This nonprovisional application claims the benefit of U.S. Provisional Application No. 61/510,830, titled “Thermal Expansion Joint for High Temperature Heat Exchanger,” filed Apr. 23, 2012, which is incorporated by reference herein in its entirety.
This disclosure is generally directed to a thermal expansion joint that can be used in high temperature environments. More specifically, this disclosure is directed to a high temperature heat exchanger that includes thermal expansion joints that are shielded from high temperature fluid streams.
Known heat exchangers can be of the plate or the tubular type. These heat exchangers may be used in a variety of applications, for example, in space heaters, industrial process heat exchange, refrigeration, air conditioning, power plants, thermal incineration preheater, and the like. A typical fluid-to-fluid plate heat exchanger includes multiple thin, slightly separated plates with large surface areas. A typical tubular heat exchanger includes a series of tubes including the fluid or fluid that would need to be heated or cooled.
In conventional heat exchangers, joints are needed to allow a hot inner casing to expand and contract in dimensions relative to a cooler outer casing, while still maintaining a barrier to fluid migration between the cooler fluid flow and hotter fluid flow.
Expansion joints are typically positioned at fluid inlets and outlets of heat exchangers. When the hot fluid enters and exits a conventional heat exchanger, it will contact the expansion joints, which are often unable to withstand extremely high temperatures and will deform or fail with prolonged exposure to heat. Such a failure involves significant maintenance because fixing or removing a failing expansion joint requires removing outer duct work and removing or hand-welding the failing joint. Further, a deformed or failed expansion joint may result in the outer casing being heated in an unwanted or unsafe manner.
Additionally, in the conventional tubular heat exchanger, slip joints between the outer and inner casing may be required near the hottest fluid flows, because expansion joints can fail at hot temperatures. However, in the event that one of the expansion joints on another inlet or outlet fails, hot fluid will pass through the slip joint and will travel to unwanted portions of the heat exchanger.
Disclosed herein is a heat exchanger that includes expansion joints arranged in such a manner so that an inner casing is still allowed to move with respect to an outer casing, but the expansion joints are not subject to the very high temperatures exhibited at or near the hottest fluid flow portions of the heat exchanger.
Embodiments of the heat exchanger of the present application may include an inner casing that houses a fluid path configured to accommodate a fluid flow; an outer casing separated from and surrounding at least a part of the inner casing; a fluid port that includes an opening corresponding to an inlet or outlet of the fluid path through the heat exchanger, the fluid port including a port wall; and an expansion joint provided proximate to the fluid port, the expansion joint being fixed to the inner casing and the outer casing, and having a bellows that is provided between the inner casing and the outer casing. The port wall may be provided between the fluid flow and the expansion joint and is spaced apart from the bellows, and the port wall may shield the expansion joint from the fluid flow.
In another aspect, a heat exchanger includes a first fluid port with a first port wall and a second fluid port with a second port wall, and an inner casing and an outer casing that surrounds at least a part of the inner casing. The inner casing houses a first fluid path that accommodates a first fluid flow that enters the heat exchanger at the first fluid port and houses a second fluid path that accommodates a second fluid flow that enters the heat exchanger at the second fluid port. The flow direction of the first fluid flow at the first fluid port can be substantially orthogonal to the second fluid flow at the second fluid port. The heat exchanger includes a first expansion joint provided proximate to the first fluid port, and the first expansion joint is positioned between the inner casing and the outer casing and accommodates thermal expansion of the inner casing in a first direction. The first expansion joint has a first bellows that is provided between the inner casing and the outer casing. The heat exchanger includes a second expansion joint provided proximate to the second fluid port, and the second expansion joint is positioned between the inner casing and the outer casing and accommodates thermal expansion of the inner casing in a second direction that is substantially orthogonal to the first direction. The second expansion joint likewise includes a second bellows that is provided between the inner casing and the outer casing. The first port wall is provided between the first fluid flow and the first expansion joint and is spaced apart from the first bellows, and the first port wall shields the first expansion joint from the first fluid flow. The second port wall is provided between the second fluid flow and the second expansion joint and is spaced apart from the second bellows, and the second port wall shields the second expansion joint from the second fluid flow.
In some aspects, the expansion joints described herein can be fixed to a first casing and a separate second casing, the first casing exhibiting temperature expansion relative to the second casing in a high temperature environment, the expansion joint comprising a bellows that is positioned between the first casing and the second casing and allows the first casing to expand when its temperature increases. A wall that is part of the first casing may be provided between the bellows and the high temperature environment, and the bellows can be spaced apart from the wall and maintained at a lower temperature than the wall.
Exemplary embodiments are described in detail below with reference to the accompanying drawings in which:
Exemplary embodiments of the broad principles outlined herein are described with reference to the various drawings.
