Patent Grant
11867427
This application relates to a compact fluid heating system with enhanced heat exchanger bulk heat flux.
Fluid heating systems are used to provide a heated production fluid for a variety of commercial, industrial, and domestic applications such as hydronic, steam, and thermal fluid boilers, for example. Because of the desire for improved energy efficiency, compactness, reliability, and cost reduction, there remains a need for an improved fluid heating system, as well as improved methods of manufacture thereof.
Provided is a fluid heating system including: a pressure vessel including a first inlet and first outlet and an inside and an outside; an assembly including: a heat exchanger core including a second inlet and a second outlet, and an inner surface and an outer surface, wherein the heat exchanger core is inside the pressure vessel; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; and a blower in fluid connection with the first conduit, the blower configured for forcing a gas under pressure through the assembly; wherein the heat exchanger core further includes a flow passage between the second inlet and the second outlet, wherein the flow passage is configured to contain a thermal transfer fluid; wherein the fluid heating system satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 45 kW/m2 and 300 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heating Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the BTS-2000 Testing Standard, Method to Determine Efficiency of Commercial Heating Boilers, published by The Hydronics Institute Division of AHRI, Second Edition, Rev. 06.07, Copyright 2007 (herein referred to as “AHRI BTS-2000”), and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 3 kiloPascals and 30 kiloPascals.
Also provided is method of heat transfer, the method including: providing a fluid heating system including a pressure vessel comprising an inside and an outside and a first inlet and a first outlet; a heat exchanger core comprising a second inlet and a second outlet, wherein the heat exchanger core is inside the pressure vessel; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a blower disposed in the first conduit; and disposing a thermal transfer fluid in the heat exchanger core and a production fluid between the inside of the pressure vessel and the heat exchanger core to transfer heat from the thermal transfer fluid to the production fluid wherein the fluid heating system has a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit between 45 kW/m2 and 300 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heated Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 3 kiloPascals and 30 kiloPascals.
A method of manufacturing a fluid heating system, the method including: providing a pressure vessel including a first inlet and a first outlet and an inside and an outside; disposing a heat exchanger core entirely in the pressure vessel, the heat exchanger core including a second inlet and a second outlet; connecting the second inlet of the heat exchanger core to a first conduit, which extends outside the pressure vessel; and connecting the second outlet of the heat exchanger core to a second conduit, which extends outside the pressure vessel is provided.
A fluid heating system including: a pressure vessel including a first inlet and first outlet and an inside and an outside, wherein the pressure vessel is configured to contain a production fluid including liquid water, steam, a C1 to C10 hydrocarbon, a thermal fluid, a thermal oil, a glycol, air, carbon dioxide, carbon monoxide, or a combination thereof; a tube heat exchanger core including a first tube sheet, a second tube sheet, a plurality of heat exchanger tubes, each heat exchanger tube independently connecting the first tube sheet and the second tube sheet, a second inlet disposed on the first tube sheet, a second outlet disposed on the second tube sheet, wherein the first inlet and second outlet define a flow passage, and wherein the tube heat exchanger core is configured to contain a gas phase thermal transfer fluid in the flow passage of the heat exchanger core, wherein the thermal transfer fluid comprises water, a substituted or unsubstituted C1 to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, combustion byproducts, a thermal fluid, a thermal oil, a glycol or a combination thereof; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; and a blower for forcing the thermal transfer fluid under pressure through an assembly including the first conduit, the heat exchanger and the second conduit wherein the blower is in fluid communication with the first conduit, the first conduit further comprises a burner assembly and a furnace assembly disposed in the first conduit; wherein the fluid heating system satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 47 kW/m2 and 120 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heating Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between than 3 kiloPascals and 12 kiloPascals is provided.
A fluid heating system including: a pressure vessel including a first inlet and first outlet and an inside and an outside, wherein the pressure vessel is configured to contain a production fluid including liquid water, steam, a C1 to C10 hydrocarbon, a thermal fluid, a thermal oil, a glycol, air, carbon dioxide, carbon monoxide, or a combination thereof; a tubeless heat exchanger core including a top head, a bottom head, an inner casing disposed between the top head and the bottom head, the inner casing including an inner surface, an outer casing disposed between the top head and the bottom head and opposite the inner surface of the inner casing, a first inlet and a second inlet on the inner casing, the outer casing, or a combination thereof, and a first outlet and a second outlet on the inner casing, the outer casing, or combination thereof, wherein at least one of the inner casing and the outer casing comprises a rib, a ridge, a spine or a combination thereof, wherein the inner casing and the outer casing define a flow passage between the inlet and the outlet of the tubeless heat exchanger core, and wherein the flow passage is configured to contain a gas phase thermal transfer fluid in the flow passage of the heat exchanger core, wherein the thermal transfer fluid comprises water, a substituted or unsubstituted C1 to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, combustion byproducts, a thermal fluid, a thermal oil, a glycol or a combination thereof; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; and a blower for forcing the gas phase thermal transfer fluid under pressure through the first conduit, the heat exchanger and the second conduit wherein the blower is in fluid communication with the first conduit the first conduit further comprises a burner assembly disposed in the first conduit and the first conduit further comprises a furnace assembly disposed in the first conduit; wherein the fluid heating system satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 47 kW/m2 and 120 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heating Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 3 kiloPascals and 12 kiloPascals is provided.
The above and other advantages and features of this disclosure will become more apparent by describing in further detail exemplary embodiments thereof with reference to the accompanying drawings where like numbers indicate like elements:
Fluid heating systems are desirably thermally compact, provide a high ratio between the thermal output and the total size of the fluid heating system, and have a design which can be manufactured at a reasonable cost. This is particularly true of hydronic (e.g., liquid water), steam, and thermal fluid heating systems designed to deliver a heated production fluid, such as steam, for temperature regulation, domestic hot water, or commercial or industrial process applications. In a fluid heating system, a thermal transfer fluid comprising, e.g., a hot combustion gas, is generated by combustion of a fuel, and then the heat is transferred from the thermal transfer fluid to the production fluid using a heat exchanger.
The inventors hereof have developed a high pressure boiler system that increases the heat transfer coefficient by raising the airspeed through the heat exchanger and decreases the width of the turbulent boundary layer. This allows the heat exchanger to have less heat transfer surface area. The disclosed configuration provides unexpectedly improved efficiency and compactness compared with conventional approaches.
Shown in
Thermal heat energy is transferred from the gas flowing through the gas path assembly comprising the first conduit 102, heat exchanger 104 and second conduit 106 to the production fluid flowing through the pressure vessel 124, across the Heating Surfaces. Heating Surfaces are those surfaces that have one face in contact with the thermal transfer fluid and another face in contact with the production fluid where augmented surfaces (e.g., fins) on the thermal transfer fluid side are included. Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid. For example, in the embodiment shown in
The components comprising the thermal fluid flow path, including the heat exchanger, and the production fluid flow path, including the pressure vessel, can each independently comprise any suitable material, and can be a metal such as iron, aluminum, magnesium, titanium, nickel, cobalt, zinc, silver, copper, or an alloy comprising at least one of the foregoing. Representative metals include carbon steel, mild steel, cast iron, wrought iron, stainless steel (e.g., 304, 316, or 439 stainless steel), Monel, Inconel, bronze, and brass. Specifically provided is an embodiment in which the heat exchanger core, the pressure vessel, and the components comprising the gas flow path are mild or stainless steel.
