WO2013114071A2

WO2013114071A2 - Steam generation

Info

Publication number: WO2013114071A2
Application number: PCT/GB2013/000040
Authority: WO
Inventors: Michael Alan BURNS; Paul Andrew BURNS
Original assignee: Clean Thermodynamic Energy Conversion Ltd
Priority date: 2012-01-31
Filing date: 2013-01-31
Publication date: 2013-08-08
Also published as: EP2847514B1; EP4148324A2; US10845131B2; US20150136374A1; WO2013114070A2; WO2013114070A3; EP2872827A2; US20150121875A1; EP2847514A2; EP2872827B1; US9952003B2; EP3961094A1; WO2013114071A3

Abstract

A steam generator for generating a superheated fluid from a working fluid using a stream of heated gas, the steam generator comprising : a housing, which defines a gas flow path having an inlet at one, upstream end thereof into which a stream of heated gas is delivered and an outlet at the other, downstream end thereof; and a steam generation module which is disposed within the gas flow path of the housing, the steam generation module comprising a heat exchanger which receives a working fluid and is operative to raise the temperature of the working fluid to provide a saturated fluid, and a superheater which receives the saturated fluid from the heat exchanger and is operative to raise the temperature of the saturated fluid and provide a supersaturated fluid.

Description

STEAM GENERATION

The present invention relates to a steam generator which generates superheated fluid from a stream of heated gas, and a power generation system which incorporates such a steam generator to generate power, typically electricity using an electrical generator.

The present invention has particular application to any kind of burner, such as a biomass burner, or any kind of combustion engine, such as a landfiii anaerobic digestion gas engine, a methane burning engine, a diesel engine, a marine engine and coal gas engine.

Preferred embodiments of the present invention wil! now be described hereinbeiow by way of example only with reference to the accompanying drawings, in which ;

Figures 1(a) to (c) schematically represent a power generation system in accordance with a preferred embodiment of the present invention;

Figures 2 and 3 illustrate part cut-away perspective views of the steam generator of the power generation system of Figure 1;

Figures 4(a) to (j) illustrate views of the housing of the steam generator of the power generation system of Figure 1;

Figures 5(a) to (g) illustrate views of the steam generation module of the steam generator of the power generation system of Figure 1 ;

Figures 6(a) to (e) illustrate views of the heat exchanger arrangement of the steam generation module of Figure 5;

Figures 7(a) to (f) illustrate views of one heat exchanger module of the heat exchanger arrangement of Figure 6; Figures 8(a) to (c) illustrate one U-shaped tube section of the heat exchanger module of Figure 7;

Figures 9(a) to (d) illustrate one pipe end coupling of the heat exchanger module of Figure 7;

Figures 10(a) and (b) illustrate a test tool in accordance with one embodiment of the present invention;

Figure 11 illustrates a perspective view of the sheet element of one fin of the heat exchanger module of Figure 7;

Figures 12(a) to (d) illustrate views of the fin coupling element of one fin of the heat exchanger module of Figure 7;

Figure 13 illustrates a fragmentary, part cut-away perspective view of a plurality of stacked fins of the heat exchanger module of Figure 7 at the junction with one tube element;

Figures 14(a) to (f) illustrate views of the superheater unit of the steam generation module of Figure 5;

Figures 15(a) to (c) illustrate views of one superheater coil of the superheater unit of Figure 14.

The power generation system comprises a steam generation unit 1 for generating a superheated fluid, in this embodiment superheated steam, from a working fluid, in this embodiment pure, de-mineralised water, at least one, in this embodiment a plurality of steam engines 3a-c which receive the superheated steam from the steam generation unit 1, and at least one, in this embodiment a plurality of power generators 5a-c which are driven by the respective steam engines 3 to generate power, in this embodiment electricity, which can be supplied to the electrical grid.

The steam generation unit 1 comprises a steam generator 11 which receives a stream of heated gas, typically an exhaust gas from a combustion engine, and generates a superheated fluid, in this embodiment superheated steam. in this embodiment the stream of heated gas has a temperature of from about 425 °C to about 650 °C.

In this embodiment the combustion engine is a landfil! anaerobic digestion engine or a diesei engine, typically having a power output in the range of from about 0.2 W to about 3.2 MW.

The steam generation unit 1 further comprises a buffer tank 15 for storing a supply of the working fluid, in this embodiment water, and a pump unit 17 for delivering the water from the tank 15 to the steam generator 11 at a required flow rate and/or pressure.

The steam generation unit 1 further comprises a condenser 21 which receives used steam from the steam engine 3, condenses the used steam to a saturated Iiquid, in this embodiment water, and delivers the same to the tank 15.

With this configuration, the steam generator 11, the steam engine 3, the condenser 21 and the tank 15 define a circulatory loop through which the working fluid is circulated, in being converted from a saturated Iiquid, here water, to a superheated fluid, here superheated steam, and back to a saturated liquid.

In this embodiment the steam generation unit 11 further comprises a bypass valve unit 23, here comprising first and second valves 25a, b, which can be selectively operated between a first, by-pass mode, as illustrated in Figure 1(b), in which the exhaust gas by-passes the steam generation unit 11 and passes directly through a muffler 27, and a second, operative mode, as illustrated in Figure 1(c), in which the exhaust gas is delivered through the steam generation unit 11 prior to the muffler 27.

The steam generator 11 comprises a housing 31, which defines a gas f!ow path 33 and has an inlet 35 at one, upstream end thereof into which a stream of heated gas is delivered and an outlet 37 at the other, downstream end thereof through which the stream of heated gas exits, and a steam generation module 39 which disposed within the gas flow path 33 of the housing 31.

In this embodiment the housing 31 comprises a main housing part 41 and first and second end housing parts 43, 44.

In this embodiment the housing 31 is formed of stainless steel, here having a thickness of 2 mm.

In this embodiment the main housing part 41 has a rectangular Internal cross-section.

In this embodiment one of the end housing parts 43 is fixed, here by welding, to the main housing part 41, and the other of the end housing parts 44 is removable from the main housing part 41, in this embodiment by a flange coupling 45, here a bolted flange coupling.

In this embodiment the removable end housing part 44 is at the upstream end of the housing 31, and removal of that end housing part 44 allows for the steam generation module 39 to be loaded into or unloaded from the housing 31. In this embodiment the main housing part 41 provides a main flow path Fl through a central region thereof, and first and second ancillary flow paths F2 to the respective outer, lateral sides of the steam generation module 39,

In this embodiment the ancillary flow paths F2 receive iess than 10% of the gas flow through the housing 31.

In one embodiment the ancillary flow paths F2 receive less than 5% of the gas flow through the housing 31.

In this embodiment the housing 31 includes a support 46 for supporting the steam generation module 39, which is disposed within the main housing part 41 and allows for the steam generation module 39 to be slideably introduced into or withdrawn from the main housing part 41 on removal of the removable end housing part 44.

In this embodiment the support 46 provides rails 47, here first and second rails 47a, b at the respective outer edges thereof, along which the steam generation module 39 is siideabie.

In this embodiment the support 46 includes a locator fixture 51, here disposed at one, downstream end of the support 46, for locating one, downstream end of the steam generation module 39, and a locking fixture 53, here disposed at the other, upstream end of the support 46, for locking the steam generation module 39 to the support 46 in a manner which allows for expansion of the steam generation module 39, as will be described in more detail hereinbelow.

In this embodiment the locator fixture 51 comprises first and second locating elements 55a, b, here including locating apertures 56, which are disposed at the downstream ends of the rails 47a, b. In this embodiment the locking fixture 53 comprises first and second locking elements 57a, b, here including locking apertures 58, which are disposed at the upstream ends of the rails 47a, b.

The steam generation module 39 comprises a pre-heater unit 61 which is operative to raise the temperature of a received working fluid, here water, as a saturated liquid, typically having a temperature of about 70 °C, to a temperature of from about 100 °C to about 120 °C, and optionally to a temperature of from about 100 °C to about 110 °C.

The pre-heater unit 61 comprises at least one pre-heater circuit 63, in this embodiment a plurality of pre-heater circuits 63a-c, which each comprise pre-heating pipework 65, and each has an input fluidly connected to the tank 15 and an output from which the working fluid of raised temperature is delivered.

In this embodiment the pipework 65 of the pre-heater circuits 63a-c extend within and along a lateral side of the main housing part 41, here from one, upstream end of the main housing part 41 to the other, downstream end of the main housing part 41, such as to be heated by one of the ancillary gas flows F2.

In this embodiment the pre-heating pipework 65 is formed of stainless steel tube having an external diameter of 12.7 mm and a 16 swg wail thickness.

The steam generation module 11 further comprises at least one, in this embodiment first and second heat exchanger units 71a, b which are located in series upstream of the pre-heater unit 61, and are operative to raise the temperature of the working fluid as received from the pre-heater unit 61 to a temperature of about 260 °C, thereby providing the working fluid as saturated steam. The heat exchanger units 71a, b each comprise at least one heat exchanger circuit 73, in this embodiment a p!uraiity of heat exchanger circuits 73a-c, which each have an input fluid!y connected to a respective one of the pre- heater circuits 63a-c of the pre-heater unit 61 and an output from which the working fluid, as saturated steam, is delivered.

In this embodiment the heat exchanger units 71a, b each comprise at least one heat exchanger assembly 75, in this embodiment a p!ura!ity of heat exchanger assemblies 75a-c, which each provide a respective one of the heat exchanger circuits 73a-c and are stacked to provide the respective heat exchanger unit 71a, b.

