SYSTEM AND METHOD FOR CRYOGENIC CONDENSING
A method and apparatus for condensing vapor in a gas. A cryogen, such as liquid nitrogen, may be provided into first and second coil sets in a condenser housing to cool the condensable vapor in the housing to condense the vapor into a liquid or solid form. The flow of cryogen in the first and second coil sets may be independently controlled, coils in the first and/or second coil sets may have a substantially equal length, and/or coils in the first and/or second coil sets may have uppermost portions that are located at a substantially equal height.
This application claims priority to U.S. provisional application Ser. Nos. 61/498,869 filed Jun. 20, 2011, the disclosure of which are incorporated by reference herein.
FIELD OF THE INVENTIONThe present invention relates to methods and systems for removing a condensable vapor, such as water vapor, from a gas, and more particularly, to a cryogenic condenser.
BACKGROUNDCryogenic condenser systems for removing condensable vapor from a gas such as those describes in U.S. Pat. No. 6,505,472 are generally known in the art. In some applications, particularly freeze-drying applications that use alcohol base formulations, very low condensation temperatures are required (i.e. colder than −100 C and lower than the freezing point of most heat transfer fluids).
Freeze drying is a sublimation process that removes water from a product in the form of ice. Freeze drying is especially useful in the pharmaceutical industry to remove water from biological products because it preserves the integrity of the biological products. In freeze drying, the water-containing or alcohol containing product is frozen and, under vacuum with the partial pressure of water vapor reduced below the triple point of water, the frozen water sublimes and the sublimated ice is removed from the dryer.
Accordingly, what is needed is an improved cryogenic condensing system and method for effectively removing a condensable vapor, such as water vapor, from a gas stream and which can operate efficiently and effectively at very low or cryogenic temperatures often seen during freeze drying cycles. Ideally, the cryogenic condensing system should be able to handle large thermal cycling in a freeze drying process without stress cracking caused by thermal expansion and contraction.
SUMMARY OF INVENTIONAspects of the invention relate to systems and methods for condensing or otherwise removing a condensable vapor from a gas stream, such as a gas stream used to effect a freeze drying process. In one embodiment, a gas stream, such as a nitrogen gas stream containing condensable water vapor, is provided to a cryogenic condenser that includes two or more coils that carry a cryogen, such as liquid nitrogen or other similar material. By passing the gas stream across/near the coils, the coils may remove heat from the gas stream, causing the condensable vapor in the gas stream to condense into liquid and/or solid form. Thereafter, the condensed vapor may be removed from the condenser, and the gas, now having a reduced amount of condensable vapor, exhausted.
In one embodiment, the two or more coils of the condenser may have a substantially equal length from an inlet to an outlet. This feature may permit the coils to operate in removing condensable vapor in a more uniform way, e.g., the coils may operate at the same or similar rate in generating condensate, may carry similar amounts of cryogen, and/or have other similar operating characteristics that allow the condenser to operate more efficiently.
In another embodiment, the coils may have uppermost portions that are located at a substantially equal height relative to each other. This arrangement may allow the coils to experience a same fluid pressure of cryogen carried in the coils, e.g., due to the force of gravity, in the coils, and thus the coils may have the same or similar cryogen flow rates. This may help the coils to operate in the same, or substantially the same, way with respect to condensate production.
In yet another embodiment, the cryogen flow in the coils may be independently controllable. Such an arrangement may permit the condenser to continue operation even if one coil fails or otherwise stops proper operation. For example, if a first coil begins to leak cryogen, the first coil may be shut down (such as by stopping cryogen supplied to the coil) while a second coil continues to operate.
In one embodiment, a cryogenic condenser includes a housing defining an interior space with a gas inlet for introducing gas with a condensable vapor into the interior space and a gas outlet for exhausting gas. First and second coil sets may be located in the interior space, with each of the coil sets including at least one coil having an inlet and an outlet and arranged to conduct a cryogen from the inlet to the outlet. The coils may therefore be arranged to cool the condensable vapor in the interior space to condense the vapor into a liquid or solid form. A cryogen supply including at least one valve may be arranged to independently control flow of cryogen in each of the coils and/or coil sets. Coils of the first and second sets, or coils within at least one of the sets, may have a substantially equal length from the inlet to the outlet, and/or may have uppermost portions that are located at a substantially equal height relative to each other.
