WO2009023840A1

WO2009023840A1 - Modular shell and tube heat exchanger system

Info

Publication number: WO2009023840A1
Application number: PCT/US2008/073337
Authority: WO
Inventors: Michael R. Bonner
Original assignee: Bonner Michael R
Priority date: 2007-08-15
Filing date: 2008-08-15
Publication date: 2009-02-19
Also published as: US20100300653A1; EP2265879A1

Abstract

A shell and tube heat exchanger system comprising at least one adjustable modular end assembly and an adjustable modular end assembly for use with the same.

Description

MODULAR SHELL AND TUBE HEAT EXCHANGER SYSTEM

BACKGROUND

[0001] The present invention relates to a heat exchanger systems. More particularly, the present invention pertains to shell and tube heater exchanger systems.

[0002] Traditionally, the design of heat exchangers is based on a combination of thermal transfer requirements and fluid properties with regard for temperature, flow and pressure drop characteristics. Plate type heat exchangers can be assembled with the appropriate number of pre-designed plates to balance these criteria. Multiple plates may be used in parallel to attain the necessary thermal transfer without increasing the pressure drop. The flow through the plate pack can be routed in single or multi-pass configurations to balance the flow, pressure drop and thermal demands.

[0003] Shell and tube heat exchangers, on the other hand, are traditionally not comprised of standard, expandable components. The number of tubes and the overall length of the final assembly determine its flow, pressure drop and thermal performance. Once a given tube bundle structure, shell, tube sheet and head configuration have been designed, only length is variable to balance the configuration with the demands of the application.

SUMMARY

[0004] Disclosed herein is a shell and tube heat exchanger system comprising at least one adjustable modular end assembly; at least one inner tube in fluid communication with an interior conduit defined in the modular end assembly and at least one shell surrounding in the interior conduit, the shell defining and interior space in fluid communication with an exterior conduit in the adjustable end assembly, wherein the inner tube and the interior space defined by the shell are isolated from contact with one another.

[0005] Also disclosed herein is a modular end block assembly suitable for use in a shell and tube heat exchanger assembly, the modular block assembly comprising at least one first fitting having a first planar face and opposed side faces angularly positioned relative to the first face. The modular block assembly has at least one through bore defined therein extending from one opposed face to the other. The modular block assembly also has at least one bore located on the first planar face-in fluid communication with the through bore.

[0006] The modular block assembly also includes at least one mating fitting configured to be positioned in fluid tight contact with the first face of the first fitting.

[0007] The modular block assembly can communicate with a suitable shell and tube heat exchanger assembly having a multi-tube bundle through which a material such as a temperature conditioned material can be routed The multi-tube bundle passes through a shell where a thermal transfer fluid can be circulated.

[0008] Where desired ore required, the modular block assembly can include a suitable baffle element adapted to be seated in the bore located in the first planar face. The baffle element includes multiple baffles that may be used to hold the multi-tube bundle in position and may be configured to route the thermal transfer fluid around the tubes. Energy passes through the walls of the multi-tube bundle and is exchanged between the thermal transfer fluid(s) circulating around the outside of the walls of the tubes and the material to be temperature conditioned contained within the walls of the tubes.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:

[0010] Figure 1 is an isometric view of a first tube block clement of a modular assembly according to an embodiment as disclosed herein;

[0011] Figure 2 A is a top view of the first tube block element of the modular block assembly of Figure 1 ;

[0012] Figure 2B is a side view of the first tube block element of the modular block assembly of Figure 1 .

[0013] Figure 3 is an isometric view of the second tube block clement of the modular block assembly according to an embodiment as disclosed herein;

[0014] Figure 4A is a detail view of the first face of the element of figure 3;

[0015] Figure 4 B is a detail view of the side face of the element of Figure 3 [0016] Figure 5 is an isometric view of a baffle suitable for use in the modular block assembly according to an embodiment as disclosed herein;

[0017] Figure 6A is a top view of the baffle of Figure 5;

[0018] Figure 6 B is a side view of the baffle of Figure 5;

[0019] Figure 7 is an isometric view of an assembly according to an embodiment as disclosed herein with ports commonly aligned;

[0020] Figure 8 A is a detail side view of an assembly with ports commonly aligned as depicted in Figure 7.