With this configuration, the heat exchanger assemblies 75a-c of the first and second heat exchanger units 71a, b define an nxm array, here a 2x3 array.

In this embodiment the heat exchanger assemblies 75a-c each have a power output of at least 30 kW, optionally at least 40 kW, with each heat exchanger circuit 73a-c having a power output of at least 60 kW, optionally at least 80 kW, and together provide a total power output at least 180 kW, optionally at least 240 kW,

In this embodiment the heat exchanger assemblies 75a-c each comprise first and second support elements 77a, b which are disposed in spaced relation and define a width of the heat exchanger unit 71a, b.

In this embodiment the support elements 77a, b of the heat exchanger assemblies 75a-c are formed from stainless steel sheet having a thickness of 6 mm.

In this embodiment the support elements 77a, b of the heat exchanger assemblies 75a-c are interconnected by sliding couplings, which allow relative movement of the heat exchanger assemblies 75a-c, thus accommodating relative expansion thereof. In this embodiment the support elements 77a, b of one, the lowermost, of the heat exchanger assemblies 75a-c each include a rail guide 79 at the lower edge thereof, which overiies a respective one of the rails 47a, b of the support 46 of the housing 31, such as to provide for sliding engagement with the rails 47a, b.

In this embodiment the heat exchanger assemblies 75a-c each comprise heat exchanger pipework 85 which extends between the support elements 77a, b of the heat exchanger assemblies 75a-c, and a plurality of fins 87 which extend in spaced, parallel relation to the support elements 77a, b of the heat exchanger assemblies 75a-c. For purposes of illustration, only some of the fins 87 are illustrated in certain of the views.

In this embodiment the heat exchanger pipework 85 comprises a plurality of bent, U-shaped tube sections 91, which each provide two spaced, parallel elongate tube elements 93, one ends 95 of which are continuously fluidly connected by a 180 degree radiused bend 96, and the other ends 97 of which are open and in spaced relation.

In this embodiment, as illustrated in Figure 7(d), the tube sections 91 comprise first tube sections 91a, which are arranged as a plurality of rows 92a-f, such that the flow of the working fluid is along the rows 92a-f in series, and second, cross-over tube sections 91b, which provide for a crossover transfer flow between the respective rows 92a-f.

In this embodiment the tube elements 93 of the first tube sections 91a have a closer spacing than the tube elements 93 of the second tube sections 91b.

In this embodiment the rows 92a-f are arranged as vertical rows in spaced relation along a length of the heat exchanger assembly 75a-c, such that the flow is through each row 92a-f, here vertically upwards or downwards, with the flow passing laterally across the heat exchanger assembly 75a-c in alternate directions.

In this embodiment the other, open ends 97 of the tube sections 91 extend to a generally common plane, and the open ends 97 of the tube elements 93 of adjacent tube sections 91 have a common spacing, which allows for fluid connection of the open ends 97 by a single size of tube end coupling 103, as will be described in more detail hereinbelow.

In this embodiment the tube sections 91 are formed of stainless steel tube having an external diameter of 12.7 mm and a 16 swg wall thickness.

In this embodiment the open ends 97 of the tube elements 93 each include an outwardly-inclined internal chamfer 101, here of 45 degrees.

In this embodiment the heat exchanger pipework 85 further comprises a plurality of tube end couplings 103 which fluidly connect the open end 97 of one tube element 93 from each of two adjacent tube sections 91.

With this configuration, the tube sections 91 and the pipe end couplings 103 provide a single, continuous flow path which extends in alternate directions across a width of the heat exchanger assembly 75a-c, and thus the gas flow passage 33 of the housing 31.

In this embodiment the pipe end couplings 103 each comprise a main body part 105 to which the open ends 97 of the adjacent tube sections 91 are fixed, and an enclosure part 107 which is fixed to the main body part 105 and provides a closed fluid connection between the respective open ends 97 of the adjacent tube sections 91.

In this embodiment the main body part 105 comprises a body 111, which includes a flange 115 which encloses a surface 117, and first and second bores 119, 121 which extend to the surface 117, such as to provide fluid communication thereto.

In this embodiment the flange 115 defines an annular seat 123 to which the enclosure part 107 is fixed, and an upstand 125 which extends around the seat 123 and includes an invvardiy-inciined internal chamfer 127, here of about 45 degrees.

As will be described in more detail hereinbelow, this configuration allows the enclosure part 107 to be located on the seat 123, and the enclosure part 107 to be fixed to the main body part 105, in this embodiment by providing an annular weld at the junction of the internal chamfer 127.

In this embodiment the main body part 105 includes at least one clamping fixture 129 for engagement by a testing too! 151, as will be described in more detail hereinbelow, here first and second clamping fixtures 129a, b, which are each configured to engage a clamping fixture 164 on the testing tool 151.

In this embodiment the clamping fixtures 129a, b each comprise first and second pairs of detents 130, here lugs, which are disposed to opposite sides of the respective through bores 191, 121.

In this embodiment the through bores 119, 121 each include at least one, here a plurality of grooves 131, into which the open end 97 of a respective one of the cube elements 93 of the adjacent tube sections 91 is expanded, here by swaging .

In this embodiment the through bores 119, 121 each terminate at an upstand 135 which projects from the surface 117 and to which the open end 97 of a respective one of the tube elements 93 of the adjacent tube sections 91 is fixed, here by an annular weld. In this embodiment the upstand 135 includes an inwardiy-indined internal chamfer 137, here of 45 degrees, which, together with the outwardly- inclined externa! chamfer 101 on the open end 97 of the respective tube element 93, defines a channel for receiving the weld.

In this embodiment the enclosure part 107 includes an internal cavity 141 which defines an arcuate surface having first and second bend radii 143, which are disposed opposite the through bores 119, 121 in the main body part 105, thereby defining a 180 degree radiused bend between the through bores 119, 121.

In this embodiment the enclosure part 107 includes a flange 145 which extends around the internal cavity 141.

In this embodiment the flange 145 defines an annular seat 147 which corresponds to the annular seat 123 as defined by the flange 115 of the main body part 105, and includes an outwardly-inclined external chamfer 149, here of about 45 degrees.

With this configuration, the enclosure part 107 can be fixed to the main body part 105 by providing an annular weld at the junction of the internal chamfer 127 of the main body part 105 and the external chamfer 149 of the enclosure part 107.

In this embodiment the main body part 105 and the enclosure part 107 are formed of stainless steel.

In this embodiment the main body part 105 and the enclosure part 107 are fabricated by casting, here investment casting, but other fabrication methods could be employed.

Figures 10(a) and (b) illustrate a testing tool 151 in accordance with one embodiment of the present Invention for pressure testing the fixing of the tube elements 93 to the through bores 119, 121 of the main body parts 105 of the tube end couplings 103.

The testing tool 151 comprises a test body 153, which includes a chamber 155, which, when the testing tool 151 is fitted to the main body part 105 of one tube end coupling 103, is fluidly connected to one through bore 119, 121 of the main body part 105 under test.

In this embodiment the test body 153 includes a first, coupling port 156, here a circular aperture, and a sealing element 157, here an annular seal, which surrounds the coupling port 156, such as to provide for sealing engagement between the chamber 155 and the main body part 105 under test,

In this embodiment the coupling port 156 is shaped and sized to fit over the upstand 135 of one of the through bores 119, 121 of the main body part 105, with the sealing element 157 engaging the surface 117 of the main body part 105.

In this embodiment the test body 153 further includes a pressure connection port 159 which is fluidly connected to the chamber 155 and allows for connection of one or both of a pressure source 160 for delivery of a pressure to the chamber 155 or a pressure detector 161 for detection of a pressure at the chamber 155.

The testing tool 151 further comprises a clamping arrangement 162 for clamping the test body 153 to the main body part 105 under test.

In this embodiment the clamping arrangement 162 comprises a clamp body

163 to which the test body 153 is movabiy disposed, and a clamping fixture

164 for clamping the damp body 163, and the test body 153 which is supported thereby, to the main body part 105 under test, here by engagement with one clamping fixture 129a, b on the main body part 105. In this embodiment the clamping fixture includes a pair of clamping arms 165a, b, which are configured to engage a respective pair of clamping fixtures 129a, b on the main body part 105,

In this embodiment the damping arms 165a, b are movably disposed to the cSamp body 163, here pivotaily coupled, and each include a detent 166, here a lug, at one end thereof for engagement with the counterpart detent 130 of the clamping fixture 129a, b of the main body part 105.

In this embodiment the clamping arrangement 162 further comprises a biasing mechanism 167 for biasing the test body 153 relative to the clamp body 163, such as to fix the test body 153 in sealing engagement with the respective through bore 119, 121, here by sealing engagement with the surface 117 of the main body part 105,

In this embodiment the biasing mechanism 167 comprises a drive member 168 which is axiaily displaceable relative to the clamp body 163, here by a threaded coupling 169 with the clamp body 163, such that rotation of the drive member 168 causes axiai displacement of the test body 153. In other embodiments the drive member 168 could be operated by an electrically- operated actuator,

The testing too! 151 further comprises a pressure source 160 which is fluldiy connected to the pressure connection 159 of the test body 153, and a pressure detector 161 for providing an indication of the acceptability of the fixing of the tube elements 93 to the through bores 119, 121 of the main body part 105 under test.

With this configuration of the main body part 105 of the tube end coupling 103, and, through use of the testing tool 151, the acceptability of the fixing of each main body part 105 can be assured before completing the tube end coupling 103 by fixing, here welding, the enclosure part 107 to the respective main body part 105.

