The invention relates to a high-temperature heat exchanger, in particular for gaseous media.
The energy efficiency of high-temperature processes can be increased considerably with the help of gas/gas heat exchangers, if the heat exchangers transfer the heat content of a gas flow to another gas flow as completely as possible. The gas flows can be reactants and products, for example, of a chemical reaction process, for example in the form of a combustion process. The reaction can take place in a SOFC combustion cell or a fuel cell system, for example, in micro gas turbines or other thermal engines. In many cases, the mass or heat capacity flows, respectively, of the two gases (e.g. fresh air and exhaust gas) are thereby approximately the same.
Corresponding heat exchangers must satisfy different requirements, which can only be combined with difficulty to some extent. The heat exchangers must be suitable for:
Various heat exchanger arrangements are known for bringing media in heat exchange with one another. For example, WO 96/20808 discloses a heat exchanger comprising a closed, approximately cylindrical vessel, which is closed by means of rounded end caps and tube sheets, which are arranged at opposite ends of the vessel. The tube sheets divide the interior into three separate spaces, namely, e.g., two collecting spaces and a tube bundle space therebetween. The connections of the collecting spaces are arranged, e.g., so as to be concentric to the longitudinal axis of the cylindrical housing at the end caps thereof. Inflow and outflow of the tube bundle space are arranged radially, e.g. at the cylindrical housing wall. Depending on the embodiment, the tubes of the tube bundle are embodied so as to be straight, e.g., and are provided with sections of a different cross section. Circular cross sections alternate with oval cross sections.
While the above-mentioned document discloses a closed heat exchanger, EP 1 995 516 B1 shows an open heat exchanger comprising flat tubes, which are only encased on one side. At their ends, the tubes are round and are embodied so as to be flat in a central section. In the flat section, the cross section of the tube is formed by two sections, which delimit a gap and which are curved with a large radius, wherein they are connected to one another at their ends by means of sections, which are curved with a large radius. The flat tubes are arranged on concentric circles of the heat exchanger, which, as whole, is embodied so as to be substantially rotationally symmetrical. The same number of tubes is thereby provided on each circle. Corrugated spacers are arranged between the tubes. This flat tube heat exchanger is operated in countercurrent flow. Nozzles, which effect a high gas outlet speed, are arranged at the side of the flat tubes facing a combustion chamber. Specifically, this is an exhaust gas heat recuperator, which is to effect a flameless oxidation in the connected combustion chamber due to the high gas outlet speed.
It is the task of the invention to specify a heat exchanger, which fulfills the above-mentioned conditions. In particular, it is to combine a large temperature difference, a high transfer efficiency, a high packaging density and a long service life with low pressure drops and low production costs.
This task is solved by means of the flat tube heat exchanger according to claim 1:
The flat tube heat exchanger according to the invention encompasses a closed housing, in which two tube sheets and a tube bundle, which is arranged between the tube sheets and which is supported by the tube sheets is arranged. The tube bundle comprises at least some flat tubes, which extend in longitudinal direction of the tube bundle. At their ends, the flat tubes are round and are flat in a central section. The ends of the flat tubes, which have a round cross section, can be circular or can encompass a different round shape. E.g., they can encompass an elliptical cross section, an oval cross section or also a polygonal cross section (triangular, square, rectangular, hexagonal or the like), which becomes similar to a round shape. The cross section of the round section is preferably between 50% and 70% of the cross section of the flat cross section. While the round cross sections are circular, the flat cross sections have an oval shape, which preferably consists of curved end sections comprising a small radius and straight wall sections without a curvature. For example, such flat tubes are produced in starting with a tube, which encompasses a section comprising a circular cross section and a larger diameter between two sections comprising a circular cross section and a smaller diameter. The section comprising the larger diameter can be flattened, e.g. between cylinder rollers, in a reshaping process, e.g. a rolling process. The configuration of the flat tubes described in this respect is preferred for all embodiments of the heat exchanger according to the invention.
