Method for producing a heat exchanger module with at least two fluid circulation circuits and heat exchanger obtained using this method

Abstract

The present invention relates to an novel method of producing heat exchangers having at least two fluid circuits each comprising channels, the method employing diffusion bonding achieved using the hot isostatic pressing (HIP) technique, and to a heat exchanger obtained using this method.

Claims

1. A method for producing a heat exchanger module with at least two fluid circuits each comprising channels, comprising the following steps: a/ producing at least two separate groups of metal tubes, each tube being of elongated shape and having at least two straight ends, one thereof being open and the other being blind; b/ aligning each of the two groups with side-by-side positioning of the tubes in at least one row per group; c/ stacking in a stacking direction to obtain a stack having longitudinal sides and lateral sides, said stacking comprising alternate stacking with top-to-toe positioning of the row(s) of one group and the row(s) of the other group so as to have the rows on top of one another and the blind ends of the tubes of one group arranged on the same lateral side of the stack as the open ends of the tubes of the other group; d/ offsetting, in a direction at right angles to the stacking direction, of the row(s) of one group relative to the row(s) of the other group, so as to create gaps on each lateral side of the stack, between the blind ends of the tubes of one group and the open ends of the tubes of the other group; e/ encapsulating the stack by positioning respectively one metal casing on the longitudinal sides of the stack of tubes and metal strips at the end of the offset blind ends of the tubes in each gap created; f/ welding on the periphery of the casing, each strip and each open end of the tube so as to seal the inside of the encapsulated stack whilst leaving free the open ends of the tubes; i/ applying a hot isostatic pressing (HIP) cycle at high pressure to the stack, which has been previously degassed, allowing the pressurizing gas to penetrate into all of the tubes via their open ends so as to obtain welding by diffusion between the tubes of the encapsulated stack, the tubes of each group welded by diffusion forming the channels of a fluid circuit of the module.

2. The method as claimed in claim 1, the casing comprising a through-opening according to which the following steps are carried out between steps f/ and i/: g/ degassing the interior of the sealed stack via the through-opening; h/ closing the through-opening.

3. The method as claimed in claim 1, the tubes produced according to step a/ being straight tubes.

4. The method as claimed in claim 1, the tubes all being identical to one another.

5. The method as claimed in claim 3, the tubes of at least one group being straight and having a square cross-section over a majority of their length.

6. The method as claimed in claim 3, the tubes of at least one group being straight and having a circular cross-section over a majority of their length, wherein their open and blind ends have a square cross-section.

7. The method as claimed in claim 6, wherein at least one of the ends having the square cross-section being formed by drawing the circular cross-section of the tubes.

8. The method as claimed in claim 7, wherein at least one of the ends of the square cross-section being produced by welding a solid stopper having an end with a square cross-section.

9. The method as claimed in claim 8, the stopper being a solid stopper, thus forming a blind end of a tube.

10. The method as claimed in claim 9, the solid stopper being made of material capable of being dissolved by chemical means.

11. The method as claimed in claim 7, wherein at least one of the ends having the square cross-section being formed by an end piece having a square cross-section in which the length of the circular cross-section of the tube is press-fitted.

12. The method as claimed in claim 11, wherein the heat exchanger module further comprises at least one single end piece for a row of tubes, wherein each tube in the row of tubes is press-fitted inside said end piece.

13. The method as claimed in claim 1, the step e/ being carried out with a casing comprising four metal plates, each being pressed against one of the four longitudinal edges of the stack and the step f/ being carried out by welding the four metal plates in pairs.

14. The method as claimed in claim 1, the HIP cycle according to step i/ being carried out at a pressure of between 500 and 2000 bar.

15. The method as claimed in claim 1, comprising a step j/, subsequent to step i/, consisting of a heat treatment designed to restore properties of the metal materials of the components which constitute said module.

16. The method as claimed in claim 1, comprising a step l/ of transverse boring of the tubes to produce orifices, in the plane of each row and in the vicinity of the lateral sides of the stack, the orifices of each group of tubes, produced by boring, opening out onto one longitudinal side of the stack through the casing, forming a column, the two columns of orifices each being arranged in the vicinity of one lateral side of the stack and opposing one another.

17. The method as claimed in claim 16, comprising a step m/ of welding a fluid collector to the casing, opposite and around each column of orifices.

18. The method as claimed in claim 2, comprising a step of cleaning the constituent parts of the encapsulated stack before the degassing step g/.

19. The method as claimed in claim 4, wherein the tubes of at least one group being straight and having a square cross-section over their length.

