MULTIPLE PASS OR MULTIPLE FLUID HEAT EXCHANGE APPARATUS AND METHOD FOR USING SAME

Abstract

A heat exchanger with a uniquely designed header system which allows tubes carrying independent products to exchange heat with a product in one common shell. Multiple tube sheets provide for tubes carrying different independent products to exchange heat with the product passing through the shell side of the exchanger. The design advantages to this heat exchanger system are threefold, this exchanger design eliminates the need for multiple heat exchangers that perform the same task, it greatly reduces the size and footprint of a traditionally designed multiple heat exchanger systems, which rely on multiple independent heat exchangers to perform the same task, and lastly this new designed heat exchanger reduces the high cost of having to use multiple exchangers to obtain the same results.

Claims

1. A heat exchanger comprising: a shell, wherein said shell is cylindrical; a shell interior extending inside said shell from a first aperture at a first end of said shell to a second aperture at a second end of said shell; a shell outlet near said first end of said shell; a shell inlet near said second end of said shell; a tube bundle comprising a multiplicity of tube sets, said tube sets comprising a multiplicity of tubes inside said hollow portion of said shell; a second input tube sheet coupled to said first end of said shell across said first aperture, wherein said second input tube sheet has a multiplicity of holes the number of which is corresponding with the number of said tubes in said shell; a second input head, wherein said second input head is cylindrical and hollow creating a second input head chamber, and wherein a first end of said second input head is coupled to said second input tube sheet opposite said shell, said second input head having a second input head inlet; a second output tube sheet coupled to said second end of said shell across said second aperture, wherein said second output tube sheet has a multiplicity of holes the number of which is corresponding with the number of said tubes in said tube bundle; a second output head, wherein said second output head is cylindrical and hollow creating a second output head chamber, and wherein a first end of said second output head is coupled to said second output tube sheet opposite said shell, said second output head having a second output head inlet; a first input tube sheet coupled to a second end of said second input head, wherein said first input tube sheet has a multiplicity of holes the number of which corresponds with the number of tubes in a first tube set; a first input head, wherein said first input head is hemispherical and hollow creating a first input head chamber, and wherein an equatorial end of said first input head is coupled to said first input tube sheet opposite said second input head, said first input head having a first input head inlet; a first output tube sheet coupled to a second end of said second output head, wherein said first output tube sheet has a multiplicity of holes the number of which corresponds with the number of holes in said first input tube sheet; a first output head, wherein said first output head is hemispherical and hollow creating a first output head chamber, and wherein an equatorial end of said first output head is coupled to said first output tube sheet opposite said second output head, said first output head having a first output head outlet; wherein each of said tubes pass through a unique hole of said holes in said second input tube sheet and each of said tubes pass through a unique hole of said holes in said second output tube sheet; wherein said tubes in a second tube set are sized such that an interior of said tubes in said second tube set is open to said second input head chamber and said second output head chamber; wherein said tubes in said first tube set are sized such that an interior of said tubes in said first tube set is open to said first input head chamber and said first output head chamber; wherein any gaps between said tubes in said tube bundle and said holes in said second input and second output tube sheets are sealed; and wherein any gaps between said tubes in said first tube set and said holes in said first input and first output tube sheets are sealed.

2. The heat exchanger of claim 1, further comprising: a third input tube sheet coupled to said first end of said shell across said first aperture, wherein said third input tube sheet has a multiplicity of holes the number of which is corresponding with the number of said tubes in said shell; a third input head, wherein said third input head is cylindrical and hollow creating a third input head chamber, and wherein a first end of said third input head is coupled to said third input tube sheet opposite said shell, said third input head having a third input head inlet; a third output tube sheet coupled to said second end of said shell across said second aperture, wherein said third output tube sheet has a multiplicity of holes the number of which is corresponding with the number of said tubes in said tube bundle; a third output head, wherein said third output head is cylindrical and hollow creating a third output head chamber, and wherein a first end of said third output head is coupled to said third output tube sheet opposite said shell, said third output head having a third output head inlet; wherein said tubes in said first tube set are sized such that an interior of said tubes in said first tube set is open to said third input head chamber and said third output head chamber; and wherein any gaps between said tubes in said tube bundle and said holes in said third input and third output tube sheets are sealed.

