Description:DESCRIPTION
“A SHELL AND TUBE HEAT EXCHANGER WTH TUBE BUNDLES”
FIELD OF INVENTION
[0001] The present disclosure relates to the Heat exchangers. More particularly the heat exchanger used in the high temperature applications. This invention relates to the unique arrangement of shell and tube heat exchanger where the tube sheet is replaced with the headers to address the differential expansion of tubes and the shell.
BACKGROUND
[0002] In high-temperature and lethal service heat exchangers, it is crucial to efficiently transfer heat from one fluid to another while ensuring the equipment's safety and longevity. To achieve this, the heat exchanger's design needs to consider several factors, including the temperature and material properties of the components involved.
[0003] In such applications, heat exchangers often consist of tubes that carry one fluid and a shell that surrounds these tubes to carry another fluid. The temperature within the tubes can be significantly higher than in the shell. As a result, the tubes are typically made from high-grade materials capable of withstanding the elevated temperatures, while the shell can be constructed from lower-grade materials since it operates at a lower temperature.
[0004] However, the difference in material grades and the temperature gradient between the tubes and the shell can lead to a phenomenon known as differential expansion. This occurs when the tubes and the shell expand and contract at different rates due to their varying temperatures. Such differential expansion can create stress and strain on the components, potentially leading to the failure of the tubes or other structural issues within the heat exchanger.
[0005] The existing heat exchanger system, which utilizes headers to mitigate the problem of differential expansion between high-temperature tubes and a lower-grade material shell, offers cost savings but is not without drawbacks. It introduces complexity, potentially raises initial costs, may limit overall efficiency gains, and requires additional maintenance. Compatibility issues, space constraints, structural considerations, and the need for corrosion-resistant materials are further concerns.
[0006] Therefore, it is quite evident that all of the above disclosures has drawbacks and thereby the system with utilizing headers in heat exchanger design, offers cost-efficiency by addressing differential expansion, maintains safety, minimizes high-grade material usage, and enhances adaptability to diverse applications is required.

OBJECTS OF THE INVENTION
[0007] Some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0008] It is an object of the present subject matter to overcome the aforementioned and other drawbacks existing in the prior art systems and methods.
[0009] It is a principal object of the present subject matter to introduce a heat exchanger arrangement that effectively resolves the issue of differential expansion when using dissimilar materials for the shell and tubes.
[0010] It is another significant object of the present subject matter to propose the system enhance the safety and longevity of heat exchanger systems by mitigating the stress and strain caused by temperature differentials between components.
[0011] It is another significant object of the present subject matter to propose the system to reduce the overall cost of heat exchanger construction by avoiding the necessity of using high-grade materials for the entire shell and improve the versatility and applicability of heat exchanger designs, making them suitable for various applications and industries.
[0012] These and other objects and advantages of the present subject matter will be apparent to a person skilled in the art after consideration of the following detailed description taking into consideration with accompanied drawings in which preferred embodiments of the present subject matter are illustrated.
SUMMARY OF THE INVENTION
[0013] This summary is provided to introduce the concept of a shell and tube heat exchanger with tube bundles The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0014] The present invention relates to a shell and tube heat exchanger with tube bundles. The heat exchanger comprises a conical shell for gas flow, an outer shell, an outlet port for gas outflow, an inlet header, a plurality of steam tubes for heat transfer, a plurality of sub-headers to manage steam flow, and an outlet header for collecting heated steam. Gas is fed through the conical shell, and steam is supplied from the header, which is then distributed to sub-headers and steam tubes. The steam rises through the tubes and collects in the outlet header.
[0015] To further understand the characteristics and technical contents of the present subject matter, a description relating thereto will be made with reference to the accompanying drawings. However, the drawings are illustrative only but not used to limit the scope of the present subject matter.
[0016] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0017] It is to be noted, however, that the appended drawings illustrate only typical embodiments of the present subject matter and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments. The detailed description is described with reference to the accompanying figures. In the figures, a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the figures to reference like features and components. Some embodiments of system or methods or structure in accordance with embodiments of the present subject matter are now described, by way of example, and with reference to the accompanying figures, in which
[0018] Fig. 1 illustrates a perspective view of a shell and tube heat exchanger with tube bundles in accordance with an embodiment of the present disclosure;
[0019] Fig. 2 illustrates a block diagram of flow of gas and steam in shell and tube heat exchanger with tube bundles in accordance with an embodiment of the present disclosure.
