Spiral baffle heat exchanger

Abstract

The heat exchanger includes a shell having a longitudinal axis, a plurality of baffles, such as elliptical sector baffles, each of which is formed at a helix angle H B The plurality of baffles are mounted in the housing to direct fluid flow through the housing into a spiral pattern. Each of the plurality of baffles includes an outer circumferential edge, a proximal radial edge, a distal radial edge, a proximal side, a distal side, and a plurality of spaced-apart holes, the plurality of spaced-apart holes being passed through by a plurality of axially extending tubes. Each of the first plurality of sealing strips is disposed from a proximal end of the plurality of baffles to a distal end of the plurality of baffles.

Description

Background Art

[0001] The heat exchange assembly achieves enhanced performance by maximizing the ratio of heat transfer to pressure drop while providing reduced installation and maintenance costs and effective protection against efficiency losses due to vibration or due to fouling.

[0002] Whether it is offshore, refineries, power, petrochemical or paper and food industries, heat exchangers are often central to the purposes listed above. Various configurations of heat exchangers are known and used in a variety of applications. One of the widely used configurations of heat exchangers is the shell and tube heat exchanger, as an example Figure 1 as shown in . Figure 1 The shell and tube heat exchanger comprises a cylindrical shell 10 containing a parallel tube bundle 11 extending between two end plates 12. A first fluid 13 flows into and passes through the space between the two end plates so as to contact the parallel tube bundle 11, and a second fluid 14 passes through the parallel tube bundle 11. In order to provide improved heat exchange between the two fluids, the flow of the first fluid 13 is limited by intermediate baffles 15 forming respective compartments, and the intermediate baffles 15 are arranged so that the flow of the first fluid 13 changes its direction from one compartment to the next compartment. The baffles 15 configured as circular segments are installed perpendicular to the longitudinal axis 16 of the shell 10 to provide a zigzag flow 17 of the first fluid 13.

[0003] Unfortunately, in shell and tube heat exchangers such as Figure 1 In the heat exchanger shown in ), the second fluid must change its flow direction sharply several times along the length of the shell. These sharp changes in flow direction result in a reduction in the dynamic pressure of the second fluid and its uneven flow rate, which in combination adversely affect the performance of the heat exchanger. In addition, cleaning of the shell and tube heat exchanger requires that the parallel tube bundle 11 be removed from the shell 10, or that only a cleaning fluid be used as the first fluid 13 flowing within the shell 10 of the shell and tube heat exchanger. Making the parallel tube bundle 11 removable requires sufficient clearance between the parallel tube bundle 11 and the shell 10 to allow non-destructive disassembly. Typically, the clearance between the parallel tube bundle 11 and the shell 10 is large enough so that a large amount of the first fluid 13 to be heated or cooled will bypass the parallel tube bundle 11 and mix with the first fluid 13 that has been heated or cooled at the outlet of the shell and tube heat exchanger.

[0004] Still referring to the shell and tube heat exchanger (e.g. Figure 1), it is well known that the vertical position of the baffles relative to the longitudinal axis of the shell results in a relatively inefficient heat transfer rate / pressure drop ratio because the baffles create a large resistance. Adjacent baffles extend parallel to each other and at right angles to the longitudinal axis of the shell, thereby defining a cross-flow path characterized by many sharp turns between adjacent channels. The heat transfer efficiency can be improved by reducing the spacing between the baffles. However, reducing the spacing results in large recirculation areas and forces a larger portion of the flow to leak between the tubes and the baffles and along the outer edges of the baffles. The unevenness of the flow distribution within each segment defined between adjacent baffles causes many eddies, stagnant zones and expansions / contractions, which reduce the local temperature differences. Another factor that contributes to the reduction in heat transfer rate is attributed to the fact that the tubes traversed by the first fluid must be positioned at a certain radial distance from the shell. Therefore, the cross-flow around the tubes located at the periphery is faster than the cross-flow around the centrally mounted tubes.

[0005] Thus, conventional baffle arrangements as described above result in flow bypass through the baffle-shell gap and flow leakage through the tube-baffle gap. The bypass and leakage flows reduce cross-flow heat transfer, while the flow maldistribution caused by the significant velocity variations increases backflow and eddy currents in the dead zones, which in turn results in the deposition of fouling material on the outside of the tubes of the tube bundle. If the heat exchanger is allowed to continue operating after the fouling material has been deposited within the shell, a significant loss of performance will be experienced over time, which will translate into increased operating costs and energy consumption. If the heat exchanger is taken out of service to be cleaned due to the accumulation of fouling material, there will be a loss or reduction in production, which translates into operating costs similar to or higher than the value of the heat exchanger. In addition, a heat exchanger that remains in a fouled state for too long will produce hardened deposits that will be difficult to remove and may cause corrosion in localized areas with higher temperatures. The tube bundle on which the hardened deposits form and on which corrosion occurs may deteriorate to the extent that the tube bundle must be removed from use and the damaged tubes are plugged.

[0006] Furthermore, because long tubes, typically up to 24 feet in length, are supported by a series of baffles that are spaced at considerable distances to address problems associated with non-uniform velocity, conventional arrangements can be subject to flow-induced vibrations of the tubes.

[0007] Spiral baffle heat exchangers have been used to overcome the problem of uneven flow in shell and tube heat exchangers. The spiral pattern of the first fluid flow can allow the available pressure drop to be converted into heat transfer particularly efficiently, and can reduce the risk of vibration of the parallel tube bundle. However, the spiral baffles can have large gaps, which allow the first fluid flow to leak around the baffles and can result in reduced velocity through the tube bundle and reduced thermal efficiency due to the loss of temperature driving force. These problems are particularly likely to occur when a removable tube bundle with a large tube-shell gap is desired. In addition, bypassing of the tube bundle may also be particularly severe when cooling viscous liquids, whereby the viscosity of the liquid after cooling is significantly higher than the viscosity of the liquid when it enters the heat exchanger. In other words, a warmer, less viscous liquid can easily flow around and bypass the tube bundle compared to the cooled, more viscous liquid.

[0008] To help prevent bypass of the baffles of a spiral baffle heat exchanger, sealing devices have been used. The sealing devices used for such spiral baffle heat exchangers are of substantially the same type as the sealing devices used for conventional baffles and are relatively ineffective in preventing bypass in a spiral baffle heat exchanger. In addition, because a spiral baffle heat exchanger typically has a lower pressure drop than a segmented baffle heat exchanger, the losses associated with the pressure drop caused by the sealing device are relatively high relative to the improvement in heat transfer. The sealing devices used in conventional baffle heat exchangers may, at best, provide minimal improvement in heat transfer and, at worst, may interfere with the spiral flow path in the bundle, resulting in a significant reduction in heat transfer. Summary of the invention

[0009] It is desirable to configure a baffle assembly that can achieve uniformity of fluid flow without recirculation, dead zones, or leaks / bypasses of heat transfer surfaces. Further, it is desirable to configure a baffle assembly with multiple baffles and seals positioned to maintain high heat transfer rates within acceptable pressure drop and vibration limits. In addition, it is desirable to have a baffle assembly that facilitates maintenance of the tube bundle by providing greater clearance between the tube and shell to allow for rapid removal and replacement for cleaning and repair. Embodiments disclosed herein address one or more of these issues.

[0010] Embodiments of the present disclosure may provide a heat exchanger. The heat exchanger may include a housing having a longitudinal axis and configured to receive a first fluid. In addition, the heat exchanger may include a plurality of elliptical sector baffles, each baffle mounted in the housing at an angle to the longitudinal axis to direct the flow of the first fluid through the housing into a spiral pattern. In addition, the heat exchanger may include a first plurality of sealing strips having a first end and a second end, the first plurality of sealing strips being radially disposed between the housing and a plurality of axially extending tubes. In addition, each of the plurality of baffles may include an outer circumferential edge longitudinally spaced apart from the outer circumferential edge position of the remaining baffles in the plurality of baffles, a proximal radial edge spaced apart from the distal radial edge, a proximal side opposite to the distal side, and a plurality of spaced apart holes, the plurality of spaced apart holes being configured to be passed through by a plurality of axially extending tubes carrying a second fluid. The first end of each of the first plurality of sealing strips may be coupled to a distal side of one of the plurality of baffles, the distal side being between the proximal radial edge and the distal radial edge of one of the plurality of baffles. The second end of each of the first plurality of sealing strips may be coupled to a proximal side of another of the plurality of baffles, the proximal side being between a proximal radial edge and a distal radial edge of the other of the plurality of baffles. In addition, each of the first plurality of sealing strips may be disposed orthogonally to both the distal side of one of the plurality of baffles and the proximal side of another of the plurality of baffles, or at a non-orthogonal angle to the proximal side of another of the plurality of baffles, and the angle may be from greater than 0° up to 80° in a direction defined from the proximal radial edge to the distal radial edge of one of the plurality of baffles.

[0011] Embodiments of the present disclosure may also provide a method for assembling a heat exchanger. The method may include providing a center rod having a longitudinal axis. In addition, the method may include mounting a plurality of elliptical sector baffles to the center rod at an angle to the longitudinal axis of the center rod, so that a spiral pattern is formed by the plurality of baffles. Each of the plurality of baffles may include an outer circumferential edge longitudinally spaced apart from the outer circumferential edge position of the remaining baffles in the plurality of baffles, a proximal radial edge spaced apart from the distal radial edge, a proximal side opposite to the distal side, and a plurality of spaced apart holes. In addition, the method may include arranging a plurality of axially extending tubes into the plurality of spaced apart holes of each of the plurality of baffles, and the plurality of axially extending tubes may carry a second fluid. In addition, the method may include radially coupling a first plurality of sealing strips having a first end and a second end between the housing and the plurality of axially extending tubes. Coupling the first plurality of sealing strips may include coupling the first end of each of the first plurality of sealing strips to the distal side of one of the plurality of baffles, and coupling the second end of each of the first plurality of sealing strips to the proximal side of another of the plurality of baffles. Each of the first plurality of sealing strips may be disposed orthogonally to both the distal side of one of the plurality of baffles and the proximal side of another of the plurality of baffles, or at a non-orthogonal angle to the proximal side of another of the plurality of baffles, and the angle may be from greater than 0° to up to 80° in a direction defined from a distal radial edge to a proximal radial edge of one of the plurality of baffles.

[0012] In one aspect, embodiments disclosed herein relate to a heat exchanger. The heat exchanger may include a shell, a plurality of baffles, a plurality of axially extending tubes, and a plurality of sealing strips. The shell may have a longitudinal axis and may be configured to receive a first fluid. The plurality of baffles, each of which has a helix angle H B Mounted within a housing, the plurality of baffles may be configured to direct a first fluid flow through the housing into a spiral pattern. Each of the plurality of baffles may include: an outer circumferential edge longitudinally spaced apart from the outer circumferential edge position of the remaining baffles in the plurality of baffles; a proximal radial edge spaced apart from the distal radial edge; a proximal side opposite the distal side; and a plurality of spaced apart holes configured to be passed through by a plurality of axially extending tubes, the plurality of axially extending tubes configured to carry a second fluid. The plurality of sealing strips each have a first end and a second end radially disposed between the housing and the plurality of axially extending tubes, and the plurality of sealing strips are each respectively positioned between any two longitudinally adjacent baffles, wherein each of the first plurality of sealing strips is spaced apart from the proximal end of the plurality of baffles to the distal end of the plurality of baffles at a spiral angle H s Setting, helix angle H s Greater than 5° and less than the baffle helix angle H B , where the helix angle H B and H s Defined as the angle of the respective baffle or sealing strip relative to the longitudinal axis of the housing.

[0013] In some embodiments, the sealing strips can be configured in part to spirally direct the fluid flow toward the outlet. The first plurality of sealing strips can be disposed from the distal side of the first baffle from adjacent to the proximal radial edge of the first baffle to the proximal side of the second baffle adjacent to the distal radial edge of the second baffle, wherein the first baffle and the second baffle are located in the same sector or quadrant. Alternatively, the first plurality of sealing strips can be disposed from the distal side of the first baffle from between the proximal and distal radial edges of the first baffle to the proximal side of the second baffle between the proximal and distal radial edges of the second baffle, wherein the second baffle is located in a different sector or quadrant than the first baffle.

[0014] In some embodiments, a first end of each of the first plurality of sealing strips may be coupled to a distal side of a first baffle of the plurality of baffles, and a second end of each of the first plurality of sealing strips may be coupled to a proximal side of a second baffle of the plurality of baffles.

