Coil and serpentine bent fin tube condensing heat exchanger

Abstract

A heat exchanger for supplying heat includes a housing, a bundle of helical fin-coil tubes, and a flue channel. The housing includes a burner, a water inlet, a water outlet and a flue gas outlet. The burner is disposed on a top portion of the housing and connected to an air/gas mixture unit. The bundle of helical fin-tube coils is disposed tightly, circularly, and coaxially around the burner. The flue channel is disposed below the burner and is formed by a plurality of serpentine bent fin-tube coils. A flow of flue gas vents from the flue channel to the flue gas outlet. The water inlet is connected to the plurality of serpentine bent fin-tube coils which forms the flue channel below the burner. The plurality of serpentine bent fin-tube coils below the burner are connected to the bundle of helical fin-tube coils. The bundle of helical fin-tube coils are connected to the water outlet.

Claims

1. A heat exchanger for supplying heat, comprising: a housing includes: a burner; a water inlet; a water outlet; and a flue gas outlet; the burner is disposed on a top portion of the housing and connected to an air/gas mixture unit; a bundle of helical bent fin-tube coils having a plurality of fins disposed about a tube, the helical bent fin-tube coils being disposed tightly, circularly, and coaxially around the burner, wherein for all of the helical bent fin-tube coils disposed between two other of the helical bent fin-tube coils, a spacing between adjacent ones of the helical bent fin-tube coils is reduced by bending each of the plurality of fins only at a location where the adjacent ones of the helical bent fin-tube coils touch and for all of the helical bent fin-tube coils disposed adjacent to only one other of the helical bent fin-tube coils, a spacing between adjacent ones of the helical bent fin-tube coils is reduced by bending each of the plurality of tins only at a location where the adjacent ones of the helical bent fin-tube coils touch and at a location opposite to where the adjacent ones of the helical bent fin-tube coils touch; a flue channel is disposed below the burner, the flue channel being formed by a plurality of serpentine bent fin-tube coils and the housing, wherein a flow of flue gas vents from the flue channel to the flue gas outlet and wherein for all of the serpentine bent fin-tube coils disposed between two other of the serpentine bent fin-tube coils, a spacing between adjacent ones of the serpentine bent fin-tube coils is reduced by bending each of the plurality of fins only at a location where the adjacent ones of the serpentine bent fin-tube coils touch and for all of the serpentine bent fin-tube coils disposed adjacent to only one other of the serpentine bent fin-tube coils, a spacing between adjacent ones of the serpentine bent fin-tube coils is reduced by bending each of the plurality of fins only at a location where the adjacent Ones of the serpentine bent fin-tube coils touch and at a location opposite to where the adjacent ones of the serpentine bent fin-tube coils touch; the water inlet is connected to the plurality of serpentine bent fin-tube coils which forms the flue channel below the burner; the plurality of serpentine bent fin-tube coils below the burner are connected to the bundle of helical fin-tube coils; and the bundle of helical fin-tube coils are connected to the water outlet.

2. The heat exchanger according to claim 1, wherein a plurality of fins on the bundle of helical fin-tube coils are bent at a predetermined angle and the bent respective surfaces of the plurality of fins are parallel or at a predetermined angle.

3. The heat exchanger according to claim 1, wherein a plurality of fins disposed on the plurality of serpentine bent fin-tube coils are bent at a predetermined angle.

4. The heat exchanger according to claim 1, wherein the plurality of serpentine bent fin-tube coils include pairs of helical fin-tube coils assembled together with corresponding helical fin-tube coils that are coiled in the opposite orientation.

5. The heat exchanger according to claim 1, further comprising: a plurality of outer flue baffles installed around the bundle of the helical fin-tube coils.

6. The heat exchanger according to claim 5, wherein the outer flue baffle include a “V” type cross section with a radiused portion configured to mate with ones of the fins of the bundle of helical fin-tube coils and wherein the interfaces of the bundle of helical fin-tube coils is disposed in a circle that are staggered with the openings between the plurality of outer flue baffles.

7. The heat exchanger according to claim 1, further comprising: an inner flue baffle disposed below the burner is installed inside the plurality of serpentine bent fin-tube coils which formed the flue channel, wherein the inner flue baffle is strip and “V” type with a radiused cross section and the inner flue baffle is configured to mate with the fins of the serpentine bent fin-tube coils and wherein a plurality of inside interfaces of the serpentine bent fin-tube coils are staggered with the openings of the inner flue baffle.