[0021] Figure 8B is a detail front view of an assembly depicted in Figure 7;

[0022] Figure ^'9 is an isometric view of an assembly according to an embodiment as disclosed herein with ports offset;

[0023] Figure 1OA is a detail side view of an assembly with ports offset;

[0024] Figure 1OB is a detail front view of an assembly with ports offset;

[0025] Figure 11 is an isometric view of a 1 x 2 series one-component assembly according to an embodiment as disclosed herein;

[0026] Figure 12A is a detail side view of the assembly in Figure 1 1 ;

[0027] Figure 12B is a detail top view of the assembly in Figure 11 ;

[0028] Figure 13 is an isometric view of a 1 x 2 parallel one-component assembly according to an embodiment as disclosed herein;.

[0029] Figure 14A is a detail side view of the assembly in Figure 13;

[0030] Figure 14 B is a detail top view of the assembly in Figure 13;

[0031] Figure 15 is an isometric view of a 1 x 2 parallel two-component assembly according to an embodiment as disclosed herein;

[0032] Figure 16A is a detail side view of the assembly in Figure 15;

[0033] Figure 16B is a detail top view of the assembly of Figure 15; [0034] Figure 17 is an isometric view of a 2 x 4 series/parallel one-component assembly according to an embodiment as disclosed herein;

[0035] Figure 18A is a detail side view of the assembly in Figure 17; and

[0036] Figure 18 is a detail top view of the assembly in figure 17.

DETAILED DESCRIPTION

[0037] Disclosed herein is a modular heat exchanger assembly comprised of individual segments that can be arranged in series or parallel configurations as desired or required.

[0038] Each segment of the modular heat exchanger is composed of two tube sheet- head pairs or modular block assemblies connected by a sheet encasing multi-tube bundles. The tube sheet is a multi-function device (hereinafter "tube block") that directs the thermal transfer fluid and the material to be conditioned in different paths. The device includes at least one of pluggable thermal transfer fluid ports, counter bores to accommodate both the shell and tube bundle configurations, and gasket surfaces around ports to enable the tube block to be mated with both a head block and adjacent tube blocks, if desired.

[0039] It is contemplated that the modular block assemblies can be mated in either a series or parallel configuration. Furthermore, it is contemplated that the material ports may be in either a common orientation or in an offset orientation. If an adjacent tube block is not desired, the particular modular block assembly or tube block may direct material out of the heat exchanger assembly. In one non-limiting embodiment as disclosed herein, the face of the tube block featuring the tube sheet is square shaped, with the tube bundle arranged in such a fashion as to be symmetrical over a 90° rotation.

[0040] The tube blocks or modular block assembly disclosed herein includes means for directing heat transfer material in a desired transit path. In one embodiment disclosed herein, the directing means are configured such that the tube blocks or modular black assemblies include at least one thermal transfer fluid port. The thermal transfer fluid port may be suitably configured to be plugged to route material to be conditioned in a series configuration. Alternately, the thermal transfer fluid port may be unplugged to route material in a parallel configuration, while the material to be conditioned always passes to the head. [0041] In various embodiments disclosed herein, it is contemplated that the heat exchange assembly will include at least one modular block assembly or head 10 that includes at least two elements 12 and 14 (as depicted in Figures 1 and 3). It'is to be understood that the heat exchange assembly can include multiple block assemblies or heads 10 and in many embodiments, a heat exchange shell and tube assembly can be disposed between at least a pair of suitably configured heads as disclosed herein.

[0042] It is contemplated that each element 12, 14 of a modular block assembly can include a plurality of pluggable material ports communicating with suitable fluid channels that extending inward into the body of the block from the associated face of the respective element. The various pluggable material ports can be configured to direct either the material to be conditioned or the heat exchange material as desired or required. As depicted in the various drawing figures, at least one element of the head 10 directs the material to be conditioned either to adjacent head devices or in and out of the associated heat exchanger assembly.