20. The method as claimed in claim 4, wherein the tubes of at least one group being straight and having a circular cross-section over a majority of their length, wherein their open and blind ends have a square cross-section.

Description

DETAILED DESCRIPTION

(1) Further advantages and features of the invention will be revealed more clearly from reading the detailed description of exemplary embodiments of the invention made by way of illustrative and non-limiting example, with reference to the following figures, in which:

(2) FIG. 1 is a perspective and partially exploded view of an assembly of components from which a first example of the method for producing a heat exchanger module with two fluid circuits according to the invention is implemented;

(3) FIG. 1A is a perspective exploded view of a metal tube with one of its ends used in the assembly of FIG. 1;

(4) FIG. 1B is a perspective view of a heat exchanger module obtained from the assembly of components of FIG. 1 partially broken away and integrating an inlet collector and an outlet collector for one of the two fluids;

(5) FIG. 2 is a perspective and partially exploded view of an assembly of components from which a second example of the method for producing a heat exchanger module with two fluid circuits according to the invention is implemented;

(6) FIGS. 2A to 2C are perspective views respectively of a metal tube and its ends used in the assembly of FIG. 2;

(7) FIG. 3 is a perspective and partially exploded view of an assembly of components from which a third example of the method for producing an exchanger-reactor module according to the invention is implemented.

(8) In the following description the terms upper and lower are to be considered with reference to the direction Z of stacking the tubes according to the invention.

(9) Similarly, the terms longitudinal and lateral are to be considered in relation to the geometric shape of the stack, itself determined by the elongated shape of the tubes which constitute said stack. Thus, the four longitudinal sides of the stack are those which extend parallel to the longitudinal axis X of the tubes. The two lateral sides of the stack are those at the end of the tubes and which extend at right angles to the longitudinal axis X of the tubes.

Example 1

(10) Step a/: a heat exchanger module 1 with two fluid circuits is produced from a plurality of metal tubes 2 all identical with one another.

(11) As illustrated most clearly in FIG. 1A, each metal tube 2 is straight with a longitudinal axis X, of square section over its entire length with an open end 20 left as after manufacture and with the other of its ends 21 closed in a sealed manner by a solid stopper 3 also of square section. In other words, once finished, each straight tube 2 is open at one of its ends 20 and blind at the opposing end 21, 3.

(12) By way of example, a manufactured tube 2 is made of 316L stainless steel and has an external square section of 66 mm over a length of 400 mm and a wall thickness of 1.5 mm. By way of example also, a solid stopper 3 is also made of 316L stainless steel and is welded by TIG welding at the end 21 of the tube 2.

(13) Each metal tube 2 of square section thus defines a fluid circulation channel of the exchanger as explained below.

(14) Steps b/ to d/: the tubes 2 obtained are aligned forming adjacent rows 2.1, 2.2 . . . 2.i1, 2.i . . . , i.e. each row is formed by a plurality of tubes 2 joined to one another by one of their longitudinal sides in the same plane. All the adjacent rows 2.1, 2.2 . . . 2.i1, 2.i . . . , have the same number of straight tubes 2.

(15) The adjacent rows 2.1, 2.2 . . . 2.i1, 2.i . . . are stacked alternately with top-to-toe positioning in a stacking direction Z, so as to have all the rows on top of one another and the blind ends of the tubes 21, 3 of one row 2.1, 2.3, . . . 2.i1 . . . arranged on the same lateral side of the stack as the open ends 20 of the tubes 2 of an adjacent row 2.2, 2.4, . . . 2.i.

(16) In the example illustrated in FIG. 1, it is possible to see that each adjacent row having the index i with an even number 2.2, 2.4, . . . 2.i . . . has its open end 20 visible, whilst each adjacent row having the index i1 with an odd number 2.1, 2.3, . . . 2.i1 . . . has its blind end 21, 3 visible. Also as illustrated in FIG. 1, each adjacent row consists of a number equal to twenty straight tubes 2 and the stack consists of a number equal to twenty rows 2.2, 2.2, 2.3 . . . 2.20 of straight tubes.

(17) In the example illustrated in FIG. 1, two adjacent rows 2.1, 2.2, . . . 2.i1, 2.i, i.e. in contact with one another in the stack are positioned top-to-toe as above. A top-to-toe positioning of a group of rows may also be provided, each group being formed from a plurality of adjacent rows superposed in the same orientation. Thus, for example, it is possible to provide a group of two rows 2.1, 2.3 stacked on top of one another and alternating and positioned top-to-toe with a group of two rows 2.2, 2.4 in turn stacked on top of one another.

