The present invention relates to an energy transfer unit and a method of constructing such an energy transfer unit.
Energy transfer units are well known and commonly used to transfer energy in the form of heat from one medium to another. As such they are generally referred to as heat exchangers. Such units are used in many industrial and commercial processes and are designed to meet the particular operating conditions of those processes.
Energy transfer units are used extensively in HVAC (heating, ventilating and it conditioning) applications where they must operate at high efficiencies and at the same time be relatively economical to produce. One particular HVAC application arises in geothermal heating and cooling systems in which a heat exchanger is an integral part of exchanging energy between a ground source and a fluid circulating between the ground source and a heat pump. The ground source is a thermal reservoir that may be a body of water, such as at lake, river or stream, or may be the ground itself at a depth that provides a substantially uniform temperature.
The heat exchangers presently used in geothermal applications may be as simple as a pipe buried within the ground or submerged in a lake, or may be a mesh of smaller pipes interconnected to a manifold. The effectiveness of the heat exchanger determines to a lame extent to the overall efficiency of the heating and cooling system, but the form of the heat exchanger has been maintained as inexpensive as possible despite e inefficiencies that such an arrangement introduces.
In the Applicant's co pending application, International Application No. PCT/CA2011/000846, published as WO 2012/009802, there is disclosed an arrangement of energy transfer unit in which heat exchange cores formed from spirally wound small bore tubing, referred to as capillaries, are located within an external housing and a flow of water induced through the housing to increase the efficiency of the heat transfer. This arrangement has proven highly effective and has introduced significant efficiencies to the overall system. The efficiencies within the energy transfer unit have made increased thermal capacities possible within a compact overall envelope. However, such increased capacity has in turn made the control of flow within the housing more complex over a range of operating conditions. The manufacturer of the heat exchange core itself is however labour intensive and therefore relatively expensive.
It is an object of the present invention to provide an energy transfer unit in which the above disadvantages are obviated or mitigated.
In general terms, one aspect of the present invention provides an energy transfer nun having one or more modules. Each of the modules has a support structure to support a capillary spirally wound between an inlet header and an outlet header. The modules may be stacked one above the other, with the headers interconnected to provide a common inlet and a common outlet for the modules. The capillaries are arranged in parallel between the inlet and outlet. The heat exchanger may be sized to the particular requirements by selecting the appropriate number of modules.
Preferably, each module has a frusto conical shell with a support structure integrated with the shell to support spirally wound capillaries. The frusto conical shells may be stacked one above the other in spaced relationship to provide a passage between adjacent shells and to promote flow between the shells and over the capillaries retained between the shells.
In another aspect there is provide an energy transfer unit having a heat exchange core and a baffle juxtaposed over the core to direct fluid from a heat source radially relative to the core.
Preferably, the baffle in inclined to the direction of flow of fluid, and as a further preference, the baffle directs the fluid to a chimney.
Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:
Referring therefore to
The energy transfer unit 10 is formed from a number of modules 20, indicated individually as 20a, 20b, 20c, 20d, that are stacked one above the other to provide a multi layered body to the energy transfer unit 10. A base 22 extends across the lower most of the modules 20d and a tether assembly 24 is secured to the base 22. The tether assembly 24 includes a ballast 26 and a pair of the lines 28 that allow the energy transfer unit 10 to be secured in location in a heat source, for example in a body of water. A flared collar 29, is secured to the upper module 20a to promote flow through the heat exchanger 10.
Each of the modules 20 is of similar design and therefore only one will be described in detail. Each of the modules 20 has a frusto conical shell 30 formed from plastics, such as polyethylene or similar material. Headers 32 are integrally formed at spaced intervals about the outer periphery 31 of the shell 30 and the shell 30 terminates at its upper edge at a central aperture 34. The shell has a half angle α in the order of 45° with the lower most portion adjacent the radially outer periphery flared to provide a shallow skirt 36. The half angle β of the flared skirt is in the order of 25° and smoothly blends with the balance of the shell 30.
