US20160231072A1 - Mixed material tubular heat exchanger - Google Patents
Mixed material tubular heat exchanger Download PDFInfo
- Publication number
- US20160231072A1 US20160231072A1 US14/464,152 US201414464152A US2016231072A1 US 20160231072 A1 US20160231072 A1 US 20160231072A1 US 201414464152 A US201414464152 A US 201414464152A US 2016231072 A1 US2016231072 A1 US 2016231072A1
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- Prior art keywords
- temperature
- heat exchanger
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- 239000000463 material Substances 0.000 title claims abstract description 28
- 239000012809 cooling fluid Substances 0.000 claims abstract description 24
- 238000001816 cooling Methods 0.000 claims abstract description 15
- 239000012530 fluid Substances 0.000 claims description 45
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 20
- 238000005219 brazing Methods 0.000 claims description 18
- 229910045601 alloy Inorganic materials 0.000 claims description 14
- 239000000956 alloy Substances 0.000 claims description 14
- 239000000945 filler Substances 0.000 claims description 12
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 10
- 229910052759 nickel Inorganic materials 0.000 claims description 10
- 229910052719 titanium Inorganic materials 0.000 claims description 10
- 239000010936 titanium Substances 0.000 claims description 10
- 239000010935 stainless steel Substances 0.000 claims description 8
- 229910001220 stainless steel Inorganic materials 0.000 claims description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 7
- 229910052782 aluminium Inorganic materials 0.000 claims description 7
- 238000000034 method Methods 0.000 claims description 6
- 239000007787 solid Substances 0.000 claims description 6
- 229910001069 Ti alloy Inorganic materials 0.000 claims description 4
- 239000003570 air Substances 0.000 description 33
- 238000010586 diagram Methods 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 238000000429 assembly Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000002828 fuel tank Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
Images
Classifications
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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
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C6/00—Plural gas-turbine plants; Combinations of gas-turbine plants with other apparatus; Adaptations of gas-turbine plants for special use
- F02C6/04—Gas-turbine plants providing heated or pressurised working fluid for other apparatus, e.g. without mechanical power output
- F02C6/06—Gas-turbine plants providing heated or pressurised working fluid for other apparatus, e.g. without mechanical power output providing compressed gas
- F02C6/08—Gas-turbine plants providing heated or pressurised working fluid for other apparatus, e.g. without mechanical power output providing compressed gas the gas being bled from the gas-turbine compressor
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02C—GAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
- F02C7/00—Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
- F02C7/12—Cooling of plants
- F02C7/16—Cooling of plants characterised by cooling medium
- F02C7/18—Cooling of plants characterised by cooling medium the medium being gaseous, e.g. air
- F02C7/185—Cooling means for reducing the temperature of the cooling air or gas
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
- F02M26/00—Engine-pertinent apparatus for adding exhaust gases to combustion-air, main fuel or fuel-air mixture, e.g. by exhaust gas recirculation [EGR] systems
- F02M26/13—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories
- F02M26/22—Arrangement or layout of EGR passages, e.g. in relation to specific engine parts or for incorporation of accessories with coolers in the recirculation passage
- F02M26/29—Constructional details of the coolers, e.g. pipes, plates, ribs, insulation or materials
-
- 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
- F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
- F28D1/02—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid
- F28D1/04—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits
- F28D1/053—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with heat-exchange conduits immersed in the body of fluid with tubular conduits the conduits being straight
- F28D1/05316—Assemblies of conduits connected to common headers, e.g. core type radiators
- F28D1/05333—Assemblies of conduits connected to common headers, e.g. core type radiators with multiple rows of conduits or with multi-channel conduits
-
- 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
- F28D21/0001—Recuperative heat exchangers
- F28D21/0003—Recuperative heat exchangers the heat being recuperated from exhaust gases
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F1/00—Tubular elements; Assemblies of tubular elements
- F28F1/006—Tubular elements; Assemblies of tubular elements with variable shape, e.g. with modified tube ends, with different geometrical features
-
- 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
- F28F13/14—Arrangements for modifying heat-transfer, e.g. increasing, decreasing by endowing the walls of conduits with zones of different degrees of conduction of heat