In one embodiment, the condenser housing may define a cylindrical space having a top and a bottom, and a first of the coil sets may be located above a second of the coil sets in the interior space. Alternately, the coils may be nested or be arranged side-by-side. The housing may have the gas inlet arranged at a side of the cylindrical space and the gas outlet arranged at the top of the cylindrical space. An inlet baffle may be arranged at the gas inlet to direct gas toward the bottom of the cylindrical shape, and/or other baffles may be provided, e.g., at the top or bottom of the cylindrical space, to direct gas flow in the interior space in a vertical direction.
In one embodiment, each of the coil sets includes at least four coils that have a substantially equal length and that are arranged in a nested form. The coils of each set may be provided with cryogen from a common conduit. Cryogen exhausted from the outlets of the coils may be removed from the condenser via a common cryogen outlet.
In another aspect of the invention, a method for removing condensate from a gas stream includes providing a gas with a condensable vapor into a condenser housing, providing a liquid cryogen into first and second coil sets in the condenser housing to cool the condensable vapor in the interior space to condense the vapor into a liquid or solid form in the condenser housing, and independently controlling a flow of liquid cryogen in the first and second coil sets. Independent control of flow of cryogen for the coil sets may be performed by operating at least one valve for a first cryogen supply for the first coil set independently of operation at least one valve for a second cryogen supply for the second coil set. The first and second coil sets may each include first and second coils, each having an inlet and an outlet and arranged to conduct a cryogen from the inlet to the outlet. The first and second coils may be nested with the second coil being at least partially surrounded by the first coil, and the first and second coils each having a substantially equal length and/or an uppermost portion that are located at a substantially equal height. Each of the first and second coil sets may include at least a third coil that is nested with the first and second coils, with the third coil having a substantially equal length as the first and second coils and/or an uppermost portion that is located at a substantially equal height at the uppermost portions of the first and second coils. Liquid cryogen may be provided to the first, second and third coils of each coil set with liquid cryogen from a common conduit, and the first coil set may be positioned above the second coil set.
The above and other aspects, features, and advantages of the present invention will be more apparent from the following, more detailed description thereof, presented in conjunction with the following drawings, wherein:
It should be understood that illustrative embodiments are described in accordance with aspects of the invention. However, the embodiments described are not necessarily intended to show or incorporate all aspects of the invention, but rather are used to describe a few illustrative embodiments. Thus, aspects discussed herein are not intended to be construed narrowly in view of the illustrative embodiments. In addition, it should be understood that aspects of the invention described may be used alone or in any suitable combination with other aspects also described.
The condenser 1 includes first and second coil sets 13a, 13b (which may each include one or more coils) in the interior space of the housing that are arranged to cool the condensable vapor so as to condense the vapor into a liquid or solid form, e.g., for removal from the gas provided at the gas inlet 11. For example, in some applications, it may be desired to remove water vapor from a gas stream (e.g., including mostly air or nitrogen gas). The coils sets 13a, 13b may be arranged to cool the water vapor so as to cause the water vapor to condense into liquid or solid water (e.g., water droplets or ice). Once condensed into liquid and/or solid form, the water may be removed, e.g., via a condensate outlet 14 (e.g., a pipe or opening in the housing 10) located at a bottom of housing 10. If the condensable vapor is condensed into solid form, the ice or other solid may be removed from housing 10 in any suitable way, such as by scraping coils sets 13 to remove the solid, which is then removed by a conveyor belt, falling through a condensate outlet 14 opening in housing 10. Alternately, coil sets 13 may be heated (or the solid ice otherwise heated) to change the condensate to a liquid form or otherwise cause the solid to be removed from coil sets 13, which may then fall from coils sets 13 for removal.
