Abstract
A heat transfer element for a rotary heat exchanger includes a plate having a plurality of elongate notches formed therein at spaced intervals and oriented at a first angle relative to a flow direction. The plate further includes a plurality of elongate undulations formed therein at spaced intervals and oriented a second angle relative to the flow direction, wherein the first angle is different than the second angle. A first height of each of said plurality of elongate notches is larger than a second height of each of said plurality of elongate undulations. A plurality of heat transfer elements may be stacked in a container for installation in the rotary heat exchanger.
Claims
1. A heat transfer element for a rotary heat exchanger having a flow direction, said heat transfer element comprising: a plate having a plurality of elongate notches formed therein at spaced intervals, said elongate notches each being oriented at a first angle relative to the flow direction and having a first height relative to a surface of said plate, wherein said first angle is in a range of 5 to 45 relative to the flow direction; said plate further having a plurality of elongate undulations formed therein at spaced intervals, said elongate undulations each being oriented at a second angle relative to the flow direction and having a second height relative to the surface of said plate, wherein said second angle is in a range of 0 to 90 relative to the flow direction; wherein said first height of each of said plurality of elongate notches is larger than said second height of each of said plurality of elongate undulations; and wherein said first angle is different than said second angle.
2. A heat transfer element as set forth in claim 1, wherein said first angle is 20 relative to the flow direction.
3. A heat transfer element as set forth in claim 1, wherein said second angle is 30 relative to the flow direction.
4. A heat transfer element as set forth in claim 1, wherein said second height is 20% to 70% of said first height.
5. A heat transfer element as set forth in claim 1, wherein each of said plurality of elongate notches has a first depth relative to said surface of said plate and each of said plurality of undulations has a second depth relative to said surface of said plate, and wherein said second depth is smaller than said first depth.
6. A heat transfer element container for a rotary heat exchanger having a housing with a first opening in fluid communication with a first gas flow and a second opening in fluid communication with a second gas flow, said first and second gas flows each having a flow direction, and said heat transfer element container comprising: a pair of support members defining a space therebetween; a plurality of heat transfer elements stacked in said space between said pair of support members, wherein at least one of said plurality of heat transfer elements comprises: a first plate having a plurality of elongate notches formed therein at spaced intervals, said elongate notches each being oriented at a first angle relative to either of the flow directions and having a first height relative to a surface of said first plate, wherein said first angle is in a range of 5 to 45 relative to either of the flow directions; said first plate further having a plurality of elongate undulations formed therein at spaced intervals, said elongate undulations each being oriented a second angle relative to either of the flow direction and having a second height relative to the surface of said first plate, wherein said second angle is in a range of 0 to 90 relative to either of the flow directions; wherein said first height of each of said plurality of elongate notches is larger than said second height of each of said plurality of elongate undulations to define a channel for the first and second gas flows between adjacent heat transfer elements; and wherein said first angle is different than said second angle.
7. A heat transfer element container as set forth in claim 6, wherein said first angle is 20 relative to either of the flow directions.
8. A heat transfer element container as set forth in claim 6, wherein said second angle is 30 relative to either of the flow directions.
9. A heat transfer element container as set forth in claim 6, wherein said second height is 20% to 70% of said first height.
10. A heat transfer element container as set forth in claim 6, wherein each of said plurality of elongate notches has a first depth relative to said surface of said plate and each of said plurality of undulations has a second depth relative to said surface of said plate, and wherein said second depth is smaller than said first depth.
11. A heat transfer element container as set forth in claim 6, wherein at least a second of said plurality of heat transfer elements comprises: a second plate parallel and adjacent to, and in direct contact with, said first plate and having a plurality of elongate notches formed therein at spaced intervals and a plurality of elongate undulations formed therein between said plurality of elongate notches; wherein said second plate is rotated 180 relative to said first plate such that said plurality of elongate notches in said second plate are oriented crosswise relative to said plurality of elongate notches in said first plate, and wherein said plurality of undulations in said second plate are oriented crosswise relative to said plurality of undulations in said first plate.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) FIG. 1 is a schematic view of a power plant with a rotary heat exchanger that may utilize heat transfer element containers according to an example embodiment of the present invention.
