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AU2015207872B2 - Heat exchanger - Google Patents
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AU2015207872B2 - Heat exchanger - Google Patents

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AU2015207872B2
AU2015207872B2 AU2015207872A AU2015207872A AU2015207872B2 AU 2015207872 B2 AU2015207872 B2 AU 2015207872B2 AU 2015207872 A AU2015207872 A AU 2015207872A AU 2015207872 A AU2015207872 A AU 2015207872A AU 2015207872 B2 AU2015207872 B2 AU 2015207872B2
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flow tubes
heat exchanger
module
outlet port
fluid communication
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AU2015207872A
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AU2015207872A1 (en
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Rade Brcerevic
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Abstract

H"Ieat exchanger Abstract A heat exchanger (100) including a proximal module (102) having a first set of primary flow tubes (140) and a first set of secondary flow tubes (150); a distal module (104) having a second set of primary flow tubes (140) and a second set of secondary flow tubes (150); and at least one intermediate module (110) located between the proximal module (102) and the distal module (104), the intermediate module (110) being adapted to: fluidly connect the first set of primary flow tubes (140) and the second set of primary flow tubes (140); and fluidly connect the first set of secondary flow tubes (150) and the second set of secondary flow tubes (150). 1/7 104 100 11110 130 120 C 180 1944 1102 \..... Fig.I1 T Fig. 2