(18) In the longitudinal direction of the stack, i.e. at right angles to the stacking direction Z, an offsetting of the rows 2.1, 2.3, . . . 2.i1 is also carried out relative to the other rows 2.2, 2.4, . . . 2.i so as to create on each lateral side of the stack gaps between the blind ends 21, 3 of the tubes and the open ends 20 of the tubes.

(19) In the example illustrated in FIG. 1, the gaps created are all of equal value. For example, the value of said gaps obtained by the offset is equal to 3 mm.

(20) Step e/: thus an encapsulation of the stack is produced by respectively positioning a metal casing 4 on the longitudinal sides of the stack of tubes 2 and metal strips 5 at the end of the offset blind ends 3 of the tubes, in each gap formed.

(21) In the example illustrated in FIG. 1, the metal casing 4 consists of four metal plates 40, 41, 42, 43, including two 40, 42 respectively forming upper and lower terminal plates of the stack and the two others 41, 43 constitute closing plates of the stack. A through-opening 44 is bored into one of the plates of the casing 4.

(22) By way of example, said four plates 40, 41, 42, 43 are made of 316L stainless steel and each with a thickness of 4 mm.

(23) Also by way of example, all the metal strips 5 are identical and of equal thickness to the offset gap produced. They may be produced from 316L stainless steel.

(24) As illustrated in FIG. 1, the through-opening 44 is produced in the upper terminal plate 40.

(25) Step f/: after having cleaned all of the parts, the welding is carried out on the periphery of the casing 4, each strip 5 and each open end 20 of the tube 2 so as to seal the interior of the encapsulated stack whilst leaving free the open ends 20 of the tubes. Weld seams, typically by TIG welding, may be produced to make the stack completely sealed. Thus, weld seams are advantageously produced along overlapping seams 400, in pairs, of the four metal plates 40, 41, 42, 43, further weld seams are produced along the strips 5 and finally further weld seams are produced on the interface lines 200, in pairs, of the open ends 20 of the tubes 2.

(26) Steps g and h/: a seal weld hole, not shown, is fixed in the through-opening 44. The fixing may be carried out by TIG welding. By way of example, the seal weld hole may have an internal diameter of 6 mm.

(27) The degassing of the interior of the stack is carried out via the seal weld hole, and then the actual seal welding of the seal weld hole, i.e. the pinching thereof to make the interior of the degassed stack sealed relative to the outside.

(28) Step i/: after degassing and seal welding according to steps g/ and h/, an HIP cycle at high pressure is applied to the stack, comprising heating to 1080 C., pressurizing to 1000 bar in 2 hrs, maintaining the level of temperature and pressure for 2 hrs, then concomittant cooling and depressurizing in 5 hrs. During this HIP cycle, the gas penetrates into all of the tubes 2 via the open end 20 thereof but does not infiltrate the interfaces between the parts of the stack due to the welded stopper 3 and to the sealing welds produced on the periphery of the casing 4, of each strip 5 and of each open end 20 of the tube 2.

(29) Step j/: this optional step subsequent to step i/ consists in applying to the module a heat treatment designed to restore the properties of the metal materials of the components forming the module. It may advantageously be a heat treatment of rapid quenching designed to restore the properties of the 316L steel.

(30) Step k/: then the seal weld hole is removed, for example by mechanical means.

(31) At this stage of the method, an intermediate block is obtained of generally parallelepiped shape. By way of example, such a block may be a rectangular parallelepiped with two square faces. The dimensions L*W*H of such a block may be 405*128*128 mm.

(32) Step l/: transverse boring is carried out in the plane of each row and in the vicinity of the lateral sides of the stack, through at least one closing plate 41 and through the walls of the tubes 2 of each row 2.1, 2.2, . . . 2.i with the exception of the walls of the tubes 2 which bear against the opposing closing plate 43.

(33) The boring operations carried out leave whole the metal strips 5 welded at the end of the stack. The boring operations carried out may partially or completely eliminate the solid stoppers 3. As a result, the thickness of the metal strips 5 is selected ultimately to confer to the exchanger obtained sufficient mechanical resistance, in particular to pressure, without having the need for an excessive thickness provided by all or some of the stoppers 3. By way of example, the boring may be carried out by mechanical machining.

