Patent Grant
6948559
This invention relates to heat exchangers in general, and more particularly, to evaporative heat exchangers and heat exchangers that utilize three different working fluids, and in more particular applications to such heat exchangers used in fuel cell systems.
Evaporative or vaporizing heat exchangers that transfer heat from one fluid flow to a vaporizing fluid flow to vaporize the vaporizing fluid flow are known. One example of such heat exchangers is found in the fuel processing systems for proton exchange membrane (PEM) type fuel cell systems, wherein a gaseous mixture of water vapor and a hydrocarbon are chemically reformed at high temperature to produce a hydrogen-rich gas flow stream known as reformate. Typically, to produce the gaseous mixture of water vapor and hydrocarbon, these systems will use an evaporative heat exchanger to either vaporize a liquid water and liquid hydrocarbon mixture, or to produce steam from liquid water which will then be used for humidification of a gaseous hydrocarbon fuel, such as methane. In some fuel processing systems, the heat from the reformate gas flow is used to provide at least part of the substantial amount of latent heat required for vaporization of the liquid flow of the vaporizing fluid, which is advantageous because it reduces the waste heat from the system and cools the reformate to the desired temperatures required for subsequent catalytic reactions. In this regard, in some systems the optimal temperature for the preferential oxidation reaction of the reformate gas flow is roughly the same as the boiling temperature for the liquid flow of the vaporizing fluid flow which makes it advantageous to use the reformate gas flow immediately upstream of the preferential oxidizer as the heat source for vaporization of the vaporizing fluid flow, thereby cooling the reformate gas flow to the desired temperature for the preferential oxidation reaction. However, typically the sensible heat given up by the reformate gas flow is not sufficient to completely vaporize the liquid flow. One other common source of additional heat in fuel cell systems is the anode exhaust gas produced by the combustion of the anode tail gas in a catalytic reactor. It is known to use the anode exhaust gas stream in a two stage vaporization procedure wherein the vaporizing fluid flow is first partially vaporized by the reformate gas stream entering the preferential oxidizer, and is subsequentially further vaporized by the anode exhaust gas stream.
While the above described systems may work well for their intended purposes, there is always room for improvements. For example, because the heat adsorbed by the liquid is mostly latent heat, a large portion of the length of each evaporator can be occupied by a two-phase fluid. Because different flow conditions can produce the same pressure drop (for example high mass flow with low quality change or low mass flow with superheat) and can therefor coexist in parallel passages, flow distribution in such evaporators is not self-correcting. Different flow distributions can result in heat fluxes that vary significantly from passage to passage which can result in poor performance and stability. Furthermore, when multiple stages are used for vaporization, there can be difficulty in redistributing the 2-phase mixture between the two stages of vaporization.
According to one form of the invention, an evaporative heat exchanger is provided for the transfer of heat to a first fluid from a second fluid and a third fluid to vaporize the first fluid. The heat exchanger includes a core, a first flow path in the core for the first fluid, a second flow path in the core for the second fluid, and a third flow path in the core for the third fluid. The core includes a first section, a second section, and a third section, with the second section connecting the first and third sections. The first and third sections are separated from each other at locations remote from the second section to allow for differences in thermal expansions between the first and third sections. The first flow path includes a first pass in the first section of the core and a second pass in the third section of the core, with the first flow path extending through the second section and being continuous between the first and second passes. The second flow path is juxtaposed with the first pass in the first section of the core to transfer heat from the second fluid to the first fluid in the first pass. The third flow pass is juxtaposed with the second pass in the third section of the core to transfer heat from the third fluid to the first fluid in the second pass.
In one form, the first flow path includes a plurality of first parallel flow passages to direct the first fluid through the heat exchanger, the second flow path includes a plurality of second parallel flow passages in the first section to direct the second fluid through the first section, and the third flow path includes a plurality of third parallel flow passages in the third section to direct the third fluid through the third section. One half of the first passages are interleaved with the second passages in the first section, and the other half of the first passages are interleaved with the third passages in the third section.
In one form, the second fluid has a concurrent flow relationship with the first fluid in the first pass. In a further form, the third fluid has a concurrent flow relationship with the first fluid in the second pass. In an alternate form, the third fluid has a counter flow relationship with the first fluid in the second pass.