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
- F28F21/082—Heat exchange elements made from metals or metal alloys from steel or ferrous alloys
- F28F21/083—Heat exchange elements made from metals or metal alloys from steel or ferrous alloys from stainless steel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
- F28F21/084—Heat exchange elements made from metals or metal alloys from aluminium or aluminium alloys
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
- F28F21/086—Heat exchange elements made from metals or metal alloys from titanium or titanium alloys
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F21/00—Constructions of heat-exchange apparatus characterised by the selection of particular materials
- F28F21/08—Constructions of heat-exchange apparatus characterised by the selection of particular materials of metal
- F28F21/081—Heat exchange elements made from metals or metal alloys
- F28F21/087—Heat exchange elements made from metals or metal alloys from nickel or nickel alloys
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2260/00—Function
- F05D2260/20—Heat transfer, e.g. cooling
- F05D2260/213—Heat transfer, e.g. cooling by the provision of a heat exchanger within the cooling circuit
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/50—Intrinsic material properties or characteristics
- F05D2300/522—Density
-
- 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
- F28D2021/0021—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for aircrafts or cosmonautics
-
- 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
- F28D2021/0026—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for combustion engines, e.g. for gas turbines or for Stirling engines
-
- 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
- F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
- F28D7/16—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged in parallel spaced relation
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2275/00—Fastening; Joining
- F28F2275/04—Fastening; Joining by brazing
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
Definitions
- the present invention relates to heat exchangers and, more particularly, to heat exchangers that may be employed in an aircraft to cool bleed air from an engine or on ground vehicles to cool exhaust gas or to heat compressed air.
- bleed air may be extracted from one or more engines and employed to operate various ancillary systems of the aircraft.
- bleed air may be employed to drive an environmental control system (ECS), wing ice protection systems, fuel tank inerting and the like.
- ECS environmental control system
- wing ice protection systems e.g., wing ice protection systems
- fuel tank inerting e.g., fuel tank inerting
- the bleed air In order to effectively use bleed air in such systems the bleed air must first be cooled after being extracted from an engine compressor.
- Bleed air is usually discharged from an engine compressor at a temperature of 1200° F. or higher.
- the bleed air may be cooled, in one or more heat exchangers, to a temperature of about 300° F. or lower before being introduced into an ancillary system of the aircraft.
- Heat exchangers that are capable of withstanding inlet temperatures of 1200° F. are typically constructed from dense materials such as stainless steel or nickel based alloy.
- Bleed air cooling may be performed by passing the bleed air through one or more heat exchangers which may employ ambient air as a cooling medium.
- the ambient cooling air may be by-pass air propelled with a by-pass fan of the engine or ram air or air from an external fan.
- a heat exchanger capable of reducing temperature from 1200° F. to 300° F. must be large enough to allow for sufficient residence time of the bleed air to achieve the requisite reduction of temperature.
- Such a heat exchanger may be quite heavy when constructed from dense stainless steel or nickel based alloy.
- apparatus for cooling bleed air on an aircraft may comprise: a source of cooling fluid driven by an engine of the aircraft; a source of bleed air driven by the engine; a heat exchanger configured to allow the cooling fluid to pass over tubes through which the bleed air flows, the heat exchanger having, a) a high-temperature zone constructed from material with a first density, and b) a low-temperature zone constructed from material with a second density lower than the first density.
- a heat exchanger may comprise: a high-temperature zone constructed from material with a first density, and a low-temperature zone constructed from material with a second density lower than the first density.
- a method for cooling hot fluid may comprise the steps: passing the hot fluid through first tube segments of a heat exchanger; passing the hot fluid through second tube segments of the heat exchanger directly from the first tube segments, the second tube segments having a lower temperature tolerance than the first tube segments; passing cooling fluid over the first segments to cool the hot fluid to a temperature within a range of temperature tolerance of the second tube segments; and passing the cooling fluid over the second segments to further cool the hot fluid.