8. The heat exchanger according to claim 1, further comprising: an air pre-heater disposed inside the flue channel, wherein the air pre-heater is located inside and along the flue channel and connected with an air inlet, the flue exhaust being a 4-way connector, wherein the flue exhaust is disposed on a top portion of the 4-way connector; and a condensate outlet disposed at a bottom portion of the 4-way connector and the air inlet being disposed in a middle portion of the 4-way connector.

9. The heat exchanger according to claim 8, wherein the air pre-heater disposed inside the flue channel includes one or more cuboidal or cylindrical air inlet tubes.

10. A heat exchanger comprising: a housing having a flue gas outlet and a water outlet; a burner disposed in a lower portion of the housing; a bundle of helical bent fin-tube coils having a plurality of fins disposed about a tube, the helical bent fin-tube coils being mounted adjacent to each other around the burner, wherein for all of the helical bent fin-tube coils disposed between two other of the helical bent fin-tube coils, a spacing between adjacent ones of the helical bent fin-tube coils is reduced by bending each of the plurality of fins only at a location where the adjacent ones of the helical bent fin-tube coils touch and for all of the helical bent fin-tube coils disposed adjacent to only one other of the helical bent fin-tube coils, a spacing between adjacent ones of the helical bent fin-tube coils is reduced by bending each of the plurality of fins only at a location where the adjacent ones of the helical bent fin-tube coils touch and at a location opposite to where the adjacent ones of the helical bent fin-tube coils touch; a flue gas channel is disposed above the burner, the flue gas channel being formed by a plurality of serpentine bent fin-tube coils and the housing, wherein a flow of flue gas is vented from the flue gas channel to the flue gas outlet and wherein for all of the serpentine bent fin-tube coils disposed between two other of the serpentine bent fin-tube coils, a spacing between adjacent ones of the serpentine bent fin-tube coils is reduced by bending each of the plurality of fins only at a location where the adjacent ones of the serpentine bent fin-tube coils touch and for all of the serpentine bent fin-tube coils disposed adjacent to only one other of the serpentine bent fin-tube coils, a spacing between adjacent ones of the serpentine bent fin-tube coils is reduced by bending each of the plurality of fins only at a location where the adjacent ones of the serpentine bent fin-tube coils touch and at a location opposite to where the adjacent ones of the serpentine bent fin-tube coils touch; a water inlet connected to the plurality of serpentine bent fin-tube coils, wherein the plurality of serpentine bent fin-tube coils are connected to the bundle of helical fin-tube coils which are then connected to the water outlet.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1. is a main view of a forced convection helical and serpentine bent fin-tube coils condensing heat exchanger for supplying heat according to an embodiment.

(2) FIG. 2 is a right side sectional view of the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger for supplying heat according to the embodiment of FIG. 1.

(3) FIG. 3 is a cross sectional view and the operation view of the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger for supplying heat according to the embodiment of FIG. 1.

(4) FIG. 4 is a right side sectional view of the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger for supplying heat with one air pre-heater according to the embodiment of FIG. 1.

(5) FIG. 5 is a right side sectional view of the forced convection helical fin-tube coils condensing heat exchanger for supplying heat with the air pre-heater in the upper portion of the heat exchanger according to the embodiment of FIG. 1.

(6) FIG. 6 is a perspective view of a bundle of helical fin-tube coils according to the embodiment of FIG. 1.

(7) FIG. 7 is a main view of a bundle of helical fin-tube coils according to the embodiment of FIG. 1.

(8) FIG. 8 is a section view of FIG. 7 A-A direction of a bundle of helical fin-tube coils according to the embodiment of FIG. 1.

(9) FIG. 9 is an enlarged view of FIG. 8 of a bundle of helical fin-tube coils according to the embodiment of FIG. 1.

(10) FIG. 10 is an operation view of the flue gas flow through the outside flue baffle according to the embodiment of FIG. 1.

(11) FIG. 11 is a main view of a group of serpentine bent fin-tube coils according to the embodiment of FIG. 1.

(12) FIG. 12 is an enlarged A-A view of FIG. 11 of a group of serpentine bent fin-tube coils according to the embodiment of FIG. 1.

(13) FIG. 13 is an operation view of the flue gas flow through the inner flue baffle according to the embodiment of FIG. 1.

(14) FIG. 14 is a right side sectional of the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger for supplying heat with air pre-heater according to the embodiment of FIG. 1.

(15) FIG. 15 is a right side sectional of another a forced convection helical and serpentine bent fin-tube coils condensing heat exchanger for supplying heat with air pre-heater in accordance with another embodiment.

