WO2019169397A1 - Échangeur de chaleur sans tubes à sections multiples, système de chauffage de fluide comprenant celui-ci, et leurs procédés de fabrication - Google Patents

Échangeur de chaleur sans tubes à sections multiples, système de chauffage de fluide comprenant celui-ci, et leurs procédés de fabrication Download PDF

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Publication number
WO2019169397A1
WO2019169397A1 PCT/US2019/020579 US2019020579W WO2019169397A1 WO 2019169397 A1 WO2019169397 A1 WO 2019169397A1 US 2019020579 W US2019020579 W US 2019020579W WO 2019169397 A1 WO2019169397 A1 WO 2019169397A1
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WO
WIPO (PCT)
Prior art keywords
section
core
heat exchanger
inlet
fluid
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Application number
PCT/US2019/020579
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English (en)
Inventor
Keith Richard WALTZ
Richard James SNYDER
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Fulton Group N.A., Inc.
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Publication date
Application filed by Fulton Group N.A., Inc. filed Critical Fulton Group N.A., Inc.
Publication of WO2019169397A1 publication Critical patent/WO2019169397A1/fr

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Classifications

    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D7/10—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged one within the other, e.g. concentrically
    • F28D7/12—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being arranged one within the other, e.g. concentrically the surrounding tube being closed at one end, e.g. return type
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D1/00—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators
    • F28D1/06—Heat-exchange apparatus having stationary conduit assemblies for one heat-exchange medium only, the media being in contact with different sides of the conduit wall, in which the other heat-exchange medium is a large body of fluid, e.g. domestic or motor car radiators with the heat-exchange conduits forming part of, or being attached to, the tank containing the body of fluid
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D7/00—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D7/02—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being helically coiled
    • F28D7/026—Heat-exchange apparatus having stationary tubular conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being helically coiled the conduits of only one medium being helically coiled and formed by bent members, e.g. plates, the coils having a cylindrical configuration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F28—HEAT EXCHANGE IN GENERAL
    • F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
    • F28D9/00—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall
    • F28D9/04—Heat-exchange apparatus having stationary plate-like or laminated conduit assemblies for both heat-exchange media, the media being in contact with different sides of a conduit wall the conduits being formed by spirally-wound plates or laminae
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F24—HEATING; RANGES; VENTILATING
    • F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
    • F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
    • F24H1/10—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium
    • F24H1/12—Continuous-flow heaters, i.e. heaters in which heat is generated only while the water is flowing, e.g. with direct contact of the water with the heating medium in which the water is kept separate from the heating medium

Definitions

  • This disclosure relates to a multi-section tubeless heat exchanger for a fluid heating system, methods of manufacture of the multi-section tubeless heat exchanger, and fluid heating systems including the multi-section tubeless heat exchanger.
  • Heat exchangers are used in fluid heating systems to transfer heat from a thermal transfer fluid, such as a combustion gas produced by combustion of a fuel such as petroleum or natural gas, to a production fluid.
  • the production fluid can then be used for a variety of commercial, industrial, or domestic applications such as hydronic, steam, and thermal fluid boilers, for example. Because of the desire for improved energy efficiency, compactness, and cost reduction, there remains a need for improved heat exchangers, and fluid heating systems including the same, as well as improved methods of manufacture thereof.
  • a fluid heating system including: a pressure vessel shell including a first inlet and first outlet; a plurality of tubeless heat exchanger core sections disposed entirely in the pressure vessel shell, each tubeless heat exchanger core section including an inlet and an outlet; an outlet member, which penetrates the pressure vessel shell and which connects an outlet of a tubeless heat exchanger core and an outside of the pressure vessel shell; and a conduit having a first end connected to an inlet of a tubeless heat exchanger core section and a second end disposed on the outside of the pressure vessel shell.
  • a method of heat transfer including: providing a fluid heating system including a pressure vessel shell including a first inlet and first outlet, a plurality of tubeless heat exchanger core sections entirely disposed in the pressure vessel shell, each tubeless heat exchanger core section including a inlet and an outlet, an outlet member, which penetrates the pressure vessel shell and which connects an outlet of a tubeless heat exchanger core section and an outside of the pressure vessel shell, and a conduit having a first end connected to an inlet of a tubeless heat exchanger core and a second end disposed on the outside of the pressure vessel shell; and disposing a thermal transfer fluid in the tubeless heat exchanger core sections and a production fluid in the pressure vessel shell to transfer heat from the thermal transfer fluid to the production fluid.
  • a method of manufacturing a fluid heating system including: providing a pressure vessel shell including a first inlet and a first outlet; disposing a plurality tubeless heat exchanger core sections entirely in the pressure vessel shell, each tubeless heat exchanger core including an inlet and an outlet; connecting an inlet of a tubeless heat exchanger core section to a conduit, which penetrates an end of the pressure vessel shell; and connecting a first end of an outlet member to an outlet of a tubeless heat exchanger core and disposing a second opposite end of the outlet member on an outside of the pressure vessel shell to manufacture the fluid heating system.
  • a fluid heating system including: a pressure vessel shell including a first inlet and first outlet, a cylindrical shell, a first top head and a first bottom head, wherein the cylindrical shell is disposed between the first top head and the first bottom head, and wherein the first inlet and the first outlet are each independently on the cylindrical shell, the first top head, or the first bottom head; a plurality of tubeless heat exchanger core sections entirely disposed in the pressure vessel shell, the tubeless heat exchanger core including a cylindrical inner casing, a cylindrical outer casing, a flow guide or flow element (e.g., a rib, ridge or spine element) disposed between the inner casing and the outer casing, a second top head, a second bottom head, second inlet and a second outlet, wherein the cylindrical inner casing is surrounded by the cylindrical outer casing and the cylindrical inner casing, wherein the cylindrical outer casing are both between the second top head and the second bottom head, and wherein the second inlet and the second outlet are each independently on the
  • FIG. l is a schematic diagram of an embodiment of a ribbed tubeless heat exchanger core with a single heat transfer section, and a pressure vessel in accordance with embodiments of the present disclosure.
  • FIG. 2 is a schematic cutaway view of an embodiment of a vertical fluid heating system which includes an embodiment of a ribbed tubeless heat exchanger core with a single heat transfer section, and a pressure vessel in accordance with embodiments of the present disclosure.
  • FIG. 3 is a schematic diagram of an embodiment of a vertical fluid heating system which includes an embodiment of a tubeless heat exchanger core with two nested heat transfer sections, and a pressure vessel in accordance with embodiments of the present disclosure.
  • FIG. 4A shows a cross-section of a tubeless heat exchanger core with two nested heat transfer sections, and a pressure vessel wherein the heat exchanger inlet is disposed on the innermost casing in accordance with embodiments of the present disclosure.
  • FIG. 4B shows a cross-section of a tubeless heat exchanger core with two nested heat transfer sections, and a pressure vessel wherein the heat exchanger inlet is disposed on the outermost casing in accordance with embodiments of the present disclosure.
  • FIG. 5 is a schematic diagram of an embodiment of a horizontal fluid heating system which includes an embodiment of a tubeless heat exchanger core with two nested heat transfer sections, and a pressure vessel in accordance with embodiments of the present disclosure.
  • FIG. 6 is a cutaway schematic of a tubeless heat exchanger core with two nested heat transfer sections, and a pressure vessel wherein the heat exchanger inlet is disposed on the innermost casing wherein the thermal transfer fluid flows through the core sections in parallel in accordance with embodiments of the present disclosure.
  • FIG. 7 is a cross-section of a tubeless heat exchanger core with two non-nested heat transfer sections, and a pressure vessel wherein the heat exchanger inlet is disposed on the innermost casing wherein the thermal transfer fluid flows through the core sections in series in accordance with embodiments of the present disclosure.
  • FIG. 8 is a cutaway drawing of an embodiment of a vertical fluid heating system which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections, and a pressure vessel in accordance with embodiments of the present disclosure.
  • FIG. 9 is a cross-section schematic of an embodiment of a vertical fluid heating system which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections, and a pressure vessel showing the flow of production fluid in accordance with embodiments of the present disclosure.
  • FIG. 10 is a cutaway drawing of an embodiment of a vertical fluid heating system for the production of steam which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections, and a pressure vessel wherein the inlet conduit is proximal to the pressure vessel bottom head in accordance with embodiments of the present disclosure.
  • FIG. 11 is an axial cross-section of an embodiment of a vertical fluid heating system for the production of steam which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections, and a pressure vessel wherein the inlet conduit is proximal to the pressure vessel bottom head in accordance with embodiments of the present disclosure.
  • FIG. 12A is an axial cross-section schematic of an embodiment of a vertical fluid heating system which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections showing the points that connect to the heat exchanger core sections in accordance with embodiments of the present disclosure.
  • FIG. 12B shows an insert of the embodiment of FIG. 12A illustrating how the heat exchanger core section upper casings are free to expand in accordance with embodiments of the present disclosure.
  • FIG. 12C shows an insert of the embodiment of FIG. 12A illustrating how the heat exchanger core section lower casings are free to expand in accordance with embodiments of the present disclosure.
  • FIG. 13 is a cutaway drawing of an embodiment of a hydronic vertical fluid heating system which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections within the body cover in accordance with embodiments of the present disclosure.
  • FIG. 14 is a cutaway drawing of an embodiment of a vertical fluid heating system for the production of steam which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections including a section with vertical ribs in accordance with embodiments of the present disclosure.
  • FIG. 15A shows a perspective diagram of the conduit region for two concentric, sequential heat exchanger core sections in accordance with embodiments of the present disclosure.
  • FIG. 15B shows a plot of the ideal (dotted line) and typically realized (solid line) fluid flow velocity in the conduit region for two concentric, sequential heat exchanger core sections in accordance with embodiments of the present disclosure.
  • FIG. 15C shows a perspective diagram of a vertical cutaway view of an embodiment of inter-section conduits with circular cross-section oriented perpendicularly to a tangent of the heat exchanger casings in accordance with embodiments of the present disclosure.
  • FIG. 15D shows a horizontal cross-sectional diagram of an embodiment of inter-section conduits oriented perpendicularly to a tangent of the heat exchanger casings in accordance with embodiments of the present disclosure.
  • FIG. 16A shows a horizontal cross-sectional diagram of an embodiment of inter-section conduits oriented at an oblique angle to a tangent of the heat exchanger casings in accordance with embodiments of the present disclosure.
  • FIG. 16B shows a horizontal cross-sectional diagram of an embodiment of inter-section conduits showing the three angles used to specify the oblique disposition of the conduit relative to the core casings in accordance with embodiments of the present disclosure.
  • FIG. 16C shows the detail of an inter-section conduit with semicircular cross-section for oblique disposition between two core sections in accordance with embodiments of the present disclosure.
  • FIG. 16D shows a perspective view of the top of an embodiment of a vertical heating system multi-core heat exchanger with obliquely-oriented intersection conduits in accordance with embodiments of the present disclosure.
  • FIG. 16E shows a perspective view of the top of an embodiment of a vertical heating system multi-core heat exchanger with obliquely-oriented intersection conduits with the top head removed revealing the details of the semicircular conduits in accordance with embodiments of the present disclosure.
  • FIG. 16F shows plots of pressure and heat flux in the conduit region for two concentric, sequential heat exchanger core sections using a single circular inter-core conduit in accordance with embodiments of the present disclosure.
  • FIG. 16G shows plots of pressure and heat flux in the conduit region for two concentric, sequential heat exchanger core sections using a plurality of obliquely oriented inter-core conduits in accordance with embodiments of the present disclosure.