Referring particularly to Figures 11 to 13, in this embodiment the fins 87 each comprise a single, continuous sheet element 171, which includes a plurality of apertures 173 through which extend respective ones of the tube eiements 93 of the tube sections 91 of the respective heat exchanger assembly 75a-c, and a plurality of fin coupling eiements 175 which are located within each aperture 173 to interface the tube elements 93 of the tube sections 91 to the sheet eiements 171, as will be described further hereinbeiow.

By forming the fins 87 from a single, continuous sheet element 171, a uniform temperature distribution can be promoted over the length of the heat exchanger assembly 75a-c, in the sense of the flow direction of the heated gas flow through the housing 31,

In this embodiment the sheet element 171 is formed from stainless steel sheet having a thickness of 1 mm.

In this embodiment the apertures 173 each include a locator 177, here a cut-out, which acts to locate the rotational position of the respective fin coupling element 175 within the aperture 173,

In this embodiment the fin coupling eiements 175 each comprise a body part 181 which is thermally connected to the sheet element 171 and includes an aperture 183 through which extends a respective one of the tube eiements 93, and a flange 185 which extends from the body part 181 and around the aperture 183 therein and through the respective aperture 173 in the sheet element 171, and is thermally connected to the respective tube element 93. In this embodiment the flange 185 comprises a tubular section, here having a length of at least 3 mm, which is a close fit to the outer diameter of the tube elements 93 of the tube sections 91.

By utilizing fin coupling elements 175 of the kind as described, fitting of the sheet elements 171 to the tube elements 93 of the tube sections 91 is facilitated, as the apertures 173 in the sheet elements 171 can be made greater than the outer diameter of the tube elements 93, which allows for relatively-free movement of the sheet elements 171 over the array of tube elements 93 to the required positions along the axial length of the tube elements 93, with fitting of the fin coupling elements 175 to a respective sheet element 171 only being required when the sheet element 171 is in the required axial position.

In addition, with this configuration, the flange 185, which is a close fit to the respective tube element 93, can have an extended length, which promotes thermal transfer between the tube element 93 and the sheet element 171.

In this embodiment the body part 181 has the form of a fiat, annular part, in the manner of a thin washer, and the flange 185 extends in one direction orthogonally thereto.

In this embodiment the fin coupling elements 175 each further comprise at least one, here a plurality of projections 191 which extend in an opposite direction to the flange 185.

In this embodiment the projections 191 each comprise an upstand which extends in an opposite direction to the flange 185, and act to support the adjacent sheet element 171, as will be described in more detail hereinbeiow.

With this configuration, the spacing d of the sheet elements 171 is set by the length of the projections 191, thus allowing the spacing d of the sheet elements 171 to be precisely controlled. In this embodiment the projections 191 extend from an outer peripheral edge of the body part 181, which is spaced radially from the flange 185.

In this embodiment the projections 191 are located to one, rear side of the fin coupling element 175, in the sense of the gas flow direction through the housing 31, and present a forwardiy-facing surface 193 which acts to disrupt the gas flow to the rear side of the respective tube element 93, here by causing a vortical flow, which is such as to promote heat transfer between the gas flow and the respective tube element 93.

In this embodiment the fin coupling element 175 includes a locator 195, here a lug, which is configured to locate with the locator 177 in the respective aperture 173 in the sheet element 171 of the fin 87, thereby locating the rotational position of the respective fin coupling element 175 within the aperture 173, and ensuring that the projections 191 on the fin coupling element 175 are located in the required orient relative to the tube element 93 as to promote heat transfer.

In one embodiment the fin coupling element 175 could be coated at least partially with a brazing material, which allows for brazing of the fin coupling elements 175 to the tube elements 93 and the sheet element 171, thus avoid brazing material having to be provided separately where the fixing of the coupling elements 175 is by brazing.

In one embodiment the fin coupling elements 175 are formed of stainless steel and coated with brazing material, in one embodiment with a thickness of less than 0.5 mm, optionally less than 0.3 mm, optionally less than 0.2 mm. In one embodiment the coating has a thickness of about 0.1 mm.

In one embodiment the coating of brazing material is of pure, oxygen-free copper. in this embodiment the heat exchanger assemblies 75a-c are manufactured as follows.

In a first step, one support element 77a is located in a jig.

In a second step, the tube sections 91 are in turn located in the jig and arranged such that the tube elements 93 thereof extend in a required pattern through the apertures in the one support eiement 77a, and such that the bends 96 of the tube sections 91 are located outwardly, here downwardly, of the one support element 77a, with the elongate tube elements 93 of the tube sections 91 extending in parallel relation upwardly from the one support eiement 77a.

In a third step, a fin coupling eiement 175 is located over each of the tube elements 93. This fin coupiing element 175 acts as a spacer to space the first sheet element 171 from the one support element 77a.

In a fourth step, a ring of brazing material, which has an internal diameter corresponding to the outer diameter of the tube elements 93, is located over each of the tube elements 93 so as to be positioned at the aperture 183 in the body part 181 of the fin coupling element 175. In this embodiment the ring of brazing material is formed of pure, oxygen-free copper,

In a fifth step, a ring of brazing material, which has an internal diameter corresponding to the outer diameter of the body part 181 of the fin coupling element 175, is located over each of the fin coupiing elements 175 so as to be positioned at the junction of the body part 181 of the fin coupling element 175 and the sheet element 171. In this embodiment the ring of brazing material is formed of pure, oxygen-free copper.

In a sixth step, a sheet element 171 is located over the tube elements 93, by passing the tube elements 93 through the respective apertures 173 in the sheet eiement 171. As the apertures 173 in the sheet eiement 171 have a greater diameter than the outer diameter of the tube elements 93_f the sheet element 171 can be fitted relatively easily over the tube elements 93.

In a seventh step, a fin coupling element 175 is located over each of the tube elements 93, and the flange 185 of the fin coupiing element 175 is located in the respective aperture 173 in the sheet element 171, with the locator 195 of the fin coupling element 175 being located in the locator 177 of the respective aperture 173 in the sheet element 171.

In an eighth step, a ring of brazing material, which has an internal diameter corresponding to the outer diameter of the tube elements 93, is located over each of the tube elements 93 so as to be positioned at the aperture 183 in the body part 181 of the fin coupling element 175. In this embodiment the ring of brazing material is formed of pure, oxygen-free copper.

In a ninth step, a ring of brazing material, which has an internal diameter corresponding to the outer diameter of the body part 181 of the fin coupling element 175, is located over each of the fin coupling elements 175 so as to be positioned at the junction of the body part 181 of the fin coupiing element 175 and the sheet element 171. In this embodiment the ring of brazing material is formed of pure, oxygen-free copper.

The sixth to ninth steps are then repeated to build up a stack of fins 87 along the length of the tube elements 93.

In a tenth step, the other support element 77b is located over the tube elements 93, by passing the tube elements 93 through the respective apertures in the other support element 77b.

In an eleventh step, this core assembly is vacuum brazed, which provides a very strong rigid matrix, with each of the tube elements 93 being fixed to each of the sheet elements 171, and the sheet elements 171 having a predefined spacing d. In a twelfth step, the pipe end couplings 103 are attached to the open ends 97 of the tube elements 93 of respective pairs of adjacent tube sections 91.

In this embodiment each pipe end coupling 103 is attached as follows.

In a first sub-step, the main body part 105 of each pipe end coupling 103 is located over the open ends 97 of the tube elements 93 of adjacent tube sections 91, such that the open ends 97 of the tube elements 93 extend into the through bores 119, 121 in the main body part 105, and the open ends 97 of the tube elements 93 are expanded, in this embodiment by from about 4% to about 5%, such as to engage the grooves 131 in the respective through bores 119, 121.

In a second sub-step, the open ends 97 of the expanded tube elements 93 are each fixed to the respective upstands 135 of the through bores 119, 121, here by providing a weld in the channel defined by the external chamfer 101 on the open end 97 of the tube element 93 and the internal chamfer 137 in the upstand 135 of the respective through bore 119, 121.

In a third sub-step, the tube elements 93 are further expanded, in this embodiment by from about 4% to about 5%, such as further to engage the grooves 131 in the respective through bores 119, 121.

In a fourth sub-step, the effectiveness of the coupling of the tube elements 93 to the main body part 105 is tested using the testing tool 151. in the manner as described above.

In a fifth sub-step, where an effective coupling of the tube elements 93 to the main body part 105 is determined, the enclosure part 107 of the pipe end coupling 103 is fixed to the main body part 105, in this embodiment by providing an annular weld at the junction of the interna! chamfer 127 of the main body part 105 and the external chamfer 149 of the enclosure part 107. As discussed hereinabove, in one alternative embodiment, the fourth, fifth, eighth and ninth steps can be omitted where the fin coupling elements 175 are pre-coated with brazing material,

The steam generation module 11 further comprises a superheater unit 201 which is located at an upstream end thereof and upstream of the at ieast one heat exchanger unit 71a, b, and is operative further to raise the temperature of the received working fluid, in this embodiment saturated steam, to a temperature of from about 300 °C to about 400 °C, preferably at a temperature of about 350 °C, and with a pressure of up to 60 bar, thereby providing superheated fluid.

The superheater unit 201 comprises at ieast one superheater circuit 203, in this embodiment a plurality of superheater circuits 203a-c, which each comprise superheater pipework 205, and each has an input fiuidly connected to the output of a respective one of the heat exchanger circuits 75a-c and an output from which a superheated fluid, in this embodiment superheated steam, is delivered.