DETAILED DESCRIPTION

(16) Various embodiments of the present invention provide for an increase the heat exchanger efficiency of a heat exchanger. In embodiments of this invention the heat exchanger has a counter flow design with two-stage heat exchanger. The burner is on the top and the flue outlet on the bottom. After burning, the combustion flue gas flows through the group of fin tubes around the burner and flue baffles located outside these tubes first, then it flows through the serpentine bent fin tubes above the flue channel and the flue baffles under these tubes. Thereafter, the flue gas flows out from the flue outlet along the flue channel and counter flow with inlet air. The water inlet is close to the flue outlet at the bottom, and the water outlet is on the top of the heat exchanger. The water flows through inlet, fin tubes, and the cavities connected to the upper and lower fin tube bundles at both ends, such as front and rear water manifolds, and then out from the outlet. The boiler water supply temperature is higher than exhaust flue temperature by applying this type of count flow structure. In this way, the heat transfer efficiency and the amount of available heat are both able to be increased.

(17) The helical fin-tube coils with the bent fins, fabricated in an additional process are able to increase the heat exchange efficiency significantly in embodiments of this invention. The fin-tube is as the basic element in the forced convection condensing heat exchanger. The heat transfer surface at flue side is increased by adding the fins on the external of the heat exchanger tube. The enhanced heat transfer at flue side increases the heat exchange efficiency, and makes the whole heat exchanger smaller. By the additional manufacturing process on the fins, for example bending, squeezing or cutting, the distance between tubes could be made smaller. Therefore, this makes flue gas have more contact with tubes, adds gas flue turbulences, increase heat transfer and heat exchanger efficiency, which in turn makes heat exchanger smaller.

(18) There are flue baffles outside the circular fin-tubes bundle around the burner and flue baffles inside the fin-tubes bundle formed the cylindrical flue channel. It is good to eliminate the “dead zone” on the flue path and improve the flue distribution on the shell side. In embodiments of this invention, the flue baffles force the flue gas flow along the fins and cross bare tubes very closely, therefore it enhance the heat transfer, and improve flue flow distribution at the shell side. The “dead zone” and “short circuit” at the flue flow path is decreased markedly.

(19) Another additional device is the air pre-heater in embodiments of this invention. It can also increase the efficiency. In embodiments of this invention, the air pre-heater is integrated inside the flue channel of the heat exchanger. When the outdoor temperature is below −20° C. in the winter, the waste heat in the flue warms the coming air. Meanwhile, it decreases the exhaust flue temperature further, and the efficiency of the boiler could reach 96%˜98% or more.

(20) The following is specific description of the implementation case. The mentioned implementation case is shown in the attached figures. These figures are used to demonstrate and explain the invention, but not to set the limitation to the invention.

(21) As shown in FIG. 1 through FIG. 15, a heat exchanger 20 has the following major components: Upper water manifold 1; Front shell 2; Heat exchanger housing 3; A bundle of helical fin-tube coils 4; Outer flue baffle 5; Burner 6; Inner flue baffle 7; A plurality of complex serpentine bent fin-tube coils 8; Lower water manifold 9; Rear shell 10; Air pre-heater 11; Flue gas outlet 12; Water outlet 13; Water inlet 14; Cylindrical flue channel 15; Condensate exit 16; and Air inlet 17.

(22) Refer to FIG. 1 to FIG. 3: the invention describes an embodiment of the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger 20. As shown in FIGS. 1, 2 and 3, the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger 20 includes the heat exchanger housing 3, burner 6, a bundle of helical fin-tube coils 4, and the group of complex serpentine bent fin-tube coils 8. On both sides of the heat exchanger housing 3, there are upper water manifold 1 and lower water manifold pipes 9. On one side, the upper water manifold 1 is connected to the lower water manifold 9. On the other side, the lower water manifold has the water inlet 14 and the upper water manifold 1 has the water outlet 13. Multiple helical fin-tube coils are compact together with each other in opposite orientation. The bundle of helical fin-tube coils 4 are mounted around the burner 6. Below the burner 6 is the flue channel 15 which formed by the heat exchanger housing 3 and a group of complex serpentine bent fin-tube coils 8.

(23) On the two sides of the sidewall of the housing, there are front shell 2 and rear shell 10. In one case, the front shell 2 and the rear shell 1 are welded to the sidewall of the housing. In another cases, the front shell 2 and the rear shell 1 are all made of insulation material.

