The present invention generally relates to a heat exchanger apparatus and process for vaporizing cryogenic liquefied gas such as in industrial gas plant back up, which utilize a liquefied gas supply. More particularly, the present invention relates to natural convection water bath vaporizers which are heated by suitable means to vaporize and heat the liquefied gas to ambient temperatures suitable for use, for example to a temperature of about 0° to 60° F.
Cryogenic liquefied industrial gases and fuel gases such as nitrogen and oxygen and liquefied natural gases (LNG) are stored in many locations throughout the world. The gases are stored in cryogenic liquid form rather than as ambient temperature gas form since the volume of the liquid is in the range of 1/1000 times the same weight of gas in gaseous form. At locations where an industrial gas plant supplies gas or where a natural gas pipeline supplies the natural (fuel) gas, a temporary plant backup or LNG peak shave supply of cryogenic liquid is stored and vaporized on demand in case of gas plant shutdown or to augment the pipeline or plant supply in a peak shaving situation. Hence, the vaporization system may be called a plant back-up vaporizer or a peak shave system.
Vaporizers are a class of heat exchangers, which use various heat sources for the vaporization process. Since the vaporized gas generally is discharged from the vaporizers at ambient temperatures, many sources of heat are used such as ambient air, steam, seawater, ambient temperature or heated water. Cryogenic vaporizers may be operated continuously or for shorter periods down to the ½ hour range depending on the overall industrial gas supply process or particular system requirements. The source of vaporizer heat depends upon individual site conditions, space, economics, period of operation and capacity. Prior patent art describes many of the different types of vaporizers, generally named by heat source such as ambient air vaporizer, submerged combustion vaporizers, open-rack sea water vaporizers, steam sparged water bath vaporizers, immersed fire tube water bath vaporizers. The vaporizers may be classed according to service such as continuous, intermittent or ballasted, plant back up or peak-shaving or a combination of these service classes.
Water bath vaporizers are comprised of a water tank or bath into which is submerged a vaporizing coil or tube bundle for the purpose of transferring heat from the water bath to the cryogenic liquid flowing through the tubular coil or tubes of the tube bundle said coil or tube bundle is generally made of austenitic stainless steel due to the cryogenic temperature range of −200° F. to −400° F. Generally, the water transfers the heat via a natural convection heat transfer process as opposed to forced convection, which uses pumping means. It is well known that forced circulation of fluids improves the heat transfer process. In a plant back up situation, the water bath vaporizer is kept heated to a maximum temperature of about 160° F. to prevent the vaporized and superheated gas from exceeding an exit temperature of 160° F. regardless of the rate of gas throughput. At maximum throughput, the exit gas temperature is kept to about 60° F. and in no case lower than the lower limit of approximately 0° F. to avoid pipeline icing conditions. The vaporizer may be operated continuously provided the said water heating means continues to maintain the water bath at the said water temperature of about 160° F. Some of these water bath vaporizers are required to store enough heated water, referred to as thermal ballast, to supply vaporized gas for a certain time period of for example between 15 minutes to one hour in the event of a failure of the heat system, such as loss of steam or loss of electric power, which would shut down the combustion system in fire tube or submerged combustion heating means or any water circulating pumping means. Due to the increasing capacity requirements of these standby vaporizers, with present capacities in the range of heat transfer of 15,000,000 to 30,000,000 Btu/hr and thermal ballast periods of ½ to 1 hour, the physical size of the units, which may require about 20,000 to 40,000 gallons of water storage, presents fabrication, shipping and field erection problems, as well as high cost.
The natural convection water bath heat transfer process is characterized by the Equation:
Q=hAΔTw (Equation 1)
Q being the rate of heat transfer, BTU/hr; h being the water natural convection heat transfer coefficient, BTU/hr ft2 ° F., A being the heat exchanger tubular surface area in square feet and ΔTw being the temperature difference between the water and tubular heat exchanger surface in ° F. The thermal energy stored in the water tank is defined as
Qw=W Cp ΔTs (Equation 2)
Qw is the heat available in BTU in W lb of water having a specific heat Cp of about 1 BTU/lb ° F. when the water temperature is lowered from T1 to T2° F., rewritten as ΔTs the water temperature is reduced during a ballast run without heat being replaced, the natural convection heat transfer coefficient h is reduced and the delta Tw (ΔTw) temperature difference is also reduced. Thus combining Equations 1 and 2, it is shown that as the water temperature is reduced, to maintain the heat transfer rate Q in Equation (1), the surface area must be increased since both h and ΔTw are reduced. It is well known by those skilled in the art of cryogenic water bath vaporizers that as the water temperature falls from a bath temperature 160° F. about 120° F. when the heat exchange surface is at 32° F., the freezing point of water, that the heat exchanger surface area A must be increased approximately two times to maintain the rate of heat transfer Q, and a fall from 160° F. to 80° F. requires an increase of heat exchanger surface area A of 3½ to 4 times greater than what is required at a bath temperature of 160° F. A restraint in cryogenic vaporizers is that the extreme low temperature range between −200° F. and −300° F. of the vaporizing cryogenic liquefied gas will produce ice on the heat exchange surface when the surface reaches 32° F. the freezing point of water. Ice layers are known to increase in thickness as the water cools, which can interrupt the heat transfer process and cause system failure by the vaporizer exit gas low temperature shutdown. Natural convection water bath vaporizers produce an ice layer more readily than forced convection water vaporizers. It is also common practice to use alternate fluids other than water, such as glycol (anti-freeze) which alters the water freezing point to a lower value. Such alternates do not change the basic heat transfer process herein.