(2) FIG. 2 is a partially cut-away perspective view of a rotary heat exchanger of a type that may use heat transfer element containers according to an example embodiment of the present invention.
(3) FIG. 3 is a perspective view of a heat transfer element container for a rotary heat exchanger according to an example embodiment of the present invention.
(4) FIG. 4 is a planar view of a heat transfer element according to an example embodiment of the present invention.
(5) FIG. 4A is a cross-sectional view of the heat transfer element of FIG. 4 taken through section 4A-4A.
(6) FIG. 5 is a perspective view of adjacent heat transfer elements according to an example embodiment of the present invention.
(7) FIG. 6 is a perspective view of adjacent heat transfer elements according to another example embodiment of the present invention.
(8) FIG. 7 is a planar view of a heat transfer element according to yet another example embodiment of the present invention.
(9) FIG. 7A is a cross-sectional view of the heat transfer element of FIG. 7 taken through section 7A-7A.
(10) FIG. 8 is a planar view of a heat transfer element according to still another example embodiment of the present invention.
(11) FIG. 8A is a cross-sectional view of the heat transfer element of FIG. 8 taken through section 8A-8A.
(12) FIG. 9 is a perspective view of a heat transfer element according to a further example embodiment of the present invention.
(13) FIG. 10 is a perspective view of a heat transfer element according to an additional example embodiment of the present invention.
DESCRIPTION OF EXAMPLE EMBODIMENTS
(14) The present inventive concept is best described through certain embodiments thereof, which are described in detail herein with reference to the accompanying drawings, wherein like reference numerals refer to like features throughout. It is to be understood that the term invention, when used herein, is intended to connote the inventive concept underlying the embodiments described below and not merely the embodiments themselves. It is to be understood further that the general inventive concept is not limited to the illustrative embodiments described below and the following descriptions should be read in such light.
(15) An example power plant 10 of a type that may incorporate a rotary heat exchanger 12 with heat transfer elements according to the present invention is illustrated in FIG. 1. The power plant 10 includes a generator 14 coupled with a steam turbine 16 to produce electricity. The turbine 16 is driven by steam from a boiler 18, which receives air for combustion via an air intake 20 and expels combustion gases via an exhaust 22. Fans 24a and 24b may be used to supply air to the boiler intake 20 and to draw combustion gases from the exhaust 22 through a dust removal system 26 before it is released to the atmosphere. A rotary regenerative heat exchanger 12 may be positioned adjacent the air intake 20 and the exhaust 22 to preheat air entering the boiler 18 using heat from combustion gases expelled from the boiler. Rotary regenerative heat exchangers may also be used in gas-gas heaters to control emissions from the plant.
(16) Referring now to FIG. 2, a partially cut-away perspective view of a rotary heat exchanger 12 utilizing heat transfer elements and containers according to an example embodiment of the present invention is shown. The rotary heat exchanger 12 includes a housing 28 with a first duct or opening 30 and a second duct or opening 32. The first opening 30 communicates with the boiler air intake 20 and the second opening 32 communicates with the boiler exhaust 22. A rotor 34 containing a plurality of heat transfer element containers 36 is mounted for rotation in the housing 28 such that the heat transfer element containers 36 in the rotor circulate past the openings 30 and 32, thus causing heat transfer elements in the containers to be heated by exhaust gases when aligned with the second opening and preheating incoming air when aligned with the first opening.
