initial section of the heat exchanger
- this has the effect of increasing cooling on the product further down the heat exchanger (where the rate of heat release is lower)
- This can be undesirable because it can overcool and stall the reaction (or even freeze the product in the heat exchanger)
- Excessive heating or cooling in some zones can lead to a variety of problems as undesirable temperatures, burning, boiling freezing or fouling
- insufficient heating or cooling in some areas can lead to poor temperature control or oversized heat exchangers
- some reactions are temperature sensitive and if the temperature is wrong, the reaction may progress too slowly, too quickly or the wrong reaction may take place.
- the present invention provides a system wherein process material flows through a heat exchanger comprising multiple heat transfer stages and that the heating and or cooling power applied to each stage can be modified independently.
- the quantity of heat applied to each stage may be determined from calculations of theoretical heating or cooling requirements, by a heat balance method or by a control system (manual or automated) which measures the temperature of the process material in a given stage.
- the invention is especially useful for processes where the conditions (such as heat liberation, heat absorption, specific volume or mass flow) within the heat exchanger change.
- the present invention provides an improved method of designing and using heat exchangers where the heat transfer surface is broken up into multiple separate heat transfer elements and each element can be independently set or controlled. This is done so as to achieve more uniform temperature profiles throughout the heat exchanger where processes are liberating or absorbing heat. It is also used to create non uniform temperature profiles where these are required.
- the technique is also used where a combination of heating and cooling within the same heat exchanger is required. The technique can be used to initiate strong exotherms on the cooling surface. The technique is also used to vary the strength of heating or cooling within a heat exchanger where the tolerance to heating or cooling changes by virtue of chemical or physical changes within the product.
- the process material may be a liquid, an emulsion, a super critical fluid, a vapour, a gas, a paste, solid particulates or a combination of these.
- process conduit area' refers to the cross-sectional area of the aperture through which the process material flows at a given point.
- phrase 'uniform flow 1 is used to describe a velocity profile of the process material passing through the process conduit (in a laminar or turbulent fashion) which is substantially constant across the face of the process conduit. It also implies that there are no pockets or dead spaces within the process conduit.
- the term 'substantially' is used because some variation in velocity will arise as a result of drag effects caused by the conduit walls or some other effect. Uniform flow is a desirable flow condition for many types of process for which the present invention is intended. Uniform flow is not observed with all applications of this invention however.
- a vapour condenser may contain a combination of gas and condensed liquid.
- the gas and liquid will travel at different velocities.
- this invention is suitable for systems which may use pulsed flow and in such cases; transient reverse flow and back mixing will be observed.
- uniform flow conditions cannot be achieved due to the internal geometry of the process conduit. In some cases (such as many condensing duties) uniform flow conditions may not be necessary.
- heat transfer perimeter in this document refers to the length of wetted perimeter in contact with the process material which serves to transmit heat into or out of the process material.
- the phrase 'variable volume' in this document describes heat exchangers where the process conduit area is different at different points along the process conduit.
- a simple example of a 'variable volume' heat exchanger would be a circular pipe (with for example a cooling or heating jacket wrapped around the outside) which varies in diameter at different points along the pipe. The variation in diameter may be achieved by step changes (or by a gradual change) in the diameter.
- There are also other methods for varying the process conduit area such as using displacement inserts or by varying the spacing of two plates (between which flows the process material).
- the phrase 'variable heat flux' in this document describes a heat exchanger where the heat transfer surface is broken up into multiple zones and the amount of heating or cooling applied to each zone can be independently set or controlled. It can be argued that heat flux variation is a characteristic of any heat exchanger given that the heat flux will vary as the temperature of the process material or heat transfer fluid changes.
- 'variable plate heat exchanger' in this document refers to a novel design of heat exchanger which is suitable for use as a conventional heat exchanger or it may be used as a 'variable volume' or 'variable heat flux' heat exchanger or a combination of these.
- 'plate stack' refers to a group of heat exchanger plates which are grouped together as part of a single machine.
- a unitary system (for the purposes of this document) is a single item of equipment with one or more stages.
- the process conduit can (but does not have to) pass from one stage to an adjacent stage without the need for an interconnecting pipe or duct.
- a single assembled 'variable plate' heat exchanger is a 'unitary system' (even if stages are connected to each other via a pipes or ducts from the side). The issue here is that the user could (if he wished) transfer the process fluid from one stage of the heat exchanger to an adjacent stage without the use of a pipe or duct.
- the phrase 'variable power' may be used in association with 'variable volume' or 'variable heat flux' where such methods are employed to provide non uniform heating or cooling capabilities.
- Heat exchangers are often treated as single stage systems for design purposes. As a result, a single design value may be used as the basis for sizing the heating or cooling capacity and/or the process conduit area. In practice however the heat load may be significantly different at different points within the heat exchanger. The specific volume (e.g. gas cooling) or mass flow (e.g. scrubbers) of the process material may also be different at different points. If account is not taken of these localised variations, the heat exchanger may be oversized (in terms of heat transfer capacity and process conduit area) in some areas and undersized in others.
- the process material (1) is a reacting mixture of two chemicals (5 & 6) which is liberating heat. If the heat exchanger is designed as a single stage, the zone where the two chemicals meet will get very hot even though the final temperature is within specification. The heat generated in this 'hot spot' (7) is gradually removed as the process material passes down the heat exchanger.
- Hot spots can be very undesirable as they can damage the product or promote unwanted reactions. Cold spots (in the case of endotherms) can also be equally unwelcome. If extra cooling is applied to eliminate the hotspot, the product downstream of the hot spot will also be subject to a higher level of cooling. This will result in a product temperature which is too low and this may inhibit desirable process changes in the zone downstream of the hot spot. Alternatively, the excessive cooling may damage the product or cause ice or wax to form. Control problems can also be encountered in heat exchangers where significant changes to the heat transfer conditions (such as changing condensing loads or where the process material viscosity is changing) are encountered.