Preferably, three zones are embodied in the tube bundle space, namely two transverse flow zones, which are embodied at the tube bundle space connections, and one longitudinal flow zone, which is embodied between said transverse flow zones. The transverse flow zones are preferably defined in that provision is in each case made on both sides, which adjoin the tube sheets, for a section, in that the flat tubes encompass a round cross section (preferably circular cross section) or a polygonal cross section similar to a circle and are tapered, so as to provide for the inflow or outflow, respectively, of the gas transversely to the flat tubes. Preferably, corresponding channels are embodied between the individual flat tubes for this purpose. It is preferred to orient these channels in inflow or outflow direction, respectively. In the case of a rotationally symmetrical design, these channels are preferably oriented in radial direction. The inflow or outflow can flow radial from the inside or also radial from the outside or to the outside. The transverse flow direction, which is defined by the transverse flow zone, is preferably oriented vertically to the flat sides of the flat tubes, that is, parallel to the surface normal direction of the flat sides. This concept can also be applied in the case of all of the embodiments of the heat exchanger.
The longitudinal flow zone is defined in that substantially no transverse flow exists in it. The flow, which occurs between the flat tube sections, runs anti-parallel to the flow, which flows in the flat tubes. In particular, the flow preferably does not change between the different longitudinal flow ducts, which are present between the flat tubes. This is achieved in that adjacent flat tubes are arranged so as to touch one another or so as to almost touch one another with a slight gap.
The flat tube heat exchanger can be designed as a rectangle or also as a round arrangement. In the rectangular arrangement, it encompasses a cube-shaped tube bundle space. In the round arrangement, it encompasses a cylindrical tube bundle space. Preferably, the heat exchanger is designed in round arrangement as ring heat exchanger. Its housing is then delimited cylindrically or also polygonally, e.g.. Coaxially to the outer wall, the heat exchanger housing can encompass an inner wall. The latter can surround further aggregates, such as, e.g., a reactor, in which the supplied process gas runs through a chemical process, a burner, another heat source of combinations thereof. In the case of a preferred embodiment, the longitudinal flow space, in which the flat sections of the flat tubes are arranged, is embodied in a ring-shaped manner (that is, hollow cylindrically). In contrast, at least one of the two transverse flow spaces is preferably embodied in a cylindrical manner and encompasses a free central gas distribution space (gas collecting space), from which the gas flow leads radial to the outside between the round sections of the flat tubes (or vice versa).
In transverse flow direction, the tube bundle preferably encompasses an expansion, which is maximally twice as large as the length of the transverse inflow zone, which is measured in longitudinal tube bundle direction. A uniform distribution of the gas can be achieved through this before it flows through the longitudinal flow zone between the flat tubes. The mentioned measure also creates a good prerequisite for being able to arrange the flat tubes in the tube bundle in a relatively tight manner, thus resulting in a good utilization of space and thus in a compact design. Adhering to certain dimensions for the flat tubes can also contribute to this. Preferably, the flat tubes have an inner gap width s of between 1 mm and 5 mm, preferably between 1 mm and 3 mm. Optimally, the gap width is 2 mm. The free width of the flat tube interior is preferably between 7 mm and 20 mm. The flat tubes are preferably arranged in a packing density p of between 0.9 m2/dm3 and 0.2 m2/dm3.
Space-maintaining structures, e.g. in the shape of imprinted burls, ribs or the like, can also be present at the flat tubes, so as to fix the distance between the tubes. The maximum distance between the flat tubes is preferably in the size of the gap width. The gap width is preferably a few millimeters at best. The distance of the rounded areas of the flat tubes from one another is preferably smaller than the gap width. The channels, which are formed between the flat tubes, are thus virtually separated from one another. The uniform gas distribution in the transverse flow zone is of considerable importance.
Instead of flat tubes, so-called structured tubes can also be used, in the case of which the heat transfer is improved by means of turbulence vortices. To generate turbulence vortices, turbulence-generating elements, e.g. ribs, protrusions, dents or the like, can be embodied at the inner and/or outer surfaces of the flat tubes.
Preferably, all of the flat tubes have the same shape, are thus embodied uniformly, which keeps the production effort low.
The tubes can be embodied in one piece or in several pieces. This can be advantageous in particular in the case of a very large temperature difference. Tubes made of different materials can be joined to one another bluntly, in particular by means of welding. In the cold zone, different materials can thus be used than in the warm zone. An expansion element, which compensates the expansion differences between the housing and the tube bundle, can be arranged at the housing. The expansion compensation element is preferably arranged at the cold side of the heat exchanger.