[0043] The various elements 12, 14 can be configured with suitable gasket surfaces proximate to the associated material port. It is contemplated that the various gasket surfaces located on the head or modular block assembly surround the various ports located in the body of the block assembly to enable the head element to be mated as desired or required to an adjacent tube block and/or with adjacent heads as desired or required.

[0044] It is also contemplated that one or more of the material ports may be configured in a manner to accept a suitable fluid tight plug. Plugging is accomplished to enable the material port to be configured to route thermal transfer fluid in a series configuration. Alternatively, the port may be unplugged to route theπnal transfer fluid in a parallel configuration. Where desired or required, the material ports can also be configured with suitable attachment regions to fasten various devices to the head elements in suitable mating fashion. Nonlimiting examples of various devices that can be included and mated in the assembly include the various tubes and shell members of the associated heat exchanger assembly as well as various nozzles, hoses, conduits and plugs to deliver material to and from the associated assembly and direct fluids so delivered. [0045] In the embodiment as depicted in the various drawing figures, the attachment region can be configured as an internally threaded surface that can.mate with suitably threaded detachable devices (not shown). It is contemplated that the internally threaded surface can be integral to the element 12, 14 (not shown) or can be configured as part of a sleeve 18 as seen associated with port 20 as defined in element 12 depicted in Fig. 1. Such element can be referred to in certain application as a tube sheet. The sleeve 18 can be either permanently affixed to the associate port 20 or can be insertable therein as desired or required.

[0046] It is contemplated that the region immediately surrounding the opening of port

20 can be configured with a suitable setback if desired or required. The setback can have any suitable configuration, however, in many situations, it will be understood that the port and the associated orifice and setback will have a circular or near circular configuration. However other configurations that permit and/or facilitate fluid flow are contemplated. In the embodiment of element 12 as depicted in figure 1, the sleeve 18 is set back in the associated port 20 relative to the surrounding outer face 22 to produce and define setback 24. It is contemplated that setbacks such as the setback 24 can define a suitable gasket surface configured to receive a suitable gasket and that such gaskets can be configured and composed of materials suitable to achieve suitably fluid tight coupling with associated mating parts during operation of the associated device. Port 20 communicates with channel 23.

[0047] The element or tube sheet 12 as set forth in Fig 1 also has a surface 26 angularly contiguous with surface 22. In the embodiment depicted in Fig. 1, the port 28 is centrally located in surface 26. The port 28 may be positioned in element 12 at any suitable location relative to face 26 and communicates with channel 40.

[0048] The port 28 is configured with a suitable setback 29 defining a recess configured to receive and position an element such as a tube bundle manifold 30 therein. The tube bundle manifold 30 can have any configuration suitable to receive and hold material conveying tubes such as those to be described subsequently. In the embodiment depicted in Fig. 1, the tube bundle manifold 30 is a circular plate configured to conform to the opening defined by port 28. It is contemplated that other geometries may be employed if desired or required. The circular plate is configures with suitable tube receiving apertures 31 configured to receive respective material conveying tubes of a suitable tube bundle. The apertures 31 can have any suitable outer geometry selected for that purpose and can have suitable regions configured to promote fluid tight sealing and performance according to the use requirements of the associated heat transfer device. In the embodiment depicted, the ports 31 have a circular configuration.

[0049] The apertures 31 can be positioned in the tube bundle manifold 30 in any suitable orientation relative to the manifold. In many embodiments, it is contemplated that the apertures 31 will be positioned to provide a tube bundle manifold that is symmetrical as the manifold is rotated over 90°. In the embodiment depicted in Figs 1 and 2A, the tube bundle manifold has 9 ports 31. Other patterns that are symmetrical over a 90° rotation can be used.

[0050] While a separate and/or separable tube bundle manifold 30 has been discussed, it is contemplated that the tube bundle manifold 30 can be formed with and/or integrally connected to the element 12 as desired or required. The tube bundle manifold 30 may include suitable seats and/or other devices to permit and achieve fluid tight connection between the element 12 and the associated material conveying tubes and an associated shell.

[0051] As can be seen in various Figures such as Figures 2B and 8A and B, face 26 is configured to matingly connect with face 26' of element 14 in a suitable manner, nonlimiting examples of which will be described subsequently. In many situations, it can be appreciated that element 14 can be referred to as a head member.