In this embodiment the superheater pipework 205 comprises a plurality of coils 206, which accommodate longitudinal and lateral expansion.

In this embodiment, as illustrated in Figures 15(a) to (c), the superheater coils 206 comprise a coil element 207, here a heiicaliy-wound coil, having an inlet 208 and an outlet 209, which are located on the longitudinal axis thereof.

In this embodiment the coil element 207 is wound about the longitudinal axis.

With this symmetric configuration, the spring force caused by expansion of the coil 206 is uniform. In this embodiment the coils 206 comprise slip couplings 210, here in the form of sleeves, which shroud the inlet 208 and the outlet 209 of the coil element 207, such as to protect the coil element 207 from frictional engagement with support elements 211a, b.

In this embodiment the superheater unit 201 comprises first and second support elements 211a, b which support the superheater pipework 205 of the superheater circuits 203a-c and are disposed in spaced relation and define a width of the superheater unit 201.

In this embodiment the support elements 211a, b each include a rail guide 215 at the lower edge thereof, which overlies a respective one of the rails 47a, b of the support 46 of the housing 31, such as to provide for sliding engagement with the rails 47a, b.

In this embodiment the support elements 211a, b of the superheater unit 201 are formed from stainless steel sheet having a thickness of 6 mm.

In this embodiment the support elements 211a, b of the superheater unit 201 have the same spacing as the support elements 77a, b of the heat exchanger assemblies 75a-c of the at least one heat exchanger unit 71a, b.

In this embodiment, as illustrated in Figures 14(a) to (f), the coils 206 of the superheater circuits 203a-c extend in spaced, parallel relation between the support elements 211a, b,

In this embodiment the superheater pipework 205 is formed of stainless steel tube having an external diameter of 19,05 mm and a wall thickness of 1,65 mm.

In this embodiment the steam generation module 11 further comprises a pressure-relief valve (not illustrated) which provides for venting of the steam generation module 11 in the event of the system pressure exceeding a predetermined threshold, here 65 bar. In this embodiment the pressure relief valve is located downstream of the superheater unit 201.

Finally, it will be understood that the present invention has been described in its preferred embodiments and can be modified in many different ways without departing from the scope of the invention as defined by the appended claims.

Claims

1. A steam generator for generating a superheated fluid from a working fluid using a stream of heated gas, the steam generator comprising:

a housing, which defines a gas flow path having an inlet at one, upstream end thereof into which a stream of heated gas is delivered and an outlet at the other, downstream end thereof; and

a steam generation module which is disposed within the gas flow path of the housing, the steam generation module comprising a heat exchanger which receives a working fluid and is operative to raise the temperature of the working fluid to provide a saturated fluid, and a superheater which receives the saturated fluid from the heat exchanger and is operative to raise the temperature of the saturated fluid and provide a supersaturated fluid.

2. The steam generator of claim 1, wherein the stream of heated gas has a temperature of from about 425 °C to about 650 °C.

3. The steam generator of claim 1 or 2, wherein the stream of heated gas is an exhaust gas from a burner, optionally a biomass burner, or an exhaust gas from a combustion engine, optionally a landfill anaerobic digestion gas engine, a methane burning engine, a-diesel engine, a marine engine or a coal gas engine, optionally having a power output in the range of from about 0.2 MW to about 3.2 MW.

4. The steam generator of any of claims 1 to 3, wherein the housing comprises a main housing part which provides a gas flow path therethrough and first and second end housing parts, optionally the main housing part has an internal cross-section/ preferably a rectangular internal cross-section, in which the steam generation module is disposed.

5. The steam generator of claim 4, wherein the main housing part provides a main gas flow path through a central region thereof and first and second ancillary gas flow paths to the respective outer, lateral sides of the steam generation module, optionally the ancillary flow paths receive less than 10% or less than 5% of the gas flow through the housing.

6. The steam generator of claim 4 or 5, wherein one of the end housing parts is fixed to the main housing part and the other of the end housing parts is removable from the mairi housing part, whereby the steam generation module is slideably loadable into and unloadable from the main housing part.

7. The steam generator of claim 6, wherein the removable end housing part is at the upstream end of the housing in the gas flow direction.

8. The steam generator of any of claims 4 to 7, wherein the housing includes a support which is disposed within the main housing part thereof, and allows for the steam generation module to be slideably loaded into and unloaded from the main housing part.

9. The steam generator of claim 8, wherein the housing includes at least one locator for locating the steam generation module on the support, optionally for locating a support structure of the steam generation module, optionally the at least one locator is disposed at one, downstream end of the support, optionally the housing includes first and second locators.

10. The steam generator of claim 8, wherein the housing further includes at least one locking fixture for locking the steam generation module to the support, optionally for locking a support structure of the steam generation module, optionally the at least one locking fixture is disposed at the other, upstream end of support, optionally the housing includes first and second locking fixtures.

11. The steam generator of any of claims 1 to 10, wherein the heat exchanger is operative to raise the temperature of the received working fluid and provide a saturated fluid at a temperature of at least about 250 °C, optionally at least about 260 °C.

12. The steam generator of any of claims 1 to 11, wherein the heat exchanger comprises at least one heat exchanger circuit, each including heat exchanger pipework having an input and an output, optionally the heat exchanger comprises a plurality of heat exchanger circuits.

13. The steam generator of claim 12, wherein the heat exchanger comprises at least one heat exchanger unit, optionally a plurality of heat exchanger units.

14. The steam generator of claim 13, wherein the heat exchanger units are provided in at least one heat exchanger assembly, optionally in a plurality of heat exchanger assemblies, optionally the at least one heat exchanger assembly defines an nxm array of heat exchanger units, where n is at least 1, 2 or greater and m is at least 1, 2 or greater.

15. The steam generator of claim 13 or 14, wherein respective ones of the heat exchanger units are connected in series to provide one or more heat exchanger circuits.

16. The steam generator of any of claims 13 to 15, wherein each heat exchanger unit comprises tube elements which extend in spaced relation, and a plurality of fins which extend in spaced relation orthogonally to the tube elements.

17. The steam generator of claim 16, wherein the tube elements are provided by a plurality of U-shaped tube sections, which each provide two spaced elongate tube elements, one ends of which are fluidly connected by a 180 degree bend and the other ends of which are open and in spaced relation, and a plurality of pipe end couplings which fluidly connect open ends of respective tube elements of adjacent tube sections, optionally the tube sections and the pipe end couplings together provide a single continuous flow path which extends in alternate directions across a width of the gas flow path of the housing.

18. The steam generator of claim 17, wherein the pipe end couplings each comprise a main body part to which the open ends of the tube elements of adjacent tube sections are fixed, and an enclosure part which is fixed to the main body part and provides a closed fluid connection between the respective open ends of the adjacent tube sections.

19. The steam generator of claim 18, wherein the main body part comprises a body, which includes a flange which encloses a surface, and first and second bores which extend to the surface and provide fluid communication thereto, optionally the flange defines an annular seat to which the enclosure part is fixed, optionally the flange defines an upstand which extends around the seat to which the enclosure part is fixed by an annular weld, optionally the upstand includes an inwardly-inclined internal chamfer for receiving the weld.

20. The steam generator of claim 19, wherein the main body part includes at least one detent, optionally a plurality of detents, for engagement by a testing tool.

21. The steam generator of claim 19 or 20, wherein the bores each include at least one groove, optionally a plurality of grooves, into which the open end of a respective one of the tube elements of the adjacent tube sections is expanded.

22. The steam generator of any of claims 19 to 21, wherein the bores each terminate at an upstand which projects from the surface and to which the open end of a respective one of the tube elements of the adjacent tube sections is fixed by an annular weld, optionally the upstand includes an inwardly-inclined internal chamfer, the open end of the respective tube element includes an outwardly-inclined external chamfer, and the chamfers together define a channel for receiving the weld.

23. The steam generator of any of claims 19 to 22, wherein the enclosure part includes an internal cavity which defines an arcuate surface having first and second bend radii, which are disposed opposite the bores in the main body part, thereby defining a 180 degree bend between the bores, optionally the enclosure part includes a flange which extends around the internal cavity to which the main body part is fixed by an annular weld, optionally the flange defines an outwardly-inclined external chamfer for receiving the weld, optionally the flange defines an annular seat, which corresponds to an annular seat as defined by the flange of the main body part.

24. The steam generator of any of claims 16 to 23, wherein the fins each comprise a sheet element, optionally a single, continuous sheet element, which includes a plurality of apertures through which extend respective ones of the tube elements of the tube sections.

25. The steam generator of claim 24, wherein the fin sheet element has a thickness of at least about 1 mm.

26. The steam generator of claim 24 or 25, wherein the fin sheet elements are spaced by a spacing of at least about 2 mm, optionally at least about 3 mm.

27. The steam generator of any of claims 24 to 26, wherein the fin apertures in the fin sheet element each include a locator, optionally a cut-out, which acts to locate a rotational position of a respective fin coupling element within the fin aperture.

28. The steam generator of any of claims 24 to 27, wherein the fins each further comprise a plurality of fin coupling elements which are located within fin apertures to interface the tube elements to the fin sheet elements, optionally the fin coupling elements each comprise a body part which is thermally connected to the sheet element and includes an aperture through which extends a respective one of the tube elements, and a flange which extends from the fin body part and through the respective fin aperture in the fin sheet element and is thermally connected to the respective tube element.