- FIG. 1 is a schematic diagram of a cooling system in accordance with an embodiment of the invention
- FIG. 2 is a perspective, partially cut-away view of a heat exchanger in accordance with a second embodiment of the invention
- FIG. 3 is exploded view of a tube of the heat exchanger of FIG. 2 in accordance with an embodiment of the invention.
- FIG. 4 is a flow chart of a method for cooling a hot fluid in accordance with an embodiment of the invention.
- the present invention generally provides a system by which hot fluid such as bleed air may be cooled in a heat exchanger that has some portions of its structure comprised of low density materials.
- FIG. 1 a schematic diagram may illustrate a cooling system 100 constructed in accordance with an exemplary embodiment of the invention.
- An engine 102 of an aircraft may be provided with a high-pressure bleed air port 104 , an intermediate-pressure bleed air port 106 and a by-pass air port 108 .
- a heat exchanger 110 may be positioned to receive hot fluid 111 , such as bleed air, from a hot-fluid inlet line 112 and to receive cooling fluid 113 , such as engine by-pass air, from a cooling-fluid inlet line 114 .
- Cooled bleed air may be discharged through a hot-fluid outlet line 116 and by-pass air may be discharged through a cooling-fluid outlet line 118 .
- the heat exchanger 110 is illustrated in a simplified cut-away format.
- the heat exchanger 110 may be constructed with multiple zones. In the embodiment of FIG. 2 , three zones are illustrated: a high-temperature zone 120 ; a medium-temperature zone 122 ; and a low-temperature zone 124 .
- Hot fluid 111 or hot bleed air may enter the heat exchanger 110 at an inlet end 126 .
- the hot fluid 111 may pass through a plurality of tubes 128 as cooling air 113 passes over the tubes 128 .
- each of the tubes 128 may comprise a high-temperature segment 132 .
- each of the tubes 128 may comprise a medium-temperature segment 134 in the medium temperature zone 122 and a low-temperature segment 136 in the low-temperature zone 124 .
- the heat exchanger 110 may comprise only two zones, the high-temperature zone 120 and the low-temperature zone 124 .
- the tubes 128 may include only the high-temperature segment 132 and the low-temperature segment 136 .
- the tubes 128 may be constructed as brazed assemblies.
- the segments 132 and 136 may be provided with at least one bell end 140 .
- Non-bell ends 142 of the segments 134 may be inserted and brazed into the bell ends 140 of the segments 132 .
- the non-bell ends 142 of the segments 134 may be inserted and brazed into the bell ends 140 of the segments 136 .
- the segments 132 may be constructed from stainless steel or a nickel-based alloy so that they are capable of withstanding high inlet temperature of 1200° F. or higher.
- the segments 134 may be a distance D 1 away from the inlet end 126 of the heat exchanger 110 .
- the distance D 1 may be great enough so that temperature of the hot fluid 111 may be reduced from about 1200° F. to about 1000° F.
- the segments 134 may be constructed from titanium or a titanium alloy if exposed to temperatures of 1000° F. or less.
- the segments 136 may be a distance D 2 away from the inlet end 126 of the heat exchanger 110 . The distance D 2 may be great enough so that temperature of the hot fluid 111 may be reduced to about 600° F.
- the segments 136 may be constructed from aluminum or an aluminum alloy if exposed to temperature of 600° F. or less.
- a multiple step brazing operation may be employed to construct the heat exchanger 110 .
- the high-temperature segments 132 may be inserted into holes 151 of hot-fluid inlet manifold 150 .
- the inlet manifold 150 may be constructed from material that can tolerate exposure to inlet temperatures of the hot fluid 111 of 1200° F. or higher.
- the inlet manifold 150 may be constructed from the same type of material as that used for the segments 132 .
- High-temperature brazing filler 152 may be employed to produce brazed connections between the segments 132 and the manifold 150 .