[0015] The first plurality of sealing strips may each have an inner surface and an outer surface. The first plurality of sealing strips may be angled non-orthogonally to the housing from the outer surface to the inner surface in a direction defined from a proximal radial edge to a distal radial edge of one of the plurality of baffles.

[0016] In some embodiments, each of the first plurality of sealing bars may be angled between 15° and 45° non-orthogonal to the housing such that the first fluid stream strikes the sealing bar at an angle between 105° and 135°.

[0017] The outer surface of each of the first plurality of sealing strips may be disposed substantially proximate to the inner surface of the housing. In some embodiments, the inner surface of each of the first plurality of sealing strips may be spaced apart from the outer diameter of the closest tube in the plurality of axially extending tubes by a distance equal to the distance between the outer diameters of two adjacent tubes in the plurality of axially extending tubes.

[0018] Each of the plurality of baffles may include at least one of the first plurality of sealing strips coupled to the proximal side and at least one of the first plurality of sealing strips coupled to the distal side of the baffle. In some embodiments, each of the first plurality of sealing strips coupled to the distal side of each of the plurality of baffles may be rotationally offset about the longitudinal axis from each of the plurality of sealing strips coupled to the proximal side of each of the plurality of baffles.

[0019] In some embodiments, each of the first plurality of sealing strips has a curved outer diameter having an elliptical curvature, and / or wherein each of the first plurality of sealing strips has a curved inner diameter having an elliptical curvature.

[0020] Each of the first plurality of sealing strips may have a width (outer diameter minus inner diameter) that varies along the length of the sealing strip (first end to second end), and / or wherein each of the first plurality of sealing strips has a depth (proximal side to distal side) that varies along the width or length of the sealing strip.

[0021] In some embodiments, an equal number of sealing strips may be coupled to each baffle of the plurality of baffles. In some embodiments, the number of sealing strips per rotation about the longitudinal axis of the housing is a multiple of the number of baffles per rotation about the longitudinal axis of the housing.

[0022] The heat exchanger according to the embodiments herein may further include a second plurality of sealing strips, each of the second plurality of sealing strips having a first end and a second end radially disposed between the shell and the plurality of axially extending tubes, and each of the second plurality of sealing strips is positioned between any two baffles. Each of the second plurality of sealing strips may be formed from the proximal end of the plurality of baffles to the distal end of the plurality of baffles at a helical angle H 2s Set the helix angle H 2s Greater than 5°, different from the helix angle H s , and is smaller than the baffle helix angle H B , where the helix angle H B , H s , H 2s Defined as the angle of the respective baffle or sealing strip relative to the longitudinal axis of the housing.

[0023] The heat exchanger according to embodiments herein may include a second plurality of sealing strips. Each of the second plurality of sealing strips may have a first end and a second end radially disposed between the housing and the plurality of axially extending tubes, and each of the second plurality of sealing strips may be disposed between any two adjacent baffles, respectively, wherein each of the second plurality of sealing strips is disposed from a proximal radial edge of a baffle to a distal radial edge of an adjacent baffle. In some embodiments, the inner diameter of each of the second plurality of sealing strips may be spaced from the outer diameter of the closest tube in the plurality of axially extending tubes by a distance equal to the distance between the outer diameters of two adjacent tubes in the plurality of axially extending tubes.

[0024] In another aspect, embodiments herein relate to a method of assembling a heat exchanger. The method may include providing a center rod having a longitudinal axis, and mounting a plurality of elliptical sector baffles to the center rod at an angle to the longitudinal axis of the center rod such that a spiral pattern is formed by the plurality of baffles. Each of the plurality of baffles may include an outer circumferential edge longitudinally spaced apart from the outer circumferential edge position of the remaining baffles of the plurality of baffles; a proximal radial edge spaced apart from the distal radial edge; a proximal side opposite the distal side; and a plurality of spaced apart holes; and disposing a plurality of axially extending tubes into the plurality of spaced apart holes of each of the plurality of baffles, wherein the plurality of axially extending tubes are configured to carry a second fluid. The method may also include radially coupling a first plurality of sealing strips each having a first end and a second end between the housing and the plurality of axially extending tubes. Coupling the first plurality of sealing strips may include coupling a first end of each of the first plurality of sealing strips to a proximal end of one of the plurality of baffles; and coupling a second end of each of the first plurality of sealing strips to another more distal baffle of the plurality of baffles. Each of the first plurality of sealing strips may be formed from the proximal end of the plurality of baffles to the distal end of the plurality of baffles at a pitch greater than 5° and less than the baffle helix angle H B The helix angle H s Set, where the helix angle H B and H s is defined as the angle of the respective baffle or sealing strip relative to the longitudinal axis of the housing.The method may further include disposing the assembled center rod, plurality of baffles, plurality of axially extending tubes, and first plurality of sealing strips within a housing configured to receive a first fluid.

[0025] The coupled first plurality of sealing strips may each have an inner diameter and an outer diameter. In some embodiments, coupling the first plurality of sealing strips may further include: adjusting the coupled first plurality of sealing strips from the outer diameter to the inner diameter to an angle that is not orthogonal to the housing in a direction defined from a proximal radial edge to a distal radial edge of one of the plurality of baffles. In some embodiments, coupling the first plurality of sealing strips may further include: spacing the inner diameter of each of the first plurality of sealing strips from the outer diameter of the closest tube in the plurality of axially extending tubes by a distance equal to the distance between the outer diameters of two adjacent tubes in the plurality of axially extending tubes. And, in some embodiments, coupling the first plurality of sealing strips may further include: rotationally offsetting each of the first plurality of sealing strips coupled to the distal side of each of the plurality of baffles from each of the plurality of sealing strips coupled to the proximal side of each of the plurality of baffles.

[0026] The assembly method may further include: radially coupling a second plurality of sealing strips having a first end and a second end between the housing and the plurality of axially extending tubes. Coupling the second plurality of sealing strips may include: coupling the first end of each of the second plurality of sealing strips to a proximal radial edge of a distal end side of one of the plurality of baffles; and coupling the second end of each of the second plurality of sealing strips to a distal radial edge of a proximal end side of another of the plurality of baffles, wherein each of the second plurality of sealing strips extends parallel to a longitudinal axis of the housing.

[0027] In another aspect, embodiments herein relate to a heat exchanger. The heat exchanger may include: a housing having a longitudinal axis and configured to receive a first fluid; a plurality of baffles mounted in the housing at an angle relative to the longitudinal axis, spaced apart from each other along the longitudinal axis, and configured to direct the first fluid to flow through the housing along a spiral pattern, each of the baffles including: an outer circumferential edge; a proximal radial edge spaced apart from a distal radial edge; a proximal side opposite to a distal side; and a plurality of spaced apart holes formed through each baffle from the proximal side to the distal side, the holes configured to be passed through by a plurality of axially extending tubes, the tubes configured to carry a second fluid; and a plurality of sealing members, each including a first end and a second end, the sealing members being radially disposed between the housing and the plurality of axially extending tubes, and the first end of each sealing member being coupled to the distal side of a corresponding baffle, and the second end of each sealing member being coupled to the proximal side of a corresponding baffle. In some embodiments, the sealing member may include a sealing strip or a sealing rod.

[0028] In another aspect, embodiments herein relate to a heat exchanger comprising a housing having a longitudinal axis, the housing being configured to receive a first fluid. B The heat exchanger is provided with a plurality of baffles and a plurality of circumferentially offset sealing strips. The plurality of baffles are provided with ...

[0029] Other aspects and advantages of the invention will become apparent from the following description. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 A schematic diagram showing the flow distribution in a conventional shell and tube heat exchanger.

[0031] Figure 2 A schematic perspective view of a heat exchanger according to one or more embodiments of the present disclosure is shown.

[0032] Figure 3 A perspective view of a baffle cage of a heat exchanger according to one or more embodiments of the present disclosure is shown.

[0033] Figure 4A and Figure 4B A perspective view of a baffle of a heat exchanger according to one or more embodiments of the present disclosure is shown.

[0034] FIG. 5A to FIG. 5E Various views of a heat exchanger according to one or more embodiments of the present disclosure are shown.

[0035] FIG. 6A to FIG. 6D A perspective view of a heat exchanger according to various embodiments of the present disclosure is shown.

[0036] Figure 7 A side view of a heat exchanger according to one or more embodiments of the present disclosure is shown.

[0037] Figure 8 A side view of a heat exchanger according to one or more embodiments of the present disclosure is shown.

[0038] Fig. 9 A side view of a heat exchanger according to one or more embodiments of the present disclosure is shown.

[0039] Fig.10 is a graphical representation of data comparing a heat exchanger according to embodiments herein with a prior art heat exchanger. DETAILED DESCRIPTION

[0040] Embodiments of the present disclosure are described in detail below with reference to the accompanying drawings. For consistency, the same elements in each of the accompanying drawings may be represented by the same reference numerals. In addition, in the following detailed description, many specific details are set forth to provide a more thorough understanding of the claimed subject matter. However, it is apparent to those of ordinary skill in the art that the described embodiments may be practiced without these specific details. In other cases, well-known features are not described in detail to avoid unnecessarily complicating the description.

[0041] refer to Figure 2, in one or more embodiments, a spiral baffle heat exchanger 200 according to one or more embodiments of the present disclosure is shown. The heat exchanger 200 may include a shell 220 through which a first fluid passes, a plurality of axially extending tubes 230 through which a second fluid passes, and a plurality of elliptical sector-shaped baffles 240. "Elliptical sector" should be understood as a baffle that takes the general form of an elliptical sector, whose geometry includes an area defined by an arc and a line segment connecting the center (origin) of the ellipse and the endpoints of the arc, but may not include the entire sector in order to take into account other components of the heat exchanger (tubes, etc.) and the installation method of the baffles (for example, surrounding or adjacent to the center tube, or accommodating the tube along the periphery of the elliptical sector, such as Figure 3 and as shown in Figure 4).

[0042] The housing 220 may include an inlet 228 and an outlet 229, and the first fluid may pass between the inlet 228 and the outlet 229 within the housing 220. Each of the baffles 240 may be positioned at an angle λ relative to a line (NN) orthogonal to the longitudinal axis 221 of the housing 220 so as to direct the first fluid flow 222 into a spiral pattern 231, passing through the housing 220 from the inlet 228 to the outlet 229. The spiral pattern 231 of the first fluid flow 222 may allow for efficient conversion of available pressure drop into heat transfer, and reduce the risk of vibration due to the fact that the unsupported tube length is minimized. In one or more embodiments, there may be no dead spots for scaling along the first fluid flow 222, and the amount of heat transfer may be increased due to the elimination of eddies or backmixing. In addition, in one or more embodiments, the direction of the first fluid flow 222 may be opposite to the direction of the second fluid flow 232 within the tube 230. In other words, in one or more embodiments, the second fluid may flow in a direction substantially from the outlet 229 to the inlet 228. In addition, although as Figure 2 As shown in FIG. 2 , the baffles 240 are flat, but in one or more embodiments, the opposing sides of each baffle may be curved to direct the first fluid flow 222 along a spiral pattern.

[0043] Reference now Figure 3 , shows a baffle cage 341 according to one or more embodiments of the present disclosure. The baffle cage 341 may include consecutive baffles 340 positioned at angles that are not orthogonal to a longitudinal axis (not shown) of the baffle cage 341, and the consecutive baffles 340 may be rotationally and longitudinally offset from one another so as to form a spiral pattern. The rotational offset between consecutive baffles 340 may cause at least a proximal radial edge 344 of one baffle 340 to overlap or be adjacent to a distal radial edge 345 of an adjacent baffle 340 in a longitudinal direction. For example, Figure 3An embodiment is shown in which the proximal radial edge 344 of each baffle 340 overlaps the distal edge 345 of the consecutive baffle 340. In one or more embodiments, the proximal radial edge 344 of each baffle 340 can be the radial edge of the baffle 340 that is axially closest to the inlet (not shown) of the shell (not shown) of the heat exchanger, and the distal radial edge 345 of each baffle 340 can be the radial edge of the baffle 340 that is axially farthest from the inlet of the shell of the heat exchanger. In addition, in one or more embodiments, there can be an equal number of baffles 340 for every 360° rotation around the longitudinal axis, and the baffles 340 are arranged around the longitudinal axis. In addition, the baffles 340 can support multiple tubes 330 and can guide the first fluid flow in a spiral path (not shown). In addition, in one or more embodiments, the baffles 340 can be interconnected by multiple rods 342. Spacers 349 can optionally be used during construction to ensure baffle spacing. As shown, the spacers 349 are rectangular, although other shapes can also be used. Still referring to Figure 3 In one or more embodiments, each of the baffles 340 may have an outer circumferential edge 343, and each outer circumferential edge 343 may be spaced apart from the outer circumferential edge 343 of an adjacent baffle 340. Each of the baffles may also include a proximal radial edge 344 at one end of the outer circumferential edge 343 and a distal radial edge 345 at the other end of the outer circumferential edge 343, such that the elliptical sector baffle 340 is defined by the outer circumferential edge 343, the proximal radial edge 344, and the distal radial edge 345. In addition, each of the baffles may have a proximal side 346 and a distal side 347 that are opposite to each other, and a plurality of spaced apart holes 348 extending from the proximal side 346 through the baffle 340 to the distal side 347. In one or more embodiments, the proximal side 346 of each baffle 340 may be the side of the baffle 340 that is axially closest to the inlet of the housing of the heat exchanger, and the distal side 347 may be the side of each baffle 340 that is axially farthest from the inlet of the housing of the heat exchanger. One tube 330 of the plurality of axially extending tubes 330 may pass through each of the holes 348 in the baffle 340. In one or more embodiments, the holes 348 of one baffle 340 may be aligned with the holes on another baffle 340 so that the axially extending tube 330 may fit through the holes 348 and may be supported by the plurality of baffles 340. It should be noted that, although not shown on all baffles 340, each of the baffles 340 may include a through hole 348.