  • FIG. 17 shows a vertical cross-sectional diagram of an embodiment of a top head of a vertical fluid heating system for the production of steam which includes an embodiment of a tubeless heat exchanger core with three nested heat transfer sections including a section with vertical ribs in accordance with embodiments of the present disclosure.
  • FIGS. 18A, 18B, 18C, 18D, 18E, and 18F show a sequence diagram for an embodiment of a series method for the manufacture assembly of an embodiment of two nested, concentric heat exchanger sections, in accordance with embodiments of the present disclosure.
  • FIGS. 19 A, 19B, and 19C show a sequence diagram for an embodiment of a parallel method for the manufacture assembly of an embodiment of two nested, concentric heat exchanger sections, in accordance with embodiments of the present disclosure.
  • fluid heating systems which provide more thermally compact designs, e.g., configurations that provide an increased ratio between the power and volume or footprint of the fluid heating systems (FITS), and which can be manufactured at a reasonable cost, with satisfactory material requirements, and reduced complexity. Improvements in the state-of- the-art for fluid heating system design, methods, and manufacture that enable increases in the thermal power achievable for a prescribed size or, conversely, enable a reduction in size for a prescribed thermal power level, accomplished for the same or lower manufacturing cost and complexity, are desirable.
  • FITS fluid heating systems
  • Heat exchangers are desirably thermally compact, provide a high ratio of the thermal output to the total size of the heat exchanger, and have a design which can be manufactured at a reasonable cost. This is particularly true of gas-liquid heat exchangers, which can be incorporated into hydronic (e.g., liquid water), steam, and thermal fluid heating systems designed to deliver a hot fluid such as steam for temperature regulation, domestic hot water, or commercial or industrial process applications.
  • hydronic e.g., liquid water
  • steam e.g., steam
  • thermal fluid heating systems designed to deliver a hot fluid such as steam for temperature regulation, domestic hot water, or commercial or industrial process applications.
  • the heat is transferred from the thermal transfer fluid, e.g., a combustion gas generated by a fuel-fired combustor and driven under pressure through the heat exchanger by a blower, to a production fluid (e.g., liquid water, steam, or another thermal fluid) across the walls of numerous thin-walled fluid conduits, i.e. tubes, having a wall thickness of less than 0.5 centimeters (cm).
  • the tubes are rigidly connected to a tube sheet.
  • Tubeless heat exchangers are also used. Tubeless heat exchangers avoid the use of the thin-walled tubes and the tube sheets associated with tube-and shell heat exchangers. Known practical designs for tubeless heat exchangers also have drawbacks. In available tubeless heat exchangers, the pressure vessel outer shell contacts a hot heat transfer fluid, e.g., along the exit path of the flue gas exhaust, resulting in a hot surface on the outside of the pressure vessel.
  • a hot heat transfer fluid e.g., along the exit path of the flue gas exhaust
  • a refractory barrier outside the pressure vessel is provided, wherein the refractory barrier is separated from the pressure vessel by a gap through which the hot thermal transfer fluid flows, e.g., through an array of longitudinal ribs, thereby transferring thermal energy from the thermal transfer fluid into the outside of the shell, and ultimately transferring heat to the production fluid.
  • Such tubeless designs suffer from refractory deterioration and loss of thermal efficiency due to some amount of heat being transferred into and through cracks in the refractory layer, and ultimately into the environment around the boiler.
  • the hot outer surface of the pressure vessel presents safety issues due to the temperature of the skin which overlays the refractory material and due to leaking of thermal transfer fluid (e.g.
  • Tubeless heat exchangers incorporating ribbed, ridged and spined elements provides a variety of features. For example, no direct contact occurs between the thermal transfer fluid and the production fluid. Furthermore, such heat exchangers avoid use of thin-walled tubing, thereby avoiding the inherent fragility and susceptibility to material failure and corrosion of thin-walled tubing. Such heat exchangers can be provided using metal alloy tubing having an average wall thickness of 0.5 to 5 cm, for example, as the primary member between the thermal transfer fluid and the production fluid, and thus can avoid the fragility problems associated with thin-walled tubing.
  • such heat exchangers can also avoid tight turnabouts in flow passages for both the thermal transfer fluid and the production fluid, thereby avoiding configurations that would be susceptible to fouling, clogging, and corrosion blockage.
  • such heat exchangers provide for improved compactness (i.e., energy density, having the units of kilowatts per cubic meter, kW/m 3 ) and improved performance characteristics compared to tube- and-shell heat exchanger alternatives of the same production capability.
  • all outer surfaces of the heat exchanger core are contacted by the production fluid, thereby fully utilizing the outer surfaces of the heat exchanger core for thermal energy transfer and avoiding thermal stress in the heat exchanger core.
  • tubeless heat exchanger design particularly incorporating ribbed, ridged and spined elements
  • a fluid heating system comprising a single ribbed heat exchanger core (alternatively,“core section”).
  • a tubeless heat exchanger incorporating a heat exchanger single core and a ribbed element comprises: a heat exchanger core comprising a top head; a bottom head; a first casing disposed between the top head and the bottom head; a second casing disposed between the top head and the bottom head, wherein an inner surface of the first casing is opposite an inner surface of the second casing; an inlet on the first casing, the second casing, or combination thereof; an outlet on the first casing, the second casing, or combination thereof; a rib disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a pressure vessel; an inlet member on the inlet for fluidly connecting the inlet to an outside of the pressure vessel; and an outlet member on the outlet for fluidly connecting the outlet to an outside of the pressure vessel, wherein the bottom head, the first casing, and the second casing are contained entirely within the pressure vessel, and where
  • the first casing can be surrounded by the second casing, in which case the first casing may be an inner casing and the second casing may be an outer casing.
  • the second casing can be surrounded by the first casing, in which case the second casing may be an inner casing and the first casing may be an outer casing. As shown in FIG.
  • a heat exchanger 100 comprises: a heat exchanger core 110 comprising a top head 112; a bottom head 114; a first casing 116 disposed between the top head and the bottom head; a second casing 118 disposed between the top head and the bottom head, wherein an inner surface 116A of the first casing 116 is opposite an inner surface 118A of the second casing; an inlet 120 on the first casing; an outlet 122 on the second casing; a rib 124 disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a pressure vessel 150; an inlet member 152 on the inlet and for fluidly connecting the inlet to an outside of the pressure vessel; and an outlet member 154 on the outlet and for fluidly connecting the outlet to an outside of the pressure vessel, wherein the bottom head, the first casing, and the second casing are contained entirely within the pressure vessel.
  • the inner surface 116A of the first casing and the inner surface 118A of the second casing are interior to the flow passage defined by the first casing 116, the second casing 118, and the rib 124.
  • the pressure vessel top head 160, the pressure vessel bottom head 162, and the pressure vessel shell 164 which is disposed between the pressure vessel top head and the pressure vessel bottom head.
  • the pressure vessel top head, the pressure vessel bottom head, or combination thereof may comprise an opening for a conduit (not shown FIG. 1).
  • the conduit is connected to the inlet member 152, and may pass through the pressure vessel top head 160 and the top head 112 of the heat exchanger core.
  • FIG. 2 Another embodiment of the heat exchanger core is shown in FIG. 2.
  • the pressure vessel shell 164A is disposed between the pressure vessel top head 160A and bottom head 162A.
  • a curved inlet member 152A may be connected to an inlet 120A.
  • a conduit 230 which fluidly connects the inlet member to an outside of the heat exchanger.
  • the conduit may contain a combustion system (not shown) for heating the thermal transfer fluid.
  • the conduit may pass through the pressure vessel top head 160 A and the top head of the heat exchanger core 112 A.
  • the top head, the bottom head, the first casing, the second casing, the inlet, the outlet, the rib, the pressure vessel, the inlet member, and the outlet member can each independently comprise any suitable material.
  • a metal is specifically mentioned.
  • Representative metals include iron, aluminum, magnesium, titanium, nickel, cobalt, zinc, silver, copper, and an alloy comprising at least one of the foregoing.
  • Representative metals include carbon steel, mild steel, cast iron, wrought iron, a stainless steel such as a 300 series stainless steel or a 400 series stainless steel (e.g., 304, 316, or 439 stainless steel), Monel, Inconel, bronze, and brass.
  • the heat exchanger core and the pressure vessel each comprise steel, specifically mild steel.
  • the first casing and the second casing of a single heat exchanger core may be coaxial, and may be concentric. In an embodiment, the first casing and the second casing are coaxial, as shown in FIG 1 and FIG. 2. Non-coaxial configurations are also contemplated.
  • the first casing and the second casing of the heat exchanger core may have any suitable shape and may each independently have a circular cross-sectional shape, an elliptical cross- sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross-sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof.
  • An embodiment in which the first casing, e.g., the inner casing, and the second casing, e.g., the outer casing, each have a cylindrical shape is specifically mentioned.
  • the first casing and the second casing may have a same cross- sectional shape, however other configurations are contemplated.
  • the heat exchanger core may comprise a first casing having a triangular cross-sectional shape and a second casing having a cylindrical cross-sectional shape.
  • the first casing and the second casing may each independently have a largest outer diameter of 15 centimeters (cm), 25 cm, or 30 cm to 350 cm, 650 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • the first casing and the second casing may each independently have a largest outer diameter of 15 cm to 1,400 cm.
  • An embodiment in which the first casing and the second casing each independently have a largest outer diameter of 30 cm to 350 cm is preferred.
  • the first casing and the second casing may each independently have a largest outer diameter of 50 cm, 100 cm, or 200 cm to 500 cm, 700 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • the first casing and the second casing may each independently have a maximum height of 15 cm, 25 cm, or 30 cm to 350 cm, 650 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined, and wherein the height is determined in a direction of a major axis.
  • the first casing and the second casing may each independently have a maximum height of 15 cm to 1,400 cm.
  • the first casing and the second casing may each independently have a height of 50 cm, 100 cm, or 200 cm to 500 cm, 700 cm, or 1,400 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • first casing and the second casing each independently have a largest outer diameter of 30 cm to 350 cm and a height of 50 cm to 1,000 cm is preferred.
  • a top head is disposed on a first end of the first casing and the second casing, and a bottom head is disposed on a second opposite end of the first casing and the second casing.
  • the top head and the bottom head may each independently be rigidly attached to the first casing and the second casing by any suitable method, such as by a weld, an adhesive, a fastener, or a combination thereof.
  • An embodiment in which the top head and the bottom head are each welded to the first casing and the second casing is specifically mentioned. As shown in FIG.
  • the top head and the bottom head of the heat exchanger are distinct members.
  • the top head and the bottom head may each independently be formed by providing a weld seam between the first casing and the second casing.
  • the ends of the first casing and the second casing may be contacted, e.g., pinched together or rolled, to form the top head and the bottom head.
  • a thickness, e.g., an average thickness, of the top head, the bottom head, the first casing, and the second casing may be any suitable dimension, and the thickness of the top head, the bottom head, the first casing, and the second casing may each independently be 0.5 cm to 3 cm, e.g., 0.5 cm, 0.6 cm, 0.7 cm, or 1 cm to 5 cm, 4 cm, 3.5 cm, or 3 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • An embodiment in which the top head, the bottom head, the first casing, and the second casing each independently have a thickness of 0.5 cm to 1 cm is specifically mentioned.
  • an inner surface 116A of the first casing 116, an inner surface 118A of the second casing 118, and the rib 124 define a flow passage between the inlet and the outlet of the heat exchanger core, which comprises, e.g., consists of, the first casing, the second casing, the rib, and the top head and the bottom head of the heat exchanger core. It has been surprisingly discovered that certain configurations of the flow passage provide improved performance, including a desirable combination of pressure drop between the inlet and the outlet, and thermal performance.