Although Applicants do not intend to be bound by any theory presented here, it is believed thermal heat energy is transferred from the thermal transfer fluid to the production fluid across the Heating Surfaces by three heat transfer mechanisms: conduction, convection, and radiation. While the rate of heat transfer across the Heating Surfaces by conduction and radiation are inherently limited by both the properties of the construction materials and the chosen fuel, the rate of convective heat transfer to the production fluid across the Heating Surfaces is significantly affected by the flow characteristics of the gaseous thermal transfer fluid traversing the gas path from the first conduit, through the heat exchanger and into the second conduit. In particular, the rate of convective heat transfer is higher for thermal transfer fluid flow with turbulent boundary layers along the Heating Surfaces than for laminar flows, and the heat transfer rate increases with increasing Nusselt number.
The capacity of the fluid heating system is the total heat transferred from the thermal transfer fluid to the production fluid under standard conditions. By convention, where the production fluid is liquid (e.g., water, thermal fluid or thermal oil) the capacity is expressed in terms of British thermal units per hour (BTU/hr); where the production fluid is wholly or partly gaseous or vapor (e.g., steam) the standard unit of measurement is expressed in boiler horsepower (BHP). In embodiments where the production fluid is liquid (e.g., water, thermal fluid or thermal oil), the capacity of the fluid heating system can be 100,000 BTU/hr to 50,000,000 BTU/hr, or 150,000 BTU/hr to 50,000,000 BTU/hr, or 200,000 BTU/hr to 40,000,000 BTU/hr, or 250,000 BTU/hr to 35,000,000 BTU/hr, or 300,000 BTU/hr to 30,000,000 BTU/hr, or 350,000 BTU/hr to 25,000,000 BTU/hr, or 400,000 BTU/hr to 20,000,000 BTU/hr, or 450,000 BTU/hr to 20,000,000 BTU/hr, or 500,000 BTU/hr to 20,000,000 BTU/hr, or 550,000 BTU/hr to 20,000,000 BTU/hr, or 600,000 BTU/hr to 20,000,000 BTU/hr, for example. The upper limit of capacity of the fluid heating system when the production fluid is liquid can be 50,000,000 BTU/hr, 40,000,000 BTU/hr, 30,000,000 BTU/hr, 20,000,000 BTU/hr, 15,000,000 BTU/hr, 14,000,000 BTU/hr, 13,000,000 BTU/hr, 12,000,000 BTU/hr, 10,000,000 BTU/hr, 9,000,000 BTU/hr, or 8,000,000 BTU/hr, for example. The lower limit of the capacity of the fluid heating system when the production fluid is liquid can be 100,000 BTU/hr, 150,000 BTU/hr, 200,000 BTU/hr, 250,000 BTU/hr, 300,000 BTU/hr, 350,000 BTU/hr, 400,000 BTU/hr, 450,000 BTU/hr, 500,000 BTU/hr, 550,000 BTU/hr, or 600,000 BTU/hr, for example The foregoing upper and lower bounds can be independently combined, preferably 300,000 BTU/hr to 20,000,000 BTU/hr.
In an embodiment where the production fluid is wholly or partly gaseous or vapor (e.g., steam), the capacity of the fluid heating system can be between 1.5 HP to 1,500 HP, or 2.0 HP to 1,200 HP, or 2.5 HP to 1000 HP, or 3.0 HP to 900 HP, or 3.5 HP to 800 HP, or 4 HP to 800 HP, or 4.5 HP to 800 HP, or 5 HP to 1,500 HP, or 10 HP to 1,500 HP, or 15 HP to 1,500 HP, or 20 HP to 1,500 HP, or 25 HP to 1,500 HP, or 30 HP to 1,500 HP, for example. The upper limit of the capacity of the fluid heating system when the production fluid is wholly or partly gaseous or vapor can be 2,500 HP, 2,000 HP, 1,800 HP, 1,600 HP, 1,500 HP, 1,400 HP, 1,300 HP 1,200 HP, 1,100 HP, 1,000 HP, 900 HP, 800 HP, for example, or any other capacity determined by the specific fluid heating system footprint and weight requirements. The lower limit of the capacity of the fluid heating system when the production fluid is wholly or partly gaseous or vapor can be 1.5 HP, 2.0 HP, 2.5 HP, 3.0 HP, 3.5 HP, 4 HP, 5 HP, 10 HP, 15 HP, 20 HP, 25 HP, or 30 HP, for example The foregoing upper and lower bounds can be independently combined. Fluid heating system capacities of 10 HP to 1000 HP and 10 HP to 1,600 HP are specifically cited.
In an embodiment, the fluid heating system capacity where the production fluid is liquid (e.g., water, thermal fluid or thermal oil) is between 500,000 BTU/hr to 30,000,000 BTU/hr. In an embodiment, the fluid heating system capacity where the production fluid is liquid (e.g., water, thermal fluid or thermal oil) is between 700,000 BTU/hr to 1,000,000 BTU/hr. In an embodiment, the fluid heating system capacity where the production fluid is wholly or partly gaseous or vapor (e.g., steam) is between 2.5 HP to 800 HP. In an embodiment, the fluid heating system capacity where the production fluid is wholly or partly gaseous or vapor (e.g., steam) is between 3.5 HP, 4 HP, 5 HP, 10 HP, 15 HP, 20 HP, 25 HP, or 30 HP to 500 HP, or 600 HP, or 700 HP, or 800 HP, or 900 HP, or 1,000 HP, or 1,100 HP, or 1,200 HP, or 1,300 HP, or 1,400 HP or 1,600 HP, or 1,800 HP, or 2,000 HP.
Overall, the equation governing the heat transfer of the boiler operating in steady state is given by the equation, Q=UA ΔTLM, where Q is the heat transfer rate, U is the heat transfer coefficient, A is the Heating Surface area, and ΔTLM is the log-mean temperature difference between the thermal transfer fluid and production fluid on opposite sides of the Heating Surfaces.
In a preferred embodiment, the stream of hot gases across the Heating Surfaces is fully turbulent flow for all normal operating conditions, implying that the convective heat flux across the Heating Surfaces occurs across a fully turbulent boundary layer. The Nusselt number and thickness of that turbulent boundary layer, and the resulting Q, the heat transfer rate are affected by several factors, including the velocity of the gaseous thermal transfer fluid flow and the surface characteristics of the Heating Surface.
Increasing the heat transfer rate (or, equivalently, increasing the heat transfer efficiency) can be used to reduce the size, complexity, and cost of a compact fluid heating system. Two approaches are typically used to enhance the heat transfer rate, Q, in the equation Q=UA ΔTLM: The first involves increasing the effective Heating Surface area (A) over which the heat transfer occurs. This can be accomplished by increasing the number of heat transfer elements (e.g., number of tubes in a shell-and-tube heat exchanger), the dimensions of the heat transfer components (e.g., length of the heat exchanger elements), or augmenting the surface area with structural elements (e.g., “fins”) specifically designed to promote heat transfer. The disadvantage to increasing the Heating Surface area is that it increases the volume, weight, material cost, and manufacturing complexity of the fluid heating system.
The second approach to increasing the heat transfer rate is to increase the heat transfer coefficient (U). An approach to increasing the heat transfer coefficient is by treating the Heating Surface by introducing surface features designed to promote turbulence in the boundary layer of the thermal transfer fluid (hot “gas-side” flow) over the Heating Surfaces. These surface treatments (e.g., corrugations and/or turbulators on the gas-side of the Heating Surface serve to increase Nusselt number of the turbulent boundary layer and increase the Heating Surface area. The disadvantage to incorporating corrugations and turbulators on the gas-side Heating Surface is that only a limited benefit can ultimately be realized on the heat transfer rate using this approach and, moreover, that surface treatments increase the fluid heating system material cost and manufacturing complexity.