3. The heat exchanger of claim 1, wherein said tubes are mounted in said shell on one or more baffles.

4. The heat exchanger of claim 2, wherein said tubes are mounted in said shell on one or more baffles.

5. The heat exchanger of claim 1, wherein said heat exchanger is mounted on a sled.

6. The heat exchanger of claim 2, wherein said heat exchanger is mounted on a sled.

7. The heat exchanger of claim 1, wherein said first input head chamber, said second input head chamber, said shell interior, said second output head chamber, and said first output head chamber are oriented linearly relative to each other.

8. The heat exchanger of claim 2, wherein said first input head chamber, said second input head chamber, said third input head chamber, said shell interior, said third output head chamber, said second output head chamber, and said first output head chamber are oriented linearly relative to each other.

9. The heat exchanger of claim 7, wherein said heat exchanger is mounted on a sled.

10. The heat exchanger of claim 8, wherein said heat exchanger is mounted on a sled.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1. is a perspective, cut-away view a first embodiment of the present invention.

[0025] FIG. 2. is a perspective, cut-away view of a second embodiment of the present invention.

[0026] FIG. 3a. is a side, cross-sectional view of a traditional apparatus for heat exchange using multiple heat exchangers.

[0027] FIG. 3b. is a side, cross-sectional view of the present invention.

[0028] FIG. 4 is a schematic illustrating the heat exchange system using the present invention.

[0029] FIG. 5 is a side, cross-sectional view of the present invention.

[0030] FIG. 6 is a front, cross-sectional view along line A-A from FIG. 5 of a second tube sheet of the present invention.

[0031] FIG. 7 is a front, cross-sectional view along line B-B from FIG. 5 of a first tube sheet of the present invention.

[0032] FIG. 8 is a side, cross-sectional view along line Y-Y from FIG. 7 of a first tube sheet of the present invention.

[0033] FIG. 9 is a side, perspective view of the present invention installed on a first embodiment of a sled.

[0034] FIG. 10 is a side view of the present invention installed on a first embodiment of a sled.

[0035] FIG. 11 is a side view of the present invention as it might be installed on a sled.

[0036] FIG. 12 is a top view of the present invention installed on a first embodiment of a sled.

[0037] FIG. 13 is a top view of the present invention as it might be installed on a sled.

[0038] FIG. 14 is a bottom, perspective view of the present invention as it might be installed on a sled.

[0039]

TABLE-US-00001 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Ref. Element 10 Improved Heat Exchanger 12 Shell 14 First Input Head 16 First Output Head 18 Second Input Head 20 Second Output Head 22 Third Input Head 24 Third Output Head 26 First Input Head Inlet 28 First Output Head Outlet 30 Second Input Head Inlet 32 Second Output Head Outlet 34 Third Input Head Inlet 36 Third Output Head Outlet 38 Shell Outlet 40 Shell Inlet 42 First Input Tube Sheet 44 First Output Tube Sheet 46 Second Input Tube Sheet 48 Second Output Tube Sheet 50 Third Input Tube Sheet 52 Third Output Tube Sheet 54 Tube Sheet Aperture 56 First Tube 58 Second Tube 60 Third Tube 62 Tube Bundle 64 Baffle 66 Baffle Aperture 68 First Input Head Chamber 70 Second Input Head Chamber 72 Third Input Head Chamber 74 Shell Chamber 76 Second Shell 78 Second Shell Chamber 80 First Output Head Chamber 82 Second Output Head Chamber 84 Source Pipe 86 Coalescing Filter Separator 88 Thermostatically Controlled Temperature Valve 90 Joule-Thomson Valve 92 Cold Separator 94 Cold Separator Inlet 96 Cold Separator 98 Cold Separator Outlet 100 Transfer Pipe 102 First Hot Liquid Pipe 104 Second Hot Liquid Pipe 106 Bypass Pipe 108 Natural Gas Liquid (NGL) 110 Cold Gas 112 NGL Outlet 114 Cold Gas Outlet 116 NGL Pipe 118 Cold Gas Pipe 120 NGL Outflow Pipe 122 Cold Gas Outflow Pipe 124 First Output Head Chamber 126 Second Output Head Chamber 128 Tube Sheet Shoulder 130 Rim 132 Center 134 Sled 136 Platform 138 Sled Side 140 Sled End 142 Sled Runner 144 Tow Bar 146 Sled Bottom