- the result can be a very aggressive temperature control dynamic which can cause freezing, boiling or some form of thermal damage (according to the nature of the process).
- a heat exchanger which has the same process conduit geometry throughout and only controls the process temperature at one point (usually the discharge point) is not ideal for certain categories of process and especially those where changing exothermic or endothermic activity is observed or where the physical properties are changing within the heat exchanger. It is also not ideal for processes which require unusual temperature profiles as they pass through the system or where other intermediate heating or cooling effects (e.g. strong agitation) might exist.
- the specific volume of process material can change (e.g. cooling and heating of gases) as it passes through the heat exchanger.
- the mass of gas passing along the heat exchanger may change (condensation or scrubbing).
- the heat exchanger has a small but uniform process conduit area along its length, the process material velocity will change as it passes through the heat exchanger. This can have disadvantages. High velocities in some zones may promote erosion and or corrosion. High velocities may also cause droplets to be carried out of the heat exchanger. High velocities also require higher pressure drops to transport the process material which can make the system more costly to build and operate. A solution to this is to have an oversized process conduit. This however results in some sections having very low process material velocities.
- the preferred design of the heat exchanger of the present invention is that, where possible, a single heat transfer surface such as a plate can be subdivided into multiple heat transfer zones.
- An acceptable temperature profile on an individual heat transfer element (such as a plate) can be achieved by having 2 or more different heat transfer zones which can be independently set or controlled. For some applications, 3 or more, 4 or more, 5 or more and even 10 or more heat transfer zones which can be independently set or controlled.
- the heat exchanger of the present invention can therefore provide a continuously changing heat exchange environment or a series of step changes.
- Adiabatic temperature rise/fall Traditional variable heat flux heat exchangers such as columns with internal heat transfer coils are not well suited to applications where transient temperature changes (due to exotherms or endotherms or other heating or cooling effects within the heat exchanger) affect process performance.
- the preferred design of this invention should maintain a process temperature profile whereby the peak temperature change within the heat exchanger is less than 40% of the adiabatic temperature change. More preferably this will be less than 20% or more preferably this will be less than 10% or more preferably this will be less than 5% or more preferably this will be less than 1%.
- adiabatic no heat loss or gain
- adiabatic no heat loss or gain
- the temperature will rise by the 'adiabatic temperature rise'. If the pipe has a cooling jacket, a reduced temperature rise will be observed. Even though the final temperature maybe correct, we still see an elevated peak temperature because most of the heat is liberated by the process at the beginning (in this example) but the cooling is 'relatively' even over the length of the system. This overshoot can be reduced by employing more extreme cooling or heating temperatures. In the variable heat flux concept described in this invention, these more extreme cooling or heating conditions can be employed without overcooling or overheating all of the zones. (e) Standardisation and flexibility of design
- baffles Traditional 'variable heat flux' heat exchangers such as columns with internal heat transfer coils or traditional plate heat exchangers are relatively difficult to fit with baffles because the flow path may not be rectangular or the heat transfer surface may not be flat (or both). Under these conditions it can be difficult to design and fit a baffle which delivers a uniform velocity.
- the variable plate design can offer rectangular flow profiles and substantially flat (but some profiling might be used) heat transfer surfaces.
- traditional 'variable heat flux' heat exchangers e.g. columns
- the preferred design of the present invention provides the option of baffles (given that the plates may be operated with large gaps).
- baffles are simple to remove for cleaning, maintenance or modifications.
- the 'variable plate' heat exchanger (as described in our co-published variable plate heat exchanger patent) lends itself to a simple and adaptable solution for employing baffles, (h) Scale up
- variable heat flux heat exchangers are not used in combination with 'variable volume 1 .
- the preferred design of this invention can use 'variable heat flux' in conjunction with 'variable volume' (as described in our copending Patent Application GB0509747.2).
- the benefit of using a combination of variable heat flux and variable volume is that it increases the performance capabilities of the heat exchanger. Also, the option of variable heat flux provides a quick solution for fine tuning or modifying the cooling conditions.
- variable heat flux designs do not employ the principle of minimising the volume of the process conduit between heat transfer stages. Thus where the process material is generating or absorbing heat, the process temperature can rise or fall between the heat transfer stages.
- the design of this invention allows for systems with large or small hold-up volumes but small hold-up volumes are preferred for most duties.
- the 'variable plate' heat exchanger (as described in our co-published variable plate heat exchanger patent) satisfies these objectives.
- Fluid distribution Traditional heat exchanger designs generally do not achieve good uniform flow conditions unless they have simple unobstructed internal geometry (such as pipe or channel). Even traditional plate heat exchangers have sub optimal process material distribution (diagonal across the plate).
- FIG. 3 shows a multi stage heat exchanger (8) around a pipe carrying a process material (1) where the cooling or heating power to each stage can be adjusted with a manual valve (V1 to V6).
- the heat exchanger (8) in Figure 3 is broken up into 6 elements. Each element has a manually operated valve (V1 to V6) and a temperature measuring instrument (T1 to V6)
- the stage valves (V1 to V6) can be adjusted so that the cooling power of each stage is different. As before we have assumed that two chemicals (5 & 6) are reacted together and this operation generates heat.
- the heat exchanger can be set up by turning on the two chemical reactant streams.
- the valve V1 is then adjusted until temperature T1 is acceptable.
- the next valve V2 is then adjusted in the same way. The process is repeated until all the heat transfer elements have been tuned.
- a heat exchanger set up in this way will deliver which may be uniform temperature profile through the heat exchanger (or a non uniform profile which suits the process needs). If the respective heats of reaction are known, the reactor could be set up with an inert fluid to optimise the heating or cooling conditions right.
- the desired temperature profile across the heat exchanger may not be flat and in some cases, even a combination of heating and cooling elements may be used to achieve the ideal temperature profile.
- V7 automatic master valve
- T7 final temperature
- the manual stage valves could be tuned as a set and replaced with different sets for other process operations.