In a first aspect of the disclosed described systems and methods, it has been discovered that use of a heat transfer assembly characterized by a high pressure drop, together with an energy efficient high pressure blower (equivalently, high fan power) can be used to enhance the heat transfer rate, Q, by increasing the heat transfer fluid velocity across the Heating Surfaces. The higher the fan power (equivalently, fan speed or fan pressure), the thinner the turbulent boundary layer and, hence, the more efficient the heat transfer from the combustion gas to the production fluid.
The key functional characteristics of the prime mover may be described in terms of four measurable quantities: the fan pressure, volumetric flow rate, absorbed power and the efficiency of energy conversion. The prime mover 130 efficiency can be further separated into the fan efficiency (efficiency converting electrical power into fan power) and the combustion system efficiency (conversion of fuel stored energy into heat energy). The prime mover delivers 138 a mixture of air and combustion gases and byproducts under pressure to the heat exchanger 104 at an exit pressure, PA, from the furnace exhaust (point “A”). The hot gas mixture enters the heat exchanger 104 and traverses its structure comprising surfaces 146 that are simultaneously exposed to hot combustion gas on the interior surfaces of the heat exchanger 104 and production fluid on the outside surfaces of the heat exchanger. These heat transfer surfaces 146 enable the bulk heat flow 145 of heat energy from the hot gas mixture 138 entering the heat exchanger 104 to the production fluid flowing within the pressure vessel 110. The air combustion mixture, depleted of most of the heat energy, exits 142 the heat exchanger 104 and enters the exhaust flue (point “B”) at a pressure, PB, exceeding the ambient pressure, Pamb, just enough to drive the exhaust gases out through the flue. As a result, the heat exchanger 104 presents a pressure drop from the pressure at the furnace exit, PA, to the pressure at the flue inlet, PB, denoted as the “furnace-to-flue” pressure drop, Pfurnace-to-flue.
Since the blower 132 is the sole apparatus responsible for generating positive flow pressure the combustion inlet air 150 as it enters the combustion system 134, it produces the driving forces responsible for the pressure and volumetric mass flow of hot gas 138 entering the heat exchanger 104, after the pressure drop incurred by the combustion system 134. Increasing the fan power produces higher combustion gas pressure entering the heat exchanger 138, permitting the use of heat exchanger designs and configurations requiring high furnace-to-flue pressure drops, Pfurnace-to-flue while still maintaining a sufficient residual pressure, PB, at the exhaust entering the flue. Furthermore, an important system design parameter was the electrical power utilized by the prime mover, where the user requirements typically limit the acceptable current and voltage consumption during installed operation.
Fluid heating system design conventions have limited fan design options the produce relatively low fan pressures, characterized by low electrical efficiencies. Consequently, fluid heating systems in practice have been limited to the use of heat transfer assemblies with a pressure drop to about 3.5 kPa or less and use blowers that create fan pressure of typically 0.5 pounds per square inch (psi) or less, and in all cases strictly less than 0.7 psi, above ambient pressure. As a result, current industry products utilize small, low-pressure blower fans to drive the thermal transfer fluid through heat transfer assemblies characterized by low inlet-to-outlet pressure drops, and adjust the geometry of the heat exchanger, the Heating Surface area, and surface treatments to achieve a desired heat transfer rate.
Recent advances in efficient electric motor technologies and sophisticated fan blade geometries have resulted in the advent of efficient high pressure fan options heretofore unavailable to the industrial and commercial fluid heating system designer.
The increased heat transfer fluid velocity has at least two effects. The high velocity flow reduces the height of the turbulent boundary layer on the gas-side thermal transfer fluid flow and it increases the average overall turbulence of the flow (equivalently, the average Nusselt number of the flow through the thermal transfer apparatus). This discovery has been exploited by the inventors to produce a novel fluid heating system with a compact volume and footprint, improved thermal transfer efficiency, and reduced Heated Surface area with corresponding reductions in materials, cost, and manufacturing complexity.
Since the critical heat transfer property is the average improvement in the heat transfer coefficient, U, throughout the thermal transfer assembly (including the heat exchanger), the benefit of utilizing high pressure drop can be compared by using the Bulk Heat Flux, which can be computed by dividing the Gross Output by the total Heated Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, the content of which is incorporated herein by reference in its entirety, and the total Heating Surface area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid.
In greater detail, the Bulk Heat Flux of a fluid heating system is a quantification of how much heat is passed through the walls of the heat exchanger, furnace, and any other heated parts, from the gas (thermal transfer fluid) side of the heater, to the water or steam (production fluid) side of the heater. The heat exchanger typically contributes between 65% and 100% of the total system bulk heat transfer from the thermal transfer fluid to the production fluid, with 85% to 90% being common.
Heaters with a high bulk heat flux, by nature, will be smaller than those with a lower bulk heat flux, assuming the same output heat is in the production fluid is desired, and that the architecture remains reasonably the same.
In this way, bulk heat flux can be said to indicate how effectively a design is using the material and surface area available for heat transfer.
Bulk Heat Flux in its simplest form can be defined as:
Bulk Heat Flux=q″=Gross Output/Heated Surface Area=q/A
where q″ is the bulk heat flux (typically W/m2 or BTU/hr/ft2), Gross Output (also denoted qproduction fluid, in units of W or BTU/Hr) is the amount of heat transferred per time into the production fluid through the wall, and A is the surface area in contact with the thermal transfer fluid, responsible for heat transfer to the production fluid.
Calculating the heat transfer surface area, A, is straight forward utilizing standard geometrical relationships.
The area of the external side of a cylinder is: A=πDoutsideL, where Doutside is the diameter of the exposed surface and L is the length of the cylinder;
The area of the internal side of a cylinder is: A=πDinsideL
Area of a fin would be: A=2*hfin*Lfin, where hfin and Lfin are the height and length of the fin, respectively;
and so on for all other geometries of the component heat transfer surface elements.
The heat output of the heater is slightly less straight forward, and measurement of such can be accomplished in a few different ways, depending both on method desired, and the type of production fluid being heated.
One method, referred to as “Combustion Efficiency” is a calculation method based on losses. The general equation can be represented as:
qout=qin−qstack loss−qSkin Loss
This is convenient, as qin is readily measured by metering the fuel input and multiplying it by the Calorific Value of the fuel (Heat/Quantity, either mass or volume pending the fuel). This is described in the AHRI BTS-2000 standard for efficiency testing, paragraph 11.1.3.
The stack loss, qstack loss, can be calculated by measuring:
These quantities can be converted into the corresponding stack loss by the equations presented in AHRI BTS-2000, Paragraph 11.1.6. This method is widely accepted in the industry by those skilled in the art.
The total skin loss can be estimated by measuring the temperature of the jackets or surface of the heating unit, and calculating a free convection thermal loss of the unit, using commonly available correlations (For example, see “Fundamentals of Heat and Mass Transfer”, by Bergman, et. al., 7th Edition, Wiley Publishing, 2001, Chapter 9.)
A more direct method is to calculate thermal efficiency or thermal output directly. This method used commonly understood heat and mass transfer equations known to those skilled in the art, but differs slightly for each production fluid choice.
In the case where all heat transfer is done by sensible heat (that is, simply raising a fluid temperature without phase change, as in hydronic boilers and thermal fluid heaters) the calculation of heat output rate simply follows:
qoutput={dot over (m)}*cp*(Tin−Tout)
This can be seen in the AHRI BTS-2000 test standard as Paragraph 11.1.11.3, where {dot over (m)} (“mdot”, the flow mass rate of change) is replaced by by W/tT
For steam boilers the procedure is slightly different, as both the sensible heat and the latent heat associated with vaporizing the liquid must be accounted for, and additionally, any liquid water that exits the boiler must also be accounted for, as it did not vaporize.