[0040] Referring to the figures, FIG. 1 illustrates the new exchanger 10 design setup to exchange heat from the shell side product with two separated products passing through the tube sides separated by multiple tube sheets (42, 44, 46, 48). A shell side product (not shown) enters a nozzle, shell inlet 40 and travels the length of the shell 12 exchanging heat with separate products (not shown) traveling through the tube bundle 62 then exits a nozzle, shell outlet 38. A first tube side product (not shown) enters a nozzle, first input head inlet 26 into the first input head 14 and is divided through multiple first tubes 56 passing through first input tube sheet 42, passing through second input tube sheet 46, traveling the length of the first tubes 56 exchanging heat with the shell side product (not shown), passing second output tube sheet 48, and then passing through first output tube sheet 44 where the product stream is reunited in the first output head 16 before exiting a nozzle, first output head output 28. A second tube side product (not shown) enters a nozzle, second input head inlet 30 into the second input head 18 and is divided through multiple second tubes 58. This cut-away view shows many of the second tubes 58 as having been cut short (so as to better show details of the interior of the heat exchanger 10), but in the invention each of the second tubes 58 would engage with a tube sheet aperture 54 of the second input tube sheet 46 and extend through an individual baffle aperture 66 of each of the baffles 64, before engaging with a tube sheet aperture 54 of the second output tube sheet 48. The second tube side product (not shown) passes through second input tube sheet 46 and traveling the length of the second tubes 58 exchanging heat with the second shell side product (not shown) then passing through second output tube sheet 48 into second output head 20 where the second shell side product (not shown) stream is reunited before exiting a nozzle, second output head outlet 32. It should be noted that the second tube side product (not shown) could either be a separate product from the first tube side product and shell side product, or the first tube side product can be passed through the heat exchanger 10 multiple times and thus being used as either the second tube side product or shell side product.

[0041] The tube bundle 62 is the collection of the multiplicity of tubes (56, 58, 60) inside of which the various tube side products (not shown) pass through the shell 12. The tubes (56, 58, 60) of the tube bundle 62 is secured by the tube sheets (42, 44, 46, 48) at their opposite ends. The tubes (56, 58, 60) are organized within the tube bundle 62 by being inserted through tube sheet apertures 54 in the tube sheets (42, 44, 46, 48) and secured there. The inner sides of the tube sheets (42, 44, 46, 48) are toward the inside of the shell, while the outer sides of the tube sheets (42, 44, 46, 48) are toward the heads (14, 16, 18, 20) of the heat exchanger 10.

[0042] Along the length of the tube bundle 62 one or more baffles 64 may be placed. The main roles of a baffle 64 in a shell 12 of the tube heat exchanger 10 are to hold the tubes (56, 58, 60) in position (preventing sagging), and to promote cross-wise movement of the shell side product (not shown) in addition to the length-wise move of the shell side product (not shown) within the shell 12, and thus increase heat transfer between the shell side product (not shown) and the tube side products (not shown) in the tubes (56, 58, 60).

[0043] FIG. 2 shows the new exchanger design setup to exchange heat from the shell side product with three separated products passing through the tube sides separated by multiple tube sheets. As in FIG. 1, this cut-away view shows many of the second tubes 58 as having been cut short (so as to better show details of the interior of the heat exchanger 10), but in the invention each of the second tubes 58 would engage with a tube sheet aperture 54 of the second input tube sheet 46 and extend through an individual baffle aperture 66 of each of the baffles 64, before engaging with a tube sheet aperture 54 of the second output tube sheet 48.