In one form, the first flow path has a serpentine configuration in the first and second passes.
In one form, the first flow path has a flow area that increases in the downstream flow direction of the first fluid.
In accordance with one form of the invention, an evaporative heat exchanger is provided for the transfer of heat to a first fluid from a second fluid and a third fluid to vaporize the first fluid. The heat exchanger includes a plurality of first parallel flow passages to direct the first fluid through the heat exchanger, a plurality of second parallel flow passages to direct the second fluid through the heat exchanger, and a plurality of third parallel flow passages to direct the third fluid through the heat exchanger. Each of the first parallel flow passages has a first pass connected to a second pass. The second flow passages are interleaved with the first passes to transfer heat from the second fluid to the first fluid flowing through the first passes. The third flow passages are interleaved with the second passes to transfer heat from the third fluid to the first fluid flowing through the second passes.
In one form, each of the first flow passages has a flow area that is larger in the second pass than in the first pass.
According to one form of the invention, an evaporative heat exchanger is provided for the transfer of heat to a first fluid from a second fluid and a third fluid to vaporize the first fluid. The heat exchanger includes a plurality of parallel flow plates, and a plurality of parallel plate pairs. Each flow plate includes a first section, a second section, a third section connected to the first section by the second section, and a slot extending continuously through the first, second, and third sections to define a flow path for the first fluid through the heat exchanger. Each plate pair includes a first section interleaved with the first sections of the flow plates and enclosing a flow channel to direct the second fluid through the heat exchanger, and a second section interleaved with the third sections of the flow plates and enclosing a flow channel to direct the third fluid through the heat exchanger.
In one form, the first and second pair sections of each plate pair are separated at locations remote from the second sections of the flow plates to allow for differences in thermal expansion between the first and second sections of the plate pair. In a further form, the first and third sections of each of the flow plates are separated at locations remote from the second section of the flow plate to allow for differences in thermal expansion between the first and third sections of the flow plate.
In one form, each of the slots has a serpentine configuration in the first and third sections of the flow plate.
According to one form, each of the slots has a width that is larger in the third section than in the first section of the flow plate.
In accordance with one form of the invention, an evaporative heat exchanger is provided for use in the fuel processing system for a fuel cell system wherein the fuel processing system produces a reformate gas flow by first vaporizing a vaporizing fluid flow that comprises water, and the fuel cell system produces an anode exhaust gas flow. The evaporative heat exchanger includes a core, a first flow path in the core for the vaporizing fluid flow, a second flow path in the core for the reformate gas flow, and a third flow path in the core for the anode exhaust gas flow. The core includes a first section, a second section, and a third section, with the second section connecting the first and third sections. The first flow path includes a first pass in the first section of the core and a second pass in the third section of the core, with the first flow path extending through the second section and being continuous between the first and second passes. The second flow path is juxtaposed with the first pass in the first section of the core to transfer heat from the reformate gas flow to the vaporizing fluid flow with the first pass. The third flow path is juxtaposed with the second pass in the third section of the core to transfer heat from the anode exhaust gas flow to the vaporizing fluid flow in the second pass.
In one form, the first flow path includes a plurality of first parallel flow passages extending through the first, second, and third sections to direct the vaporizing fluid flow through the heat exchanger, the second flow path includes a plurality of second parallel flow passages in the first section to direct the reformate gas flow through the first section, and the third flow path includes a plurality of third parallel flow passages in the third section to direct the anode exhaust gas flow through the third section. The second passages are interleaved with the first passages in the first section, and the third passages are interleaved with the first passages in the third section.
Further objects, advantages, and aspects of the invention will be apparent based on the entire specification, including the appended claims and drawings.
As seen in
It should be understood that while the heat exchanger 10 is described herein in connection with the fuel processing system 12 of a PEM type fuel cell system 14, the heat exchanger 10 may prove useful in other types of fuel cell system and/or in systems other than fuel cell systems. Accordingly, the invention is not limited to the fuel processing system 12, or to a particular type of fuel cell system, or to fuel cell systems, unless expressly recited in the claim.