[0044] like Figure 3, the tubes 330 and through holes 348 do not extend all the way to the circumferential edge 343. Therefore, when installed in a housing (not shown), there will be a gap between the housing and the outermost tubes 330. According to embodiments herein, the tube cage 341 may include a plurality of sealing rods or strips 350 that are arranged at an angle so that fluid flowing through the housing is at least partially directed back to the tubes 330. Thus, the strips 350 may provide the dual functions of enhanced sealing and structural support, reducing the amount of fluid that can bypass the plurality of tubes, as well as supporting the structure of the cage 341.

[0045] In addition to the sealing and structural support functions of the strips 350 (which may be referred to herein as sealing strips), the strips 350 may be positioned so as to provide a sealing function with a low pressure drop, thereby providing a flow barrier to prevent fluid from flowing through the entire spiral flow path in the gap between the tubes 330 and the baffle edge 343. Alternatively, the flow barrier function may be achieved by using other structures, such as longitudinal strips having a substantially rectangular shape so that the space between the tube bundle and the shell is effectively blocked; however, such flow barriers will come at the expense of a significant pressure drop. In contrast to longitudinal strips, embodiments herein relate to strips designed and oriented to provide enhanced sealing, structural support, and relatively low pressure drop, as will be described more fully below.

[0046] As mentioned above, rod 342 is optional and may serve the additional purpose of supporting the baffle during tube insertion. Figure 3 340, but in one or more embodiments of the present disclosure, the rods need not support and interconnect the baffles 340. Instead, as shown and described in more detail below, in one or more embodiments, straps may be used to support and interconnect the baffles around the central rod.

[0047] Reference now Figure 4A and 4B, baffles 440 according to one or more embodiments of the present disclosure are shown. In one or more embodiments, a plurality of baffles 440 may be coupled to a central rod 423 within a shell (not shown) of a heat exchanger (not shown). Successive baffles 440 may be positioned at angles that are not orthogonal to a longitudinal axis 424 of the central rod 423, and successive baffles 440 may be rotationally and longitudinally offset from one another so as to form a spiral pattern. The rotational offset between successive baffles 440 may be such that at least a proximal radial edge 444 of one baffle 440 overlaps a distal radial edge 445 of an adjacent baffle 440 in a longitudinal direction. In one or more embodiments, the proximal radial edge 444 of each baffle 440 may be a radial edge of the baffle 440 that is axially closest to an inlet (not shown) of a shell (not shown) of the heat exchanger, and the distal radial edge 445 of each baffle 440 may be a radial edge of the baffle 440 that is axially farthest from the inlet of the shell of the heat exchanger.

[0048] Still reference Figure 4A and 4B In one or more embodiments, the baffles 440 may be elliptical sectors. Each of the baffles 440 may have an outer circumferential edge 443, and each outer circumferential edge 443 may be spaced apart from the outer circumferential edge 443 of an adjacent baffle 440. Each of the baffles may also include a proximal radial edge 444 at one end of the outer circumferential edge 443 and a distal radial edge 445 at the other end of the outer circumferential edge 443, such that the elliptical sector shaped baffle 440 is defined by the outer circumferential edge 443, the proximal radial edge 444, and the distal radial edge 445. In addition, each of the baffles may have a proximal side 446 and a distal side 447 that are opposite to each other and a plurality of spaced apart holes 448 that extend through the baffle 440 from the first side 446 to the second side 447. In one or more embodiments, the proximal side 446 of each baffle 440 can be the side of the baffle 440 that is closest to the inlet of the shell of the heat exchanger, and the distal side 447 can be the side of each baffle 440 that is farthest from the inlet of the shell of the heat exchanger. One of a plurality of axially extending tubes (not shown) can pass through a hole 448 in the baffle 440. In one or more embodiments, the hole 448 of one baffle 440 can be aligned with a hole on another baffle (not shown) so that the axially extending tubes can be supported by multiple baffles. In addition, in one or more embodiments, each of the baffles 440 can include a center hole 449 at the intersection between the proximal radial edge 444 and the distal radial edge 445, and the center rod 423 can pass through the center hole 449 so as to connect each of the baffles 440 to the center rod 423. Although in Figure 4A / Figure 4B Only a few holes 448 are shown, but those skilled in the art will appreciate that each baffle includes a plurality of holes, such as Figure 3 or Figure 5B The holes shown in .

[0049] The central hole 449 of each baffle 440 can be uniquely angled such that the baffle 440 is positioned at an angle that is not orthogonal to the longitudinal axis 424 of the center rod 423. Additionally, in some embodiments, the baffle angle can vary along the length of the heat exchanger, such as where a proximal baffle is disposed at a first angle relative to the longitudinal axis, while a more distal baffle is disposed at a different angle relative to the longitudinal axis. As another example, a proximal baffle can be disposed at a first angle relative to the longitudinal axis, while more distal baffles can be disposed successively at increasing or decreasing angles relative to the longitudinal axis.

[0050] Reference now FIG. 5A to FIG. 5E , showing multiple views of a heat exchanger 500 according to one or more embodiments of the present disclosure. In one or more embodiments, the heat exchanger 500 may include a housing 520 ( Figure 5B ), a plurality of axially extending tubes 530 through which the second fluid passes, a plurality of elliptical sector baffles 540, and a first plurality of sealing strips 550 disposed between the baffles 540. The housing 520 may include an inlet (not shown) and an outlet (not shown), and the first fluid may pass between the inlet and the outlet within the housing 520. In addition, the plurality of tubes 530, the plurality of baffles 540, and the first plurality of sealing strips 550 may be disposed within the housing 520.

[0051] refer to Figure 5A and Figure 5BIn one or more embodiments, the plurality of baffles 540 may be arranged such that consecutive baffles 540 are positioned at an angle to a line orthogonal to the longitudinal axis 521 of the shell 520. In one or more embodiments, the baffles 540 may be coupled to and arranged around the central rod 523, and consecutive baffles 540 may be rotationally and longitudinally offset from each other to form a spiral pattern. The rotational offset between consecutive baffles 540 may be such that at least the proximal radial edge 544 of one baffle 540 is adjacent to or overlaps with the distal radial edge 545 of an adjacent baffle 540 in the longitudinal direction. In one or more embodiments, the proximal radial edge 544 of each baffle 540 may be the radial edge of the baffle 540 axially closest to the inlet of the shell 520 of the heat exchanger 500, and the distal radial edge 545 of each baffle 540 may be the radial edge of the baffle 540 axially farthest from the inlet of the shell 520 of the heat exchanger 500. Additionally, in one or more embodiments, there may be an equal number of baffles 540 for every 360° rotation about the longitudinal axis 521 that the baffles 540 are disposed about. For example, in one or more embodiments, there may be four baffles 540 for every 360° rotation about the longitudinal axis 521 of the housing 520. Although four elliptical sector-shaped baffles are shown for every 360° rotation about the longitudinal axis of the housing, in one or more embodiments, any number of baffles of varying shapes for every 360° rotation about the longitudinal axis of the housing may be used, as long as the baffles are longitudinally and rotationally offset to form a spiral flow path.

[0052] Still reference Figure 5A and Figure 5B In one or more embodiments, the baffles 540 may be elliptical sectors. Each of the baffles 540 may have an outer circumferential edge 543, and each outer circumferential edge 543 may be spaced apart from the outer circumferential edge 543 of an adjacent baffle 540. Each of the baffles 540 may also include a proximal radial edge 544 at one end of the outer circumferential edge 543 and a distal radial edge 545 at the other end of the outer circumferential edge 543, such that the elliptical sector baffle 540 is defined by the outer circumferential edge 543, the proximal radial edge 544, and the distal radial edge 545. In addition, each of the baffles 540 may have a proximal side 546 and a distal side 547 that are opposite to each other, and a plurality of spaced apart holes 548 extending from the proximal side 546 through the baffle 540 to the distal side 547. In one or more embodiments, the proximal side 546 of each baffle 540 may be the side of the baffle 540 axially closest to the inlet of the shell 520 of the heat exchanger 500, and the distal side 547 may be the side of each baffle 540 axially farthest from the inlet of the shell 520 of the heat exchanger 500.

[0053] In one or more embodiments, one tube 530 of the plurality of axially extending tubes 530 may pass through the hole 548 in the baffle 540, and the direction of the second fluid flow in the tube 530 may be opposite to the direction of the first fluid flow from the inlet of the shell to the outlet of the shell. In addition, in one or more embodiments, the hole 548 of one baffle 540 may be aligned with the hole on another baffle 540, so that the tube 530 may extend axially along the entire length of the heat exchanger 500, and so that each of the tubes 530 is supported by the plurality of baffles 540. In addition, the distance 534 between the outer diameter 535 of each of the tubes 530 disposed in each of the holes 548 may be consistent throughout the plurality of tubes 530. In addition, as described above, in one or more embodiments, each of the baffles 540 may include a central hole 549 at the intersection between the first radial edge 544 and the second radial edge 545, and the center rod 523 may pass through the central hole 549 so as to couple each of the baffles 540 to the center rod 523. The central aperture 549 of each baffle 540 may be uniquely angled such that the baffle 540 is positioned at an angle to a line that is orthogonal to the longitudinal axis 521 of the housing 520 .

[0054] In addition, reference FIG. 5A to FIG. 5E In one or more embodiments, each of the first plurality of sealing strips 550 may be disposed between the first baffle 540 and a corresponding continuous baffle 540, the continuous baffle 540 being at least a full 360° rotated from the first baffle 540. In addition, each of the first plurality of sealing strips 550 may be radially disposed between the plurality of tubes 530 and the inner surface 525 of the shell 520. In one or more embodiments, the inner surface 525 may have a diameter 590. In addition, in one or more embodiments, each of the first plurality of sealing strips 550 may be coupled to each of the first baffle 540 and a corresponding continuous baffle 540. In one or more embodiments, the first plurality of sealing strips 550 may be disposed such that each of the first plurality of sealing strips 550 is substantially orthogonal to the spiral path defined by the baffles within the shell 520 of the heat exchanger 500. Reference Figure 5A , Figure 5D and Figure 5E In one or more embodiments, the first end 551 of each of the first plurality of sealing strips 550 can be connected to the distal side 547 of one of the plurality of baffles 540 between the proximal radial edge 544 and the distal radial edge 545, and the second end 552 of each of the first plurality of sealing strips 550 can be connected to the proximal side 546 of another of the plurality of baffles 540 between the proximal radial edge 544 and the distal radial edge 545.

[0055] like Figure 5A and Figure 5DAs shown in FIG. 5 , in one or more embodiments, each of the first plurality of sealing strips 550 may be disposed orthogonally to both the distal side 547 of one baffle 540 and the proximal side 546 of another baffle 540. Figure 5E As shown in , in other embodiments, each of the plurality of sealing strips 550 may be connected between two baffles 540. Figure 5E , the sealing strip 550 can be arranged such that an angle 595 is formed between the sealing strip 550 and a line orthogonal to the proximal side 546 of one baffle 540 and the distal side of another baffle 540. In some embodiments, the angle 595 can be from greater than 0° up to 80°. In another embodiment, the angle 595 can be one of from greater than 0° up to 30°, from 15° up to 45°, from 45° up to 80°, or from 15° up to 30°. Because the first fluid may leak between consecutive baffles in the plurality of baffles 540, the direction 522 of the first fluid flow may be slightly different from the spiral path formed by the plurality of baffles 540. In addition, due to this possible change in the first fluid flow direction, the angle 595 of the sealing strip 550 can be varied so that each of the first plurality of sealing strips 550 can be orthogonal to the spiral first fluid flow direction 522.