Minimally, the following parameters must be measured:
standard steam property tables are used to determine the temperature of the steam at the given saturated pressure.
This set of values allows the calculation of thermal output directly, utilizing the AHRI BTS-2000 test standard in Paragraph 11.1.11.2.
The rest of the AHRI BTS-2000 standard describes the methods of measurement needed, apparatus setup, and standard conditions at which the thermal output is measured. For hydronic Boilers, this requires a determination of the production fluid flow rate that generates a 100° F. change in temperature across the heater, with the inlet condition held at 80° F. For Steam boilers, this is holding the boiler at 2 psig or less steam pressure. In both cases, the maximum heat input the unit is rated for should be supplied, within approximately 2%.
Traditional boiler and heater design was centered around commonly available, inexpensive, and ultimately inefficient fan designs. Furthermore, most commonly available burners were typically offered in package format, with the fan already selected and integrated into the burner assembly.
This creates the scenario represented by D1 in
This results in design philosophies which embrace low bulk heat flux and low back pressure solutions, so that commonly available parts are able to be used, and results in a relatively large heat exchanger with which to provide the output power to the customer.
This ultimately resulted in a design culture which held as a constant that boiler blowers are low pressure, high flow blowers, which perform very inefficiently against any degree of back pressure. The state of the art during this period also had limited efficiency motors available, and limited or no ability o change the operating speed of the blower or prime mover.
Breaking these blower constraints, and embracing modern, highly efficient, high pressure fan designs allows a substantive change in the design space available to the typical boiler designer, as represented by the enlarged design space 176 denoted by D2. While high pressure fans are typically large (due to the mechanics of compression, particularly as related to the tip speed of the wheel), when these highly efficient fans with high discharge pressure are combined with high efficiency motors, and the ability to manipulate the operating speed of the machine, the blower can be shrunk back near the same size as traditional fans, and the additional shaft power used to create high pressure air streams is not experienced by the user, as it is compensated for by the highly efficient motor.
In fact, by embracing variable speed operation, and mildly increase electrical requirements are only felt at peak output, where heaters are only rarely operated.
Furthermore, with the heat exchanger design space greatly broadened, the thermal efficiency of a given heater can be greatly increased, while simultaneously shrinking the geometry, resulting in a heater which does not consume any more power (on a holistic, total basis) than their inefficient, and large footprint predecessors.
These great increases in efficiency and compactness are enabled by carefully optimizing the design pressure used by the product, and carefully engineering the heat exchanger flow path to provide the user with an optimum in energy usage, output power, and space constraints.
For fluid heating systems described herein, the thermal resistance on the production fluid (equivalently, “waterside” in the case of a hydronic or steam fluid heating system) side of a heat transfer surface is several orders of magnitudes smaller than on the thermal transfer fluid side (equivalently, “fireside” where the thermal transfer fluid is a heated gaseous mixture). Therefore, boiler designs that augment heat transfer surface area (e.g., addition of thermal fins) do so on the thermal transfer fluid side since adding surface area to the production fluid side is ineffective. When augmented surface areas are not incorporated into the design, increasing heat transfer surface area means enlarging the total surface area exposed on both sides to fluid, adding heat transfer surfaces thermal fluid and production sides equally. Therefore, in this disclosure heat flux determination as defined and computed is described on the thermal transfer fluid side of the exchange surfaces.
In an embodiment, the Bulk Heat Flux across the heat transfer assembly can be 30 kilowatt-hours per hour per square meter (kW/m2) to 500 kW/m2, or 30 kW/m2 to 300 kW/m2, or 32 kW/m2 to 450 kW/m2, or 34 kW/m2 to 450 kW/m2, or 36 kW/m2 to 450 kW/m2, or 38 kW/m2 to 450 kW/m2, or 40 kW/m2 to 400 kW/m2, or 42 kW/m2 to 400 kW/m2, or 45 kW/m2 to 400 kW/m2, or 45 kW/m2 to 400 kW/m2, or 45 kW/m2 to 400 kW/m2, or 45 kW/m2 to 300 kW/m2, or 45 kW/m2 to 300 kW/m2, or 45 kW/m2 to 300 kW/m2, or 45 kW/m2 to 450 kW/m2, or 45 kW/m2 to 400 kW/m2, or 45 kW/m2 to 350 kW/m2, or 45 kW/m2 to 300 kW/m2, or 45 kW/m2 to 250 kW/m2, or 45 kW/m2 to 200 kW/m2, or 45 kW/m2 to 150 kW/m2, or 45 kW/m2 to 125 kW/m2, or 45 kW/m2 to 120 kW/m2, for example. In an embodiment, the Bulk Heat Flux is 45 kW/m2 to 300 kW/m2. In an embodiment, the Bulk Heat Flux across the heat transfer assembly is 45 kW/m2 to 120 kW/m2. In an embodiment, the Bulk Heat Flux across the heat transfer assembly is 45 kW/m2 to 100 kW/m2. In an embodiment, the Bulk Heat Flux across the heat transfer assembly is 47 kW/m2 to 100 kW/m2. In an embodiment, the Bulk Heat Flux across the heat transfer assembly is 47 kW/m2 to 120 kW/m2. The upper limit of the Bulk Heat Flux across the heat transfer assembly can be 1,000 kW/m2, 800 kW/m2, 600 kW/m2, 500 kW/m2, 400 kW/m2, 450 kW/m2, 350 kW/m2, 300 kW/m2, 250 kW/m2, 200 kW/m2, 150 kW/m2, 125 kW/m2, 120 kW/m2, or 100 kW/m2, for example, and is determined by the upper limit of what the material can transfer without impacting durability, limit of boiling curve to avoid film boiling, and limits on the total Q (heat transfer) imposed by the production fluid. The lower limit of the Bulk Heat Flux across the heat transfer assembly can be 30 kW/m2, 35 kW/m2, 40 kW/m2, 45 kW/m2, for example The upper and lower limits provided can be independently combined
An aspect of the disclosed systems and methods is that utilizing a high pressure heat transfer assembly can be used with a high pressure blower to provide a compact, efficient, and practical fluid heating systems characterized by enhanced thermal heat transfer from a heated thermal transfer fluid to a production fluid. This discovery by the inventors applies to any configuration of fluid heating system where heat transfer is accomplished using Heating Surfaces exposed to a turbulent thermal transfer fluid flow, including (but not limited to) firetube and watertube hydronic, steam, and thermal fluid boilers. For simplicity, aspects of the disclosed system and methods are described where the gas path travels through a cavity in the production fluid (for example, in a firetube boiler). However, the disclosed system and methods can applied to other applications by a person of ordinary skill in the art and the disclosed system and methods are not limited to particular a configuration, such as a shell-and-tube or tubeless heat exchanger.
In an embodiment, the Pressure Drop across the heat transfer assembly can be 2.5 kiloPascals (kPa) to 50 kPa, or 2.5 kPa to 45 kPa, or 3.0 kPa to 40 kPa, or 3.5 kPa to 40 KPA, or 4.0 kPa to 30 kPa, or 4.5 kPa to 30 kPa, or 5.0 kPa to 30 kPa, or 5.5 kPa to 20 kPa, or 6 kPa to 20 kPa, or 6.5 kPa to 20 kPa, or 7 kPa to 50 kPa, or 7.5 kPa to 50 kPa, or 8 kPa to 50 kPa, or 8.5 kPa to 50 kPa, or 9 kPa to 50 kPa, for example, wherein the foregoing upper and lower bounds can be independently combined. The lower limit of the Pressure Drop across the heat transfer assembly can be 2.5 kPa, 2.6 kPa, 2.7 kPa, 3.0 kPa, 3.2 kPa, 3.5 kPa, 3.7 kPa, 4.0 kPa, for example The upper limit of the Pressure Drop across the heat transfer assembly can be 50 kPa, 45 kPa, 40 kPa, 35 kPa, 30 kPa, 25 kPa, 20 kPa 15 kPa, 12 kPa, 10 kPa, for example In an embodiment, the Pressure Drop between the measurement point 116 of the conduit 102 and the measurement point 118 of conduit 106 in
Shown in
Heat exchanger designs vary, and a person of ordinary skill in the art can adapt the disclosed systems and methods to specific heat exchanger configurations without undue experimentation. In an embodiment, a shell-and-tube heat exchanger is incorporated, where the primary element of the Heating Surface comprises a collection of thin-wall tubes that convey the heated thermal transfer fluid from the furnace to the exhaust conduit.