- the brazing filler 152 must be capable of maintaining a solid connection when exposed to hot-fluid inlet temperatures of 1200° F.
- the segments 134 may be brazed into a sub-assembly that includes the manifold 150 and the segments 132 . As shown in FIG. 3 , the ends 142 of the segments 134 may be inserted into the bell ends 140 of the segments 132 .
- Medium-temperature brazing filler 154 may be employed to produce brazed connections between the segments 132 and the segments 134 .
- the brazing filler 154 must be capable of maintaining a solid connection when exposed to hot-fluid temperatures of about 1000° F.
- the segments 136 may be brazed into a sub-assembly that includes the manifold 150 , the segments 132 and the segments 134 . As shown in FIG. 3 , the ends 142 of the segments 134 may be inserted into the bell ends 140 of the segments 136 . Low-temperature brazing filler 156 may be employed to produce brazed connections between the segments 134 and the segments 136 . The brazing filler 156 must be capable of maintaining a solid connection when exposed to hot-fluid temperatures of about 600° F.
- the segments 136 may be brazed into holes 161 of a hot-fluid outlet manifold 160 .
- the outlet manifold 160 may be constructed from the same type of material as the segments 136 .
- the brazing filler 156 may be employed to perform brazing of the outlet manifold 160 .
- the heat exchanger 110 may weigh less than a high-temperature heat exchanger constructed completely from stainless steel or nickel-based alloy.
- the segments 134 which may be constructed from titanium or titanium alloy, may be less dense than equivalent sections of tubing constructed from stainless steel or nickel-based alloy.
- the segments 136 and the outlet manifold 160 which may be constructed from materials less dense than equivalent elements constructed from stainless steel, nickel-based alloy.
- the segments 136 and the outlet manifold 160 may be titanium or titanium based alloy.
- the low-temperature segments 136 and the outlet manifold may be aluminum or aluminum based alloys. Through employment of these lower density materials the light-weight heat exchanger 110 may be particularly suited for weight-critical applications such as aircraft or other aerospace vehicles.
- the heat exchanger 110 may be vulnerable to damage under conditions in which cooling fluid flow is interrupted while high-temperature fluid passes through the heat exchanger. Under these circumstances, the medium temperature brazing filler 154 and the low-temperature brazing filler 156 may be exposed to hot fluid temperatures of about 1200° F. However, these problematic conditions will not occur when the heat exchanger 100 is employed as an element in the cooling system 100 of FIG. 1 .
- the hot fluid 111 i.e., bleed air
- the cooling fluid 113 in this case by-pass air, is continuously produced whenever the engine 102 is running. Thus cooling fluid flow will cease only when bleed air flow ceases. Consequently, the light-weight heat exchanger 110 may be employed in the cooling system 100 without concern for risk of damage that might result from cessation of cooling fluid flow.
- a flow chart 400 may illustrate a method for cooling hot fluid.
- hot fluid may be passed through first tube segments of a heat exchanger (e.g., hot fluid 111 may be passed though tube segments 132 of the heat exchanger 110 ).
- the hot fluid may be passed through second tube segments of the heat exchanger directly from the first tube segments, the second tube segments having a lower temperature tolerance than the first tube segments (e.g. the hot fluid 111 may be passed directly from the tube segments 132 directly into the tube segments 134 ).
- cooling fluid may be passed over the first segments to cool the hot fluid to a temperature within a range of temperature tolerance of the second tube segments (e.g., the cooling fluid 113 may be passed over the tube segments 132 ).
- the cooling fluid may be passed over the second segments to further cool the hot fluid.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Geometry (AREA)
- Heat-Exchange Devices With Radiators And Conduit Assemblies (AREA)
Abstract
Apparatus for cooling bleed air on an aircraft may include a source of cooling fluid driven by an engine of the aircraft, a source of bleed air driven by the engine and a heat exchanger configured allow the cooling fluid to pass over tubes through which the bleed air flows. The heat exchanger may have a high-temperature zone constructed from material with a first density, and a low-temperature zone constructed from material with a second density lower than the first density.