  • This improvement can be parameterized in terms of an aspect ratio of the flow passage, wherein the aspect ratio of the flow passage defined as the maximum centerline dimension divided by the minimum centerline dimension of the flow passage, where both dimensions are determined normal to a flow direction and perpendicular to each other, and wherein the shorter dimension is defined at the midpoint of the longer dimension. It has been further surprisingly discovered that configurations wherein an aspect ratio of the flow passage is 3 to 500, e.g., 3, 5, 10, 15, or 20 to 80, 100, 200, or 500, preferably 5 to 100, more preferably 10 to 80, provide an improved combination of pressure drop and thermal performance, wherein the foregoing upper and lower bounds can be independently combined.
  • each core can be tuned independently to achieve systems engineering level goals. For instance, tuning each passage can affect the overall heat flux of the passage, and thus it’s mean temperature during operation. Doing so enables the deign to optimally match the thermal expansion rates of the various heat exchanger cores present in a given embodiment.
  • heat exchangers core sections subsequent to the first core section can be designed with higher aspect ratios, thereby improving heat flux rates by raising the velocity of the fluid to offset the effect of its drop in temperature.
  • the height H can be determined between opposite surfaces of a same rib, e.g., between a first rib surface and a second rib surface when viewed in a cross-sectional dimension, and the width W is determined between and inner surface of the first casing 116 and an inner surface of the second casing 118.
  • the height H can be determined between opposite surfaces of neighboring ribs.
  • the height H of the flow passage may be 0.6 cm to 600 cm, and may be 0.6 cm, 1 cm, 2 cm, 4 cm, 10 cm, 20 cm, 40 cm, 80 cm, or 160 cm to 600 cm, 550 cm, 500 cm, 450 cm, 400 cm, 350 cm, 300 cm, or 250 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • the width may be 0.6 cm to 600 cm, and may be 0.6 cm, 1 cm, 2 cm, 4 cm, 10 cm, 20 cm, 40 cm, 80 cm, or 160 cm to 600 cm, 550 cm, 500 cm, 450 cm, 400 cm, 350 cm, 300 cm, or 250 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • the height is 20 cm to 120 cm and the width is 1 cm to 5 cm. In a more preferred embodiment, the height is 100 cm to 120 cm and the width is 2.5 cm to 3.5 cm. In another embodiment, the height is 100 cm to 1 l5cm and the width is 2.0 cm to 3 cm.
  • any suitable number of ribs may be used.
  • a single rib may be used.
  • a plurality of ribs may be used such as 2 to 100 ribs, e.g., 2, 4, or 8 to 100, 50, or 10 ribs, wherein the foregoing upper and lower bounds can be independently combined.
  • the rib may have any suitable configuration.
  • the rib may have a helical shape, a stepped shape, a shape of a segment of a circle, a shape of a segment of a helix, or a combination thereof.
  • the rib 124 may have a helical shape.
  • a rib may have a spiral triangular shape, a shape of a segment of a circle, a stepped shape or a linear shape.
  • the rib may have any suitable cross-sectional shape.
  • the rib may have a circular cross-sectional shape, an annular cross-sectional shape, an elliptical cross-sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross- sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof.
  • the rib may have a circular cross-sectional shape.
  • a rib may have a square cross-sectional shape, a rectangular cross-sectional shape.
  • a rib may be tubular, i.e., have a hollow center, and may have a stadium cross-sectional shape. In yet another embodiment, a rib may have a triangular cross-sectional shape. Alternatively, the rib may have a rectilinear shape, and if desired the rib may be bent to provide a bent rectilinear rib.
  • the rib may have any suitable cross-sectional dimensions.
  • the rib may have a cross-sectional height and width of the rib may be independently selected, may be 0.3 cm to 600 cm, and may be 0.3 cm, 0.5 cm, 0.6 cm, 1 cm, 10 cm, or 50 cm, to 100 cm, 200 cm, 400 cm, or 600 cm, wherein the foregoing upper and lower bounds can be independently combined and wherein the height is measured in a direction of a major or longitudinal axis of the heat exchanger core and wherein the width is measured in a direction perpendicular to the longitudinal axis of the heat exchanger core.
  • a rectilinear rib may have a height of 0.3 cm to 600 cm and a width of 0.5 cm to 365 cm.
  • a rib having a circular cross-section and having a diameter of 1 cm to 5 cm is specifically mentioned.
  • a wall thickness of the tubular rib may be 0.1 cm to 1 cm, and may be 0.1 cm, 0.2 cm, or 0.4 cm to 0.6 cm, 0.8 cm, or 1 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • the rib may contact the first casing and the second casing, may be rigidly attached to one or both of the first casing and the second casing, or may fit loosely between the first and second casings.
  • the rib may form an interference fit with the inner surface of the first casing, the inner surface of the second casing, or a combination thereof.
  • the first casing and the rib, the second casing and the rib, or a combination thereof may be rigidly attached at one point, or at a plurality of points along the length of the rib.
  • the attachment may be provided by any suitable attachment member, such as a weld, an adhesive, a fastener, or combination thereof.
  • a weld such as a spot or stitch weld
  • a continuous weld extending the length of the rib may be used.
  • the rib may be rigidly attached to the first casing by a first weld and rigidly attached to the second casing by a second weld, wherein the first weld and the second weld may be the same type of weld or may be different types of welds.
  • the rib may be stitch-welded to the first or second casing anywhere along its length, or continuously welded along its length, to hold the rib in a selected position relative to the first casing, the second casing, or both.
  • the rib may be welded to an inner surface of the first casing by a fillet weld and the rib seam or butt welded to the second casing.
  • the fillet weld may be used to attach the rib to the inner surface of the second casing and the rib seam or butt welded to the first casing.
  • a weld such as (but not limited to) seam weld, may be used to rigidly attach the rib to the first casing, the second casing, or combination thereof.
  • first casing, the second casing, or combination thereof may be deformed to secure the rib.
  • first casing, the second casing, or combination thereof may comprise a groove which is configured to accept the rib.
  • first casing, the second casing, or combination thereof may be deformed to provide a ridge which protrudes in a direction of and optionally contacts the rib.
  • the rib may have a pitch, e.g., a slope, having any suitable angle with respect to a longitudinal axis of the heat exchanger core, the inner casing, or the outer casing. As illustrated in FIG.
  • a pitch Q may be defined with respect to a tangent direction t, wherein the tangent direction is perpendicular to a longitudinal axis, a, of the outer casing.
  • a pitch of the rib is 0 degrees to 90 degrees with respect to the tangent direction, and can be 0 degrees, 2 degrees, or 5 degrees to 90 degrees, 50 degrees, or 45 degrees with respect to the tangent direction, wherein the foregoing upper and lower bounds can be independently combined.
  • a pitch of 5 degrees to 45 degrees with respect to the tangent direction is specifically mentioned.
  • the heat exchanger core comprises a plurality of ribs, and a pitch of each rib of the plurality of ribs may each independently be 0 degrees to 90 degrees with respect to the tangent direction, and can be 0 degrees, 2 degrees, or 5 degrees to 90 degrees, 50 degrees, or 45 degrees with respect to the tangent direction, wherein the foregoing upper and lower bounds can be independently combined.
  • a pitch of each rib of the plurality of ribs may each independently be 0 degrees to 90 degrees with respect to the tangent direction, and can be 0 degrees, 2 degrees, or 5 degrees to 90 degrees, 50 degrees, or 45 degrees with respect to the tangent direction, wherein the foregoing upper and lower bounds can be independently combined.
  • An embodiment in which the pitch is 5 degrees to 45 degrees with respect to the tangent direction is specifically mentioned.
  • the rib may be parallel to an axis, e.g., a longitudinal axis, of the first casing, the second casing, or combination thereof.
  • the heat exchanger core may comprise a plurality of ribs, and each rib may be parallel to a longitudinal axis of the first casing, the second casing, or combination thereof.
  • the heat exchanger core comprises a rib which provides a serpentine flow passage between the inlet and the outlet.
  • the serpentine flow passage may be defined by a plurality of linear ribs, or may be defined by a combination of curved ribs and linear ribs.
  • the bottom head, the first casing, and the second casing of the heat exchanger core are contained entirely within the pressure vessel.
  • the top head, the bottom head, the first casing, and the second casing of the heat exchanger core are contained entirely within the pressure vessel.
  • an entirety of the heat exchanger core, i.e., the top head, the bottom head, the first casing, the second casing, the inlet, and the outlet are contained entirely within the pressure vessel.
  • “entirety” means that the component referred to is fully contained within the pressure vessel.
  • the pressure vessel when the pressure vessel is filled with a fluid, an entire outer surface of a component of the heat exchanger core which is contained entirely with the pressure vessel would be contacted by the fluid.
  • the top head may also be contained entirely within the pressure vessel, in which case when the pressure vessel is filled with a production fluid, the production fluid can contact an entire outer surface 113 of the top head as well.
  • an entirety of the heat exchanger core i.e., the top head, the bottom head, the first casing, the second casing, the inlet, and the outlet, is contained entirely within the pressure vessel.
  • the heat exchanger further comprises an inlet member 152 or 152A which fluidly connects the inlet 120 or 120A, respectively, to an outside of the pressure vessel, e.g. for providing a flow of a thermal transfer fluid, such as a combustion gas, to the inlet of the heat exchanger core.
  • an outlet flue conduit 154 which fluidly connects the outlet 122 of the heat exchanger core to an outside of the pressure vessel can be provided.
  • the pressure vessel comprises an inlet 155, and an outlet 156 for providing a flow of a production fluid into and out of the pressure vessel.
  • the heat exchanger core may be used to exchange heat between any suitable fluids, i.e., a first fluid and the second fluid, wherein the first and second fluids may each independently be a gas or a liquid.
  • the disclosed heat exchanger may be used as a gas-liquid, liquid-liquid, or gas-gas heat exchanger.
  • the first fluid, which is directed through the heat exchanger core is a thermal transfer fluid, and may be a combustion gas, e.g., a gas produced by fuel fired combustor, and may comprise water, carbon monoxide, carbon dioxide, or combination thereof.
  • the second fluid which is directed through the pressure vessel and contacts an entire outer surface of the heat exchanger core, is a production fluid and may comprise water, steam, oil, a thermal fluid, or combination thereof.
  • the thermal fluid may comprise an ester, a diester, a glycol, a silicone, water, a petroleum oil, a mineral oil, or a chlorofluorocarbon such as a halogenated fluorocarbon, a halogenated chlorofluorocarbon, or a perfluorocarbon.
  • a combination comprising at least one of the foregoing may be used.
  • a thermal fluid comprising glycol and water is specifically mentioned.
  • the thermal fluid may be formulated from an alkaline organic or inorganic compound and used in diluted form with a concentration ranging from 3 weight percent to 10 weight percent, based on a total weight of the thermal fluid.
  • the second fluid may comprise water, and may be used as a production fluid in a domestic, commercial, or industrial heating application.
  • the first fluid e.g., the thermal transfer fluid, which is directed through the inlet member, through the flow passage of the heat exchanger core, and out the outlet member, does not contact the pressure vessel. As a result, thermal heat energy transfer occurs between the hot first fluid flowing inside the core to the second fluid separately flowing in the pressure vessel.
  • the second fluid contacts an entire outer surface of the of the heat exchanger core and at no point does the surface of the pressure vessel contact the first fluid. Because the pressure vessel does not contact the first fluid, which can have a temperature of lO°C to l800°C, such as lO°C, 50°C, l00°C, 200°C, or 400°C to l800°C, l600°C, l400°C, l200°C, or l000°C, wherein the foregoing upper and lower bounds can be independently combined, the exterior surface of the pressure vessel remains relatively cool and use of insulation, e.g., a refractory material, to insulate the pressure vessel can be avoided.