In the event that the heat exchanger tubes are arranged in one ring zone, which surrounds a central area, a burner comprising a combustion chamber can be arranged at that location, e.g. so as to heat a reactor, which is present at that location. An insulating layer is preferably arranged between the combustion chamber and the heat exchanger. This combination of heat exchanger and combustion chamber is suitable, for example, for heating the cathode air for a SOFC fuel cell.
A catalytic reactor can also be attached in the interior, in particular in the tube bundle space of the heat exchanger. Said catalytic reactor can be arranged, e.g. as reformer, in the anode gas cycle of a SOFC fuel cell system.
Efficiencies above 80% can be achieved by means of the flat tube exchanger according to the invention. Preferably, the gas, which is to be heated, is guided in the tubes, and the gas, which releases heat, is guided between the tubes. Gases comprising very high inlet temperatures, such as 1000° C., e.g., can be processed. Based on the construction volume, the heat transfer rates are within the same range as the heat transfer rates of plate heat exchangers and regenerators, which have comparable gap widths. However, welded plate heat exchangers are not suitable for such high temperatures. The proposed flat tube heat exchangers is thus suitable in particular in the case of the local energy production, e.g. in the case of SOFC fuel cells or micro gas turbines. The switchover valves and control systems, which are required in the case of regenerators, are not necessary.
Other objects and advantages of the present invention will become apparent to those skilled in the art upon a review of the following detailed description of the preferred embodiments and the accompanying drawings.
A tube bundle 21 is arranged between the tube sheets 14, 15. Said tube bundle 21 consists of numerous flat tubes 22, which are preferably embodied equally among one another. The transverse sections of the flat tubes 22 encompass straight shoulders, which delimit the inner gap cross section between one another. The flat shoulders are connected to one another by means of sections, which are curved with a slight radius. Each flat tube 22 is preferably embodied so as to be straight and is arranged parallel to an imaginary central axis 23 of the housing 11. With their ends, 24, 25, the flat tubes 22 are anchored to the tube sheets 14, 15. For example, they are welded, hard-soldered, pressed, crimped or connected in a different suitable manner to the respective tube sheet 14, 15. Preferably, the connection is fluid-tight and temperature-resistant.
Each flat tube 22 encompasses a comparatively long central section A comprising a flat cross section and a shorter section B comprising a round section at its two ends 24, 25.
Within the row, the flat tubes 22 are at least preferably arranged such that the individual flat tubes 22 do not touch one another with their sections, which are heavily curved. However, the remaining gaps between the flat tubes 22 within a row are small. In the alternative, the flat tubes can also touch one another at every temperature or only at certain temperatures. The flat sides of the flat tubes are oriented in circumferential direction, thus tangentially to the respective circle, on which they are arranged.
The ring-shaped spaces formed between the rows or boundaries of different flat tubes 22 are relatively narrow. These are ring-shaped flow ducts, which are largely kept free from other components. The individual ring-shaped flow ducts are largely separated from one another by means of the flat tube wreaths.
It is pointed out that other flat tube configurations can be used. For example, the flat tubes can be arranged in a single row, which is wound into a coil. They can also be slightly inclined against the circumferential direction, thus slightly rotated about their respective longitudinal axis. They then draw an acute angle with the tangential direction. However, the above explanations with regard to the cross sectional shape and tube distances apply accordingly.
Preferably, the number of the tubes, which are arranged in every ring-shaped row illustrated in
As can be seen from
The sections A of the flat tubes 22, which are located between the two transverse flow zones 29, form a longitudinal flow zone 30, which serves for the actual heat exchange.
Tube bundle space connections 31, 32, which can be arranged coaxially to the central axis 23, e.g., and which, in this case, permeate the cover lids 12, 13 and the tube sheets 14, 15, serve to introduce and divert fluid in the tube bundle space 17. It is pointed out that the tube bundle connections 32, 33 can also be arranged elsewhere. For example, they can be embodied so as to be attached radially or tangentially to the housing 11 in the areas B while permeating the housing 11. In addition, an inner housing wall 33 can be arranged concentric to the central axis 23. Said housing wall 33 can be formed by means of a solid body or a hollow body. It can surround further system parts, a heat storage vessel or the like, or can also be empty.