It is a more recent feature of present art natural convection water bath or alternate liquid bath vaporizers to take particular advantage of the natural thermal stratification within the water bath by placing the vaporizer tube bundle in the uppermost portion of the water bath where the water remains warmer during operation. While a gain in performance is achieved, of about 25% in a particular geometry, trial and error is required to establish such gain for each particular vaporizer configuration.
It will be appreciated from the above that the particular restraints placed on the operation of natural convection-water bath vaporizers including thermal ballast systems and the extreme low temperatures of the cryogenic fluid being vaporized result in very large and very costly systems. Improvements in the heat transfer process, reduction in the icing potential on the heat transfer surface and increasing the temperature range which may be used in the water bath thermal ballast system are highly desired in the art. Such improvements would desirably mitigate the combined reduction in heat transfer coefficient h (Equation 1) and the restrictive temperature drop ΔTs (Equation 2) in the thermal ballast system without the use of power compared to the conventional systems described above.
Several objectives of this invention follow:
To provide a process and apparatus for vaporizing cryogenic liquefied gas which utilizes heated or ambient temperature water to provide the heat for the vaporization process;
To provide a natural convection water bath vaporizer in combination with a non-condensable and inert gas sparger system and apparatus;
To provide a more compact vaporizing system;
To provide a vaporizer with greater resistance to ice formation;
To provide a thermal ballast water bath vaporizer system to operate continuously when heated and for longer time periods in the thermal ballast mode without the heat source than the prior art;
To provide a water bath vaporizer in combination with a gas bubbler with provisions for confining the sparged gas to the vaporizing tube bundle heat transfer surfaces; and
To provide an improved heat transfer process which requires no power. To provide a process and apparatus to reduce thermal stratification in water bath vaporizers.
These and other objectives of this invention will become apparent from the following detailed description and drawings thereof.
In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
The present invention provides a process and apparatus for vaporizing cryogenic liquefied gases and comprises a natural convection heated water bath, which includes an air or inert gas bubble agitation system and gas sparging manifold to improve the natural convection heat transfer process to vaporize and superheat the cryogenic liquefied gas. The gas sparging manifold, positioned below the vaporizer heat exchange tube bundle, which lies immersed in the heated water bath, is supplied with either an external source of inert gas or a gas/air recirculating blower. The use of inert gas of this invention reduces the potential of stress corrosion cracking or SCC, of the austenitic stainless steel of the cryogenic liquid vaporizing tube bundle. Such SCC being, in part, caused by the dissolved oxygen in the water which effect is well known to those skilled in the art.
Important features of this invention are the ability of the process to extract a greater quantity of heat from the water bath upon failure or interruption of the water heating means, to allow the reduction in the surface area of the vaporizer tube bundle coil, and to reduce or eliminate the ice layer thickness on the vaporizer heat transfer surface.
The use of liquids, other than water in the natural convection heat transfer process herein described will likewise benefit from the bubble agitation provided by the present invention.
The invention will be described in more detail with reference to the drawings, which illustrate both the process and the apparatus according to this invention.
Looking now in greater detail at the accompanying drawings,
The illustrated system is characterized by an oversized water tank which water contained therein acts as a thermal energy storage or ballast to supply heat to the vaporization process for a period of time between 3 to 60 minutes in the event that water heating means 3 malfunctions. Because of this condition, of so called water ballast operation among other considerations, the use of forced convection heat transfer processes to provide a more efficient heat transfer process are not employed. The requirement to employ the low performing natural convection heat transfer process restricts the useable temperature range of the water bath time from the high limit of about 160° F. to the lower limit of about 120° F. where detrimental ice formation on the tube bundle vaporizer tubes and a reduced said natural convection heat transfer coefficient h become significant factors resulting in a large vaporizer tube bundle surface area A from above shown Equation (1) and large thermal water storage requirement Qw from above shown Equation (2).