Description

1/7
11110
104
100
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Fig.I1
Fig. 2
AUSTRALIA
Patents Act 1990
Standard Patent Specification
Title: Heat exchanger
Applicant(s): Rade Brcerevic
Inventor(s): Rade Brcerevic
Agent: COTTERS Patent & Trade Mark Attorneys
The following is a full description of the invention which sets forth the best method known to the applicant of performing it.
Heat exchanger
Field of the Invention The present invention relates to a heat exchanger. In particular, the present invention relates to a heat exchanger for gas to liquid heat exchange in industrial applications. However, it will be appreciated by those skilled in the art that the heat exchanger can be applied to various different technology areas.
Background of the Invention Heat exchangers are used to transfer thermal energy between two or more objects which are typically fluids, that are brought into thermal contact with each other. Heat exchangers can be used for example to either raise or lower the temperature of a fluid, for various applications, such as heating or cooling, and large industrial heat exchangers are used in various industrial applications such as automotive, air conditioning, and power generation and shipping among others.
Typical uses for heat exchangers include the heating or cooling of a fluid stream, evaporation or condensation of a fluid stream or the recovery of heat from a system. In a power plant, heat exchangers are employed in various stages of the power generation process, such as to condense steam down-stream of the turbine rotor, to cool lubricating oil, and to boil water to generate steam.
The present invention in particular relates to a gas to liquid heat exchangers. Gas to liquid heat exchangers are widely used within power plants and various other industrial applications.
The two fluids of the heat exchanger are normally not in direct contact with each other, so the thermal properties of the individual components of the heat exchanger limit the thermal efficiency of the system. Over time, as the heat exchanger is used continuously, the thermal efficiency of the heat exchanger may significantly be reduced on account of impurities in the liquid causing fouling of the tubes, or alternatively impurities in the gas causing fouling of the fins. Overtime, the tubes may accumulate a layer of calcium carbonate, calcium sulphate or a deposit of other salts, oxides, hydroxides or other impurities. In addition the fins exposed to gasses may become fouled by gaseous suspensions, soot particles or dust particles or other pollutants. Fouling reduces the efficiency of the heat exchange process because the diameter of the tubes is reduced by the fouling, which results in a pressure drop across the tube overtime, and the gas flow path becomes restricted. The increased thickness of the tube wall reduces the thermal conduction of energy between the liquid within the tube, and a gas external to the tube shell. Overtime, once a sufficient degree of fouling occurs, it may become necessary to replace parts of the heat exchanger.
However, because heat exchangers are typically manufactured as an integrally formed welded assembly, it is often very difficult to readily remove any fouled or otherwise damaged portions. In applications such as power plants, refineries and other large scale industrial applications, the time associated with a shutdown to replace or repair a heat exchanger can result in a significant loss of revenue.
When only a portion of a power plant heat exchange unit has fouled to a point of being unusable, it is known to conduct a repair by removing a blocked section of the tube, and capping or otherwise sealing the removed portion of tube. Whilst such repairs are typically faster and less costly than replacing the entire exchanger, the removal of any portion of the tube can significantly interfere with the intended liquid flow path within the tubing, and reduce the overall thermal efficiency of the heat exchanger.
A further problem with existing heat exchangers is that it can be difficult to identify the source of any blockages or restrictions, as the tubes are permanently welded or otherwise secured to each other, making it difficult to pinpoint the specific location of any fouled or blocked portions of the heat exchanger.
For large scale industrial applications, heat exchangers are typically custom made to suit various site specific parameters. Whist this helps to achieve the correct level of heat exchange during operation, this inherently mandates that each unit is heavily customised, which can add to production time and cost.
Object of the Invention It is an object of the present invention to substantially overcome or at least ameliorate one or more of the above disadvantages, or to provide a useful alternative.
s Summary of the Invention In a first aspect, the present invention provides a heat exchanger comprising: a proximal module having a first set of primary flow tubes and a fluidly independent first set of secondary flow tubes; a distal module having a second set of primary flow tubes and a second set of secondary flow tubes; and at least one intermediate module located between the proximal module and the distal module, the intermediate module being adapted to: fluidly connect the first set of primary flow tubes and the second set of primary flow tubes; and fluidly connect the first set of secondary flow tubes and the second set of secondary flow tubes.
The proximal module preferably includes an inlet port in fluid communication with the first set of primary flow tubes and an outlet port in fluid communication with the first set of secondary flow tubes.
The proximal module preferably includes a first outlet port in fluid communication with the first set of primary flow tubes and a second outlet port in fluid communication with the first set of secondary flow tubes; further wherein the distal module includes a first inlet port in fluid communication with the second set of primary flow tubes and a second inlet port in fluid communication with the second set of secondary flow tubes.
The intermediate module preferably includes a pair of generally parallel primary flow tubes, and a pair of generally parallel manifolds which together define a generally rectangular perimeter of the intermediate module.
The pair of primary flow tubes and the pair of generally parallel manifolds are preferably fluidly isolated relative to each other.
A plurality of secondary flow tubes preferably extend between and are generally perpendicular to and in fluid communication with the pair of generally parallel manifolds.
Preferably a first one of the pair of generally parallel manifolds has a first manifold s inlet/outlet port, and a second one of the pair of generally parallel manifolds has a second manifold inlet/outlet port.
