Heat Exchanger
A device for exchanging heat between first and second fluid streams is disclosed. The device includes a core housing configured to channel the first stream through heat exchange elements and out through a first half exhaust port. A shell housing encloses the core housing and is configured to channel the second stream past the heat exchange elements, the shell housing being isolated from the core housing by a space. A second half exhaust port is formed on the shell adjacent with the first half exhaust port, the first and second half exhaust ports being separated by a gap. An expansion joint couples the core housing to the shell housing, the expansion joint configured such that the expansion joint allows the core housing to float within the shell. The expansion joint includes a flexible ring flange having an inner edge mounted to the core housing adjacent the first half exhaust port and a peripheral edge mounted to the shell housing at a circular attachment point surrounding the second half exhaust port.
This application is a continuation-in-part of U.S. application Ser. No. 13/644,037 filed Oct. 3, 2012, which is incorporated herein by reference
FIELD OF THE INVENTIONThe invention relates generally to a heat exchanger for exchanging heat between a cooler fluid and a hotter fluid, and in particular for exchanging heat between two separate streams of gas.
BACKGROUND OF THE INVENTIONHeat exchangers are often used in industrial applications to transfer heat from one gas or liquid to another. One type of heat exchanger uses a plurality of tubes to carry one of the fluids. The tubes are usually arranged in a circular fashion around a central opening, as seen in U.S. Pat. no. 5,355,945 to Sanz et al. The parallel tubes are generally mounted to headers at their ends and can be held in a substantially vertical orientation. The other gas is then passed over and between the tubes in a current or counter current arrangement to effect the transfer of heat from the hotter gas (or fluid) to the cooler gas (or fluid). One stream of gas (or fluid) enters the heat exchanger through an intake port which then passes the gas through the heat exchange tubes and then out of an exhaust. The other stream of gas (or fluid) enters the heat exchanger through another intake port, then passes over and between the heat exchange tubes and then out another exhaust port. Heat is exchanged between the two fluids through the walls of the heat exchange tubes as the two currents pass each other in opposite directions.
While this sort of heat exchanger is heat transfer wise effective, it suffers from a series of drawbacks, such as complexity of design, difficulty in assembling, bulkiness and the need to periodically repair leaks in the heat exchange mechanism, particularly where the heat exchange tubes are secured to their headers. One factor necessitating the large bulk associated with heat exchangers is the cyclical heating and cooling of portions of the heat exchanger. During the operation of the heat exchanger, heat from the fluids passing through the heat exchanger tends to cause the heat exchange tubes and the housings enclosing the heat exchange tubes to expand. When the heat exchanger cools down when the flow of hot fluid is stopped, the tubes and housings contract. This constant expanding and contracting generally requires the housings to be built large enough to absorb the expansions and contractions without causing faults in the system. As a result, heat exchangers tend to be large and bulky.
In order to control the temperature exciting the heat exchanger, external piping is generally provided so that a portion of one of the gas (fluid) streams can be shunted directly towards the exhaust port without going through or between the heat exchange tubes. The piping required for the shunting adds to the overall size and bulk of the heat exchanger.
One factor contributing to the complexity and cost of building shell and tube heat exchangers is the necessity of mounting a series of baffles around the heat exchange tubes. These baffles generally take the form of annular metal members which surround the bundle of heat exchange tubes and extend between the tubes and the outer housing. Mounting these baffles often involves many steps, which in turn increases the overall cost of the heat exchanger.
Another factor contributing to the maintenance requirements of the heat exchanger is the failure of the joints holding the ends of the heat exchange tube to their respective headers. As a result of the joints being repeatedly heated and cooled by exposure to the hotter and cooler gases and in conjunction with the thermal stresses in the heat exchanger, the welded or rolled in joints are prone to failure from cracking This in turn requires periodic inspection and occasional repair. Another factor contributing to the maintenance requirements and limiting the service life of these heat exchangers is the failure of tubes at a result of fluid impingement causing erosion and tube vibration failures at the proximity of the shell ports of the vessels.
All of the above limitations add to the expense and inconvenience of utilizing these types of heat exchanges. An improved heat exchanger design which overcomes these limitations is therefore required.