The shell 30 is integrally moulded with spars 40 that extend from the header 32 to the aperture 34. Each of the spars 40 depends downwardly from the shell 30 and has a lower edge that is formed with v shaped notches 42. Flanks 44, 46 of the notches 42 are formed with part circular recesses 48 to receive tubing 50. A heat exchange core is provided by an array of tubing 50 that extends from an inlet header to an outlet header. Preferably, the tubing 50, as can best be seen in
The diameter of the recesses 48 is selected such that the tubing 50 is a press fit within the recess 48 and thereby retained on the spar 40. The press fit is such that the interior diameter of the tubing 50 is not reduced to avoid restrictions along the length of the tubing 50.
Each of the headers 32 is formed with an internal shoulder 60 at its upper end and an external shoulder 62 at its lower end. The shoulders 60, 62 facilitate the stacking of the headers 32 one above the other so that the shells 30 overlie one another in spaced relationship. The conical void between the adjacent shells accommodates the spirally wound tubing 50.
A pair or the headers 32 of the lower most module 20 is connected to the inlet 12 by conduits 70, 72 and the diametrically opposite headers 32 interconnected to the outlet 14 by conduits 74, 76 (
The base 22 has a central aperture 23, aligned with the aperture 34 but of smaller diameter, to create a central chimney through the energy transfer unit 10.
Each of the modules 20 may be assembled by feeding the tubing 50 in its spiral pattern on the underside of the shell 30. The notches 42 present an open access to the recesses 48 thereby avoiding the need to thread the pipes 50 through the spars 40. Once the tubing 50 is installed on the spars 40, it may be connected to the nipples 52 to provide a self contained module 20 that provides a heat exchange core.
The modules 20 may then be assembled by stacking one on the other until the requisite number of modules 20 has been assembled. The shoulders 60, 62 locate the headers 32 on one another and allow the modules to be secured by fusion welding or adhesive. The conduits 70-76 are then secured between the headers 32 and respective ones of the inlets and outlets 12, 14 and the base 22 secured to the lowermost module 20. The tether 24 may then be connected. The headers 32 maintain the peripheral edges 31 of the shells 30 in spaced relationship to allow fluid to pass between the shells and around the tubing 50 arranged on the spars 40.
In use, the pipes 16, 18 are connected to the inlet 12 and outlet 14 respectively and the assembled heat exchanger 10 submersed within a body of water or other ground source that serves as a thermal reservoir. Heat exchange fluid is circulated through the pipes 16, 18 where it flows through the headers 32 and in to the tubing 50 to move between the inlet 16 and the outlet 18. As the fluid flows, heat is transferred between the water surrounding the tubing 50 and the heat exchange fluid in the tubing 50. The change in temperature of the fluid between the shells 30, creates a density imbalance which imparts a flow of fluid between the shells 30 from the radially outer edge 31 to the aperture 34 in the case where heat is rejected to the body of water. The inclined surface of the shell 30 promotes the radial flow to the aperture 34. The flow is enhanced by the skin 36, which accelerates the flow radially inwardly between the shells 30 to enhance the circulation. The flow induced between the shells 30 enhances the heat transfer with the tubing 50. The flared collar 29 promotes the flow of fluid out of the energy transfer unit 10, and the aperture 23 in the base 22 promotes a chimney effect from the lower base 22 to the aperture 34 to further reinforce the flow through the shells.
It will be noted that the runs of tubing 50 provide parallel paths between the inlet headers 32 and outlet headers 32 so that the pressure drop is maintained relatively small.
The capacity of the energy transfer unit 10 may readily be adjusted by adding or subtracting the modules 20 and it will be noted that assembly of the modules may be performed prior to their assembly in to the energy transfer unit 10. Of course, the energy transfer unit may consist of a single module, or may have multiple modules where an increased capacity is required.
A further embodiment of modular heat exchanger is shown in
Referring to
Four runs of tubing 50a extends from each of a pair of diametrically opposed headers 32a and are received in alternate notches 42a along the spars 40a of the uppermost shell 30a. The runs of tubing 50a are spaced apart vertically in each of the notches 42a and spiral inwardly to the central aperture 34a. At the radially inner extent of the spars 40a, the sets of tubing 50a are directed in to the lowermost shell 30a of the nun where they are received in the notches 42a as they spiral radially outwardly. The tubing 50a spirals in the same hand in the upper and lower shells 30a to minimise flow restriction in the tubes 50a. The tubing 50a of the lower shell 30a is connected to headers 32a located between the headers 32a of the upper shell to provide a circulation between inlet and outlet.