The first manifold inlet/outlet port is preferably located on a side of the intermediate module which is closest to the proximal module, and the second manifold inlet/outlet port is located on a side of the intermediate module which is closest to the distal module.
The first manifold inlet/outlet port is preferably a different size relative to the second manifold inlet/outlet port such that adjacent modules are adapted to engage each other by a male to female connection.
The proximal module is preferably mounted to a lower mounting plate and the distal module is mounted to an upper mounting plate, further wherein a plurality of adjustable tensioning bars extend between the lower mounting plate and the upper mounting plate.
The secondary flow tubes are preferably sheathed within a plurality of fins or another thermally conductive structure.
The intermediate module preferably includes a rib extending generally around the rectangular perimeter, the rib being adapted to be located between adjacent intermediate modules when two or more intermediate modules are interconnected and adjacent to each other.
The distal module preferably includes a fluid flow passage between the second set of primary flow tubes and the second set of secondary flow tubes.
Brief Description of the Drawings A preferred embodiment of the invention will now be described by way of specific example with reference to the accompanying drawings, in which: Fig. I is a partially sectioned perspective view showing a heat exchanger according to a first embodiment; Fig. 2 is a schematic diagram depicting the fluid flow path of the heat exchanger assembly of Fig. 1; Fig. 3 is a partially sectioned perspective view showing a heat exchanger according to a second embodiment; Fig. 4 is a schematic diagram depicting the fluid flow path of the heat exchanger assembly of Fig. 3; Fig. 5 depicts a single cell of the heat exchangers of Figs. I and 3; Fig. 6 is an exploded view depicting the heat exchanger of Fig. 1; Fig. 7 shows a base cell and lower mounting plate of the heat exchanger of Figs. 1 and 3; Fig. 8 is a cross sectional view of the base cell and lowermounting plate of Fig. 7; Fig. 9 is a partial cross-section perspective view showing the heat exchanger of Fig. 1; Fig. 10 is a partial cross-section perspective view showing the heat exchanger of Fig. 3; Fig. 11 shows the upper most cell and upper mounting plate of the heat exchanger of Fig. 1; Fig. 12 depicts a portion of the lower mounting plate of the heat exchanger of Figs. 1 and 3; and Fig. 13 depicts a connection between two adjacent cells.
Detailed Description of the Preferred Embodiments A heat exchanger 100 according to a first embodiment is depicted in Figs. 1 and 2, and a heat exchanger 200 according to a second embodiment is depicted in Figs. 3 and 4. The two embodiments of the heat exchangers 100, 200 are both modular, and each include the same proximal module 102, and a plurality of intermediate modules 110. However, the distal module 104 of the first embodiment 100 provides a different liquid flow path relative to the distal module 105 of the second embodiment 200.
A single intermediate module 110 is depicted in isolation in Fig. 5. The term intermediate module 110 refers to any module of the heat exchanger 100, 200 which is not the first (proximal) 102 or last (distal) module 104, 105. The heat exchanger 100, 200 is used for liquid to gas heat exchange and has various industrial applications.
The heat exchanger 100 of the first embodiment will now be described. The heat exchanger 100 has a lower mounting plate 120 and an upper mounting plate 130. The mounting plates 120, 130 allow the heat exchanger 100 to be mounted and secured to a suitable frame or other such structure in a desired location. The heat exchanger 100 has a proximal module 102 located adjacent to the lower mounting plate 120, depicted in Fig. 8. In addition, the heat exchanger 100 includes a distal module 104 located adjacent to the upper mounting plate 130.
As shown in Fig. 1, and Fig. 5, each intermediate module 110 (located in a stacked arrangement between the proximal module 102 and the distal module 104) is formed with two primary liquid flow tubes 140, which are defined by a pair of generally parallel long tubes 140. Each intermediate module 110 also includes a pair of manifolds 144 which are defined by a pair of parallel, short tubes 144. The primary liquid flow tubes 140 and the manifolds 144 define a rectangular perimeter of the intermediate module 110. However, it will be appreciated that alternative geometric shaped modules 110 may be used, such as a square, polygonal, etc.
In the embodiment depicted in Fig. 5, the primary tubes 140 each have a generally circular cross section, and are connected to the manifolds 144 by welding, or another suitable fabrication process. As shown in Fig. 8, the primary liquid flow tubes 140 are not in fluid communication with each of the adjacent manifolds 144. This also applies to the proximal module 102, in that the primary liquid flow tubes 140 are not in fluid communication with each of the adjacent manifolds 144.
Each intermediate module 110 includes a plurality of smaller diameter secondary liquid flow tubes 150 which extend perpendicular to and generally between the manifolds 144. The secondary liquid flow tubes 150 intersect the manifolds 144 at approximately 90 degrees, and are in fluid communication with the manifolds 144. This permits the flow of liquid between the manifolds 144 which are parallel to each other, as best seen in Fig. 8.
The secondary liquid flow tubes 150 are each encased with a plurality of fins or another such thermally conductive material adapted to transfer thermal energy from a gas or vapour passing between the secondary liquid flow tubes 150 to or from a liquid circulating within the secondary liquid flow tubes 150.
As seen in Fig. 6, the primary flow tubes 140 and manifolds 144 of each module 110 each includes a circumferential fin or rib 160. The ribs 160 provide enhanced thermal dissipation/absorption on account of the increased surface area, and also act to prevent gas from unintentionally escaping laterally between the modules 110, as the preferred gas flow direction is generally vertical, between the secondary liquid flow tubes 150.
Each of the intermediate modules 110 is in fluid communication with the adjacent modules 110, and the fluid transfer may be facilitated by the connection shown in detail in Fig. 13. As shown in Fig. 13, each primary flow tubes 140 has one or more upwardly extending annular flanges 300, and one or more further downwardly extending annular flanges 302, adapted such that the two flanges of adjacent modules 110 engage with each other to define a male to female connection. Similarly, in each intermediate module 110, one of the manifolds 144 has an upwardly extending annular flange 312, and the opposing manifold 144 has a downwardly extending annular flange 314.