[0044] Again, as illustrated in FIG. 1, a shell side product (not shown) enters a nozzle, shell inlet 40 and travels the length of the shell 12 exchanging heat with separate products (not shown) traveling through the tube bundle 62 then exits a nozzle, shell outlet 38. Tube side products (not shown) enter an input head inlet (26, 30) into an input head (14, 18) and are divided through multiple tubes (56, 58) passing through one or both of the input tube sheets (42, 46), traveling the length of the tubes (56, 58) exchanging heat with the shell side product (not shown), passing through one or both of the output tube sheets (48, 44), where the product streams are reunited in the appropriate output head (16, 20) before exiting an output head outlet (28, 32).

[0045] However, FIG. 2 additionally illustrates that additional paired input and output heads (and their associated tube sheets and tubes) can be integrated into the improved heat exchanger 10. Here, a third tube side product (not shown) enters a nozzle, third input head inlet 34 into the third input head 22 and is divided through multiple third tubes 60 passing through third input tube sheet 50, traveling the length of the third tubes 60 while exchanging heat with the shell side product (not shown), then passing through third output tube sheet 52 where the product stream is reunited in the third output head 24 before exiting a nozzle, third output head output 36.

[0046] Additional paired input and output heads (and their associated tube sheets and tubes) can be integrated into the improved heat exchanger 10, up until the diameter of the restricts the addition of more tubes, or the addition of additional paired input and output heads is limited by the number of tubes that fit in the shell 12, are in communication (or associated with) with the paired input and output heads, and are sufficient to provide for heat exchange at an efficiency acceptable to the user.

[0047] FIGS. 3a and 3b can be compared in order to demonstrate the advantages of the present invention versus the traditional method using multiple heat exchangers. FIG. 3a illustrates a traditional multi-pass method using multiple heat exchangers. There are multiple separate shellsas shown in this figure, shell 12 and second shell 76. The multiple shells each have a single pair of associated heads (14/16 and 18/20). The shell side product (not shown) passes through the first shell 12 exchanging heat with a first tube side product (not shown) that had entered the first shell 12 through the input side head inlet 26, the first input head chamber 68, through the first input tube sheet 42 and through the first shell 12 in the first tubes 56. The first tube side product (not shown) exits the first shell 12 through the first output head chamber 80 and out the first output head outlet 28. The shell side product (not shown) passes out of the first shell 12 and is transferred to the second shell 76 via a transfer pipe 100 where it will exchange heat with a second tube side product (not shown).

[0048] FIG. 3b demonstrates the advantages of the improved heat exchanger 10 over the traditional method using multiple heat exchangers to exchange heat with two are more products. A shell side product exchanges heat with multiple tube side products in a single common shell 12 with the use of multiple tubes sheets (42, 46, 48, and 44), thus eliminating the need for a separate heat exchangers. The same heat exchange between multiple products is effectuated with less bulk and weight, thus increasing efficiency while decreasing cost to the user.

[0049] FIG. 4 illustrates a method to lower hydrocarbon dew point by using Low Temperature Separation. In this example, a Joule-Thomson valve (JT valve) is used to reduce the temperature with a heat exchanger to further lower the temperature in order to separate the Natural Gas Liquids (NGL) from the lighter hydrocarbons that remain in the gas phase. High pressure gas inters pipe 84 is passed through coalescing filter 86 particulates and water vapor is removed.

[0050] Exiting the coalescing filter separator 86, the hydrocarbon liquid passes through a transfer pipe 100 until it arrives at a junction with a thermostatically controlled temperature valve 88. The purpose of the control valve 88 is to control set-point temperature. Thermostatically controlled temperature valves 88 provide automatic and accurate temperature control of fluids. These self-contained, 3-way temperature control regulating valves 88 may be used in either mixing or diverting applications and require no external power source.

[0051] Exiting the 3-way temperature valve the hot gas is directed to pipe 102 or to pipe 106 depending on set temperature. If the hot gas is directed through pipe 102, it next enters the heat exchanger 74 through shell side inlet 38, the hot shell side gas now travels the full length of the heat exchanger exchanging heat with the tube side gas and the tube side NGL traveling in the opposite direction, the shell side gas exits outlet 40 at a reduced temperature. The gas then travels through pipe 104 where it enters the JT Valve.