Description
- This invention was made with Government support under Contract FA8650-09-d-2922, program GE AETD Ti HX Demo awarded by U.S. Air Force. The Government has certain rights in this invention.
- The present invention relates to heat exchangers and, more particularly, to heat exchangers that may be employed in an aircraft to cool bleed air from an engine or on ground vehicles to cool exhaust gas or to heat compressed air.
- In a typical turbine-engine powered aircraft, bleed air may be extracted from one or more engines and employed to operate various ancillary systems of the aircraft. For example, bleed air may be employed to drive an environmental control system (ECS), wing ice protection systems, fuel tank inerting and the like. In order to effectively use bleed air in such systems the bleed air must first be cooled after being extracted from an engine compressor.
- Bleed air is usually discharged from an engine compressor at a temperature of 1200° F. or higher. The bleed air may be cooled, in one or more heat exchangers, to a temperature of about 300° F. or lower before being introduced into an ancillary system of the aircraft. Heat exchangers that are capable of withstanding inlet temperatures of 1200° F. are typically constructed from dense materials such as stainless steel or nickel based alloy.
- Bleed air cooling may be performed by passing the bleed air through one or more heat exchangers which may employ ambient air as a cooling medium. In some instances, the ambient cooling air may be by-pass air propelled with a by-pass fan of the engine or ram air or air from an external fan. In this context, a heat exchanger capable of reducing temperature from 1200° F. to 300° F. must be large enough to allow for sufficient residence time of the bleed air to achieve the requisite reduction of temperature. Such a heat exchanger may be quite heavy when constructed from dense stainless steel or nickel based alloy.
- As can be seen, there is a need for a system for reducing bleed air temperature without incurring a weight penalty associated with a heat exchanger constructed entirely from dense high-temperature tolerant materials.
- In one aspect of the present invention, apparatus for cooling bleed air on an aircraft may comprise: a source of cooling fluid driven by an engine of the aircraft; a source of bleed air driven by the engine; a heat exchanger configured to allow the cooling fluid to pass over tubes through which the bleed air flows, the heat exchanger having, a) a high-temperature zone constructed from material with a first density, and b) a low-temperature zone constructed from material with a second density lower than the first density.
- In another aspect of the present invention, a heat exchanger may comprise: a high-temperature zone constructed from material with a first density, and a low-temperature zone constructed from material with a second density lower than the first density.
- In still another aspect of the present invention, a method for cooling hot fluid may comprise the steps: passing the hot fluid through first tube segments of a heat exchanger; passing the hot fluid through second tube segments of the heat exchanger directly from the first tube segments, the second tube segments having a lower temperature tolerance than the first tube segments; passing cooling fluid over the first segments to cool the hot fluid to a temperature within a range of temperature tolerance of the second tube segments; and passing the cooling fluid over the second segments to further cool the hot fluid.
- These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
-
FIG. 1 is a schematic diagram of a cooling system in accordance with an embodiment of the invention; -
FIG. 2 is a perspective, partially cut-away view of a heat exchanger in accordance with a second embodiment of the invention; -
FIG. 3 is exploded view of a tube of the heat exchanger ofFIG. 2 in accordance with an embodiment of the invention; and -
FIG. 4 is a flow chart of a method for cooling a hot fluid in accordance with an embodiment of the invention. - The following detailed description is of the best currently contemplated modes of carrying out the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
- Various inventive features are described below that can each be used independently of one another or in combination with other features.
- The present invention generally provides a system by which hot fluid such as bleed air may be cooled in a heat exchanger that has some portions of its structure comprised of low density materials.