[0052] As can also be appreciated from the drawing figures 2B, 8A and 8B among others, the tube sheet member such as element 12 the channel 40 communicating with port 28 passes through the member 12 and terminated in opening 41. Opening 41 can have any suitable configuration and can include a suitable setback 43 that can be configured to receive suitable seals as well as communicating with the shell member of the associated heat exchange assembly in a manner that will be describe subsequently. Thus it is contemplated that the material conveying tubes will pass through aperture 41 and pass through the body of element 12 to connect with and terminate at the tube bundle manifold 30.

[0053] It is contemplated that channel 23 will communicate with channel 40 in that material introduced into channel 23 will be conveyed out through channel 40. It is also contemplated that the direction of fluid travel can be reversed where desired or required. In the embodiment depicted in drawing figures 2A and 2B, the channel 23 can pass through the element 12 to a face 25 opposed to the face 22. The channel 23 can be configured to be dead headed if desired or required for the particular application.

[0054] The assembly 10 disclosed herein can also be include at least one mating element 14 that can be referred to as a head. Element 14 is configured with channel 20' that connects with a mating channel 40 communicating with orifice 42 located in face 26'. The channel 20' can extend through the body of the element 14 to receive material conveyed through material conveying tubes (or transfer material thereto).

[0055] In the embodiment depicted in Fig. 3, element 14 includes an outer face 22^" with port 20' defined therein. Port 20 can be suitably configured to connect with associated parts as desired or required. In the embodiment depicted in Figure 3, Port 20' includes a nonthreaded surface 21 ' with a setback gasket receiving detent 24'. It is to be understood that the region can be threaded and or include an insert as described previously depending upon particulars of the given application and associated heat exchange unit.

[0056] The port 20' communicates with a channel 23' that can pass through the body of the element 14 if desired or required and exit through the opposed face defining a channel that traverses the body of element 14. Where desired or required, channel 23' can be configured with one or more threaded openings. In the embodiment depicted in Fig 3 and 4A and 4B, the element 14 is configured with one threaded or non threaded insert 21 '. It is contemplated that when an insert or threading is employed, the ID of the channel can be modified to accommodate this feature. Thus one end of the channel 23' may have a slightly greater ID than the other end with the two respective IDs meeting and tapering at a suitable central point in the channel 23'. This is depicted in the drawing figures as region or line 44. In the embodiment depicted, the

[0057] Element 14 also has orifice 40 defined in face 26' that communicates with channel 46. Channel 46 is in fluid communication with channel 23' and is configured to convey process material to or from the material conveying tube bundle as desired or required. The channel can have any geometry suitable for conveying material. In the embodiment depicted, the channel has a conical configuration (when viewed in cross-section) tapering to a minimum at the point of communication with the channel 23. It is contemplated that the orifice 40 can have a geometry and size that matingly corresponds with orifice 28 of associated clement 12.

[0058] Elements 12 and 14 can be used with a suitable tube bundle and shell to produce a heat exchange assembly having one or more segments. A non-limiting example of an embodiment of an heat assembly segment 100 is depicted in Figures 7, 8A and 8B. A segment 100 is created when one modular block assembly or head-sheet block combination 10 is linked to another head-sheet block combination 10' with the shell 110 transporting the desired fluids in between.

[0059] In one non-limiting embodiment, it is contemplate that the thermal transfer fluid ports on the tube block 10, 10' may be both threaded for female NPT pipe connection and contain gaskets for tube-block to tube-block mating and the ports on the head (elements 12 and 12') may have gasket surfaces that allow a connection plate to be attached that can adapt to any type of threaded or sanitary connection desired.