29. The steam generator of claim 28, wherein the flange comprises a tubular section which is a close fit to an outer dimension of the tube elements, optionally the flange has a length of at least 3 mm, and/or the fin body part has the form of a flat, annular part.

30. The steam generator of claim 28 or 29, wherein the fin coupling elements each further comprise at least one projection, optionally a plurality of projections, optionally the at least one projection is disposed radially outwardly of the flange, optionally the at least one projection extends from an outer peripheral edge of the body part, optionally the flange and the at least one projection extend in opposite directions, optionally the at least one projection has a length which acts to space the adjacent sheet element, optionally the fin coupling elements each comprise a plurality of projections, which are located to one, rear side of the fin coupling element in a gas flow direction through the heat exchanger unit, and present a forwardly-facing surface which acts to disrupt a gas flow to a rear side of the respective tube element.

31. The steam generator of any of claims 28 to 30, wherein the fin coupling elements each include a locator, optionally a lug, which is configured to locate with a locator in a respective aperture of the sheet element, thereby locating the rotational position of the respective fin coupling element, optionally the locator includes a detent for engaging the sheet element and thereby retain the fin coupling element in the sheet element before fixing the fin coupling elements to the sheet element.

32. The steam generator of any of claims 16 to 31, wherein each heat exchanger unit comprises first and second outer support elements which are disposed in spaced relation and define a width of the heat exchanger unit, optionally each heat exchanger unit comprises intermediate support elements which are disposed in spaced relation between the outer support elements.

33. The steam generator of any of claims 1 to 32, wherein the steam generation module further comprises a superheater which is operative further to raise the temperature of the saturated fluid as received from the heat exchanger and provide superheated fluid, optionally the superheater is operative to provide a superheated fluid at a temperature of at least about 300 °C to about 400 °C, optionally about 300 °C to about 400 °C, optionally the superheater is operative to provide a superheated fluid at a pressure of up to about 60 bar, optionally from about 10 bar to 60 bar, optionally the superheater is located upstream of the heat exchanger.

34. The steam generator of claim 33, wherein the superheater comprises at least one superheater circuit, each including superheater pipework having an input fluidly connected to the heat exchanger and an output, optionally the superheater comprises a plurality of superheater circuits, each having an input fluidly connected to a respective heat exchanger circuit of the heat exchanger.

35. The steam generator of claim 34, wherein the superheater comprises first and second support elements which support the superheater pipework and are disposed in spaced relation and define a width of the superheater, optionally the superheater pipework comprises a plurality of coils, which accommodate longitudinal and lateral expansion, optionally the coils of the at least one superheater circuit extend in spaced relation between the support elements.

36. The steam generator of claim 35, wherein the support elements each include a rail guide at the lower edge thereof, which overlies a support of^~the housing, such as to provide for sliding engagement, optionally the support elements of the superheater have the same spacing as the support elements of the heat exchanger.

37. The steam generator of any of claims 1 to 36, wherein the steam generation module further comprises a pre-heater unit which is operative to raise the temperature of a working fluid, from which the heat exchanger receives a raised-temperature working fluid, optionally the pre-heater unit is operative to raise the temperature of the received working fluid to a temperature of from about 100 °C to about 120 °C or from about 100 °C to about 110 °C, optionally the pre-heater unit comprises at least one pre-heater circuit, optionally comprising a plurality of pre-heater circuits, each including pre- heater pipework having an input and an output.

38. The steam generator of claim 37, wherein the pre-heater unit is disposed within a downstream end of the housing.

39. The steam generator of claim 37 or 38, wherein the steam generation module further comprises an economizer which is disposed downstream of the housing.

40. The steam generator of claim 39, wherein the economizer comprises tube elements which extend in spaced relation and are provided by a plurality of U-shaped tube sections, which each provide two spaced elongate tube elements, one ends of which are fluidly connected by a 180 degree bend and the other ends of which are open and in spaced relation, and a plurality of pipe end couplings which fluidly connect open ends of respective tube elements of adjacent tube sections, optionally the tube sections and the pipe end couplings together provide at least one economizer flow circuit, optionally a plurality of economizer flow circuits.

41. The steam generator of claim 40, wherein the pipe end couplings each comprise a main body part to which the open ends of the tube elements of adjacent tube sections are fixed, and an enclosure part which is fixed to the main body part and provides a closed fluid connection between the respective open ends of the adjacent tube sections.

42. The steam generator of claim 41, wherein the main body part comprises a body, which includes a flange which encloses a surface, and first and second bores which extend to the surface and provide fluid communication thereto, optionally the flange defines an annular seat to which the enclosure part is fixed, optionally the flange defines an upstand which extends around the seat to which the enclosure part is fixed by an annular weld, optionally the upstand includes an inwardly-inclined internal chamfer for receiving the weld.

43. The steam generator of claim 42, wherein the bores each include at least one groove, optionally a plurality of grooves, into which the open end of a respective one of the tube elements of the adjacent tube sections is expanded.

44. The steam generator of claim 42 or 43, wherein the bores each terminate at an upstand which projects from the surface and to which the open end of a respective one of the tube elements of the adjacent tube sections is fixed by an annular weld, optionally the upstand includes an inwardly-inclined internal chamfer, the open end of the respective tube element includes an outwardly- inclined external chamfer, and the chamfers together define a channel for receiving the weld.

45. The steam generator of any of claims 42 to 44, wherein the enclosure part includes an internal cavity which defines an arcuate surface having first and second bend radii, which are disposed opposite the bores in the main body part, thereby defining a 180 degree bend between the bores, optionally the enclosure part includes a flange which extends around the internal cavity to which the main body part is fixed by an annular weld, optionally the flange defines an outwardly-inclined external chamfer for receiving the weld, optionally the flange defines an annular seat, which corresponds to an annular seat as defined by the flange of the main body part.

46. A steam processing unit, comprising:

the steam generator of any of claims 1 to 45 for providing a superheated fluid; and

a processing station which receives and utilizes the superheated fluid generated by the steam generator.

47. The steam processing unit of claim 46, wherein the processing station comprises at least one steam engine which receives and is driven by the superheated fluid generated by the steam generator, optionally comprising a plurality of steam engines, each optionally driven by respective circuits of the steam generator.

48. The steam processing unit of claim 46, wherein the processing station comprises at least one heat treatment unit which utilizes the superheated fluid generated by the steam generator to treat material, optionally a pasteurizing unit for treating food and waste products, optionally comprising a plurality of heat treatment units, each optionally driven by respective circuits of the steam generator.

49. The steam processing unit of any of claims 46 to 48, further comprising: a buffer tank for storing a supply of the working fluid; and

a pump unit for delivering the working fluid from the buffer tank to the steam generator at a required flow rate and/or pressure;

optionally further comprising:

a condenser which receives used working fluid, condenses the used working fluid to a saturated liquid, and delivers the same to the buffer tank, optionally the steam generator, the processing station, the condenser and the buffer tank define a closed loop through which the working fluid is circulated.

50. A power generation system, comprising: the steam processing unit of claim 46 or 47, wherein the processing station comprises at least one steam engine; and

a power generator which is driven by the at least one steam engine, optionally the power generator is an electrical power generator, optionally supplying electricity to the electrical grid.

51. A method of manufacturing a heat exchanger unit, comprising the steps of: providing a plurality of tube elements in spaced, parallel relation and with a predetermined arrangement, wherein the tube elements are provided by a plurality of U-shaped tube sections, which each provide two spaced elongate tube elements, one ends of which are fluidly connected by a 180 degree bend and the other ends of which are open and in spaced relation;

locating a fin over the tube elements, the fin comprising a sheet element having a plurality of apertures in correspondence with the arrangement of the tube elements;

locating a fin coupling element over each of the tube elements and within the apertures in the sheet element to interface the tube elements to the sheet element;

repeating the locating steps to provide a stacked arrangement of fins;

attaching body parts of a plurality of pipe end couplings to the open ends of respective tube elements of adjacent tube sections;

processing a resulting assembly to fix the fin coupling elements to the tube elements and the sheet elements, and thereby provide a single, integral structure; and

attaching enclosure parts to the body parts of each of the pipe end couplings so as to provide a closed fluid connection between the respective open ends of the adjacent tube sections.

52. The method of claim 51, wherein the tube sections and the pipe end couplings together provide a single continuous flow path which extends in alternate directions across a width of the gas flow path of the housing.

53. The method of claim 51 or 52, wherein the body parts of the pipe end couplings comprise a body, which includes a flange which encloses a surface, and first and second bores which extend to the surface and provide fluid communication thereto, optionally the flange defines an annular seat to which the enclosure part is fixed, optionally the flange defines an upstand which extends around the seat to which the enclosure part is fixed by an annular weld, optionally the upstand includes an inwardly-inclined internal chamfer for receiving the weld,

54. The method of claim 53, wherein the body parts of the pipe end couplings each include at least one detent, optionally a plurality of detents, for engagement by a testing tool.

55. The method of claim 53 or 54, wherein the bores each include at least one groove, optionally a plurality of grooves, into which the open end of a respective one of the tube elements of the adjacent tube sections is expanded.

56. The method of any of claims 53 to 55, wherein the bores each terminate at an upstand which projects from the surface and to which the open end of a respective one of the tube elements of the adjacent tube sections is fixed by an annular weld, optionally the upstand includes an inwardly-inclined internal chamfer, the open end of the respective tube element includes an outwardly- inclined external chamfer, and the chamfers together define a channel for receiving the weld.