In accordance with one aspect of the invention, one or more coils in the coil sets may have a length from an inlet to an outlet that is the same or substantially the same. That is, a length of a coil in the first coil set 13a may be equal or substantially equal to a length of a coil in the second coil set 13b, and/or a length of a coil in the first coil set 13a may be equal or substantially equal to a length of another coil in the first coil set 13a. In this context, the length of a coil from the inlet to the outlet is the length of a region of the coil between the inlet and the outlet where the coil functions to remove heat from gas in the housing 10 to help cause condensation of the condensable vapor. By having the length of the coils be the same or substantially the same, the coils may remove heat from the interior space at a same or similar rate, may produce condensate at a same or similar rate, may carry a same or similar amount of cryogen or other cooling substance, and/or have other similar operating characteristics. Having the coils (or at least some coils) in the housing 10 operate with the same or similar condensate forming characteristics, the condenser 1 may operate more efficiently and/or effectively. For example, equal length coils may carry a same volume and/or flow rate of cryogen, and thus share the same or similar cooling rate, condensate generation or other characteristics, helping to avoid one coil being colder or warmer (on average) than another. Avoiding such an imbalance may help avoid excessive ice production on one coil versus another, and/or undesirably low condensate production by one coil versus another.
Accordingly, in one aspect of the invention, one coil set, such as the first coil set 13a, may include two or more coils that have a same or substantially the same length from inlet to outlet as each other. In another embodiment, one or more coils in one coil set (such as the first coil set 13a) may have the same or substantially the same length as one or more coils in the other coil set (such as the second coil set 13b). The coils may be stacked one on the other, e.g., as shown for the coil sets 13a, 13b in
In another aspect of the invention, the cryogen supply for the coil sets in a condenser may be individually controlled. Such an arrangement may permit the condenser to continue operation, albeit at a potentially lower output (e.g., a lower condensate output), if one of the coil sets fails or otherwise stops proper operation. For example, if the first coil set 13a in the
Another aspect of the invention shown in
To help illustrate the coil arrangement in the coil sets 13,
As can also be generally seen in
The coils of the coil sets, the cryogen supply conduits, supply and exhaust manifolds and cryogen outlet may be made of any suitable material, such as a stainless steel tubing or other suitable material, e.g., that can withstand temperature gradients to be experienced using a liquid cryogen in the coils and a potentially significantly warmer gas environment around the coils. Similarly, other components of the condenser 1 may be made of stainless steel or other suitable material, e.g., to withstand the expected temperature variations, potentially corrosive environments (such as for use with a volatile vapor condensate that is highly corrosive to metals or other materials), and other operating conditions. Although the coils in the embodiments described above have a helical shape with generally circularly shaped loops, other arrangements are possible. For example, the coils could have a helical configuration with loops having a square, rectangular, elliptical, triangular or other suitable shape, the coils could have a flat, spiral shape (e.g., where each coil is generally located in a single plane), a serpentine shape, or other suitable configurations. The cryogen may be a liquid material, such as a liquid nitrogen, liquid carbon dioxide, liquid argon, liquid oxygen, liquid helium, liquid air or other suitable material, or may be a higher temperature liquid, gas or mixture of liquid and gas. Flow of cryogen in the coils may be controlled in any suitable way, and using any suitable control parameters. For example, the condenser 1 may include one or more sensors to detect temperature, gas flow rates, condensate production rates, condensable vapor concentration in the inlet gas, cryogen flow rates, cryogen supply and/or outlet temperatures, and/or other parameters at one or more locations. A controller (e.g., including a suitably programmed general purpose computer with suitable software or other operating instructions or other suitable electronic circuitry, one or more memories (including non-transient storage media that may store software and/or other operating instructions), valves, pumps, temperature sensors, pressure sensors, input/output interfaces (such as a visible display, keyboard, mouse or other pointing device, printer, speaker, etc.), communication buses or other links, switches, relays, triacs, or other components necessary to perform desired input/output or other functions) may use the condenser parameter information (which may include user input information) to control one or more aspects of the condenser operation, such as gas inlet flow rate, cryogen flow rate to one or more coils, condensate removal (e.g., operate a scraper to remove ice from one or more coils based on detected conditions), and so on.
Having thus described several aspects of at least one embodiment of this invention, it is to be appreciated various alterations, modifications, and improvements will readily occur to those skilled in the art. Such alterations, modifications, and improvements are intended to be part of this disclosure, and are intended to be within the spirit and scope of the invention. Accordingly, the foregoing description and drawings are by way of example only. It will be apparent that other embodiments and various modifications may be made to the present invention without departing from the scope thereof. The foregoing description of the invention is intended merely to be illustrative and not restrictive thereof. The scope of the present invention is defined by the appended claims and equivalents thereto.