Now referring to
Compressed inert gas supply 14 flows through pressure regulation 15, passes through gas conduit 13 which is arranged with an anti-siphon loop 13A rising above water level 6 to prevent water 5 from entering gas line 13. Gas from line 13 enters manifold sparger 10 and is ejected into water 5 via a multiplicity of sparger holes 11. The inert gas bubbles streams 12 rise vertically, over and around the tubes 9 of tube bundle 2. Bubbles 12 leave water 5 at water level 6 and exit tank 1 at vent 19. This embodiment uses no power during the vaporization process.
Again referring to inert gas supply 14 (
Alternatively, gas may be continuously recirculated by means of gas conduit means or recirculating gas line 17, gas blower 16 and recirculating inert gas connection 18 to said loop 13A. Water heating means 3 may or may not be in operation during the period of gas bubble agitation illustrated in
Now referring to
Since, as described above, that even rates of heat transfer to the heat exchanger tubes and that heat transfer rate is a function of the superficial gas velocity VS, it is beneficial to equalize the velocity VS. Again referring to
The following example illustrates how the present invention achieves a higher rate of heat transfer comparable to present commercial cryogenic natural convection water bath vaporizers providing a lower cost and reduced size of the water ballast systems while at the same time eliminates or greatly reduces ice formation in these cryogenic vaporizers allowing a more compact and lower cost for the vaporizer tube bundle contained in these systems. Referring to
Now referring to
It can now be understood that by using the heat transfer improvement of this invention that at the same water bath temperature a much reduced heat transfer surface area A from Equation 1 may be used to significantly reduce the size and cost of said vaporizer tube bundle 2. Surprisingly, for the cryogenic water bath vaporizers, which operate for a period of time without the addition of heat to the water bath, that the ice layer thickness is reduced at a particular water temperature, or alternatively a lower water bath temperature may be used. Now considering the ice layer thickness of 0.03 inch in the above example at a natural convection water bath temperature of about 120° F. together with the improvement of heat transfer rate of the present invention, combining the results of equations 1 and 2, it can be determined that a water bath temperature of 70° F. will produce a heat transfer rate of 15,000 Btu/hr ft2 and the corresponding thickness of ice remains at about 0.03 inch. The surprising result is that the same tube bundle surface area A from Equation 1 using natural convection heat transfer can be used when the heat source 3 is maintaining water 5 at a temperature of 160° F. and in the absence of heat addition, the water temperature can be allowed to drop to 70° F. using the gas bubble agitation of this invention rather than 120° F. without the advantages of this invention. Consideration of Equation 2 will show that the amount of water W required is inversely proportional to the water temperature drop ΔTs or that for this example 160−120/160−70=0.45 illustrating that the water volume or weight W may be reduced by over 50% for the same ballast operating period without the addition of heat and with no increase in ice layer thickness. Table 1 summarizes these expected values.
It is an unexpected advantage of this invention, that when comparing the combination of heat transfer rates made possible over the prior art and the surprising reduction in said ice layer which results during operation of to cryogenic water bath vaporizers that the simple addition of the gas bubbler of this invention to an existing water bath vaporizer would permit either an economic gain due to the increased vaporization capacity when operating between 160° F. and about 120° F. or lower, or it permits a ballast run period increase from 30 minutes where water ΔTS is 40° F. to over 1 hour where the water temperature ΔTS drop is 90° F., greatly increasing the capacity of any existing water-bath vaporizer.
From the above, it will be appreciated that the gas bubble agitated liquid water bath heat exchange process and apparatus of this invention as applied to natural convection heat transfer processes is a highly desirable advance in the art, which never before was appreciated enabling either separately or in combination enhanced heat transfer and reduction in ice layer formation to be achieved in these cryogenic vaporizer systems. The size of the vaporizer tube bundle can thus be reduced and the thermal energy storage capacity of a given volume of water can be increased or a combination of both can be advantageously maximized.
Numerous modifications and alternative embodiments of the invention will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the best mode of carrying out the invention. The details of the apparatus and process may be varied substantially without departing from the spirit of the invention, and the exclusive use of all modifications, which come within the scope of the appended claims, is reserved.
Applicants claim the benefit of U.S. Provisional Patent Application Ser. No. 61/195,599 filed Oct. 9, 2008.
Number | Date | Country | |
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61195599 | Oct 2008 | US |