The modules may be stacked one above the other as illustrated above to vary the capacity of the energy transfer unit 10a with the headers 32a nesting to provide a common inlet and outlet for each of the shells 30a. Again, only a single module may be required, although typically more than one module is provided. With the arrangement of
An alternate configuration of modular energy transfer unit is shown in
Referring therefore to
The tube 80 locates a radially inner edge of a spar 140 that extends radially outwardly towards the flange 136. The radially inner edge of each of the spars 140 is received within a groove 84 (
Each of the spars 140 is formed from a sot of comb like strips indicated at 88. Each of the edges of the strip 88 has a series of part circular recesses 148 to receive the capillary tubing 150. When arranged edge to edge, the strips 88 locate the capillary tubing 150 between opposite edges of the strips to maintain a uniform spaced relationship.
Headers 132 are provided at diametrically opposite locations on the shell 130. Each of the headers 132 comprises a pair of tubes 90. A row of spaced outlets 92 is provided along each of the tubes 90 facing in opposite directions for connection to the tubes 150. The connection between the tubes 90 and the tubing 50 is typically performed by welding.
The arrangement of the array of tubing 150 within the spars 140 is similar to that described above in that each is spirally wound and of opposite hand. A run of tubing 150 therefore proceeds from one of the tubes 90 through the spars 140 toward the central tube 80 and thereafter radially outwardly to terminate at the diametrically opposite tube 90.
To assemble the heat energy transfer unit 130, the first strip 88 of the spar 140 is secured in each of the grooves 84 on the central tube 80. The tubing 150 is then spirally wound and placed into the part circular grooves and is secured in situ by placement of the next of the strips 88. The strips are preferably are the snap fit within the grooves 84 so as to securely hold these strips 88 in alignment. The strips 88 may extend radially outwardly to the flange 136 to provide extra rigidity or ma be joined to one another at the radially outer edge by a common channel or similar mechanical fastening device.
The next spiral array of tubing 150 is located in the open set of recesses 148 and the next to the strips 88 then added. This continues until all of the strips 88 have been inserted to locate the tubing 150.
It will be appreciated that the arrangement of the spars 140 made from the individual strips could be replaced with a single rectangular spar with holes formed therein and the tuning threaded through those holes. Such an arrangement would require less individual components but would increase the complexity of threading of the tubing.
Each of the central tubes 80 and the tubes 90 forming the headers 132 is formed with shoulders, as shown above with respect to
In operation, the heat transfer fluid is circulated through the inlet header 132 where it is discharged into the tubing 150 to flow in opposite directions to the outlet header 132. The inlet 116 is provided from the lower point of the header 132 and the outlet 118 is taken from the highest point of the opposite header 132. The transfer of heat to the surrounding water causes a radial flow of the water either from the flange 136 to the central tube 80 through the ports 82 where heat is being rejected to the cooling water or in the opposite direction when heat is being absorbed from the water. The inclination of the central disk 131 promotes the radial flow between the apertures 134 and the flange 136. The inclination of the central disk 131 has a half angle between 65 and 75 degrees relative to the longitudinal axis of the tube 80 and the flange is radially outwardly inclined at a half angle of 10 degrees to the longitudinal axis.
The stacking of the tubes 80 and the positioning of the ports 82 to control flow between the tube 80 and the space between adjacent shells 130 that accommodates the heat exchange tubing 150 provides a pronounced chimney effect along the longitudinal axis of the energy transfer unit. The chimney promotes the radial flow of fluid around the tubing and therefore increases the efficiency of the unit.
The provision of the shell 130 and the chimney effect from the central tube 80 may also be utilized in an energy transfer unit located within a housing in a manner shown in PCT Publication WO 2012/009802. Such an arrangement is shown in
Referring therefore to
The energy transfer unit 210 has a housing 216 made from upper and lower shells 218 to 220 respectively. The shells 218 and 220 are connected to one another at an equator 222. A number of inlet apertures 224 are provided on the equator around the periphery of the housing 216. The upper shell 218 has a circular outlet 226 to receive a chimney described in greater detail below and the lower shell has a number of spaced apertures 223 (
The housing 216 contains a heat exchange unit 230 as best seen in
A central tube 244 extends through the housing 216 and projects though the aperture 226. The lower end of the central tube 244 is sealed by a plate 246. The inlet 212 and outlet 214 extends along the housing 210 at diametrically opposite sides of the tube 244. The inlet 212 and outlet 214 respectively extend radially between the coils 232 to 234 to the radially outer periphery of the coils to a distribution conduit 248. The distribution conduit 248 in turn is connected through a T-piece to a manifold 250 (
A conical baffle 260 is interposed between the coils 232 and 234. The baffle 260 extends radially from the outer periphery of the coil 234 to the tube 244. Ports 262 are provided in the tube 244 adjacent to the intersection of the baffle 260 with the tube. The ports 262 permit flow of fluid between the interior of the tube 244 and the underside of the baffle 260 with the inclination of the baffle promoting radially inward and upward flow of fluid.