[0060] It is contemplated that multiple segments such as segment 100 may be configured in series or in parallel in order to create a heat exchanger assembly with the desired thermal transfer properties. Additionally, an assembly can be configured to transfer heat between multiple materials and a single thermal transfer fluid to cool or heat all materials to the same temperature as in the manner describe subsequently

[0061] Tube Block Design: as discussed previously in conjunction with the specific elements 12 and 14, in various elements of the device as disclosed herein, it is contemplated that modular block assembly 10, 10' will be configured in a manner that facilitate orientation of the associated tube bundle 120 in the heat exchanger segment 100 such that the tubes are arranged in such a fashion as to be symmetrical over a 90° rotation. This configuration can be accomplished by tube bundle manifold 30 associated with the head member (element 12 shown in Figures 1 and 2). In the embodiment as depicted, the tube bundle 110 is a oriented in a three-by-three square pattern. It is to be understood that various patterns and configurations are considered to be within the scope of this disclosure. Thus other patterns that are symmetrical over a 90° rotation could be used. [0062] The individual tubes 122 of the tube bundle 120 can be fastened to the tube block 10, 10' by any suitable method that is capable of withstanding pressure levels contemplated in the application and associated method. Nonlimiting examples of such methods include welding, gluing, forming, or other liquid tight means capable of withstanding the design pressure. In the embodiment depicted in the various drawing figures such as figures 7 and 8A and 8B, the individual tubes are fastened to the tube bundle manifold 30 and held in place thereby. It is also considered within the purview of this invention Io employ additional anchoring devices as desired or required.

[0063] In at least some of the embodiments depicted herein, the tube block 10, 10' incorporates two ports directly opposite one another that are designed for both threaded connection and gasket connection. These ports are used to route the thermal transfer fluid into or out of the area defined by shell 112 around the tube bundle 120 and to adjoining segments in the overall assembly.

[0064] It is contemplated that the top surface 26 of the tube sheet (element 12) also employs a gasket recess 28 around the tube bundle manifold 30 that provides for sealing the head-tube block interface as well as threaded holes (not shown) to facilitate fastening of the head to the tube block. It is also contemplate that cross bored ports 32 can be provided in the body of the tube (clement 12) that will allow bolts or threaded rods to be employed to hold the adjacent segments in the assembly together.

[0065] Additionally, though it is not shown in Figure 1 or 2, one embodiment of the tube block 10, 10' can also features four bores at 90° intervals around the ports to facilitate connection of a nozzle, if desired or required.

[0066] Head Design: Details of the head design (also referred to as element 14) are shown in Figures 4A and 4B. These are designed with material ports positioned to direct material flow as required between the adjacent shell and tube segments and through the tube bundles 120. Gasket surfaces are incorporated to enable the head (element 14, 14') to be mated both with its respective tube sheet block (element 12) and with adjacent material routing heads. For example, one port region in Figure 4B may be suitably threaded and deadheaded to block the flow of material through the element 14 head, forcing it only through the gasket-only port 40 located on the associated upper face 26' . In the embodiment as depicted, the design of the head (element 14) is symmetrical over any centerline enabling it to be positioned in any of the four possible orientations on or relative to the associated tube sheet (such as element 12, 12'). This allows the head to direct material as required in any configuration.

[0067] Baffles: One embodiment of the baffle manifold 50 as disclosed herein is shown in Figures 5 and 6. Λs depicted the baffle manifold 50 is configured to be symmetrical and can be placed in any of the four available hemispherical orientations available in the tube bundle 120 This offset location style is further shown in figures 8, 10, 12, 14 and 16. The baffles 50 as depicted change fluid direction and add turbulence to the thermal transfer fluid flow to improve the thermal efficiency of the heat exchanger.

[0068] It is contemplated that the baffles 50 can be placed at spaced intervals also the tubing bundle 120 and will have at least one surface adapted to engage and contact the corresponding inner surface of the shell 112.

[0069] As depicted, baffles 50 are configured as a planar sheet element 52 with a plurality of apertures 54 configured to each receive an individual tube 122 therethrough. It is contemplated that the number and location of apertures 54 in planar sheet element 52 will correspond position of a number of the tubes 122 in the respective tube bundle 120. It is contemplated that the baffle 50 will be configured to be symmetrical over 90 degree rotation. In the embodiment depicted the planar sheet also has a plurality of semicircular detents 56 in which additional tubes 122 of the tube bundle 120 can be positioned.