One or more O-rings 304 are included for hermetically sealing the flanges 300, 302. This provides a liquid tight seal which can be readily disassembled for maintenance or repair. Such an O-ring seal provides a suitable seal at temperatures up to around 230 degrees Celsius. However, different seal arrangements may be used depending on specific temperature and pressure conditions.
The heat exchanger 100 includes a plurality of tensioning bars 400, best seen in Figs. 10 and 12. The tensioning bars 400 provide a tension or clamping force to secure the modules 110 together. In the embodiment depicted in the drawings there are four tensioning bars 400, one located adjacent to each corner of the heat exchanger 100. However, the size and number of tensioning bars 400 may be altered to accommodate design parameters such as the internal pressure within the liquid flow tubes 140, 150 and the number of intermediate modules 110. As shown in the detail of Fig. 12, one or both ends of each tensioning bar 400 has a threaded portion 402. A nut 404 is seated on the threaded portion 402. The nut 404 abuts against a support 410 best seen in Fig. 12. There is a support 410 located at each of the lower mounting plate 120 and the upper mounting plate 130, and a nut 404 present at each of the supports 410. By adjusting the nuts 404, a user can vary the clamping force between the modules 110. The intermediate modules 110 can be fluidly connected to each other with any suitable connection such as a gasket connection, a threaded plumbing connection or another suitable hermetic system.
As shown in Fig. 1, in the heat exchanger 100 of the first embodiment, the lower mounting plate 120 is secured to the proximal module 102 which has two liquid inlet ports 180, and one liquid outlet port 190.
As seen in the partial cross-sectional view of Fig. 1, each of the inlet ports 180 is in fluid communication with one of the two primary liquid flow tubes 140. The two primary liquid flow tubes 140 of the proximal module 102 are connected to the two primary liquid flow tubes 140 of each adjacent intermediate module 110 at alternating ends of the module 110. This is shown by the schematic liquid flow 192 in Fig. 1. As the liquid flows from each long tube 140 to the adjacent long tube 140, it alternates direction in each adjacent tube from right to left and then from left to right, following a generally serpentine flow path.
Once the liquid has passed through each of the intermediate modules 110 it reaches the distal module 104 which is secured to the upper mounting plate 130. The distal module 104 is different to the intermediate modules 110 because in the distal module 104, the two primary liquid flow tubes 140 are in direct fluid communication with one of manifolds 144. The liquid is then directed from the manifold 144 into the secondary liquid flow tubes 150. The liquid passes through the network of interconnected manifolds 144 and secondary liquid flow tubes 150.
The liquid eventually returns to the proximal module 102. The flow through the manifolds and secondary liquid flow tubes 150 occurs in a similar manner to the flow described above, because the flow alternates directions between each adjacent module 110. In this embodiment, the liquid flow through the secondary flow tubes 150 and manifolds 144 s in a direction generally opposite to the gas/vapour flow 170, such that the heat exchanger 100 generally provides cross-flow exchange between the liquid and the gas.
The liquid is permitted to exit through the outlet port 190 and is recirculated through the system or otherwise recycled.
As depicted in Fig. 1, the outlet port 190 and the inlet ports 180 each have flangemounting plates 192 which permit the heat exchanger 100 to be coupled to the liquid circulation system.
Advantageously, in the heat exchanger 100 of the first embodiment each of the inlet ports 180 and the outlet ports 190 are located in the same plane and close to each other, which can assist to simplify connection to the pumping/circulation system.
The heat exchanger of the second embodiment 200 will now be described. The components of the heat exchanger 200 are generally the same as those described above. However, the portions which are different concern the distal module 105. The heat exchanger 200 of the second embodiment is depicted in Figs. 3 and 4, and is a true cross-flow heat exchanger, as the flow direction of the liquid in each of the primary liquid flow tubes 140 and the secondary liquid flow tubes 150 both oppose the flow direction of the gas 170.
As depicted in Fig. 3, two ports 210 located in the distal module 105 provide an input into the primary liquid flow tubes 140, and a single port 212 also located in the upper most module 110 provides an input into the network of manifolds 144 and secondary liquid flow tubes 150.
Also referring to Fig. 3, two outports 230 permit the liquid to exit from the primary liquid flow tubes 140, and exit port 232 permits the liquid to exit from the manifolds 144 and the secondary liquid flow tubes 150.
As such, the heat exchanger of the second embodiment 200 permits two or three fluids to be used if desired, as there is no mixing of flow among the network of primary liquid flow tubes 140, and the network of secondary liquid flow tubes 150 and manifolds 144.
In both the first and second embodiments, 100, 200, the liquid flowing in each of the primary liquid flow tubes 140 and the secondary liquid flow tubes 150 travel in a generally serpentine flow direction, providing enhanced thermal transfer. This is depicted in the fluid flow diagrams of Figs. 2 and 4.
As shown in Fig. 5 the ribs 160, assist to provide additionalsupport and structural integrity for the upwardly extending annular flanges 300.
Advantageously, the same intermediate modules 110 can be used for either of the heat exchanger of either the first embodiment 100 or the second embodiments 200.
Advantageously, the intermediate modules 110 can be readily separated from each other, permitting easy replacement of any damaged module 110, or inspection of a module 110, for example to assess the internal condition of the primary liquid flow tubes 140, manifolds 144 or secondary liquid flow tubes 150.
Advantageously, the number of intermediate modules 100 can be readily increased or decreased with a minimal amount of additional labour. This can be done to accommodate performance changes in the system over time or during different seasons for example.
The space around the sides of the heat exchanger of the first embodiment 100, or the second embodiment 200 may be insulated. This assists to ensure that the thermal energy contained by the liquid is used efficiently during heat exchange with the gas 170, rather than leaking from the system.
Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the alt that the invention may be embodied in many other forms.