(24) As figure shown, the heat exchanger housing 3 has water outlet 13 and water inlet 14. The heat exchanger housing also has flue gas outlet 12. The flue gas outlet fitting 12 is a cross. The top opening is flue gas outlet 12. The bottom opening is condensate exit 16. The middle opening is air inlet 17 for the air pre-heater 11.

(25) As shown in FIG. 3, it is demonstrated that the structure sectional and the operation principle of an embodiment of this invention, a forced convection helical and serpentine bent fin-tube coils condensing heat exchanger 20 for supplying heat. In this configuration, the helical and serpentine bent fin-tube coils condensing heat exchanger 20 consists of the housing 3, the burner 6 in the housing 3 and the bundle of complex helical and serpentine bent fin-tube coils, water inlet 14, water outlet 13, and flue gas outlet 12 on the housing 3. The burner 6 is on the upper portion of the heat exchanger housing 3, and it is connected to the air & fuel mixing unit. Disposed around the burner is the helical fin-tube coils bundle 4. The outer flue baffles 5 are mounted outside of the helical fin-tube coils bundle 4. This flue baffle 5 has helical and “V” type with radian in cross section. The interface between the helical fin-tube coils are staggered with the gaps of the outer flue baffles 5. Below the burner 6, the group of complex serpentine bent fin-tube coils 8 forms the flue channel 15 with the exchanger housing 3. The flue vents through the flue channel 15 to the gas outlet 12 on the heat exchanger 20. The air pre-heater 11 which includes one or more square or circular air ducts is located in the flue channel 15. The air pre-heater 11 may include the fresh air inlet pipe. The water inlet 14 is connected to the group of complex serpentine bent fin-tube coils 8 below the burner 6. This bundle of complex coils 8 are soldered, brazed, welded or otherwise connected to the bundle of coils around the burner 6, then connect to the water outlet 13. In other examples, the connection may include various fasteners. In some examples, this connection may be operable to convey thermal energy across the connection.

(26) Below the burner, the inner flue baffle 7 is installed inside the flue channel 15 which formed by a group of complex serpentine bent fin-tube coils and exchanger housing. This inner flue baffle 7 has strip and “V” type with radian in cross section. The inner flue baffles 7 are mounted inside of the serpentine bent fin-tube coils bundle 7. The inside interfaces of the fin-tube coils in serpentine bend are staggered with the opening on the inner flue baffle 7.

(27) The air pre-heater 11 is located inside and along the flue channel 15 and connects to the air inlet device. The flue gas outlet fitting 12 is 4-way connector, the flue exhaust 12 on the top, the condensate outlet 16 at the bottom and the fresh air inlet 17 in the middle.

(28) As shown in FIG. 4, it is demonstrated that the right side structure cross sectional of one case in this invention, the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger 20 for supplying heat with the air pre-heater 11. The bundle of helical fin-tube coils 4 is above the number of complex serpentine bent fin-tube coils 8, and parallel with each other. The burner 6 is located in the upper bundle of helical fin-tube coils 4 and concentric to the coil group 4. Below the burner is the flue channel 15 which forms by a group of complex serpentine bent fin-tube coils 8 and exchanger housing.

(29) In embodiments of this invention, two stage heat exchanging method is applied, and used an overall counter flow structure. The high temperature flue flows downstream through the helical fin-tube coils bundle 4 and the serpentine bent fin-tube coils bundle 8. However, the water flow is opposite to the direction of the flue. It goes through the serpentine bent fin-tube coils bundle 8 firstly, and then the helical fin-tube coils bundle 4. The air pre-heater 11 is located in the flue channel 15. The air gains the heat from the flue further. Therefore, the temperature of the air, which enters the combustion chamber, is increased; and at the same time, the flue temperature can be further reduced.

(30) In this configuration, the water inlet 14, lower bundle of complex serpentine bent fin-tube coils 8, upper water manifold 1, upper bundle of complex helical fin-tube coil 4, lower water manifold 9, and water outlet 13 form the water flow path.

(31) As shown in FIG. 5, it demonstrates the right side structure cross sectional of one case in this invention, the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger 20 for supplying heat with an air pre-heater in the upper bundle of serpentine bent fin-tube coils. In this configuration, the burner 6 is located in the lower portion of the heat exchanger housing 3. A bundle of complex helical fin-tube coils 4 are installed around and concentric to the burner 6. Above the burner 6 is a group of serpentine bent fin-tube coils 8 that forms the flue channel 15 with exchanger housing 3. Flue gas vents through the flue channel 15 to the flue gas outlet 12 on the housing. The water inlet 14 is connected to the upper group of coils 8. And the upper group of coils 8 is soldered, brazed, welded or otherwise connected to another bundle of coils 4 around the burner 6, then connected to the water outlet 13. In other examples, the connection may include various fasteners. In some examples, this connection may be operable to convey thermal energy across the connection.