A conventional heat exchanger 100 is shown in
The slip joints 120 of
To accommodate the expansion of the inner casing 201 with respect to outer casing 202, expansion joints are located at fluid ports 203, 213 and 233. As can be seen in the cross-sectional view, each of these fluid ports include expansion joints 210 that accommodate axial expansion of the inner casing and further include an expansion joints 212 that accommodate lateral expansion of the inner casing. Referring to
The expansion joints 210, 212 are positioned to be in direct contact with a fluid from fluid flow 215 at port 213. Indeed, the port wall 204 forms a part of expansion joint 210 and flange 206 forms a part of expansion joint 212. The fluid flow 215 can have very high temperatures, which is transferred directly to the expansion joints 210, 212 and causes them to operate at substantially the same temperature of fluid flow 215.
The yield stress of the expansion joint will deteriorate significantly once subjected to high temperatures over prolonged use, which causes joint failure. For example, Table 1 shows the yield strength, tensile strength and elongation percentage of 309S stainless steel at increasing temperatures. Yield strength decreases linearly with temperature until approximately 1500° F., at which time the yield strength begins to decrease exponentially. Significant decrease of the yield stress for an expansion joint requires repair or replacement, which can be costly and time-consuming.
The heat exchanger 300 includes an outer casing 302. The outer casing may be separated from and may additionally surround at least a part of the inner casing 301 and preferably substantially the entire inner casing 301. The outer casing may be made of any suitable material, and is preferably made of 11 gauge carbon steel or similar. The inner casing 301 of the heat exchanger 300 can be made of any suitable material, and is preferably made of 12 gauge stainless steel, the alloy being somewhat dependent upon temperature of operation and corrosive materials present within the airstream.
The heat exchanger 300 processes a cooler fluid inlet flow 305 and a relatively warmer fluid outlet flow 315. The cooler fluid inlet flow 305 enters the heat exchanger 300 at fluid port 303 and travels along a straight fluid path (similar to the fluid path illustrated in
Expansion joints are not visible in the fluid ports of
The fluid port 403 may include a port wall 404 that is positioned between the fluid flow 415 and the expansion joint 410. Likewise, the fluid port 423 can include port wall 414 that is positioned between fluid flow 425 and expansion joint 420. The port walls can be part of the inner casing 401. In the embodiment depicted in
Fluid port 403 can include an end flange 408 that is fixed to the end of port wall 404 and extends in a direction substantially orthogonally to fluid flow 415. Because the expansion joint 410 provides a seal between the inner casing 401 and the outer casing 402, the end flange 408 does not need to be connected to the outer casing 402 and is preferably movable with respect to the outer casing 402, i.e., to accommodate lateral expansion of the inner casing 401. In the embodiment depicted in
Referring to
Referring again to
Referring to expansion joint 410 as an example, the expansion joint can be positioned such that base 411 a of the bellows is closer to the outer casing 402 than it is to the inner casing 401 or port wall 404, e.g., preferably the distance from the base 411a to the port wall 404 is at least twice, and preferably at least three times, the distance from the base 411 a to the outer casing 402. In some embodiments, the expansion joint can be positioned so that the closed end 432 is positioned closer to the outer casing 402 than it is to the inner casing 401 or port wall 404.
Insulation 406 can be filled in between the outer casing and inner casing, particularly so that insulation exists between the bellows 411 of the expansion joints and the respective port walls that shield the expansion joint from the heat of the fluid flows. For simplicity, in
Because the bellows in the heat exchanger endure the load when the inner casing expands at high temperatures, they are the component that is most likely to fail after prolonged use. According to embodiments of the invention, the expansion joint is thus designed so that the closed end of the bellows is maintained at much lower operating temperatures than in conventional designs so that the bellows can maintain good strength properties over time. For example, referring to Table 1 above, if the closed end of the bellows is maintained in the range of 75° F. to 500° F., it will exhibit a significantly higher yield strength as compared to a bellows that is maintained at 1500° F. or higher.
As can be seen by the heat exchanger illustrated in
Additionally, in embodiments of the invention, the total unit length and duct connection length can be reduced as compared to conventional heat exchangers.
In some embodiments of the invention, the expansion joints are not limited to heat exchanger devices and can be used to connect two casings of an apparatus where one casing exhibits thermal expansion relative to the other casing. In such an apparatus, the expansion joint can be configured similarly as discussed above to accommodate relative movement between the casings while shielding the bellows of the expansion joint from high temperatures.
Although the disclosed joints and heat exchangers have been described in conjunction with exemplary embodiments, these embodiments should be viewed as illustrative, not limiting. It should be understood that various modifications, substitutes, combinations or the like are possible within the spirit and scope of the disclosed devices.
Number | Date | Country | |
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61687303 | Apr 2012 | US |