Claims (12)

The claims defining the invention are as follows:
1. A heat exchanger comprising: a proximal module having a first set of primary flow tubes and a fluidly independent first set of secondary flow tubes; a distal module having a second set of primary flow tubes and a second set of secondary flow tubes; and at least one intermediate module located between the proximal module and the distal module, the intermediate module being adapted to: fluidly connect the first set of primary flow tubes and the second set of primary flow tubes; and fluidly connect the first set of secondary flow tubes and the second set of secondary flow tubes.
2. The heat exchanger of claim 1, wherein the proximal module includes an inlet port in fluid communication with the first set of primary flow tubes and an outlet port in fluid communication with the first set of secondary flow tubes.
3. The heat exchanger of claim 1, wherein the proximal module includes a first outlet port in fluid communication with the first set of primary flow tubes and a second outlet port in fluid communication with the first set of secondary flow tubes; further wherein the distal module includes a first inlet port in fluid communication with the second set of primary flow tubes and a second inlet port in fluid communication with the second set of secondary flow tubes.
4. The heat exchanger of any one of the preceding claims, wherein the intermediate module includes a pair of generally parallel primary flow tubes, and a pair of generally parallel manifolds which together define a generally rectangular perimeter of the intermediate module.
5. The heat exchanger of claim 4, wherein the pair of primary flow tubes and the pair of generally parallel manifolds are fluidly isolated relative to each other.
6. The heat exchanger of claim 5, wherein a plurality of secondary flow tubes extend between and are generally perpendicular to and in fluid communication with the pair of generally parallel manifolds.
7. The heat exchanger of claim 6, wherein a first one of the pair of generally parallel manifolds has a first manifold inlet/outlet port, and a second one of the pair of generally parallel manifolds has a second manifold inlet/outlet port.
8. The heat exchanger of claim 7, wherein the first manifold inlet/outlet port is located on a side of the intermediate module which is closest to the proximal module, and the second manifold inlet/outlet port is located on a side of the intermediate module which is closest to the distal module.
9. The heat exchanger of claim 8, wherein the first manifold inlet/outlet port is a different size relative to the second manifold inlet/outlet port such that adjacent modules are adapted to engage each other by a male to female connection.
10. The heat exchanger of any one of the preceding claims, wherein the proximal module is mounted to a lower mounting plate and the distal module is mounted to an upper mounting plate, further wherein a plurality of adjustable tensioning bars extend between the lower mounting plate and the upper mounting plate.
11. The heat exchanger of any one of the preceding claims, wherein the secondary flow tubes are sheathed within a plurality of fins or another thermally conductive structure.
12. The heat exchanger of any one of claims 4 to 9, wherein the intermediate module includes a rib extending generally around the rectangular perimeter, the rib being adapted to be located between adjacent intermediate modules when two or more intermediate modules are interconnected and adjacent to each other.
Rade Brcerevic By Patent Attorneys for the Applicant
PnCOTTERS Patent &Trade Mark Attorneys
AU2015207872A 2014-08-14 2015-07-29 Heat exchanger Expired - Fee Related AU2015207872B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2015207872A AU2015207872B2 (en) 2014-08-14 2015-07-29 Heat exchanger