[0070] Segment Configurations: Segments can be built with the tube blocks 10, 10' in a common port orientation as shown in Figures 7 & 8, where the respective ports 20, 20' of the respective tube blocks are parallel with one another. In the embodiments depicted in the various drawing figures, the reference character A and associated arrow designates "water in" while the reference character B and associated arrow represents "water out". It is to be understood that, in its broadest sense, the term "water" as applied in this context is used to denote various organic and inorganic fluid thermal transfer media. "Thermal transfer" is taken to include both transfer of thermal energy such as heat to and/or from at least one material. [0071] The embodiments depicted also employ reference character C and associates arrow as well as reference character D and associated arrow to denote "material in" and "material out" respectively.

[0072] In the embodiment depicted in Figures 7 and 8, elements 14 and 14' (also referred to as heads) are each deadheaded on one side by plugs 60, 60' respectively. Elements 12 and 12' are each deadheaded by plugs 62, 62' respectively.

[0073] It is also contemplated that the segments can be built with the respective tube blocks in an offset port orientation as shown in Figures 9 & 10, whereas the ports of the tube sheets are at a 90° orientation to one another. These two differing configurations are comprised with exactly the same components with only the alignment of the tube sheets changed at the assembly step. This allows control over the direction of flow of the thermal transfer fluid.

[0074] Though the segments can be used individually, Figures 11 through 18 show how the common port and offset port configurations are used in combination to create some of the various arrangements afforded by this design to solve specific problems associated with liquid temperature control.

[0075] The Series Configuration: Figures 11 and 12 show two common port segments combined to create a simple series circuit. Thermally, this is the same as a heat exchanger twice the length, but because it is "folded" in half, it takes up much less space. Here, the thermal transfer fluid enters the bottom port of the right-hand side of the tube block in the lower segment. The opposite port in the tube block is plugged, so the fluid is forced through the lower shell and over the tube bundle. When the thermal transfer fluid reaches the tube block at the left side of the segment, the plug in the lower port forces the fluid up into the adjacent tube block above it.

[0076] A suitable sealing device such as an elastomeric o-ring seal prevents leaking between the upper and lower tube blocks. The plug in the top port in the top tube block forces the thermal transfer fluid through the upper shell and over the tube bundle in that segment. When the fluid reaches the tube block at the opposite end of the segment, the lower plug in the tube block and the elastomeric o-ring seal between the tube block and the one beneath it force the fluid up and out of the heat exchanger. (Note that the same series configuration could be created with the offset port segments, but the inlet and outlet would be rotated 90° to the face where the material inlet and outlet are shown.)

[0077] Material flow can be in the opposite direction from the thermal transfer fluid flow to maximize thermal transfer efficiency, so the material enters the top head. The plug in the rear port of the head forces the material through the tubes of the tube bundle and through the opposite tube sheet. When the material enters the head, the plugged port on the top of the head forces the material down into the lower head. A suitable gasket seal prevents leaking between the heads. The plugged port in the bottom of the lower head forces the material through the tubes of the tube bundle through the opposite tube sheet.

[0078] When the material enters the opposite head, the plugged port on the back of the head forces the material out of the heat exchanger through the front port. Additional segments could be added to obtain a desired thermal length. For the two segment unit shown, simple bolts could be run through the cross-bored holes to hold the segments together. As more segments are added, these simple bolts could be replaced with segments of threaded rod to cover the distance required. The smooth gasket ports on the faces of the heads are designed to be interfaced with a port plate that allows any type of material connection (NPT, FPT, Tri-clamp, Cherry-Burrell, etc.) to be fitted to the assembly, thus continuing the total modular flexibility of the design.

[0079] The Parallel Configuration: Figures 13 and 14 show two common port segments combined to create a simple parallel circuit. Thermally, the heat exchanged in this configuration is twice that of a single segment and equal to the series configuration shown in Figures 11 and 12. However, due to the parallel configuration the pressure drop is VA the pressure drop resulting from the series configuration in Figures 11 and 12. Here we see that the thermal transfer fluid enters the top port of the top tube block on the left end of the assembly. The bottom port in the bottom tube sheet is plugged, but the port between the upper and lower tube blocks is open. An elastomeric o-ring seal prevents leaking between the tube blocks. The thermal transfer fluid is forced simultaneously through both shells and over both tube bundles. The relationship between flow rate and pressure drop assures that the flow will be balanced between the two segments. When the thermal transfer fluid reaches the tube sheets at the opposite end of the segments, the plug in the bottom port of the lower tube sheet forces the fluid up and out through the open port in the upper tube sheet. (Note that, in contrast to the series configuration, this parallel configuration cannot be created with the offset port segments.)