SUMMARY OF THE INVENTIONIn accordance with an aspect of the present invention, there is provided a heat exchanger for exchanging heat between a first and second fluid streams. The device includes a core housing configured to channel the first stream through heat exchange elements and out through an exhaust port formed as a first and second half exhaust ports. A shell housing encloses the core housing and is configured to channel the second stream around the heat exchange elements, the shell housing being isolated from the core housing by a space. The first half exhaust port is formed on the core housing while the second half exhaust port is formed on the shell housing adjacent to the first half exhaust port, the first and second halves exhaust ports being separated by a gap. A circular expansion joint bridges the gap between the first and second half exhaust ports. The inner circumferential edge of the expansion joint attaches around the first half exhaust port while the outer edge is attached to the shell housing surrounding the second half exhaust port. The flexibility of the joint derived from its circular corrugations and elbows permits the core housing to float within the shell housing.
In the drawings like characters of reference indicate corresponding parts in the different figures.
DETAILED DESCRIPTION OF THE INVENTIONReferring to
Referring now to
Gap (space) 40 is bridged by ring flange (expansion joint) 18. The inner circumferential edge 38 of ring flange 18 attaches around half port 34 on core housing portion 22 while the outer circumferential edge 36 is attached at circular contact point 30 of shell housing portion 42 surrounding half port 29. Ring flange 18 has corrugations and elbows ribs between its circumferential edges 34 and 36 and is adequately flexible to permit the core housing to float within the shell housing. Item 44 is the joint assembly internal liner.
The above described expansion joint permits that the heat exchanger outer diameter be made smaller and less bulky because there is no need for a greater diameter shell to absorb thermal expansion/contraction. Instead, the flexibility of flange 18 of the joint absorbs the thermal expansion/contraction of the shell and core housings. Essentially, the core housing via flange 18 floats within the isolated shell. Flange 18 is preferably designed according to the pressure differential between the two fluid streams rather than the usual higher pressure code requirements. This allows flange 18 to be thinner and more flexible because it only has to compensate for the pressure difference between the two fluid streams.
Referring now to
A specific embodiment of the present invention has been disclosed; however, several variations of the disclosed embodiment could be envisioned as within the scope of this invention.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
Claims
1. A heat exchanger for exchanging heat between a first stream of fluid and a second stream of fluid, the two fluids being at different temperature, the heat exchanger comprising:
- a core housing configured to channel the first stream through heat exchange elements and out through a first half exhaust port, this first half exhaust port being mounted on the core housing;
- a second half port to complete the exhaust of the first stream;
- the first half exhaust port being separated from the second half exhaust port by a gap;
- an expansion joint bridging the above gap and coupling the core housing to the shell housing;
- an inner edge of the expansion joint mounted to the first half port mounted on the core housing;
- an outer edge of the expansion joint mounted to the shell housing at a circular point surrounding the second half exhaust port;
- the expansion joint comprising a flange with circular corrugations and elbow ribs for flexibility;
- the flexibility of the joint allowing the core housing to float within the shell.
2. A heat exchanger for exchanging heat between a first stream of fluid and a second stream of fluid, the two fluid streams being at different temperatures, the heat exchanger comprising:
- a core housing configured to channel the first stream through heat exchange elements and out through a first exhaust port;
- a shell enclosing the core housing and configured to channel the second stream past the heat exchange elements, the shell housing being isolated from the core housing by a space;
- a second exhaust port formed on the shell adjacent to and coaxially aligned with the first exhaust port, the first and second exhaust ports being separated by a gap;
- an expansion joint coupling the core housing to the shell housing, the expansion joint configured such that the expansion joint allows the core housing to float within the shell, the expansion joint comprising a corrugated ring flange having an inner edge mounted to the core housing adjacent the first exhaust port and a peripheral edge mounted to the shell housing at a circular attachment point surrounding the second exhaust port.
3. The heat exchanger of claim 1 wherein the shell housing has opposite first and second ends and a central axis, the secondary port being formed on the first end of the shell housing, a peripheral port formed on the shell housing adjacent the second end of the shell housing, the shell housing configured to pass the second fluid stream through the peripheral port, the shell having a first cylindrical portion extending from the first end of the shell housing to a second portion of the shell housing surrounding the peripheral port where the shell housing bulges asymmetrically away from the central axis.
4. The heat exchanger defined in claim 1 wherein the expansion joint has a thickness, the thickness of the expansion joint being selected to compensate for the relative movement between the core and shell housing as a result of a difference in pressure between the first and second fluid streams.
Type: Application
Filed: Nov 8, 2012
Publication Date: May 8, 2014
Inventor: Delio Sanz (Aurora)
Application Number: 13/671,916
International Classification: F28D 1/00 (20060101);