  • An embodiment in which the first fluid has a temperature of l00°C to l350°C is specifically mentioned.
  • the pressure vessel top head, the pressure vessel bottom head, and the pressure vessel shell may each independently have any suitable shape, and may be rectilinear or curvilinear, and may be flat, domed, or spherical.
  • the pressure vessel top head and the pressure vessel bottom head may have a flat shape.
  • the pressure vessel top head and the pressure vessel bottom head may have a curved shape.
  • the pressure vessel shell may have any suitable shape, maybe curvilinear or rectilinear, and may be cylindrical as shown in FIG. 1.
  • a method of manufacturing a heat exchanger core comprising: providing a first casing, e.g., an inner casing; disposing a rib on an inner surface of the first casing; providing a second casing, e.g., an outer casing, comprising a slot; aligning the rib and the slot by disposing the first casing on the second casing; rigidly attaching the rib to the second casing; disposing a top head on a first end of the second casing; disposing a bottom head on a second end of the second casing; disposing an inlet on the first casing, the second casing, or a combination thereof; and disposing an outlet on the first casing, the second casing, or a combination thereof to manufacture the heat exchanger core, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet.
  • the first casing is in inner casing.
  • the first casing may be an outer cas
  • the first casing may be a tube or a section of a pipe, for example, and may be provided by rolling a flat sheet and connecting opposite edges to provide a tube.
  • the rib may be disposed on the inner surface of the first casing by any suitable method, such as by welding, adhesive bonding, or fastening, or combination thereof. In a preferred embodiment the rib is welded to the surface of the first casing. An embodiment in which the rib is welded to the surface of the first casing using a fillet weld is specifically mentioned.
  • the fillet weld may transverse an entire length of the rib, or may be present on a portion of the rib, such as 10% to 100% of the total rib length, e.g., 10%, 15%, or 20% to 100%, 90%, 80%, or 70% of the total rib length, wherein the foregoing upper and lower bounds can be independently combined.
  • An embodiment in which the fillet weld transverses 100% of the total rib length is specifically mentioned.
  • the second casing may be provided, for example, by cutting a slot at a selected pitch angle in a pipe.
  • the slot may have a width selected to correspond to a dimension of the rib and may have a width of 1 millimeter (mm) to 5 centimeters (cm).
  • a width of the slot is 1 mm, 2 mm, or 4 mm to 5 cm, 3 cm, or 1 cm, wherein the foregoing upper and lower bounds can be independently combined.
  • a width of the slot is 2 mm to 2 cm is specifically mentioned.
  • the slot may comprise a bevel to facilitate the formation of a weld between the outer casing and the rib.
  • the outer casing comprising the slot may be disposed on the inner casing comprising the rib and then the rib rigidly attached to the outer casing by welding, for example.
  • Use of a full penetration weld or butt weld is specifically mentioned, and the weld may be selected based upon the shape and dimensions of the rib.
  • the top head of the heat exchanger core may be welded to the first end of each of the first casing and the second casing, and the bottom head of the heat exchanger core welded to the opposite second end of each of the first casing and the second casing, for example, to form a cavity between the first casing and the second casing for the thermal transfer fluid.
  • the inlet and the outlet may each independently be disposed, e.g., welded, on the first casing the second casing or combination thereof. An embodiment in which the inlet is disposed on an outer surface of the first casing, and in which the outlet is disposed on an outer surface of the second casing is specifically mentioned.
  • an inlet member for fluidly connecting the inlet to an outside of the pressure vessel, e.g., to the source of a thermal transfer fluid, may be disposed on the inlet.
  • an outlet member for fluidly connecting the outlet to an outside of the pressure vessel, e.g., to a vent, may be disposed on the outlet.
  • fluid heating systems incorporating heat exchangers comprising a plurality of heat exchangers cores can be used to configure compact, large capacity systems with high bulk heat flux rates.
  • heat exchanger core designs incorporate rib, ridge and spine elements the advantages and benefits can be preserved.
  • FIG. 3 shows a schematic of one embodiment of a vertical fluid heating system with two coaxially nested heat exchanger cores.
  • a first tubeless heat exchanger core 110A comprising: a top head 112B; a bottom head 114A; a first casing 116B disposed between the top head and the bottom head; a second casing 118B disposed between the top head and the bottom head, wherein an inner surface 116C of the first casing is opposite an inner surface 118C of the second casing; an inlet 120B on the first casing, the second casing, or combination thereof; an outlet 300 on the first casing, the second casing, or combination thereof; a rib 124 A disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a second tubeless heat exchanger core 340 comprising: a top head 345; a bottom head 350; a third casing 355 disposed between the top head and the bottom head; a fourth casing 360 disposed between the top head and the bottom head, wherein an inner surface 370 of the third
  • Thermal transfer fluid is directed under pressure through the conduit 230A and inlet member 152B of the first heat exchanger core to the inlet 120B.
  • the thermal transfer fluid traverses the first heat exchanger core section, through the outlet 300 and conduit 310 into the second heat exchanger core inlet 320.
  • the thermal transfer fluid traverses the second heat exchanger core section through the outlet 122 A and outlet member 397 where it penetrates the pressure vessel 380 to the flue conduit 154A.
  • the production fluid is forced under pressure through the inlet 155 A where it passes the outer surface of the fourth casing 360 of the second heat exchanger 340, between the first core top head 112B and second core top head 345, through the space formed by the outer surfaces of the second and third casings, past the first heat exchanger core bottom head 114A, past the outer surface of the first casing 116B and through the pressure vessel outlet 156A and outlet member 385.
  • a top production fluid guide 390 and bottom production fluid guide 395 direct the production fluid between the coaxial nested heat exchanger cores to maintain a uniform velocity field and avoid areas of stagnant flow that can lead to thermal hot spots.
  • the entire outer surface of the first 110A and second 340 heat exchanger core sections are exposed to production fluid. Thermal energy is transferred from the inner core section surfaces (exposed to thermal transfer fluid) down the temperature gradient to the production fluid wetting the outer surfaces of the core section casings.
  • FIG. 4 shows a cross-section schematic of an embodiment of a tubeless heat exchanger with two nested core sections analogous to the embodiment shown in FIG. 3.
  • FIG. 4 shows a cross-section schematic of an embodiment of a tubeless heat exchanger with two nested core sections analogous to the embodiment shown in FIG. 3.
  • thermal transfer fluid, I enters the first heat exchanger core 110B through the inlet 120C, the core section comprising a first casing 116D and a second casing 118D; after traversing the flow path created by the first casing, the second casing and a rib (not shown), the thermal transfer fluid passes through the conduit 310A connecting the outlet of the first heat exchanger core to the inlet of the second heat exchanger core 340A comprising a third casing 355 A and a fourth casing 360 A; after traversing the flow path created by the third casing, the fourth casing and a rib (not shown), the thermal transfer fluid passes through the outlet 122B.
  • the heat exchanger core sections are numbered according to their occurrence along the thermal transfer fluid flow path from the heat exchanger inlet 120C to the heat exchanger outlet 122B.
  • the first casing is that which has the smaller average cross-sectional diameter
  • the second casing is that which has the larger average cross-sectional diameter.
  • thermal transfer fluid, I enters the first heat exchanger core 110C through the inlet 120D, the core section comprising a first casing 116E and a second casing 118E; after traversing the flow path created by the first casing, the second casing and a rib (not shown), the thermal transfer fluid passes through the conduit 31 OB connecting the outlet of the first heat exchanger core to the inlet of the second heat exchanger core 340B comprising a third casing 355B and a fourth casing 360B; after traversing the flow path created by the third casing, the fourth casing and a rib (not shown), the thermal transfer fluid passes through the outlet 122C.
  • the heat exchanger core sections are numbered according to their occurrence along the thermal fluid flow path from the heat exchanger inlet 120D to the heat exchanger
  • a second feature of using multi-core heat exchangers according to the disclosed embodiments is that the axial orientation of the heat exchanger assembly may be vertical (as in FIG. 3), horizontal or any angle between 0 degrees to 180 degrees required to achieve the system compactness and production parameters.
  • FIG. 5 shows a schematic of one embodiment of a horizontal fluid heating system with two coaxially nested heat exchanger cores.
  • first tubeless heat exchanger core 110D comprising: a first casing 116F disposed between the top head 112C and the bottom head 114B; a second casing 118F disposed between the top head 112C and the bottom head 114B; an inlet 120E on the first casing, the second casing, or combination thereof; an outlet 300 A on the first casing, the second casing, or combination thereof; a rib 124B disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a second tubeless heat exchanger core 340C comprising: a top head 345B; a bottom head 350A; a third casing 355C disposed between the top head 345B and the bottom head 350A; a fourth casing 360C disposed between the top head 345B and the bottom head 350A; an inlet 320A on the third casing, the fourth casing, or combination thereof; a conduit
  • Production fluid enters the pressure vessel inlet 155B traversing the space between the outer surface of the fourth casing and the inner surface of the pressure vessel shell, passes around 500 the top head 345B of the second heat exchanger core to flow between the outer surface of the third casing and the outer surface of the second casing, around the bottom head of the first heat exchanger core section 114B, and through the space created between the thermal fluid conduit 230B and the outer surface of the first casing 116F.
  • a top production fluid guide 390 A and bottom production fluid guide 395 A direct the production fluid between the coaxial nested heat exchanger cores to maintain a uniform velocity field and avoid areas of stagnant flow that can lead to thermal hot spots.
  • thermal transfer fluid may flow through the plurality of heat exchanger core sections in series, parallel or any combination thereof.
  • FIG. 6 shows a schematic of one embodiment of a vertical fluid heating system with two coaxially nested heat exchanger cores wherein the thermal transfer fluid flows through the two core sections in parallel.
  • thermal transfer fluid flows through the conduit 230C into a flow splitter 600 that directs part of the flow mass into a first inlet member 152D and through a first inlet 120F into a first heat exchanger core section 110E.
  • the thermal transfer fluid is directed through the passage formed by the first casing, the second casing and a first rib to the outlet 300B of the first heat exchanger core section.
  • a second part of the thermal transfer fluid mass in the conduit 230C is directed by the flow splitter 600 into a second inlet member 610 and through a second inlet 320B into a second heat exchanger core section 340D.
  • the thermal transfer fluid is directed through the passage formed by the third casing, the fourth casing and a second rib to the outlet 122E of the second heat exchanger core section.
  • the two heat exchanger core sections are contained within a pressure vessel comprising a top head 160D; a bottom head 162D; and a pressure vessel shell 164D disposed between the top head and the bottom head.
  • the flow through the first heat exchanger core outlet 300B is directed through a conduit 310D and flows concurrently with the flow through the second heat exchanger core outlet 122E to a conduit that passes through the pressure vessel 380B to an outside of the pressure vessel.
  • Production fluid enters the pressure vessel through an inlet 155C, flows past the outer surfaces of the first and second heat exchanger cores and exits the pressure vessel outlet 156C through a conduit 385C to an outside of the pressure vessel.
  • FIG. 7 shows a schematic of one embodiment of a vertical fluid heating system with two heat exchanger cores wherein the thermal transfer fluid flows through the two core sections in series.
  • thermal transfer fluid enters a conduit 230D, passing through an inlet member 152E into the inlet 120G of a first heat exchanger core section 110F.
  • Thermal transfer fluid is directed through the flow passage formed by a first casing, second casing and rib to the outlet 300C of the first heat exchanger core section, through a conduit 310E and into the inlet 320C of a second heat exchanger core section 340E.