- Turning now to the description and with reference first to
FIG. 1 , a schematic diagram may illustrate acooling system 100 constructed in accordance with an exemplary embodiment of the invention. Anengine 102 of an aircraft (not shown) may be provided with a high-pressure bleedair port 104, an intermediate-pressure bleedair port 106 and a by-pass air port 108. Aheat exchanger 110 may be positioned to receivehot fluid 111, such as bleed air, from a hot-fluid inlet line 112 and to receivecooling fluid 113, such as engine by-pass air, from a cooling-fluid inlet line 114. Cooled bleed air may be discharged through a hot-fluid outlet line 116 and by-pass air may be discharged through a cooling-fluid outlet line 118. - Referring now to
FIG. 2 , theheat exchanger 110 is illustrated in a simplified cut-away format. In an exemplary embodiment, theheat exchanger 110 may be constructed with multiple zones. In the embodiment ofFIG. 2 , three zones are illustrated: a high-temperature zone 120; a medium-temperature zone 122; and a low-temperature zone 124.Hot fluid 111 or hot bleed air may enter theheat exchanger 110 at aninlet end 126. Thehot fluid 111 may pass through a plurality oftubes 128 ascooling air 113 passes over thetubes 128. Within the high-temperature zone 120 each of thetubes 128 may comprise a high-temperature segment 132. Similarly each of thetubes 128 may comprise a medium-temperature segment 134 in themedium temperature zone 122 and a low-temperature segment 136 in the low-temperature zone 124. - In an alternate exemplary embodiment, the
heat exchanger 110 may comprise only two zones, the high-temperature zone 120 and the low-temperature zone 124. In such a two zone configuration, thetubes 128 may include only the high-temperature segment 132 and the low-temperature segment 136. - In an exemplary embodiment the
tubes 128 may be constructed as brazed assemblies. As shown inFIG. 3 , thesegments bell end 140.Non-bell ends 142 of thesegments 134 may be inserted and brazed into thebell ends 140 of thesegments 132. Similarly, the non-bell ends 142 of thesegments 134 may be inserted and brazed into thebell ends 140 of thesegments 136. Thesegments 132 may be constructed from stainless steel or a nickel-based alloy so that they are capable of withstanding high inlet temperature of 1200° F. or higher. As shown inFIG. 2 , thesegments 134 may be a distance D1 away from theinlet end 126 of theheat exchanger 110. The distance D1 may be great enough so that temperature of thehot fluid 111 may be reduced from about 1200° F. to about 1000° F. Thesegments 134 may be constructed from titanium or a titanium alloy if exposed to temperatures of 1000° F. or less. Thesegments 136 may be a distance D2 away from theinlet end 126 of theheat exchanger 110. The distance D2 may be great enough so that temperature of thehot fluid 111 may be reduced to about 600° F. Thesegments 136 may be constructed from aluminum or an aluminum alloy if exposed to temperature of 600° F. or less. - A multiple step brazing operation may be employed to construct the
heat exchanger 110. In a first brazing step, the high-temperature segments 132 may be inserted intoholes 151 of hot-fluid inlet manifold 150. Theinlet manifold 150 may be constructed from material that can tolerate exposure to inlet temperatures of thehot fluid 111 of 1200° F. or higher. For example, theinlet manifold 150 may be constructed from the same type of material as that used for thesegments 132. High-temperature brazing filler 152 may be employed to produce brazed connections between thesegments 132 and themanifold 150. Thebrazing filler 152 must be capable of maintaining a solid connection when exposed to hot-fluid inlet temperatures of 1200° F. - In a second brazing step, the
segments 134 may be brazed into a sub-assembly that includes themanifold 150 and thesegments 132. As shown inFIG. 3 , theends 142 of thesegments 134 may be inserted into thebell ends 140 of thesegments 132. Medium-temperature brazing filler 154 may be employed to produce brazed connections between thesegments 132 and thesegments 134. Thebrazing filler 154 must be capable of maintaining a solid connection when exposed to hot-fluid temperatures of about 1000° F. - In a third brazing step, the