Tubeless heat exchangers are also used. Tubeless heat exchangers avoid the use of the thin-walled tubes and the tubesheets associated with tube-and shell heat exchangers. In an embodiment, a tubeless heat exchanger comprises at least two flow cavities, a heat exchanger core section designed to convey a thermal transfer fluid from an inlet port to an exhaust port, and a pressure vessel designed to convey a production fluid from a separate inlet port to a separate outlet port. The heat exchanger core can be partly or entirely contained within the pressure vessel and the thermal transfer fluid flow through the heat exchanger can be contained within the core section. The pressure vessel comprises an external shell, all external surfaces of the heat exchanger core, the outer surfaces of the core inlet and exhaust ports, and other fluid heating system components. The flow of production fluid through the heat exchanger is contained entirely within the pressure vessel.
If desired, the tubeless heat exchanger core can further comprise a flow element, e.g., a rib or a ridge, to direct the flow of the thermal transfer fluid, e.g., to provide a longer path between the inlet and the outlet of the tubeless heat exchanger core. As shown in
Details for the design, use and manufacture of ribbed and ridged tubeless heat exchangers and fluid heating systems incorporating ribbed and ridged tubeless heat exchangers are provided in U.S. Provisional Patent application Ser. No. 62/124,502, filed on Dec. 22, 2014; U.S. provisional patent application Ser. No. 62/124,235, filed on Dec. 11, 2014; U.S. Non-Provisional patent application Ser. No. 14/949,948, filed on Nov. 24, 2015; U.S. Non-Provisional patent application Ser. No. 14/949,968, filed on Nov. 24, 2015; and U.S. Non-Provisional Patent Application number 24172713, filed on Nov. 24, 2015, the contents of which are included herein by reference in their entirety.
Alternatively, a deformation in the inner casing, the outer casing, or combination thereof can be used to provide the flow element. In an embodiment, the tubeless heat exchanger core comprises a top head, a bottom head, an inner casing disposed between the top head and the bottom head, an outer casing disposed between the top head and the bottom head and opposite an inner surface of the inner casing, wherein at least one of the inner casing and the outer casing comprises a ridge, wherein the inner casing and the outer casing define a flow passage between the second inlet and the second outlet of the tubeless heat exchanger core, wherein the second inlet of the tubeless heat exchanger core is disposed on the inner casing, the outer casing, or a combination thereof, and wherein the second outlet of the tubeless heat exchanger core is disposed on the inner casing, the outer casing, or a combination thereof. The ridge can be provided by stamping, or hydraulic or pneumatic deformation, for example.
The heat exchanger and boiler industries—and persons with ordinary skill in the art in these industries—distinguish tubes used for heat transfer surfaces in tube-and-shell heat exchangers from other conduits (e.g., flow passages in tubeless heat exchangers) using the following definitions: A tube is a hollow conduit with circular or elliptical cross-section whose dimension is specified by the outside diameter and wall thickness is usually provided in terms of the Birmingham Wire Gauge (BWG) or Stubbs' Wire Gauge convention ranging from 5/0 gauge (0.500 inch wall thickness) to 36 gauge (0.004 inch wall thickness). Other metal conduits for thermal transfer fluid—like pipes—use different specification conventions; for example, pipe is customarily identified by “Nominal Pipe Size” (NPS) whose diameters only roughly compare to either the actual inside or outside diameter and with wall thickness defined by “Schedule Number” (SCH).
However, this definition of “tube” obfuscates the functional properties that are useful in classifying and characterizing the distinctions between tube-and shell heat exchangers—as opposed to tubeless design alternatives—particularly in regards to the surprising, state-of-the-art advance represented by the present systems and methods. For the purposes of this disclosure, unless otherwise specified, definitions are provided based on the functional distinctions between tubes and more robust heat transfer components. A tube-and-shell heat exchanger is a design classification wherein the primary location of heat exchange occurs across the wall surfaces of a numerous plurality of thin-wall (≤0.5 centimeters (cm) wall thickness) metal or metal alloy fluid conduits—which may or may not have circular cross-section—called tubes, secured at either or both ends to a tubesheet, e.g., by welded portions, or weldments. Functional characteristics of a tube-and shell heat exchanger include the presence of a large number of weldments or other mechanical fastening means (mandrel expansion for instance) between the thin-wall conduits (tubes) and the tubesheets and the presence of a numerous plurality of thin-wall conduits, both of which are susceptible to cracking and other material failures induced by corrosion, mechanical movement and thermal stresses. Because they occur within the pressure vessel, tubes, tubesheets, and connection failures are difficult and expensive to service or replace, particularly in field installations.
Tubeless heat exchangers refer to heat exchanger designs that avoid the use of thin-wall metal or metal alloy fluid conduits and the resulting plethora of conduit weldments to tubesheets in favor of other—less fragile—alternatives as heat transfer surfaces. In particular, tubeless conduit-and-shell heat exchangers are characterized by the presence of few fluid conduits comprising components of thicker (≥0.5 cm) average minimum dimension and the absence of tubesheets with many conduit-to-tubesheet weldments. In practice, tubeless conduit-and-shell heat exchangers share some features with tube-and-shell designs including the structure and manufacture of the pressure vessel, methods of supplying hot thermal transfer fluid and cooler production fluid, and the design of regulatory control systems. However, the heat exchange core section of a tubeless conduit-and-shell heat exchanger substitutes a less fragile thermal transfer fluid conduit structure with fewer than half the distinct flow paths comprising robust metal and metal alloy components with the same or greater heat transfer capacity as compared to an equivalent tube and tubesheet structure.
Shown in
The heat exchanger core can have any suitable dimensions. Specifically provided is the case where inner casing and the outer casing each independently have a largest outer diameter of 15 centimeters (cm), 25 cm, 30 cm, 350 cm, 650 cm, or 1,400 cm. For example, the inner casing and the outer casing can each independently have a largest outer diameter of 15 cm to 1,400 cm. An embodiment in which the inner casing and the outer casing each independently have a largest outer diameter of 30 cm to 350 cm or 40 cm to 300 cm is preferred.
The inner casing and the outer casing can each independently have a maximum height of 15 centimeters (cm), 25 cm, 30 cm, 350 cm, 650 cm, or 1,400 cm. For example, the inner casing and the outer casing can each independently have a maximum height of 15 cm to 1,400 cm. An embodiment in which the inner casing and the outer casing each independently have a largest outer diameter of 30 cm to 650 cm or 40 cm to 500 cm is preferred.