  • the thermal transfer fluid flows through the flow passage between the inlet and the outlet of the second heat exchanger core in fluid communication with the fluid flow passage between the third and fourth casings.
  • a pressure vessel comprising: a top head 160E, a bottom head 162E and a pressure vessel shell 164E disposed between the pressure vessel top head and bottom head; a pressure vessel inlet 155D and outlet 156D; wherein the pressure vessel entirely encloses the first 11 OF and second 340E heat exchanger core sections.
  • Thermal transfer fluid exits the second heat exchanger core section through a second outlet 122F through a conduit that passes through the pressure vessel 380C to an outside of the pressure vessel.
  • FIG. 8 shows a schematic of one embodiment of a vertical fluid heating system with three coaxially nested heat exchanger cores including a mixed fuel-air combustion system to deliver thermal transfer fluid into the heat exchanger inlet.
  • a fan 800 forces air under pressure through the fan conduit 810 through the top of the furnace 820 into the combustion burner 830.
  • a mixture of air and fuel ignites releasing thermal energy heating the mixture of air and combustion products forming the thermal transfer fluid which is forced into the heat exchanger inlet conduit 230E, through the inlet member 152F and into the heat exchanger first core section inlet 120H.
  • the first tubeless heat exchanger core 110G comprises: a first casing 116G disposed between the top head 112D and the bottom head 114C; a second casing 118G disposed between the top head 112D and the bottom head 114C; an inlet 120H on the first casing, the second casing, or combination thereof; an outlet 300D on the first casing, the second casing, or combination thereof; a rib 124C disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a second tubeless heat exchanger core 340F comprising: a top head 345C; a bottom head 350B; a third casing 355D disposed between the top head 345C and the bottom head 350B; a fourth casing 360D disposed between the top head 345C and the bottom head 350B; an inlet 320D on the third casing, the fourth casing, or combination thereof; a conduit 310F
  • the number of heat exchanger core sections is only limited by practical physical dimension and gas/fluid flow constraints. Depending upon the height, width and cross-sectional thickness of the core sections as required by the production capacity and overall system physical dimensions, the number of coaxial (concentric) heat exchanger core sections in each heat exchanger unit may be between 100, or 90, or 80, or 70, or 60, or 50, or 40, or 30, or 20, or 15, or
  • a heat exchange my comprise a plurality of units of coaxial (concentric) heat exchanger core sections arranged in any physically practicable arrangement wherein the total number of units of coaxial (concentric) heat exchanger core sections may be between 100, or 90, or 80, or 70, or 60, or 50, or 40, or 30, or 20, or 15, or 14, or 13, or 12, or 11, or 10, or 9, or 8, or 7, or 6, or 5, or 4, or 3 and 2 or 1 wherein the foregoing upper and lower bounds can be independently combined.
  • FIG. 9 shows a schematic of one embodiment of a vertical fluid heating system with three coaxially nested heat exchanger cores.
  • the output production fluid is hot water, which flows in the pressure vessel 900 comprising a top head 160G, bottom head 162G and a pressure vessel shell 164G disposed between the top head and the bottom head.
  • Production fluid enters the pressure vessel inlet 155F and flows 910 around the bottom of the third heat exchanger core 840A; between the opposing outer surfaces of the fifth and fourth casings; around 920 the top head of the second heat exchanger core section 340G; between the opposing outer surfaces of the third and second casings; around 930 the bottom head of the first heat exchanger core section 110H; through 940 the space bounded by the outer surface of the first casing.
  • a first top production fluid guide 985 directs the production fluid between the third and second coaxial nested heat exchanger cores; a bottom production fluid guide 995 directs the production fluid between the second and first coaxial nested heat exchanger cores; and a second top production fluid guide 990 limits the production fluid flow to the space bounded by the outer surface of the first casing.
  • the entire outer surface of the first 11 OH, second 340G and third 840A heat exchanger core sections are exposed to production fluid. Thermal energy is transferred from the inner core section surfaces (exposed to thermal transfer fluid) down the temperature gradient to the production fluid wetting the outer surfaces of the core section casings.
  • a sixth feature of using multi-core heat exchangers according to the disclosed embodiments is that the heat exchanger core sections, pressure vessel and heat exchanger inlet and outlet can be adjusted to accommodate variations in the component geometry to satisfy product design requirements for specific applications.
  • FIG. 10 shows a schematic diagram of one embodiment of a vertical fluid heating system that illustrates this feature with three coaxially nested heat exchanger cores wherein the thermal fluid conduit enters proximate to the bottom heat exchanger core section head together with a combustion burner to generate a hot air thermal fluid.
  • the embodiment shown is configured for the production of steam (water vapor) wherein the inner volume of the pressure vessel is partially filled with liquid water 1020 to a phase transition surface 1000 above which is occupied by water vapor 1010 under normal operating conditions.
  • the steam is forced under pressure through 1030 a conduit penetrating 156G the pressure vessel core to an outside of the pressure vessel.
  • the inlet conduit 230F penetrates the pressure vessel 900A comprising a top head 160H, bottom head 162H and a pressure vessel shell 164H disposed between the top head and the bottom head near the bottom head.
  • a fuel-air mixture enters the inlet conduit under pressure where it is ignited in the combustion burner 830A flows through the conduit 203F and the inlet member 152G to the first heat exchanger core section 1101 inlet 1201.
  • the first heat exchanger core section 1101 is the outermost core in the set of three coaxial nested heat exchanger core sections, with a height Hi.
  • a second heat exchanger core section 340H is fluidly connected to the first heat exchanger core section and has a height 3 ⁇ 4, where 3 ⁇ 4 is less than Hi, to provide clearance for the inlet member to be disposed on the outer surface of the first casing at the inlet 1201.
  • a third casing 840B is disposed coaxially to the second heat exchanger core section 340H and also has a height less than Hi to provide clearance above the inlet member 152G and inlet conduit 230F. After the thermal transfer fluid traverses the third heat exchanger core section 840B through the flow channel formed by the fifth casing, the sixth casing and the rib, the thermal transfer fluid exits through the outlet 122G on the outer surface of the fifth casing, the sixth casing or a combination thereof.
  • the exhaust thermal transfer fluid After passing though the outlet 122G the exhaust thermal transfer fluid flow the outlet member 397 A which penetrates 380D the pressure vessel top head, shell or combination thereof to an outside of the pressure vessel.
  • the production fluid is steam, which is produced by heating a combination of liquid water and water vapor in pressure vessel 160H.
  • the fluid is not forced in a prescribed flow pattern through the vessel by pressure. Instead cold water, also known to the industry as feed water, is forced under pressure through inlet 155G. It then mixes with water volume already in the pressure vessel. Feedwater is introduced to the vessel at a rate sufficient to maintain a water/steam interface line 1000 in approximately the same location, when measured in height.
  • This interface line can be established by the manufacturer at any convenient location within the height of the pressure vessel, but typically exists at a location which ensures that all heat transferring surfaces are submerged below the steam interface line at all stages of operation.
  • the outer surfaces of the heat exchanger inlet conduit 230F, inlet member 152G and outlet member 397A are also fully immersed in the production fluid and may participate in transferring heat energy from the thermal transfer fluid to the production fluid, enhancing the overall bulk heat transfer efficiency.
  • FIG. 11 shows a cross-section schematic of the vertical fluid heating system with three coaxially nested heat exchanger cores wherein the thermal fluid conduit enters proximate to the bottom heat exchanger core section head together with a combustion burner to generate a hot air thermal fluid as shown in FIG. 10.
  • An inlet conduit 230G penetrates 1101 the pressure vessel shell 1641 proximal to the pressure vessel 900B bottom head. Hot thermal transfer fluid is directed through the conduit 230G and the inlet member 152H to the inlet 120J of a first heat exchanger core section 110J.
  • Thermal transfer fluid is guided by the space formed by a first casing, a second casing and a rib (not shown) to the outlet 300E of the first core section.
  • Thermal transfer fluid flows through a conduit 301G into the inlet 3401 of a second heat exchanger core section in fluid communication with the first core section.
  • Thermal transfer fluid is guided by the space formed by a third casing, a fourth casing and a rib (not shown) to the outlet 122H of the second core section.
  • Thermal transfer fluid flows through a conduit 875A into the inlet 870A of a second heat exchanger core section in fluid communication with the first core section.
  • Thermal transfer fluid is guided by the space formed by a fifth casing, a sixth casing and a rib (not shown) to the outlet 880A of the second core section where it enters an exhaust conduit 397B.
  • a seventh feature of using multi-core heat exchangers is that certain embodiments of multi-core tubeless heat exchanger embodiments - particularly those incorporating rib, ridge and spine flow guides - retain the negligible thermal expansion stress properties of similar heat exchangers with single core sections.
  • Heat exchangers suffer from thermal stress material failures caused by longitudinal differential thermal expansion of the heated components, e.g., the thermal expansion of the combustor and heat exchanger assembly relative to the thermal expansion of a pressure vessel shell. Material failures in the delicate heat exchanger structural components may be induced by rigidly attaching the combustor and heat exchanger assembly to the pressure vessel shell. Available techniques in practice for mitigating thermal stresses in heat exchangers all have drawbacks.
  • floating head assemblies are complex and are located inside the pressure vessel shell, and thus are difficult to service.
  • inclusion of curves and bends in the delicate heat exchanger tubes add compliance but increase the manufacturing cost and material failure risk.
  • compliant elements e.g., bellows or expansion joints inside the pressure vessel shell, result in poor system and component field serviceability.
  • FIG. 12A shows a schematic of one embodiment of a vertical hydronic fluid heating system with three coaxially nested heat exchanger cores configured to produce hot water.
  • the first 110K, second 340J and third 840D heat exchanger cores are coaxially nested and contained entirely within the pressure vessel 1641.
  • the first heat exchanger core is attached along its circumference to the pressure vessel top head 1601 by the fluid guide 990 A.
  • the fluid guide is exposed during operation to production fluid on both exposed surfaces, so it remains relatively cool during operation.
  • the upper end of the first heat exchanger core is also attached to the second heat exchanger core by the conduit 310F that provides for fluid communication between the first core and the second core, it is close to the fluid guide, is relatively small and the conduit can be designed with some material flexibility.
  • the first heat exchanger core is rigidly attached only at one end (upper) of the core, and the majority of the first heat exchanger core section inner and outer casings are free to expand downward as hot thermal transfer fluid flows from the inlet 120K to the outlet 3 OOF.
  • the component is free to expand without constraint or restriction, reducing or eliminating the potential for thermal stress altogether.
  • the bottom (unpinned) end of the is free to expand longitudinally away from the pinned end, resulting in a length change Ei in the operating (HOT) condition compared with the quiescent (COLD) condition.
  • FIG. 12C shows the free end inner and outer casing expansion for the second heat exchanger core section 340J.
  • the second heat exchanger core section is attached to the first core section by a conduit 310F disposed on the first heat exchanger core section outlet 300F, and by a conduit 875A providing fluid communication between the second 340J and third 840D heat exchanger core sections.
  • these attachment points are relatively small in extent (e.g., as a fraction of the casing surface area) and admit some inherent compliance using design methods known to those skilled in the art.
  • E 2 As the inner surfaces of the inner and outer casings are exposed to hot thermal transfer fluid, these components expand and the casings exhibit an overall increase in length, E 2.
  • a benefit of using multi-core heat exchangers according to the disclosed embodiments is that the thermal expansion rates are matched. That is, when each heat exchanger core is allowed to expand and contract freely, the net expansion/contraction from furnace to flue points does not differ substantially from the thermal expansion of the pressure vessel shell.