[0052] The Joule-Thomson effect in theory, is a thermodynamic process that occurs when a fluid expands from high pressure to low pressure at constant enthalpy. Such a process can be approximated in the real world by expanding a fluid from high pressure to low pressure across a valve. Under the right conditions, this can cause cooling of the fluid.

[0053] Gas passes through JT valve 90 causing a pressure and temperature drop, the temperature causes some of the heaver hydrocarbons and water in the gas stream to condense into liquid phase. The gas stream is allowed into cold separator 92 through the cold separator inlet 94. After entering the cold separator the velocity of the two phase gas stream is slowed in the larger diameter cold separator allowing the hydrocarbon liquids 108 and water to separate from the lighter hydrocarbon gas 110, the liquids fall to the bottom of the cold separator where it is periodically dumped. The NGL exits through cold separator NGL outlet 112. After traveling through pipe 116, the NGL enters heat exchanger end cap inlet 26. The NGL stream is separated through multiple NGL tubes 56 which are secured and pass through corresponding holes in NGL tube sheet 42 which serves to separate the NGL side from the shell side gas, after passing through tube sheet 42 the cold NGL passes channel head 18. The NGL leaves channel head 18 and passes through tube sheet 46, the NGL now travels the full length of the heat exchanger cooling the hotter shell side gas as it travels in the opposite direction. From cold separator gas outlet 114 the now colder gas travels through pipe 118 and enters heat exchanger channel head 18 through channel head inlet 30, after entering channel head the gas is separated and passed through multiple gas tubes 58 which are secured through corresponding holes in tube sheet 46, which serves to separate the tube gas stream from the shell side gas stream, after passing through tube sheet 46 the cold gas now travels through the multiple tubes the full length of the heat exchanger as it cools the hotter shell side gas traveling in the opposite direction, the tube side gas now passes through tube sheet 48 entering channel head 20 then exits channel head outlet 32, the treated fuel grade gas now exits the fuel conditioning skid through pipe 122.

[0054] FIG. 4 illustrates how heat exchangers are used to improve the performance of low temperature separation systems. The drop in temperature from passing a gas/liquid through a JT Valve is affected by many variables (gas/liquid pressure, inlet gas/liquid temp, gas/liquid composition) which can limit the JT Valves ability to lower the gas/liquid temperature to operating levels necessary to achieve desired results. One way to improve the performance of any pressure/temperature reducing device (JT Valve, Expander) is to lower the inlet temperature of the gas/liquid before passing through the JT Valve. If for instance the inlet pressure and temperature before passing through the JT Valve is 1,000 psi at 100 degrees Fahrenheit and the JT Valve is set to have 800 psi pressure differential between the JT Valve inlet gas/liquid and the JT Valve outlet gas/liquid then the change in pressure and temperature would now be 200 psi at around 60 degrees Fahrenheit. The now colder 60 degree gas/liquid enters the cold separator were the NGL is separated from the gas. The system can now take advantage of both the 60 degree gas and the 60 degree NGL by sending them separately to heat exchangers where they are used to cool the 100 degree pre JT Valve inlet gas/liquid down to around 70 degrees. After leaving the exchanger the post JT Valve fuel grade gas and NGL exit process skid. The 1000 psi at 70 degree pre JT Valve gas/liquid now passes through the JT Valve 30 degrees cooler with the use of a heat exchanger, as a result the post JT Valve temperature is now 30 degrees Fahrenheit. With time the systems temperature will continue to fall until the design limits are met based on several variables.

[0055] FIG. 5 illustrates a cross-sectional side view of the heat exchanger 10 of the present invention. This view illustrates the multiple inlets and chambers through which either multiple substances or a single substance can be passed multiple times at different temperatures. Thus, the single heat exchanger can act to cool or heat either multiple substances or the same substance multiple times at different heat levels. It also illustrates the multiple baffles 64 through which the various tubes (56, 58) travel and which cause the shell side product (not shown) to travel through the shell 12 in a nonlinear path which is believed to increase the efficiency of the heat exchange.