[0056] like Figure 5A and Figure 5B As shown in , the baffles 540 can be arranged in four quadrants. In some embodiments, the sealing strip 550 can couple the first baffle 540 to the second baffle 540 in the same quadrant (or the same sector, where baffles other than four baffles are used per 360° rotation). As described above, the sealing strip can be coupled from the distal side 547 of the first baffle 540 to the proximal side 546 of the second baffle 540 at a position adjacent to the distal edge 545 of the second baffle 540. For example, the sealing strip can couple the distal side 547 of the first baffle 540 from adjacent to the proximal edge 544 of the first baffle to the proximal side 546 of the second baffle adjacent to the distal edge 545 of the second baffle. As another example, the sealing strip can couple the distal side 547 of the first baffle 540 from adjacent to the proximal edge 544 of the first baffle to the proximal side 546 of the second baffle adjacent to the proximal edge 544 of the second baffle.

[0057] In some embodiments, the sealing strip 550 can connect the first baffle 540 to the second baffle 540 in the adjacent quadrant (sector). As described above, the sealing strip can be coupled from the distal side 547 of the first baffle 540 to the proximal side 546 of the second baffle 540. For example, in some embodiments, the sealing strip can couple the distal side 547 of the first baffle 540 from the middle of the proximal edge 544 and the distal edge 545 of the first baffle to the proximal side 546 of the second baffle in the middle of the proximal edge 544 and the distal edge 545 of the second baffle.

[0058] In other embodiments, the heat exchanger may include some sealing strips 550 connected between baffles 540 in the same quadrant, while other sealing strips 550 may be connected between baffles 540 in adjacent quadrants.

[0059] In some embodiments, Figure 5E As shown in , improved heat exchange and reduced pressure drop can be achieved, wherein the sealing strip can partially guide the flow helically toward the outlet. In other words, the sealing strip 550 can be formed at a helical angle H smaller than that of the baffle 540. B The helix angle H s In some embodiments, the helix angle H is defined as the angle of the baffle or sealing strip relative to the longitudinal axis of the heat exchanger. s It can be in the range of greater than 0° to 80°, such as from a lower limit of 5°, 10°, 15°, 20°, 25°, 30°, 35°, 40° or 45° to an upper limit of 25°, 30°, 40°, 45°, 50°, 60°, 70°, 75° or 80°, wherein any lower limit can be combined with any greater upper limit according to embodiments herein. It has been found that in some embodiments, having a helix angle H greater than the baffle plate B The helix angle H s The strips of H can disrupt the spiral flow path of the fluid (i.e., attempt to drive the flow back toward the inlet) while providing a better seal. Conversely, where the sealing strip promotes spiral flow, a proper seal is provided while reducing pressure drop (relative to conventional seals) and improving heat transfer results. In various embodiments, the baffle angle H B The angle of the baffle plate may be uniform or may vary along the length of the heat exchanger. For example, when a variable baffle angle is used, the proximal baffle plate may be at a first angle (H) relative to the longitudinal axis. B1 , not shown), while the more distal baffle may be arranged at a second different angle (H) relative to the longitudinal axis. B2 As another example, the proximal side baffle may be disposed at a first angle relative to the longitudinal axis, while the more distal baffles may be disposed successively at increasing or decreasing angles relative to the longitudinal axis (H B1 <H B2 <H B3 wait).

[0060] As described above, in one or more embodiments, the first plurality of sealing strips 550 can be arranged such that each of the first plurality of sealing strips 550 is orthogonal or substantially orthogonal to the spiral path defined by the baffles within the shell 520 of the heat exchanger 500. In other embodiments, due to leakage and possible variations in the first fluid flow direction, the angle 595 of the sealing strips 550 can be varied such that each of the first plurality of sealing strips 550 can be orthogonal to the spiral first fluid flow direction. Although it is desirable that the fluid flows as close to the geometric lead as possible, it is recognized herein that this is not always the case. Therefore, as shown, the fluid flow path may not be orthogonal to the sealing strips 550. Leakage and the amount of variation in the first fluid flow direction may also vary depending on the characteristics of the fluid being transported and the size of the shell and baffles. Therefore, embodiments herein may include estimating the first fluid flow direction, such as by computational fluid dynamics or other simulations or experimental studies, so that the angle of the strips 550 can be installed to account for the expected difference between the geometric spiral lead and the actual fluid path, so that the strips are orthogonal to the flow.

[0061] although FIG. 5A to FIG. 5E The embodiments shown in the figure may include a plurality of sealing strips that are all disposed at the same angle between one baffle and another baffle, but in one or more embodiments, the sealing strips may be disposed at different angles within the heat exchanger. In other words, in one or more embodiments, one of the plurality of sealing strips may be disposed orthogonally to both the distal side of one baffle and the proximal side of another baffle, and another of the plurality of sealing strips may be disposed at a non-orthogonal angle to the proximal side of one baffle and the distal side of another baffle, wherein the angle may be from greater than 0° up to 80°. Thus, while in one or more embodiments, all of the sealing strips may be disposed at the same angle between the baffles, in other embodiments, a combination of sealing strips disposed at different angles may be used. Furthermore, while in one or more embodiments, sealing strips disposed at a first angle may be used between the first few rotating baffles around the longitudinal axis, and sealing strips disposed at a second angle may be used between the remaining rotating baffles around the longitudinal axis, in other embodiments, different patterns of sealing strips disposed at the first angle and sealing strips disposed at the second angle may be used. Furthermore, in one or more embodiments, more than two angularly arranged sealing strips may be used in different patterns throughout the heat exchanger.

[0062] In addition, reference Figure 5B and Figure 5CIn one or more embodiments, each of the first plurality of sealing strips may have a curved inner surface 553 and a curved outer surface 554. In one or more embodiments, the curved outer surface 554 of each sealing strip 550 may be disposed substantially close to the inner surface 525 of the housing 520. Furthermore, in one or more embodiments, the curved outer surface 554 of one or more of the sealing strips 550 may have a gap of 1 to 5 mm from the inner surface 525 of the housing 520. For example, the curved outer surface 554 of one or more of the sealing strips 550 may have a gap of 3 mm from the inner surface 525 of the housing 520. Additionally, the curvature of the curved outer surface 554 of the sealing strip 550 may be elliptical and may match the curvature of the inner surface 525 of the housing 520. While it is noted that the sealing strip may be elliptical, the appearance of the sealing strip may vary with angle. For example, at H S In smaller cases, the stripes can be almost straight. S In larger cases, the strip will be elliptical. The elliptical shape ensures that the space between the shell and the strip and the space between the tube bundle and the strip can be the same along the length of the strip. In addition, because the strip is elliptical, the strip can be represented by a minor diameter and a major diameter (not shown), where the shell diameter, the spacing from the shell diameter, and the strip angle H are the same. S The elliptical nature of the strips may be defined.

[0063] Furthermore, in one or more embodiments, the curvature of the curved inner surface 553 of each of the first plurality of sealing strips 550 may be elliptical, and the curvature of the inner surface 553 may be different from the curvature of the outer surface 554 of each of the first plurality of sealing strips 550. In other words, in one or more embodiments, the curvature of the inner surface 553 of each sealing strip 550 may match the curvature of an imaginary cylinder having a diameter equal to the diameter 590 of the inner surface 525 of the housing 520 minus the radial width of the sealing strip 550. Furthermore, the inner surface 553 of each of the first plurality of sealing strips 550 may be spaced apart a distance 557 from the outer diameter 535 of the closest tube 530 among the plurality of axially extending tubes 530. The distance 557 between the inner surface 553 of the sealing strip 550 and the outer diameter 535 of the closest tube 530 may be equal to the distance 534 between the outer diameters 535 of two adjacent tubes 530. In addition, the first plurality of sealing strips 550 can be at an angle 556 from the outer surface 554 to the inner surface 553 in the direction of the first fluid flow 522, which is a line 555 normal to the shell 520. For example, in one or more embodiments, each of the first plurality of sealing strips 550 disposed perpendicular to the inclined baffle 540 can be at an angle of 15° to 45° to the line 555 normal to the shell 520, so that the first fluid flow 522 contacts the sealing strip at an angle of 105° to 135° and is deflected back toward the plurality of tubes 530. In addition, the first plurality of sealing strips 550 can have a thickness 558, and a larger thickness 558 can be used for a heat exchanger 500 having a larger diameter 590 of the inner surface 525 of the shell 520.

[0064] As described in some embodiments herein, each of the first plurality of sealing strips 550 may have a curved outer diameter with an elliptical curvature, and / or wherein each of the first plurality of sealing strips has a curved inner diameter with an elliptical curvature. In other embodiments, the sealing strip 550 may be wider in areas where the gap between the bundle and the shell is larger. Since the grid layout of the holes through the baffle may not result in a circular pattern of the outermost holes, a sealing strip with a variable width may provide a better seal. In some embodiments, the width may be achieved by changing the elliptical curvature of each of the inner and outer diameters of the sealing strip. In other embodiments, the width may be systematically varied to match the profile gap or to provide a consistent profile gap between the inner diameter of the sealing strip and each of the corresponding tubes. Similarly, the depth of the sealing strip may vary. Therefore, in various embodiments, each of the first plurality of sealing strips may have a width of the outer diameter minus the inner diameter, which varies along the length of the sealing strip (first end to second end), and / or each of the first plurality of sealing strips may have a depth from the proximal side to the distal side, which varies along the width or length of the sealing strip.

[0065] Additionally, in one or more embodiments, the number of the first plurality of sealing strips 550 per 360° rotation about the longitudinal axis 521 may be a multiple of the number of baffles per 360° rotation about the longitudinal axis 521. Additionally, the number of the first plurality of sealing strips 550 disposed between a baffle 540 and a corresponding consecutive baffle 540 fully 360° rotated from the baffle 540 may be equal for all baffles 540 in the plurality of baffles 540. For example, in one or more embodiments, there may be four baffles 540 per 360° rotation about the longitudinal axis 521, and there may be four first plurality of sealing strips 550 per 360° rotation about the longitudinal axis 521, such that each baffle 540 may have one first plurality of sealing strips 550 per 360° rotation about the longitudinal axis 521. In other embodiments, there may be four baffles 540 per 360° rotation about the longitudinal axis 521 and there may be eight first plurality of sealing strips 550 per 360° rotation about the longitudinal axis 521, such that there may be two first plurality of sealing strips 550 per baffle 540 per 360° rotation about the longitudinal axis 521. The number of first plurality of sealing strips 550 per 360° rotation about the longitudinal axis 521 may depend on the size of the inner surface 525 of the shell 520, the number of the plurality of tubes 530 disposed within the heat exchanger, and the distance 534 between the outer diameters 535 of the plurality of tubes 530. In one or more embodiments, there may be one of the first plurality of sealing strips 550 disposed within the shell 520 for every 8 to 10 rows of the plurality of tubes 530 disposed within the heat exchanger 500.

[0066] In addition, reference Figure 5A In one or more embodiments, at least one of the first plurality of sealing strips 550 may be coupled to the proximal side 546 of the baffle 540, and at least one of the first plurality of sealing strips 550 may be coupled to the distal side 547 of the baffle 540. Additionally, in one or more embodiments, each of the first plurality of sealing strips 550 coupled to the distal side 547 of each of the plurality of baffles 540 may be rotationally offset from each of the first plurality of sealing strips 550 coupled to the proximal side 546 of each of the plurality of baffles 540 about the longitudinal axis 521 of the housing 520. In one or more embodiments, the rotationally offset sealing strips 550 may follow a predetermined pattern along the entire length of the heat exchanger 500. Additionally, although in Figure 5A 5 shows rotationally offset adjacent sealing strips 550, but in one or more embodiments, adjacent sealing strips 550 may be longitudinally aligned along the entire length of the heat exchanger. In addition, in one or more embodiments, the first plurality of sealing strips 550 may be formed of steel.