(34) As illustrated in FIG. 1B, once the boring operations have been carried out, all of the tubes 2 of the same row 2.1, 2.2, . . . 2.i communicate with one another via the orifices 22 which extend transversely to the axis X of the tubes 2 and open out onto the same orifice 410 bored in the closing plate 41 in the vicinity of the metal strip 5 of the relevant row.

(35) As illustrated in FIG. 1B, the orifices 22 and 410 may be elongated slots of rectangular section.

(36) Thus, once the boring has been carried out, all of the orifices 410 bored in the closing plate 41, and onto which the orifices 22 of a group of rows 2.1, 2.3, . . . 2.i1 or 2.2, 2.4, . . . 2i positioned in the same orientation during the steps b/ to d/ open, are aligned forming a column.

(37) In other words, in one column, two adjacent orifices 410 are separated from one another by a height equal to the thickness of a row of tubes 2 positioned top-to-toe during steps b/ to d/ and not bored at this point.

(38) Thus, once the boring has been carried out two columns of orifices 22, 410 are obtained, opening out into a longitudinal side of the stack and each arranged in the vicinity of one of its two lateral sides.

(39) In the example illustrated in FIG. 1B, a column of orifices 22, 410 opens through the closing plate 41 in the vicinity of one lateral side of the stack and the other column opens out onto the closing plate 43 opposing the closing plate 41 in the vicinity of the other lateral side of the stack.

(40) Alternatively, it is naturally possible to produce bored areas 22, 410 which open out solely through a single closing plate 41. According to this variant, therefore, the two columns of orifices open out through the same closing plate, one of the columns being arranged in the vicinity of one lateral side of the stack and opposing the other column arranged in the vicinity of the other lateral side of the stack.

(41) Thus, once the boring step l/ is carried out, a fluid circulation channel of the exchanger module is delimited longitudinally by a tube 2 of one row, at the end by a strip 5 and/or by the solid stopper 3 of the row concerned, and finally transversely via the orifices 22 and 410 of the row concerned.

(42) Step m/: a fluid collector 6, 7 is welded to the metal casing opposite and around each column of orifices 22, 410.

(43) As illustrated in FIG. 1B, each collector 6, 7 respectively consists of a semi-cylindrical closed portion 60, 70 and a tubular portion 61, 71 opening out into the semi-cylindrical portion.

(44) As illustrated in FIG. 1B, the semi-cylindrical closed portion 60, 70 is welded solely onto one of the closing plates 41, 43.

(45) Although not shown, a fluid collector is also welded at the end on both sides of the exchanger module so as to supply a fluid in the region of the open ends 20 of the tubes 2.

(46) Due to the method according to steps a/ to m/ a heat exchanger module is obtained which is compact and assembled by HIP diffusion-welding at high pressure.

(47) Such a heat exchanger module according to the example 1/ may be considered as having fluid circulation channels of small dimensions.

(48) In such a heat exchanger module, each fluid follows an L-shaped path and the heat transfer from one of the two fluids to the other is carried out between two adjacent rows in the stack since a fluid circulates in the rows of the uneven line of tubes 2.1, 2.3, . . . 2.i whilst the other circulates in the rows of the even line of tubes 2.2, 2.4, . . . 2.i.

(49) Such an exchanger module may function according to a concurrent or counter-current transfer mode. In the concurrent transfer mode, one of the fluids penetrates the module via the open ends 20 of the tubes 2 from one lateral side of the stack and the other fluid penetrates via the fluid collector 6 or 7 in the vicinity of the same lateral side. In the counter-current transfer mode, one of the fluids penetrates into the module via the open ends 20 of the tubes 2 from one lateral side of the stack and the other fluid penetrates via the fluid collector 7 or 6 in the vicinity of the opposing lateral side.

(50) Thus, the collector 6 or 7 welded to one of the closing plates may be an inlet collector or outlet collector for one of the fluids.

Example 2

(51) Step a/: a heat exchanger is produced with two circuits of a plurality of metal tubes 2 which are all identical to one another.

(52) As best illustrated in FIG. 2A, each metal tube 2 is straight having the longitudinal axis X and of circular section over the major part 2 of its length, its open 20 and blind 3 ends being of square section.

(53) In the illustrated example, the open end 20 is formed by drawing the circular section of the tubes. The blind end is produced by TIG welding of a solid stopper 3. Said solid stopper 3 comprises a square section 30 extended by a circular tubular section 31 positioned at the end 21 of the circular straight part 2 before the welding thereof to produce the blind end 3.