57. The method of any of claims 53 to 56, wherein the enclosure part of the pipe end couplings includes an internal cavity which defines an arcuate surface having first and second bend radii, which are disposed opposite the bores in the main body part, thereby defining a 180 degree bend between the bores, optionally the enclosure part includes a flange which extends around the internal cavity to which the main body part is fixed by an annular weld, optionally the flange defines an outwardly-inclined external chamfer for receiving the weld, optionally the flange defines an annular seat, which corresponds to an annular seat as defined by the flange of the body part.

58. The method of any of claims 51 to 57, wherein the sheet element comprises a sheet element, optionally a single, continuous sheet element, optionally the fin element has a thickness of at least about 1 mm, optionally the sheet elements are spaced by a spacing of at least about 2 mm, optionally at least about 3 mm.

59. The method of any of claims 51 to 56, wherein the apertures in the sheet element each include a locator, optionally a cut-out, which acts to locate a rotational position of a respective fin coupling element within the fin aperture.

60. The method of any of claims 51 to 57, wherein the fin coupling elements each comprise a body part which is thermally connected to the sheet element and includes an aperture through which extends a respective one of the tube elements, and a flange which extends from the fin body part and through the respective fin aperture in the fin sheet element and is thermally connected to the respective tube element.

61. The method of claim 60, wherein the flange comprises a tubular section which is a close fit to an outer dimension of the tube elements, optionally the flange has a length of at least 3 mm, and/or the fin body part has the form of a flat, annular part.

62. The method of claim 60 or 61, wherein the fin coupling elements each further comprise at least one projection, optionally a plurality of projections, optionally the at least one projection is disposed radially outwardly of the flange, optionally the at least one projection extends from an outer peripheral edge of the body part, optionally the flange and the at least one projection extend in opposite directions, optionally the at least one projection has a length which acts to space the adjacent sheet element, optionally the fin coupling elements each comprise a plurality of projections, which are located to one, rear side of the fin coupling element in a gas flow direction through the heat exchanger unit, and present a forwardly-facing surface which acts to disrupt a gas flow to a rear side of the respective tube element.

63. The method of any of claims 51 to 62, wherein the fin coupling elements each include a locator, optionally a lug, which is configured to locate with a locator in a respective aperture of the sheet element, thereby locating the rotational position of the respective fin coupling element, optionally the locator includes a detent for engaging the sheet element and thereby retain the fin coupling element in the sheet element before fixing the fin coupling elements to the sheet element.

64. The method of any of claims 51 to 63, further comprising the steps of:

locating a first outer support element over the tube elements prior to the fin locating steps, the first outer support element having a plurality of apertures in correspondence with the arrangement of the tube elements; and locating a second outer support element over the tube elements subsequent to the fin locating steps, the second outer support element having a plurality of apertures in correspondence with the arrangement of the tube elements.

65. The method of any of claims 51 to 64, further comprising the step of:

locating at least one intermediate support element over the tube elements intermediate the fin locating steps, the first outer support element having a plurality of apertures in correspondence with the arrangement of the tube elements, optionally locating a plurality of intermediate support elements in spaced relation, each having a plurality of fins therebetween.

66. The method of any of claims 51 to 65, further comprising the step of:

prior to the processing step, providing a plurality of formers between the support elements to support the same during the processing step; and optionally removing the formers subsequent to the processing step.

67. The method of any of claims 51 to 66, wherein the processing step comprises bra2ing, optionally vacuum brazing.

68. A steam generation module, comprising:

at least one heat exchanger unit which receives a working fluid and is operative to raise the temperature of a working fluid to provide a saturated fluid;

a superheater unit which receives the saturated fluid from the at least one heat exchanger unit and is operative to raise the temperature of the saturated fluid and provide a supersaturated fluid; and

a supporting structure which supports the at least one heat exchanger unit and the superheater unit as a single, integral module which can be loaded into and unloaded from a housing of a steam generator.

69. A heat exchanger assembly, comprising:

heat exchanger pipework which includes a plurality of elongate tube elements which extend in spaced relation, wherein the heat exchanger pipework comprises a plurality of U-shaped tube sections, which each provide two spaced elongate tube elements, one ends of which are fluidly connected by a 180 degree bend and the other ends of which are open and in spaced relation, and a plurality of pipe end couplings which fluidly connect the open ends of respective tube elements of adjacent tube sections; and

a plurality of fins which extend in spaced relation and substantially orthogonally to the tube elements.

70. The assembly of claim 69, wherein the tube sections and the pipe end couplings together provide a single continuous flow path which extends in alternate directions across a width of the heat exchanger assembly.

71. The assembly of claim 69 or 70, wherein the pipe end couplings each comprise a main body part to which the open ends of the respective tube elements are fixed, and an enclosure part which is fixed to the main body part and provides a closed fluid connection between the open ends of the respective tube sections.

72. The assembly of claim 71, wherein the main body part comprises a body, which includes a flange which encloses a surface, and first and second bores which extend to the surface and provide fluid communication thereto.

73. The assembly of claim 72, wherein the flange defines an annular seat to which the enclosure part is fixed.

74. The assembly of claim 73, wherein the flange defines an upstand, which extends around the seat, to which the enclosure part is fixed by an annular weld.

75. The assembly of claim 74, wherein the upstand includes an inwardly-inclined internal chamfer for receiving the weld.

76. The assembly of any of claims 72 to 75, wherein the bores each include at least one groove, optionally a plurality of grooves, into which the open end of a respective one of the tube elements is expanded.

77. The assembly of any of claims 72 to 76, wherein the bores each terminate at an upstand which projects from the surface and to which the open end of the respective one of the tube elements is fixed by an annular weld.

78. The assembly of claim 77, wherein the upstand includes an inwardly-inclined internal chamfer, the open end of the respective tube element includes an outwardly-inclined annular chamfer, and the chamfers together define a channel for receiving the weld.

79. The assembly of any of claims 72 to 78, wherein the enclosure part includes an internal cavity which defines an arcuate surface having first and second bend radii, which are disposed opposite the bores in the main body part, thereby defining a 180 degree bend between the through bores.

80. The assembly of claim 79, wherein the enclosure part includes a flange, which extends around the internal cavity, to which the main body part is fixed by an annular weld.

81. The assembly of claim 80, wherein the flange of the enclosure part defines an outwardly-inclined external chamfer for receiving the weld.

82. The assembly of claim 80 or 81, wherein the flange defines an annular seat, which corresponds to an annular seat as defined by the flange of the main body part.

83. The assembly of any of claims 69 to 82, wherein the main body part and the enclosure part are formed of stainless steel.

84. The assembly of claim 83, wherein the main body part and the enclosure part are fabricated by casting.

85. The assembly of any of claims 69 to 84, wherein the fins each comprise a sheet element, optionally a single, continuous sheet element, which includes a plurality of apertures through which extend respective ones of the tube elements.

86. The assembly of claim 85, wherein the sheet element has a thickness of at least about 1 mm.

87. The assembly of claim 85 or 86, wherein the sheet elements are spaced by a spacing of at least about 2 mm, optionally at least about 3 mm.

88. The assembly of any of claims 85 to 87, wherein the fin apertures in the sheet element each include a locator element, optionally a cut-out.

89. The assembly of any of claims 85 to 88, wherein the fins each further comprise a plurality of fin coupling elements which are located within respective ones of the fin apertures to interface the tube elements to the sheet elements.

90. The assembly of claim 89, wherein the fin coupling elements each comprise a body part which is thermally connected to the sheet element and includes an aperture through which extends a respective one of the tube elements, and a flange which extends from the fin body part around the aperture therein and through the respective fin aperture in the sheet element and is thermally connected to the respective tube element.

91. The assembly of claim 90, wherein the flange comprises a tubular section which is a close fit to the outer dimension of the tube elements.

92. The assembly of claim 91, wherein the flange has a length of at least 3 mm.

93. The assembly of any of claims 90 to 92, wherein the fin body part has the form of a flat, annular part.

94. The assembly of any of claims 90 to 93, wherein the fin coupling elements each further comprise at least one projection, optionally a plurality of projections.

95. The assembly of claim 94, wherein the at least one projection is disposed radially outwardly of the flange.

96. The assembly of claim 95, wherein the at least one projection extends from an outer peripheral edge of the body part.

97. The assembly of any of claims 94 to 96, wherein the flange and the at least one projection extend in opposite directions.

98. The assembly of claim 97, wherein the at least one projection has a length which acts to space the adjacent sheet element.

99. The assembly of any of claims 94 to 98, wherein the fin coupling elements each comprise a plurality of projections, which are located to one, rear side of the fin coupling element in a gas flow direction through the heat exchanger assembly, and present a forwardly-facing surface which acts to disrupt a gas flow to a rear side of the respective tube element.

100. The assembly of any of claims 89 to 99, wherein the fin coupling elements each include a locator which is configured to locate with a locator in a respective aperture of the sheet element, thereby locating the rotational position of the respective fin coupling element.

101. The assembly of any of claims 89 to 100, wherein the fin coupling elements are coated at least partially with a brazing material.

102. The assembly of claim 101, wherein the fin coupling elements are formed of stainless steel and coated with brazing material, optionally with a thickness of less than 0.5 mm, optionally less than 0.3 mm, optionally less than 0.2 mm, optionally less than 0.1 mm, optionally having a thickness of from about 0.2 μιη to about 50 ym.

103. The assembly of any of claims 69 to 102, further comprising:

first and second support elements which are disposed in spaced relation at respective ends of the tube elements and define a width of the heat exchanger assembly.