  • An eighth feature of using multi-core heat exchangers is the relatively low temperature of the outer surface of the pressure vessel shell and the avoidance of a high temperature on the outer surface of the pressure vessel shell.
  • the thermal transfer fluid which can have a temperature of 200°C to l800°C, such as l0°C, 50°C, l00°C, 200°C, or 400°C to l800°C, l600°C, l400°C, l200°C, or l000°C, is disposed, e.g., urged or pumped, through the tubeless heat exchanger core, the thermal transfer fluid does not directly contact the pressure vessel shell.
  • the heat exchanger core and thus the flow passage between the inner casing and the outer casing for the thermal transfer fluid, is contained entirely within the pressure vessel shell, and because the entire outer surface of the heat exchanger core is contacted by the production fluid, and because the thermal transfer fluid does not directly contact the pressure vessel shell, and because the exhaust thermal transfer fluid is not conveyed to the flue in the space between the pressure vessel outer surface and the body cover or body cover lined with an insulation material, a high temperature on a surface of the pressure vessel shell is avoided.
  • a temperature of the surface of the pressure vessel shell may be lO°C to 400°C, e.g., 20°C to l00°C, and may be lO°C, l5°C, 20°C, 25°C, 30°C, 50°C, 60°C, 70°C or 80°C to 200°C, l90°C, l80°C, l70°C , 220°C, 300°C, or 400°C, wherein the foregoing upper and lower bounds can be independently combined.
  • an average temperature of the surface of the pressure vessel shell may be lO°C to 400°C, e.g., 50°C to 200°C, and may be lO°C, l5°C, 20°C, 25°C, 30°C, 50°C, 60°C, 70°C or 80°C to 200°C, l90°C, l80°C, l70°C, 220°C, 300°C, or 400°C, wherein the foregoing upper and lower bounds can be independently combined.
  • an average temperature of the surface of the pressure vessel shell is 20°C to 220°C, preferably 25 °C to 220°C.
  • an insulating material between the pressure vessel shell and the body cover may have thickness less than 10 cm, e.g., 1 cm to 7 cm, and selected to provide that the temperature of the outer surface of the body cover is maintained below 65°C, below 40°C, or at 20°C to 50°C when the heating system is operating at full operating capacity.
  • FIG. 13 This benefit of some embodiments of a fully-wetted multi-core section vertical heat exchanger configured to produce hydronic fluid heating system with three coaxially nested heat exchanger cores configured to produce hot water is shown in FIG. 13.
  • the first 100L, second 340K and third 840E heat exchanger core sections are entirely contained within the pressure vessel 164J.
  • the pressure vessel is filled with production fluid 1310 (water).
  • production fluid 1310 water
  • the outer surfaces of each casing (casings one (1) through six (6)) are exposed to - and in direct contact with - production fluid flowing through the pressure vessel and the outer surface of the pressure vessel remains relatively cool. Since the thermal transfer fluid neither directly contacts, nor is brought in close proximity to, the body cover 1300, the external surfaces of the fluid heating system remain cool, obviating or reducing the need for insulation between the pressure vessel and the body cover.
  • FIG. 14 shows a schematic of an embodiment of a vertical fluid heating system with three coaxially nested heat exchanger cores wherein the thermal fluid conduit enters proximate to the bottom heat exchanger core section head together with a combustion burner to generate a hot air thermal fluid.
  • the embodiment shown is configured for the production of steam (water vapor) wherein the inner volume of the pressure vessel 164K is partially filled with liquid water 1432 to a phase transition surface 1434 above which is occupied by water vapor 1430 under normal operating conditions.
  • the steam is forced under pressure through 385B a conduit penetrating 156H the pressure vessel core to an outside of the pressure vessel.
  • the inlet conduit 23 OH containing a furnace and burner penetrates the pressure vessel shell 164K and is disposed on an inlet 120K of the first heat exchanger core section 110M.
  • a fuel-air mixture enters the inlet conduit 230H under pressure where it is ignited in the combustion burner.
  • the first heat exchanger core section 110M is the outermost core in the set of three coaxial nested heat exchanger core sections and is a ribbed tubeless heat exchanger with a spiral rib 124D.
  • a second heat exchanger core section 340L comprising a ribbed tubeless heat exchanger core with a spiral rib 365D is fluidly connected to the first heat exchanger core section through an inter-core conduit 1414 disposed on an outlet 1416 of the first core and an inlet 1418 of the second core.
  • a third heat exchanger core section 1400 comprising an outer casing 1404, and inner casing 1402 and a plurality of vertical ribs 1428 is disposed coaxially to the second heat exchanger core section 340L. After the thermal transfer fluid traverses the second heat exchanger core section 340L, it passes through an inter-core conduit 1420 disposed on a section outlet 1422 of the second core section 340L and a core section inlet 1424 of the third core section 1400.
  • the production fluid is steam, which is produced by heating a combination of liquid water and water vapor in pressure vessel 164K.
  • feedwater is introduced to the vessel at a rate sufficient to maintain a water/steam interface line 1434 in approximately the same location.
  • This interface line can be established by the manufacturer at any convenient location within the height of the pressure vessel, but typically exists at a location which ensures that all heat transferring surfaces are submerged below the steam interface line at all stages of operation.
  • the outer surfaces of the heat exchanger inlet conduit 230H, inlet member 1521 and the heat exchanger core section casing surfaces are also fully immersed in the production fluid and may participate in transferring heat energy from the thermal transfer fluid to the production fluid, enhancing the overall bulk heat transfer efficiency.
  • the first heat exchanger core section 110M and the second heat exchanger core section 340L are spiral rib tubeless heat exchanger cores, while the third head exchanger core section 1400 comprises a plurality of vertical ribs. This permits the rib elements in the first and second core sections to guide the flow in a spiral path through the inner and outer casings, effectively elongating the flow path and opportunity for extended heat transfer from the hot thermal transfer fluid (combustion gas and byproducts) to the production fluid.
  • the vertically-oriented ribs of the third heat exchanger core section effectively act to: (a) increase the heat transfer surface area present in the cavity formed by the inner casing 1402, the outer casing 1404, and the vertical ribs 1428 of the third casing 1400; and, (b) permit easy cleaning of the third heat exchanger core 1400 by disposing a collection manifold 1406 to accumulate debris.
  • a tenth feature of using multi-core heat exchangers according to the disclosed embodiments is that the geometry of inter-core conduits connecting two fluidly connected cores can be adjusted to promote thermally efficient transfer fluid flow between heat exchanger core sections.
  • a primary advantage of the features disclosed is that heat exchangers comprising a plurality of core sections can achieve very compact, high capacities for heat exchange in small apparatus volumes.
  • tubeless heat exchanger cores that utilize flow guides (or flow elements), e.g., but not limited to, ribbed, ridged or spined elements, may comprise regions where flow of the thermal transfer fluid can become entrained or trapped, underutilizing the available surface area for heat transfer.
  • thermal transfer fluid e.g., combustion gas and byproducts
  • FIG. 15A illustrates these challenges using an embodiment of two concentric, sequential heat exchanger core sections.
  • the core section exhaust end (or core section outlet) of a first (or outer or outer-most) heat exchanger core section 1501 (or first core section) may comprise a spiral rib 1500 disposed on an inner casing 1502 and an outer casing (not shown) of the first core section 1501, at a rib angle ARi which forms a flow path for thermal transfer fluid into a circular (or circumferential) inter-core (or“inter-section” or“section”) conduit“C” (or“passage” or“flow passage”), and a core section outlet 1503 connected to the inter-section conduit C.
  • the thermal transfer fluid (for example, but not limited to, combustion gases and combustion byproducts) flows through the triangular region, Ti, along the flow path 1520 of the first core section 1501, through core section outlet 1503, along the conduit C, into the second core section 1505 and down the triangular region, T 2 , along the flow path 1520 of the second core section 1505.
  • FIG. 15B illustrates how the challenges listed above can affect the flow of thermal transfer fluid through the two heat exchanger sections fluidly connected by the inter-core (or“inter section” or“section”) conduit unless the transfer properties is properly balanced.
  • Curve 1508 shows a (suboptimal) flow velocity profile corresponding to the single circular inter-core conduit C.
  • the flow through the body of the first heat exchanger core section 1501, Hxi may be accelerated as it enters the triangular region, Ti, near the first core section outlet 1503 (or core section exhaust end) due to a narrowing of the flow path 1520, causing an increase in flow momentum since the flow 1520 must be turned by the conduit C.
  • the position of the first core section outlet 1503 opening in the triangular region Tl can result in a region 1507 of low velocity or stagnant flow at the end of the flow path 1520 producing a section of surface area where heat transfer is degraded or fails to contribute to the heat transfer process.
  • a similar situation occurs for the second core section 1505 in a region 1507A, where flow enters the second core inlet 1503 A and flows to the right along the flow path 1522, and the region 1507A would exhibit low velocity or stagnant flow at the beginning of the flow path 1522 in the second core section 1505.
  • the hydrodynamic diameter of the conduit, C is typically chosen larger than that of the core section flow path hydrodynamic diameter, the average flow velocity drops as it passes through the conduit, C, and through the second core section inlet 1503 A of the triangular flow region, T 2 , of the second core section 1505.
  • the flow 1522 upon entering the second core section inlet 1503 A will be accelerated as it enters section T 2 , a flow path with smaller hydrodynamic diameter with a concurrent loss of flow momentum.
  • the flow velocity of the flow 1522 then decreases to a nominal value as it enters the main body of the second heat exchanger core section 1505, Hx 2 .
  • tubeless heat exchanger configuration parameters and the inter-core conduit geometry can be used in concert to balance the pressure drop and achieve nearly uniform flow. These parameters include - but are not limited to - the core section guide angles (e.g., ARi and AR 2 in FIG. 15 A) and hydrodynamic diameters, the number and placement of the inter-core conduits, and the geometry of the inter-core conduit entry and exit ports.
  • FIG. 15C shows a cross-sectional perspective view of the first and second core sections of the embodiment described in FIG. 14, illustrating a plurality (six shown in this embodiment) of inter-core conduits 1414A each disposed between a core section outlet 1416A of the first core section and a core section inlet 1418A of the second core section.
  • the outer wall 1512 spans the space between first and second core sections to convey the thermal transfer fluid (combustion gas and byproducts) guided by the rib 124E traveling between the core casings to the second heat exchanger core.
  • FIG. 15D shows the cross-sectional detail of the core casings and the inter-core conduits.
  • Each conduit 1414B is disposed between an outlet 1416B of the first core and an inlet 1418B of the second core with the outer wall 1512A at a 90 degree angle 1514 to the tangent line of the core casing.
  • the inter-core (or section, inter-section or inter-core-section) conduit 1414C is disposed between the outlet 1416C of the first core section and the inlet 1418C of the second core section, but the wall of the conduit 1600 is positioned at an angle 1602, A, relative to a radial axis 1605 or the direction normal to the local inner casing wall at the center of the flow passage.
  • the primary design goals for adjusting the entrance and exit angles through the inter-core conduit are to: (a) keep flow velocities reasonably constant through the transition; and, (b) preserve a reasonably uniform pressure drop gradient throughout the conduit openings; that is, to minimize or eliminate sudden drops in pressure due to flow acceleration, deceleration and turning.
  • FIG. 16A angles the ports or inter-section conduits to be as similar to the direction of flow as possible. The result is that the local heat fluxes are reduced to nominal levels, and that sharp edges are eliminated on the“inside of the corner” where gas velocities are most likely to do damage over time. In this way, the inventor has solved not only the problems associated with needlessly high pressure drop, but extended the usable life of the invention as well.