(54) By way of example, a manufactured tube 2 is made of 316L stainless steel and has a wall thickness of 1 mm and a circular section 2 of external diameter 4 mm over a length of 127.5 mm to which is added an open end 20 formed by drawing with a square geometry 44 mm over a length of 4 mm, the transition zone between the square section and the circular section being 4 mm. Also, by way of example, a solid stopper 3 made of nickel has a square section 30 44 mm over a length of 4 mm, a transition zone between the square section 30 and the circular section 31 of 4 mm and a circular section of diameter 4 mm over a length of 5 mm. The total length is 135.5 mm.

(55) Thus each metal tube 2 of circular section over the major part of its length defines a fluid circulation channel of the exchanger as explained below.

(56) Steps b/ to d/ are also carried out as in the example 1/ with a single row per group of stacked tubes alternating with a single row of the other group.

(57) In contrast, in this example 2, the metal tubes 2 of one row are joined together by their square sections and with those of the adjacent row also by their square sections.

(58) In the example illustrated in FIG. 2, each row consists of a number equal to five straight tubes 2 and the stack consists of a number equal to four rows of straight tubes.

(59) In the example illustrated in FIG. 2, the gaps created are all of equal value. For example, the value of these gaps obtained by offsetting is 2 mm.

(60) As illustrated in FIG. 2, the example 2/ is also distinguished from the example 1/ by the presence of wires 8, 9 inserted individually in the space left free between two tubes 2 side-by-side.

(61) The wires 8 are made of a material which is a very good thermal conductor. They may be advantageously made of copper. By way of example, the wires 8 have a diameter of 1 mm over a length of 122 mm.

(62) A wire 9 is inserted in the extension of each of these wires 8 and on the side of the solid stoppers 3, the function thereof being to protect the wire 8 in case of a subsequent step of dissolving the solid stopper 3 by chemical means. These wires 9 may be made, for example, of 316L stainless steel. By way of example, each wire 9 has a diameter of 1 mm over a length of 10 mm.

(63) Step e/ is carried out as in the example 1/ with encapsulation of the stack by respectively positioning a metal casing 4 on the longitudinal sides of the stack of tubes 2 and metal strips 5 at the end of the offset blind ends 3 of the tubes, in each gap formed.

(64) By way of example, the four plates 40, 41, 42, 43 of the example 2/ of FIG. 2/ are made of 316L stainless steel and each having a thickness of 4 mm. As in the example 1/a through-opening to accommodate a seal weld hole is bored into the upper plate 40. By way of example, the seal weld hole has an internal diameter of 6 mm.

(65) Also by way of example, all of the metal strips 5 are identical and of a thickness equal to the offset gap produced. They may be produced from 316L stainless steel.

(66) As illustrated in FIG. 2, the example 2/ is also distinguished from the example 1/ by the presence of orifices 410 bored in the two closing plates 41, 43 prior to the HIP step i/. Said orifices 410 are thus bored on both opposing sides of each row of tubes 2 but solely opposite the solid stoppers 3. Inside each of said orifices 410 produced by boring is inserted a stud 10 advantageously of complementary shape.

(67) The function of said studs 10 is to fill the internal space of the orifices 410 during the HIP step i/ and to be able to be eliminated by dissolving by chemical means.

(68) Said studs 10 are preferably made of the same material as the solid stoppers 3. They are advantageously made of nickel.

(69) In this example 2/, the encapsulation casing comprises metal strips 11 which bear against the closing plates 41, 43 covering the studs 10 housed in the orifices 410. By way of example, the strips 11 are made of 316L stainless steel.

(70) The welding step f/ is implemented as in the example 1/ after having cleaned each of the components of the stack, and also by means of weld seams, preferably by TIG welding, produced around each of the metal strips 11 on the closing plates 41, 43 and also to make the stack completely sealed.

(71) Step h/ is carried out as in the example 1/.

(72) Step i/ is carried out by applying to the stack an HIP cycle comprising heating to 1040 C., simultaneous pressurizing to 1000 bar for 2 hrs, maintaining the level of temperature and pressure for 2 hrs, then cooling and depressurizing for 5 hrs. During this operation, the gas penetrates into the channels via their open end 20 which has the result of slightly modifying the geometry of their circular section by the elimination of the gaps located between the tubes 2 and the wires 8.

(73) Step j/ of a heat treatment of rapid quenching designed to restore the properties of the 316L steel is carried out, if required, as in the example 1/.

(74) Step k/ is carried out as in the example 1/ but without the metal strips 11, preferably by machining, which has the effect of making accessible the solid stoppers 3 and studs 10 made of material capable of being dissolved via chemical means, such as nickel.