104. A method of manufacturing a heat exchanger assembly, comprising the steps of:

providing a plurality of U-shaped tube sections, each comprising two spaced elongate tube elements, one ends of which are fluidly connected by a 180 degree bend and the other ends of which are open and in spaced relation; arranging the tube sections such that the tube elements thereof extend in spaced relation with a defined pattern, with the open ends of the tube elements extending to one common end;

providing a plurality of sheet elements, optionally single, continuous sheet elements, which each include a plurality of apertures;

providing a plurality of fin coupling elements, each comprising a body part which includes an aperture, and a flange which extends from the fin body part;

locating a fin sheet element over the tube elements, by passing the open ends of the tube elements through the respective fin apertures in the fin sheet element;

locating a fin coupling element over each of the open ends of the tube elements, with the flange of each fin coupling element being located in the respective fin aperture in the fin sheet element;

repeating the fin sheet element locating and the fin coupling element locating steps to build up a stack of fins along a length of the tube elements, providing a heat exchanger arrangement; and

brazing the heat exchanger arrangement, with each of the tube elements being thermally connected to each of the sheet elements by the respective fin coupling elements.

105. The method of claim 104, wherein the fin coupling elements are coated at least partially with a brazing material.

106. The method of claim 105, wherein the fin coupling elements are formed of stainless steel and coated with brazing material, optionally with a thickness of less than 0.5 mm, optionally less than 0.3 mm, optionally less than 0.2 mm, optionally less than 0.1 mm, optionally having a thickness of from about 0.2 μιη to about 50 pm.

107. The method of any of claims 104 to 106, wherein the brazing material comprises oxygen-free copper.

108. The method of any of claims 104 to 107, further comprising the steps of: providing first and second support elements, which each include a plurality of support apertures;

prior to the fin sheet element locating step, locating a first support element over the tube elements, by passing the open ends of the tube elements through the respective support apertures in the first support element; and prior to the brazing step, locating a second support element over the tube elements, by passing the open ends of the tube elements through the respective support apertures in the second support element.

109. The method of any of claims 104 to 108, wherein the fin sheet element has a thickness of at least about 1 mm.

110. The method of any of claims 104 to 109, wherein the flange comprises a tubular section which is a close fit to an outer dimension of the tube elements.

111. The method of claim 110, wherein the flange has a length of at least 3 mm.

112. The method of any of claims 104 to 111, wherein the fin coupling elements each further comprise at least one projection, optionally a plurality of projections.

113. The method of claim 112, wherein the at least one projection is disposed radially outwardly of the flange.

114. The method of claim 113, wherein the at least one projection extends from an outer peripheral edge of the fin body part.

115. The method of any of claims 112 to 114, wherein the flange and the at least one projection extend in opposite directions.

116. The method of claim 115, wherein the at least one projection has a length which acts to space the adjacent sheet element.

117. The method of claim 116, wherein the fin sheet elements are spaced by a spacing of at least about 2 mm, optionally at least about 3 mm.

118. The method of any of claims 112 to 117, wherein the fin coupling elements each comprise a plurality of projections, which are located to one, rear side of the fin coupling element in a gas flow direction through the heat exchanger assembly, and present a forwardly-facing surface which acts to disrupt a gas flow to a rear side of the respective tube element.

119. The method of any of claims 104 to 118, wherein the fin apertures in the fin sheet element each include a locator element, optionally a cut-out, and the fin coupling elements each include a locator, optionally a lug, and the locators on the fin coupling elements are located in the locators on the respective fin apertures of the fin sheet element, thereby locating the rotational position of the fin coupling elements.

120. The method of any of claims 104 to 119, wherein the fin body part has the form of a flat, annular part.

121. The method of any of claims 104 to 120, further comprising the steps of: providing a plurality of pipe end couplings; and

subsequent to the brazing step, fixing pipe end couplings to the open ends of the tube elements of adjacent tube sections,

122. The method of claim 121, wherein the pipe end couplings each comprise a main body part which comprises a body, which includes a flange which encloses a surface, and first and second bores which extend to the surface and provide for fluid communication thereto, and an enclosure part which, when fixed to the main body part, provides a closed fluid connection between the first and second bores, and the pipe end coupling fixing step comprises, for each pipe end coupling, the steps of:

fixing the open ends of the tube elements of adjacent tube sections in the respective bores of the main body part; and

fixing the enclosure part to the main body part, such as to provide a closed fluid connection between the open ends of the tube elements.

123. The method of claim 122, wherein the flange defines an annular seat to which the enclosure part is fixed.

124. The method of claim 123, wherein the flange defines an upstand which extends around the seat, and the enclosure part fixing step comprises the step of:

welding the enclosure part to the main body part with an annular weld at the upstand.

125. The method of claim 124, wherein the upstand includes an inwardly-inclined internal chamfer for receiving the weld.

126. The method of any of claims 122 to 125, wherein the bores each include at least one groove, optionally a plurality of grooves, and the tube element fixing step comprises, for each tube element, the step of:

expanding the open end of the tube element into the respective bore.

127. The method of claim 126, wherein the open end of the tube element is expanded by from about 3% to about 5%, optionally from about 4% to about 5%.

128. The method of claim 126 or 127, wherein the bores each terminate at an upstand which projects from the surface, and the tube element fixing step further comprises, for each tube element, the step of:

welding the open end of the tube element to the respective upstand with an annular weld.

129. The method of claim 128, wherein the upstand includes an inwardly-inclined internal chamfer, the open end of the respective tube element includes an outwardly-inclined external chamfer, and the chamfers together define a channel for receiving the weld.

130. The method of claim 128 or 129, wherein the tube element fixing step further comprises, for each tube element, the step of:

subsequent to the tube element welding step, expanding the open end of the tube element into the respective bore.

131. The method of claim 130, wherein the open end of the tube element is expanded by from about 3% to about 5%, optionally from about 4% to about 5%.

132. The method of any of claims 122 to 131, further comprising, for each pipe end coupling, the step of:

prior to the enclosure part fixing step, pressure testing the fixing of the open ends of the tube elements to the pipe end coupling.

133. The method of claim 132, wherein the pressure testing step comprises the steps of:

providing a pressure testing tool, which comprises a test coupling for fluidly connecting to at least one of the tube elements at the pipe end coupling; fluidly connecting the test coupling to at least one of the tube elements at the pipe end coupling;

applying a pressure to the test coupling to determine acceptability of the fixing of at least one tube element to a respective bore of the main body part.

134. The method of claim 133, wherein the main body part includes at least one detent, optionally a plurality of detents, and the test coupling includes at least one engagement fixture, optionally a plurality of engagement fixtures, for engaging the at least one detent on the main body part to fix the test coupling to the main body part.

135. The method of claim 134, wherein the at least one engagement fixture comprises a clamping mechanism for clamping the test coupling to the main body part under test.

136. The method of claim 135, wherein the clamping mechanism comprises at least one clamp catch, optionally a plurality of clamp catches, which engages the at least one detent on the main body part.

137. The method of any of claims 133 to 136, wherein the test coupling comprises a test enclosure part, which, when the testing tool is fitted to the main body part of one pipe end coupling, fluidly connects the bores of the main body part under test, and a seal which provides for sealing engagement with a seat of the main body part under test.

138. The method of any of claims 133 to 137, wherein the enclosure part includes an internal cavity, optionally defining an arcuate surface having first and second bend radii, which are disposed opposite the bores in the main body part, thereby defining a 180 degree bend between the through bores.

139. The method of any of claims 133 to 138, wherein the enclosure part includes a flange which extends about the internal cavity, and the enclosure part welding step comprises the step of:

welding the flange of the enclosure part to the main body part with an annular weld.

140. The method of 139, wherein the flange defines an outwardly-inclined external chamfer for receiving the weld.

141. The method of claim 139 or 140, wherein the flange defines an annular seat, which corresponds to an annu\ar seat as defined by the flange of the main body part.

142. The method of any of claims 132 to 141, wherein the main body part and the enclosure part are formed of stainless steel.

143. The method of claim 142, wherein the main body part and the enclosure part are fabricated by casting.

144. A steam generation module for generating a superheated fluid, comprising: a superheater unit comprising at least one superheater circuit, each superheater circuit comprising superheater pipework, wherein the superheater pipework comprises a plurality of coils which can accommodate longitudinal and lateral expansion.

145. The module of claim 144, wherein the coils each comprise a coil element having an inlet and an outlet, which are located on the longitudinal axis of the coil.

146. The module of claim 145, wherein the coil element is wound about the longitudinal axis of the coil.

147. The module of claim 146, wherein the coil has a symmetric configuration, whereby the spring force caused by expansion of the coil element is along the longitudinal axis of the coil.

148. The module of claim 146 or 147, wherein the coil is a helically-wound coil.

149. The module of any of claims 145 to 148, wherein the coil comprises slip couplings which shroud the inlet and the outlet of the coil element.

150. The module of any of claims 144 to 149, further comprising:

first and second support elements which support the coils in spaced relation therebetween.

151. The module of any of claims 144 to 150, wherein the superheater unit is operative to raise the temperature of a received working fluid to a temperature of at least 300 °C, optionally from about 300 °C to about 400 °C, and provide a superheated fluid.

152. The module of claim 151, wherein the superheated fluid has a pressure of up to about 60 bar, optionally from about 10 bar to about 60 bar.

153. The module of claim 151 or 152, wherein the received working fluid is saturated steam and the superheated fluid is superheated steam.

154. The module of any of claims 144 to 153, wherein the superheater unit comprises a plurality of superheater circuits.

155. The module of any of claims 144 to 154, further comprising:

at least one heat exchanger unit downstream of the superheater unit.