- FIG. 4 An alternative design is shown in Figure 4. This uses a substantially constant flow of heat transfer fluid (which may be recycled around the heat exchanger if necessary) but modifies the feed temperature of the heat transfer fluid by blending in a colder (or hotter) stream of heat transfer fluid using the master valve (V7).
- Automated valves can be used for tuning the heat exchanger (8) as shown in Figure 5.
- the temperature elements (T1 to T6) are used to control the position of the respective valves (V1 to V6).
- T1 is used to control V1 etc (for purposes of drawing clarity, the individual controllers have not been shown).
- valve positions can be set or modified automatically and information about the valve positions can be stored in the software.
- the master value (V7) referred to in Figures 3 and 4 has not been shown.
- V7 is not essential since V6 provides control of the final process temperature.
- the 'variable heat flux' (or 'variable volume') heat exchanger can also be used as a calorimeter as shown in the simplified diagram Figure 6 (where the valve and control details have not been show for diagrammatic simplicity).
- the instruments shown in Figure 6 include a mass flow meter for the heat transfer fluid (m), an inlet heat transfer fluid temperature (T 1n ) and outlet heat transfer fluid temperature (T ou t).
- the specific heat of the heat transfer fluid in and out (Cp 1n and Cp 0Ut ) can be determined from published literature, by experimentation or from a known mathematical relationship.
- the system may use a recycle loop.
- the heat balance mass flow and temperature shift of the heat transfer fluid
- the system will have to be zeroed for ambient losses, pump energy etc.
- a heat balance on the process material can also be carried out by a similar method (by measuring the mass flow and temperature change as it passes through the heat exchanger).
- the overall heat balance provides information about the efficiency of the reaction and allows the user to make intelligent decisions about such parameters as process feed rate, operating temperatures, recycle rates etc.
- An alternative temperature control strategy is to use fixed stage valves positions (V1 to V6) and cascade them open with a multi port valve as shown in Figure 7.
- the design shown in Figure 7 uses manual stage valves (V1 to V6) and these are set using the method described earlier.
- the multi port valve is used to switch on the heat exchanger and to control the temperature of the product leaving the heat exchanger.
- the multi-port valve allows the user to control the outlet temperature from the heat exchanger. In this design, it may be desirable to provide a number of similarly tuned stages at the back end (e.g. stages 3 to 6) to create some linearity of control for the final temperature.
- a heat exchanger with automated stage valves and a multi port valve is shown in Figure 8 where the common pipe (9) is a source of hotter (or colder) heat transfer fluid.
- the design shown in Figure 8 allows the user to set the system up with different heat transfer areas. This is useful for modifying the sensitivity of the calorimetry or for changing the temperature control dynamics.
- Variable volume heat exchanger design The best way of illustrating the principle of 'variable volume' is to use a worked example as described in Table 1. The example is based on an exothermic reaction and the numbers used in this example have been created for illustration purposes only.
- the heat load can be broken up into six time components that give comparable enthalpy releases as shown in the table below.
- the heat load could be broken up into more components, or could be divided into different ratios (for example the enthalpy values could be modified to compensate for variations in the heat transfer coefficient along the conduit).
- the cooling power (q) required per stage within the heat exchanger.
- the heat exchanger shall be designed as a six stage system with each stage removing 1000 Joules (per kg) and that that product is fed to the reactor at a rate of 1 kg.s '1 .
- the heat load on the first stage is 1000 J and the residence time needs to be 0.2 seconds.
- the heat transfer area (A) required per stage It is possible to calculate the heat transfer area (A) required per stage. For the example calculation, it is assumed that all stages have the same heat transfer area, the heat transfer coefficient is 1000 W.m "2 .K '1 and that the process is operating at 3O 0 C and the cooling jacket is at O 0 C.
- each plate stage (L) is then calculated. For the example calculation, it is assumed that the plate is 3 times as long as it is wide
- the length (L) of the plate on each stage is:
- the length of the plate on the first stage is also:
- the plate area for the first stage is half the heat transfer area. The reason for this is that there are two parallel plates on either side of the flow channel in the first stage.
- the width of the stage is:
- the linear velocity (V 1 ) on the first stage is:
- V 1 L/ ⁇ , (m.s 1 )
- L the flow path length of the stage (m)
- ⁇ residence time of first stage (s)
- the next step is to find the volumetric flow rate of process material (G). It is assumed that the density (D) of the process material is 800 kg.m "3 .
- Vi linear velocity of process material (m.s '1 )
- the plates for this design are 500 mm long and 167 mm wide.
- the plate separation on the first stage is 3 mm.
- the plate separation gap on the second stage (Z 2 ) can then be derived in the same way.
- Z 2 6 mm
- the plate spacing can get very large in the latter stages (for this particular reaction). This can create fluid distribution problems and an option is to fit baffles in the latter stages (to increase the effective path length for the process fluid).
- Another option is to carry out the last few stages in a different type of heat transfer device. For example, the last few stages could be carried out in a large stirred batch tank or using a loop design. It could also be done semi batch mode with a cascade of medium sized stirred vessels. Alternative if uniform flow is required, the reaction could be carried out in a long pipe (with cooling) or in a shorter fatter tube with pulsating flow (with cooling).
- a more rigorous analysis of each stage can be undertaken to evaluate the temperature profile across an individual plate. This may reveal that more than 6 stages are required to achieve a sufficiently uniform temperature profile. In some cases it may be necessary to vary the cooling power per stage in a non uniform way in order to create a specific temperature profile. In some cases this may require both heating and cooling on the same heat exchanger.
- the 'variable heat flux' technique can be applied to the plates (if necessary) to modify or fine tune the process temperature profile. This avoids the need for further mechanical modification of the plate gaps.
- variable volume design is that, if the right solution is employed a single temperature controller can deliver the preferred heating or cooling profile across the heat exchanger (even though the cooling or heating requirements are different in different parts of the heat exchanger. Whilst 'variable volume' is a good solution, the additional or alternative option provided by the present invention of multiple independently controlled heat transfer zones is valuable enhancement for a variety of reasons: • There is a limit to how high the ratio of surface area to plate spacing can be altered. If the heat exchanger is designed as a series of small pipes, blockages will start to become a problem as the pipes get very small.
