The following relates to air cooled condensers, heat exchanger fins and arrays thereof for air cooled condensers, and so forth.
Traditional heat exchange fins are of the straight or plain variety. Heat transfer occurs through a fin channel wherein air enters in the channel and establishes a fluid boundary layer. Heat transfer normalizes once the fluid boundary layer is established. Some straight fins may have blemishes or other features on their surface as a result of manufacturing processes. As such traditional fin designs may not be entirely straight nor uniform from fin to fin within a fin array.
A known modification of the straight fin design is to include perforations in the fins to disturb air flow with the flow channel, i.e. pressed or cut perforations. They offer cross channel flow paths and are commonly used in automotive applications. The perforations, while effective at disturbing the fluid boundary layer increasing heat transfer, can be impractical in certain applications as they increase the pressure drop of the air flow.
Another known fin design employs offset fins. In this design the straight path is cyclically offset within a channel to disturb the boundary layer. This design, as with the perforations, increase heat transfer capability but in doing so also increases pressure drop.
Another known fin design employs wavy or ruffled fins. In this design the straight fins are curved to form sinusoidal waves. The periodic waves enables disruption of the fluid boundary layer. Haushalter, U.S. Pat. No. 5,209,289 issued May 11, 1993, discloses a modified fin array incorporating wavy offsets in a unique combination.
Bugler et al., U.S. Publication No. 2018/0023901 A1 published Jan. 25, 2018, discloses a heat exchange tube fin design in which a plurality of arrowhead shapes are pressed into or embossed onto each fin. The pressed arrowhead shapes are grouped into nested pairs, and one of the arrowheads in a pair is pressed as a positive relative to the fin plane and the other of the pair is pressed as a negative relative to the fin plane. The arrowhead pairs are placed in rows parallel to the air flow direction and arrowhead pairs in one row are preferably staggered relative to the arrowhead pairs in the adjacent row along the fin in the air flow direction.
In some aspects disclosed herein, an air cooled condenser fin comprises flow channel walls defining an air flow channel. The flow channel walls include planar sections separated by intermittent flow interruptions which are spaced apart along the air flow channel. The intermittent flow interruptions are defined by the flow channel walls.
In some illustrative embodiments, the intermittent flow interruptions comprise splits formed by a staggered arrangement in which the planar sections of the flow channel walls before and after each split are staggered. In some embodiments, the staggering of the flow channel walls after each split is about one-half of a width of the air flow channel.
In some illustrative embodiments, the intermittent flow interruptions comprise intermittent sinusoidal waves formed into the flow channel walls.
In some illustrative embodiments, the intermittent flow interruptions comprise louvers formed into the flow channel walls to create openings passing through the flow channel walls at the louvers. In some embodiments, the louvers are angled between 1 degree and 30 degrees to an air flow direction of the air flow channel. In some embodiments, the flow channel walls are secured to a tube of an air cooled condenser.
In any of the foregoing embodiments, the intermittent flow interruptions are in some more specific embodiments spaced between 5 hydraulic diameters and 10 hydraulic diameters apart along the air flow channel.
In any of the foregoing embodiments, the intermittent flow interruptions are in some more specific embodiments spaced apart along the air flow channel by at least 5 hydraulic diameters.
In some aspects disclosed herein, a plurality of air cooled condenser fins as set forth in any of the preceding paragraphs is provided, in which the air flow channels of the air cooled condenser fins are arranged in parallel.
In some aspects disclosed herein, an air cooled condenser comprises steam/condensate tubes and fins attached to the steam/condensate tubes. The fins comprise flow channel walls defining parallel air flow channels. The flow channel walls include planar sections separated by intermittent flow interruptions which are spaced apart along the air flow channels. The intermittent flow interruptions are defined by the flow channel walls. The intermittent flow interruptions in some embodiments comprise splits formed by a staggered arrangement in which the planar sections of the flow channel walls before and after each split are staggered. The staggering of the flow channel walls after each split is, in some more specific embodiments, about one-half of a width of the air flow channel. The intermittent flow interruptions in some embodiments comprise intermittent sinusoidal waves formed into the flow channel walls. The intermittent flow interruptions in some embodiments comprise louvers formed into the flow channel walls to create openings passing through the flow channel walls at the louvers. The louvers are, in some more specific embodiments, angled between 1 degree and 30 degrees to an air flow direction of the air flow channel. In any of the foregoing embodiments of this paragraph, the intermittent flow interruptions may in some more specific embodiments be spaced between 5 hydraulic diameters and 10 hydraulic diameters apart along the air flow channel. In any of the foregoing embodiments of this paragraph, the intermittent flow interruptions may in some more specific embodiments be spaced apart along the air flow channel by at least 5 hydraulic diameters.
Some embodiments of an air cooled condenser as set forth in the immediately preceding paragraph further comprise distribution headers connected to feed steam into the steam/condensate tubes, and an air moving system comprising a fan arranged to drive an airflow across the fins attached to the steam/condensate tubes. Some more specific embodiments further include risers connected to feed the steam into the distribution headers, wherein the steam/condensate tubes, the distribution headers, the risers, and the air moving system are arranged to form the air cooled condenser as an A-frame type air cooled condenser or other types.
In some aspects disclosed herein, a method of cooling using an air cooled condenser fin is disclosed. The method comprises flowing air through an air flow channel defined by flow channel walls, and interrupting the flowing of air at intermittent flow interruptions defined by the flow channel walls which are spaced apart along the air flow channel. In some more specific embodiments, the intermittent flow interruptions are placed at locations where a boundary layer of the flowing air has normalized. In some more specific embodiments, the intermittent flow interruptions are spaced apart along the air flow channel by at least 5 hydraulic diameters.
These and other non-limiting aspects and/or objects of the disclosure are more particularly described below.