The fluid heating system can be used to exchange heat between any suitable fluids, e.g., between a first fluid and the second fluid, wherein the first and second fluids can each independently comprise a gas, a liquid, or a combination thereof. In a preferred embodiment the first fluid, which is directed through the heat exchanger core, is a gaseous thermal transfer fluid, and can be a combustion gas, e.g., a gas produced by fuel fired combustor, and can comprise water, carbon monoxide, carbon dioxide, or combination thereof. Herein, reference to “high pressure” or “high pressure drop” refer to pressure measurements of the thermal transfer fluid; equivalently referred to as the fireside pressure in embodiments where the thermal transfer fluid is a gaseous heated gas or the result of a combustion process.
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 can comprise water, steam, oil, a thermal fluid (e.g., a thermal oil), or combination thereof. The thermal fluid can comprise water, a C2 to C30 glycol such as ethylene glycol, a unsubstituted or substituted C1 to C30 hydrocarbon such as mineral oil or a halogenated C1 to C30 hydrocarbon wherein the halogenated hydrocarbon can optionally be further substituted, a molten salt such as a molten salt comprising potassium nitrate, sodium nitrate, lithium nitrate, or a combination thereof, a silicone, or a combination thereof. In hydronic products, a glycol-water mixture with a glycol concentration between 10-60% by volume may be used. Representative halogenated hydrocarbons include 1,1,1,2-tetrafluoroethane, pentafluoroethane, difluoroethane, 1,3,3,3-tetrafluoropropene, and 2,3,3,3-tetrafluoropropene, e.g., chlorofluorocarbons (CFCs) such as a halogenated fluorocarbon (HFC), a halogenated chlorofluorocarbon (HCFC), a perfluorocarbon (PFC), or a combination thereof. The hydrocarbon can be a substituted or unsubstituted aliphatic hydrocarbon, a substituted or unsubstituted alicyclic hydrocarbon, or a combination thereof. Commercially available examples include THERMINOL VP-1, (Solutia Inc.), DIPHYL DT (Bayer A. G.), DOWTHERM A (Dow Chemical) and THERM S300 (Nippon Steel). The thermal fluid can be formulated from an alkaline organic and inorganic compounds. Also, the thermal fluid can be used in a diluted form, for example with concentrations ranging from 3 weight percent to 10 weight percent. An embodiment in which the thermal transfer fluid is a combustion gas and comprises liquid water, steam, or a combination thereof and the production fluid comprises liquid water, steam, a thermal fluid, or a combination thereof is specifically mentioned.
Also disclosed is a method of heat transfer, the method comprising: providing a fluid heating system comprising a pressure vessel comprising a first inlet and first outlet, a heat exchanger core which can be entirely disposed in the pressure vessel; and disposing a gaseous or vapor thermal transfer fluid in the tubeless heat exchanger core and a production fluid in the pressure vessel to transfer heat from the thermal transfer fluid to the production fluid. The disposing of the thermal transfer fluid into the tubeless heat exchanger core can be conducted by directing a combustion gas into the heat exchanger core using a blower, for example. The method of heat transfer can comprise directing the thermal transfer fluid from the first inlet to the first outlet to provide a flow of the thermal transfer fluid through the pressure vessel, and directing the production fluid from the second inlet to the second outlet to provide a flow of the production fluid through a flow passage of the tubeless heat exchanger core. The directing and can be provided using a pump, for example. The combination recited satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 45 kW/m2 and 300 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heated Surface Area where the Gross Output is determined in accordance Section 11.1.12 of the AHRI BTS-2000, the content of which is incorporated herein by reference in its entirety, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 2.5 kiloPascals (kPa) to 50 kPa, or 2.5 kPa, 3.0 kPa, 3.5 kPa, 4.0 kPa, 4.5 kPa, 5.0 kPa, 5.5 kPa, 6 kPa, 6.5 kPa, 7 kPa, 7.5 kPa, 8 kPa, 8.5 kPa or 9 kPa to 50 kPa, 40 kPa, 30 kPa, 20 kPa, 15 kPa or 12 kPa, wherein the foregoing upper and lower bounds can be independently combined. An embodiment in which the Pressure Prop between 3 kPa to 30 kPa is specifically provided.
In any of the foregoing embodiments, the pressure vessel can be configured to contain a production fluid such that an entirety of an outer surface of the heat exchanger core is contacted by the production fluid; and/or an entirety of a flow passage of the heat exchanger core can be disposed entirely in the pressure vessel.
Computer modeling and simulations were performed to demonstrate aspects of several boiler configurations. Computer modeling and simulation enable a direct comparison of the boilers of different sizes and configurations at similar thermodynamic and operational conditions.
It is surprising that the heat flux vs. furnace-to-flue pressure drop curve is steep out to values of 3-5 kPa. Current industry practice is to design well below the inflection point—typically, 1.5 kPa—despite the fact that considerable improvements can be realized from operation at higher pressures. Also, near the inflection point, the performance improvements available are substantial in both thermodynamic characteristics and the potential for unit size reduction due to higher power densities available.
However, several obstacles are present at these higher power densities. First, the Bulk Heat Fluxes shown represent the averages of all heat flows through all heated surface areas. Concentrated local heat fluxes can produce local hot spots in certain components causing high stresses and the potential for material failures.
Second, since heat flux is proportional to both the difference in temperature between the production fluid and the thermal transfer fluid and the heat transfer coefficient on the gas side of the heat exchanger surface, fluid heating systems designs must manage the local surface heat transfer rates to maintain local heat flux conditions below failure thresholds.
Third, for steam boilers, designs must limit local conditions to prevent the transition to film boiling, which is not typically a consideration with fuel fired boilers but can be present when the power density is increased by enhancing the furnace-to-flue pressure drop. This is one example of a heat flux consideration that has caused the industry to teach away from higher pressures in the past.
Fourth, for hydronic boilers, boiling at low flow conditions must be managed, particularly in local hot spots like areas surrounding the heat exchanger tubes. As a result, careful layout of the water management path is critical, which in other products is almost irrelevant to the performance and longevity of a standard boiler.
Analogous results are shown in
Analogous results are obtained for a numerical simulation of a 30 HP high pressure vertical fluid heating system incorporating a tubeless exchanger configured for hydronic production fluid as shown in
The simulated test shows that while the specific point selected varies in pressure drop, in all cases the design point selected is in the range where the differential is reduced below 1. Thus, heat flux rapidly increases with increasing furnace-to-flue pressure drop until a certain point, after which additional pressure drop does very little to improve heat flux. From the differential plots show that, in the range of boiler sizes typical for commercial applications, the inflection point occurs at 5 kPa or greater.
Tests have also been conducted by the inventors to verify operational aspects of the disclosed systems. Table 1 shows operational test data for a 3,000,000 BTU/hr high pressure vertical fluid heating system incorporating a tube-and-shell heat exchanger configured for steam production fluid, as described in
Table 2 shows the results of an operational test of a 6,000,000 BTU/hr high pressure vertical fluid heating system incorporating a tube-and-shell heat exchanger configured for steam production fluid as described in
Table 3 shows operational test data for an instrumented 30 HP high pressure vertical fluid heating system incorporating a spiral ribbed tubeless heat exchanger configured for hydronic production fluid, as described
Table 4 shows certification test data for an instrumented 30 HP high pressure vertical hydronic boiler product incorporating a spiral ribbed tubeless heat exchanger configured for hydronic production fluid, corresponding to the prototype test rig described
These data can be used to calculate the Bulk Heat Flux as displayed on
First, calculate qin:
qin=Vtotal gas*Cgas meas*CalVal=1269.2f t3*1.8745* 1010.735BTU/SCF=2,404,655BTU
Calculate Sensible Heat according to the AHRI BTS-2000:
Calculate the Latent Heat per AHRI BTS-2000:
Calculate the Total Heat Output Rate
Next, calculate the total area for heated surfaces using geometrical formulas for the components:
A=61ft{circumflex over ( )}2
Finally, calculate Bulk Heat Flux:
In an embodiment, disclosed is a fluid heating system comprising: a pressure vessel comprising a first inlet and first outlet and an inside and an outside; an assembly comprising: a heat exchanger core comprising a second inlet and a second outlet, and an inner surface and an outer surface, wherein the heat exchanger core is inside the pressure vessel; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; and a blower in fluid connection with the first conduit, the blower configured for forcing a gas under pressure through the assembly; wherein the heat exchanger core further comprises a flow passage between the second inlet and the second outlet, wherein the flow passage is configured to contain a thermal transfer fluid; wherein the fluid heating system satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 45 kW/m2 and 300 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heating Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 3 kiloPascals and 30 kiloPascals.