- the user may want to vary the heat exchanger operating conditions without having to rebuild the heat exchanger. This may be because the user wants to try out different temperature profiles. It could also be because the heat exchanger is required to handle different products or different product feed rates.
- Heat exchangers can be designed with a variety of intrusive heat transfer surfaces (such as internal coils, pipes or plates) within the process material. Intrusive heat transfer surfaces however have complex design relationships since any change to the heat transfer surface affects the process conduit area. They can also be difficult to clean and can be vulnerable to blockages. They can also create sub-optimal flow profiles such as uneven flow and or stagnant pockets. This can be undesirable for the process and make custom design or modifications difficult. These problems can be overcome by using heat exchangers according to the present invention.
- Heat exchangers with simple geometric profile A preferred solution is a heat exchanger where the process conduit has simple internal geometry (apart from surface profiling for enhancing the heat transfer conditions and flow characteristics) and which only uses the process conduit containment surface as the heat transfer surface and does not have projections such as leaves coils or pipes within the process material.
- a simple manifestation of this concept is a round (or other simple geometric shape) pipe surrounded by a heating/cooling surface. For a given pipe diameter, the amount of heating or cooling that can be applied is dependant on fluid velocity and pipe diameter. By using a series of connected pipes of different diameters, the heat transfer perimeter to process conduit area can be adapted to meet the heat transfer needs at different stages of the process. To alter the heating or cooling capacity for a given pipe size, the process material velocity is changed.
- Plate design A plate heat exchanger is an improvement on the simple pipe concept. It has a simple relationship between heat transfer perimeter and process conduit area (by varying the plate spacing). It has no obstructions and it is easy to build and clean. The plate solution is therefore a good solution for 'variable volume' heat exchangers.
- variable plate heat exchanger For many reasons the traditional plate heat exchanger does not lend itself to the concepts of 'variable volume' or 'variable heat flux'.
- the section below describes a new type of heat exchanger which is designed for use both as 'variable volume' and 'variable heat flux 1 (or a combination of the two). It is referred to a 'variable plate heat exchanger and further descriptions can be found in the copending Patent Applications GB0509746.4 and GB0509747.2 on 'variable heat flux' and 'variable plate heat exchangers'. The considerations and solutions of the new variable plate design are discussed below. (a) Variable plate - variable volume
- FIG. 11 illustrates how multiple plates can be stacked together in alternating directions to create a large multi stage variable plate heat exchanger.
- Figure 11 shows a four stage heat exchanger made up with five plates where the process material enters at the bottom (18) and exits at the top (19). Header plates (20) are fitted on either end of the heat exchanger. The plates can be assembled with spacers (21 ) and gaskets and compressed together using tie bolts (22) (or some other method). As the diagram shows, the plate spacings (in this example) get progressively larger as the process material proceeds through the heat exchanger (this would be suitable for an exothermic reaction where heat liberation is strongest in the early stages). In the case of a condenser, the plate spaces would tend to be large at the beginning and get progressively smaller through the heat exchanger.
- Figure 12 shows how a wedge shaped design can be used to create free draining characteristics across the whole system. For diagrammatic simplicity the variable plate spacing has not been shown.
- the ratio of process conduit area to heat transfer perimeter can be altered by modifying the either the process conduit area or the heat perimeter (at different points through the heat exchanger) however the preferred design of this invention is that the heat transfer area per unit length of conduit path remains constant.
- FIG. 18 shows how a single plate can also be broken up into multiple heat flux stages by segmenting the heat transfer surface into zones (38).
- zones (38) In this example three zones (38) have been created on a single plate.
- the process material enters through the slot from the previous plate (36), and flows along the plate surface (39) and exits in the slot (37) to the next plate.
- the heat transfer fluid enters (40) and exits (41) the zone.
- the inlet and outlet pipes (40 and 41) can be joined together to create a single long conduit. This arrangement would give the user the option to change from a single zone to multiple zones with minimal modifications.
- plate heat exchangers have uniform plate gaps of usually between 1 and 5 mm.
- the preferred design of this invention may use multiple plate gaps which can vary from less than 0.01 mm to more than 100 mm. A typical range however will be between 0.5 mm and 50 mm. If catalyst material is contained within the process conduit, the plate spacing may vary from 10 mm (or smaller) to 300 mm (or larger).
- Figure 14 shows a sealing arrangement with a spacer.
- the plate separation is created by a hard spacer or shim (30) around the perimeter of the plate. Inside this sits a gasket or O ring (29) to form a seal.
- Figure 15 shows a larger plate separation arrangement.
- the spacer (32) shown has seals (31) on the top and bottom faces (in this diagram, the seal material has also been used to protect the wetted face of the spacer) of the spacer.
- O rings can be used.
- the plate spacers can be designed to be tapered from one end of the plate to the other. This allows the ratio of the heat transfer perimeter to the process conduit area to be varied across the plate (in the direction of the process flow path), (e) Variable plate: 'Variable volume' and 'variable heat flux' stages
- the preferred design of this invention will use two or more plates which have independent means of setting or controlling the plate temperature.
- three or more such plates (or groups of plates) may be used and in some cases this number may be 4 or more, five or more or even 10 or more.
- the preferred design of this invention will use two or more zones on each plate (or some plates) with heating (or cooling) profiles which can be independently set or controlled.
- variable plate heat exchanger may have between two and more than two hundred stages.
- Variable plate Simultaneous heating and cooling
- Traditional plate heat exchangers employ heating or cooling. Where a combination of heating and cooling is required, a break in the plate pack is required.
- the design of the variable plate heat exchanger permits any combination of heat and cooling services to each plate without breaks or special modifications to the plate pack,
- Variable plate Standardisation of fabrication
- Traditional plate heat exchangers use pipe conduits to deliver and remove process material from the plates. To alter the size of this pipe conduit requires a different gasket size, a different hole size in the plate and a different pipe size.