A similar baffle 264 is provided above the coil 236 which terminates at to collar which is concentric to the tube 244 to define an annulus.
In use, the heat exchanger is located between the shells 218 and 220 of the housing 210 with the collar 268 projecting through the aperture 226. The shells 218 to 220 are dimensioned to secure the heat exchangers within the housing 216 through engagement of abutments in the housing with the spars 240. Such an arrangement is described in more detail in the PCT Publication noted above and need be described in greater detail at this time.
Heat exchange fluid is provided trough the inlet 212 to the coils 232 to 234 and returned through the outlet 214. The housing 216 is immersed within a body of water that provides a uniform temperature heat reservoir. If heat is being rejected to the water, i.e. as in the case where cooling is being affected b the associated heat pump, the temperature of the heat exchange fluids circulated through the inlet 212 and outlet 214 is higher than that of the surrounding water and heat is transferred to the water. The heating of the water causes a density imbalance that induces flow across the coils 234 to 232 so that fluid abuts against the underside of the baffles 260 and 264. The inclination of the baffles 260, 264 causes a flow to move radially inwardly and, in the case of fluid passing over the lower through the ports 262. The fluid then flows along the tube 244 and upwardly to the exterior of the housing 210.
Similarly fluid passing over the coil 236 is directed by the inclined baffle 264 to the annular between the collar 268 and tube 244 to emerge through the upper surface of the housing.
The fluid lost through the tube 244 and collar 268 is replenished through ports 223 on the underside of the shell 220 and through the ports 224 provided around the equator of the housing 216. The ports 224 are positioned above the baffle 260 so that a separate fluid inlet is provided for each of the coils. In this manner, a steady state of heat transfer between the heat exchange fluid provided through the inlet 212 and the surrounding water is accomplished. It will be appreciated that where more than two coils are provided within the housing 216, a baffle is provided between each of the coils and set of ports provided in the housing to supply each of the coils, with a corresponding set of ports 262 in the tube 244. In this manner, a modular arrangement is provided that can be adjusted to suit the particular installations. Where only a single core is required, flow may be provided from the ports 223 and the baffle is spaced from the top of the housing 216 to promote the radial flow.
It will be appreciated that in a heat absorbing mode, that is when heat is being supplied through the heat pump, the temperature in the inlet 212 will be lower than that in the surrounding water and heat will be absorbed from the water. In this case the flow is in an opposite direction that is through the tube 244 and radially outwardly over the coils.
The inclination of the baffles 260, 264 is typically in the range of 5° or 30° and preferably at 20°.
As noted above, the tubing 236 is shown in
The flow of water across the coils is induced by the density imbalance caused by the heating of water. The chimney effect provided by the tube 244 acts to increase the flow through the lower heat exchange coil 234. Moreover, the positioning of the collar 268 concentric to the tube 244 also increases the fluid flow across the coil 236 by inducing the flow under the baffle 264 where the tube and collar emerge.
The provision of flow through the tube 244 and collar 268 also facilitates the installation of the heat exchange unit in a manner that avoids degradation of the heat source. As shown schematically in
As shown in
This also permits the energy transfer unit to be utilized in an environment where the ground water provides the heat transfer medium to the surrounding earth. Conventional systems cause a thermal saturation of the ground water due to its limited flow and the lower thermal conductivity of the earth, but with the chimney provided by the tube 244 and collar 268, the elevated temperature water is delivered to the surface where evaporation promotes the dispersion of the heat at a reduced flow rate.
This application claims priority from U.S. Provisional Patent Application No. 61/536,331 filed Sep. 19, 2011.
Number | Date | Country | |
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61536331 | Sep 2011 | US |