Also disclosed is method of heat transfer, the method comprising: providing a fluid heating system comprising a pressure vessel comprising an inside and an outside and a first inlet and a first outlet; a heat exchanger core comprising a second inlet and a second outlet, wherein the heat exchanger core is inside the pressure vessel; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a blower disposed in the first conduit; and disposing a thermal transfer fluid in the heat exchanger core and a production fluid between the inside of the pressure vessel and the heat exchanger core to transfer heat from the thermal transfer fluid to the production fluid wherein the fluid heating system has a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit between 45 kW/m2 and 300 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heated Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 3 kiloPascals and 30 kiloPascals.
In an embodiment, disclosed is a method of manufacturing a fluid heating system, the method comprising: providing a pressure vessel comprising a first inlet and a first outlet and an inside and an outside; disposing a heat exchanger core entirely in the pressure vessel, the heat exchanger core comprising a second inlet and a second outlet; connecting the second inlet of the heat exchanger core to a first conduit, which extends outside the pressure vessel; and connecting the second outlet of the heat exchanger core to a second conduit, which extends outside the pressure vessel.
In an embodiment, disclosed is A fluid heating system comprising: a pressure vessel comprising a first inlet and first outlet and an inside and an outside, wherein the pressure vessel is configured to contain a production fluid comprising liquid water, steam, a C1 to C10 hydrocarbon, a thermal fluid, a thermal oil, a glycol, air, carbon dioxide, carbon monoxide, or a combination thereof; a tube heat exchanger core comprising a first tube sheet, a second tube sheet, a plurality of heat exchanger tubes, each heat exchanger tube independently connecting the first tube sheet and the second tube sheet, a second inlet disposed on the first tube sheet, a second outlet disposed on the second tube sheet, wherein the first inlet and second outlet define a flow passage, and wherein the tube heat exchanger core is configured to contain a gas phase thermal transfer fluid in the flow passage of the heat exchanger core, wherein the thermal transfer fluid comprises water, a substituted or unsubstituted C1 to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, combustion byproducts, a thermal fluid, a thermal oil, a glycol or a combination thereof; a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; and, a blower for forcing the thermal transfer fluid under pressure through an assembly comprising the first conduit, the heat exchanger and the second conduit wherein the blower is in fluid communication with the first conduit the first conduit further comprises a burner assembly and a furnace assembly disposed in the first conduit; wherein the fluid heating system satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 47 kW/m2 and 120 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heating Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between than 3 kiloPascals and 12 kiloPascals.
In an embodiment, disclosed is A fluid heating system comprising: a pressure vessel comprising a first inlet and first outlet and an inside and an outside, wherein the pressure vessel is configured to contain a production fluid comprising liquid water, steam, a C1 to C10 hydrocarbon, a thermal fluid, a thermal oil, a glycol, air, carbon dioxide, carbon monoxide, or a combination thereof; a tubeless heat exchanger core comprising a top head, a bottom head, an inner casing disposed between the top head and the bottom head, the inner casing comprising an inner surface, an outer casing disposed between the top head and the bottom head and opposite the inner surface of the inner casing, a first inlet and a second inlet on the inner casing, the outer casing, or a combination thereof, and a first outlet and a second outlet on the inner casing, the outer casing, or combination thereof, wherein at least one of the inner casing and the outer casing comprises a rib, a ridge, a spine, or a combination thereof wherein the inner casing and the outer casing define a flow passage between the inlet and the outlet of the tubeless heat exchanger core, and wherein the flow passage is configured to contain a gas phase thermal transfer fluid in the flow passage of the heat exchanger core, wherein the thermal transfer fluid comprises water, a substituted or unsubstituted C1 to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, combustion byproducts, a thermal fluid, a thermal oil, a glycol or a combination thereof, a first conduit having a first end connected to the second inlet of the heat exchanger core and a second end disposed outside of the pressure vessel; a second conduit having a first end connected to the second outlet of the heat exchanger core and a second end disposed outside of the pressure vessel; and, a blower for forcing the gas phase thermal transfer fluid under pressure through the first conduit, the heat exchanger and the second conduit wherein the blower is in fluid communication with the first conduit the first conduit further comprises a burner assembly disposed in the first conduit and the first conduit further comprises a furnace assembly disposed in the first conduit; wherein the fluid heating system satisfies the condition that a Bulk Heat Flux between the first end of the first conduit and the first end of the second conduit is between 47 kW/m2 and 120 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heating Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid, and wherein the Pressure Drop between the first end of the first conduit and the first end of the second conduit is between 3 kiloPascals and 12 kiloPascals.
In any of the various embodiments, the heat exchanger core may be a tubeless heat exchanger core; and/or the heat exchanger core may be a tube heat exchanger core; and/or the heat exchanger core may have a hydrodynamic diameter of 1.25 centimeters to 100 centimeters; and/or the heat exchanger core may have an average hydrodynamic diameter of 1.25 centimeters to 100 centimeters; and/or the pressure vessel may be configured to contain a production fluid; and/or the production fluid may comprise water, a substituted or unsubstituted C1 to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, a thermal fluid, a thermal oil, a glycol, or a combination comprising at least one of the foregoing; and/or the heat exchanger core further may comprise a flow passage between the second inlet and the second outlet, wherein the flow passage is configured to contain a thermal transfer fluid; and/or the thermal transfer fluid may comprise a gaseous or non-gaseous fluid; and/or the thermal transfer fluid may comprise water, a substituted or unsubstituted C1 to C30 hydrocarbon, air, carbon dioxide, carbon monoxide, a thermal fluid, a thermal oil, a glycol or a combination thereof, and/or the flow passage may be contained entirely inside of the pressure vessel; and/or the heat exchanger core may be a tubeless heat exchanger core and comprise a top head, a bottom head, an inner casing disposed between the top head and the bottom head, the inner casing comprising an inner surface, an outer casing disposed between the top head and the bottom head and opposite the inner surface of the inner casing, a third inlet on the inner casing, the outer casing, or a combination thereof, and a third outlet on the inner casing, the outer casing, or combination thereof, wherein at least one of the inner casing and the outer casing comprises a rib, a ridge, or a combination thereof wherein the inner casing and the outer casing may define a flow passage between the third inlet and the third outlet of the tubeless heat exchanger core; and/or the inner casing may be coaxial with the outer casing; and/or at least one of the inner casing and the outer casing may have a thickness of 0.5 centimeters to 5 centimeters; and/or optionally configured to contain a production fluid between the inside of the pressure vessel and the outer surface of the heat exchanger core, wherein the production fluid contacts the entirety of the outer surface of the heat exchanger core, wherein the production fluid comprises a liquid, a gas, or a combination thereof, and optionally configured to contain a gaseous thermal transfer fluid in the flow passage of the heat exchanger core; and/or the production fluid may comprise liquid water, steam, a thermal fluid, a thermal oil, a glycol, or a combination thereof; and/or the first conduit may further comprises a burner assembly disposed in the first conduit; the first conduit may further comprises a furnace assembly