(17) FIG. 3 is a perspective view of a heat transfer element container or pack 36 for a rotary heat exchanger according to an example embodiment of the present invention. The heat transfer element container 36 includes a plurality of heat transfer elements 38 in the form of sheets or plates arranged in a stack between a pair of support members 40. In an example embodiment, the support members may be end plates. In the example shown, the sheets are rectangular sheets oriented vertically between horizontally spaced end plates. The sheets are of the same height and of increasing width in a horizontal direction to provide a trapezoidal cross-section when viewed from above. The trapezoidal shape of the container 36 in this example permits multiple containers of this type to be arranged in a circular pattern or ring within a rotor of a rotary heat exchanger. The example heat transfer element container 36 may also include one or more support bars 42 extending above and below the heat transfer elements 38 between the support members 40 to help provide structural support for the assembly and/or one or more stiffening bars 44 extending transversely across the one or more support bars 42 for additional support. One or more steel bands 46 may be wrapped around the assembly to help retain the elements 38 in position during transportation. Any of the heat transfer elements described herein may be used in such a container.
(18) FIG. 4 is a planar view of a heat transfer element 38 according to an example embodiment of the present invention. The heat transfer element 38 comprises a rectangular sheet or plate formed of a thermally conductive material, such as steels, that can withstand being repeatedly heated to high temperatures when exposed to exhaust gases and cooled when exposed to incoming air at ambient temperature. A plurality of ribs or notches 48 are formed in the sheet at a first angle .sub.1 relative to the direction of air or gas flowing through the heat transfer element container (e.g., by feeding sheet stock through a pair of rollers with notched profiles). The notches 48 may be parallel as shown, with a first pitch P.sub.1 between notches. While two notches 48 are shown by way of example, it will be appreciated that the heat transfer element may be formed with more than two notches. As best seen in the cross-sectional view of the heat transfer element 38 shown in FIG. 4A, each notch 48 has a peak with a first height H.sub.1 and a trough with a first depth D.sub.1, which are selected to establish a desired spacing between stacked elements. The spacing between stacked elements is chosen to define a channel through which air and/or exhaust gases can flow.
(19) A plurality of undulations 50 are also formed in the sheet between the notches 48 (e.g., by feeding sheet stock through a pair of rollers with undulated profiles beforeor simultaneously as the notches are formed). The undulations 50 are configured to induce turbulence in the air and/or gas flowing through the channel defined between adjacent heat transfer elements 38. The undulations 50 are oriented at a second angle .sub.2 relative to the direction of air or gas flowing through the heat transfer element container. In the example heat transfer element shown in FIG. 4, the second angle .sub.2 is selected to be in a direction opposite the first angle .sub.1 relative to the flow direction (e.g., clockwise vs. counterclockwise) so that the undulations 50 cross the notches 48. For example, if the first angle is measured counterclockwise from the direction of air/gas flow, the second angle may be measured clockwise from the direction of air/gas flow. The undulations 50 may be parallel to one another as shown, with a second pitch P.sub.2 that is smaller than the first pitch P.sub.1. As best seen in the cross-sectional view of the heat transfer element 38 shown in FIG. 4A, the undulations 50 may each have a second height H.sub.2 that is smaller than the first height H.sub.1 and a second depth D.sub.2 that is smaller than the first depth D.sub.1.
(20) In an example embodiment, the first angle .sub.1 may be in the range of 5 to 45, and the second angle .sub.2 may be in the range of 0 to 90. In another example, the first angle .sub.1 may be 20 and the second angle .sub.2 may be 30. In an example embodiment, the first height H.sub.1 and depth D.sub.1 may each be 5-9 mm, the second height and depth H.sub.2 and D.sub.2 may each be 3 mm, the first pitch P.sub.1 may be 35 mm, and the second pitch P.sub.2 may be 15 mm.
(21) FIG. 5 is a perspective view of a pair of heat transfer elements 38 and 38 stacked according to an example embodiment of the present invention. The first heat transfer element 38 is shown in partial cutaway so that details of the second heat transfer element 38 can be seen. Both heat transfer elements 38 and 38 have a configuration as shown in FIG. 4. However, their respective orientations relative to the direction of air flow are reversed relative to one another. That is, the first heat transfer element 38 has a first orientation and the second heat transfer element 38 has a second orientation that is rotated 180 relative to the first orientation so that the diagonally spaced notches on one heat transfer element cross the diagonally spaced notches on adjacent heat transfer elements and so on through the stack.