[0080] Material flow is again in the opposite direction from the thermal transfer fluid flow to maximize thermal transfer efficiency. The material enters the top port of the top head on the right end of the assembly. The bottom port in the bottom head is plugged, but the port between them is open. A gasket seal prevents leaking between the heads. The material is forced simultaneously through both tube bundles. Again, the relationship between flow rate and pressure drop assures that the flow will be balanced, not only between the two bundles, but also between the tubes in each bundle. When the material reaches the heads at the opposite end of the segments, the plug in the bottom port of the lower head forces the material up and out through the open port in the upper head. This is referred to as a "one- component" configuration.

[0081] A second embodiment of the parallel configuration is shown in Figures 15 and

16. The path of the thermal transfer fluid is identical to that described in the simple parallel circuit above. In this embodiment, however, the heads are completely isolated from one another and a different material is passed through each heat exchanger tube bundle. This is referred to as a "multi-Component" configuration in that a single temperature control system can simultaneously control multiple materials.

[0082] The Series-Parallel Configuration: Figures 17 and 18 show a four by two series-parallel circuit. This combines the series configuration with the parallel configuration to create a large heat exchanger. Thermally, this is the same as a heat exchanger four times the segment length with twice the number of tubes, but takes up little space due to its "folded" shape. The thermal transfer fluid enters the top port of the upper tube block. The back port in the back tube block is plugged, but the port between them is open. Once again, an elastomeric o-ring seal prevents leaking between the tube sheets. The thermal transfer fluid is forced simultaneously through both top shells and over both tube bundles. The relationship between flow rate and pressure drop assures that the flow will be balanced between the two segments. When the thermal transfer fluid reaches the tube blocks at the opposite end of the segments, the plug in the top ports force the fluid down and through the open ports between the first and second layers of tube blocks as described for the series circuit above. Again, the thermal transfer fluid is forced simultaneously through the shells and over the tube bundles to the tube blocks at the opposite end of the assembly where the porting between the tube blocks between the second and third layers of the assembly redirect the thermal transfer fluid in the opposite end. The route is repeated a final time and the thermal transfer fluid from the two parallel segments exits the assembly through the lower right hand tube block. In short, this creates a serpentine series flow with two parallel paths.

[0083] Material flow is again in the opposite direction from the thermal transfer fluid flow to maximize thermal transfer efficiency. The material enters the bottom right pair of heads. The plug in the rear port of the back head forces the material through the tubes of the two parallel tube bundles and through the tube sheets at the opposite end. When the material enters the heads, the plugged ports on the bottom of the heads force the material up into the second pair of heads. A gasket seal prevents leaking between them. The plugged ports in the top of both second layer heads force the material through the tubes of the two parallel tube bundles through the opposite tube sheets. As with the thermal transfer fluid, this serpentine pattern continues until the material in the two parallel paths meet in the upper right heads and exit the assembly. As described above, segments of threaded rod are used to hold the assembly together due to the distance required. The smooth gasket ports on the faces of the heads are designed to be interfaced with a port plate that allows any type of material connection (NPT, FPT, Tri-clamp, Cherry-Burrell, etc.) to be fitted to the assembly thus continuing the total modular flexibility of the design.

SOME FEATURES OF THE DISCLOSED DEVICE [0084] A tube sheet comprising: a solid mass with two intercepting through bores extending from and ending at planar surfaces of the mass, with a manifold partitioning one bore.