The heat exchanger 10 includes a core 40 having a first section 42, a second section 44, and a third section 46, with the second section 44 connecting the first and third sections 42 and 46. The heat exchanger 10 further includes an inlet port 48 to direct the vaporizing fluid flow 30 into the first section 42, an outlet port 50 to direct the vaporizing fluid flow 30 from the third section 46, an inlet port 52 to direct the reformate gas flow 28 into the first section 42, an outlet port 54 to direct the reformate gas flow 28 from the first section 42, an inlet port 56 to direct the anode exhaust gas flow 22 into the third section 46, and an outlet port 58 to direct the anode exhaust gas flow 22 from the third section 46. A vaporizing flow path, shown schematically at 60 is provided in the core 40, for the vaporizing fluid flow 30. The vaporizing flow path 60 includes a first pass, shown schematically at 62, in the first section 42 of the core 40 and a second pass, shown schematically at 64, in the third section 46 of the core 40. The vaporizing flow path 60 extends through the second section 44 and is continuous between the first and second passes 62 and 64. A second flow path, shown schematically at 66, is provided in the first section 42 for the reformate gas flow 28. The second flow path 66 is juxtaposed with the first pass 62 in the first section 42 to transfer heat from the reformate gas flow 28 to the vaporizing fluid flow 30 in the first pass 62. A third flow path, shown schematically at 68, is provided in the third section 46 for the anode exhaust gas flow 22. The third flow path 68 is juxtaposed with the second pass 64 in the third section 46 to transfer heat from the anode exhaust gas flow 22 to the vaporizing fluid flow 30 in the second pass 64.
Turning in more detail to the construction of a preferred embodiment of the heat exchanger 10, as best seen in
The core 40 also includes a plurality of separator plate pairs 80 interleaved with the flow plates 70, with each pair 80 including a pair of separator plates 81. Each plate 81 include a first section 82 corresponding to the first sections 42 and 72, a second section 84 corresponding to the second sections 44 and 74, and a third section 86 corresponding to the third sections 46 and 76. Each of the plate pairs 80 includes a frame 90 sandwiched between the plates 81 of the plate pair 80, with the frame 90 including a first section 92 corresponding to the first sections 42, 72 and 82, a second section 94 corresponding to the second sections 44, 74, and 84, and a third section 96 corresponding to the third sections 46, 76, and 86. The first section of each of the frames 92 have a continuous peripheral rim 98 that surrounds a flow chamber 100 for the reformate gas flow 28, and each of the third sections 96 has a peripheral rim 102 surrounding a flow chamber 104 for the anode exhaust gas flow 22. Preferably, the thickness of the frame 90 in the stacked direction is the same in all of the sections 92, 94, and 96. Preferably, suitable turbulators or fins, such as fins 106 and 108 are provided in each of the flow chambers 100 and 104, respectively, and are bonded on each of their sides to the plates 81 of the pair 80 to improve the heat transfer between the respective gas flows 28 and 22 and the plates 81 of the pair 80. Each of the plates 81 of the plate pairs 80 are solid in the areas that overlie the flow channel 78 so as to enclose the flow channel 78 when the plate pairs 80 are interleaved with the flow plates 70. Plates 110 and 111 are provided on the top and bottom of the core 40 to serve as one of the plates 81 of the topmost and bottommost plate pairs 80, respectively, and to mount the ports 48, 50, 52, 54, 56 and 58 of the heat exchanger 10.
The first and third sections 42 and 46 and the corresponding first and third sections 72, 82, 92, and 76, 86, and 96 are separated at locations remote from the second sections 44, 74, 84, and 94, so that the heat exchanger 10 can accommodate relatively unconstrained differential thermal expansion of each of the sections 42 and 46 of the core 40 relative to each other, thereby minimizing mechanical stresses due to the thermal growth.