  • FIG. 16B shows the three angles under consideration to reduce turning of the flow 1603 (Fig. 16A) between two core sections connected by an inter-core section conduit.
  • the angle into the inner pipe will always be greater than that of the outer.
  • the passage angle, A, 1602 measured (from the radial axis 1605) through the center of the passage as a deviation relative to the tangent of the inner (smaller diameter) core casing at the center of the inter-core conduit described the disposition of the conduit to the inner core section.
  • the specification of angle A 1602 is useful for the purpose of manufacturing assembly.
  • the entrance angle Ai 1604 of the inter-core conduit passage measured from a line 1607 that is tangent to the outer casing of the inner core section, relative to the second core section (relative to the cross-section intersection 1418C) and the exit angle Ao 1603, measured from a line 1609 that is tangent to the inner casing of the outer core section (relative to the cross-section intersection 1416C) are necessarily different.
  • the design goal is to maximize each angle subject to the constraints of geometry (e.g., core section diameters, core section separation distances) and manufacturability (e.g., practical limits on component welding) wherein the upper limit is 180 degrees.
  • Ai 1604 and Ao 1603 are between 95 degrees, 100 degrees, 105 degrees or 110 degrees and 140 degrees, 145 degrees, 150 degrees, 155 degrees, 160 degrees, 165 degrees, 170 degrees or 175 degrees where the upper and lower limits may be independently combined.
  • An angular range between 105 degrees and 150 degrees is specifically mentioned.
  • FIG. 16C shows an embodiment of a semicircular inter-core conduit 1512B with oblique passage angle 1602, A.
  • the goal of the inter-core conduit shape design is to achieve reasonably evenly distributed flow through the conduit (or each conduit in an embodiment where a plurality of conduits is used).
  • the inventors have empirically discovered that a useful design rule is the sum of the cross-sectional areas of the conduits providing fluidic connection between two sequential core sections is approximately three to six times nominal flow area of the cross-sectional area of the core section flow passage.
  • the hydrodynamic area of each conduit when selected to be about twice the hydrodynamic diameter of the core section flow passage area provides reasonably low pressure drops through the conduits, reducing the effects to the flow dynamics due to perturbations through the transition.
  • inter-core conduits when viewed in cross-section from above, must not take up an excessive amount of surface area, as the hot water or steam flow in the area between two sequential core sections must be preserved.
  • the area is restricted too much the velocity of the rising steam is accelerated, resulting in excess liquid water being carried with the steam.
  • the height of the conduit is important particularly in the case of ribbed tubeless heat exchanger core sections such as depicted in the embodiment of FIG. 14.
  • Inter-core conduits with taller cross-sections implies the last port to exit the first core section cannot be placed as far downstream leaving a larger dead zone beyond the last port. Concurrently, the first port that entering the subsequent core section would be similarly restricted, together resulting in a reduced surface area available for total heat transfer.
  • wide flat transition conduits make more effective use of the heat exchanging surfaces, but would overly restrict the flow of steam between the heat exchangers.
  • FIG. 16D illustrates the positioning of the inter-core conduit for the embodiment depicted in FIG. 16C in an embodiment of a multi-core heat exchanger with two core sections similar to that shown in FIG. 14.
  • the top surfaces of the plurality of semicircular inter-core conduits 1414 forms openings 1605 for the flow of production fluid between the first core section 110M and the second core section 340L.
  • FIG. 16E shows a perspective cutaway drawing showing the semicircular shape of the inter-core conduit 1414 structure.
  • the conduit 1414 forms and oblique angle 1602 with the radial vector at the center of the conduit as it exits the first casing 110M.
  • the flow enters the second casing 340L on a path designed to allow a smooth transition between the core sections.
  • both heat exchanger cores are disposed with helical ribs
  • a natural flow balancing can be achieved.
  • the angle of the rib on the second heat exchanger core can be reversed (that is, when the direction of rotation is kept the same is kept the same in both core section), that the rib elevation drops rather than rises, a radial array of conduits 1414B, properly aligned are arranged, the mean flow length of all flow particles is nearly the same. That is, the fluid which is allowed to exit the first heat exchanger first is exhausted as far upstream as possible in the second heat exchanger core. The fluid is held in the first heat exchanger core the longest (it reaches the last conduit, is exhausted into the second heat exchanger core at a point which is furthest downstream).
  • the flow balancing achieved minimizes pressure drop by not needlessly accelerating any portion of the flow. Additionally, this also creates uniformity in the temperature fields experienced by the heat exchanger cores, and the conduits which connect them. This uniform temperature field minimizes local elevated temperatures, and thus minimizes local thermal stresses, promoting long term durability.
  • FIG. 15B depicts the effect of sharply perturbed flow geometry on the pressure drop across the inter-core transition path. Contrast that unfavorable effect with the results from applying the systems engineering effect to adjustment of the flow efficiency using the discoveries discussed above as illustrated in FIG. 16F and Fig. 16G.
  • These drawings show results from numerical simulation of the flow quantities, pressure drop (P) and heat flux(Q), along the flow path of a vertical steam boiler as it traverses between the first and second core sections using two conduit configurations.
  • 16F shows the computed values of the large perturbations in both pressure drop 1604, P, and heat flux 1606, Q, as the flow passes from the region (Ti) near the outlet in the first core section, through the conduit (C), and out the region (T 2 ) near the inlet in the first core section for a single circular inter-core section oriented perpendicular to the casings of the first core section (e.g., along a radial vector).
  • FIG. 16G shows simulated improvements after the application of the principles described above resulting in the use of a plurality of inter-core conduits as shown in FIG. 16D, oriented at an oblique angle, A, relative to the radial vector to the first core section. Since the perturbations to the flow path, acceleration, deceleration momentum and velocity in the transition from the first core section, Hxi, through the conduit to the second core section, Hx 2 , have been reduced, the pressure drop 1608, P, across the inter-core conduit is reduced as is the simulated heat flux 1610, Q. Table 1 shows the simulation parameters corresponding to the results shown in Fig. 16G. TABLE 1
  • An important systems engineering design principle pertaining to heat transfer equipment is to design out any locally high pressure drops and heat fluxes.
  • High heat fluxes are associated with higher wall temperatures. If a local heat flux is high enough, when compared to the surrounding material, the material subject to the high heat flux will experience greater degrees of local thermal expansion, leading to high stress gradients in the effected region. Additionally, any sharp corners, or edges should be eliminated wherever possible, as these locations can be subject to erosion, as a result of high velocity, high temperature gas flowing over them for extended periods of time. Both of these effects result in degradation of durability and lifetime of the invention.
  • An eleventh feature is that the flexibility inherent in geometries according to the disclosed embodiments of the multicore approach enable those with skill in the art to generate dryer steam production fluid, extracting a high fraction of water droplets in the vapor and recovering more energy that results in greater thermodynamic efficiency.
  • FIG. 17 provides further details of the steam path for the embodiment disclosed in FIG. 14.
  • FIG. 18A to Fig. 18F shows a series approach to manufacturing a sequential pair of heat exchanger core sections in series fluid communication.
  • FIG. 18A shows the spiral 1802 disposed on the inner casing 1800 of the first core.
  • FIG. 18B the outer casing 1804 - including the inlet and outlet port 1810 - is disposed on the assembly shown in FIG. 18 A, and the top head 1806 and bottom head 1808 of the core are disposed on the assembly.
  • FIG. 18C an inter-core conduit 1812 is disposed on the assembly.
  • FIG. 18C an inter-core conduit 1812 is disposed on the assembly.
  • FIG. 18D the inner casing 1814 of the second heat exchanger core section, with its rib 1816, is disposed concentrically on the exterior of the first core assembly from Fig. 18C.
  • FIG. 18E the outer casing 1820 of the second heat exchanger core section is disposed on the exterior of the assembly and the top head 1822 and bottom head 1818 are disposed.
  • FIG. 18 F shows a cross-sectional view of the final result of the serial assembly, including the first heat exchanger core section 1824 and the second heat exchanger core section 1826, connected by the inter-core conduit 1828.
  • the series assembly method suffers from at least three potential drawbacks: First, since the assembly is being constructed by adding new elements onto a growing structure, the weight of the assembly grows with each processing step. This makes manipulating the assembly unwieldy due to its growing weight and requires sophisticated tooling to perform the required steps. Second, since the addition of each new element to the assembly requires proper alignment, the tolerance requirements are additive through the process, requiring tight tolerances - particularly on elements added in later steps - to ensure proper fit and function. Finally, a series approach to assembly is the slowest manufacturing option, since each step must be completed before the next can be performed.
  • FIG. l9A-Fig. 19C illustrates one possible embodiment of a parallel assembly method.
  • FIG. 19A shows one embodiment of a process of creating a first core section 1912.
  • the spiral 1902 is disposed on the inner casing 1900 of a first partial core assembly 1903.
  • the outer casing 1904 - including the inlet and outlet port 1910 - is disposed on the assembly 1903, and the top head 1906 and bottom head 1908 of the core section are further disposed on the assembly 1903 to complete the first core section subassembly 1912.
  • FIG. 19B one embodiment of a process of creating a second core section 1918 is shown.
  • the spiral 1926 is disposed on the inner casing 1924 - including the inlet and outlet 1925 port - of the second partial core assembly 1927.
  • the outer casing 1920 of the second core section 1928 is disposed on the assembly 1927, and the top head 1922 and bottom head 1918 of the core section are further disposed on the assembly 1927 to complete the second core section subassembly 1928.
  • FIG. 19C one embodiment of a process of performing the final assembly is shown.
  • the second core section subassembly 1928 from Fig. 19B is disposed concentrically on the first core section subassembly 1912 from Fig. 19A, and the conduit 1920 is disposed to form the inter-core conduit 1926 enabling fluid communication between the first heat exchanger core section 1922 and the second heat exchanger core section 1924.
  • Embodiment 1 A tubeless heat exchanger comprising: a plurality tubeless heat exchanger core sections, each tubeless heat exchanger core comprising an inlet and an outlet; an outlet member, which disposed on the outlet of one or a plurality of tubeless heat exchanger core sections; a first conduit having a first end connected to one or a plurality of tubeless heat exchanger core inlets; one or more conduits having a first end connected to an outlet of a tubeless heat exchanger core section and an inlet of another heat exchanger core section.
  • Embodiment 2 The tubeless heat exchanger of embodiment 1 wherein a heat exchanger core section comprises: a top head, a bottom head, a first casing disposed between the top head and the bottom head, a second casing disposed between the top head and the bottom head, wherein an inner surface of the first casing is opposite an inner surface of the second casing, an inlet on the first casing, the second casing, or combination thereof, an outlet on the first casing, the second casing, or combination thereof, and a rib disposed between the first casing and the second casing, wherein the rib, the first casing, and the second casing define a flow passage between the inlet and the outlet; a pressure vessel; an inlet member on the inlet for fluidly connecting the inlet to an outside of the pressure vessel; and an outlet member on the outlet for fluidly connecting the outlet to an outside of the pressure vessel, wherein the bottom head, the first casing, and the second casing are contained entirely within the pressure vessel.
  • Embodiment 3 The heat exchanger of embodiment 2, wherein the top head is contained entirely within the pressure vessel.
  • Embodiment 4 The heat exchanger of any of embodiment 2 to 3, wherein the first casing and the second casing are coaxial.
  • Embodiment 5 The heat exchanger of any of embodiment 2 to 4, wherein the first casing and the second casing each independently have a circular cross-sectional shape, an elliptical cross- sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross-sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof.
  • Embodiment 6 The heat exchanger of any of embodiment 2 to 5, wherein the first casing and the second casing have a same cross-sectional shape.