[0056] FIG. 6 is a front, cross-sectional view along line A-A from FIG. 5 of a second tube sheet 46 of the present invention 10. While FIG. 7 is a front, cross-sectional view along line B-B from FIG. 5 of a first tube sheet 42 of the improved heat exchanger 10. These figures illustrate tube sheets (42, 44, 46, 48) that have a pattern of apertures 54 which allow the tubes (56, 58, 60) to pass through the tube sheet (42, 44, 46, 48). Because of the multiple phases and passes through the heat exchanger 10, the specific pattern of tube sheet apertures 54 of each individual tube sheet (42, 44, 46, 48) helps keep the multiplicity of tubes (56, 58, 60) from becoming twisted or unorganized inside the shell 12. Additionally, by interspersing the tubes from different products or passes, the efficiency of the heat exchange is improved.

[0057] FIG. 8 is a side, cross-sectional view along line Y-Y from FIG. 7 of a tube sheet (42, 44, 46, 48, 50, 52) of the present invention. It illustrates the shape of the tube sheet (46 as shown but applicable to other tube sheets) having a thicker center 132 with a tube sheet shoulder 128 and a rim 130 that extends beyond the center 132 and which is thinner than the center 132. The relatively thinner rim 130 and shoulder 128 allow for attachment and positioning of the shell 12 and heads (14, 16, 18, 20, 22, 24) which can be urged against the shoulder 128 and coupled to the rim 130 via an appropriate attachment mechanism such as welding, gluing, bolting, riveting, screwing, or other like fastening which are well known in the art.

[0058] FIG. 9 illustrates the improved heat exchanger 10 installed into a heat exchange system as shown in FIG. 4. Additionally, illustrated in this figure is a sled 134 onto which the heat exchange system is installed. As used herein, sled refers to any sort of wagon or cart which may be pushed or pulled onto which the heat exchange system may be installed, and the sled used to move the heat exchange system from place to place. It is anticipated that there may be many embodiments of sleds 134. As shown in FIG. 9, the sled 134 as a platform 136 onto which the heat exchange system is installed and rests. The sled 134 may be further comprised of two sled sides 138 which ended in opposing sled ends 140. In order to help the mobility of the sled 134, the sides 138 may extend outwardly and end in sled runners 142. The runners 142 would help the entire apparatus slide along the ground surface. It is also anticipated that the sled 134 might have axles and wheels, skis, or other apparatus that are well known in the art to provide for better movement of the sled 134. Additionally, the sled 134 may have a towbar 144 or other type of hitch installed in the front, back, or both in order to couple the sled 134 to a towing vehicle (not shown).

[0059] FIG. 10 is an illustration showing the improved heat exchanger 10 and in exchange system installed on a sled 134. As shown in this figure, the sled 134 has depth from its bottom 146 to the platform 136. It is anticipated that the sides 138, platform 136, bottom 146 and ends 140 be connected so as to create a hollow space (not shown) in the body of the sled 134. In order to more efficiently perform heat exchange, it is anticipated that one or more of the improved heat exchanger 10 may be installed in the hollow space of the sled 134. It is further anticipated that the heat exchangers 10 may be surrounded by insulation (not shown) so as to better isolate the heat exchanger 10 from the ambient environment. It is also anticipated that the runners 142 (or wheels or other structure coupled to the sled 138 and used to increase mobility) will contact the ground or substrate while the bottom 146 will be raised off the ground or substrate.

[0060] FIGS. 11-14 are various views of illustrations of the exchanger 10, heat exchange system as it might be installed on a sled 134. FIGS. 11, 13, and 14, show the sled 134 removed to better show the heat exchangers 10. While FIG. 12 shows a top view of the sled 134 and system.

[0061] In interpreting the claims appended hereto, it is not intended that any of the appended claims or claim elements invoke 35 U.S.C. 112(f) unless the words means for or step for are explicitly used in the particular claim.

[0062] It should be understood that, although exemplary embodiments are illustrated in the figures and description, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and description herein. Thus, although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various embodiments may include some, none, or all of the enumerated advantages. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components in the methods described may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.