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
AU2014903176A AU2014903176A0 (en) 2014-08-14 Heat exchanger
AU2014903176 2014-08-14
AU2015207872A AU2015207872B2 (en) 2014-08-14 2015-07-29 Heat exchanger

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AU2015207872A1 AU2015207872A1 (en) 2016-03-03
AU2015207872B2 true AU2015207872B2 (en) 2020-06-18

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3153446A (en) * 1960-08-12 1964-10-20 United Aircraft Corp Heat exchanger
US20050006064A1 (en) * 1999-02-19 2005-01-13 Iowa State University Research Foundation, Inc. Method and means for miniaturization of binary-fluid heat and mass exchangers
US20080110604A1 (en) * 2006-11-10 2008-05-15 Rolf Konrad Janssen Heat exchanger
US20080219086A1 (en) * 2007-03-09 2008-09-11 Peter Mathys Apparatus for the heat-exchanging and mixing treatment of fluid media

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3153446A (en) * 1960-08-12 1964-10-20 United Aircraft Corp Heat exchanger
US20050006064A1 (en) * 1999-02-19 2005-01-13 Iowa State University Research Foundation, Inc. Method and means for miniaturization of binary-fluid heat and mass exchangers
US20080110604A1 (en) * 2006-11-10 2008-05-15 Rolf Konrad Janssen Heat exchanger
US20080219086A1 (en) * 2007-03-09 2008-09-11 Peter Mathys Apparatus for the heat-exchanging and mixing treatment of fluid media

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