- the preferred design of this invention allows the size of the process conduit between the plates to be modified by altering a single component. The preferred size can be achieved by machining a slot (as shown by (15) in Figure 10) or drilling holes in the plate. If necessary, the plates can also be designed with large slots and have insert plates with different hole sizes or slots used to achieve the preferred profile.
- the design of the present invention will permit instruments to be fitted into the inter plate process conduit and that such instruments can be inside the body of the plate pack and fully surrounded by process fluid (where necessary).
- the size of the inter plate process conduit shown as item (15) in Figure 10 has a process conduit area (whether it is a single slot or a series of holes) which is the largest that may be required for that that particular heat exchanger range. This means that a single plate design can be used for any position on the plate stack. There are however instances where this principle would not be employed (for example where the inventory of the inter plate process material needs to be minimised).
- the inter plate process conduit (15) of Figure 10 can be formed as an integral part of the heat transfer plate. By making the heat transfer plate wider (and longer) the inter plate process conduit can be made as large as is required. By creating a hole through the side or back of the plate, equipment like temperature probes, drains, sample points, instrument probes, emergency relief, and injection points can be fitted where ever needed. Also such instruments can be added or removed after the plate pack has been assembled.
- Process material can also be diverted into or out of the plate at any point (as describe elsewhere and shown in Figure 21).
- Access to the process material can also be achieved from underneath the plate (from the heat transfer side) at any point. In this case, the penetration passes through part of the heat transfer slot (12) in figure 10. Alternatively, the process material can be accessed through holes in the spacer where it is thick enough. This is shown (21) in Figure 11.
- Variable plate heat transfer fluid conduit geometry
- the plates of traditional plate heat exchangers are not fed by heat transfer fluid with independent conduits to each plate and the heat transfer conduits pass through the main body of the plate pack.
- the preferred design of this invention is that the heat transfer fluid conduit enters each plate from the side to facilitate independent temperature control (or monitoring) of each plate.
- the + symbol indicates heat transfer fluid entering the system and - symbol indicates heat transfer fluid leaving the system (the direction of flow of the heat transfer fluid is optional). This allows heating and cooling fluids to be used simultaneously on different plates within the same plate stack and also different heat transfer fluids and different temperature control strategies on individual plates within the same stack.
- Q) Variable plate Plate size The plates of traditional heat exchangers are built in a range of different sizes.
- the plate area (on one side) can be the same size as any traditional plate heat exchanger may vary from less than 10 mm 2 to more than 10 m 2 but is normally in the range of 100 mm 2 to 1 m 2 .
- Variable plate Internal profile Traditional plate heat exchangers do not have clean crevice free and fully draining internal profiles.
- the preferred design of the present invention is for a heat exchanger which can have a clean internal profile and which can be fully draining and can be free of pockets or obstructions. Also the preferred design should be fully drainable either by fitting drains to each plate stage (or every other plate stage depending on orientation) or have a plate profile such that all the plates drain to a single point.
- inter plate process conduit can also be profiled such that the internal surface has no sharp corners which can trap dirt or product.
- Variable plate Cleaning and dismantling
- the preferred design of the present invention is a system which can be totally flexible including co-current, counter current, cross flow, or a mixture of these (for either process material or heat transfer fluid).
- the reason for this flexibility is that heat transfer fluid and process material can be diverted into and out of the plate pack on every plate.
- This provides total flexibility for flow strategies. For example (which might be used for an exothermic process), the process material could flow through four plates in parallel followed by two plates in parallel followed by five single plates in series. The ability to use parallel and series flow together is valuable for scale up where narrow plate spaces on one stage could represent a capacity constraint. In some cases, plates can be skipped or the process fluid from one plate can be used as the heat transfer fluid for another plate (for heat recovery purposes).
- Variable plate Flow distribution
- good flow distribution can be achieved by feeding the process material from the full width of the plate and discharging off the plate via the full width of the plate as shown by item 15 in figure 10.
- inter plate slot multiple inter plate holes can be drilled across the face of the plate. These small holes can be located within a slot or larger shallow holes to reduce the effect of non uniform velocity profiles near the inter plate holes.
- Relatively long (in the direction of process flow) and narrow heat exchangers can be desirable for some applications as they offer more scope for cross mixing on the plate and have a reduced tendency for channelling by virtue of the plate width.
- a greater number of relatively short plates can also be desirable, especially where narrow plate spacings are used.
- short plates the impact of imperfections in the heat transfer surface (which will promote bias in the flow profile) is reduced.
- Profiling of the heat transfer surface can be used to improve heat transfer area, heat transfer coefficient, and induce some cross mixing of process material across the surface of the heat exchanger
- a good flow profile can be promoted by having profiled ridges or baffles (across the full height of the plate gap) that follow the same direction of flow as the process material can be used to break up the flow path into a series of parallel channels
- full width baffles and near full width baffles can be used.
- Full width baffles can be used to create a uniform flow (by having a series of small holes or slots across the full flow path)
- a different kind of baffle can be used to draw all the process material through a small hole on the plate for the purpose of mixing If necessary, multiple flow control and mixing baffles can be used across the plate
- Another kind of baffle can be used to induce the process material to travel across the plate via a longer route (side to side or up and down) Baffle arrangements of this type can be used to maintain substantially uniform flow where the plate spacings are wide Variable plate Heat transfer
- An alternative technique is to use one or more small heat transfer conduits to deliver the heat transfer fluid
- Reduced volume heat exchangers were described in Patent WO2004/017007 A2
- an intermediate layer of conductive material is used to transmit heat between the heat transfer fluid conduits and the heat transfer surface This is desirable for a number of reasons including more efficient and more uniform transmission of heat
- a very small inventory of heat transfer fluid can be used and good control and efficient transmission of heat remains possible even at very low flow rates This latter benefit is useful for heat balance calorimetry
- heat from the heat transfer fluid is transmitted to the process heat transfer surface using conductive plates.