[0067] In other embodiments, the first plurality of sealing strips 550 can be arranged such that each of the first plurality of sealing strips 550 is substantially parallel (substantially parallel to + / - 1° or another small manufacturing tolerance) to the longitudinal axis of the heat exchanger. When parallel to the longitudinal axis, each sealing strip should be connected to the proximal baffle 540 and the longitudinally adjacent distal baffle 540. It has been found that a single sealing strip between longitudinally adjacent baffles provides better sealing and reduced pressure drop compared to the prior art that includes holes for sealing strips in each baffle and uses a single long sealing strip from one end of the exchanger to the other. In some embodiments, the sealing strips connected to longitudinally adjacent baffles can be circumferentially offset. For example, each of the plurality of baffles can be connected to at least two sealing strips 550, including a distal sealing strip 550 connected to the distal side of the baffle and a proximal sealing strip 550 connected to the proximal side of the same baffle, wherein the proximal sealing strip is circumferentially offset from the distal sealing strip. In some embodiments, the circumferential offset may be at least 10°, at least 15°, or at least 20°, but must be offset less than the total degree of the corresponding elliptical sector of the sector baffle. Thus, the rotationally or circumferentially offset sealing strips may include one, two or more sealing strips connected to the proximal side of the baffle and one, two or more sealing strips connected to the distal side of the baffle, wherein the number of sealing strips connected to the distal side and the proximal side may be equal in some sectors and unequal in other sectors. In some embodiments, an equal number of sealing strips may be connected to each of the plurality of baffles. In other embodiments, the sealing strip may not be connected to each of the plurality of baffles. For example, in the case of using four baffles per 360° rotation, including quadrants A, B, C, and D, the sealing strips may be used only for, for example, quadrants A and C or B and D, and in other embodiments, for example, sealing strips may be used for every three quadrants (A, D, C, B, A... in sequence). The number and position of the sealing strips may depend on the sealing and structural requirements of the specific heat exchanger.

[0068] Reference now FIG. 6A to FIG. 6D , showing a portion of a heat exchanger 600 according to several embodiments of the present disclosure. FIG. 5A to FIG. 5EAs discussed, in one or more embodiments, the heat exchanger 600 may include a plurality of elliptical sector baffles 640 and a first plurality of sealing strips 650 disposed between the baffles 640. The first plurality of sealing strips 650 may each be disposed between the first baffle 640 and a corresponding continuous baffle 640 fully rotated 360° from the first baffle 640. In addition, a first end 651 of each of the first plurality of sealing strips 650 may be coupled to a distal side 647 of one of the plurality of baffles 640 between the proximal radial edge 644 and the distal radial edge 645, and a second end 652 of each of the first plurality of sealing strips 650 may be coupled to a proximal side 646 of another of the plurality of baffles 640 between the proximal radial edge 644 and the distal radial edge 645. In one or more embodiments, the proximal radial edge 644 of each baffle 640 may be the radial edge of the baffle 640 closest to the inlet of the shell of the heat exchanger 600, and the distal radial edge 645 of each baffle 640 may be the radial edge of the baffle 640 farthest from the shell inlet of the heat exchanger 600. Similarly, in one or more embodiments, the proximal side 646 of each baffle 640 may be the side of the baffle 640 closest to the shell inlet of the heat exchanger 600, and the distal side 647 may be the side of each baffle 640 farthest from the shell inlet of the heat exchanger 600.

[0069] refer to Fig. 6A In one or more embodiments, each of the first plurality of sealing strips 650 may be disposed orthogonal to both the distal side 647 of one baffle 640 and the proximal side 646 of another baffle 640. In other embodiments, each of the plurality of sealing strips 650 may be disposed at an angle (not shown) orthogonal to the proximal side 646 of one baffle 640 and the distal side 647 of another baffle 640, and the angle may be greater than 0° up to 80°.

[0070] For example reference only Figure 6B, a sealing strip 650 may be connected between the first baffle 640 and the second baffle 640 in the same quadrant. Each of the plurality of sealing strips may be disposed at an angle that is not orthogonal to the proximal side 646 of the first baffle 640, and the angle may be from greater than 45° to 80° in a direction defined from the distal radial edge 645 to the proximal radial edge 644 of the second baffle 640. Further, as described above, in other embodiments, the angle may be one of greater than 0° to 30°, from 15° to 45°, or from 15° to 30°. Due to possible leakage of the first fluid between consecutive baffles in the plurality of baffles 640, the direction of the first fluid flow may vary slightly from the spiral path formed by the plurality of baffles 640. Further, due to such possible variation in the direction of the first fluid flow, the angle of the sealing strip 650 may vary such that each of the first plurality of sealing strips 650 may be orthogonal to the spiral first fluid flow direction.

[0071] For reference only as an example Figure 6C , a sealing strip 650 may be connected between a first baffle 640 in a first quadrant and a second baffle 640 in an adjacent quadrant. Each of the plurality of sealing strips may be disposed at an angle that is not orthogonal to the proximal side 646 of the first baffle 640, and the angle may be from greater than 45° to 80° in a direction defined from a distal radial edge 645 to a proximal radial edge 644 of the second baffle 640. In addition, as described above, in other embodiments, the angle may be one of from greater than 0° to 30°, from 15° to 45°, or from 15° to 30° in a direction defined from a distal radial edge 645 to a proximal radial edge 644 of the second baffle 640. Due to possible leakage of the first fluid between consecutive baffles in the plurality of baffles 640, the direction of the first fluid flow may be slightly changed from the spiral path formed by the plurality of baffles 640. Furthermore, due to this possible variation in the first fluid flow direction, the angle of the sealing strips 650 may vary such that each of the first plurality of sealing strips 650 may be orthogonal to the helical first fluid flow direction.

[0072] In some embodiments, some sealing strips 650 may be connected between baffles 640 in the same quadrant, such as Figure 6B As shown in FIG. , other sealing strips 650 may be connected between baffles 640 in adjacent quadrants, such as Figure 6C as shown in .

[0073] although FIG. 6A to FIG. 6C The embodiment shown in FIG. 5 may include a plurality of sealing strips 650, which are all disposed at the same angle between one baffle 640 and another baffle 640, with reference to FIG. Figure 6CIn one or more embodiments, the sealing strip 650 may be disposed within the heat exchanger at different angles (not shown). Figure 6C In one or more embodiments, one sealing strip 650a of the plurality of sealing strips 650 may be disposed orthogonally to both the distal side 647 of one baffle 640 and the proximal side 646 of another baffle 640, and another sealing strip 650b of the plurality of sealing strips 650 may be disposed at a non-orthogonal angle to the proximal side 646 of one baffle 640 and the distal side 647 of another baffle 640, wherein the angle may be from greater than 0° to 80°. Therefore, although in one or more embodiments, all sealing strips 650 may be disposed between baffles having the same angle arrangement, in other embodiments, a combination of sealing strips 650 having different angle arrangements may be used. Furthermore, while in one or more embodiments, a first angularly arranged sealing strip 650a may be used between a first number of rotating baffles 640 about the longitudinal axis, and a second angularly arranged sealing strip 650b may be used between the remaining rotating baffles 640 about the longitudinal axis, in other embodiments, different patterns of first angularly arranged sealing strips 650a and second angularly arranged sealing strips 650b may be used. Furthermore, in one or more embodiments, more than two angularly arranged sealing strips may be used in different patterns throughout the heat exchanger. In some embodiments, both the angular arrangement of the sealing strips and the quadrants between which the sealing strips are arranged may vary within the heat exchanger.

[0074] Reference now Figure 7 , shows a portion of a heat exchanger 700 according to one or more embodiments of the present disclosure. In one or more embodiments, the heat exchanger 700 may include a shell (not shown) through which a first fluid passes, a plurality of axially extending tubes 730 through which a second fluid passes, a plurality of elliptical sector baffles 740, and a first plurality of sealing strips 750 disposed between the baffles 740. The shell may include an inlet (not shown) and an outlet (not shown), and the first fluid may pass between the two within the shell. In addition, the plurality of tubes 730, the plurality of baffles 740, and the first plurality of sealing strips 750 may be disposed within the shell.

[0075] refer to Figure 7, similar to the heat exchanger described above, in one or more embodiments, a plurality of baffles 740 may be arranged such that consecutive baffles 740 are positioned at an angle to a line orthogonal to a longitudinal axis (not shown) of the shell. In one or more embodiments, the baffles 740 may be coupled about the longitudinal axis, and consecutive baffles 740 may be rotationally and longitudinally offset from one another to form a spiral pattern. The rotational offset between consecutive baffles 740 may be such that at least a proximal radial edge 744 of one baffle 740 overlaps a distal radial edge 745 of an adjacent baffle 740 in the longitudinal direction. In one or more embodiments, the proximal radial edge 744 of each baffle 740 may be a radial edge of the baffle 740 that is closest to the shell inlet of the heat exchanger 700, and the distal radial edge 745 of each baffle 740 may be a radial edge of the baffle 740 that is farthest from the shell inlet of the heat exchanger 700. Additionally, as described above, in one or more embodiments, there may be an equal number of baffles 740 for every 360° rotation about the longitudinal axis, wherein the baffles 740 are disposed about the longitudinal axis.

[0076] Still reference Figure 7 In one or more embodiments, the baffles 740 may be elliptical sectors. Each of the baffles 740 may have an outer circumferential edge 743, and each outer circumferential edge 743 may be spaced apart from the outer circumferential edge 743 of an adjacent baffle 740. Each of the baffles 740 may also include a proximal radial edge 744 at one end of the outer circumferential edge 743 and a distal radial edge 745 at the other end of the outer circumferential edge 743, such that the elliptical sector shaped baffle 740 is defined by the outer circumferential edge 743, the proximal radial edge 744, and the distal radial edge 745. In addition, each of the baffles 740 may have a proximal side 746 and a distal side 747 that are opposite to each other, and a plurality of spaced apart holes (not shown) extending from the proximal side 746 through the baffle 740 to the distal side 747. In one or more embodiments, the proximal side 746 of each baffle 740 may be the side of the baffle 740 closest to the shell inlet of the heat exchanger 700, and the distal side 747 may be the side of each baffle 740 farthest from the shell inlet of the heat exchanger 700. In addition, in one or more embodiments, one tube 730 of the plurality of axially extending tubes 730 may pass through the hole in the baffle 740. Thus, as described above, the plurality of tubes 730 may extend axially along the entire length of the heat exchanger 700, and each of the tubes 730 may be supported by the plurality of baffles 740 equally spaced along the length of the tubes 730. In addition, the distance between the outer diameters of each of the tubes 730 disposed in each of the holes may be uniform over the entirety of the plurality of tubes 730.

[0077] In addition, reference Figure 7In one or more embodiments, the first plurality of sealing strips 750 may each be disposed between the first baffle 740 and a corresponding continuous baffle 740 that is fully rotated 360° from the first baffle 740. In addition, each of the first plurality of sealing strips 750 may be radially disposed between the diameter of the plurality of tubes 730 and the inner surface of the shell. As described above, in one or more embodiments, each of the first plurality of sealing strips 750 may be coupled to the first baffle 740 and each of the corresponding continuous baffles 740. In one or more embodiments, the first plurality of sealing strips 750 may be disposed such that each of the first plurality of sealing strips 750 is orthogonal to the spiral first fluid flow direction within the shell of the heat exchanger 700. In addition, in one or more embodiments, the first end 751 of each of the first plurality of sealing strips 750 can be connected to the distal side 747 of one of the plurality of baffles 740 between the proximal radial edge 744 and the distal radial edge 745, and the second end 752 of each of the first plurality of sealing strips 750 can be connected to the proximal side 746 of another of the plurality of baffles 740 between the proximal radial edge 744 and the distal radial edge 745.

[0078] As described above, in one or more embodiments, each of the first plurality of sealing strips 750 can be disposed orthogonal to both the distal side 747 of one baffle 740 and the proximal side 746 of another baffle 740. Furthermore, in other embodiments, each of the plurality of sealing strips 750 can be disposed at an angle (not shown) that is not orthogonal to the proximal side 746 of one baffle 740 and the distal side 747 of another baffle 740; the angle can be from greater than 0° up to 80°. In other embodiments, the angle can be one of greater than 0° up to 30°, from 15° up to 45°, from 45° up to 80°, or from 15° up to 30°. Due to possible leakage of the first fluid between consecutive baffles in the plurality of baffles 740, the direction of the first fluid flow can vary slightly from the spiral path formed by the plurality of baffles 740. Furthermore, due to this possible variation in the direction of the first fluid flow, the angle of the sealing strips 750 can vary such that each of the first plurality of sealing strips 750 can be orthogonal to the spiral first fluid flow direction. The baffles 740 may be arranged in quadrants. In some embodiments, the sealing strip 750 may be connected between the baffles 740 located in the same quadrant. In some embodiments, the sealing strip 750 may be connected between the baffles 740 located in adjacent quadrants. In some embodiments, the sealing strip 750 may be connected between the baffles 740 located in the same quadrant and the baffles 740 located in adjacent quadrants.