(22) The diagonally spaced crossed notches 48 and 48 perform the function of keeping a desired gap or spacing between adjacent heat transfer elements. The number of notches, their angle and their pitch contribute to having sufficient contact points to achieve a good tight, rigid pack when compressed. The diagonal crossing of the notches 48 and 48 also helps avoid skew flow, keeping an even flow across the full cross sectional flow area of the element pack.
(23) The angled undulations 50 and 50 between the notches in respective heat transfer elements 38 and 38 act as turbulators to induce turbulence. The turbulence inducing angled undulations 50 and 50 are incorporated to improve heat transfer, particularly at lower gas velocities and Reynolds Numbers. High efficiency heat transfer elements of the type described herein are thus suitable for fracked gas firing, in which flue gas exit temperatures may be significantly reduced in comparison with conventional coal fired boilers. The increased pressure drop resulting from higher turbulence is minimal and the heat rate benefits far outweigh any slight fan power increase that may be required. The clean flue gas will also not cause fouling so there is no tendency for pressure drop drift. While two heat transfer elements are shown for purposes of illustration, it will be appreciated that a stack may comprise more than two heat transfer elements of alternating orientation as shown. The heat transfer elements shown in FIG. 5 may be stacked in an alternating manner with each other or with any of the other heat transfer elements described herein.
(24) FIG. 6 is a perspective view of a pair of stacked heat transfer elements 52 and 52 according to another example embodiment of the present invention. The heat transfer elements 52 and 52 are configured the same but are of reversed orientation. Each of the heat transfer elements 52 and 52 includes a plurality of angled notches 48 or 48, respectively, separated by a plurality of dimples 54 or 54, respectively. The angled notches 48 and 48 are the same as described above. However, dimples 54 and 54 are formed in between the notches 48 and 48 (e.g., by feeding sheet stock through a pair of dimpled rollers before or simultaneously as the notches are formed), instead of undulations. In an example embodiment, the dimples 54 and 54 may be hemispherical and either concave or convex. In an example embodiment, two or three rows of dimples are formed between each pair of angled notches. The rows may be parallel to the notches as shown or oriented at an angle relative to the notches. Dimples in adjacent rows may be aligned with each other or staggered. In an example embodiment, the depth of the dimples is less than the height/depth of the notches, and the spacing between adjacent dimples is smaller than the spacing between the notches. Like the undulations, the dimples between the notches act as turbulators to induce turbulence. The turbulence inducing dimples improve heat transfer to facilitate use in fracked gas firing and other applications. Again, while two heat transfer elements are shown for purposes of illustration, it will be appreciated that a stack may comprise more than two heat transfer elements of alternating orientation as shown. The heat transfer elements of FIG. 6 may be stacked in an alternating manner with any of the other heat transfer elements described herein.
(25) FIG. 7 is a planar view of heat transfer element 56 according to yet another example embodiment of the present invention. FIG. 7A is a cross-sectional view of the heat transfer element 56 of FIG. 7 taken through section 7A-7A. The heat transfer element 56 includes a pair of notches 48 oriented parallel to the direction of air flow and a plurality of dimples 54 formed in between the notches. The dimples 54 are arranged in two columns of angled rows, with each row comprising three dimples and being oriented at an angle relative to the direction of air and/or gas flow. In an example embodiment, the rows of dimples 54 are each arranged at an angle of about 45 relative to the direction of air and/or gas flow. Like the heat transfer element of FIG. 6, the dimples in the heat transfer element of FIG. 7 may be hemispherical in shape and may have a depth less than the height/depth of the notches, and a spacing between adjacent dimples that is smaller than the spacing between the notches. The dimples between the notches act as turbulators to induce turbulence. The turbulence inducing dimples improve heat transfer to facilitate use in fracked gas firing and other applications. The heat transfer element of FIG. 7 may be stacked in an alternating manner with the heat transfer element of FIG. 6 or with any of the other heat transfer elements described herein.