[0020] The figures depict embodiments of the present subject matter for the purposes of illustration only. A person skilled in the art will easily recognize from the following description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the disclosure described herein.
DETAILED DESCRIPTION OF THE INVENTION WITH REFERENCE TO THE ACCOMPANYING DRAWINGS
[0021] A few aspects of the present disclosure are explained in detail below with reference to the various figures. Example implementations are described to illustrate the disclosed subject matter, not to limit its scope, which is defined by the claims. Those of ordinary skill in the art will recognize a number of equivalent variations of the various features provided in the description that follows.
[0022] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.
[0023] Each of the appended claims defines a separate invention, which for infringement purposes is recognized as including equivalents to the various elements or limitations specified in the claims. Depending on the context, all references below to the "invention" may in some cases refer to certain specific embodiments only. In other cases, it will be recognized that references to the “invention" will refer to subject matter recited in one or more, but not necessarily all, of the claims.
[0024] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all groups used in the appended claims.
[0025] Various embodiments are further described herein with reference to the accompanying figures. It should be noted that the description and figures relate to exemplary embodiments and should not be construed as a limitation to the subject matter of the present disclosure. It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the subject matter of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the subject matter of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof. Yet further, for the sake of brevity, operation or working principles pertaining to the technical material that is known in the technical field of the present disclosure have not been described in detail so as not to unnecessarily obscure the present disclosure.
EXEMPLARY EMBODIMENT
[0026] The present invention relates to a shell and tube heat exchanger with tube bundles. Fig. 1 illustrates a perspective view of a shell and tube heat exchanger with tube bundles in accordance with an embodiment of the present disclosure. The shell and tube heat exchanger with tube bundles(100) comprises of a conical shell(1) facilitating the flow of the gas within the heat exchanger(100), a shell(2) configured as the outer casing for conical shell (1) of the heat exchanger(100) , an outlet port (3) positioned at the lower end of the conical shell(1) configured for the outflow of the gas from the heat exchanger(100), a plurality of steam tubes (6) embedded inside the conical shell (1) configured for the transfer of heat from the gas to the steam. A plurality of sub header(5) are connected to the steam, tubes (6) feeding the steam to and from the plurality of steam tubes(6) and a plurality of inlet headers (4) are connected to the sub headers(5) configured for the flow of the gas into the heat exchanger (100).A plurality of sub header(7) connected to the steam tubes (6) collecting the steam from the plurality of steam tubes(6) and an outlet header(8) facilitating the outflow of the steam by collecting the steam from the sub-headers (7) after heat exchange. The heat exchanger (100) facilitates the differential expansion of the tubes and shell.
[0027] Further the Conical Shell (1) primary function is to allow the entry of gas into the heat exchanger system. It shapes the gas flow path, ensuring efficient heat exchange. The gas exits through the bottom of the conical shell, marked as the outlet port (3).
[0028] The outer shell (2) serves as a protective casing for the conical shell and other components within the heat exchanger and provides structural integrity and helps maintain the shape of the conical shell (1).
[0029] The inlet header (4) is connected to the sub headers (5) and is responsible for the controlled introduction of gas into the heat exchanger (1) and ensures uniform gas distribution, allowing for even heat exchange.
[0030] The steam Tubes (6) are embedded inside the conical shell (1) and serve as conduits for transferring heat from the gas to the steam. As gas passes over these tubes (6), it heats the steam within, facilitating the exchange process.
[0031] The sub-Headers (5 & 7) manages the flow of steam. In the case of sub-header (5), it receives steam from the inlet header (4) and channels it into the steam tubes (6). Sub-header (7) connected to the steam, tubes (6) collects the steam from after heat exchange. These components ensure the orderly flow of steam throughout the system.
[0032] The outlet Header (8) serves as a collection point for the heated steam. After heat exchange occurs in the steam tubes (6), the resulting hot steam is collected in the outlet header (8) before it is directed for further use or processing.