[0079] In addition, reference Figure 7 In one or more embodiments, each of the first plurality of sealing strips 750 may have the same FIG. 5A to FIG. 5Eand FIG. 6A to FIG. 6D The first plurality of sealing strips 750 may have substantially similar structures. Therefore, the first plurality of sealing strips 750 may have a curved inner surface and a curved outer surface. In one or more embodiments, the curved outer surface of each sealing strip 750 may be arranged to be substantially close to the inner surface of the housing. In addition, in one or more embodiments, the curved outer surface of one or more sealing strips 750 may contact the inner surface of the housing. In addition, the curvature of the curved outer surface of the sealing strip 750 may be elliptical and may match the curvature of the inner surface of the housing.

[0080] In addition, in one or more embodiments, the curvature of the curved inner surface of each of the first plurality of sealing strips 750 may be elliptical, and the curvature of the inner surface may be different from the curvature of the outer surface of each of the first plurality of sealing strips 750. In other words, in one or more embodiments, the curvature of the inner surface of each sealing strip 750 may match the curvature of an imaginary cylinder having a diameter equal to the diameter of the inner surface of the shell minus the radial width of the sealing strip 750. In addition, the inner surface of each of the first plurality of sealing strips 750 may be spaced a distance from the outer diameter of the closest tube 730 among the plurality of axially extending tubes 730. The distance between the inner surface of the sealing strip 750 and the outer diameter of the closest tube 730 may be equal to the distance between the outer diameters of two adjacent tubes 730. In addition, in one or more embodiments, the first plurality of sealing strips 750 may be at an angle to a line orthogonal to the shell from the outer surface to the inner surface in the direction of the first fluid flow. In addition, the first plurality of sealing strips 750 may have a thickness that varies according to the diameter of the inner surface of the shell.

[0081] Still reference Figure 7 In one or more embodiments, at least one of the first plurality of sealing strips 750 may be coupled to the proximal side 746 of the baffle 740, and at least one of the first plurality of sealing strips 750 may be coupled to the distal side 747 of the baffle 740. In addition, in one or more embodiments, each of the first plurality of sealing strips 750 coupled to the distal side 747 of each of the plurality of baffles 740 may be longitudinally aligned with each of the first plurality of sealing strips 750 coupled to the proximal side 746 of each of the plurality of baffles 740 in a direction parallel to the longitudinal axis of the housing of the heat exchanger 700. As described above, in one or more embodiments, for all of the baffles 740 in the plurality of baffles 740, the number of the first plurality of sealing strips 750 disposed between the baffle 740 and the corresponding consecutive baffle 740 fully rotated 360° from the baffle 740 may be equal, and thus, the number of the first plurality of sealing strips 750 per 360° rotation around the longitudinal axis may be a multiple of the number of the baffles 740 per 360° rotation around the longitudinal axis.

[0082] Reference now Figure 8 , shows a portion of a heat exchanger 800 according to one or more embodiments of the present disclosure. In one or more embodiments, the heat exchanger 800 may include a shell (not shown) through which a first fluid passes, a plurality of axially extending tubes 830 through which a second fluid passes, a plurality of elliptical sector baffles 840, a first plurality of sealing strips 850 disposed between the baffles 840, and a second plurality of sealing strips 860 disposed between the baffles 840. The shell may include an inlet (not shown) and an outlet (not shown), and the first fluid may pass between the two within the shell. In addition, a plurality of tubes 830, a plurality of baffles 840, a first plurality of sealing strips 850, and a second plurality of sealing strips 860 may be disposed within the shell.

[0083] Still reference Figure 8 , similar to the heat exchanger described above, in one or more embodiments, a plurality of baffles 840 can be arranged such that consecutive baffles 840 are positioned at an angle to a line orthogonal to a longitudinal axis (not shown) of the housing. In one or more embodiments, the baffles 840 can be coupled about the longitudinal axis, and consecutive baffles 840 can be rotationally and longitudinally offset from one another to form a spiral pattern. The rotational offset between consecutive baffles 840 can cause at least a proximal radial edge 844 of one baffle 840 to overlap a distal radial edge 845 of an adjacent baffle 840 in a longitudinal direction. In addition, the longitudinal offset of the overlapping proximal radial edges 844 and distal radial edges 845 between consecutive baffles 840 can create a gap 870 between the proximal radial edges 844 and the distal radial edges 845, through which the first fluid flow can be able to travel. In one or more embodiments, the proximal radial edge 844 of each baffle 840 may be the radial edge of the baffle 840 closest to the shell inlet of the heat exchanger 800, and the distal radial edge 845 of each baffle 840 may be the radial edge of the baffle 840 farthest from the shell inlet of the heat exchanger 800. In addition, as described above, in one or more embodiments, there may be an equal number of baffles 840 for every 360° rotation around the longitudinal axis, and the baffles 840 are arranged around the longitudinal axis.

[0084] In addition, reference Figure 8In one or more embodiments, the baffles 840 may be elliptical sectors. Each of the baffles 840 may have an outer circumferential edge 843, and each outer circumferential edge 843 may be spaced apart from the outer circumferential edge 843 of an adjacent baffle 840. Each of the baffles 840 may also include a proximal radial edge 844 at one end of the outer circumferential edge 843 and a distal radial edge 845 at the other end of the outer circumferential edge 843, such that the elliptical sector shaped baffle 840 is defined by the outer circumferential edge 843, the proximal radial edge 844, and the distal radial edge 845. In addition, each of the baffles 840 may have a proximal side 846 and a distal side 847 that are opposite to each other, and a plurality of spaced apart holes (not shown) extending from the proximal side 846 through the baffle 840 to the distal side 847. In one or more embodiments, the proximal side 846 of each baffle 840 may be the side of the baffle 840 closest to the shell inlet of the heat exchanger 800, and the distal side 847 may be the side of each baffle 840 farthest from the shell inlet of the heat exchanger 800. In addition, in one or more embodiments, one tube 830 of the plurality of axially extending tubes 830 may pass through each of the holes in the baffle 840. Thus, as described above, the plurality of tubes 830 may extend axially along the entire length of the heat exchanger 800, and each of the tubes 830 may be supported by the plurality of baffles 840 equally spaced along the length of the tubes 830. In addition, the distance between the outer diameters of each of the tubes 830 disposed in each of the holes may be uniform throughout the plurality of tubes 830.

[0085] In addition, reference Figure 8 In one or more embodiments, the first plurality of sealing strips 850 may each be disposed between the first baffle 840 and a corresponding continuous baffle 840 that is fully rotated 360° from the first baffle 840. In addition, each of the first plurality of sealing strips 850 may be radially disposed between the diameter of the plurality of tubes 830 and the inner surface of the shell. As described above, in one or more embodiments, each of the first plurality of sealing strips 850 may be coupled to the first baffle 840 and each of the corresponding continuous baffles 840. In one or more embodiments, the first plurality of sealing strips 850 may be disposed such that each of the first plurality of sealing strips 850 is orthogonal to the spiral first fluid flow direction within the shell of the heat exchanger 800. In addition, in one or more embodiments, the first end 851 of each of the first plurality of sealing strips 850 is connected to the distal side 847 of one of the plurality of baffles 840 between the proximal radial edge 844 and the distal radial edge 845, and the second end 852 of each of the first plurality of sealing strips 850 is connected to the proximal side 846 of another of the plurality of baffles 840 between the proximal radial edge 844 and the distal radial edge 845.

[0086] As described above, in one or more embodiments, each of the first plurality of sealing strips 850 can be disposed orthogonal to both the distal side 847 of one baffle 840 and the proximal side 846 of another baffle 840. Furthermore, in other embodiments, each of the plurality of sealing strips 850 can be disposed at an angle (not shown) that is not orthogonal to the proximal side 846 of one baffle 840 and the distal side 847 of another baffle 850; the angle can be from greater than 0° up to 80°. In other embodiments, the angle can be one of greater than 0° up to 30°, from 15° up to 45°, from 45° up to 80°, or from 15° up to 30°. Due to possible leakage of the first fluid between consecutive baffles in the plurality of baffles 840, the direction of the first fluid flow can vary slightly from the spiral path formed by the plurality of baffles 840. Furthermore, due to this possible variation in the direction of the first fluid flow, the angle of the sealing strips 850 can vary such that each of the first plurality of sealing strips 850 can be orthogonal to the spiral first fluid flow direction.

[0087] The baffles 740 may be arranged in quadrants. In some embodiments, the sealing strip 750 may be connected between the baffles 740 located in the same quadrant. In some embodiments, the sealing strip 750 may be connected between the baffles 740 located in adjacent quadrants. In some embodiments, the sealing strip 750 may be connected between the baffles 740 located in the same quadrant and the baffles 740 located in adjacent quadrants.

[0088] In addition, refer to Figure 8 In one or more embodiments, each of the first plurality of sealing strips 850 may have the same FIG. 5A to FIG. 7The first plurality of sealing strips 850 may have a substantially similar structure to that described above. Thus, the first plurality of sealing strips 850 may have a curved inner surface and a curved outer surface. Additionally, in one or more embodiments, at least one of the first plurality of sealing strips 850 may be coupled to the proximal side 846 of the baffle 840, and at least one of the first plurality of sealing strips 850 may be coupled to the distal side 847 of the baffle 840. Additionally, in one or more embodiments, each of the first plurality of sealing strips 850 coupled to the distal side 847 of each of the plurality of baffles 840 may be longitudinally aligned with each of the first plurality of sealing strips 850 coupled to the proximal side 846 of each of the plurality of baffles 840 in a direction parallel to the longitudinal axis of the housing of the heat exchanger 800. In addition, as described above, in one or more embodiments, for all baffles 840 among the plurality of baffles 840, the number of the first plurality of sealing strips 850 disposed between the baffle 840 and the corresponding continuous baffle 840 rotated a full 360° from the baffle 840 can be equal, and therefore, the number of the first plurality of sealing strips 850 per 360° rotation around the longitudinal axis can be a multiple of the number of baffles per 360° rotation around the longitudinal axis.

[0089] Still reference Figure 8, each of the second plurality of sealing strips 860 may be disposed between one of the baffles 840 and a continuous baffle 840, within a gap 870 formed between a proximal side 846 of one of the baffles 840 and a distal side 847 of a continuous baffle 840, in which gap 870 a distal radial edge 845 of one of the baffles 840 overlaps a proximal radial edge 844 of a continuous baffle 840. In addition, each of the second plurality of sealing strips 860 may be coupled to the baffle 840 in a direction parallel to a longitudinal axis of a shell of the heat exchanger 800, and the second plurality of sealing strips 860 may be radially disposed between the shell and the plurality of tubes 830. In addition, each of the second plurality of sealing strips 860 may have a first end 861 and a second end 862, the first end 861 may be coupled to a proximal radial edge 844 of a distal side 847 of one of the plurality of baffles 840, and the second end 862 may be coupled to a distal radial edge 845 of a proximal side 846 of another of the plurality of baffles. In addition, in one or more embodiments, each of the second plurality of sealing strips 860 may be a trapezoid having an inner surface 863 and an outer surface 864. The inner surface 863 of each of the second plurality of sealing strips 860 may be spaced apart from the outer diameter of the closest tube 830 of the plurality of axially extending tubes 830 by a distance that may be equal to the distance between the outer diameters of two adjacent tubes 830 of the plurality of axially extending tubes 830. In addition, in one or more embodiments, the number of the second plurality of sealing strips 860 disposed between the baffles 840 and the successive baffles 840 in the gap 870 formed by the overlap region between the baffles 840 may be equal to the number of baffles per 360° rotation around the longitudinal axis.

[0090] Reference now Fig. 9 , shows a heat exchanger 900 according to one or more embodiments of the present disclosure. Fig. 9 A heat exchanger with a double spiral flow pattern is shown, which may include strips as described above between the spirals. Although these strips are not shown for ease of understanding the flow pattern, the following description includes these strips and explains how these strips are incorporated into a heat exchanger with multiple spiral flow paths.