comprising an inlet and an outlet disposed in the first conduit; and the second conduit may further comprises an exhaust flue comprising an inlet and an outlet disposed in the second conduit; and/or the thermal transfer fluid may be a combustion gas from the burner assembly; and/or the Pressure Drop between the furnace assembly inlet and the exhaust flue inlet may be between 3 kiloPascals and 30 kiloPascals; and/or a Bulk Heat Flux between the furnace assembly outlet and the exhaust flue inlet may be between 45 kW/m2 and 300 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heating Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid; and/or the furnace assembly may be directly connected to the heat exchanger core; and/or the blower may not be present between the furnace assembly and the heat exchanger core; and/or the method may further comprise directing the production fluid from the first inlet to the first outlet to provide a flow of the production fluid through the pressure vessel, and directing the thermal transfer fluid from the second inlet to the second outlet to provide a flow of the thermal transfer fluid through a flow passage between the second inlet and the second outlet of the heat exchanger core, wherein the flow passage is configured to contain a thermal transfer fluid in the heat exchanger core; and/or the production fluid may comprise liquid water, steam, a C1 to C10 hydrocarbon, a thermal fluid, a thermal oil, a glycol, air, carbon dioxide, carbon monoxide, or a combination thereof, and/or the production fluid may comprise liquid water, steam, or a combination thereof; and/or the blower may be in fluid communication with the first conduit; the first conduit further may comprise a burner assembly disposed in the first conduit; may comprise the first conduit further comprises a furnace assembly disposed in the first conduit, wherein the furnace assembly comprises a furnace inlet and a furnace outlet; and the second conduit may further comprises an exhaust flue assembly comprising an inlet and an outlet disposed in the second conduit, wherein the fluid heating system has a Bulk Heat Flux between the furnace outlet and the exhaust flue inlet between 45 kW/m2 and 300 kW/m2 wherein Bulk Heat Flux is determined by dividing the Gross Output by the Total Heated Surface Area where the Gross Output is determined in accordance with Section 11.1.12 of the AHRI BTS-2000, and the Total heated Surface Area is calculated by summing all of the heat transfer surfaces that are directly exposed to thermal transfer fluid; and/or the method may further comprise directing the production fluid from the first inlet to the first outlet to provide a flow of the production fluid through the pressure vessel, and directing the thermal transfer fluid from the second inlet to the second outlet to provide a flow of the thermal transfer fluid through a flow passage between the second inlet and the second outlet of the heat exchanger core, wherein the flow passage is configured to contain a thermal transfer fluid in the heat exchanger core; and/or the production fluid may comprise liquid water, steam, a C1 to C10 hydrocarbon, a thermal fluid, a thermal oil, a glycol, air, carbon dioxide, carbon monoxide, or a combination thereof, and/or the production fluid may comprise liquid water, steam, or a combination thereof; and/or the thermal transfer fluid may be a combustion gas from the burner assembly; and/or optionally further comprising generating the combustion gas by directing a combustible mixture into the burner assembly and combusting the combustible mixture to produce the combustion gas; and/or optionally further comprising pressurizing a combustible mixture with the blower, which blower is in fluid communication with the second end of the conduit; and/or the heat exchanger core maybe tubeless; and/or the heat exchanger core may further comprise an inner casing having an inner surface and an outer surface, and wherein the second inlet is disposed on an outer surface of the inner casing of the heat exchanger core.
The systems and methods have been described with reference to the accompanying drawings, in which various embodiments are shown. This disclosure may, however, be embodied in many different forms, and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Like reference numerals refer to like elements throughout.
It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements can be present therebetween. In contrast, when an element is referred to as being “directly on” or “directly connected” or other terms or connection or attachment with another element, there are no intervening elements present. Also, the element can be on an outer surface or on an inner surface of the other element, and thus “on” can be inclusive of “in” and “on.”
It will be understood that, although the terms “first,” “second,” “third,” etc. can be used herein to describe various elements, components, regions, layers, and/or sections, these elements, components, regions, layers, and/or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another element, component, region, layer or section. Thus, “a first element,” “component,” “region,” “layer,” or “section” discussed below could be termed a second element, component, region, layer, or section without departing from the teachings herein.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms, including “at least one,” unless the content clearly indicates otherwise. “Or” means “and/or.” As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” or “includes,” and/or “including” when used in this specification, specify the presence of stated features, regions, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, regions, integers, steps, operations, elements, components, and/or groups thereof.
Furthermore, relative terms, such as “lower” or “bottom” and “upper” or “top,” can 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. Similarly, if the device in one of the figures is turned over, elements described as “below” or “beneath” other elements would then be oriented “above” the other elements. The exemplary terms “below” or “beneath” can, therefore, encompass both an orientation of above and below.
Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
“Hydrocarbon” means an organic compound having at least one carbon atom and at least one hydrogen atom, wherein one or more of the hydrogen atoms can optionally be substituted by a halogen atom (e.g., CH3F, CHF3 and CF4 are each a hydrocarbon as used herein)
“Substituted” means that the compound is substituted with at least one (e.g., 1, 2, 3, or 4) substituent independently selected from a hydroxyl (—OH), a C1-9 alkoxy, a C1-9 haloalkoxy, an oxo (═O), a nitro (—NO2), a cyano (—CN), an amino (—NH2), an azido (—N3), an amidino (—C(═NH)NH2), a hydrazino (—NHNH2), a hydrazono (═N—NH2), a carbonyl (—C(═O)—), a carbamoyl group (—C(O)NH2), a sulfonyl (—S(═O)2—), a thiol (—SH), a thiocyano (—SCN), a tosyl (CH3C6H4SO2—), a carboxylic acid (—C(═O)OH), a carboxylic C1 to C6 alkyl ester (—C(═O)OR wherein R is a C1 to C6 alkyl group), a carboxylic acid salt (—C(═O)OM) wherein M is an organic or inorganic anion, a sulfonic acid (—SO3H2), a sulfonic mono- or dibasic salt (—SO3MH or —SO3M2 wherein M is an organic or inorganic anion), a phosphoric acid (—PO3H2), a phosphoric acid mono- or dibasic salt (—PO3MH or —PO3M2 wherein M is an organic or inorganic anion), a C1 to C12 alkyl, a C3 to C12 cycloalkyl, a C2 to C12 alkenyl, a C5 to C12 cycloalkenyl, a C2 to C12 alkynyl, a C6 to C12 aryl, a C7 to C13 arylalkylene, a C4 to C12 heterocycloalkyl, and a C3 to C12 heteroaryl instead of hydrogen, provided that the substituted atom's normal valence is not exceeded.
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 can, typically, have rough and/or nonlinear features. Moreover, sharp angles that are illustrated can 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.
This application is a continuation of U.S. patent application Ser. No. 16/010,112, filed Jun. 15, 2018, which is a continuation-in-part of U.S. patent application Ser. No. 15/374,169, filed Dec. 9, 2016, which claims priority to U.S. Provisional Patent Application Ser. No. 62/264,934, filed Dec. 9, 2015, each of which is hereby incorporated by reference in its entirety to the extent permitted by applicable law.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4090362 | Bourque | May 1978 | A |
| 20150233578 | Monteiro | Aug 2015 | A1 |
| Number | Date | Country |
|---|---|---|
| WO-2015028823 | Mar 2015 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 20210215392 A1 | Jul 2021 | US |
| Number | Date | Country | |
|---|---|---|---|
| 62264934 | Dec 2015 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 16010112 | Jun 2018 | US |
| Child | 17213616 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15374169 | Dec 2016 | US |
| Child | 16010112 | US |