(75) Step l/: now the stack is immersed in a bath of nitric acid which has the effect of dissolving all the solid stoppers 3 and the studs 10 and thus makes it possible for the ends of the tubes to be opened transversely in the plane of each row, whilst leaving the metal strips 5 in place. Thus, the seal at the end of each row is ensured by a welded metal strip 5. During this step of immersion of the stack, the wires 9, for example made of 316L steel, prevent the nitric acid from reaching the thermal conductor wires 8, for example made of copper, also welded by diffusion to the tubes 2.

(76) The step m/ of welding is carried out as in the example 1/ but here two fluid collectors are attached per circuit, each opposite and around the orifices 410 of a column. Thus, for one fluid circuit, in this case two collectors are welded opposite one another and on both sides of the stack.

(77) Due to the method according to steps a/ to m/, a heat exchanger module is obtained which is compact and assembled by HIP diffusion-welding at high pressure.

(78) Such a heat exchanger module according to the example 2/ may be considered as having fluid circulation channels of small dimensions and improved thermal performance by the presence of the thermal conductor wires 9 inside the stack and welded by diffusion to the channels.

Example 3

(79) Step a/: a heat reactor-exchanger with two circuits of a plurality of metal tubes 2A, 2B of two different types.

(80) As illustrated in FIG. 3, the tubes 2A of greater section constitute the reaction part of the reactor whilst the tubes 2B of smaller section constitute the part usually called the utility part.

(81) As best illustrated in FIG. 3, each metal tube 2A is straight, of circular section over its entire length with an open end 20 left as after manufacture and with the other of its ends 21 closed in a sealed manner by a solid stopper 3A also of circular section. In other words, once finished, each straight tube 2A is open at one of its ends 20A and blind at the opposing end 21A, 3A.

(82) By way of example, a manufactured tube 2A is made of 316L stainless steel and has an external diameter of 12 mm over a length of 450 mm and a wall thickness of 1 mm. Also by way of example, the solid stopper 3A is also a nickel pellet and welded by TIG welding at the end 21A of the tube 2A. By way of example, a pellet 3A is of 4 mm thickness, reducing to 2 mm.

(83) Each tube 2B is straight, of square section over its entire length, with an open end 20B left as after manufacture and with the other of its ends 21B closed in a sealed manner by a solid stopper 3B, also of square section.

(84) By way of example, a manufactured tube 2B is made of 316L stainless steel and has a square section of 44 mm, over a length of 450 mm, and wall thickness of 1 mm. By way of example also, a solid stopper 3B is made of nickel and welded by TIG welding to the end 21B of the tube 2B. By way of example, a solid stopper 3B has dimensions of 4*4*22 mm, reducing to 2 mm.

(85) Steps b/ to d/: they are different from those of the examples 1/ and 2/ as here a single row 2.3 of the group of tubes 2A of circular section is stacked alternately with two rows 2.1, 2.2 of the group of tubes 2B of square section.

(86) In other words, as illustrated in FIG. 3, two rows 2.1, 2.2 of tubes 2B of square section are stacked on top of one another and both stacked alternately with top-to-toe positioning, with a single row 2.3 of tubes 2A of circular section.

(87) As illustrated in FIG. 3, the ends 20A and 21A of the tubes 2A of circular section of the same row 2.3 are formed in a square and each are press-fitted inside an end piece 12, 13 of square section. Preferably, the end pieces 12, 13 are made of the same material as the tubes 2A of circular section, for example 316L stainless steel.

(88) Thus, in this example 3, the tubes 2A of one row are not completely joined together due to the wall thicknesses of the end pieces 12, 13.

(89) Also as illustrated in FIG. 3, each row of the group of straight tubes 2A of circular section consists of a number equal to ten tubes and each row of the group of straight tubes of square section 2B consists of a number equal to thirty two tubes.

(90) Each row of the group of straight tubes 2A of circular section is inserted between two advantageously identical grooved plates 14, 15. Said two grooved plates 14, 15 act as half shells about the tubes 2A of one row. In other words, positioned about the straight tubes 2A of the same row, the grooves of the plates 14, 15 individually espouse the shape of each straight tube of circular section 2A.

(91) Thus, as illustrated in FIG. 3, in the stack, two grooved plates 14, 15 encapsulate by contact one row 2.3 of tubes of circular section 2A and are each in surface contact with an adjacent row 2.2 of the group of tubes 2B of square section.