[0091] In one or more embodiments, the heat exchanger 900 may include a shell 920 through which a first fluid passes, a plurality of axially extending tubes (not shown) through which a second fluid passes, a first plurality of elliptical sector baffles 940, a second plurality of elliptical sector baffles 980 longitudinally offset from the first plurality of baffles 940, a first plurality of sealing strips (not shown) each disposed between the first baffle 940 and the second baffle 980, and a second plurality of sealing strips 960 disposed between the baffles 940. The shell may include an inlet 928 and an outlet (not shown), and the first fluid may pass between the two within the shell. In addition, the plurality of tubes, the first plurality of baffles 940, the second plurality of baffles 980, the first plurality of sealing strips, and the second plurality of sealing strips may be disposed within the shell 920.

[0092] Still reference Fig. 9 , similar to the heat exchanger described above, in one or more embodiments, the first plurality of baffles 940 can be arranged such that consecutive first baffles 940 are positioned at an angle to a line orthogonal to the longitudinal axis 921 of the housing 920. In one or more embodiments, the first plurality of baffles 940 can be coupled around the longitudinal axis 920, and consecutive first baffles 940 can be rotationally and longitudinally offset from each other to form a spiral pattern. The rotational offset between consecutive first baffles 940 can cause at least a first radial edge (not shown) of one first baffle 940 to overlap with a second radial edge (not shown) of an adjacent first baffle 940 in the longitudinal direction. In addition, the longitudinal offset of the overlapping first radial edges and second radial edges between consecutive first baffles 940 can create a gap between the first radial edge and the second radial edge, through which the first fluid flow can be able to travel. In addition, as described above, in one or more embodiments, there can be an equal number of first plurality of baffles 940 for every 360 degrees of rotation around the longitudinal axis 921, and the first plurality of baffles 940 are arranged around the longitudinal axis 921.

[0093] Similarly, the second plurality of baffles 980 can be arranged such that consecutive second baffles 980 are positioned at an angle to a line orthogonal to the longitudinal axis 921 of the housing 920. In one or more embodiments, the second plurality of baffles 980 can be coupled about the longitudinal axis 921, and consecutive second baffles 980 can be rotationally and longitudinally offset from each other to form a spiral pattern substantially the same as the spiral pattern of the first plurality of baffles 940. The rotational offset between consecutive second baffles 980 can cause at least a first radial edge (not shown) of one second baffle 980 to overlap with a second radial edge (not shown) of an adjacent second baffle 980 in the longitudinal direction. In addition, the longitudinal offset of the overlapping first and second radial edges between consecutive second baffles 980 can be the same as the longitudinal offset of the first baffle 940, and can create the same gap between the first and second radial edges through which the first fluid stream can be able to travel. Furthermore, as described above, in one or more embodiments, in every 360° rotation about the longitudinal axis 921, there can be an equal number of the second plurality of baffles 980, the second plurality of baffles 980 being disposed about the longitudinal axis 921. Additionally, the second plurality of baffles 980 can be longitudinally offset from the first plurality of baffles 940 such that the flow path between successive rotations of the first baffles 920 is split into two separate flow paths. In one or more embodiments, the second plurality of baffles can be longitudinally offset from the first plurality of baffles by half the distance between the first baffles 940 rotated 360° from each other.

[0094] In addition, in one or more embodiments, each of the first plurality of baffles 940 and the second plurality of baffles 980 may be an elliptical sector. Each of the baffles 940, 980 may have an outer circumferential edge (not shown), and each outer circumferential edge may be spaced apart from the outer circumferential edge of an adjacent baffle 940, 980. Each of the baffles 940, 980 may also include a first radial edge at one end of the outer circumferential edge and a second radial edge at the other end of the outer circumferential edge, such that the elliptical sector baffles 940, 980 are defined by the outer circumferential edge, the first radial edge, and the second radial edge. In addition, each of the baffles 940, 980 may have a first side (not shown) and a second side (not shown) opposite to each other, and a plurality of spaced apart holes (not shown) extending from the first side through the baffle 940, 980 to the second side. In one or more embodiments, each first baffle 940 can be aligned with an adjacent second baffle 980 such that the hole of each first baffle 940 is aligned with the hole of the adjacent second baffle 980, and one tube of the plurality of axially extending tubes can pass through each of the holes in the baffles 940, 980. Thus, as described above, the plurality of tubes can extend axially along the entire length of the heat exchanger 900, and each of the tubes can be supported by a plurality of baffles of each of the first plurality of baffles 940 and the second plurality of baffles 980. In addition, the distance between the outer diameters of each of the tubes disposed in each of the holes can be consistent throughout the plurality of tubes.

[0095] Furthermore, in one or more embodiments, the first plurality of sealing strips may each be disposed between a first baffle of the first plurality of baffles 940 and a corresponding adjacent baffle of the second plurality of baffles 940 aligned with the first baffle of the first plurality of baffles 940. In other words, each of the first plurality of sealing strips may be coupled between one of the first side and the second side of one of the first plurality of baffles 940 and a corresponding first side or second side of one of the second plurality of baffles 980. Additionally, each of the first plurality of sealing strips may be disposed within the housing 920 of the heat exchanger 900, as described above with respect to other embodiments, and each of the first plurality of sealing strips may have a substantially similar structure to the first plurality of sealing strips as described above with respect to other embodiments. In addition, each of the second plurality of sealing strips may be disposed between one of the first plurality of baffles 940 and a continuous baffle of the first plurality of baffles 940, and between one of the second plurality of baffles 980 and a continuous baffle of the second plurality of baffles 980, within a gap formed between a first side of one of the baffles 940, 980 and a second side of a continuous baffle 940, 980, the gap being in an area where a first radial edge of one of the baffles 940, 980 overlaps a second radial edge of a continuous baffle 940, 980. In addition, each of the second plurality of sealing strips may be disposed within the housing 920 of the heat exchanger 900, as described above with respect to other embodiments, and each of the second plurality of sealing strips may have a substantially similar structure to the second plurality of sealing strips as described above with respect to other embodiments.

[0096] Embodiments disclosed herein also relate to a method for assembling a heat exchanger. The method may include providing a center rod having a longitudinal axis, and mounting a plurality of elliptical sector baffles to the center rod at an angle to the longitudinal axis of the center rod, thereby forming a spiral pattern by the plurality of baffles. Each of the plurality of baffles may include: an outer circumferential edge longitudinally spaced apart from the outer circumferential edge position of the remaining baffles in the plurality of baffles; a proximal radial edge spaced apart from the distal radial edge; a proximal side opposite to the distal side; and a plurality of spaced apart holes. A plurality of axially extending tubes may be disposed in the plurality of spaced apart holes of each of the plurality of baffles, wherein the plurality of axially extending tubes are configured to carry a second fluid.

[0097] The method may also include radially coupling a first plurality of sealing strips having a first end and a second end between the housing and the plurality of axially extending tubes. Coupling of the first plurality of sealing strips may include: coupling a first end of each of the first plurality of sealing strips to a distal side of one of the plurality of baffles; and coupling a second end of each of the first plurality of sealing strips to a proximal side of another of the plurality of baffles. Each of the first plurality of sealing strips is disposed orthogonal to both the distal side of one of the plurality of baffles and the proximal side of another of the plurality of baffles; or at a non-orthogonal angle to the proximal side of one of the plurality of baffles and the distal side of another of the plurality of baffles, wherein the angle is from greater than 0° to 80°. The assembled center rod, the plurality of baffles, the plurality of axially extending tubes, and the first plurality of sealing strips may then be disposed within a housing configured to receive a first fluid.

[0098] The coupled first plurality of sealing strips have an inner diameter and an outer diameter. Coupling the first plurality of sealing strips may include adjusting the coupled first plurality of sealing strips to an angle that is not orthogonal to the housing from the outer diameter to the inner diameter in a direction defined from a proximal radial edge to a distal radial edge of one of the plurality of baffles.

[0099] Coupling the first plurality of sealing strips may further include spacing an inner diameter of each of the first plurality of sealing strips from an outer diameter of a closest tube in the plurality of axially extending tubes by a distance equal to a distance between outer diameters of two adjacent tubes in the plurality of axially extending tubes. Coupling the first plurality of sealing strips may further include rotationally offsetting each of the first plurality of sealing strips coupled to a distal side of each of the plurality of baffles from each of the plurality of sealing strips coupled to a proximal side of each of the plurality of baffles.

[0100] In some embodiments, the assembly method may further include radially coupling a second plurality of sealing strips having a first end and a second end between the housing and the plurality of axially extending tubes. Coupling the second plurality of sealing strips may include: coupling the first end of each of the second plurality of sealing strips to a distal radial edge of a distal side of one of the plurality of baffles; and coupling the second end of each of the plurality of second sealing strips to a proximal radial edge of a proximal side of another of the plurality of baffles, wherein each of the plurality of second sealing strips extends parallel to the longitudinal axis of the housing.

[0101] According to one or more embodiments of the present disclosure, a heat exchanger having a sealing strip disposed orthogonally to each of a plurality of baffles, such that the sealing strip is orthogonal to the flow direction of the first fluid, provides many advantages over conventional heat exchangers and other spiral baffle heat exchangers. For example, compared to a heat exchanger including a sealing strip disposed parallel to the longitudinal axis of the heat exchanger, a sealing strip disposed orthogonally to each of the baffles can allow a lower pressure drop over the entire length of the heat exchanger. In addition, for example, compared to a sealing strip disposed parallel to the longitudinal axis of the heat exchanger, a sealing strip disposed orthogonally to the direction of the first fluid flow and at a certain angle so that the first fluid flow is directed back to a plurality of tubes carrying the second fluid can allow less first fluid to bypass the plurality of tubes. In addition, for example, in one or more embodiments, radially offsetting a plurality of sealing strips along the length of the heat exchanger can allow for local heat transfer enhancement to be provided to a greater number of a plurality of tubes. In addition, for example, a second plurality of sealing strips disposed adjacent to the first radial edge and the second radial edge of the baffle can allow less first fluid to leave the spiral flow path by leaking around overlapping baffles. Therefore, a heat exchanger according to one or more embodiments may allow for higher heat transfer efficiency in addition to having lower manufacturing costs and lower maintenance costs than conventional heat exchangers and other spiral baffle heat exchangers.

[0102] Several surprising results are noted with respect to embodiments of the present disclosure. First, experiments have shown that conventional sealing strips (not arranged as disclosed herein) have little direct effect on heat transfer. In this manner, they do not significantly improve the efficiency of the heat exchanger to which they are added. In fact, these experiments have shown that conventional sealing strips can cause a significant pressure drop within the heat exchanger compared to the same heat exchanger without the sealing strips. The pressure drop can reduce the efficiency of heat transfer in the heat exchanger. This result is unexpected because the prior art teaches that any sealing strip improves the performance of the heat exchanger by preventing fluid from bypassing the tube bundle. However, the current findings show that sealing strips arranged according to the embodiments herein can improve the performance of the heat exchanger.

[0103] Reference now Fig.10 , the heat exchanger performance of three heat exchangers is compared: (1) a heat exchanger without sealing strips (triangle); (2) a heat exchanger including four longitudinal sealing strips (square), the longitudinal sealing strips extending in the length direction of the exchanger, and the longitudinal sealing strips are arranged to pass through corresponding through holes in each baffle; and (3) a heat exchanger including angled sealing strips (circle), wherein the sealing strips guide the fluid in a manner that promotes spiral flow of the fluid through the heat exchanger. The experimental data is shown as including Reynolds number on the bottom axis, pressure drop conversion ratio on the left axis, and Peclet number on the right axis. As shown, for a given Reynolds number of the fluid flow, the pressure drop conversion ratio and Peclet number are improved for the sealing strips arranged according to the embodiments described herein, which indicates a higher conversion efficiency of pressure drop to heat transfer.

[0104] Second, experiments have shown that connecting the sealing strips so that they are opposite to the fluid flow, i.e., connected in the opposite direction to what is taught herein, can significantly reduce heat transfer. In some experiments, these sealing strips reduced heat transfer by as much as 60% relative to heat exchangers without sealing strips. This is surprising because it is expected that any type of seal can prevent bypassing and thereby improve heat transfer. However, these results show that not only must bypassing be prevented, but also significant pressure drops must be avoided in order to improve heat transfer in a heat exchanger. Therefore, the specific arrangement and orientation of the sealing strips taught herein are important in achieving improved heat transfer.

[0105] Third, experiments have shown that sealing strips connected as disclosed herein can increase heat transfer without causing significant pressure drop. These sealing strips are connected to promote spiral flow of fluid through the heat exchanger. This is unexpected because the prior art teaches that any seal causes a pressure drop loss of approximately 30% to 50%. Therefore, the results of the present disclosure are significantly more optimistic than those expected based on the prior art because they provide improved heat transfer without a corresponding increase in pressure drop.