- WO2004/017007 described how the conductive plates could be fitted to the heat transfer surface by clamping or spring loaded mechanisms and that conductive mats or grease could be used to exclude air between the copper plate and the heat transfer surface.
- the heat transfer pipe (carrying the heat transfer fluid) (33) can be connected externally to a thermally conductive sheet which is sandwiched between the process plates as shown in Figure 16.
- conductive plates within the heat transfer slot can be used.
- the alternative to a conductive plate is to use a thermally conductive filler to transmit heat between the heat transfer fluid conduit and the heat transfer surface. The following options can be used.
- the space between the plates can be filled with a good thermally conductive material like metal. Materials like lead, silver, tin, aluminium and copper are ideal for this as they have low melting points and good thermal conductivity. They can be melted into the space between the plates after the small pipe has been inserted (assuming that the process conduit material does not melt.
- the space between the plates can be filled with a conductive solid such as copper powder. Mixtures of different power sizes can be used to achieve the best packing density. A mixture such as copper granules, copper powder and fine carbon black can also be used to achieve good packing densities.
- the powder can be compressed into place with inserts or other methods.
- a heat transfer element can be cast around a copper pipe (pipes) with thermosetting or thermo plastic. This can then be inserted between the leaves of the two plates in the location shown by (59) in Figure 22.
- the space between the plates can be filled with solids as described previously and then filled with an inert liquid such as silicone oil to exclude the air. Such filling operations can be done under vacuum and/or at elevated temperatures to reduce the air.
- the system can then be sealed with a plate or a layer of filler material.
- the conductive solids can be set in a plastic, synthetic rubber or polymer material. Alternatively some form of grease can be used.
- a fluid can be used to transmit the heat from the heat transfer fluid pipe to the process heat transfer surface. This should be as thermally conductive as possible
- Figure 17 shows a 'reduced volume' design where the heat transfer fluid pipe (34) is sandwiched between two process plates. In this case two heat transfer fluid pipes are shown. It shows a plan view (showing a plate with the process slot (35) similar to the diagram featured in Figure 10.
- the heat transfer fluid can be delivered in a variety of co-current and counter current and cross flow configurations within each plate. This can be achieved with a flow plenum for the heat transfer fluid or a single or multiple small copper pipes.
- the use of co current and counter current flow strategies can be used to reduce non uniformity of heating or cooling.
- Some plates may only have one side heated or cooled. For some applications it may be desirable to have a relatively thick plate (to create a large inter plate conduit for example). With very thick plates, it may be preferable to provide separate heating (or cooling) supplies to each side of the plate. In other cases a wedge shaped plate might be preferred. (p) Variable plate: special fittings
- Figure 19 shows how instruments can be fitted to the inter plate slots (42).
- a probe (43) could be fitted into the slot to measure such things as temperature or pH.
- a pocket could also be fabricated for a temperature probe (44) without cutting right through to the process conduit.
- the process is unaffected by the plate thickness (other than a small increase in the inter stage process material hold up volume).
- the heat transfer plates can be made thicker (where necessary) to mount larger probes within the inter plate slots.
- the inter plate slots (42) or holes can also be fitted with drain points for such operations as draining condensate, cleaning or decontamination.
- the heat exchanger is used as a condenser, it could be oriented so that the flow of the process material passes up and down through the plates.
- the lower inter-plate slots could be fitted with drain points.
- FIG. 20 shows how addition can be made across any plate.
- multiple reactant injection nozzles (46) are drilled into the inter plate slot between the plates (47).
- the reactant is then supplied through a common reactant flow slot (48) (sealed with a slot cover (49) from a single reactant addition conduit (50).
- the holes for the injection points can be drilled to intercept at right angles or at a more oblique angle to create a venturi effect.
- FIG. 21 illustrates a bypass arrangement whereby product flowing (51) over the heat transfer zone (56) on one side of the plate reaches the process slot (53).
- variable plate design as shown in Figure 10 lends itself to cleaning in place systems (CIP).
- Spray nozzles can be drilled into the plate around the process material slot (15) or mounted on a shoulder between the process slot and the gasket. Spray points could also be fitted within the spacer that separates the plates (item 21 in Figure 11).
- Variable plate heat exchangers can be built in any normal material such as plastic, steel, alloy, glass, glass lined steel, plastic lined steel, titanium, tantalum, exotic alloys, stainless steel and a variety of other materials.
- the plates can also be lined or dipped or coated by some other means to create a protective layer.
- the thickness of the plates can be from less than 0.5 mm thick to more than 10 mm thick depending on the operating conditions such as pressure and temperature.
- the plates for the variable plate heat exchanger can be cast, machined or fabricated in sections and welded together. They can also be fabricated out of two or three layers of material and joined together by welding, soldering, gaskets, gluing or some other method.
- Figure 22 shows a three layer system with the process slot (57) sealed with a gasket (58) to create the heat transfer slot (59).
- bleed holes (60) across the width of the plate can be provided to ensure that leaks by either the heat transfer fluid or the process fluid do not cross contaminate each other.
- the plates with their accompanying spacer may be welded together if this is preferred. Where access is required for cleaning, maintenance or modifications, the plates can be compressed together with gaskets.
- the gasket material may be metal, synthetic rubber, natural rubber, plastic, a composite of several materials (such as PTFE envelope gaskets).
- a double seal arrangement with a leak channel between the two seals can also be used if required.
- An alternative fabrication method for the process conduit is to have two long strips of material (such as metal) folded into a series of passes and then sealed together with side panels to form a containment volume. Heat transfer surfaces can then be inserted into the folds from the outside.
- variable plate concept can be exploited in other ways, such as a cylindrical design as shown in Figure 13 where the process material enters at the bottom (18) and exits at the top (19).
- relatively large pipes (26) with a displacement inserts (27) are used to different process conduit areas.
- Each of the pipes is then surrounded by a heating/cooling jacket (28).