Tab-like extensions 112, 114 and 116 are provided on the flow plates 70, the plates 81, and the frames 90, respectively, to define an inlet manifold 118 underlying the inlet 48 for directing the vaporizing fluid 30 from the inlet port 48 into the slots 78 of the flow path 60. Tab like extensions 120, 122, and 124 are provided on the flow plates 70, plates 81, and frames 90, respectively, to define an outlet manifold 126 underlying the outlet port 50 for directing the vaporizing fluid flow 30 from the slots 78 of the flow path 60 to the outlet port 50. Peripheral rim extensions 128 and 130 are provided on the flow plates 70 and the plates 81, respectively, to define, in combination with the rims 98, an inlet manifold 132 underlying the inlet port 52 for directing the reformate gas flow 28 from the inlet port 52 into the flow channels 100 of the second flow path 66. Peripheral rim extensions 134 and 136 are provided on the flow plates 70 and the plates 81, respectively, to define, in combination with the rims 98, an outlet manifold 138 underlying the outlet port 54 for directing the reformate gas flow 28 from the flow channels 100 of the second flow path 66 into the outlet port 54. Peripheral rim extensions 140 and 142 are provided on the flow plates 70 and the plates 81, respectively, to define, in combination with the rims 102, an inlet manifold 144 overlying the inlet port 56 for directing the anode exhaust gas flow 22 from the port 54 into the flow channels 104 of the third flow path 68. Peripheral rim extensions 146 and 148 are provided on the flow plates 70 and separator plates 81, respectively, to define, in combination with the rims 102, an outlet manifold 150 overlying the outlet port 58 for directing the anode exhaust gas flow 22 from the flow channels 104 into the outlet port 58.
Preferably, each of the above described components of the heat exchanger 10 are made of a suitable metal material, such as aluminum, steel, or copper, with the plates 70 and 81 being made from thin metal sheets and all of the components being joined together using suitable bonding techniques such as soldering, brazing, or welding.
As an option, the portion of the each of the slots 78 immediate downstream of the inlet manifold 118 can be designed, such as by locally narrowing each of the portions, to have a large pressure drop, as may be available from the pump for the vaporizing fluid flow 30, so as to force an even distribution of the vaporizing fluid flow 30 to each of the slots 78. One of the advantages of such a design is that it would provide, inherently, a low likelihood of maldistribution. Because the first pass 62 preferably has a long “pinched” region, any potential maldistribution of the liquid from layer to layer would have a strong impact on pressure drop. Vapor quality is almost fixed in the first pass 62 because the available heat in the gas flow 28 is entirely consumed (temperature drops to the boiling point of the fluid flow 30). This effectively dampens out the maldistribution possibility mentioned in the Background section.
It should be appreciated that while a bar-plate type design is shown, other types of constructions could be employed for the core 40, such as for example, a drawn cup type construction for each of the plate pairs 80. It should also be appreciated that while it is preferred to provide turbulators or fins between the plates 81 of each pair 80, in some applications it may be desirable to forego the turbulators or fins 106 and/or 108, or to provide dimples in the plates 81 that abut the dimples in the opposite plate 81 of the pair 80. It should also be appreciated that the width of each of the flow chambers 100 and 104 can vary between the two different types of gasses flowing therethrough, as shown, and also can vary from application to application, as can the details of the particular type and configuration of turbulators or fins employed therein.
As best seen in
In the illustrated embodiment, each gas flow 28 and 22 has a concurrent flow relationship with the vaporizing fluid flow 30 in their respective sections 42 and 46 of the core 40.
It is preferably to have both of the hot gas flows 28 and 22 concurrent with the vaporizing fluid flow 30 in their respective sections 42 and 46 of the heat exchanger because this flow arrangement can help to ensure stability of the fluid temperatures exiting the heat exchanger and maximize the structural integrity of the heat exchanger. However, in some applications, it may be desirable to have one or both of the hot gas flows 28 and 22 to be counter flows with respect to the vaporizing fluid flow 30 in their respective sections 42 and 46. For example, in some applications, it may be necessary to ensure full vaporization and superheating of the vaporizing fluid flow 30 under all conditions, which may necessitate counter flow of the anode exhaust gas flow 22 in the third section 46 so as to provide a sufficient temperature differential for heat transfer in the superheat region of the third section 46. However, this type of counter flow arrangement can result in high thermal induced stresses in the plates 81 at the dry out location. Accordingly, care must be taken to address thermal stress concerns in this type of counter flow design.
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| Number | Date | Country |
|---|---|---|
| 56010692 | Feb 1981 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20040159424 A1 | Aug 2004 | US |