Claims
1. A cryogenic condenser, comprising:
- a housing defining an interior space, the housing having a gas inlet for introducing gas with a condensable vapor and a gas outlet for exhausting gas;
- first and second coil sets, each coil set including at least one coil located in the interior space, each of the coils having an inlet and an outlet and arranged to conduct a cryogen from the inlet to the outlet, the coils being arranged to cool the condensable vapor in the interior space to condense the vapor into a liquid or solid form; and
- a cryogen supply including at least one valve and arranged to independently control flow of cryogen in at least two of the coils.
2. The condenser of claim 1, wherein the housing defines a cylindrical space having a top and a bottom, and first coil set is located above the second coil set.
3. The condenser of claim 1, wherein the housing has a cylindrical shape having a top and a bottom, and the gas inlet is arranged at a side of the cylindrical shape and the gas outlet is arranged at the top of the cylindrical shape.
4. The condenser of claim 3, comprising an inlet baffle arranged at the gas inlet to direct gas toward the bottom of the cylindrical shape.
5. The condenser of claim 4, further comprising at least one baffle at the top or bottom of the cylindrical shape to direct gas flow in the interior space in a vertical direction.
6. The condenser of claim 4, wherein the inlet baffle is positioned between the gas inlet and the coils.
7. The condenser of claim 4, further comprising a bottom baffle at the bottom of the cylindrical shape that inhibits gas flow in a horizontal direction, and at least one top baffle at the top of the cylindrical shape that inhibits gas flow in a horizontal direction.
8. The condenser of claim 1, wherein the coils in the first and second coil sets have a substantially equal length.
9. The condenser of claim 1, wherein each of the coil sets includes at least two coils that have a substantially equal length.
10. The condenser of claim 9, wherein the coils in each coil set have a common inlet conduit and a common outlet conduit.
11. The condenser of claim 9, wherein the coils in each coil set are nested.
12. A cryogenic condenser, comprising:
- a housing defining an interior space, the housing having a gas inlet for introducing gas with a condensable vapor and a gas outlet for exhausting gas;
- first and second coils, each coil being located in the interior space, having an inlet and an outlet and arranged to conduct a cryogen from the inlet to the outlet, and having a substantially equal length from the inlet to the outlet, the coils being arranged to cool the condensable vapor in the interior space to condense the vapor into a liquid or solid form; and
- a cryogen supply arranged to provide cryogen to the inlet of each of the coils.
13. The condenser of claim 12, wherein the first and second coils are part of a first coil set that further includes at least a third coil, the third coil having a length from an inlet to an outlet that is substantially equal to the length of the first and second coils.
14. The condenser of claim 12, wherein the first and second coils are part of a first coil set, the condenser further comprising a second coil set that includes third and fourth coils that have a substantially equal length.
15. A method for removing a condensable vapor from a gas stream, comprising:
- providing a gas with a condensable vapor into a condenser housing;
- providing a liquid cryogen into first and second coil sets in the condenser housing to cool the condensable vapor in the interior space to condense the vapor into a liquid or solid form in the condenser housing; and
- independently controlling a flow of liquid cryogen in the first and second coil sets.
16. The method of claim 15, wherein the step of independently controlling comprises operating at least one valve for a first cryogen supply for the first coil set independently of operation of at least one valve for a second cryogen supply for the second coil set.
17. The method of claim 15, wherein the first and second coil sets each include:
- first and second coils, each having an inlet and an outlet and arranged to conduct a cryogen from the inlet to the outlet, the first and second coils being nested with the second coil being at least partially surrounded by the first coil, and the first and second coils each having an uppermost portion that are located at a substantially equal height.
18. The method of claim 17, wherein the first and second coil sets each include at least a third coil that is nested with the first and second coils, the third coil having an uppermost portion that is located at a substantially equal height at the uppermost portions of the first and second coils.
19. The method of claim 15, wherein first coil set is positioned above second coil set.
Type: Application
Filed: Jun 19, 2012
Publication Date: Dec 20, 2012
Inventor: Alan T. Cheng (Naperville, IL)
Application Number: 13/526,614
International Classification: F25J 1/02 (20060101);