At a suitable location, the housing 11 can be provided with an expansion compensation element 34. Preferably, the latter is attached in the cylindrical area of the housing 11 between the tube sheets 14, 15, preferably in the vicinity of the colder tube sheet, that is, of the connection 19 at the inlet side. The expansion compensation element can allow an axial expansion and compression of the housing 11 within certain limits, so that the distance between the tube sheets 14, 15 is defined by the temperature and thus by the length of the tube bundle 21. The housing 11 adapts accordingly.
The flat tube heat exchanger 10, which has been described in this respect, works as follows:
During operation, hot, preferably gaseous fluid, for example exhaust gas of a micro gas turbine or the like, is supplied to the flat tube heat exchanger 10 via the tube bundle space connection 31. Above the approximately cylindrical central body, which is surrounded by the inner housing wall 33, this flow is deflected substantially in radial direction. It reaches the channels 26 to 28, which can be seen in
At the same time, cold gas, e.g. air comprising ambient temperature, is guided via the connection 19 at the inlet side into the colleting space 16. From there, it enters into the round lower ends of the flat tubes 22 and flows through the inner gap volumes of the flat tubes 22 into the colleting space 18 located on the opposite side. It thereby flows in countercurrent flow to the hot gas, the inlet temperature of which can be approximately 1000°, e.g.. The supplied cool air absorbs a large portion of the heat and can reach 800° or 900°, e.g., in the collecting space. It then discharges via the connection 20 at the outlet side.
Due to the illustrated flow structure, the flat tube heat exchanger 10 has only a slight differential pressure demand for the hot gas flow as well as for the cold gas flow. The resulting pressure loss is low. Due to the narrow gap width of the flat tubes 22 and of the tight arrangement thereof, a high heat utilization is reached. The exhaust gas, which leaves the tube bundle space 17 via the tube bundle space connection 32, is cooled down, e.g. to low temperatures of a few 100° C., e.g., 200° C. or 300° C.
As a further option, in particular the flat sides of section A of each flat tube 22 can be provided with protrusions 35, e.g. in the form of burls or ribs, fins or the like. These protrusions 35 can serve as spacers, so as to prevent that flat tubes 22 from different rows come too close to one another and block the flow duct, which is present therebetween. It is also possible to use these protrusions 35 as turbulence-generating elements, so as to improve the heat transfer of the hot gases, which flow between the flat tubes 22, to the flat tubes 22.
The above-described principles can also be realized at non-ring-shaped or non-cylindrical heat exchangers, respectively.
A further modified heat exchanger 10 is illustrated in
To improve the energy efficiency of high-temperature processes, a flat tube heat exchanger 10 is proposed, which is suitable for high temperatures, tolerates a large temperature difference, and achieves transfer efficiencies above 80% in countercurrent-flow operation. In addition, it encompasses a high packing density, low pressure drops, for example less than 50 mbar, high durability and robustness, and low production costs. The flat tube heat exchanger encompasses flat tubes, which encompass flat tube heat exchanger sections and round ends. The round ends define transverse inflow zones, which produce a uniform gas distribution of a hot gas among the flat sections of the flat tubes 22 with low pressure drops. The efficiency of such a flat tube heat exchanger is comparable to the efficiency of a plate heat exchanger, wherein, however, such a flat tube heat exchanger is substantially more robust.
The above detailed description of the present invention is given for explanatory purposes. It will be apparent to those skilled in the art that numerous changes and modifications can be made without departing from the scope of the invention. Accordingly, the whole of the foregoing description is to be construed in an illustrative and not a limitative sense, the scope of the invention being defined solely by the appended claims.
Number | Date | Country | Kind |
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11 185 815.5 | Oct 2011 | EP | regional |
The present application is based upon and claims the benefit of PCT/EP2012/069873, filed 8 Oct. 2012; which is based on European patent application no. 11 185 815.5, filed 19 Oct. 2011.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2012/069873 | 10/8/2012 | WO | 00 | 4/15/2014 |