(92) The grooved plates 14, 15 are made of a material which is a very good thermal conductor. They may be advantageously made of copper alloy CuCrZr.

(93) The plates 14, 15 are preferably all identical to one another in the stack.

(94) By way of example, a grooved plate 14 or 15 has a thickness of 7 mm and has grooves having a diameter of 12.2 mm produced with a pitch of 12.7 mm.

(95) Thus, by way of example, the dimensions of a row of tubes of circular section 2A are 45212814 mm.

(96) In comparison, by way of example and with the numbered data indicated above, the dimensions of the two rows 2.1, 2.2 stacked on top of one another of the group of tubes of square section 2B are 4701288 mm.

(97) The rows 2.1, 2.2 of the group of tubes of square section 2B are thus longer by 18 mm than a row 2.3 of the group of tubes of circular section 2A.

(98) Thus, in the example illustrated in FIG. 3, the gaps created at the blind ends 21A, 3A of the tubes 2A of circular section have a value greater than those of the blind ends 21B, 3B of the tubes 2B of square section.

(99) Here, to fill up the gaps of different value at the blind ends 21A, 3A of the tubes 2A of circular section and at the blind ends 21B, 3B of the tubes 2B of square section, a bar 16 is added at the end of each blind end 21A, 3A of the tubes 2A of circular section. The bar 16 is made of a material capable of being dissolved by chemical means. By way of example, it is made of nickel. Its dimensions may be 1812814 mm.

(100) Step e/: this is carried out as in the example 1/ with encapsulation of the stack by respectively positioning a metal casing 4 on the longitudinal sides of the stack of tubes 2A, 2B but with metal strips 5A and 5B of different heights at the end of the offset blind ends 3 of the tubes, respectively 2A and 2B.

(101) By way of example, the four plates 40, 41, 42, 43 of the example 3/ of FIG. 3/ are made of 316L stainless steel, each having a thickness of 4 mm. All as in the example 1/, the upper plate 40 is bored by a through-opening to accommodate a seal weld hole. By way of example, the seal weld hole has an internal diameter of 6 mm.

(102) By way of example, the metal strip 5A has dimensions of 10*128*14 mm and a metal strip 5B has dimensions of 10*128*8 mm.

(103) The welding step f/ is carried out as in the examples 1/ and 2/ after having cleaned each of the components of the stack, and also with weld seams, preferably by TIG welding, produced around each end 12, each strip 5A and 5B and each of the open ends 20A of the tubes of circular section to make the stack completely sealed.

(104) Step i/ is carried out by applying an HIP cycle to the stack comprising heating to 1040 C. simultaneous pressurizing to 1000 bar for 2 hrs, maintaining a level of temperature and pressure for 3 hrs, then concomittantly cooling and depressurizing for 5 hrs. During this operation, the gas penetrates the tubes 2A, 2B via their open end 20A, 20B but does not infiltrate the interfaces between the components of the stack due to the solid stoppers welded 3A, 3B to the strips 5A, 5B and to the peripheral sealing welds.

(105) The heat treatment step j/ consists in a rapid quenching treatment, simultaneously permitting the dissolution of the copper alloy CuCrZr and 316L steel followed by an ageing treatment of CuCrZr.

(106) Step k/ is carried out as in the example 1/.

(107) Step l/: as in the example 1/ at least one closing plate 41 is bored by machining, on the one hand, opposite the bars 16 and solid stoppers 3A and, on the other hand, opposite the solid stoppers 3B.

(108) Thus the stack is immersed in a bath of nitric acid as in the example 2, which has the result of dissolving all the solid stoppers 3A and 3B and the bars 16 and thus permits the ends of the tubes 2A, 2B to be opened transversely in the plane of each row whilst leaving the metal strips 5A, 5B in place. Thus the seal at the end of each row is ensured by a welded metal strip 5A or 5B. During this step of immersion of the stack, the end pieces 12, 13, for example made of 316L steel, prevent the nitric acid from reaching the grooved plates 14, 15 which are very good thermal conductors, for example made of CuCrZr, and also welded by diffusion to the tubes 2A and 2B. Static mixers may be inserted into the reaction tubes 2A.

(109) The welding step m/ is carried out as in the example 1/.

(110) Due to the method according to steps a/ to m/, a heat exchanger-reactor module is obtained which is compact and assembled by HIP diffusion-welding at high pressure.

(111) Such a heat exchanger module according to the example 3/ may be considered as having fluid circulation channels of small dimensions and improved thermal performance and continuous reaction by the presence of plates 14, 15 which are very good thermal conductors and welded by diffusion to the channels and which surround the tubes of circular section 2A which preferably constitute the reaction channels.