- Options such as spiral baffles and profiled surfaces can be used to control the flow.
- This design can use heat transfer surfaces on the inner and outer layers however this would be a relatively complicated arrangement.
- variable plate heat exchanger of the present invention has advantages over conventional plate heat exchangers in many respects. It can be built for general heating and cooling duties in the same way as a conventional heat exchanger (with uniform plate spacings). Because the user can define the plate spacings however, the heat exchanger can be set up with the ideal ratio of heat transfer capacity to mass flow capacity for a given application. Thus, by changing the plate spacers, the same heat exchanger plates could be adapted for use on high or low throughput of process material.
- a heat exchanger of this design can also have better heat transfer characteristics, drain points, sample points, inline line instruments on one or more plates, addition points, inter stage boost pump and more flexible options for flow strategies for the heat transfer fluid and the process fluid. This design also offers cleaner internal geometry and free draining characteristics (and cleaning in place where necessary)
- variable plate design is also ideal for exploiting the 'variable volume' and 'variable heat flux' principles. The benefits and uses of all of these are discussed below.
- Temperature control is essential for many process operations. Traditional temperature control techniques can provide very good temperature control of the final product but are not always good at preventing hot or cold spots. Transient deviations in temperature within a process can be undesirable. For example, temperature deviations can variously stop reactions from taking place or promote the wrong type of process change (such as the wrong reaction). In some cases temperature deviations can trigger dangerous runaway reactions. Temperature deviations can also cause undesirable changes to take place such as boiling, freezing or burning within a process. In the case of a polymerisation process, unwanted transient temperature deviations can affect product quality. Very good temperature control can enhance selectivity in some processes to give better yields and quality.
- variable volume principle the heat transfer capabilities of a heat exchanger can be profiled in such a way that a uniform temperature profile is maintained through the heat exchanger despite the uneven process heat load (on a per unit volume basis).
- strong heating or cooling can be desirable at one point in the heat exchanger but cause damage in another (e.g. where viscosity is changing in heat sensitive products).
- the variable volume principle allows the user to moderate heating or cooling where required.
- Variable heat flux heat exchangers may also be used for more sophisticated control strategies. It might, for example, be desirable to allow a moderate temperature rise of the feed materials (by applying very weak cooling) followed by strong cooling at the end of reactor. In other cases it might be desirable to use heating and cooling simultaneously.
- the reactants of a very strong exotherm could be mixed together in a very cold condition (to inhibit the reaction) and warmed by a small section of the heat transfer surface to initiate the reaction. By doing this, the reactants could be well mixed and in the ideal position on the heat transfer surface when the reaction starts. In some circumstances a given heat exchanger might employ a number of heating and cooling cycles.
- variable volume and variable heat flux concepts separately or in combination are good for process operations where a change in the physical properties of the process material could lead to problems.
- a change in the viscosity of the process material as it passes through the heat exchanger can affect the heat transfer properties and as a result lead to thermal damage or freezing or boiling in the product.
- variable volume and/or variable heat flux strong heating or cooling can be applied at some stages and gentler heat transfer conditions can be applied elsewhere.
- the 'variable volume' concept is ideal for handling process materials which vary in specific volume or mass flow rates. Examples include heating and cooling of gases and condensation or evaporation of liquids. 'Variable volume' for these applications provides better scope for optimising performance, size, cost, efficiency and pressure drop through a given heat exchanger. This offers the prospect of heat exchangers that give better performance, are cheaper to build and more energy efficient to operate. Variable heat flux can be an additional advantage for such applications given that the heat transfer coefficient and or heat load may vary significantly in such processes.
- variable volume and variable heat flux can be used to good effect. This is particularly useful for systems designed to remove moisture or volatile compounds from gases.
- the formation of ice or wax can be monitored (using temperature, condensate flow, pressure drop, proximity switch to detect ice, electrical continuity, temperature changes in the heat transfer fluid etc) in vulnerable stages.
- the heat flux within the given stage (or group of stages) can be modified to arrest the problem.
- the cooling power can then be increased on other stages as necessary to compensate for this.
- the heat exchanger can thus be set up with manual valves or continuously monitored for signs of icing and adjusted as necessary.
- Another control strategy (which does not have to use 'variable heat flux') is to monitor for ice formation and adjust the temperature of the whole system.
- Another control strategy (which does not have to use 'variable heat flux') is to monitor for ice formation and control the heat transfer area as shown in Figure 7.
- reaction liberate or absorb too much heat for conventional heat transfer equipment.
- An example of this is a chemical reaction where the transient temperature rise (or fall) of the reaction damages the product or affects the process in some way. In some cases, this effect can prevent the reaction being operated at all whilst in other cases the problem is managed by diluting the reaction mixture with a solvent (which may be undesirable and reduces the capacity of the equipment).
- the cooling that can be applied within a given time (and per unit volume of process material) can be increased by increasing velocity and reducing the thickness of the layer of process material as it passes over the heat transfer surface. As the velocity increases and the layer (between the two heat transfer surfaces) gets thinner however, so the pressure required to move the fluid increases. Pressure drop ultimately becomes the limiting factor to how thin the process conduit can be made for a given velocity. If the heat exchanger has a process conduit with a constant process conduit area, then a high pressure drop has to be applied across the entire unit rather than where the heat liberation (or absorption) is most vigorous.
- variable volume design can always deliver better heat transfer performance where the liberation (or absorption) of heat from the process is non uniform.
- heat exchangers built on the variable volume principle can control the temperature of stronger exotherms or more concentrated mixtures of reactants. This has numerous advantages such as faster reactions, better selectivity, reduced use of diluents etc.
- the heat transfer fluid in a variable plate heat exchanger is piped into each plate separately and the same can be achieved with the process conduits.
- any number of flow strategies can be employed such as heat recovery systems. (E.g. where the process feed material is heated by the process discharge material).