segments 136 may be brazed into a sub-assembly that includes themanifold 150, thesegments 132 and thesegments 134. As shown inFIG. 3 , theends 142 of thesegments 134 may be inserted into thebell ends 140 of thesegments 136. Low-temperature brazing filler 156 may be employed to produce brazed connections between thesegments 134 and thesegments 136. Thebrazing filler 156 must be capable of maintaining a solid connection when exposed to hot-fluid temperatures of about 600° F. - During the third brazing step, the
segments 136 may be brazed intoholes 161 of a hot-fluid outlet manifold 160. Theoutlet manifold 160 may be constructed from the same type of material as thesegments 136. Thebrazing filler 156 may be employed to perform brazing of theoutlet manifold 160. - The
heat exchanger 110 may weigh less than a high-temperature heat exchanger constructed completely from stainless steel or nickel-based alloy. Thesegments 134, which may be constructed from titanium or titanium alloy, may be less dense than equivalent sections of tubing constructed from stainless steel or nickel-based alloy. Similarly, thesegments 136 and theoutlet manifold 160 which may be constructed from materials less dense than equivalent elements constructed from stainless steel, nickel-based alloy. For example, in one of the heat exchangers with only two temperature zones, thesegments 136 and theoutlet manifold 160 may be titanium or titanium based alloy. In one of theheat exchangers 110 that is constructed with three temperature zones, the low-temperature segments 136 and the outlet manifold may be aluminum or aluminum based alloys. Through employment of these lower density materials the light-weight heat exchanger 110 may be particularly suited for weight-critical applications such as aircraft or other aerospace vehicles. - It may be noted that the
heat exchanger 110 may be vulnerable to damage under conditions in which cooling fluid flow is interrupted while high-temperature fluid passes through the heat exchanger. Under these circumstances, the mediumtemperature brazing filler 154 and the low-temperature brazing filler 156 may be exposed to hot fluid temperatures of about 1200° F. However, these problematic conditions will not occur when theheat exchanger 100 is employed as an element in thecooling system 100 ofFIG. 1 . In thecooling system 100, thehot fluid 111, i.e., bleed air, is produced only when theengine 102 is running. The coolingfluid 113, in this case by-pass air, is continuously produced whenever theengine 102 is running. Thus cooling fluid flow will cease only when bleed air flow ceases. Consequently, the light-weight heat exchanger 110 may be employed in thecooling system 100 without concern for risk of damage that might result from cessation of cooling fluid flow. - Referring now to
FIG. 4 , aflow chart 400 may illustrate a method for cooling hot fluid. In astep 402, hot fluid may be passed through first tube segments of a heat exchanger (e.g.,hot fluid 111 may be passed thoughtube segments 132 of the heat exchanger 110). In astep 404, the hot fluid may be passed through second tube segments of the heat exchanger directly from the first tube segments, the second tube segments having a lower temperature tolerance than the first tube segments (e.g. thehot fluid 111 may be passed directly from thetube segments 132 directly into the tube segments 134). In astep 406, cooling fluid may be passed over the first segments to cool the hot fluid to a temperature within a range of temperature tolerance of the second tube segments (e.g., the coolingfluid 113 may be passed over the tube segments 132). In astep 408, the cooling fluid may be passed over the second segments to further cool the hot fluid. - It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims.
Claims (20)
1. Apparatus for cooling bleed air on an aircraft comprising:
a source of cooling fluid driven by an engine of the aircraft;
a source of bleed air driven by the engine;
a heat exchanger configured to allow the cooling fluid to pass over tubes through which the bleed air flows;
the heat exchanger having,
a) a high-temperature zone constructed from material with a first density, and
b) a low-temperature zone constructed from material with a second density lower than the first density.
2. The apparatus of claim 1 ;
wherein the heat exchanger has a medium-temperature zone interposed between the high-temperature zone and the low-temperature zone; and
wherein the medium-temperature zone is constructed from material with a third density lower than the first density and higher than the second density.
3. The apparatus of claim 2 wherein the medium-temperature zone includes tube segments constructed from titanium or titanium alloy.