(112) Naturally, the present invention is not limited to the described variants and embodiments provided by way of illustrative and non-limiting examples.

(113) Thus, for example, tubes of circular, square, rectangular, hexagonal section or any other cross-sectional geometry suitable for the application of the desired exchanger may also be used to produce the fluid circulation channels. The tubes may also have a geometry in a zigzag shape or the like, all having an elongated shape and with ends of straight section and, in this case, additional metal strips may be added on both sides of the rows of tubes so as to fill the space therebetween and the metal plates constituting the metal encapsulation casing.

(114) The open end of the tubes may be shaped by any means adapted to a cross-sectional geometry which is different from that of the current length, or welded to a bored stopper, the solution retained depending on the presence or not of the plates clamping the tubes as in the example 3/ and on the facility of shaping the tubes (nature of the material, wall thickness, etc.).

(115) The blind end of the tubes may be obtained by pinching, by the welding of a stopper, a pellet or by any other suitable means.

(116) As indicated in the example 3/, the size of the channels for each of the fluid circuits may be different according to the nature and the properties of the fluids to be transported, the admissible losses of load and the desired flow rate. Several (at least two) rows of circulation channels of the same circuit may be stacked, with the purpose of optimizing the functionality of the exchanger, for example the heat exchange or the flow rate of one of the fluids.

(117) The space between tubes arranged side-by-side may be left free, in this case there may be a slight expansion of the tubes during the HIP, or may be filled entirely or partially by the use of a solid material (wires 8, 9 of example 2 and grooved plates 14, 15 of example 3) or a powdery material. The advantages obtained by the possibility of filling these spaces are, on the one hand, the possibility of using tubes of circular section without the risk of breaking them during the HIP step i/ and, on the other hand, the possibility of inserting into the component a different material so as to improve one of its functions, for example the heat exchange performance, as in the examples 2/ and 3/ or the mechanical strength by inserting a material mechanically stronger than the material which constitutes the tubes.

(118) Whilst the illustrated examples 1/ to 3/ relate to exchangers having specifically two fluid circuits, it is possible to manufacture an exchanger with three or more fluid circuits, by inserting in the stack additional rows comprising tubes sealed at one of their ends.

(119) Whilst in the illustrated examples 1/ to 3/ the metal encapsulation casing consists of four plates, it is possible to replace them by a previously manufactured container, with the advantage of simplifying the sealing welding. Said container then forms a sleeve in which the rows of tubes are previously stacked.

(120) Whilst in the illustrated example 1/, the two collectors are arranged on both sides of the stack, it is possible to arrange them on the same closing plate 41 or 43.

(121) In the example 3/, it is perfectly possible to equip the fluid circuit of the reaction part (tubes 2A of circular section) with static mixers, the geometry thereof being suitable for the most effective mixing of the reactants in the tubes 2A. Such mixers may be inserted individually into a tube 2A after the HIP step i/ according to the invention. The fixing thereof may be carried out, for example, by TIG welding, laser welding or the like.

(122) To reach step d/ the tube may be placed tube per tube or row(s) of a group by row(s).

(123) The heat exchanger modules obtained according to the method of the invention may be assembled with one another, for example by using flanges or by welding pipes for supplying fluids. Thus it is conceivable to produce a heat exchanger system with several modules connected together in which the exchanges are carried out in several steps at different average temperatures or differences in temperature per module which are sufficiently reduced to lower the thermal stresses in the materials. For example, in the case of a heat exchanger in which it is desired to transfer the heat from a first fluid to a second fluid, it is possible to conceive of a modular exchanger system in which each module permits the temperature of the first fluid to be reduced by a given value, thus limiting the stresses relative to a design with a single module having a greater difference in temperature. To achieve this, the inlet temperature of the second fluid may differ from one module to the other. In a further example, a reactor-exchanger module system permits a complex chemical reaction to be carried out in stages, precisely controlling the reaction temperature at each stage, to minimize the risks and maximize the efficiency.

(124) A system of heat exchangers with several modules also permits the costs of maintenance to be reduced, permitting the separate replacement of a faulty module, or even the cost of manufacture by standardizing the modules.

CITED REFERENCE

(125) [1] Fusion reactor first wall fabrication techniques G. Le Marois, E. Rigal, P. Bucci, (Fusion Engineering and Design pp 61-62 (2002) 103-110 Elsevier Science B.V);