(26) FIG. 8 is a planar view of a heat transfer element 58 according to still another example embodiment of the present invention. FIG. 8A is a cross-sectional view of the heat transfer element 58 of FIG. 8 taken through section 8A-8A. In this embodiment, a plurality of dimples 54 are formed in the heat transfer element 58 in a plurality of columns and rows. In an example embodiment, at least three columns of rows comprising three dimples each are shown. However, the rows may contain fewer or more dimples than shown. The rows of dimples are oriented at an angle relative to the direction of air flow. In an example embodiment, the rows of dimples are arranged at an angle of about 45 relative to the direction of air flow. The dimples act as turbulators to induce turbulence. The turbulence inducing dimples improve heat transfer to facilitate use in fracked gas firing and other applications. The heat transfer element of FIG. 8 may be stacked in an alternating manner with the heat transfer element of FIG. 7 or with any of the other heat transfer elements described herein.
(27) FIG. 9 is a perspective view of a heat transfer element 60 according to a further example embodiment of the present invention. The heat transfer element 60 of FIG. 9 includes a repeating pattern of diamond shaped bumps or ridges 62 that serve as turbulators to induce turbulence. The turbulence inducing diamond pattern 62 increases the number of contact points and improves heat transfer to facilitate use in fracked gas firing and other applications. The diamond shaped bumps or ridges 62 may be formed by double rolling a sheet with the angle of the undulations on the first roller opposite the angle of the undulations on the second roller. For example, the first roller may be configured to produce undulations oriented at an angle of +30 relative to the direction of air/gas flow and the second roller may be configured to produce undulations oriented at an angle of 30 relative to the direction of air/gas flow. This process results in a diamond profile and the angles of the undulations can be varied to alter the diamond shape. The heat transfer element of FIG. 9 may be stacked in an alternating manner with the heat transfer element of FIG. 7, with a heat transfer element having an undulating or corrugated profile parallel to the direction of air/gas flow, or with any of the other heat transfer elements described herein.
(28) FIG. 10 is a perspective view of a heat transfer element 64 according to an additional example embodiment of the present invention. The heat transfer element 64 of FIG. 10 includes a complex pattern of bumps or ridges 66 that serve as turbulators to induce turbulence. The turbulence inducing pattern of FIG. 10 increases the number of contact points and improves heat transfer to facilitate use in fracked gas firing and other applications. The pattern shown in FIG. 10 may be formed by putting a sheet through an undulated roller to produce undulations oriented at an angle relative to the direction of air/gas flow, followed by a corrugated roller that produces corrugations oriented parallel to the direction of air/gas flow. This process creates bumps 66 on the sides of the corrugations to induce turbulence and improve heat transfer. The heat transfer element of FIG. 10 may be stacked in an alternating manner with a heat transfer element having angled undulations (e.g., oriented at an angle opposite the undulations in the heat transfer element of FIG. 10), with the heat transfer element of FIG. 9, or with any of the other heat transfer elements described herein.
(29) It will be appreciated that the embodiments described above and illustrated in the drawings represent only a few of the many ways of implementing embodiments of the present invention. For example, in the embodiment shown in FIG. 4, the angle of the undulations relative to the notch angles and the height of the undulations relative to the notch height can be varied to optimize heat transfer/pressure drop performance depending on the particular application or client specification. Also, while the dimples have been described as being hemispherical, it will be appreciated that they may comprise a smaller spherical segment (e.g., the height or depth of the dimples may be less than the radius) or have other configurations such as a pyramidal shape. Furthermore, while a heat transfer element container having a trapezoidal cross section has been shown, it will be appreciated that the container can be configured to have a rectangular cross-section, a curved cross-section, or any other shape suitable for installation in a rotary heat exchanger.