4. The apparatus of claim 1 wherein the high-temperature zone includes tube segments constructed from stainless steel, nickel or nickel-based alloy.
5. The apparatus of claim 1 wherein the low-temperature zone includes tube-segments constructed from aluminum or aluminum-based alloy.
6. The apparatus of claim 1 wherein the source of cooling fluid is a by-pass fan of the engine.
7. The apparatus of claim 1 :
wherein the heat exchanger includes a hot-fluid inlet manifold constructed from the material with the first density; and
wherein the heat exchanger includes a hot-fluid outlet manifold constructed from the material with the second density.
8. A heat exchanger comprising:
a high-temperature zone constructed from material with a first density, and
a low-temperature zone constructed from material with a second density lower than the first density.
9. The heat exchanger of claim 8 further comprising a medium-temperature zone interposed between the high-temperature zone and the low-temperature zone, wherein the medium-temperature zone is constructed from material with a third density lower than the first density and higher than the second density.
10. The heat exchanger of claim 9 wherein the medium-temperature zone includes tube segments constructed from titanium or titanium-based alloy.
11. The heat exchanger of claim 9 comprising:
a plurality of hot-fluid passage tubes, each of the tubes including,
a) a high-temperature tube segment constructed from the material with the first density,
b) a low-temperature tube segment constructed from the material with the second density and
c) a medium-temperature tube segment constructed from material with a third density, said third being lower than the first density and higher than the second density.
12. The heat exchanger of claim 8 wherein the high-temperature zone includes tube segments constructed from stainless steel, nickel or nickel-based alloy.
13. The heat exchanger of claim 8 wherein the high-temperature zone includes tube segments constructed from titanium or titanium-based alloy.
14. The heat exchanger of claim 8 wherein the low-temperature zone includes tube-segments constructed from aluminum, aluminum-based alloy, titanium or titanium alloy.
15. The heat exchanger of claim 8 further comprising:
a hot-fluid inlet manifold constructed from the material with the first density; and
a hot-fluid outlet manifold constructed from the material with the second density.
16. The heat exchanger of claim 15 :
wherein the medium-temperature tube segments are brazed to the high-temperature tube segment with a first brazing filler that remains solid at a temperature of at least 1000° F.; and
wherein the medium-temperature tube segments are brazed to the low-temperature tube segments with a second brazing filler that remains solid at a temperature of at least 600° F.
17. The heat exchanger of claim 15 wherein the high-temperature tube segments are brazed to a hot-fluid inlet manifold with brazing filler that remains solid at a temperature of at least 1200° F.
18. A method for cooling hot fluid comprising the steps:
passing the hot fluid through first tube segments of a heat exchanger;
passing the hot fluid through second tube segments of the heat exchanger directly from the first tube segments, the second tube segments having a lower temperature tolerance than the first tube segments;
passing cooling fluid over the first segments to cool the hot fluid to a temperature within a range of temperature tolerance of the second tube segments; and
passing the cooling fluid over the second segments to further cool the hot fluid.
19. The method of claim 18 further comprising the steps:
passing the hot fluid through third tube segments of the heat exchanger, the third tube segments having a lower temperature tolerance than the second tube segments;
passing the cooling fluid over the second segments to cool the hot fluid to a temperature within a range of temperature tolerance of the third tube segments; and
passing the cooling fluid over the third segments to further cool the hot fluid.
20. The method of claim 18 :
wherein the hot fluid is bleed air driven with an engine of the aircraft; and
wherein the cooling fluid is by-pass air driven by the engine.
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US14/464,152 US20160231072A1 (en) | 2014-08-20 | 2014-08-20 | Mixed material tubular heat exchanger |
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US14/464,152 US20160231072A1 (en) | 2014-08-20 | 2014-08-20 | Mixed material tubular heat exchanger |
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US20160231072A1 true US20160231072A1 (en) | 2016-08-11 |
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US14/464,152 Abandoned US20160231072A1 (en) | 2014-08-20 | 2014-08-20 | Mixed material tubular heat exchanger |
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