The invention may take form in various components and arrangements of components, and in various process operations and arrangements of process operations. The drawings are only for purposes of illustrating preferred embodiments and are not to be construed as limiting the invention. This disclosure includes the following drawings.
For certain applications, such as air-cooled condensers, excessive pressure drop creates design constraints when applying fins to a tube geometry. A need exists for new and improved fin and fin array designs that minimize heat exchanger footprint opposite need for additional power input needed to move air/overcome excessive pressure drops of existing designs.
Air-cooled condenser applications have some requirements regarding the steam flow area and resultant pressure drop that places constraints on the minimum sizing of the heat exchanger fin tube base. Use of existing non-planar fin designs (Louvered, Offset, Wavy, etc.) requires additional power input (larger air mover sizing) to apply the fin to the required tube geometry. Further, redesigning tube geometry to incorporate a non-planar fin design in a lower power input design is often uneconomical.
Flow on the air-side of an air-cooled condenser generally operates in the laminar regime, which is defined by Reynolds numbers less than 2000. In this regime, momentum and energy transport occur via the mechanism of molecular diffusion, which is driven by gradients in the velocity profile. The velocity gradients near the fin wall are especially important in determining the momentum and energy transport rates in the local region as the air flows through the fin channel. As the air in the free-stream approach region enters the fin channels, extremely high velocity gradients result, based on the large velocity differential between the entering air velocity and the zero-velocity condition at the fin wall. This results in large friction factors and heat transfer coefficients at the lead edge of the fin. As the flow progresses down the fin channel, the velocity profile approaches the fully developed profile (generally parabolic). As this transition occurs, the local velocity gradients at the fin wall are reduced, and the local friction factor and heat transfer coefficient values gradually approach the fully developed values. This transition often occurs within ten (10) hydraulic diameters from the entrance to the fin section. The hydraulic diameter, DH, is a commonly used term when handling flow in non-circular tubes and channels, and is defined as
where A is the cross-sectional area of the flow and P is the wetted perimeter of the cross-section (where the wetted perimeter includes all surfaces acted upon by shear stress from the fluid). For a closed rectangular channel of dimensions a×b, the hydraulic diameter DH is given by:
The entrance region of the fin is therefore more effective in terms of heat transfer than the remainder of the fin, although the increase in heat transfer comes at the cost of added pressure drop.
With reference to
With reference to
With reference to
The concepts of split-fins is not intended to be limited by the preceding discussion. Split features may be repeating or intermediate. Flow channel walls may be discontinuous or continuous. Flow along the wall of a planar fin may be perturbed by the channel being cut, and a new channel formed with the opening offset from the outlet of the original channel. Fin channels may consist of single or multiple splits.
Channel length of the fin sections 12 is preferably determined by finding the point along the wall in which the air flow boundary layer approaches fully developed profile. In one embodiment having multiple splits the splits are spaced between about 5 hydraulic diameters and about 10 hydraulic diameters apart.
With reference to
With reference to
The innovations disclosed herein may be used on a single channel, a combination of channels, and/or combined with one another to form new and unique fin arrays that improve heat transfer over a variety of tube geometries that may be subject to space constraints and otherwise have limitations on ability to overcome pressure drop concerns. Further advantageous is the reduction in materials requirements for fin arrays enabled by the approaches disclosed herein.
With reference now to
The inventors have performed computer simulations of the performance of various designs of split fins 10 (
More generally, for an air flow channel of arbitrary cross sectional dimensions the first expression of Equation (3) holds, i.e.
where A is the cross-sectional area of the air flow channel and P is the perimeter of the cross-section of the air flow channel, and with a tube bundle length “L” (also indicated as bundle length 82 if
These simulations confirm the mechanism for improved performance disclosed herein, namely that employing mostly planar fins but with intermittent flow interruptions positioned at points where the boundary layer normalizes can achieve the desired heat transfer efficiency improvement while only imposing a modest increase in pressure drop. It was found that the intermittent flow interruptions are in some embodiments preferably spaced between about 5 hydraulic diameters and about 10 hydraulic diameters apart to optimally balance heat transfer efficiency (improved by the intermittent flow interruptions) against pressure drop introduced by the interruptions. The intermittent flow interruptions can be fin splits 20 (as in the embodiments of
It should be noted that the term “planar fin” is used herein in its usual and ordinary meaning in the art, as a fin that channels air flow principally along a single planar channel. In a planar section of a fin, the flow channel walls defining the air flow channel may have some deviations from geometrically perfect planar form, for example due to unintended manufacturing-induced variations, dimples, wall curvature, or so forth. Such a imperfections typically do not have a meaningful impact on air flow and hence are considered “planar” fin sections as used herein. Likewise, the term “intermittent flow interruption” as used herein is an intentional (i.e. design-basis) modification to a fin wall or walls, or a fin split, that is sufficient to induce air flow interruption as described herein. Hence, unintended manufacturing-induced variations, dimples, wall curvature, or so forth are not considered “intermittent flow interruptions” as used herein.
Illustrative embodiments including the preferred embodiments have been described. While specific embodiments have been shown and described in detail to illustrate the application and principles of the invention and methods, it will be understood that it is not intended that the present invention be limited thereto and that the invention may be embodied otherwise without departing from such principles. In some embodiments of the invention, certain features of the invention may sometimes be used to advantage without a corresponding use of the other features. Accordingly, all such changes and embodiments properly fall within the scope of the following claims. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the present disclosure be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.
This application claims the benefit of U.S. Provisional Application No. 62/835,706 filed Apr. 18, 2019. U.S. Provisional Application No. 62/835,706 filed Apr. 18, 2019 is incorporated herein by reference in its entirety.
Number | Date | Country | |
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62835706 | Apr 2019 | US |