[0085] A tube sheet assembly comprising: the tube sheet of Claim 1 adjacent to a second solid mass with a through bore extending from and ending at planar surfaces of the second mass and a port in a planar surface of the second mass extending into the second mass and intercepting the bore at a right angle, with the tube sheet and second mass aligned such bore in the tube sheet with the manifold abuts the port of the second mass, and with a seal interposed between the tube sheet and the second mass.

[0086] A heat exchanger segment comprising: two of the sheet tube assemblies as disclosed in Claim 2 interposed by a sheet containing a bundle of tubes.

[0087] A heat exchanger assembly comprising: at least two of the heat exchanger segments disclosed in Claim 3.

[0088] The tube sheet of Claim 1 wherein the through bores intercept at a ninety degree angle.

[0089] The tube sheet of Claim 1 wherein the manifold is symmetrical over a ninety degree angle.

[0090] The tube sheet of Claim 1 wherein the through bore without the manifold is threaded to accept a threaded plug.

[0091] The tube sheet of Claim 1 wherein the surface of the mass around the perimeter of at least one through bore is recessed to accept a gasket.

[0092] The tube sheet of Claim 1 wherein the mass is cube shaped.

[0093] The tube sheet of Claim 9 wherein each face of the cube contains a plurality of bores that are cross-bored with the bores in perpendicular faces.

[0094] The tube sheet of Claim 9 wherein the bore without the manifold is surrounded by a plurality of bores.

[0095] The tube sheet assembly of Claim 2 wherein the bore without the manifold in the tube sheet is aligned parallel to the bore in the second mass.

[0096] The tube sheet assembly of Claim 2 wherein the bore without the manifold in the tube sheet is aligned perpendicularly to the bore in the second mass.

[0097] The heat exchanger segment of Claim 3 wherein a thermal transfer fluid runs inside the sheet but outside the bundled tubes and a material to be conditioned runs inside the bundled tubes.

Claims

1. An adjustable modular end assembly configured for use in a heat exchanger segment comprising: a solid mass with two intercepting through bores extending from and ending at planar surfaces of the mass.

2. A heat exchanger segment comprising: the modular end assembly of claim 1 positioned adjacent to a second modular end assembly with a through bore extending from and ending at planar surfaces of the second modular end assembly and a port in a planar surface of the second mass extending into the second mass and intercepting the bore at a right angle, with the tube sheet and second mass aligned such bore in the tube sheet with the manifold abuts the port of the second mass, and with a seal interposed between the first and second adjustable modular end assemblies; and at least one tube bundle having a plurality of material conveying tubes and an outer shell surrounding the tubes in fluid communication with the first and second modular block assemblies.

3. The heat exchanger segment of claim 2 further comprising: at least two additional modular end assemblies in fluid communication with the material conveying tubes and an outer shell at a location distal to the first modular end assemblies.

4. A heat exchanger assembly comprising: at least two of the heat exchanger segments as defined in Claim 3.

5. The adjustable modular end assembly of Claim 1 wherein the through bores intercept at a ninety degree angle.

6. The adjustable modular end assembly of Claims 1 or 5 wherein the manifold is symmetrical over a ninety degree angle.

7. The adjustable modular end assembly of Claims 1 , 5, or 6 wherein the through bore without the manifold is threaded to accept a threaded plug.

8. The adjustable modular end assembly of claims 1 , 5, 6, or 7 wherein the surface of the mass around the perimeter of at least one through bore is recessed to accept a gasket.

9. The adjustable modular end assembly of claims 1 , 5, 6, 7, or 8 wherein the mass is cube shaped.

10. The adjustable modular end assembly of claim 9 wherein each face of the cube contains a plurality of bores that are cross-bored with the bores in perpendicular faces.

1 1. The adjustable modular end assembly of claim 9 wherein the bore without the manifold is surrounded by a plurality of bores.

12. The heat exchanger segment of claim 2 wherein the bore without the manifold in the tube sheet is aligned parallel to the bore in the second mass.

13. The heat exchanger segment of claim 2 or 3 wherein the bore without the manifold in the tube sheet is aligned perpendicularly to the bore in the second mass.

14. The heat exchanger segment of claim 2 or 3 wherein a thermal transfer fluid runs inside the sheet but outside the bundled tubes and a material to be conditioned runs inside the bundled tubes.