- variable plate design allows users to monitor and evaluate different temperature profiles across the heat exchanger. It also offers a simple means of taking samples for analysis at intermediate points. The temperature profile through the heat exchanger can be tuned to a variety of profiles. The heat liberated or absorbed by the process can be monitored. It also has good scale up characteristics (wider plate plates or multiple units). These features make it an ideal tool for research and development, scale up and full sized manufacturing plants.
- Figure 23 is a simulation study carried out which compares the system of the present invention (VHX) with a simple heat exchanger (Conv 2) and a large area heat exchanger (Convi).
- VHX system of the present invention
- Conv 2 suffers a serious overshoot followed by undershoot.
- Convi reduces the overshoot but at the expense of a severe undershoot. Accordingly both Convi and Conv 2 have poor temperature control because they undershoot at the end.
- the variable plate design does not undershoot and has a greatly reduced peak temperature.
- Conv 2 is conventional heat exchanger and the overshoot goes to 470 0 K. After the overshoot, the heat exchanger undershoots and drags the temperature down to 318 0 K (34 0 K below the starting temperature). This undershoot could be avoided at the expense of even more overshoot.
- Conv 1 is a heat exchanger with a high surface to volume relationship. Again this drags the process temperature down at the end of the process. This cooling effect at the end of the process could stall the reaction
- variable plate design can be an ideal solution.
- variable plate heat exchanger may be used with or without either the 'variable heat flux' concept or the 'variable volume' concept.
- variable heat flux, variable volume and the variable plate design are valuable for the process industries. They can be used in batch processes, semi continuous processes and continuous processes. Where it is used with batch or semi continuous processes, it is preferable that the variable plate, variable volume or variable heat flux heat exchanger is mounted within a recycle loop to achieve flow over the process surface. For these types of applications, benefits such as better selectivity of reactions, faster processes and reduced use of raw materials can be enjoyed.
- the heat exchanger can also be better sized for the process duty in terms of process conduit area (even where this is uniform across the plates).
- Variable heat flux and variable plate heat exchangers are useful for applications where particular temperature profiles are required within the heat exchanger. This includes many chemical and pharmaceutical and bio pharmaceutical processes and also the many processes in the food industry.
- Variable heat flux heat exchangers are ideal for reactions which use catalysts. For such applications, 'variable heat flux' is also a valuable addition.
- the catalyst material may be coated onto the heat transfer surface or it may be contained as some form of solid within the process conduit.
- Variable heat flux, variable volume and variable plate heat exchangers are useful for applications where space or build cost (by virtue of size) is an important consideration. Examples include road vehicles, oil rigs, ships, aircraft, off shore installations, buildings, refrigeration systems, heating and ventilation systems etc. In the case of large systems, low cost heat exchanger elements could be created by using large sheet metal panels with small copper pipes (for heating or cooling) sandwiched between the plates (and with the possible use of a thermally conductive filler).
- ⁇ Variable plate heat exchangers have applications (with or without variable volume or variable heat flux) where clean internals and good self draining properties are desirable. Good applications for this include process condensers in pharmaceutical and fine chemical applications.
- Variable plate heat exchangers are ideal for applications where disassembly for cleaning is desirable. This includes the food industry and pharmaceutical manufacturing but also other manufacturing processes where intermittent cleaning is desirable.
- Variable heat flux, variable plate and variable volume heat exchangers are ideal for removing moisture and solvents from gas streams. In this respect they can be used for pollution abatement from chemical or pharmaceutical processes or for cooling combustion processes.
- Variable plate heat exchangers can be used for heat exchange applications where a particular conduit size is required in relation to heat transfer area, or an option to modify the conduit size at minimal cost.
- variable plate heat exchangers have many applications such as heating and cooling bulk process liquids or water.
- Variable heat flux heat exchangers can be used in the generation of steam, for heat transfer in nuclear reactors, in the water industry, in the chemical industry, in the petrochemical industry. They can be used for such applications as domestic heating and cooling systems, domestic water heaters and refrigerators.
Abstract
L’invention concerne un système d’échange de chaleur dans lequel une matière de traitement (1) s’écoule à travers un échangeur de chaleur comprenant une pluralité d’étages de transfert de chaleur dont le niveau de chauffage ou de refroidissement peut être modifié individuellement. Le système comprend un échangeur de chaleur unitaire comprenant une surface de transfert de chaleur constituée d’une pluralité d’éléments ou de secteurs sur lesquels s’écoule une matière de traitement. Chaque élément ou secteur est doté de moyens individuels (V1-V6) permettant de fixer ou de réguler le niveau de chauffage ou de refroidissement au sein de cet élément ou secteur.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GBGB0509742.3A GB0509742D0 (en) | 2005-05-13 | 2005-05-13 | Variable heat flux heat exchangers |
PCT/EP2006/004551 WO2006120028A1 (fr) | 2005-05-13 | 2006-05-15 | Systeme d’echange de chaleur a flux thermique variable |
Publications (1)
Publication Number | Publication Date |
---|---|
EP1888995A1 true EP1888995A1 (fr) | 2008-02-20 |
Family
ID=34708091
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP06753618A Withdrawn EP1888995A1 (fr) | 2005-05-13 | 2006-05-15 | Systeme d echange de chaleur a flux thermique variable |
Country Status (4)
Country | Link |
---|---|
US (1) | US20090120629A1 (fr) |
EP (1) | EP1888995A1 (fr) |
GB (1) | GB0509742D0 (fr) |
WO (1) | WO2006120028A1 (fr) |
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-
2006
- 2006-05-15 US US11/920,095 patent/US20090120629A1/en not_active Abandoned
- 2006-05-15 EP EP06753618A patent/EP1888995A1/fr not_active Withdrawn
- 2006-05-15 WO PCT/EP2006/004551 patent/WO2006120028A1/fr active Application Filing
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Also Published As
Publication number | Publication date |
---|---|
GB0509742D0 (en) | 2005-06-22 |
WO2006120028A1 (fr) | 2006-11-16 |
US20090120629A1 (en) | 2009-05-14 |
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