[0106] While the present invention has been described with respect to a limited number of embodiments, those skilled in the art having benefit of this disclosure will appreciate that other embodiments can be designed which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the present invention should be limited only by the appended claims.

Claims

1. A heat exchanger, comprising: a housing having a longitudinal axis and configured to receive a first fluid; Multiple baffles, each baffle has a helix angle H B mounted in the housing to direct a first fluid flow through the housing into a spiral pattern, wherein each of the plurality of baffles comprises: an outer circumferential edge longitudinally spaced from the outer circumferential edge locations of the remaining baffles of the plurality of baffles; a proximal radial edge spaced from the distal radial edge; a proximal side, as opposed to a distal side; and a plurality of spaced apart holes configured to be passed through by a plurality of axially extending tubes configured to carry a second fluid; and a first plurality of sealing strips, each sealing strip having a first end and a second end, radially disposed between the housing and the plurality of axially extending tubes, and each sealing strip being respectively located between any two adjacent baffles; Wherein, each of the first plurality of sealing strips is arranged at a helical angle H s The first end of each sealing strip is close to the distal end side of the corresponding baffle plate and the second end of each sealing strip is close to the proximal end side of the corresponding baffle plate, and the helix angle H s Greater than 5° and less than the helix angle H of the baffle B , Wherein, the helix angle H B and the helix angle H s is defined as the angle of the respective baffle or seal relative to the longitudinal axis of the housing, and Wherein, each of the first plurality of sealing strips has an angle formed between each of the first plurality of sealing strips and a line orthogonal to a proximal side of a corresponding baffle and a distal side of the corresponding baffle, the angle ranging from greater than 0° to 80°.

2. The heat exchanger according to claim 1, wherein: The sealing strip is configured in part to direct the fluid flow partially helically toward the outlet and partially direct the fluid flow away from the housing and toward the plurality of axially extending tubes.

3. The heat exchanger according to claim 1, wherein: The first plurality of sealing strips are arranged from a distal side of a first baffle from a proximal radial edge adjacent to the first baffle to a proximal side of the second baffle adjacent to a distal radial edge of the second baffle, wherein the first baffle and the second baffle are located in the same sector or quadrant; or The first plurality of sealing strips are arranged from the distal side of the first baffle from the middle of the proximal radial edge and the distal radial edge of the first baffle to the proximal side of the second baffle in the middle of the proximal radial edge and the distal radial edge of the second baffle, wherein the second baffle is located in a different sector or quadrant from the first baffle.

4. The heat exchanger according to claim 1, wherein: The first end of each of the first plurality of sealing strips is coupled to the distal side of a first baffle of the plurality of baffles, and wherein the second end of each of the first plurality of sealing strips is coupled to the proximal side of a second baffle of the plurality of baffles.

5. The heat exchanger according to claim 1, wherein: The plurality of baffles are elliptical sector-shaped baffles.

6. The heat exchanger according to claim 1, wherein: The first plurality of sealing strips have an inner surface and an outer surface, and wherein the first plurality of sealing strips are angled from the outer surface to the inner surface, the angle being non-orthogonal to the housing in a direction defined from a proximal radial edge to a distal radial edge of the one of the plurality of baffles.

7. The heat exchanger according to claim 6, wherein: Each of the first plurality of sealing strips is angled non-orthogonally to the housing at an angle of 15° to 45°.

8. The heat exchanger according to claim 1, wherein: An outer surface of each of the first plurality of sealing strips is disposed proximate to an inner surface of the housing.

9. The heat exchanger according to claim 1, wherein: An inner surface of each of the first plurality of sealing strips is spaced apart from an outer surface of a closest tube of the plurality of axially extending tubes by a distance equal to a distance between outer diameters of two adjacent tubes of the plurality of axially extending tubes.

10. The heat exchanger according to claim 1, wherein: Each of the plurality of baffles includes at least one of the first plurality of sealing strips coupled to the proximal side, and at least one of the first plurality of sealing strips coupled to the distal side.

11. The heat exchanger according to claim 1, wherein: Each of the first plurality of sealing strips coupled to a distal side of each of the plurality of baffles is rotationally offset about the longitudinal axis from each of the plurality of sealing strips coupled to a proximal side of each of the plurality of baffles.

12. The heat exchanger according to claim 1, wherein: Each of the first plurality of sealing strips has a curved outer diameter having an elliptical curvature, and wherein each of the first plurality of sealing strips has a curved inner diameter having an elliptical curvature.

13. The heat exchanger according to claim 1, wherein: Each of the first plurality of sealing strips has a width of the outer diameter minus the inner diameter, the width varying along a length from a first end to a second end of the sealing strip, and wherein each of the first plurality of sealing strips has a depth from a proximal side to a distal side, the depth varying along the width or the length of the sealing strip.

14. The heat exchanger according to claim 1, wherein: An equal number of sealing strips are coupled to each of the plurality of baffles.

15. The heat exchanger according to claim 1, wherein: The number of sealing strips per rotation about the longitudinal axis of the housing is a multiple of the number of baffles per rotation about the longitudinal axis of the housing.

16. The heat exchanger according to claim 1, wherein: The first plurality of sealing strips are formed from steel.

17. The heat exchanger according to claim 1, further comprising: a second plurality of sealing strips, each sealing strip having a first end and a second end radially disposed between the housing and the plurality of axially extending tubes, and each sealing strip being located between any two baffles, respectively; Each of the second plurality of sealing strips is formed from the proximal end of the plurality of baffles to the distal end of the plurality of baffles at a helical angle H 2s Set the helix angle H 2s Greater than 5°, different from the helix angle H s and is smaller than the helix angle H of the baffle B , Wherein, the helix angle H B , the helix angle H s , the helix angle H 2s Defined as the angle of the respective baffle or sealing strip relative to the longitudinal axis of the housing.

18. The heat exchanger according to claim 1, further comprising: a second plurality of sealing strips, each sealing strip having a first end and a second end radially disposed between the housing and the plurality of axially extending tubes, and each sealing strip being located between any two adjacent baffles, respectively; Each of the second plurality of sealing strips is arranged from a proximal radial edge of a baffle to a distal radial edge of an adjacent baffle.

19. The heat exchanger according to claim 18, wherein: An inner surface of each of the second plurality of sealing strips is spaced apart from an outer surface of a closest tube of the plurality of axially extending tubes by a distance equal to a distance between outer diameters of two adjacent tubes of the plurality of axially extending tubes.

20. A method of assembling a heat exchanger, the method comprising: providing a center rod having a longitudinal axis; A plurality of elliptical sector baffles are mounted to the central rod at an angle to the longitudinal axis of the central rod such that a spiral pattern is formed by the plurality of baffles, wherein each of the plurality of baffles comprises: an outer circumferential edge longitudinally spaced from the outer circumferential edge locations of the remaining baffles of the plurality of baffles; a proximal radial edge spaced from the distal radial edge; a proximal side, as opposed to a distal side; and a plurality of spaced-apart holes; disposing a plurality of axially extending tubes in the plurality of spaced apart holes of each of the plurality of baffles, wherein the plurality of axially extending tubes are configured to carry a second fluid; coupling a first plurality of sealing strips radially between the housing and the plurality of axially extending tubes, each sealing strip having a first end and a second end, wherein coupling the first plurality of sealing strips comprises: coupling a first end of each of the first plurality of sealing strips to a proximal side of one of the plurality of baffles; The second end of each of the first plurality of sealing strips is coupled to a distal end side of an adjacent adjacent baffle plate among the plurality of baffle plates, wherein each of the first plurality of sealing strips is formed at a helix angle H s Set the helix angle H s Greater than 5° and less than the helix angle H of the baffle B , Wherein, the helix angle H B and the helix angle H s defined as the angle of the respective baffle or seal relative to the longitudinal axis of the housing; and Adjusting each of the first plurality of sealing strips to form an angle between each of the first plurality of sealing strips and a line orthogonal to a proximal side of a corresponding baffle and a distal side of the corresponding baffle, the angle being from greater than 0° to 80° The assembled center rod, plurality of baffles, plurality of axially extending tubes, and first plurality of sealing strips are disposed within the housing configured to receive a first fluid.

21. The method of assembling a heat exchanger according to claim 20, wherein: The coupled first plurality of sealing strips have an inner surface and an outer surface, and wherein coupling the first plurality of sealing strips further comprises: The coupled first plurality of sealing strips are adjusted at an angle that is non-orthogonal to the housing from the outer surface to the inner surface in a direction defined from a proximal radial edge to a distal radial edge of the one of the plurality of baffles.

22. The method of assembling a heat exchanger according to claim 20, wherein: Connecting the first plurality of sealing strips further comprises: An inner surface of each of the first plurality of sealing strips is spaced from an outer surface of a closest tube of the plurality of axially extending tubes by a distance equal to a distance between outer diameters of two adjacent tubes of the plurality of axially extending tubes.

23. The method of assembling a heat exchanger according to claim 20, wherein: Connecting the first plurality of sealing strips further comprises: Each of the first plurality of sealing strips coupled to a distal end side of each of the plurality of baffles is rotationally offset from each of the plurality of sealing strips coupled to a proximal end side of each of the plurality of baffles.

24. The method of assembling a heat exchanger according to claim 20, further comprising: coupling a second plurality of sealing strips having a first end and a second end radially between the housing and the plurality of axially extending tubes, wherein coupling the second plurality of sealing strips comprises: coupling a first end of each of the second plurality of sealing strips to a proximal radial edge of a distal side of one of the plurality of baffles; and coupling a second end of each of the second plurality of sealing strips to a distal radial edge of a proximal side of another of the plurality of baffles, Wherein, each of the second plurality of sealing strips extends parallel to a longitudinal axis of the housing.

25. A heat exchanger comprising: a housing having a longitudinal axis and configured to receive a first fluid; a plurality of baffles mounted in the housing at an angle to the longitudinal axis, spaced apart from one another along the longitudinal axis, and configured to direct the flow of the first fluid through the housing along a spiral pattern, each of the baffles comprising: outer circumferential edge; a proximal radial edge spaced from the distal radial edge; a proximal side, as opposed to a distal side; and a plurality of spaced apart holes formed through each baffle from the proximal side to the distal side, the holes configured to be passed through by a plurality of axially extending tubes configured to carry a second fluid; and a plurality of sealing members, each including a first end and a second end, the sealing members being radially disposed between the housing and the plurality of axially extending tubes, the first end of each sealing member being coupled to a distal side of a corresponding baffle, and the second end of each sealing member being coupled to a proximal side of a corresponding baffle, Each sealing member is disposed at a non-orthogonal angle to the proximal side of the corresponding baffle, and the angle ranges from greater than 0° to 80° in a direction defined from the proximal radial edge to the distal radial edge of the corresponding baffle.

26. The heat exchanger according to claim 25, wherein: The sealing member comprises a sealing strip or a sealing rod.

27. A heat exchanger comprising: a housing having a longitudinal axis and configured to receive a first fluid; Multiple baffles, each with a helix angle H B mounted in a housing to direct a first fluid flow through the housing into a spiral pattern, wherein each of the plurality of baffles comprises: an outer circumferential edge longitudinally spaced from the outer circumferential edge locations of the remaining baffles of the plurality of baffles; a proximal radial edge spaced from the distal radial edge; a proximal side, as opposed to a distal side; and a plurality of spaced apart holes configured to be passed through by a plurality of axially extending tubes configured to carry a second fluid; and a first plurality of circumferentially offset sealing strips, each sealing strip having a first end and a second end, radially disposed between the housing and the plurality of axially extending tubes, and each sealing strip being located between any two adjacent baffles, Wherein, each of the first plurality of circumferentially offset sealing strips has an angle between each of the first plurality of circumferentially offset sealing strips and a line normal to two adjacent baffles, the angle being greater than 0° up to 80°.

28. The heat exchanger according to claim 27, wherein: Each of the plurality of baffles is connected to at least two of the first plurality of sealing strips, the at least two of the first plurality of sealing strips comprising a distal sealing strip connected to a distal side of the baffle, and a proximal sealing strip connected to a proximal side of the same baffle, and wherein the proximal sealing strip is circumferentially offset from the distal sealing strip.

29. The heat exchanger according to claim 27, wherein: Each of the first plurality of sealing strips is parallel to a longitudinal axis of the heat exchanger.

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