(32) In embodiments of this invention, the heat exchanger 20 is also in a counter flow arrangement, and the high temperature flue flows downstream through the first stage sensible heat transfer and the second stage latent heat transfer. However, the water flow is opposite to the direction of the flue. It goes through the second stage latent heat transfer firstly, and then the first stage sensible heat transfer. The water enters the secondary condensing heat exchanger 20 to absorb flue waste heat, and then enters the first stage to absorb high temperature sensible heat. The air pre-heater 11 located in flue channel 15 makes third heat transfer. The air gains the heat from the flue further. Therefore, the temperature of the air, which enters the combustion chamber, is increased; and at the same time, the flue temperature can be further reduced.

(33) As the FIG. 6 to FIG. 11 show, the bundle of helical fin-tube coils 4 formed by a group of sub coils that are compacted together. The sub-coils are arranged in such a fashion that the other sub-coil is in the opposite orientation. The fins on the coils are pressed or bent. At the location the adjacent turns touch each other. Certainly for the same purpose, the fins tips can be cut off and fins made short. Either ways, the two surfaces formed by bending or cutting the fins on opposite side of the finned tubes, are in parallel or in certain angle. The purpose is to make the coil more compact.

(34) As shown in FIG. 10, it's the operation principle of the outer flue baffle. The outer flue baffles 5 are mounted outside of the helical fin-tube coils bundle 4. This flue baffle 5 has helical and “V” type with radian in cross section. The interface between the helical fin-tube coils are staggered with the holes and slots of the outer flue baffles 5.

(35) As the FIG. 11 to FIG. 13 show, the straight part of the complex of serpentine bent fin-tube coins 8 are arranged in parallel and in one plane. And fins on the fin-tube coils of the straight part are also processed by bending or pressing the fins inward to a certain angle axially. Certainly the fins can be cut short for the same purpose.

(36) FIG. 13 shows the operation principle of the inner flue baffle. The group of serpentine bent fin-tube coils 8 are assembled together tightly, and forms the flue channel 15 with exchanger housing 3. The inner flue baffles 7 are mounted inside of the serpentine bent fin-tube coils bundle 7. This inner flue baffle 7 has strip and “V” type with radian in cross section. The flow guiding baffle is in touch with the inside surface of the coil. The openings on the flow guiding baffle are staggered with the inside interfaces of the serpentine bent fin-tube coils 8.

(37) FIG. 14 shows a condensing heat exchanger design of the current invention with two air pre-heaters 11. In the flue channel, there are two square or cylinder ducts which are air pre-heaters 11.

(38) FIG. 15 shows a condensing heat exchanger design of the current invention with three air pre-heaters 11. In the flue channel, there are three square or cylinder ducts which are air pre-heaters 11.

(39) In conclusion, the purpose of this invention is to increase the heat transfer area and improve the structure of the heat transfer surface, therefore to increase heat exchange efficiency. The heat exchanger 20 uses the helical and serpentine bent fin-tube coils as the basic element of the forced convection helical and serpentine bent fin-tube coils condensing heat exchanger 20 for supplying heat. It enhances the heat exchange on the flue side and makes the whole heat exchanger 20 smaller.

(40) The flow of the flue is guided very close to the fins and tubes with the application of the outer flue baffles 5 and the inner flue baffle 7. They improve shell side flue passes and velocity distribution, therefore enhance heat exchange. The “dead zone” and “short circuit” of the flue flow can be reduced very much. The air pre-heater 10 is integrated into the heat exchanger 20 very clever. The wasted heat of the flue could warm the entered cold air, and at the same time the flue is cold down further. When the outdoor temperature is below −20° C. in winter, the efficiency could reach 96%˜98% or more.

(41) Some key components are designed to be the same to minimize the number of parts in this invention. This will help the mass production, improve the manufacturing process and save the cost.

(42) It shall point out that the demonstration cases above are only for explaining the technical schemes of the invention, not for limiting them. Although the detailed explanations are listed with only optimum cases in the invention, the technical persons in this field shall know that the technical scheme can be modified and replaced, but it does not separate from the spirit in this invention, and shall be included in the scope of the claims.

(43) The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.