156. A superheater unit for generating a superheated fluid, comprising at least one superheater circuit, each superheater circuit comprising superheater pipework, wherein the superheater pipework comprises a plurality of coils which can accommodate longitudinal and lateral expansion.

157. The superheater unit of claim 156, wherein the coils each comprise a coil element having an inlet and an outlet, which are located on the longitudinal axis of the coil.

158. The superheater unit of claim 157, wherein the coil element is wound about the longitudinal axis of the coil.

159. The superheater unit of claim 158, wherein the coil has a symmetric configuration, whereby the spring force caused by expansion of the coil element is along the longitudinal axis of the coil.

160. The superheater unit of claim 158 or 159, wherein the coil is a helically- wound coil.

161. The superheater unit of any of claims 156 to 160, wherein the coil comprises slip couplings which shroud the inlet and the outlet of the coil element.

162. The superheater unit of any of claims 156 to 161, further comprising first and second support elements which support the coils in spaced relation therebetween.

163. The superheater unit of any of claims 156 to 162, wherein the superheater unit is operative to raise the temperature of a received working fluid to a temperature of at least 300 °C, optionally from about 300 °C to about 400 °C, and provide a superheated fluid.

164. The superheater unit of claim 163, wherein the superheated fluid has a pressure of up to about 60 bar, optionally from about 10 bar to about 60 bar.

165. The superheater unit of claim 163 or 164, wherein the received working fluid is saturated steam and the superheated fluid is superheated steam.

166. The superheater unit of any of claims 156 to 165, wherein the superheater unit comprises a plurality of superheater circuits.

167. A method of testing a heat exchanger assembly, comprising the steps of: providing a plurality of tube elements, at least one ends of which are open; providing a plurality of pipe end couplings, wherein the pipe end couplings each comprise a main body part which comprises a body, which includes a flange which encloses a surface, and first and second bores which extend to the surface and provide for fluid communication thereto, and an enclosure part which, when fixed to the main body part, provides a dosed fluid connection between the first and second bores; and _v

fixing pipe end couplings to the open ends of the tube elements of adjacent tube sections, wherein the pipe end coupling fixing step comprises, for each pipe end coupling, the steps of:

fixing the open ends of the tube elements in the respective bores of the main body part;

fluidly connecting a test tool to at least one of the tube elements at the pipe end coupling;

applying a pressure to the test tool to determine acceptability of the fixing of at least one tube element to a respective bore of the main body part; and fixing the enclosure part to the main body part when the fixing of at least one tube element to a respective bore of the main body part is acceptable, such as to provide a closed fluid connection between the open ends of the tube elements.

168. The method of claim 167, wherein the test tool comprises a test body, which includes a chamber, which, when the test tool is fitted to the main body part of one tube end coupling, is fluidly connected to one through bore of the main body part under test.

169. The method of claim 168, wherein the test body includes a coupling port, and a sealing element which surrounds the coupling port, such as to provide for sealing engagement between the chamber and the main body part under test.

170. The method of claim 169, wherein the coupling port is shaped and sized to fit over an upstand of one of the bores of the main body part, with the sealing element engaging the surface of the main body part.

171. The method of any of claims 168 to 170, wherein the test body includes a pressure connection port which is fluidly connected to the chamber, and further comprising the step of:

fluidly connecting one or both of a pressure source for delivery of a pressure to the chamber or a pressure detector for detection of a pressure at the chamber.

172. The method of any of claims 168 to 171, wherein the test tool further comprises a clamping arrangement for clamping the test body to the main body part under test.

173. The method of claim 172, wherein the main body part includes at least one damping fixture, and the clamping arrangement comprises a clamp body to which the test body is movably disposed, and a clamping fixture for clamping the clamp body, and the test body which is supported thereby, to the at least one clamping fixture of the main body part under test.

174. The method of claim 173, wherein the main body part includes first and second clamping fixtures, and the clamping fixture of the test tool is clamped to a respective one of the clamping fixtures on the main body part under test.

175. The method of claim 173 or 174, wherein the clamping fixture of the test tool includes a pair of clamping arms, which are configured to engage detents of a clamping fixture on the main body part under test.

176. The method of claim 175, wherein the clamping arms are movably disposed to the clamp body, optionally pivotaliy coupled, and each include a detent at one end thereof for engagement with the counterpart detents of the clamping fixture of the main body part under test.

177. The method of any of claims 173 to 176, wherein the clamping arrangement further comprises a biasing mechanism for biasing the test body relative to the clamp body, such as to fix the test body in sealing engagement with the respective bore.

178. The method of claim 177, wherein the biasing mechanism comprises a drive member which is axially displaceable relative to the clamp body, such that rotation of the drive member causes axial displacement of the test body.

179. The method of claim 178, wherein the drive member is coupled to the clamp body by a threaded coupling.

180. The method of any of claims 168 to 179, further comprising the step of: arranging the tube elements to extend in spaced relation with a defined pattern, with the open ends of the tube elements extending to one common end.

181. The method of any of claims 168 to 180, wherein the tube elements are provided by a plurality of U-shaped tube sections, each comprising two spaced elongate tube elements, one ends of which are fluidly connected by a 180 degree bend and the other ends of which are open and in spaced relation.

182. The method of any of claims 168 to 181, wherein the flange of the main body part defines an annular seat to which the enclosure part is fixed.

183. The method of claim 182, wherein the flange of the defines an upstand which extends around the seat, and the enclosure part fixing step comprises the step of:

184. The method of claim 183, wherein the upstand includes an inwardly-inclined internal chamfer for receiving the weld.

185. The method of any of claims 168 to 184, wherein the bores each include at least one groove, optionally a plurality of grooves, and the tube element fixing step comprises, for each tube element, the step of:

expanding the open end of the tube element into the respective bore.

186. The method of claim 185, wherein the open end of the tube element is expanded by from about 3% to about 5%, optionally from about 4% to about 5%.

187. The method of claim 185 or 186, wherein the bores each terminate at an upstand which projects from the surface, and the tube element fixing step further comprises, for each tube element, the step of:

188. The method of claim 187, wherein the upstand includes an inwardly-inclined internal chamfer, the open end of the respective tube element includes an outwardly-inclined external chamfer, and the chamfers together define a channel for receiving the weld,

189. The method of claim 187 or 188, wherein the tube element fixing step further comprises, for each tube element, the step of:

190. The method of claim 189, wherein the open end of the tube element is expanded by from about 3% to about 5%, optionally from about 4% to about 5%.

191. The method of any of claims 168 to 190, wherein the enclosure part includes an internal cavity, optionally defining an arcuate surface having first and second bend radii, which are disposed opposite the bores in the main body part, thereby defining a 180 degree bend between the through bores.

192. The method of claim 191, wherein the enclosure part includes a flange which extends about the internal cavity, and the enclosure part welding step comprises the step of:

193. The method of 192, wherein the flange defines an outwardly-inclined external chamfer for receiving the weld.

194. The method of claim 192 or 193, wherein the flange defines an annular seat, which corresponds to an annular seat as defined by the flange of the main body part.

195. The method of any of claims 168 to 194, wherein the main body part and the enclosure part are formed of stainless steel.

196. The method of claim 195, wherein the main body part and the enclosure part are fabricated by casting.

S 197. A test tool for testing acceptability of the fixing of at least one tube element to a respective bore of the main body part of a heat exchanger assembly, the test tool comprising:

a test body, which includes a chamber, which, when the test tool is fitted to the main body part of one tube end coupling, is fluidiy connected to one through bore of the main body part under test; and

a clamping arrangement for clamping the test body to the main body part under test.

198. The test tool of claim 197, wherein the test body includes a coupling port, and a sealing element which surrounds the coupling port, such as to provide for sealing engagement between the chamber and the main body part under test.

199. The test tool of claim 198, wherein the coupling port is shaped and sized to fit over an upstand of one of the bores of the main body part, with the sealing element engaging the surface of the main body part.

200. The test tool of any of claims 197 to 199, wherein the test body includes a pressure connection port which is fluidly connected to the chamber.

201. The test tool of claim 200, further comprising:

a pressure source for delivery of a pressure to the chamber.

202. The test tool of claim 200 or 201, further comprising:

a pressure detector for detection of a pressure at the chamber.

203. The test tool of any of claims 197 to 202, wherein the clamping arrangement comprises a clamp body to which the test body is movably disposed, and a clamping fixture for clamping the clamp body, and the test body which is supported thereby, to a clamping fixture of the main body part under test.

204. The test tool of claim 203, wherein the clamping fixture of the test tool includes a pair of clamping arms, which are configured to engage detents of a clamping fixture on the main body part under test.

205. The test tool of claim 204, wherein the clamping arms are movably disposed to the clamp body, optionally pivotally coupled, and each include a detent at one end thereof for engagement with the counterpart detents of the clamping fixture of the main body part under test.

206. The test tool of any of claims 203 to 205, wherein the clamping arrangement further comprises a biasing mechanism for biasing the test body relative to the clamp body, such as to fix the test body in sealing engagement with the respective bore.

207. The test tool of claim 206, wherein the biasing mechanism comprises a drive member which is axially displaceable relative to the clamp body, such that rotation of the drive member causes axial displacement of the test body.

208. The test tool of claim 207, wherein the drive member is coupled to the clamp body by a threaded coupling.

209. A heat exchanger unit which receives a working fluid and is operative to raise the temperature of a working fluid to provide a saturated fluid.