[0033] Fig. 2 illustrates a block diagram of flow of gas and steam in shell and tube heat exchanger with tube bundles in accordance with an embodiment of the present disclosure.
[0034] In the gas circuit, the Hot synthesis gas (syngas) enters the Gas Circuit, initially passing through the conical shell (1) and then proceeds to the shell (2), which contains heat transfer tubes, where it relinquishes heat and exits chilled through the conical shell (3).
[0035] The flow chart represents a steam circuit where steam enters through an inlet header (4), is distributed via a sub-header (5), passes through heat transfer tubes (6), is collected by another sub-header (7), and exits through an outlet header (8), becoming superheated steam. The numerals (4-8) denote specific components, indicating the flow direction and transitions of the steam through the system, ultimately increasing in temperature as it progresses.
[0036] The heat exchanger (100) is a water tube heat exchanger with shell (2) contains the gas which is fed through the conical shell (1) and released through the conical shell (3). The steam is fed from the header (4) which feeds the sub-header (5) which in turn feed the tubes and the steam rises through the tubes (6) and collects in the plurality of outlet header (8).
[0037] The heat exchanger (100) accommodates the differential expansion of the tubes and shell. The bend provided in the connection between sub header -5 and Inlet header-4 will accommodate the differential expansion. The sub header (7) will take the load of heat transfer tubes (6) and sub header (5). The sub header (7) will supported by the shell (1) which in turn will supported structurally. The inlet header (4) and outlet header (8) will supported from above or below structural beams.
ADVANTAGES OF THE INVENTION
[0038] The proposed heat exchanger has the following advantages over the contemporary system
• Cost-Effective Solution: Provides an economically viable alternative to using high-grade materials throughout the shell.
• Enhanced Safety: Mitigates the risk of structural damage and failures due to differential expansion.
• Improved Efficiency: Maintains heat transfer efficiency while accommodating differing material properties.
• Versatility: Suitable for various applications where differential expansion is a concern.
• Simplified Design: Replacing the tube sheet with headers streamlines the construction and maintenance of the heat exchanger.
• Longevity: Enhances the lifespan and reliability of heat exchange systems
WORKING OF INVENTION
[0039] In field or industrial applications, this heat exchanger would be used to recover heat from hot gas streams, such as flue gases in power plants or exhaust gases in various manufacturing processes. The recovered heat can be used to produce steam for power generation, heating, or other industrial processes, making the system energy-efficient and cost-effective.
[0040] The above description does not provide specific details of the manufacture or design of the various components. Those of skill in the art are familiar with such details, and unless departures from those techniques are set out, techniques, known, related art or later developed designs and materials should be employed. Those in the art are capable of choosing suitable manufacturing and design details.
[0041] Further, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0042] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0043] It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
, Claims:We Claim:
1. A shell and tube heat exchanger with tube bundles (100) for recovering heat from hot gas streams, the heat exchanger comprising:
a conical shell (1) facilitating the flow of the gas within the heat exchanger (100);
a shell (2) configured as the outer casing for the conical shell (1) of the heat exchanger (100);
an outlet port (3) positioned at the lower end of the conical shell (1) configured for the outflow of the gas from the heat exchanger (100);
a plurality of steam tubes (6) embedded inside the conical shell (1) configured for the transfer of heat from the gas to the steam.;
a plurality of sub headers (5) connected to the steam tubes (6) feeding the steam to and from the plurality of steam tubes (6); and
a plurality of inlet headers (4) connected to the sub headers (5) configured for the flow of the gas into the heat exchanger (100).
2. The heat exchanger (100) as claimed in the claim 1, wherein a plurality of sub header (7) connected to the steam tubes (6) collecting the steam from the plurality of steam tubes (6).
3. The heat exchanger (100) as claimed in the claim 1, wherein a plurality of outlet header (8) connected to the sub headers (7) facilitating the outflow of the steam by collecting the steam from the sub-headers (7) after heat exchange.
4. The heat exchanger (100) as claimed in the claim 1, wherein the heat exchanger (100) facilitates the differential expansion of the tubes and shell.