  • Embodiment 7 The heat exchanger of any of embodiment 2 to 6, wherein the first casing and the second casing each independently have an average thickness of 0.5 centimeters to 5 centimeters.
  • Embodiment 8 The heat exchanger of embodiment 2, wherein an aspect ratio of the flow passage is between 10 and 100, wherein the aspect ratio is a ratio of a height of the flow passage to a width of the flow passage, wherein the height is a distance between opposite surfaces of a same rib and is measured normal to a first rib surface and wherein the width of the flow passage is measured from an inner surface of the first casing to an inner surface of the second casing.
  • Embodiment 9 The heat exchanger of any of embodiments 2 to 8, wherein the heat exchanger comprises a plurality of ribs, ridges or spines.
  • Embodiment 10 The heat exchanger of any of embodiment 2 to 9, wherein the rib, ridge or spine has a helical shape, a stepped shape, a shape of a segment of a circle, a shape of a segment of a helix, or a combination thereof.
  • Embodiment 11 The heat exchanger of any of embodiment 2 to 10, wherein the rib, ridge or spine has a circular cross-sectional shape, an annular cross-sectional shape, an elliptical cross- sectional shape, an oval cross-sectional shape, a stadium cross-sectional shape, a semicircular cross-sectional shape, a square cross-sectional shape, a rectangular cross-sectional shape, a triangular cross-sectional shape, or combination thereof.
  • Embodiment 12 The heat exchanger of any of embodiment 2 to 11, wherein the rib, ridge or spine is rigidly attached to the first casing, the second casing, or a combination thereof.
  • Embodiment 13 The heat exchanger of any of embodiment 2 to 12, wherein the first casing and the rib or ridge or spine, the second casing and the rib or ridge or spine, or a combination thereof are rigidly attached by a weld.
  • Embodiment 14 The heat exchanger of any of embodiment 2 to 13, and wherein the rib, ridge or spine is rigidly attached to the first casing by a first weld and is rigidly attached to the second casing by a second weld, and wherein the first weld and the second weld are different types of welds.
  • Embodiment 15 The heat exchanger of any of embodiment 2 to 14, wherein the rib, ridge or spine forms an interference fit with the inner surface of the first casing, the inner surface of the second casing, or a combination thereof.
  • Embodiment 16 The heat exchanger of any of embodiment 2 to 15, wherein a pitch of the rib, ridge or spine is between 0 degrees and 90 degrees with respect to a tangent direction, wherein the tangent direction is perpendicular to a longitudinal axis of the second casing.
  • Embodiment 17 The heat exchanger of any of embodiment 2 to 16, wherein the heat exchanger core comprises a plurality of ribs or ridges or spines, and a pitch of each rib or ridge or spine of the plurality of ribs, ridges or spines is independently between 0 degrees and 90 degrees with respect to the tangent direction.
  • Embodiment 18 The heat exchanger of any of embodiment 2 to 17, wherein a pitch of the rib or ridge or spine is parallel to a longitudinal axis of the second casing.
  • Embodiment 19 The heat exchanger of any of embodiment 2 to 18, wherein the heat exchanger core comprises a plurality of ribs or ridges or spines, and wherein a pitch of each rib or ridge or spine of the plurality of ribs is parallel to a longitudinal axis of the second casing.
  • Embodiment 20 The heat exchanger of any of embodiment 2 to 19, wherein an aspect ratio of a flow passage of the tubeless heat exchanger core is 10 to 100, wherein the aspect ratio is a ratio of a height of the flow passage to a width of the flow passage, wherein the height is a distance between opposite surfaces of a same rib and is measured normal to a first rib surface, and wherein the width of the flow passage is measured from an inner surface of the inner casing to an inner surface of an outer casing.
  • Embodiment 21 A fluid heating system comprising: a pressure vessel shell comprising a first inlet and first outlet; a plurality tubeless heat exchanger core sections disposed entirely in the pressure vessel shell, each tubeless heat exchanger core of any of embodiments 1 to 20, wherein an inlet and an outlet; an outlet member, which penetrates the pressure vessel shell and which connects the outlet of one or a plurality of tubeless heat exchanger core sections and an outside of the pressure vessel shell; a first conduit having a first end connected to one or a plurality of tubeless heat exchanger core inlets and a second end disposed on the outside of the pressure vessel shell; one or more conduits having a first end connected to an outlet of a tubeless heat exchanger core section and an inlet of another heat exchanger core section.
  • Embodiment 22 The fluid heating system of embodiment 21 wherein a heat exchanger core section is vertically oriented relative to the vertical axis of the fluid heating system.
  • Embodiment 23 The fluid heating system of embodiment 21 wherein a heat exchanger core section is horizontally oriented relative to the vertical axis of the fluid heating system.
  • Embodiment 24 The fluid heating system of embodiment 21 wherein a heat exchanger core section is oriented at an angle between 0 degrees and 180 degrees relative to the vertical axis of the fluid heating system.
  • Embodiment 25 The fluid heating system of any of embodiments 21 to 24, wherein the pressure vessel shell is configured to contain a production fluid such that an entirety of an outer surface of the tubeless heat exchanger core is contacted by the production fluid.
  • Embodiment 26 The fluid heating system of any of embodiments 21 to 24, wherein an entirety of a flow passage of the tubeless heat exchanger core is disposed entirely in the pressure vessel shell.
  • Embodiment 27 The fluid heating system of any of embodiments 21 to 26, wherein the heat exchanger core has a hydrodynamic diameter of 2.5 centimeters to 100 centimeters.
  • Embodiment 28 The fluid heating system of any of embodiments 21 to 26, wherein the heat exchanger core has an average hydrodynamic diameter of 2.5 centimeters to 100 centimeters.
  • Embodiment 29 The fluid heating system of any of embodiments 21 to 28, wherein at least one of an inner casing and an outer casing of the tubeless heat exchanger core has a thickness of 0.5 centimeters to 5 centimeters.
  • Embodiment 30 The fluid heating system of any of embodiments 21 to 29, further comprising a body cover disposed on the pressure vessel shell.
  • Embodiment 31 The fluid heating system of embodiment 30, wherein the fluid heating system is configured to have a temperature of an outer surface of the body cover of less than 65°C, wherein a dimension between an outer surface of the pressure vessel and an inner surface of the body cover is less than 0.3 centimeters.
  • Embodiment 32 The fluid heating system of any of embodiments 30 to 31, wherein the body cover surrounds at least a top surface and a side surface the pressure vessel shell, and wherein a refractory material is not present between the body cover and the pressure vessel shell.
  • Embodiment 33 The fluid heating system of any of embodiments 30 to 33, wherein a thermal transfer fluid does not contact the interior surface of the body cover.
  • Embodiment 34 The fluid heating system of any of embodiments 21 to 33, wherein a thermal transfer fluid does not contact the pressure vessel shell.
  • Embodiment 35 The fluid heating system of any of embodiments 21 to 34, further comprising a production fluid in the pressure vessel shell and on an outside of the heat exchanger core, wherein the production fluid contacts an entirety of an outer surface of the heat exchanger core, and a thermal transfer fluid in the flow passage of the heat exchanger core, wherein the production fluid and the thermal transfer fluid each independently comprise a liquid, a gas, or a combination thereof.
  • Embodiment 36 The fluid heating system of embodiment 35, wherein the production fluid and the thermal transfer fluid each independently comprise water, a substituted or unsubstituted Cl to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, or a combination thereof.
  • Embodiment 37 The fluid heating system of any of embodiments 35 to 36, wherein the production fluid comprises liquid water, steam, a thermal fluid, a glycol, or a combination thereof.
  • Embodiment 38 The fluid heating system of any of embodiments 35 to 37, wherein the conduit further comprises a burner assembly disposed in the conduit.
  • Embodiment 39 The fluid heating system of any of embodiments 21 to 38, further comprising a blower in fluid communication with the conduit.
  • Embodiment 40 The fluid heating system of embodiment 39, wherein a pressure drop between the first end of the conduit and an outlet of the tubeless heat exchanger core is greater than 3 kilopascals.
  • relative terms such as“lower” or“bottom” and“upper” or“top,” may be used herein to describe one element's relationship to another element as illustrated in the Figures. It will be understood that relative terms are intended to encompass different orientations of the device in addition to the orientation depicted in the Figures. For example, if the device in one of the figures is turned over, elements described as being on the“lower” side of other elements would then be oriented on“upper” sides of the other elements. The exemplary term“lower,” can therefore, encompasses both an orientation of“lower” and“upper,” depending on the particular orientation of the figure.
  • Exemplary embodiments are described herein with reference to cross section illustrations that are schematic illustrations of idealized embodiments. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, embodiments described herein should not be construed as limited to the particular shapes of regions as illustrated herein but are to include deviations in shapes that result, for example, from manufacturing. For example, a region illustrated or described as flat may, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated may be rounded. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region and are not intended to limit the scope of the present claims.

Abstract

L'invention concerne un système de chauffage de fluide ayant un échangeur de chaleur sans tubes à sections multiples, qui comprend une enveloppe de cuve sous pression comprenant une entrée de cuve agencée pour recevoir un fluide de production à chauffer et une sortie de cuve agencée pour fournir un fluide de production chauffé, l'enveloppe de cuve sous pression contenant le fluide de production à chauffer, une pluralité de sections centrales d'échangeur de chaleur sans tubes, chaque section étant disposée au moins partiellement dans l'enveloppe de cuve sous pression, chaque section centrale comprenant une entrée de section centrale et une sortie de section centrale, et chaque section centrale recevant le fluide de transfert thermique au niveau de l'entrée de section et fournissant un fluide de transfert thermique au niveau de la sortie de section, un élément de sortie, qui pénètre dans l'enveloppe de récipient sous pression et qui relie au moins l'une des sorties de section centrale à la sortie de cuve, un conduit d'entrée reliant au moins l'une des entrées de section centrale à l'entrée de cuve, une ou plusieurs conduites de section inter-centre reliant la sortie de section centrale d'une section centrale donnée à une entrée de section centrale d'une autre section centrale.
PCT/US2019/020579 2018-03-02 2019-03-04 Échangeur de chaleur sans tubes à sections multiples, système de chauffage de fluide comprenant celui-ci, et leurs procédés de fabrication WO2019169397A1 (fr)

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US201862637741P 2018-03-02 2018-03-02
US62/637,741 2018-03-02

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Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050139172A1 (en) * 2003-12-29 2005-06-30 Young Ryoo Water heater
KR200392327Y1 (ko) * 2005-02-22 2005-08-17 이정석 횡형 연관식 온수보일러
JP2008232477A (ja) * 2007-03-19 2008-10-02 Sansyu Sangyo Co Ltd 温風機
US20150369516A1 (en) * 2013-03-01 2015-12-24 Acv International Facility for producing a hot liquid, in particular hot water
WO2016094071A1 (fr) * 2014-12-11 2016-06-16 Fulton Group N.A., Inc. Système de chauffage de fluide sans tubes sans réfractaire et complètement noyé à contrainte de dilatation thermique négligeable

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20050139172A1 (en) * 2003-12-29 2005-06-30 Young Ryoo Water heater
KR200392327Y1 (ko) * 2005-02-22 2005-08-17 이정석 횡형 연관식 온수보일러
JP2008232477A (ja) * 2007-03-19 2008-10-02 Sansyu Sangyo Co Ltd 温風機
US20150369516A1 (en) * 2013-03-01 2015-12-24 Acv International Facility for producing a hot liquid, in particular hot water
WO2016094071A1 (fr) * 2014-12-11 2016-06-16 Fulton Group N.A., Inc. Système de chauffage de fluide sans tubes sans réfractaire et complètement noyé à contrainte de dilatation thermique négligeable

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